Beruflich Dokumente
Kultur Dokumente
Polyurethanes
Zoran S. Petrović
Pittsburg State University, Kansas Polymer Research Center, Pittsburg, Kansas
I. INTRODUCTION
The history of polyurethanes started in the 1930s in Germany when Otto Bayer proposed
using diisocyanates and diols for preparation of macromolecules. The first commercial
polyurethane, based on hexamethylene diisocyanate and butanediol, had similar proper-
ties to polyamides and is still used to make fibers for brushes. However, fast growth of
the production and expanded application range started in the 1950s with the building of
toluene diisocyanate (TDI) and polyester polyol plants for flexible foams in Germany.
However, the real jump in applications came with the introduction of polyether polyols in
foam formulations. Further development and application of polyurethanes shifted from
Europe to the USA and Japan. Today, polyurethanes are about the sixth largest polymer
by consumption, right behind high volume thermoplastics, with about 6% of the market.
The largest part of the urethane application is in the field of flexible foams (about 44%),
rigid foams (about 28%), while 28% are coatings, adhesives, sealants and elastomers
(CASE) applications. These data are taken at a certain moment in time (1996) and vary
from year to year and region to region, but they illustrate the relative consumption in
different categories. Consumption of polyurethanes in different industries is the following:
about 40% of PU is used in the furniture industry, 16% in transport, 13% in construction,
7% in refrigeration and about the same in coatings, 6% in the textile industry, 4% in the
footwear industry and 8% for other applications. Table 1 illustrates the consumption of
urethanes in the United States in 1996.
Polyurethanes are a broad class of very different polymers, which have only one
thing in common – the presence of the urethane group:
ð1Þ
urethane group
The number of these groups in a polymer can be relatively small compared with
other groups in the chain (for example ester or ether groups in elastomers), but the
polymer will still belong to the polyurethane group. Varying the structure of
polyurethanes, one can vary the properties in a wide range. Polyurethanes are formed
by reaction of polyisocyanates with hydroxyl-containing compounds, most frequently
Consumption,
Million of lb
ð2Þ
urea group
ð3Þ
ð4Þ
ð5Þ
ð6Þ
ð7Þ
Since the urethane group itself contains active hydrogen, it could react with
isocyanate to produce allophanate:
ð8Þ
This reaction proceeds to a significant degree at about 120–140 C but it could occur
also at lower temperatures at high excess of isocyanates. Similar is the reaction of biuret
formation from isocyanate and urea groups:
ð9Þ
ð10Þ
ð11Þ
ð12Þ
Polyisocyanates have no commercial application, and the conditions for their forma-
tion should be avoided when planning other urethane chemical reactions. An important
chemical reaction of isocyanates, which proceeds at high temperature without catalysts,
is carbodiimide formation. CO2 is generated in the process:
RNCO þ HCl
) R NH CO Cl
* ð15Þ
ð16Þ
ð17Þ
ð18Þ
ð19Þ
ð20Þ
ð21Þ
ð22Þ
ð23Þ
TDI is a liquid at room temperature, having density 1.22 g/cm3, boiling point 120 C
at 1333.22 Pa (1 atm) and melting point 13.6 C (TDI 80) or 5 C (TDI 65). It is used
primarily for flexible foams and different adducts-intermediaries for coatings.
Pure MDI is a solid at room temperature, having melting point 39.5 C and density
1.18 g/cm3 at 40 C.
ð24Þ
ð25Þ
Pure MDI is used mainly for preparation of thermoplastic elastomers, while crude
MDI is used for rigid and partly for flexible foams.
Paraphenylene diisocyanate is another important isocyanate. It produces excellent
elastomers but its use is limited due to a very high price.
ð26Þ
Aromatic diisocyanates are not suitable for products that are exposed to
irradiation and external influences (such as coatings) because of yellowing. Those
applications require aliphatic or cycloaliphatic isocyanates. One popular cycloaliphatic
isocyanate is isophorone diisocyanate, a liquid at room temperature (melting point
ð27Þ
p-Phenylene 36.0 46
2,4-TDI 21.0 33.1
2,6-TDI 7.4 41.9
1,5-NDI 4.0 50.2
1,6-HDI 8.3 46.0
Isocyanate k1 k2
MDI 16 8.6
2,4-TDI 42.5 2
2,6-TDI 5 2
HDI 0.2 –
B. Polyols
Second to isocyanate in the technology of polyurethane preparation is polyol. Polyether
polyols (polypropylene glycols and triols) having molecular weights between 400 and
10,000 dominate in the foam technology. Foams are usually made with triols, which form
crosslinked products with diisocyanates, whereas diols dominate in the elastomer
technology. Polyether polyols have higher hydrolytic stability than the polyester polyols,
but they are more sensitive to different kinds of irradiation and oxidation at elevated
temperatures. Polypropylene oxide (PPO) polyols, also called polypropylene glycols
(PPG), are cheaper than other polyols. PPG structure can be represented by the formula:
ð28Þ
Group R comes from the starter diol such as ethylene glycol (R ¼ –CH2–CH2).
If multifunctional starters, such as glycerin, trimethylol propane or sugars are used,
the resulting polypropyleneoxide polyol would have the functionality of the starter
component.
Due to the weak intermolecular attractive forces (low polarity) and non-crystallizing
nature, PPG polyols are liquid at room temperature even at very high molecular weight,
unlike polyester polyols, which are often crystalline greases. Weaker interactions on
the other hand cause lower strengths of the PPG based urethanes. Viscosity of polyether
polyols is a function of the hydroxyl content (due to hydrogen bonding) and molecular
weight. PPO diols have viscosities from 110 mPa s (cP) at 20 C for the molecular weight
of 425 to 1720 mPa s for MW ¼ 4000. Glycerin for example has viscosity above 1000 mPa s
at 20 C but when propoxylated to MW ¼ 1000 gives a triol with viscosity of about
400 mPa s.
Polyether polyols based on polytetramethylene oxide (PTMO), sometimes called
polytetrahydrofurane (PTHF), have better strengths than PPG polyols, mainly due
HO½CH2CH2CH2CH2On H ð29Þ
Polyester polyols are an important class of urethane raw materials, with applications
in elastomers, adhesives, etc. They are usually made from adipic acid and ethylene glycols
(polyethylene adipate):
ð30Þ
or butane diol and adipic acid (polybutylene adipate). Both would crystallize above
room temperature. In order to reduce their glass transition and destroy crystallinity,
copolyesters are prepared from the mixture of ethylene glycol and butane diol with adipic
acid. Polycaprolactone diol is another crystallizable polyester diol:
ð31Þ
Polyols for coatings, rigid foams, and adhesives may contain aromatic rings in
the structure in order to increase rigidity. These polyols may also crystallize, which is
important in some applications, e.g., adhesives. Special class of polyols are ‘polymer
polyols’ containing usually copolymers of acrylonitrile and styrene or methylmetacrylate
attached to the chains of polyether polyols, forming a dispersion. They are used for high
modulus products such as froth and integral skin foams, RIM, shoe soles and one-shot
elastomers.
An important but less frequently used group of polyols, polybutadiene diols, are
mainly used for elastomers:
Structural formula (32) shows poly-1,4-butadiene (BD), but 1,2-poly BD and the mixture
of the two are also produced.
Castor oil is a natural triol with a typical OH number 160 mg KOH/g
(functionality ¼ 2.7). Although it has three ester groups, it is not considered a polyester
type polyol.
ð33Þ
ð34Þ
C. Catalysts [1,3–8,13,14]
Rapid growth of urethane technology can be attributed to the development of catalysts.
Catalysts for the isocyanate–alcohol reaction can be nucleophilic (e.g., bases such as
tertiary amines, salts and weak acids) or electrophilic (e.g., organometallic compounds).
In the traditional applications of polyurethanes (cast elastomers, block foams, etc.) the
usual catalysts are trialkylamines, peralkylated aliphatic amines, triethylenediamine or
diazobiscyclooctane (known as DABCO), N-alkyl morpholin, tindioctoate, dibutyl-
tindioctoate, dibutyltindilaurate etc.
Usually a combination of catalysts is required to achieve proper structure and
properties, especially in applications such as integral skin foams or reaction injection
molding (RIM). The mechanism of the catalysis of isocyanate-alochol reaction in presence
of amines is assumed to proceed through an activated complex between amine and
isocyanate [15,16]
ð35Þ
Uncatalyzed 0 1
TMBDA 0.1 56
DABCO 0.1 130
TMBDA 0.5 160
DBTDL 0.1 210
DABCO 0.3 330
Sn-octoate 0.1 540
DBTDL þ DABCO 0.1 þ 0.2 1000
Sn-octoate 0.3 3500
Sn-octoate þ DABCO 0.3 þ 0.3 4250
The complex then reacts with the alcohol to form an intermediary product, which
decomposes to give urethane and regenerate the catalyst:
ð36Þ
where B is the number of ml of HCl used for titration of the blank, S is the number of ml
of HCl used for titration of the sample, N is the molarity of HCl solution, and W is the
weight of the sample in grams.
Other characteristics of isocyanates that are analyzed are total chlorine content,
the content of hydrolyzable chlorine, acid content, freezing point, density and color.
B. Analysis of Polyols
The principal property measured in polyols is hydroxyl content. According to ASTM
D4274-88, hydroxyl group content is determined by acetylation and the excess of acid is
back titrated with a base. The acetylating agent is usually a solution of acetic anhydride in
pyridine. Acetylation is carried out at 100 C. Unreacted anhydride is then converted with
water into acid and titrated with 1 N NaOH. Hydroxyl content is usually expressed as
hydroxyl number (OH number), which is defined as the number of milligrams of KOH
(MKOH ¼ 56.11) used for titration of one gram of the sample.
1:7Y
Xð%Þ ¼ ð39Þ
56:1
x 17
b¼a ¼ 0:40476ax=y ð40Þ
y 42
Mn
E¼ ð41Þ
f
If we know the functionality of a component and the content of the groups (%NCO
or %OH) we could calculate the number average molecular weight. For polyols the
expression would be:
Thus, the diol of Mn ¼ 1000 would have weight equivalent E ¼ 500 [g/equiv] and triol
of Mn ¼ 3600 would have E ¼ 1200 [g/equiv] and MDI equivalent weight would be 125
[g/equiv]. Water is a specific compound, behaving as a two-functional reactant, having
E ¼ 9 [g/equiv]. Equivalent weight of hexamethylenediamine is 116/2 ¼ 58. From the
above, 125 g of MDI should react with 500 g of the diol with Mn ¼ 1000, or 9 g of water, or
58 g of hexamethylenediamine, if 1:1 molar ratio is desired. Equivalent weight of polyols
can be calculated from the known OH number:
56,100
E¼ ð44Þ
OH#
s, strong: m, medium; w, weak; v, very; sh, shoulder; A, amorphous; C, crystalline, n, stretching; na, antisymmetric
stretching; ns, symmetric stretching; d, bending; W, wagging; t, twisting; r, rocking; b, in plane bending; g, out-of-
plane bending; U, urea; UT, urethane.
Polyurethane foams are the largest group of urethane products, covering about 80% of the
total urethane production. Polyurethane foams can be categorized as rigid and flexible.
Rigid foams are used primarily for heat insulation in refrigeration and construction,
and partly in automobile industry. Flexible foams find their application in furniture, the
automobile industry, for packaging, etc. A variety of rigidity grades of flexible foams are
manufactured, with grades having rigidity between soft and rigid foams being called semi-
rigid. Semi-rigid foams are used for automobile seats and components for interior and
exterior safety. Two basic reactions of isocyanates are used in foam production:
Isocyanate þ polyol!polymer
ð45Þ
Isocyanate þ water!CO2 for foaming
The correct foaming process requires that these two reactions take place at the same rate.
If the polymerization (the first reaction) is faster, the polymer formed will have final
strength before foaming and the result will be a high density foam (low degree of foaming).
If the second reaction is much faster, the evolved gas will blow the foam. Due to the low
‘green’ strength and viscosity of the polymerizing mixture, the gas will leave the mixture,
typically between 20 s and 120 s. Gel time is measured by touching the foaming mass with
the glass rod. Before gelation polymer is sticky and can be drawn into long fibers.
Parts per
Component hundred (pph)
E. Microcellular Foams
Microcellular foams (elastomers) differ from classical foams, because of their cell
structure, higher density of the foams, which is typically 200 kg/m3, and the structure of
the matrix. Microcellular foams are foamed segmented elastomers with smaller number of
round cells, unlike polygonal cells with ribs in standard foams. Because of their superior
mechanical properties they are used for shoe soles, car bumpers, etc. They are formed by
adding water and excess isocyanate in the elastomer formulation, which liberates CO2.
F. Rigid Foams
Rigid foam compositions differ from those of flexible foams as they use short triols or
higher functionality polyols, typically with Mn ¼ 400. They are made with crude MDI, and
main part of foaming is done with physical blowing agents. Due to the high concentration
of crosslinks the foams are rigid (the glass transition, Tg, of the PU matrix is above
room temperature). Part of the rigidity comes from the higher weight ratio of aromatic
isocyanates as well as from higher isocyanate index (usually 105 or higher). Higher rigidity
can be obtained by using sugar (sorbitol)-based polyols, which have higher functionality
( f ¼ 6). Due to the large concentration of isocyanate and hydroxyl groups, the reaction
is more exothermic than in the case of flexible foams, requiring less powerful catalysts.
A typical rigid foam formulation is given in Table 7.
This formulation uses triethylenediamine, which moderately catalyses the polyol/
isocyanate reaction. Crosslinking density is increased by adding low molecular crosslinker,
glycerin, and foaming is achieved exclusively with the physical blowing agent. However,
water may be added as co-blowing agent to increase mechanical properties. Rigid foams
are foamed usually in molds or cavities, as in refrigeration, laminates and packaging.
Standard foaming machines are used to mix the components and pour-in-place.
Alternatively reaction injection molding (RIM) machines are utilized. Rigid foams can
be also applied by spraying.
utilized. Viscosity can be reduced by heating the polyol component. Here the two or more
component streams are injected into the mixing chamber with high velocity, where they
collide and mix by turbulent flow. The advantage of high pressure machines is that they
allow exact metering, processing of very fast systems, minimize waste and may not require
cleaning between shots (self-cleaning heads). High pressure machines dominate the
market.
The molding process could be continuous as in the case of slabstock foam, Figure 2,
or discontinuous when molding in the mold is carried out. In the continuous process
the mixing head traverses from one side of the conveyer to the other in the perpendicular
direction to the direction of conveyer movement and pours the liquid urethane mixture to
the paper base on the conveyer. The liquid quickly forms a cream and then rises to form a
bun, which is cut to the desired size with razor blades.
Two structural features characterize every useful elastomer: high chain flexibility (i.e.,
glass transition below the application range) and existence of either chemical or physical
crosslinks. Flexibility of chains allows high deformation (uncoiling of the coiled chains)
while crosslinks prevent chain slip, which produces plastic (irreversible) deformation.
Polyether, polyester or polybutadiene chains having molecular weight above 1000 satisfy
the first condition. The glass transition temperature of these materials is usually between
40 C and 80 C. Polyurethane elastomers can be single or two-phase systems. One-
phase systems are homogeneous chemically crosslinked polymers. Two-phase systems
are block copolymers consisting of a hard and soft phase, separated by an interface. The
blocks are called segments. Due to the difference in structure of the blocks, they do not
mix but separate into ‘domains’. Schematic representation of the segmented polyurethanes
is given in Figure 3.
Hard domains are usually prepared from aromatic isocyanates and short glycols
or diamines, called chain extenders. Neighboring hard segments are held together by Van
der Vaals forces and hydrogen bonds, forming domains, which act as physical crosslinks.
Segmented polyurethanes are usually prepared by a prepolymer process
(reaction (46)) and subsequent chain extension (reaction (47)). A prepolymer is prepared
by reacting excess of isocyanate with a polyol (diol), typically of the molecular weight
2000.
ð46Þ
Figure 3 Schematic representation of the structure of the segmented polyurethane chain (a),
association of hard segments into domains of globular morphology (b) and co-continuous soft and
hard phase morphology (c).
ð47Þ
Here, Mpol, MISO and MCE are molecular weights of the polyol, isocyanate and chain
extender, respectively.
Setting the number of moles of the polyol, npol, to be 1, r becomes the number
of moles of the chain extender. Number of moles of the diisocyanate, nISO, at the
stoichiometric ratio of NCO/OH groups is the sum of the moles of the polyol and the
chain extender, i.e., nISO ¼ r þ 1. Thus, a prepolymer for a given SSC should be prepared
from one mole of the polyol and (r þ 1) moles of diisocyanate and extended with r moles of
the chain extender. Number average molecular weight of the soft segment is determined
by the selection of the polyol molecular weight. The hard segment molecular weight, Mnhs,
is determined by the soft segment molecular weight and soft segment concentration,
according to the expression:
At 50% SSC, the number average molecular weights of the hard and the soft segment must
be equal.
When stress is applied, soft segments uncoil to give large deformation, while hard
domains preventing slippage of the chain past each other, restrain plastic deformation.
Properties of a polyurethane elastomer depend on the selection of a diisocyanate,
chain extender and polyol but also on the length and concentration of the soft and hard
segments. At low concentrations of hard segments (below 30 wt%) the hard domains
have globular shapes and are dispersed in the (continuous) matrix of the soft phase.
By increasing hard segment concentration, the globules become ellipsoidal and more
ð50Þ
MOCA is a strong carcinogen and should be used with good safety protection.
3RT
E¼ ð51Þ
Mc
This means that longer polyols produce softer polyurethane elastomers. The Tg of the soft
phase is also related to the Mc:
K
Tg ¼ Tg1 þ ð52Þ
Mc
where Tg1 is the glass transition temperature of the linear long polymer, and K is
a constant for the given system. Glass transition temperature of the soft phase of an
elastomer based on polytetramethyleneoxide is 43 C when molecular weight of the
polyol is 650, Tg ¼ 60 C for the polyol with Mc ¼ 1000, or 86 C for the Mc ¼ 2000.
Thus, for semi-rigid elastomers and foams, polyol molecular weight should be below 1000.
Modulus of polyurethane elastomers can be elevated by adding fillers. To summarize,
the factors determining properties of a polyurethane elastomer are:
1. structure of the polyol
2. type of diisocyanate
3. type of the chain extender
4. molar ratio NCO/OH
5. soft segment concentration
6. molecular weight of the polyol
7. filler.
In all cases above it is understood that the chains are linear and crosslinking
was achieved by physical bonds and hard domain formation. Such polymers display
typical thermoplastic behavior, i.e., they flow when they are melted and harden by cooling.
Domains are destroyed above the melting point of the hard phase but are reformed
upon cooling, displaying reversible crosslinking. These materials are called ‘thermo-
plastic urethanes’ (TPU). Properties of thermoplastic urethanes are very temperature
dependent and their strength decrease dramatically above the glass transition of the
hard segments (above 100 C). They also display a large permanent set (irreversible
deformation) after being held under stress for a long period, especially at elevated
temperatures.
There is another group of polyurethanes that is chemically crosslinked with a
crosslinker, either triol or polyamine or polyisocyanate. They are single-phase elastomers,
and they display lower strengths than the thermoplastic urethanes. However, their
properties are less temperature sensitive, and elastic recovery is generally considerably
better (permanent set is smaller) than in TPUs. Their strength can be improved by adding
proper fillers. Such systems are called ‘cast systems’ since they are processed by casting
2. Vulcanizing Polyurethanes
The rubber industry uses specific processing equipment, and the transition to the standard
urethane technology would be costly. Therefore, a family of urethanes was developed that
can be processed on standard rubber equipment. High molecular weight polyurethanes
are crosslinked using sulfur, peroxides or polyisocyanates. Crosslinking of high molecular
weight polymers is called vulcanization. Vulcanization by sulfur and peroxides require
polymers with double bonds, while isocyanate crosslinking is carried out through
the active OH groups or urea (–NHCONH–), urethane (–NHCO–O–) or amide (–NHCO–)
groups.
‘Spandex’ fibers are elastomeric polyurethane fibers used in the manufacturing of high
stretch garments, such as swimsuits, sport apparel, etc. Elastomeric fibers are essentially
thermoplastic elastomers spun into fibers. Usually diamine chain extenders are used
instead of diols to produce polyureas. Polyureas have high melting points (above the onset
of degradation) and cannot be spun from the melt. They are spun from the solution. Only
non-urea polyurethanes can be melt processed. There are four basic processes for making
fibers:
1. wet spinning
2. dry spinning
3. reaction spinning
4. melt spinning.
Wet spinning or solution spinning is a process where the elastomer is dissolved in a
solvent, for example DMF or DMA, and forced through the spinneret into the coagulating
bath, which contains a nonsolvent for polyurethane miscible with the solvent. Water is
a good coagulating agent and is miscible with DMF or DMA. The solution coming out
of the spinneret comes in contact with the coagulating nonsolvent, immediately forming
the fiber. Initially the solvent is in the fiber, but it diffuses into the bath causing additional
coagulation. Thus the residence time in the coagulating bath must be sufficiently long to
allow most of the solvent to leave the fiber. This time is controlled by the length of the bath
and speed of drawing the fiber. Usually the spinneret contains a large number of holes,
producing a number of fibers which are bound together in a multifilament yarn.
The fiber may be stretched by pulling to obtain orientation and improve packing of
hard domains. The scheme of the wet spinning process is depicted in Figure 4. The process
is relatively slow and requires treatment of the wastewater from the baths.
Dry spinning starts from the solution containing pigments and additives like in wet
spinning, but instead of extruding the solution into the coagulating bath, the fibers are
extruded in the chamber heated with hot air. The solvent evaporates, and the resulting
fiber is wound on a take-up roll. More than 80% of spandex fibers are produced this way
since it is faster and more economical than the other techniques.
Reaction spinning involves simultaneous chain extension reaction and spinning.
The isocyanate-terminated prepolymer is extruded into the bath containing diamine or
polyamine. Isocyanate-amine reaction is almost instantaneous. The fiber has fairly rigid
skin on the surface, which facilitates wind-up. The advantage of this process is that
chemically crosslinked polymers can be obtained. The application of the method is,
however, limited.
Melt spinning is essentially an extrusion process applied to segmented polyurethanes.
A coating consists of binder (polymer resin), solvent, pigments and filler. Polyurethane
resins have a special place among the natural and synthetic binders in the coating industry
due to their excellent adhesion to various substrates. Polyurethane paints and varnishes
can be classified in several groups:
1. Two component systems, where one component is polyisocyanate and the
second is a polyol with additives. These systems are manufactured with or
without solvents.
2. One component systems that cure with the moisture from the surrounding air.
These systems can also be with or without solvents.
3. One component systems containing a mixture of a polyol and a blocked
isocyanate. At elevated temperatures the polyisocyanate is deblocked and reacts
with the polyol. Powder coatings also belong to this group.
4. Non-reactive urethane systems containing a polyurethane dissolved in a solvent.
The system dries upon evaporation of the solvent.
5. Urethane oils or urethane alkyds.
6. Water based dispersions.
A. Two-Component Coatings
The two components of this system are the isocyanate and the polyol with all additives.
The two components are mixed and applied by some of the standard application
ð53Þ
Aromatic isocyanates are not desirable in coatings that will be exposed to sunlight
(exterior applications) because of yellowing. Such systems are preferably based on
aliphatic (HDI) or cycloaliphatic isocyanates (isophorone diisocyanate). Polyisocyanates
are usually supplied in the form of a concentrated solution (50–80%) to reduce viscosity.
Polyols for two component coatings can be polyester, polyether, acrylic resins, or urethane
resins containing hydroxyl groups. Other components with hydroxyl groups include epoxy
resins, coal tar, cellulose esters, etc. Higher hydroxyl content in the polyol translates into
higher crosslinking density, higher film strength and higher resistance to chemicals. Lower
hydroxyl contents give better film elasticity. The isocyanate/hydroxyl molar ratio may
be off-stoichiometric and is determined by trial and error. At low NCO/OH ratios (less
than 1) the coating displays higher elasticity but lower solvent and chemical resistance.
It should be emphasized that in two-component coatings, not all isocyanate groups react
with polyol, and almost one third reacts with moisture from the surrounding air. This fact
should be taken into account when adjusting NCO/OH ratio.
B. One-Component Systems
One-component urethane coatings are usually based on MDI, TDI or HDI terminated
prepolymers containing free isocyanate groups. Pigmenting such systems is delicate due
to moisture in the pigment, which can cause premature gelation. Therefore, these systems
must contain additives for moisture removal such as zeolites (alumosilicates). Since the
chain extension in such systems is carried out with water from air, one of the products of
the reaction is CO2, which diffuses from the film without foaming.
If the film is not too thick and the isocyanate content high, the curing process is
under control and no bubbles are formed. The prepolymers may be dissolved in a solvent
to reduce viscosity. The initial phase of drying consists of solvent evaporation followed
by chemical reaction. Reaction rate in one-component coatings depends on the relative
humidity. Film thickness with two-component and one-component coatings can be
considerable (0.5 to 10 mm). The advantage of these systems is the absence of the
unpleasant solvent smell, lower fire hazard and lower price. The disadvantage is poorer
wetting of the surface, difficulty in obtaining mat surfaces and possibility of bubble
formation. One-component PU solventless systems are used for the preparation of
C. Blocked Isocyanates
Prepolymers and adducts with free NCO groups are sensitive to moisture and have limited
shelf life. If the isocyanate groups are blocked (for example with phenol, cresol, ethyl
acetoacetate, dimethyl malonate or butane oxime) one can obtain stable systems at
room temperature. Heating blocked isocyanates to 160–180 C (or about 30 C less in
the presence of a catalyst) causes deblocking to occur, and isocyanate can react with the
present co-reactant (polyol), i.e., the system becomes the two-component coating. The
polyol can be also phenolic, urea or melamine resins wit free OH groups. These systems
have to be ‘baked’ at elevated temperatures. The main application field for these systems
is in electroinsulation, such as wire enamels, impregnation varnishes, and for substrate
coating. Another important field of application of blocked isocyanate systems includes
powder coating. Here the polyol component may be a polyester from terephthalic acid
or polyacrylate with free OH groups. The isocyanate component is TDI or IPDI blocked
with caprolactam. After heating at 160–200 C for 10–35 min, the powder melts (on the
electrostatically coated metal), and the deblocked isocyanate reacts with the polyol.
D. Non-reactive PU Systems
These coatings are formed by physical drying, i.e., high molecular weight linear
polyurethane forms strong secondary bonds with substrate after solvent evaporation.
These varnishes have, however, low solvent and chemical resistance. They are used for
coating flexible substrates such as leather or flexible parts made of PU foams with integral
skin and as the modifiers for printing inks (paints), etc.
F. Polyurethane Dispersions
These systems are based on ionomers, i.e., polymers containing ionic groups, mainly
anions such as sulfonic or carboxylic groups. They are neutralized with bases to form salts,
which contribute to hydrophilicity (formation of bonds with water), and formation of
stable dispersions of polymers in water. After drying, a film on the applied surface is
formed. Orientation of molecules, hydrogen bonding, as well as coulombic forces, act as a
Polyurethane adhesives are an important group of materials thanks to the very polar
groups in their structure as well as the ability of isocyanates to form chemical bonds
with the substrate. According to the method of application adhesives are classified in the
following groups:
1. Reactive two-component adhesives based on polyisocyanates and low molecular
weight polyols, which form the polymer when mixed together.
2. One-component reactive prepolymer that reacts with moisture from the air to
give a polymer.
3. Solution adhesive consisting of the high molecular weight linear polyurethane
polymer dissolved in a suitable solvent.
4. Solution of adhesive as in (3) which has polyisocyanate as a crosslinker.
5. Solution of a non-urethane polymer, e.g., polychloroprene, with isocyanate as
the crosslinker.
6. Dispersion adhesive containing high molecular weight polyurethane with ionic
groups dispersed in water.
One can easily observe the similarity between coatings and adhesives. Polyisocya-
nates used for adhesives should have high molecular weight and thus, low vapor pressure
at the reaction temperature. Adducts such as Desmodur L, or crude MDI are often
used, as are triisocyanates such as triphenyl methane-4,40 ,400 -triisocyanate (a) or tris(p-
isocyanatophenyl) ester of thiophosphoric acid (b) dissolved in methylene chloride or
ethyl acetate:
ð54Þ
Since isocyanates are used as adhesion promoters, they can be added in excess up to
50% above stoichiometric ratio in the two-component adhesives. Excess of hydroxyl
groups, up to 10%, is used if bonding of flexible materials is carried out. The chains
with unreacted OH groups then act as plasticizers. Polyols for adhesives are usually
crystallizable components. Polyether polyols are used in spite of the lower adhesivity
because of the lower viscosity.
Resistance to various environmental factors, such as heat, light and humidity, is one of the
most important properties of materials. Stability of polyurethanes under the influence of
these factors varies with the structure of the material. Thus we will discuss just the stability
of the urethane group and a few typical chemical groups in urethane materials, such as
ether or ester.
RNHCOOR0
(
+
RNCO þ HOR0 ð55Þ
ð57Þ
ð58Þ
.Η. Η . ..
hν -Η
.Ν. CO - O - Ar-N-CO-O-
. Ar=N-CO-O-
+
(1) (2) Η2 ð59Þ
ð60Þ
Concentration of
TDI, mg/kg Effect
< 0.02 Possible asthmatic reactions
with hypersensitive humans
0.1–1.5 Small nose and throat irritation
1.3–10 Coughing, reversible bronchitis
(lasts several hours)
10–50 Irreversible bronchitis, pulmonary edema
Above 50 Life threatening
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