Adhesive composition and method
阅读说明：本技术 粘合剂组合物和方法 (Adhesive composition and method ) 是由 斯科特·D·艾伦 V·森迪亚雷维克 J·奥康纳 于 2013-04-16 设计创作，主要内容包括：本发明涵盖包含脂族聚碳酸酯链的聚氨酯粘合剂组合物。一方面,本发明涵盖来源于脂族聚碳酸酯多元醇和聚异氰酸酯的聚氨酯粘合剂,其中所述多元醇链含有具有以下结构的主要重复单元：<Image he="272" wi="545" file="DDA0002231057720000011.GIF" imgContent="drawing" imgFormat="GIF" orientation="portrait" inline="no"></Image>另一方面,本发明提供包含本发明的聚氨酯组合物的制品以及制备此类组合物的方法。(The present invention encompasses polyurethane adhesive compositions comprising aliphatic polycarbonate chains. In one aspect, the present invention encompasses polyurethane adhesives derived from an aliphatic polycarbonate polyol and a polyisocyanate, wherein the polyol chain contains a primary repeat unit having the structure: in another aspect, the present invention provides articles comprising the polyurethane compositions of the present invention and methods of makingMethods of such compositions.)
1. A reactive polyurethane adhesive composition comprising a polymer having free isocyanate groups and segments derived from one or more aliphatic polycarbonate polyols having the structure P1:
wherein R is1、R2、R3And R4Independently at each occurrence in the polymer chain, selected from the group consisting of: -H, fluorine, optionally substituted C1-40Aliphatic radical, optionally substituted C1-20A heteroaliphatic group, and an optionally substituted aryl group;
R1、R2、R3and R4Any two or more of (a) may optionally form, together with intervening atoms, one or more optionally substituted rings, optionally containing one or more heteroatoms;
y, at each occurrence, is independently-H, a reactive group, or a site attached to a chain extension;
x and y are each independently an integer from 0 to 6, wherein the sum of x and y is from 2 to 6;
n, at each occurrence, is independently an integer from 3 to 1,000;
wherein the strength of the cured bond formed by the polyurethane adhesive composition between two substrates measured at 50 ℃ is greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃, wherein the strength is measured by the ASTM D1002 lap shear test at each temperature and is indicated by testing a group consisting of: load at the time of destruction; tensile breaking energy; yield stress; and yield strain; and
wherein the reactive polyurethane binder is cured by reacting the free isocyanate groups with water or a polyol.
2. The reactive polyurethane adhesive composition of claim 1, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 50 ℃ is at least 15% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
3. The reactive polyurethane adhesive composition of claim 2, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 50 ℃ is at least 20% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
4. The reactive polyurethane adhesive composition of claim 3, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 50 ℃ is at least 30% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
5. The reactive polyurethane adhesive composition of claim 4, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 50 ℃ is at least 40% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
6. The reactive polyurethane adhesive composition of claim 5, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 50 ℃ is at least 50% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
7. The reactive polyurethane adhesive composition of claim 6, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 50 ℃ is at least 75% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
8. The reactive polyurethane adhesive composition of claim 7, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 50 ℃ is at least 100% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
9. The reactive polyurethane adhesive composition of claim 8, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 50 ℃ is 100% -200% of the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
10. The reactive polyurethane adhesive composition of claim 1, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 70 ℃ is greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
11. The reactive polyurethane adhesive composition of claim 10, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 70 ℃ is at least 15% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
12. The reactive polyurethane adhesive composition of claim 11, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 70 ℃ is at least 20% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
13. The reactive polyurethane adhesive composition of claim 12, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 70 ℃ is at least 30% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
14. The reactive polyurethane adhesive composition of claim 13, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 70 ℃ is at least 40% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
15. The reactive polyurethane adhesive composition of claim 14, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 70 ℃ is at least 50% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
16. The reactive polyurethane adhesive composition of claim 15, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 70 ℃ is at least 75% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
17. The reactive polyurethane adhesive composition of claim 16, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 70 ℃ is at least 100% greater than the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
18. The reactive polyurethane adhesive composition of claim 17, wherein the strength of the cured bond formed by the polyurethane adhesive composition measured at 70 ℃ is 100% -200% of the strength of the cured bond formed by the polyurethane adhesive composition measured at 25 ℃.
19. The reactive polyurethane adhesive composition of any one of claims 1-18, characterized in that the mass gain of a cured sample of the polyurethane adhesive composition is less than 5% at room temperature for 1 week submerged in toluene or characterized in that the mass gain of a cured sample of the polyurethane adhesive composition is less than 1% at room temperature for 1 week submerged in xylene.
20. The reactive polyurethane adhesive composition of claim 1, wherein the one or more aliphatic polycarbonate polyols are characterized in that at least 99%, at least 99.5%, at least 99.7%, or at least 99.8% of the end groups are-OH groups.
21. The reactive polyurethane adhesive composition of claim 1, wherein the one or more aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and ethylene oxide.
22. The reactive polyurethane adhesive composition of claim 1, wherein the one or more aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and propylene oxide.
23. The reactive polyurethane adhesive composition of claim 1, wherein the one or more aliphatic polycarbonate polyols comprise a terpolymer of carbon dioxide and ethylene oxide along with one or more additional epoxides selected from the group consisting of propylene oxide, 1, 2-butylene oxide, 2, 3-butylene oxide, cyclohexene oxide, 3-vinyl cyclohexene oxide, epichlorohydrin, glycidyl esters, glycidyl ethers, styrene oxide, and epoxides of higher α olefins.
24. The reactive polyurethane adhesive composition of claim 1, wherein the one or more aliphatic polycarbonate polyols comprise a terpolymer of carbon dioxide and propylene oxide along with one or more additional epoxides selected from the group consisting of ethylene oxide, 1, 2-butylene oxide, 2, 3-butylene oxide, cyclohexene oxide, 3-vinyl cyclohexene oxide, epichlorohydrin, glycidyl esters, glycidyl ethers, styrene oxide, and epoxides of higher α olefins.
25. The reactive polyurethane adhesive composition of claim 1, wherein the one or more aliphatic polycarbonate polyols have a number average molecular weight (Mn) in a range from 500g/mol to 10,000g/mol, or from 500g/mol to 5,000g/mol, or from 500g/mol to 4,000g/mol, or from 500g/mol to 3,000g/mol, or from 500g/mol to 2,500g/mol, or from 500g/mol to 1,500 g/mol.
26. The reactive polyurethane adhesive composition of claim 1, wherein the one or more aliphatic polycarbonate polyols are characterized by an average percentage of carbonate linkages in the polyol of 90% or greater, 95% or greater, or 99% or greater.
27. The reactive polyurethane adhesive composition of claim 1, wherein the one or more aliphatic polycarbonate polyols are characterized by an average percentage of carbonate linkages in the polyol of 99% or greater.
28. The reactive polyurethane adhesive composition of claim 1, wherein
29. the reactive polyurethane adhesive composition of claim 28, wherein
30. The reactive polyurethane adhesive composition of claim 28, wherein y is 0 and x is greater than 2.
31. The reactive polyurethane adhesive composition of claim 1, further comprising one or more additional polyols selected from the group consisting of polyether polyols, polyester polyols, and mixtures thereof.
32. The reactive polyurethane adhesive composition of claim 1, wherein the one or more aliphatic polycarbonate polyols are selected from the group consisting of:
wherein t is an integer from 1 to 12 inclusive, and RtIndependently at each occurrence is-H or-CH3。
33. The reactive polyurethane adhesive composition of claim 1, comprising 100 parts by weight of the polyol component, wherein the one or more aliphatic polycarbonate polyols comprise from 5 parts to 100 parts of the polyol component.
34. The reactive polyurethane adhesive composition of claim 33 further comprising 0.01 to 20 parts by weight of one or more chain extenders.
35. The reactive polyurethane adhesive composition of claim 33, further comprising 0 to 20 parts by weight of one or more reactive small molecules, wherein the one or more reactive small molecules comprise a functional group selected from the group consisting of hydroxyl, amine, thiol, and carboxylic acid.
36. The reactive polyurethane adhesive composition of claim 35, wherein the one reactive small molecule comprises a diol.
37. The reactive polyurethane adhesive composition of claim 33, further comprising 0 to 10 parts by weight of one or more additives, wherein the one or more additives are selected from the group consisting of: fillers, blocking agents, stabilizers, thixotropic materials, plasticizers, compatibilizers, colorants, UV stabilizers or flame retardants.
38. The reactive polyurethane adhesive composition of claim 1, wherein the polymer comprises urethane linkages derived from aliphatic polyisocyanates or wherein the polymer comprises urethane linkages derived from aromatic polyisocyanates.
39. An adhesive formulation comprising the reactive polyurethane adhesive composition of any one of claims 1 to 38.
40. The adhesive formulation of claim 39, wherein the formulation is a one-component adhesive.
41. The adhesive formulation of claim 39, wherein the formulation is a two-component formulation further comprising one or more aliphatic polycarbonate polyols.
42. The adhesive formulation of claim 39, wherein the formulation is a moisture-curing polyurethane hot melt formulation.
43. A method of joining two substrates comprising the steps of applying the adhesive formulation of any one of claims 39 to 42 to at least one substrate, arranging the substrates so that both substrates are in contact with the adhesive formulation, and curing the adhesive formulation.
Technical Field
The present invention relates to the field of polymers. More particularly, the present invention relates to polyurethane adhesives comprising aliphatic polycarbonate polyols derived from the copolymerization of epoxides and carbon dioxide. Polyurethane adhesives are used to form adhesive films and to join two substrates together.
Background
Polyurethane adhesives are the only urethane product group of widely varying composition and are used in many different applications and market segments. Typical product forms include reactive types (such as 1-component, 2-component and hot melt compositions) and non-reactive types (such as solvent-based, water-based and hot melt compositions among others).
Polyurethane adhesives are generally defined as those adhesives in which the molecular backbone of the polymer formed during inclusion or use contains multiple urethane groups regardless of the chemical composition of the remaining chains. Thus, typical urethane adhesives may contain aliphatic and aromatic hydrocarbon, ester, ether, amide, urea, and allophanate (allophonate) groups in addition to urethane linkages. The isocyanate groups react with the hydroxyl groups of the polyol to form repeating urethane linkages. The isocyanate will react with water to form urea linkages and carbon dioxide as by-products. Linear polyurethane adhesives can be obtained by using compounds having two reactive groups, such as diisocyanates and diols. When a polyol having three or more hydroxyl groups (i.e., a functionality of 3 or greater) is reacted with a polyisocyanate, or when an isocyanate having three or more isocyanate groups is reacted with a polyol, the resulting polymer is crosslinked. In reaction systems with excess isocyanate, crosslinking reactions may occur. Typically, excess isocyanate in the composition reacts with atmospheric moisture or moisture contained in the substrate.
One-part adhesives are typically viscous liquid isocyanate-terminated prepolymers at room temperature. By reacting the free isocyanate groups with atmospheric moisture or with moisture contained in the substrate to form polyurea groups. They generally do not need to be mixed with other components prior to curing. The prepolymer is prepared by reacting an excess of isocyanate with a polyol. If the functionality of the prepolymer is greater than 2, the cured film will be chemically crosslinked.
Two-component polyurethane adhesive compositions typically comprise components that are liquid or paste at room temperature prior to mixing together. The first component of the composition comprises polyols and other ingredients such as chain extenders, catalysts, blockers and other additives as desired. The second component comprises monomeric, polymeric or prepolymeric polyisocyanates. For bonding, the two components of the adhesive are mixed together completely and the composition is then applied to a substrate. The mixed composition then begins to cure and develop adhesive strength when converted to a solid form. A curing reaction occurs between the free isocyanate groups and the active hydrogens from the polyol. If excess free isocyanate groups are present after the primary curing reaction, the excess free isocyanate groups are cured by ambient or surface moisture from the substrate. The isocyanates and polyols employed may have a functionality of 2 or greater to provide crosslinking in the adhesive.
Reactive hot melt adhesives are characterized by readily meltable, usually solid or highly viscous polyisocyanate polyurethanes (NCO prepolymers) at room temperature. By physical (cooling) and chemical (by reaction with atmospheric moisture). Depending on the formulation, the reactive polyurethane hot melt adhesive cures to form an elastomer with a flexible to hard and tough adhesive layer. The prepolymers typically have a low free isocyanate content.
Non-reactive solvent-borne and water-borne adhesives typically consist of hydroxyl-terminated polyurethanes dissolved in a solvent. Polyurethanes are generally obtained by reacting diols with diisocyanates. The polymer solution is applied to the substrate surfaces to be bonded, allowing the solvent to evaporate for a period of time and the surfaces to be bonded together, at which time interdiffusion of the polymer chains will occur.
Non-reactive hot melt adhesives are generally composed of linear chains that are solid at room temperature and are often used in textile lamination, although they have many other applications. They are generally composed of hydroxyl-terminated polyurethanes which form adhesive bonds by cooling from the molten state. In some cases these are also referred to as thermoplastic polyurethane adhesives.
Polycarbonate polyols are commercially available in the polyurethane field. However, the commercial materials are structurally different from those used in the present invention as described below. Commercially available polycarbonate polyols are all derived from diols (such as 1, 4-butanediol, 1, 6-hexanediol, etc.) that react with phosgene (or a reactive equivalent) to produce carbonate linkages between diol units. No commercial polycarbonate polyols have only 2 carbon atoms between the carbonate linkages because the synthesis of such materials with phosgene chemistry is not possible because the reaction results in the formation of cyclic carbonates rather than polymers. The process for preparing these polyols is also not particularly green. Phosgene is toxic, diols are generally expensive and energy intensive to produce, and even non-phosgene based processes are energy intensive and expensive to operate.
Although expensive, the existing polycarbonate polyols are considered to have excellent strength and resistance to hydrolysis and UV radiation, and thus are used where high performance is required. Nevertheless, there is a need for inexpensive, green choices of these materials.
Disclosure of Invention
In one aspect, the invention encompasses compositions comprising a CO-derived polymer2Copolymerization with one or more epoxidesAnd an aliphatic polycarbonate polyol. In one aspect, the aliphatic polycarbonate polyol chain contains primary repeat units having the structure:
wherein R is1、R2、R3And R4Independently at each occurrence in the polymer chain, selected from-H, fluorine, optionally substituted C1-40Aliphatic radical, optionally substituted C1-20Heteroaliphatic and optionally substituted aryl, wherein R1、R2、R3And R4Any two or more of (a) may optionally form, together with intervening atoms, one or more optionally substituted rings optionally containing one or more heteroatoms.
As noted above, such polycarbonate polyols are distinct from existing commercial polycarbonate polyols that all have more than two bound carbon atoms between adjacent carbonate bonds. The polyols of the present invention thus have a higher density of carbonate functional groups/unit chain lengths. In certain embodiments, the incorporation of such polyols results in unique and unexpected characteristics in the resulting adhesive. In certain aspects, the adhesives of the present invention have unexpectedly superior properties compared to those based on existing commercially available polycarbonate polyols.
In certain embodiments, such aliphatic polycarbonate chains are derived from the copolymerization of carbon dioxide with one or more epoxide substrates. Such copolymerizations are exemplified in published PCT application WO2010/028362, the entire contents of which are incorporated herein by reference. In some embodiments, the aliphatic polycarbonate chains are derived from ethylene oxide, propylene oxide, or optionally substituted C3-30Aliphatic epoxides or mixtures of two or more of these. In some embodiments, the aliphatic polycarbonate chains have a number average molecular weight (Mn) of less than about 20,000 g/mol. In certain embodiments, the aliphatic polycarbonate polyol has a functionality of from about 1.8 to about 6.
In another aspect, the invention encompasses compositions comprising a plurality of epoxide-COs2-an isocyanate-terminated prepolymer of derived polyol segments linked by urethane linkages formed from reaction with a polyisocyanate compound.
In another embodiment, the invention includes a method for bonding two substrates together by contacting the adhesive composition of the invention with at least one substrate and contacting the substrates together along the portion where the adhesive is applied and allowing the adhesive to cure to bond the substrates together.
Definition of
The definitions of specific functional groups and chemical terms are described in more detail below. For the purposes of the present invention, the identification of chemical elements and specific functional groups according to the CAS version of the periodic Table of the elements, Handbook of Chemistry and Physics, 75 th edition, internal seal, is generally defined as described herein. In addition, the general principles of Organic Chemistry, as well as specific functional moieties and reactivity, are described in Organic Chemistry, Thomas Sorrell, University science Books, Sausaltito, 1999; smith and March March's Advanced Organic Chemistry, 5 th edition, John Wiley & Sons, Inc., New York, 2001; larock, Comprehensive organic transformations, VCH Publishers, Inc., New York, 1989; carrathers, Some modern methods of Organic Synthesis, 3 rd edition, Cambridge University Press, Cambridge, 1987; each of which is incorporated herein by reference in its entirety.
Certain compounds of the invention may contain one or more asymmetric centers and, thus, may exist in various stereoisomeric forms (e.g., enantiomers and/or diastereomers). Thus, the compounds of the present invention and compositions thereof may be in the form of individual enantiomers, diastereomers, or geometric isomers, or may be in the form of mixtures of stereoisomers. In certain embodiments, the compounds of the present invention are enantiomerically pure compounds. In certain embodiments, mixtures of enantiomers or diastereomers are provided.
Furthermore, as described herein, certain compounds may have one or more double bonds that may be present in either the Z or E isomer (unless otherwise indicated). The invention additionally encompasses compounds that are each isomer substantially free of the other isomer and, alternatively, are mixtures of the isomers (e.g., racemic mixtures of enantiomers). In addition to the above-mentioned compounds per se, the present invention also encompasses compositions comprising one or more compounds.
The term "isomer" as used herein includes any and all geometric isomers and stereoisomers. For example, "isomers" include cis and trans isomers, E-and Z-isomers, R-and S-enantiomers, diastereomers, (D) -isomers, (L) -isomers, racemic mixtures thereof, and other mixtures thereof as fall within the scope of the invention. For example, in some embodiments, stereoisomers may be provided that are substantially free of one or more corresponding stereoisomers and may also be referred to as "stereochemically enriched" stereoisomers.
In some embodiments, where a particular enantiomer is preferred, it may be provided substantially free of the opposite enantiomer and may also be referred to as "optically enriched". As used herein, "optically enriched" means that a compound or polymer is composed of a significantly larger proportion of one enantiomer. In certain embodiments, the compounds are made up of at least about 90% by weight of the preferred enantiomer. In other embodiments, the compound consists of at least about 95%, 98%, or 99% by weight of the preferred enantiomer. Preferred enantiomers may be isolated from racemic mixtures by any method known to those skilled in the art, including chiral High Pressure Liquid Chromatography (HPLC) and the formation and crystallization of chiral salts or prepared by asymmetric synthesis. See, e.g., Jacques, et al, eneriomers, Racemates and solutions (wiley interscience, New York, 1981); wilen, S.H., et al, Tetrahedron 33:2725 (1977); eliel, E.L. Stereochemistry of Carbon Compounds (McGraw-Hill, NY, 1962); wilen, S.H.tablet of solving Agents and Optical solutions, page 268 (E.L.Eliel, eds., Univ.of Notreddame Press, Notre Dame, IN 1972).
The term "epoxide" as used herein refers to a substituted or unsubstituted oxirane. Such substituted oxiranes include mono-substituted oxiranes, di-substituted oxiranes, tri-substituted oxiranes and tetra-substituted oxiranes. Such epoxides may be further optionally substituted as defined herein. In certain embodiments, the epoxide comprises a single oxirane moiety. In certain embodiments, the epoxide comprises two or more ethylene oxide moieties.
As used herein, the term "polymer" refers to a relatively high molecular mass molecule whose structure comprises a plurality of repeat units derived, actually or conceptually, from molecules of low relative molecular mass. In certain embodiments, the polymer is derived from CO2In some embodiments, the polymers of the present invention are copolymers, terpolymers, heteropolymers, block copolymers, or tapered heteropolymers that incorporate two or more different epoxide monomers
The terms "halo" and "halogen" as used herein refer to an atom selected from the group consisting of fluorine (fluoro, -F), chlorine (chloro, -Cl), bromine (bromo, -Br) and iodine (iodo, -I).
The term "aliphatic" or "aliphatic group" as used herein denotes a hydrocarbon moiety that may be straight-chain (i.e., unbranched), branched, or cyclic (including fused, bridged, and spiro-fused polycyclic) and may be fully saturated or may contain one or more units of unsaturation, but which is not aromatic. Unless otherwise specified, aliphatic groups contain 1-40 carbon atoms. In certain embodiments, aliphatic groups contain 1 to 20 carbon atoms. In certain embodiments, aliphatic groups contain 3 to 20 carbon atoms. In certain embodiments, aliphatic groups contain 1-12 carbon atoms. In certain embodiments, aliphatic groups contain 1 to 8 carbon atoms. In certain embodiments, aliphatic groups contain 1-6 carbon atoms. In some embodiments, aliphatic groups contain 1 to 5 carbon atoms, in some embodiments, aliphatic groups contain 1 to 4 carbon atoms, in some embodiments, aliphatic groups contain 1 to 3 carbon atoms, and in some embodiments, aliphatic groups contain 1 or 2 carbon atoms. Suitable aliphatic groups include, but are not limited to, straight or branched chain alkyl, alkenyl, and alkynyl groups, and mixtures thereof such as (cycloalkyl) alkyl, (cycloalkenyl) alkyl, or (cycloalkyl) alkenyl.
The term "heteroaliphatic", as used herein, refers to an aliphatic group in which one or more carbon atoms are independently replaced by one or more atoms selected from oxygen, sulfur, nitrogen, or phosphorus. In certain embodiments, one to six carbon atoms are independently replaced with one or more of oxygen, sulfur, nitrogen, or phosphorus. The heteroaliphatic group can be substituted or unsubstituted, branched or unbranched, cyclic or acyclic and includes saturated, unsaturated, or partially unsaturated groups.
The term "divalent C" as used herein1-8(or C)1-3) Saturated or unsaturated, linear or branched hydrocarbon chain "refers to divalent alkyl, alkenyl and alkynyl chains as defined herein as linear or branched.
The term "unsaturated" as used herein means that the moiety has one or more double or triple bonds.
The terms "alicyclic", "carbocyclic" or "carbocyclic" used alone or as part of a larger moiety refer to saturated or partially unsaturated cyclic aliphatic monocyclic or polycyclic ring systems having 3 to 12 members, as described herein, wherein the aliphatic ring system is optionally substituted as defined above and described herein. Cycloaliphatic radicals include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclopentenyl, cyclohexyl, cyclohexenyl, cycloheptyl, cycloheptenyl, cyclooctyl, cyclooctenyl, norbornyl, adamantyl, and cyclooctadienyl. In thatIn some embodiments, the cycloalkyl group has 3-6 carbons. The terms "alicyclic," "carbocyclic," or "carbocyclic" also include aliphatic rings that are fused to one or more aromatic or non-aromatic rings, such as decahydronaphthyl or tetrahydronaphthyl, where the attachment group or point is on the aliphatic ring. In certain embodiments, the term "3-to 7-membered carbocycle" refers to a 3-to 7-membered saturated or partially unsaturated monocyclic carbocycle. In certain embodiments, the term "3-to 8-membered carbocycle" refers to a 3-to 8-membered saturated or partially unsaturated monocyclic carbocycle. In certain embodiments, the terms "3 to 14 membered carbocycle" and "C3-14Carbocycle "refers to a 3-to 8-membered saturated or partially unsaturated monocyclic carbocycle, or a 7-to 14-membered saturated or partially unsaturated polycyclic carbocycle.
The term "alkyl" as used herein refers to a saturated, straight or branched chain hydrocarbon radical derived from aliphatic moieties, said alkyl radical containing from one to six carbon atoms by removal of a single hydrogen atom. Unless otherwise specified, aliphatic groups contain 1-12 carbon atoms. In certain embodiments, the alkyl group contains 1 to 8 carbon atoms. In certain embodiments, the alkyl group contains 1 to 6 carbon atoms. In some embodiments, the alkyl group contains 1 to 5 carbon atoms, in some embodiments, the alkyl group contains 1 to 4 carbon atoms, in some embodiments, the alkyl group contains 1 to 3 carbon atoms, and in some embodiments, the alkyl group contains 1 to 2 carbon atoms. Examples of alkyl groups include, but are not limited to, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, sec-pentyl, isopentyl, tert-butyl, n-pentyl, neopentyl, n-hexyl, sec-hexyl, n-heptyl, n-octyl, n-decyl, n-undecyl, dodecyl and the like.
The term "alkenyl" as used herein refers to a monovalent group derived from a straight or branched aliphatic moiety, said alkenyl having at least one carbon-carbon double bond by the removal of a single hydrogen atom. Unless otherwise indicated, alkenyl groups contain 2 to 12 carbon atoms. In certain embodiments, alkenyl groups contain 2 to 8 carbon atoms. In certain embodiments, alkenyl groups contain 2 to 6 carbon atoms. In some embodiments, alkenyl groups contain 2 to 5 carbon atoms, in some embodiments alkenyl groups contain 2 to 4 carbon atoms, in some embodiments alkenyl groups contain 2 to 3 carbon atoms, and in some embodiments alkenyl groups contain 2 carbon atoms. Alkenyl groups include, for example, ethenyl, propenyl, butenyl, 1-methyl-2-buten-1-yl, and the like.
The term "alkynyl" as used herein refers to a monovalent group derived from a straight or branched chain aliphatic moiety having at least one carbon-carbon triple bond by the removal of a single hydrogen atom. Unless otherwise indicated, alkynyl groups contain 2-12 carbon atoms. In certain embodiments, alkynyl groups contain 2-8 carbon atoms. In certain embodiments, alkynyl groups contain 2-6 carbon atoms. In some embodiments, alkynyl groups contain 2-5 carbon atoms, in some embodiments alkynyl groups contain 2-4 carbon atoms, in some embodiments alkynyl groups contain 2-3 carbon atoms, and in some embodiments alkynyl groups contain 2 carbon atoms. Representative alkynyl groups include, but are not limited to, ethynyl, 2-propynyl (propargyl), 1-propynyl, and the like.
The term "alkoxy," as used herein, refers to an alkyl group, as previously defined, attached to the parent molecule through an oxygen atom. Examples of alkoxy groups include, but are not limited to, methoxy, ethoxy, propoxy, isopropoxy, n-butoxy, tert-butoxy, neopentyloxy, and n-hexyloxy.
The term "acyl", as used herein, refers to a carbonyl-containing functional group, e.g., -C (═ O) R ', where R' is hydrogen or an optionally substituted aliphatic, heteroaliphatic, heterocyclic, aryl, heteroaryl group, or an oxygen-or nitrogen-containing functional group (e.g., forming a carboxylic acid, ester, or amide functional group) that is substituted (e.g., with hydrogen or an aliphatic, heteroaliphatic, aryl, or heteroaryl moiety). The term "acyloxy", as used herein, refers to an acyl group attached to the parent molecule through an oxygen atom.
The term "aryl", used alone or as part of a larger moiety in "aralkyl", "aralkoxy", or "aryloxyalkyl", refers to monocyclic and polycyclic ring systems having a total of 5 to 20 ring members, wherein at least one ring in the system is aromatic and whereinEach ring in the system contains three to twelve ring members. The term "aryl" may be used interchangeably with the term "aryl ring". In certain embodiments of the present invention, "aryl" refers to an aromatic ring system, including but not limited to phenyl, biphenyl, naphthyl, anthracenyl, and the like, which may have one or more substituents. Also included within the scope of the term "aryl" as used herein are groups in which an aromatic ring is fused to one or more additional rings, such as benzofuranyl, indanyl, phthalimidyl, tetrahydronaphthyl, or the like. In certain embodiments, the terms "6 to 10 membered aryl" and "C6-10Aryl "refers to a phenyl or 8 to 10 membered polycyclic aryl ring.
The terms "heteroaryl" and "heteroar-" used alone or as part of a larger moiety (such as "heteroaralkyl" or "heteroaralkoxy") refer to groups having from 5 to 14 ring atoms, preferably 5, 6, or 9 ring atoms; having 6, 10 or 14 pi electrons in common on a ring system (cyclic array); and has one to five heteroatoms in addition to carbon atoms. The term "heteroatom" refers to nitrogen, oxygen or sulfur and includes any oxidized form of nitrogen or sulfur and any quaternized form of basic nitrogen. Heteroaryl groups include, but are not limited to, thienyl, furyl, pyrrolyl, imidazolyl, pyrazolyl, triazolyl, tetrazolyl, oxazolyl, isoxazolyl, oxadiazolyl, thiazolyl, isothiazolyl, thiadiazolyl, pyridyl, pyridazinyl, pyrimidinyl, pyrazinyl, indolizinyl, purinyl, naphthyridinyl, benzofuryl, and pteridinyl. The terms "heteroaryl" and "heteroar-" as used herein also include groups in which a heteroaromatic ring is fused to one or more aryl, alicyclic or heterocyclic rings, where the attachment group or point is on the heteroaromatic ring. Non-limiting examples include indolyl, isoindolyl, benzothienyl, benzofuranyl, dibenzofuranyl, indazolyl, benzimidazolyl, benzothiazolyl, quinolinyl, isoquinolinyl, cinnolinyl, phthalazinyl, quinazolinyl, quinoxalinyl, 4H-quinolizinyl, carbazolyl, acridinyl, phenazinyl, phenothiazinyl, phenoxazinyl, tetrahydroquinolyl, tetrahydroisoquinolyl, and pyrido [2, 3-b ] -1, 4-oxazin-3 (4H) -one. Heteroaryl groups may be monocyclic-or bicyclic. The term "heteroaryl" may be used interchangeably with the terms "heteroaryl ring", "heteroaryl group" or "heteroaromatic", any of these terms including optionally substituted rings. The term "heteroaralkyl" refers to an alkyl group substituted with a heteroaryl group, wherein the alkyl and heteroaryl portions are independently optionally substituted. In certain embodiments, the term "5-to 10-membered heteroaryl" refers to a 5-to 6-membered heteroaryl ring having 1 to 3 heteroatoms independently selected from nitrogen, oxygen, or sulfur, or an 8-to 10-membered bicyclic heteroaryl ring having 1 to 4 heteroatoms independently selected from nitrogen, oxygen, or sulfur. In certain embodiments, the term "5-to 12-membered heteroaryl" refers to a 5-to 6-membered heteroaryl ring having 1 to 3 heteroatoms independently selected from nitrogen, oxygen, or sulfur, or an 8-to 12-membered bicyclic heteroaryl ring having 1 to 4 heteroatoms independently selected from nitrogen, oxygen, or sulfur.
The terms "heterocycle", "heterocyclyl" and "heterocyclic ring" are used interchangeably herein and refer to a stable 5-to 7-membered monocyclic or 7-to 14-membered polycyclic heterocyclic moiety which may be saturated or partially unsaturated and which has one or more, preferably one to four, heteroatoms in addition to carbon atoms, as defined above. When used in reference to a ring atom of a heterocyclic ring, the term "nitrogen" includes substituted nitrogens. For example, in a saturated or partially unsaturated ring having 0-3 nitrogen atoms selected from oxygen, sulfur or nitrogen heteroatoms, the nitrogen may be N (as in 3, 4-dihydro-2H-pyrrolyl), NH (as in pyrrolidinyl) or+NR (as in N-substituted pyrrolidinyl). In some embodiments, the term "3-to 7-membered heterocyclic ring" refers to a 3-to 7-membered saturated or partially unsaturated monocyclic heterocyclic ring having 1 to 2 heteroatoms independently selected from nitrogen, oxygen, or sulfur. In some embodiments, the term "3 to 12 membered heterocyclic ring" refers to a 3 to 8 membered saturated or partially unsaturated monocyclic heterocyclic ring having 1 to 2 heteroatoms independently selected from nitrogen, oxygen, or sulfur, or a 7 to 12 membered saturated or partially unsaturated polycyclic heterocyclic ring having 1-3 heteroatoms independently selected from nitrogen, oxygen, or sulfur.
The heterocyclic ring may be attached to its pendant group at any heteroatom or carbon atom that results in a stable structure and any of the ring atoms may be optionally substituted. Examples of such saturated or partially unsaturated heterocyclyl groups include, but are not limited to, tetrahydrofuranyl, tetrahydrothienyl, pyrrolidinyl, pyrrolidinonyl, piperidinyl, pyrrolinyl, tetrahydroquinolinyl, tetrahydroisoquinolinyl, decahydroquinolinyl, oxazolidinyl, piperazinyl, dioxanyl, dioxolanyl, diazepinyl, oxazepinyl, thiazepinyl, morpholinyl, and quinuclidinyl. The terms "heterocycle", "heterocyclyl ring", "heterocyclic group", "heterocyclic moiety" and "heterocyclic group" are used interchangeably herein and also include groups in which the heterocyclyl ring is fused to one or more aryl, heteroaryl or alicyclic rings, such as indolinyl, 3H-indolyl, chromanyl, phenanthridine or tetrahydroquinolinyl, wherein the attachment group or point is on the heterocyclyl ring. The heterocyclic group may be monocyclic or bicyclic. The term "heterocyclylalkyl" refers to an alkyl group substituted with a heterocyclyl, wherein the alkyl portion and the heterocyclyl portion are independently optionally substituted.
The term "partially unsaturated" as used herein refers to a cyclic moiety comprising at least one double or triple bond. The term "partially unsaturated" is intended to encompass rings having multiple sites of unsaturation, but is not intended to include aryl or heteroaryl moieties, as defined herein.
As described herein, the compounds of the present invention may contain "optionally substituted" moieties. Generally, the term "substituted" whether preceded by the term "optionally" or not, means that one or more hydrogens of the designated moiety are replaced with a suitable substituent. Unless otherwise indicated, an "optionally substituted" group may have suitable substituents at each substitutable position of the group, and when more than one position in any given structure may be substituted with more than one substituent selected from a specified group, the substituents at each position may be the same or different. The combinations of substituents envisaged by the present invention are preferably those which allow the formation of stable or chemically feasible compounds. As used herein, the term "stable" refers to a compound that does not substantially change when subjected to the following conditions: when it is produced, tested, and (in certain embodiments) recovered, purified, and used for one or more of the purposes disclosed herein.
Suitable monovalent substituents on the substitutable carbon atom of an "optionally substituted" group are independently halogen; - (CH)2)0–4Ro；–(CH2)0–4ORo；–O–(CH2)0–4C(O)ORo；–(CH2)0–4CH(ORo)2；–(CH2)0–4SRo；–(CH2)0–4Ph, which may be represented by RoSubstitution; - (CH)2)0–4O(CH2)0–1Ph, which may be represented by RoSubstitution; -CH ═ CHPh, which may be substituted by RoSubstitution; -NO2；–CN；–N3；–(CH2)0–4N(Ro)2；–(CH2)0–4N(Ro)C(O)Ro；–N(Ro)C(S)Ro；–(CH2)0–4N(Ro)C(O)NRo 2；–N(Ro)C(S)NRo 2；–(CH2)0–4N(Ro)C(O)ORo；–N(Ro)N(Ro)C(O)Ro；–N(Ro)N(Ro)C(O)NRo 2；–N(Ro)N(Ro)C(O)ORo；–(CH2)0–4C(O)Ro；–C(S)Ro；–(CH2)0–4C(O)ORo；–(CH2)0–4C(O)N(Ro)2；–(CH2)0–4C(O)SRo；–(CH2)0–4C(O)OSiRo 3；–(CH2)0–4OC(O)Ro；–OC(O)(CH2)0–4SR–，SC(S)SRo；–(CH2)0–4SC(O)Ro；–(CH2)0–4C(O)NRo 2；–C(S)NRo 2；–C(S)SRo；–SC(S)SRo，–(CH2)0–4OC(O)NRo 2；–C(O)N(ORo)Ro；–C(O)C(O)Ro；–C(O)CH2C(O)Ro；–C(NORo)Ro；–(CH2)0–4SSRo；–(CH2)0–4S(O)2Ro；–(CH2)0–4S(O)2ORo；–(CH2)0–4OS(O)2Ro；–S(O)2NRo 2；–(CH2)0–4S(O)Ro；–N(Ro)S(O)2NRo 2；–N(Ro)S(O)2Ro；–N(ORo)Ro；–C(NH)NRo 2；–P(O)2Ro；–P(O)Ro 2；–OP(O)Ro 2；–OP(O)(ORo)2；SiRo 3；–(C1–4Straight or branched alkylene) O-N (R)o)2(ii) a Or- (C)1–4Straight or branched alkylene) C (O) O-N (R)o)2Wherein each R isoMay be substituted as defined below and independently is hydrogen, C1–8Aliphatic, -CH2Ph、–O(CH2)0–1Ph or a 5-6 membered saturated, partially unsaturated, or aryl ring having 0-4 heteroatoms independently selected from nitrogen, oxygen, or sulfur, or two independently occurring R's despite the definitions given aboveoTogether with their intervening atom(s) form a 3-12 membered saturated, partially unsaturated or aryl monocyclic or polycyclic ring having 0-4 heteroatoms independently selected from nitrogen, oxygen or sulfur, which R may be substituted as defined below.
At Ro(or two independently occurring RoA ring formed together with their intervening atoms) are independently halogen, - (CH)2)0–2R·- (halogeno radical R)·)、–(CH2)0–2OH、–(CH2)0–2OR·、–(CH2)0–2CH(OR·)2(ii) a -O (halo R)·)、–CN、–N3、–(CH2)0–2C(O)R·、–(CH2)0–2C(O)OH、–(CH2)0–2C(O)OR·、–(CH2)0–4C(O)N(Ro)2；–(CH2)0–2SR·、–(CH2)0–2SH、–(CH2)0–2NH2、–(CH2)0–2NHR·、–(CH2)0–2NR· 2、–NO2、–SiR· 3、–OSiR· 3、–C(O)SR·、–(C1–4Straight OR branched alkylene) C (O) OR·or-SSR·Wherein each R is·Is unsubstituted or substituted, if preceded by "halo", only by one or more halogens and is independently selected from C1–4Aliphatic, -CH2Ph、–O(CH2)0–1Ph or a 5-6 membered saturated, partially unsaturated or aryl ring having 0-4 heteroatoms independently selected from nitrogen, oxygen or sulfur. At RoSuitable divalent substituents on the saturated carbon atom of (a) include ═ O and ═ S.
Suitable divalent substituents on the saturated carbon atom of the "optionally substituted" group include the following: is one of O, S and NNR* 2、＝NNHC(O)R*、＝NNHC(O)OR*、＝NNHS(O)2R*、＝NR*、＝NOR*、–O(C(R* 2))2–3O-or-S (C (R)* 2))2–3S-, wherein each independently occurs R*Selected from hydrogen, C1–6Aliphatic (which may be substituted as defined below) or unsubstituted 5-6 membered saturated, partially unsaturated or aryl ring having 0-4 heteroatoms independently selected from nitrogen, oxygen or sulfur. Suitable divalent substituents bound to the carbon substitutable at the ortho position of the "optionally substituted" group include: -O (CR)* 2)2–3O-, whichEach independently occurring R in*Selected from hydrogen, C1–6Aliphatic (which may be substituted as defined below) or unsubstituted 5-6 membered saturated, partially unsaturated or aryl ring having 0-4 heteroatoms independently selected from nitrogen, oxygen or sulfur.
R*Suitable substituents on the aliphatic radical of (A) include halogen, -R·- (halogeno radical R)·)、–OH、–OR·-O (halo R)·)、–CN、–C(O)OH、–C(O)OR·、–NH2、–NHR·、–NR· 2or-NO2Wherein each R is·Is unsubstituted or substituted, if preceded by "halo", only by one or more halogen, and is independently C1–4Aliphatic, -CH2Ph、–O(CH2)0–1Ph or a 5-6 membered saturated, partially unsaturated or aryl ring having 0-4 heteroatoms independently selected from nitrogen, oxygen or sulfur.
Suitable substituents on the substitutable nitrogen atom of the "optionally substituted" group include
When substituents are described herein, the term "group" or "optionally substituted group" is sometimes used. In this context, "group" means a moiety or functional group having available positions for attachment to a structure to which a substituent is bound. Typically, if the substituent is a separate neutral molecule than the substituent, then the point of attachment will have a hydrogen atom. Thus, the term "group" or "optionally substituted group" may be used interchangeably in this context with "group" or "optionally substituted group".
The term "head-to-tail" or "HT" as used herein refers to the regioselection of adjacent repeat units in a polymer chain. For example, in the poly (propylene carbonate) (PPC) herein, the term "head-to-tail" based on three regioselection possibilities is as follows:
the term "head-to-tail ratio (H: T) refers to the ratio of head-to-tail bonds to the sum of all other region selection possibilities. With respect to the description of the polymer structure, while specific regioselective orientations of the monomer units may be shown for the polymer structures herein, this is not intended to limit the polymer structure to the regioselective arrangements shown, but unless otherwise specified, should be construed to encompass all regioselective arrangements, including the regioselective arrangements described, the opposite regioselectivity, random mixtures, isotactic materials, syndiotactic materials, racemic materials, and/or enantiomerically enriched materials, and combinations of any of these.
The term "alkoxylated" as used herein means that one or more functional groups (typically, but not strictly limited to alcohols, amines or carboxylic acids) on the molecule have a hydroxyl-terminated alkyl chain attached thereto. The alkoxylated compounds may contain a single alkyl group or they may be oligomeric moieties such as hydroxyl terminated polyethers. The alkoxylate species may be derived from the parent compound by treating the functional group with an epoxide.
The term "isocyanate coefficient" as used herein means the excess isocyanate over a theoretical amount, expressed as a percentage (i.e. 1:1 ═ 100), for reaction with all active protons in the polyurethane composition (1: 1). Thus, the isocyanate index is 100 × (amount of isocyanate actually used)/(theoretical amount of isocyanate required)
Drawings
Figure 1 shows the hardness and tensile strength of the adhesive composition of the invention compared to adhesive formulations based on commercially available polyester or polycarbonate polyols.
Fig. 2 shows a spider graph (spider graph) representing several properties of the adhesive composition of the invention compared to a commercial polycarbonate polyol-based adhesive formulation.
Fig. 3 illustrates the bonding of a series of substrates of the adhesive composition of the invention.
Fig. 4 shows the strength retention at elevated temperatures for the adhesive compositions of the invention compared to adhesive formulations based on commercially available polyester or polycarbonate polyols.
Fig. 5 shows the solvent resistance of the adhesive composition of the invention compared to adhesive formulations based on commercially available polyester or polycarbonate polyols.
Fig. 6 shows the chemical resistance properties of the adhesive composition of the invention.
Fig. 7 shows the transparency of the polyurethane compositions of the present invention compared to formulations based on commercial polycarbonate polyols.
Fig. 8 shows the strength and elongation of several blended adhesive formulations of the present invention.
Fig. 9 shows the ASTM D412 tensile test for the adhesive of example 2.
Fig. 10 shows the ASTM D412 tensile test for the adhesive of example 5.
FIG. 11 shows the ASTM D624-Die C tear test for the adhesive of example 5.
Fig. 12 shows the ASTM D1938 tear test for the adhesive of example 5.
Fig. 13 shows the peel test of the PPC-containing adhesive of example 6.
Fig. 14 shows the peel test of the control adhesive from example 6 without the PPC polyol.
Detailed Description
In one aspect, the invention encompasses polymer compositions comprising aliphatic polycarbonates crosslinked or chain extended by urethane linkages. In certain embodiments, these polymer compositions comprise a polyurethane binder.
The field of polyurethane manufacture and formulation is well developed. In some embodiments, the novel materials presented herein are formulated, processed, and/or used according to methods well known in the art. Variations, modifications, and applications of the compositions and methods of the present invention will be apparent to the skilled artisan upon combination of knowledge in the art with the disclosure and teachings herein, and such variations are expressly contemplated herein. The following references generally contain information on the formulation, manufacture, and use of polyurethane adhesives, and the entire contents of each of these references are incorporated herein by reference.
Polyurethanes：Coatings Adhesives and Sealants，Ulrich Maeier-Westhues，2007(ISBN3-87870-334-1)
The Polyurethanes Book，J.Wiley&Sons，2003(ISBN 978-0470850411)
Szycher’s Handbook of Polyurethanes，CRC Press LLC，1999(ISBN0-8493-0602-7)
Poyurethane Elastomers：From Morphology to Mechanical Asoects，Springer-Verlag/Wein，2011(ISBN978-3-7091-0513-9)
Szycher’s Handbook of Polyurethanes，CRC Press LLC，1999(ISBN 0-8493-0602-7)
Polyurethane Handbook，Hanser，1994(ISBN 1569901570)
In certain embodiments, the polyurethane compositions of the present invention are obtained by combining two compositions: a first composition comprising one or more isocyanate compounds optionally containing diluents, solvents, co-reactants, and the like and a second composition comprising one or more aliphatic polycarbonate polyols optionally with additional reactants, solvents, catalysts, or additives. These compositions may be formulated separately and then combined, or all of the components of the finished polyurethane composition may be combined in a single step. Before these compositions are fully described, the polyols and isocyanates with which they are formulated will be more fully described.
I. Aliphatic polycarbonate polyols
This section describes some aliphatic polycarbonate polyols that have utility in preparing the compositions of the present invention. In certain embodiments, the compositions of the present invention comprise aliphatic polycarbonate polyols derived from the copolymerization of one or more epoxides and carbon dioxide. Examples of suitable polyols and methods of making the same are disclosed in PCT publication WO2010/028362, which is incorporated herein by reference in its entirety.
It is advantageous for many of the embodiments described herein that the aliphatic polycarbonate polyols used have a high percentage of reactive end groups. Such reactive end groups are typically hydroxyl groups, but if the polyol is treated to modify the chemistry of the end groups, other reactive functional groups may be present and such modifying materials may be terminated with amino groups, thiol groups, alkene groups, carboxyl groups, isocyanate groups, silyl groups, epoxy groups, and the like. For the purposes of the present invention, the term 'aliphatic polycarbonate polyols' includes conventional hydroxyl-terminated materials as well as compositions modified with such end groups.
In certain embodiments, at least 90% of the end groups of the polycarbonate polyol used are reactive end groups. In certain embodiments, at least 95%, at least 96%, at least 97%, or at least 98% of the end groups of the polycarbonate polyol used are reactive end groups. In certain embodiments, greater than 99%, greater than 99.5%, greater than 99.7%, or greater than 99.8% of the end groups of the polycarbonate polyol used are reactive end groups. In certain embodiments, greater than 99.9% of the end groups of the polycarbonate polyol used are reactive end groups.
In certain embodiments, at least 90% of the terminal groups of the polycarbonate polyols used are-OH groups. In certain embodiments, at least 95%, at least 96%, at least 97%, or at least 98% of the end groups of the polycarbonate polyol used are-OH groups. In certain embodiments, greater than 99%, greater than 99.5%, greater than 99.7%, or greater than 99.8% of the end groups of the polycarbonate polyol used are-OH groups. In certain embodiments, greater than 99.9% of the terminal groups of the polycarbonate polyol used are-OH groups.
Another way to express the-OH end group content of a polyol composition is to report its OH #, as measured using methods well known in the art. In certain embodiments, the aliphatic polycarbonate polyols used in the present invention have an OH # greater than about 20. In certain embodiments, the aliphatic polycarbonate polyols utilized in the present invention have an OH # greater than about 40. In certain embodiments, the aliphatic polycarbonate polyol has an OH # greater than about 50, greater than about 75, greater than about 100, or greater than about 120.
In certain embodiments, it is advantageous if the aliphatic polycarbonate polyol composition has a substantial proportion of primary hydroxyl end groups. This is normal for compositions comprising poly (ethylene carbonate),but for substituted epoxides with CO2In some embodiments, such polyols are treated to increase the proportion of primary-OH end groups this may be accomplished by reacting the secondary hydroxyl groups with reagents such as ethylene oxide, reactive lactones, etc. in some embodiments, the aliphatic polycarbonate polyol is treated with β lactone, caprolactone, etc. to introduce primary hydroxyl end groups.
In certain embodiments, the aliphatic polycarbonate chains comprise a copolymer of carbon dioxide and one or more epoxides. In certain embodiments, the aliphatic polycarbonate chains comprise a copolymer of carbon dioxide and ethylene oxide. In certain embodiments, the aliphatic polycarbonate chains comprise a copolymer of carbon dioxide and propylene oxide. In certain embodiments, the aliphatic polycarbonate chains comprise a copolymer of carbon dioxide and 1, 2-butylene oxide and/or 1, 2-hexylene oxide. In certain embodiments, the aliphatic polycarbonate chains comprise a copolymer of carbon dioxide and epoxycyclohexane. In certain embodiments, the aliphatic polycarbonate chains comprise a copolymer of carbon dioxide and cyclopentane epoxide. In certain embodiments, the aliphatic polycarbonate chains comprise a copolymer of carbon dioxide and 3-vinyl epoxycyclohexane. In certain embodiments, the aliphatic polycarbonate chains comprise a copolymer of carbon dioxide and 3-ethylepoxycyclohexane.
In certain embodiments, the aliphatic polycarbonate chains comprise a terpolymer of carbon dioxide and ethylene oxide together with one or more additional epoxides selected from the group consisting of propylene oxide, 1, 2-butylene oxide, 2, 3-butylene oxide, cyclohexane oxide, 3-vinyl cyclohexane oxide, 3-ethylcyclohexane oxide, cyclopentane oxide, epichlorohydrin, glycidyl esters, glycidyl ethers, styrene oxide, and higher α olefins.
In embodiments, the aliphatic polycarbonate chains comprise a copolymer of carbon dioxide and propylene oxide together with one or more additional epoxides selected from the group consisting of ethylene oxide, 1, 2-butylene oxide, 2, 3-butylene oxide, cyclohexane oxide, 3-vinylcyclohexene oxide, cyclopentane oxide, epichlorohydrin, glycidyl esters, glycidyl ethers, styrene oxide, and higher α olefins.
In certain embodiments, the polymer compositions described aboveWherein the aliphatic polycarbonate chains have a number average molecular weight (M) in the range of from 500g/mol to about 250,000g/moln)。
In certain embodiments, the aliphatic polycarbonate chains have a M of less than about 100,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of less than about 70,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of less than about 50,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of from about 500g/mol to about 40,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of less than about 25,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of from about 500g/mol to about 20,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of from about 500g/mol to about 10,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of from about 500g/mol to about 5,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of from about 1,000g/mol to about 5,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of from about 5,000g/mol to about 10,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of from about 500g/mol to about 1,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of from about 1,000g/mol to about 3,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of about 5,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of about 4,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of about 3,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of about 2,500g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of about 2,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of about 1,500g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of about 1,000g/moln. In certain embodiments, the aliphatic polycarbonate chains have a M of about 750g/moln. In certain embodiments, aliphatic polycarbonsThe acid ester chain has a M of about 500g/moln。
In certain embodiments, the aliphatic polycarbonate polyols used are characterized in that they have a narrow molecular weight distribution. This may be indicated by the polydispersity index (PDI) of the aliphatic polycarbonate polymer. In certain embodiments, the aliphatic polycarbonate composition has a PDI of less than 3. In certain embodiments, the aliphatic polycarbonate composition has a PDI of less than 2. In certain embodiments, the aliphatic polycarbonate composition has a PDI of less than 1.8. In certain embodiments, the aliphatic polycarbonate composition has a PDI of less than 1.5. In certain embodiments, the aliphatic polycarbonate composition has a PDI of less than 1.4. In certain embodiments, the aliphatic polycarbonate composition has a PDI of about 1.0 to 1.2. In certain embodiments, the aliphatic polycarbonate composition has a PDI of about 1.0 to 1.1.
In certain embodiments, the aliphatic polycarbonate compositions used do not have narrow PDI. If, for example, a polydisperse chain transfer agent is used to initiate epoxide CO2This may be the case if a plurality of aliphatic polycarbonate polyol compositions having different molecular weights are blended. In certain embodiments, the aliphatic polycarbonate composition has a PDI greater than 3. In certain embodiments, the aliphatic polycarbonate composition has a PDI greater than 2. In certain embodiments, the aliphatic polycarbonate composition has a PDI greater than 1.8. In certain embodiments, the aliphatic polycarbonate composition has a PDI greater than 1.5. In certain embodiments, the aliphatic polycarbonate composition has a PDI greater than 1.4.
In certain embodiments, the aliphatic polycarbonate compositions of the present invention comprise substantially alternating polymers having a high percentage of carbonate linkages and a low content of ether linkages. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 85% or more. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 90% or more. In certain embodiments, the aliphatic polycarbons of the present inventionThe acid ester composition is characterized by an average percentage of carbonate linkages in the composition of 91% or more. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 92% or more. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 93% or more. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 94% or more. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 95% or greater. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 96% or more. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 97% or more. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 98% or more. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 99% or more. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized by an average percentage of carbonate linkages in the composition of 99.5% or greater. In certain embodiments, the above percentages exclude ether linkages present in the polymerization initiator or chain transfer agent and refer to epoxide CO only2Bonds formed during the copolymerization.
In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized in that they are prepared from an epoxide CO2The resulting polymer is substantially free of ether linkages within the polymer chain or within any polymerization initiator, chain transfer agent or end groups that may be present in the polymer. In certain embodiments, the aliphatic polycarbonate compositions of the present invention are characterized in that they contain, on average, less than one ether linkage per polymer chain in the composition. In certain embodiments, the aliphatic poly of the present inventionThe carbonate compositions are characterized in that they are substantially free of ether linkages.
In certain embodiments, where the aliphatic polycarbonate is derived from a mono-substituted epoxide (e.g., such as propylene oxide, 1, 2-butylene oxide, epichlorohydrin, epoxidized α olefin, or a glycidyl derivative), the aliphatic polycarbonate is characterized by its stereoregularity the stereoregularity may be expressed as a percentage of adjacent monomer units that are positioned in a head-to-tail arrangement within the polymer chain.
In certain embodiments, the compositions of the present invention comprise an aliphatic polycarbonate polyol having the following structure P1:
wherein the content of the first and second substances,
R1、R2、R3and R4Independently at each occurrence in the polymer chain, selected from-H, fluorine, optionally substituted C1-30Aliphatic radical and optionally substituted C1-40Heteroaliphatic radicals and optionally substituted aryl radicals, where R1、R2、R3And R4Any two or more of (a) may optionally form, together with intervening atoms, one or more optionally substituted rings optionally containing one or more heteroatoms;
y, at each occurrence, is independently-H, a reactive group (as defined above), or a site attached to any chain extension or isocyanate described in classes and subclasses herein;
n, at each occurrence, is independently an integer from about 2 to about 50;
is a bond or a multivalent moiety; and
x and y are each independently integers from 0 to 6, wherein the sum of x and y is from 2 to 6.
In certain embodiments, multivalent moieties are embedded within the aliphatic polycarbonate chain
In certain embodiments, the multifunctional chain transfer agent has the formula:
wherein each one
In certain embodiments, the aliphatic polycarbonate chains in the polymer compositions of the present invention are derived from copolymerizing one or more epoxides with carbon dioxide in the presence of such multifunctional chain transfer agents as shown in scheme 2:
In certain embodiments, the aliphatic polycarbonate chains in the polymer composition of the present invention comprise chains having the following structure P2:
wherein each R1、R2、R3、R4、Y、
In certain embodiments, wherein the aliphatic polycarbonate chains have the structure P2,
in certain embodiments, wherein
In certain embodiments, whereinDerived from a diol selected from the group consisting of: diethylene glycol, triethylene glycol, tetraethylene glycol, higher poly (ethylene glycols) such as those having a number average molecular weight of 220 to about 2000g/mol, dipropylene glycol, tripropylene glycol, and higher poly (propylene glycols) such as those having a number average molecular weight of 234 to about 2000 g/mol.
In certain embodiments, wherein
In certain embodiments, wherein
In some embodiments of the present invention, the substrate is,
wherein each R1、R2、R3、R4、Y、
In certain embodiments, wherein
In some embodiments of the present invention, the substrate is,
In certain embodiments, wherein
In some embodiments of the present invention, the substrate is,
wherein each R1、R2、R3、R4、Y、
In some embodiments of the present invention, the substrate is,
wherein each R1、R2、R3、R4、Y、
In certain embodiments, the aliphatic polycarbonates of the present invention comprise a combination of difunctional chains (e.g., a polycarbonate of formula P2) in combination with higher functional chains (e.g., one or more polycarbonates of formulae P3 to P5).
In some embodiments of the present invention, the substrate is,
wherein each R1、R2、R3、R4、Y、
in some embodiments of the present invention, the substrate is,
In certain embodiments, the hydroxy acid is α -hydroxy acid in certain embodiments, the hydroxy acid is selected from the group consisting of glycolic acid, DL-lactic acid, D-lactic acid, L-lactic acid, citric acid, and mandelic acid.
In certain embodiments, the hydroxy acid is β -hydroxy acid in certain embodiments, the hydroxy acid is selected from the group consisting of 3-hydroxypropionic acid, DL 3-hydroxybutyric acid, D-3 hydroxybutyric acid, L-3-hydroxybutyric acid, DL-3-hydroxyvaleric acid, D-3-hydroxyvaleric acid, L-3-hydroxyvaleric acid, salicylic acid, and salicylic acid derivatives.
In certain embodiments, the hydroxy acid is α -omega hydroxy acid3-20Aliphatic α -omega hydroxy acids and oligomeric esters.
In certain embodiments, the hydroxy acid is selected from:
in some embodiments of the present invention, the substrate is,
wherein each R1、R2、R3、R4、Y、
In embodiments where the aliphatic polycarbonate chains have the structure P7,
wherein each R1、R2、R3、R4Y and n are as defined above and described in classes and subclasses herein.
In some embodiments of the present invention, the substrate is,
in some embodiments of the present invention, the substrate is,
In some embodiments of the present invention, the substrate is,
in some embodiments of the present invention, the substrate is,
For example, if
wherein each R1、R2、R3、R4Y and n are as defined above and described in classes and subclasses herein.
In some embodiments of the present invention, the substrate is,
in some embodiments of the present invention, the substrate is,
wherein each R and RdAs defined above and within classes and subclasses herein.
In some embodiments of the present invention, the substrate is,having the formula-PR-wherein R is optionally substituted C1-20Aliphatic or optionally substituted aryl.
In certain embodiments, each of the structures herein
wherein each RxIndependently is an optionally substituted moiety selected from: c2-20Aliphatic, C2-20Heteroaliphatic, 3-to 14-membered carbocyclic ring, 6-to 10-membered aryl, 5-to 10-membered heteroaryl, and 3-to 12-membered heterocyclic ring.
In certain embodiments, each of the structures herein
wherein R isxAs defined above and described in classes and subclasses herein.
In certain embodiments, moiety-Y in the structures herein is-H.
In certain embodiments, -Y comprises an optionally substituted C terminated with an-OH group2-40Ester linkage of linker. In certain embodiments, -Y is selected from:
in certain embodiments, -Y comprises optionally substituted with-CO2H group-terminated C2-40Ester linkage of linker. In certain embodiments, -Y is selected from:
in certain embodiments, moiety-Y in the structures herein comprises a hydroxyl-terminated polymer. In certain embodiments, -Y comprises a hydroxyl terminated polyether. In certain embodiments, -Y comprises
In certain embodiments, -Y comprises a hydroxyl terminated polyester. In certain embodiments, -Y is selected from:
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y, RxAnd n is as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one-Y and n are as defined above and described in classes and subclasses herein; and each is
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each of-Y,
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y, RxAnd n is as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each of-Y,
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each of-Y,
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each one
In certain embodiments, the aliphatic polycarbonate chains comprise:
wherein each-Y and n are as defined above and described in classes and subclasses herein.
In certain embodiments, in the polycarbonates of structures P2a, P2c, P2d, P2f, P2h, P2j, P2l, P2l-a, P2n, P2P, and P2r,
In certain embodiments, in the polycarbonate of structures P2a, P2c, P2d, P2f, P2H, P2j, P2l, P2l-a, P2n, P2P, and P2r, -Y is-H.
For polycarbonates comprising repeat units derived from two or more epoxides, such as those represented by structures P2f through P2r-a described above, it is understood that the depicted structures may represent positional isomers or mixtures of regioisomers that are not explicitly depicted. For example, the polymer repeat units adjacent to either end of the polycarbonate chain may be derived from either of two epoxides comprising the copolymer. Thus, while polymers may be derived with a particular repeat unit attached to a terminal group, the terminal repeat unit may be derived from either of the two epoxides and a given polymer composition may contain all possible mixtures in different ratios. The ratio of these end groups can be affected by several factors, including the ratio of the different epoxides used in the polymerization, the structure of the catalyst used, the reaction conditions (i.e., temperature, pressure, etc.) used, and the time of addition of the reaction components. Similarly, while defined regiochemistry (regiochemistry) may be shown in the above figures for repeat units derived from substituted epoxides, in some cases, the polymer compositions will contain a mixture of regioisomers. The regioselectivity of a given polymerization can be affected by a number of factors, including the structure of the catalyst used and the reaction conditions employed. For purposes of illustration, this means that the composition represented by structure P2r above may contain a mixture of several compounds, as shown in the following schematic. This schematic schematically shows isomers of polymer P2r, where the structure below the description of the chain shows that each regio and positional isomer is possible for the monomer units adjacent to the chain transfer agent and the end groups on each side of the polymer backbone. Each end group on the polymer may be independently selected from the groups shown on the left or right side, while the central portion of the polymer comprising the chain transfer agent and its two adjacent monomer units may be independently selected from the groups shown. In certain embodiments, the polymer composition comprises a mixture of all possible combinations of these. In other embodiments, the polymer composition is enriched in one or more of these.
In certain embodiments, the aliphatic polycarbonate polyol is selected from Q1, Q2, Q3, Q4, Q5, Q6, and mixtures of any two or more of these.
Wherein t is an integer of 1 to 12 inclusive, and RtIndependently at each occurrence is-H or-CH3。
In certain embodiments, the aliphatic polycarbonate polyol is selected from:
a poly (ethylene carbonate) of formula Q1 having a number average molecular weight of about 500g/mol to about 3,000g/mol, a polydispersity index of less than about 1.25, at least 85% carbonate linkages, and at least 98% -OH end groups;
a poly (ethylene carbonate) of formula Q1 having a number average molecular weight of about 500g/mol, a polydispersity index of less than about 1.25, at least 85% carbonate linkages, and at least 98% -OH end groups;
a poly (ethylene carbonate) of formula Q1 having a number average molecular weight of about 1,000g/mol, a polydispersity index of less than about 1.25, at least 85% carbonate linkages, and at least 98% -OH end groups;
a poly (ethylene carbonate) of formula Q1 having a number average molecular weight of about 2,000g/mol, a polydispersity index of less than about 1.25, at least 85% carbonate linkages, and at least 98% -OH end groups;
a poly (ethylene carbonate) of formula Q1 having a number average molecular weight of about 3,000g/mol, a polydispersity index of less than about 1.25, at least 85% carbonate linkages, and at least 98% -OH end groups;
poly (propylene carbonate) of formula Q2 having a number average molecular weight of about 500g/mol to about 3,000g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (propylene carbonate) of formula Q2 having a number average molecular weight of about 500g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (propylene carbonate) of formula Q2 having a number average molecular weight of about 1,000g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (propylene carbonate) of formula Q2 having a number average molecular weight of about 2,000g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (propylene carbonate) of formula Q2 having a number average molecular weight of about 3,000g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene-co-propylene carbonate) of formula Q3 having a number average molecular weight of about 500g/mol to about 3,000g/mol, a polydispersity index of less than about 1.25, at least 90% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene-co-propylene carbonate) of formula Q3 having a number average molecular weight of about 500g/mol, a polydispersity index of less than about 1.25, at least 90% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene-co-propylene carbonate) of formula Q3 having a number average molecular weight of about 1,000g/mol, a polydispersity index of less than about 1.25, at least 90% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene-co-propylene carbonate) of formula Q3 having a number average molecular weight of about 2,000g/mol (e.g., n averages about 10 to about 11), a polydispersity index of less than about 1.25, at least 90% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene-co-propylene carbonate) of formula Q3 having a number average molecular weight of about 3,000g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene carbonate) of formula Q4 having a number average molecular weight of about 500g/mol to about 3,000g/mol (e.g., about 4 to about 16 per n), a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
a poly (ethylene carbonate) of formula Q4 having a number average molecular weight of about 500g/mol, a polydispersity index of less than about 1.25, at least 85% carbonate linkages, and at least 98% -OH end groups;
a poly (ethylene carbonate) of formula Q4 having a number average molecular weight of about 1,000g/mol, a polydispersity index of less than about 1.25, at least 85% carbonate linkages, and at least 98% -OH end groups;
a poly (ethylene carbonate) of formula Q4 having a number average molecular weight of about 2,000g/mol, a polydispersity index of less than about 1.25, at least 85% carbonate linkages, and at least 98% -OH end groups;
a poly (ethylene carbonate) of formula Q4 having a number average molecular weight of about 3,000g/mol, a polydispersity index of less than about 1.25, at least 85% carbonate linkages, and at least 98% -OH end groups.
Poly (propylene carbonate) of formula Q5 having a number average molecular weight of about 500g/mol to about 3,000g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (propylene carbonate) of formula Q5 having a number average molecular weight of about 500g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (propylene carbonate) of formula Q5 having a number average molecular weight of about 1,000g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (propylene carbonate) of formula Q5 having a number average molecular weight of about 2,000g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (propylene carbonate) of formula Q5 having a number average molecular weight of about 3,000g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene-co-propylene carbonate) of formula Q6 having a number average molecular weight of about 500g/mol to about 3,000g/mol, a polydispersity index of less than about 1.25, at least 90% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene-co-propylene carbonate) of formula Q6 having a number average molecular weight of about 500g/mol, a polydispersity index of less than about 1.25, at least 90% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene-co-propylene carbonate) of formula Q6 having a number average molecular weight of about 1,000g/mol, a polydispersity index of less than about 1.25, at least 90% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene-co-propylene carbonate) of formula Q6 having a number average molecular weight of about 2,000g/mol (e.g., n averages about 10 to about 11), a polydispersity index of less than about 1.25, at least 90% carbonate linkages, and at least 98% -OH end groups;
poly (ethylene-co-propylene carbonate) of formula Q6 having a number average molecular weight of about 3,000g/mol, a polydispersity index of less than about 1.25, at least 95% carbonate linkages, and at least 98% -OH end groups; and
mixtures of any two or more of these.
In certain embodiments, an embedded chain transfer agentAre moieties derived from polymeric diols or higher polyols. In certain embodiments, such polymeric alcohols are polyether or polyester polyols. In some embodiments of the present invention, the substrate is,is a compound containing ethylene glycol or propylene glycol repeating units (-OCH)2CH2O-or-OCH2CH(CH3) O-) or combinations of these. In some embodiments of the present invention, the substrate is,
In certain embodiments, wherein
wherein the content of the first and second substances,
Rqindependently at each occurrence in the polymer chain is-H or-CH3；
Rais-H or-CH3；
q and q' are independently integers from about 0 to about 40; and is
And n is as defined above and in the examples and embodiments herein.
In certain embodiments, the aliphatic polycarbonate polyol is selected from:
in certain embodiments, wherein the aliphatic polycarbonate polyol comprises a compound conforming to structure Q7, in part
In certain embodiments, wherein
wherein the content of the first and second substances,
c is independently at each occurrence in the polymer chain an integer from 0 to 6;
d is independently at each occurrence in the polymer chain an integer from 1 to 11; and is
Each RqN, and q are as defined above and in the examples and embodiments herein.
In certain embodiments, the aliphatic polycarbonate polyol is selected from:
in certain embodiments, wherein the aliphatic polycarbonate polyol comprises a compound conforming to structure Q8, in part
Isocyanate reagent
As mentioned above, the compositions of the present invention comprise a high polymer obtained by reaction with an isocyanate reagent. The purpose of these isocyanate reagents is to react with the reactive end groups on the aliphatic polycarbonate polyols to form high molecular weight structures by chain extension and/or crosslinking.
The field of polyurethane synthesis is well developed and a variety of isocyanates and related polyurethane precursors are known in the art. While this section of this specification describes isocyanates suitable for use in certain embodiments of the present invention, it is understood that the use of alternative isocyanates, along with the teachings of the present disclosure, to formulate additional compositions of matter within the scope of the present invention is within the ability of those skilled in the art of polyurethane formulation. A description of suitable isocyanate compounds and related methods can be found in:Chemistry and Technology of Polyols for Polyurethanesionescu, Mihail 2005(ISBN 978-1-84735-.
In certain embodiments, the isocyanate reagent comprises two or more isocyanate groups per molecule. In certain embodiments, the isocyanate reagent is a diisocyanate. In other embodiments, the isocyanate reagent is a higher polyisocyanate such as triisocyanate, tetraisocyanate, isocyanate polymer or oligomer, and the like, which is typically predominantly a mixed minority component of diisocyanates. In certain embodiments, the isocyanate agent is an aliphatic polyisocyanate or a derivative or oligomer of an aliphatic polyisocyanate. In other embodiments, the isocyanate is an aromatic polyisocyanate or a derivative or oligomer of an aromatic polyisocyanate. In certain embodiments, the composition may comprise a mixture of any two or more of the above types of isocyanates.
In certain embodiments, the isocyanate reagents used to produce the polyurethane adhesive include aliphatic, cycloaliphatic, and aromatic diisocyanate compounds.
Suitable aliphatic and cycloaliphatic isocyanate compounds include, for example, 1, 3-trimethylene diisocyanate, 1, 4-tetramethylene diisocyanate, 1, 6-hexamethylene diisocyanate, 2, 4-trimethylhexamethylene diisocyanate, 2,4, 4-trimethylhexamethylene diisocyanate, 1, 9-nonylene diisocyanate, 1, 10-decamethylene diisocyanate, 1, 4-cyclohexane diisocyanate, isophorone diisocyanate, 4,4 '-dicyclohexylmethane diisocyanate, 2' -diethyl ether diisocyanate, hydrogenated xylylene diisocyanate, and hexamethylene diisocyanate-biuret.
The aromatic isocyanate compound includes, for example, p-phenylene diisocyanate, toluene diisocyanate, xylylene diisocyanate, 4 '-diphenyl diisocyanate, 2,4' -diphenylmethane diisocyanate, 1, 5-naphthalene diisocyanate, 4 '-diphenylmethane diisocyanate (MDI), 3' -methylene toluene-4, 4 '-diisocyanate, toluene diisocyanate-trimethylolpropane adduct, triphenylmethane triisocyanate, 4' -diphenyl ether diisocyanate, tetrachlorophenylene diisocyanate, 3 '-dichloro-4, 4' -diphenylmethane diisocyanate and triisocyanate phenyl thiophosphate.
In certain embodiments, the isocyanate compound employed comprises one or more of: 4,4' -diphenylmethane diisocyanate, 1, 6-hexamethylene diisocyanate and isophorone diisocyanate. In certain embodiments, the isocyanate compound employed is 4,4' -diphenylmethane diisocyanate. The above-mentioned diisocyanate compounds may be used alone or in a mixture of two or more thereof.
In certain embodiments, the isocyanate reagent is selected from: 1, 6-hexamethyl amineDiisocyanate (HDI), isophorone diisocyanate (IPDI), 4' methylene-bis (cyclohexyl isocyanate) (H)12MDI), 2, 4-Tolylene Diisocyanate (TDI), 2, 6-Tolylene Diisocyanate (TDI), diphenylmethane-4, 4' -diisocyanate (MDI), diphenylmethane-2, 4' -diisocyanate (MDI), Xylylene Diisocyanate (XDI), 1, 3-bis (isocyanatomethyl) cyclohexane (H6-XDI), 2, 4-trimethylhexamethylene diisocyanate, 2,4, 4-trimethylhexamethylene diisocyanate (TMDI), m-tetramethylxylylene diisocyanate (TMXDI), p-tetramethylxylylene diisocyanate (TMXDI), isocyanatomethyl-1, 8-octane diisocyanate (TIN), triphenylmethane-4, 4' triisocyanate, Tris (p-isocyanatomethyl) thiosulfate, 1, 3-bis (isocyanatomethyl) benzene, 1, 4-tetramethylene diisocyanate, trimethylhexane diisocyanate, 1, 6-hexamethylene diisocyanate, 1, 4-cyclohexyl diisocyanate, lysine diisocyanate, HDI allophanate (allophonate) trimer, HDI uretdione (uretdione) and HDI-trimer and mixtures of any two or more of these.
In certain embodiments, the isocyanate reagent is selected from the group consisting of 4,4' -diphenylmethane diisocyanate, 1, 6-hexamethylene diisocyanate, and isophorone diisocyanate. In certain embodiments, the isocyanate reagent is 4,4' -diphenylmethane diisocyanate. In certain embodiments, the isocyanate reagent is 1, 6-hexamethylene diisocyanate. In certain embodiments, the isocyanate reagent is isophorone diisocyanate.
Isocyanates suitable for use in certain embodiments of the present invention are commercially available under various trade names. Examples of suitable commercially available isocyanates include materials sold under the following trade names:
Additional isocyanates suitable for use in certain embodiments of the present invention are under the trade name
TABLE 1
Other isocyanates suitable for use in certain embodiments of the present invention are under the trade name from Bayer Material Science
TABLE 2
Additional isocyanates suitable for use in certain embodiments of the present invention are under the trade name
TABLE 3
Other isocyanates suitable for use in certain embodiments of the present invention are under the trade name from Bayer Material ScienceAnd (5) selling. In certain embodiments, the isocyanate is selected from the materials shown in table 4, and is typically selected from a subset of this list of 1.95 to 2.1 functional isocyanates:
TABLE 4
In certain embodiments, one or more of the above-described isocyanate compositions are provided in formulations that are generally mixtures known in the art of polyurethane adhesive manufacture. Such mixtures may comprise prepolymers formed by reacting a molar excess of one or more isocyanates with reactive molecules comprising reactive functional groups such as alcohols, amines, thiols, carboxylates, and the like. These mixtures may also contain solvents, surfactants, stabilizers and other additives known in the art.
In certain embodiments, the composition of the adhesive may comprise a blocked isocyanate. Such mixtures do not react under normal conditions even in the presence of water. Instead of curing, it is triggered by heating.
Prepolymer III
In another aspect, the present invention encompasses epoxy CO comprising an isocyanate end-cap2-a prepolymer of a derivatized polyol. In certain embodiments, such isocyanate-terminated prepolymers comprise a plurality of epoxide-CO2-a derivatized polyol segment linked by urethane linkages formed from reaction with a polyisocyanate compound.
In certain embodiments, the prepolymers of the present invention are the result of a reaction between one or more of the above-described aliphatic polycarbonate polyols and a stoichiometric excess of any one or more of the diisocyanates described herein. The degree of polymerization of these prepolymers (i.e., the average number of polyol segments contained in the prepolymer chain) can be manipulated by controlling the relative amounts of isocyanates as well as the order of reagent addition and reaction conditions.
In certain embodiments, the prepolymer comprises a compound corresponding to the formula:
In certain embodiments, the prepolymer comprises a compound corresponding to the formula:
wherein Q is 0 or an integer from 1 to about 50, each open rectangle,denotes polyol moieties, each of which may be the same or different, and
In certain embodiments, the prepolymer comprises chains corresponding to the formula:
In other embodiments, the prepolymer may be formed by reacting a stoichiometric excess of polyol with a limited amount of isocyanate. In such embodiments, the prepolymers of the present invention have-OH end groups and contain two or more polyol units linked by urethane linkages. In certain embodiments, such prepolymers conform to the following structure:
wherein
In certain embodiments, such prepolymers have a structure corresponding to:
Other co-reactants and additives
As noted above, in some embodiments, the compositions of the present invention can include one or more of the aliphatic polycarbonate polyols described in section I above. Further aliphatic polycarbonate polyols suitable for formulating such mixtures according to the invention are disclosed in WO 2010/028362.
In certain embodiments, these mixtures comprise aliphatic polycarbonate polyols in combination with one or more additional polyols and/or one or more additives. In certain embodiments, the additional polyol is selected from polyester polyols, in some cases based on adipic acid and various diols; a polyether polyol; and/or a polycaprolactone polyol. In certain embodiments, the mixture comprises additional reactive small molecules such as amines, alcohols, thiols, or carboxylic acids, referred to as chain extenders, that participate in the bonding reaction with the isocyanate. In certain embodiments, the additive is selected from: solvents, fillers, clays, blocking agents, stabilizers, thixotropes, plasticizers, compatibilizers, colorants, UV stabilizers, flame retardants, and the like.
A. Additional polyols
In certain embodiments, the mixtures of the present invention comprise an aliphatic polycarbonate polyol as described above in combination with one or more additional polyols, such as those conventionally used in polyurethane adhesive compositions. In embodiments where additional polyols are present, they may comprise up to about 95 weight percent of the total polyol content, with the remainder of the polyol mixture being comprised of one or more of the aliphatic polycarbonate polyols described in section I above and in the examples and embodiments herein.
In embodiments where the inventive mixture comprises or is derived from a mixture of one or more aliphatic polycarbonate polyols and one or more additional polyols, the additional polyol is selected from polyether polyols, polyester polyols, polystyrene polyols, polyether-carbonate polyols, polyether-ester carbonates, butanediol adipate polyols, ethylene glycol adipate polyols, hexanediol adipate polyols, polycaprolactone polyols, polytetramethylene ether glycol (PTMEG) polyols, EO/PO polyether polyols, and mixtures of any two or more of these. In certain embodiments, the inventive mixtures comprise or are derived from mixtures of one or more aliphatic polycarbonate polyols as described herein and one or more other polyols selected from those commercially available under the following trade names:
in certain embodiments, the mixtures of the present invention contain a combination of polyether polyols, polyester polyols, and/or polycaprolactone polyols with one or more aliphatic polycarbonate polyols as described herein. In certain embodiments, such polyols are characterized in that they have an Mn of from about 500 to about 10,000 g/mol. In certain embodiments, such polyols have an Mn of from about 500 to about 5,000 g/mol. In certain embodiments, such polyols have an Mn of from about 1,500 to about 25,000 g/mol.
In certain embodiments, the mixtures of the present invention contain a combination of polyether polyols, polyester polyols, and/or polycaprolactone polyols with one or more aliphatic polycarbonate polyols as described herein. In certain embodiments, such polyols are characterized in that they have a functionality of 1.9 to 2.5. In certain embodiments, such polyols are characterized in that they have a functionality of 1.95 to 2.2. In certain embodiments, such polyols have a functionality of greater than 2.5, in which case such high functionality polyols typically compromise a minority of the overall polyol formulation. Polyester polyols which may be present include those obtainable by known methods, for example, polyester polyols may be based on the reaction of adipic or succinic acid (or its corresponding reactive derivatives or anhydrides) with various diols including Butanediol (BDO), Hexanediol (HDO) and Ethylene Glycol (EG), propylene glycol (PDO).
Polyether polyols which may be present include those which can be obtained by known processes, for example polyether polyols can be produced by anionic polymerization with alkali metal hydroxides such as sodium hydroxide or potassium hydroxide or alkali metal alkoxides such as sodium methoxide, sodium ethoxide or potassium isopropoxide as catalysts and with the addition of at least one initiator molecule containing from 2 to 8, preferably 2, active hydrogens or by cationic polymerization with lewis acids such as antimony pentachloride, boron trifluoride etherate or the like or bleaching clays as catalysts with one or more olefin oxides having from 2 to 4 carbons in the olefin group. Any suitable olefin oxide may be used such as 1, 3-propylene oxide, 1, 2-butylene oxide and 2, 3-butylene oxide, pentane oxide, styrene oxide and preferably ethylene oxide and 1, 2-propylene oxide and mixtures of these oxides. The polyalkylene polyether polyols may be prepared from other starting materials, such as tetrahydrofuran and alkylene oxide-tetrahydrofuran mixtures; epihalohydrins such as epichlorohydrin; and aralkylene oxides such as styrene oxide. The polyalkylene polyether polyols may have primary or secondary hydroxyl groups, preferably secondary hydroxyl groups generated by the addition of propylene oxide to the initiator, since these groups react relatively slowly. Polyether polyols include polyoxyethylene glycol, polyoxypropylene glycol, polyoxybutylene glycol, polytetramethylene glycol, block copolymers such as polyoxypropylene glycol and polyoxyethylene glycol, poly-l, 2-oxybutylene and polyoxyethylene glycol, poly-l, 4-tetramethylene and polyoxyethylene glycol, and copolymer glycols prepared from blends or sequential additions of two or more olefin oxides. The polyalkylene polyether polyols may be prepared by any known method, such as, for example, the method disclosed by Wurtz, Encyclopedia of Chemical Technology, volume 7, page 257-262, Interscience Publishers, Inc. (1951) or in U.S. Pat. No. 1,922,459. Preferred polyethers include alkylene oxide adducts of polyhydric alcohols such as ethylene glycol, propylene glycol, dipropylene glycol, trimethylene glycol, 1, 2-butanediol, 1, 5-pentanediol, 1, 6-hexanediol, 1, 7-heptanediol, hydroquinone, resorcinol glycerol, 1,1, 1-trimethylol-propane, 1,1, 1-trimethylolethane, pentaerythritol, 1,2, 6-hexanetriol, a-methyl glucoside, sucrose, and sorbitol. The term "polyol" also includes compounds derived from phenol such as 2, 2-bis (4-hydroxyphenol) -propane, commonly referred to as bisphenol a. Suitable organic amine initiators that may be condensed with the olefin oxide include aromatic amines-such as aniline, N-alkyl phenylene-diamines, 2,4' -, 2' -and 4,4' -methylenedianiline, 2, 6-or 2, 4-toluenediamine, ortho-chloroaniline, para-aminoaniline, 1, 5-diaminonaphthalene, methylenedianiline, various condensation products of aniline and formaldehyde, and isomeric diaminotoluenes; and aliphatic amines such as mono-, di-, and trialkanolamines, ethylenediamine, propylenediamine, diethylenetriamine, methylamine, triisopropanolamine, 1, 3-diaminopropane, 1, 3-diaminobutane, and 1, 4-diaminobutane. Preferred amines include monoethanolamine, ortho-toluenediamine, ethylenediamine and propylenediamine. Yet another class of aromatic polyether polyols contemplated for use in the present invention are Mannich-based polyols (an olefin oxide adduct of phenol/formaldehyde/alkanolamine resin), commonly referred to as "Mannich" polyols such as those disclosed in U.S. patent nos. 4,883,826; 4,939,182, respectively; and 5,120,815. In embodiments where additional polyols are present, they comprise a total polyol content of from about 5 weight percent to about 95 weight percent, with the remainder of the polyol mixture being comprised of one or more aliphatic polycarbonate polyols described in section I above and in the examples and specific embodiments herein. In certain embodiments, up to about 75 weight percent of the total polyol content of the mixture is aliphatic polycarbonate polyol. In certain embodiments, up to about 50 weight percent of the total polyol content of the mixture is aliphatic polycarbonate polyol. In certain embodiments, up to about 40 weight percent, up to about 30 weight percent, up to about 25 weight percent, up to about 20 weight percent, up to about 15 weight percent, or up to about 10 weight percent of the total polyol content of the mixture is aliphatic polycarbonate polyol. In certain embodiments, at least about 5 weight percent of the total polyol content of the mixture is aliphatic polycarbonate polyol. In certain embodiments, at least about 10 weight percent of the total polyol content of the mixture is aliphatic polycarbonate polyol. In certain embodiments, at least about 15 weight percent, at least about 20 weight percent, at least about 25 weight percent, at least about 40 weight percent, or at least about 50 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol.
In certain embodiments, the polyol present in minor amounts comprises an aliphatic polycarbonate polyol. In certain embodiments, from about 10 weight percent to about 50 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol. In certain embodiments, from about 10 weight percent to about 40 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol. In certain embodiments, from about 10 weight percent to about 30 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol. In certain embodiments, from about 5 weight percent to about 20 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol. In certain embodiments, from about 5 weight percent to about 15 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol. In certain embodiments, from about 5 weight percent to about 10 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol.
In certain embodiments, the polyol present in the major amount comprises an aliphatic polycarbonate polyol. In certain embodiments, from about 50 weight percent to about 90 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol. In certain embodiments, from about 50 weight percent to about 70 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol. In certain embodiments, from about 80 weight percent to about 90 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol. In certain embodiments, from about 90 weight percent to about 95 weight percent of the total polyol content of the mixture is an aliphatic polycarbonate polyol.
B. Chain extender
In certain embodiments, the mixtures of the present invention include one or more small molecules reactive with isocyanates. In certain embodiments, the reactive small molecules included in the inventive mixtures comprise low molecular weight organic molecules having one or more functional groups selected from the group consisting of alcohols, amines, carboxylic acids, thiols, and combinations of any two or more of these.
In certain embodiments, the mixtures of the present invention comprise one or more alcohols. In certain embodiments, the mixture includes a polyol.
In certain embodiments, the reactive small molecule included in the mixture of the present invention comprises a diol. In certain embodiments, the glycol comprises C2-40A diol. The polyol compound is selected from aliphatic and cycloaliphatic polyol compounds, for example, ethylene glycol, 1, 2-propylene glycol, 1, 3-propylene glycol, 1, 2-butanediol, 1, 2-propylene glycol, 1, 3-butanediol, 1, 4-butanediol, 1, 5-pentanediol, 1, 6-hexanediol, 1, 8-octanediol, 1, 9-nonanediol, 1, 10-decanediol, neopentyl glycol, 3-methyl-1, 5-pentanediol, 3-dimethylolheptane, 1, 4-cyclohexanediol, 1, 4-cyclohexanedimethanol and 1, 4-dihydroxyethylcyclohexane; and aliphatic and aromatic polyamine compounds such as ethylenediamine, 1, 2-propylenediamine, 1, 6-hexamethylenediamine, isophoronediamine, bis (4-aminocyclohexyl) methane, piperazine and m-or p-xylylenediamine; aliphatic, cycloaliphatic and aromatic amino alcohol compounds, for example 2-ethanolamine, N-methyldiethanolamine, N-phenyldipropanolamine; hydroxyalkylsulfonamides, e.g. hydroxyethylsulfonic acidAmides and hydroxyethylaminoethylsulfonamide; urea and water. Among the above chain-extending compounds, 1, 4-butanediol, 2-ethanolamine and 1, 2-propanediamine are preferably used. In certain embodiments, the chain extender is selected from: 1, 4-cyclohexane diethanol, isosorbide, monoglyceride, glycerol monoether, trimethylolpropane monoester, trimethylolpropane monoether, pentaerythritol diester, pentaerythritol diether, and alkoxy derivatives of any of these. The above chain extension compounds may be used alone or in a mixture of two or more thereof.
In certain embodiments, the reactive small molecule included in the mixture of the present invention comprises a diol selected from the group consisting of: diethylene glycol, triethylene glycol, tetraethylene glycol, higher poly (ethylene glycols) such as those having a number average molecular weight of 220g/mol to about 2000g/mol, dipropylene glycol, tripropylene glycol, and higher poly (propylene glycols) such as those having a number average molecular weight of 234g/mol to about 2000 g/mol.
In certain embodiments, the reactive small molecule included in the mixture of the present invention comprises an alkoxylated derivative of a compound selected from a diacid, a diol, or a hydroxy acid. In certain embodiments, the alkoxylated derivative comprises an ethoxylated or propoxylated compound.
In certain embodiments, the reactive small molecule included in the mixture of the present invention comprises a polymeric glycol. In certain embodiments, the polymeric glycol is selected from the group consisting of polyethers, polyesters, hydroxy-terminated polyolefins, polyether-copolyesters, polyether-polycarbonates, polycarbonate-copolyesters, and any alkoxylated analogs thereof. In certain embodiments, the polymeric glycol has an average molecular weight of less than about 2000 g/mol.
In certain embodiments, the reactive small molecule comprises a compound having the general formula (HO)xQ(COOH)yWherein Q is a straight or branched chain hydrocarbon group containing 1 to 12 carbon atoms, and x and y are each an integer of 1 to 3. In certain embodiments, the co-reactant comprises a diol carboxylic acid. In certain embodiments, the co-reactant comprises a bis (hydroxyalkyl) alkanoic acid. In certain embodiments, the co-reactant comprises a bis (hydroxymethyl) alkanoic acid. In some instancesIn embodiments, the diol carboxylic acid is selected from the group consisting of 2,2 bis- (hydroxymethyl) -propionic acid (dimethylolpropionic acid, DMPA), 2 bis (hydroxymethyl) butanoic acid (dimethylolbutanoic acid; DMBA), dihydroxysuccinic acid (tartaric acid), and 4,4' -bis (hydroxyphenyl) pentanoic acid. In certain embodiments, the co-reactant comprises an N, N-bis (2-hydroxyalkyl) carboxylic acid.
In certain embodiments, the amino diol is selected from the group consisting of Diethanolamine (DEA), N-Methyldiethanolamine (MDEA), N-ethyldiethanolamine (EDEA), N-Butyldiethanolamine (BDEA), N-bis (hydroxyethyl) - α -aminopyridine, dipropanolamine, Diisopropanolamine (DIPA), N-methyldiisopropanolamine, diisopropanol-p-toluidine, N-bis (hydroxyethyl) -3-chloroaniline, 3-diethylaminopropane-1, 2-diol, 3-dimethylaminopropane-1, 2-diol, and N-hydroxyethylpiperidine.
In certain embodiments, the reactive small molecule is selected from: inorganic or organic polyamines having an average of about 2 or more primary and/or secondary amine groups, polyols, ureas, and combinations of any two or more of these. In certain embodiments, the reactive small molecule is selected from: diethylenetriamine (DETA), Ethylenediamine (EDA), m-xylylenediamine (MXDA), aminoethylethanolamine (AEEA), 2-methylpentanediamine, and the like, and mixtures thereof. Also suitable for practicing the invention are propylenediamine, butylenediamine, hexylenediamine, cyclohexanediamine, phenylenediamine, tolylenediamine, 3-dichlorobenzidine, 4' -methylene-bis- (2-chloroaniline), 3-dichloro-4, 4-diaminodiphenylmethane and sulfonated primary and/or secondary amines. In certain embodiments, the reactive small molecule is selected from: hydrazine, substituted hydrazines, hydrazine reaction products, and the like, and mixtures thereof. In certain embodiments, the reactive small molecule is a polyol, including those having from 2 to 12 carbon atoms, preferably from 2 to 8 carbon atoms, such as ethylene glycol, diethylene glycol, neopentyl glycol, butanediol, hexanediol, and the like, and mixtures thereof. Suitable ureas include urea and its derivatives, and the like, and mixtures thereof.
In certain embodiments, the reactive small molecule containing at least one basic nitrogen atom is selected from the group consisting of: mono-, di-or polyalkoxylated aliphatic, cycloaliphatic, aromatic or heterocyclic primary amines, N-methyldiethanolamine, N-ethyldiethanolamine, N-propyldiethanolamine, N-isopropyldiethanolamine, N-butyldiethanolamine, N-isobutyldiethanolamine, N-oleyldiethanolamine, N-stearyldiethanolamine, ethoxylated coconut oil fatty amines, N-allyldiethanolamine, N-methyldiisopropanolamine, N-ethyldiisopropanolamine, N-propyldiisopropanolamine, N-butyldiisopropanolamine, cyclohexyldiisopropanolamine, N-diethoxyaniline, N-diethoxytoluidine, N-diethoxy-1-aminopyridine, N '-diethoxypiperazine, N' -dimethyloldiethanolamine, N-methyldiethanolamine, N-ethyldiethanolamine, N-isobutyldiethanolamine, N-stearyldiethanolamine, dimethyl-bis-ethoxyhydrazine, N ' -bis- (2-hydroxyethyl) -N, N ' -diethylhexahydrop-phenylenediamine, N-12-hydroxyethylpiperazine, polyalkoxylated amines, propoxylated methyldiethanolamine, N-methyl-N, N-bis-3-aminopropylamine, N- (3-aminopropyl) -N, N ' -dimethylethylenediamine, N- (3-aminopropyl) -N-methylethanolamine, N ' -bis- (3-aminopropyl) -N, N ' -dimethylethylenediamine, N ' -bis- (3-aminopropyl) -piperazine, N- (2-aminoethyl) -piperazine, N-hydroxyethylamine, N-N ' -bis- (3-aminopropyl) -piperazine, N- (2-aminopropyl) -piperazine, N-hydroxyethylamine, N-bis- (3-aminopropyl) -piperazine, n, N '-dioxyethyl propane diamine, 2, 6-diaminopyridine, diethanol aminoacetamide, diethanol aminopropionamide, N-dioxyethyl phenyl thiosemicarbazide, N-dioxyethyl methyl semicarbazide, p' -bis-aminomethyl dibenzyl methylamine, 2, 6-diaminopyridine, 2-dimethylaminomethyl-2-methylpropane, 3-diol. In certain embodiments, the chain extender is a compound containing two amino groups. In certain embodiments, the chain extender is selected from: ethylenediamine, 1, 6-hexamethylenediamine and 1, 5-diamino-1-methyl-pentane.
C. Catalyst and process for preparing same
In certain embodiments, no catalyst is used in the mixture. In certain embodiments, conventional catalysts comprising amine compounds or tin compounds may be used to promote the reaction in the polymerization of the polyurethane. These embodiments are most common in reactive extrusion processes for polyurethane adhesive production. Any suitable urethane catalyst may be used, including tertiary amine compounds and organometallic compounds may be used. Exemplary tertiary amine compounds include triethylenediamine, N-methylmorpholine, N-dimethylcyclohexylamine, pentamethyldiethylenetriamine, tetramethylethylenediamine, 1-methyl-4-dimethylaminoethylpiperazine, 3-methoxy-N-dimethylpropylamine, N-ethylmorpholine, diethylethanolamine, N-cocomorpholine (N-cocorophylline), N-dimethyl-N ', N' -dimethylisopropylpropylenediamine, N-diethyl-3-diethylaminopropylamine, and dimethylbenzylamine. Exemplary organometallic catalysts include organomercury, organolead, organoiron, and organotin catalysts, with organotin catalysts being preferred. Suitable tin catalysts include stannous chloride, tin salts of carboxylic acids such as dibutyltin dilaurate, and other organometallic compounds such as those disclosed in U.S. Pat. No. 2,846,408. Catalysts for the trimerization of polyisocyanates (to produce polyisocyanurates), such as alkali metal alkoxides, may also optionally be used herein. Such catalysts are used in amounts that measurably increase the rate of polyurethane or polyisocyanurate formation.
In certain embodiments, wherein the mixture of the present invention comprises a catalyst, the catalyst comprises a tin-based material. In certain embodiments, the tin catalyst is selected from: dibutyltin dilaurate, dibutylbis (laurylthio) stannate, dibutyltin bis (isooctylmercaptoacetate) and dibutyltin bis (isooctylmaleate), tin octoate, and mixtures of any two or more of these.
In certain embodiments, the catalyst included in the mixture comprises a tertiary amine. In certain embodiments, the catalyst included in the mixture is selected from the group consisting of: DABCO, pentamethyldipropylenetriamine, bis (dimethylaminoethyl ether), pentamethyldiethylenetriamine, DBU phenate, dimethylcyclohexylamine, 2,4, 6-tris (N, N-dimethylaminomethyl) phenol (DMT-30), Triazabicyclodecene (TBD), N-methyl TBD, 1,3, 5-tris (3-dimethylaminopropyl) hexahydro-s-triazine, ammonium salts, and combinations or formulations of any of these.
Typical amounts of catalyst in the mixture are from 0.001 to 10 parts of catalyst per 100 parts by weight of total polyol. In certain embodiments, the level of catalyst in the formulation, when used, ranges from about 0.001pph (per hundred parts by weight) to about 3pph, based on the amount of polyol present in the mixture. In certain embodiments, the catalyst level ranges from about 0.05pph to about 1pph or from about 0.1pph to about 0.5 pph.
D. Monofunctional materials
In certain embodiments, a monofunctional component is added. Suitable monofunctional components may include molecules having a single isocyanate-reactive functional group, such as an alcohol, amine, carboxylic acid, or mercapto group. The monofunctional component will serve as a chain terminator which may be used to limit molecular weight or crosslink if higher functionality species are used. U.S. patent 5,545,706 describes the use of monofunctional alcohols in substantially linear polyurethane formulations. The monofunctional alcohol may be any compound having one alcohol (such as methanol, ethanol, propanol, isopropanol, butanol, isobutanol, pentanol, hexanol, heptanol, octanol, nonanol, decanol, dodecanol, phenol, etc.) useful for reacting with an isocyanate. In addition, monofunctional components may be added as low molecular weight polymers initiated by or reacted with monofunctional alcohols. The monofunctional alcohol may be a polyether such as polypropylene oxide or polyethylene oxide starting with any of the monofunctional alcohols listed. The monofunctional alcohol may be a polyester polymer, wherein the monofunctional alcohol is added to the formulation. The monofunctional alcohol may be a polycarbonate polymer such as a polycarbonate or polypropylene carbonate starting with a monofunctional anion such as a halide, nitrate, azide, carboxylate or monoalcohol.
Similarly, the monofunctional component may be an isocyanate. Any monofunctional isocyanate may be added for this same purpose. Possible materials include phenyl isocyanate, naphthyl isocyanate, methyl isocyanate, ethyl isocyanate, propyl isocyanate, butyl isocyanate, hexyl isocyanate, octyl isocyanate, and the like.
E. Additive agent
In addition to the above components, the mixtures of the invention may optionally contain various additives as known in the art of polyurethane adhesives. Such additives may include, but are not limited to, solvents, fillers, clays, blocking agents, stabilizers, thixotropes, plasticizers, compatibilizers, colorants, UV stabilizers, flame retardants, and the like.
1. Solvent(s)
Representative examples include, but are not limited to, acetone, acetonitrile, benzene, butanol, butyl acetate, g-butyrolactone, butyl carbitol acetate, chloroform, cyclohexane, 1, 2-methylene chloride, dibasic esters, diethylene glycol dimethyl ether, 1, 2-dimethoxyethane, dimethylacetamide, dimethyl sulfoxide, dimethylformamide, 1, 4-dioxane, ethanol, ethyl acetate, diethyl ether, ethylene glycol, hexane, hydroxymethyl methacrylate, isopropyl acetate, methanol, methyl acetate, methyl amyl ketone, methyl isobutyl ketone, methylene chloride, methyl ethyl ketone, dimethyl ether, methyl methacrylate, propylene carbonate, propylene oxide, styrene, α -terpineol, tetrahydrofuran, texanol, toluene, diethyl succinate, diethyl acetate, diethyl glycol acetate, triethyl glycol phosphate, etc.
2. Filler material
Optional components of the adhesives of the invention include fillers. Such fillers are well known to those skilled in the art and include carbon black, titanium dioxide, calcium carbonate, surface treated silica, titanium oxide, fumed silica, talc, aluminum trihydrate, and the like. In certain embodiments, the filler comprises carbon black. In certain embodiments, more than one reinforcing filler may be used, one of which is carbon black and a sufficient amount of carbon black is used to provide the desired black color to the adhesive. In certain embodiments, a sufficient amount of reinforcing filler is used to increase the strength of the adhesive and/or to provide thixotropic properties to the adhesive. The amount of filler or other additive will vary depending on the desired application.
3. Clay clay
An optional material in the adhesive composition is clay. Preferred clays for use in the present invention include kaolin, surface treated kaolin, calcined kaolin, aluminum silicates and surface treated anhydrous aluminum silicates. The clay may be used in any form that facilitates the formation of a pumpable adhesive. Preferably, the clay is in the form of a pulverized powder, spray-dried granules or finely ground granules.
4. Blocking agent
One or more blocking agents are used to provide an induction period between mixing of the two-part adhesive composition and the onset of cure. The addition of the blocking agent provides an induction period that results in an immediate reduction in the cure rate after mixing of the binder components. The reduction in cure rate results in lower initial tensile shear strength and storage modulus immediately after mixing than those found in compositions without the blocking agent. The rapid curing of the adhesive after an induction period results in tensile shear strengths and storage moduli similar to those produced by adhesives that do not contain blocking agents. Such thixotropes are well known to those skilled in the art and include hydroxyl group containing compounds such as diethylene glycol, monoalkyl ethers, butanone oxime, methyl ethyl ketoxime, nonyl phenol, phenol and cresol; amine-containing compounds such as caprolactam, diisopropylamine, 1,2, 4-triazole, and 3, 5-dimethylpyrazole; and aliphatic-containing compounds such as dialkyl malonates.
5. Stabilizer
The adhesive of the present invention may also contain stabilizers to protect the adhesive composition from moisture, thereby inhibiting advancement and preventing premature isocyanate crosslinking in the adhesive formulation. Included among such stabilizers are diethyl malonate and alkylphenol alkylates.
6. Thixotrope
Optionally, the adhesive composition may further comprise a thixotrope. Such thixotropes are well known to those skilled in the art and include alumina, limestone, talc, zinc oxide, sulfur oxides, calcium carbonate, perlite, slate flour, salt (NaCl), cyclodextrin, and the like. A thixotrope may be added to the adhesive composition in an amount sufficient to provide the desired rheological properties.
7. Plasticizer
The adhesive composition of the invention may also contain a plasticizer to modify the rheological properties to a desired consistency. Such materials should be free of water, inert to isocyanate groups and compatible with the polymer. Suitable plasticizers are well known in the art, and preferred plasticizers include alkyl phthalates such as dioctyl phthalate or dibutyl phthalate, partially hydrogenated terpenes commercially available as "HB-40", trioctyl phosphate, epoxy plasticizers, toluene-sulfamide, chlorinated paraffins, adipates, castor oil, toluene, and alkyl naphthalenes. The amount of plasticizer in the adhesive composition is that amount which provides the desired rheological characteristics and/or is sufficient to disperse any catalyst that may be present in the system.
8. Compatibilizer
In certain embodiments, the mixtures of the present invention comprise one or more suitable compatibilizers. Compatibilizers are molecules that allow two or more immiscible components to polymerize together and produce a homogeneous liquid phase. Many such molecules are known to the polyurethane industry, and these include: amides, amines, hydrocarbon oils, phthalates, polytetramethylene glycols and ureas.
9. Coloring agent
In certain embodiments, the mixtures of the present invention comprise one or more suitable colorants. Typical inorganic colorants include titanium dioxide, iron oxide, and chromium oxide. Organic pigments originate from azo/diazo dyes, phthalocyanines and dioxazines and also from carbon black. Research advances in the development of polyol-binding colorants are described in:
Miley，J.W.；Moore，P.D.“Reactive Polymeric Colorants For Polyurethane”，Proceedings Of The SPI-26th Annual Technical Conference；Technomic：Lancaster，Pa.，1981；83-86.
Moore，P.D.；Miley，J.W.；Bates，S.H.；“New Uses For Highly Miscible LiquidPolymeric Colorants In The Manufacture of Colored Urethane Systems”；Proceedings of the SPI-27th Annual Technical/Marketing Conference；Technomic：Lancaster，Pa.，1982；255-261.
Bates，S.H.；Miley，J.W.“Polyol-Bound Colorants Solve Polyurethane ColorProblems”；Proceedings Of The SPI-30th Annual Technical/Marketing Con ference；Technomic：Lancaster，Pa.，1986；160-165
violet, r.c.; haney, t.v. "Polyurethanes"; in harvesting of Plastics; webber, t.g., eds, Wiley-Interscience: new York, 1979, 191-204.
UV stabilizers
In certain embodiments, the mixtures of the present invention comprise one or more suitable UV stabilizers. Polyurethanes based on aromatic isocyanates will generally turn dark-toned yellow when aged by exposure to light. A review of the polyurethane efflorescence phenomena is shown in: davis, a.; sims, d.weather Of Polymers; applied Science: london, 1983, 222-. Photoprotective agents such as hydroxybenzotriazoles, zinc dibutylthiocarbamate, 2, 6-di-tert-butylcatechol, hydroxybenzophenones, hindered amines and phosphites have been used to improve the light stability of polyurethanes. Colored pigments have also been successfully used.
11. Flame retardant
In certain embodiments, the mixtures of the present invention comprise one or more suitable flame retardants. Flame retardants are typically added to reduce flammability. For any particular polyurethane adhesive, the selection of flame retardant is generally dependent upon the desired service application of the adhesive and the attendant flammability test protocol governing that application. Flammability aspects that may be affected by the additive include initial flammability, burn rate, and smoke generation.
The most widely used flame retardants are chlorinated phosphates, chlorinated paraffins and melamine powders. These and many other compositions are available from specific chemical suppliers. An overview of the present subject matter has been given in: kuryla, w.c.; papa, a.j.frame redardane of Polymeric Materials,
V. polyurethane adhesive composition
In another aspect, the present invention encompasses polyurethane adhesives derived from one or more of the aliphatic polycarbonate polyol compositions described above and in the specific embodiments and examples disclosed herein. In certain embodiments, the polyurethane adhesive composition comprises the reaction product of one or more isocyanates with a mixture comprising one or more aliphatic polycarbonate polyol compositions as defined above.
A. Reactive 1-component polyurethane adhesives
In one aspect, the present invention encompasses reactive one-part adhesives. In certain embodiments, such one-part adhesive compositions are derived from mixtures containing one or more aliphatic polycarbonate polyol compositions as defined above and in the embodiments and examples herein.
In certain embodiments, the one-part adhesive is a prepolymer prepared with one or more aliphatic polycarbonate polyols; these prepolymers typically have low isocyanate values and are produced by reacting an excess of isocyanate with a relatively high molecular weight polyol. These adhesives are typically cured with water, which may be added to or present in the atmosphere or the bonded material.
In certain embodiments, MDI is the preferred isocyanate to react with one or more aliphatic polycarbonate polyols and optionally one or more other polyols as described above. In certain embodiments requiring unique adhesive performance characteristics, TDI and/or aliphatic isocyanates are used in place of or in addition to MDI.
In certain embodiments, the one-part adhesive comprises 100% solids (e.g., no solvent present at the time of application). In certain embodiments, the one-part adhesive formulation may be dissolved, dispersed, and/or emulsified in a solvent or water to reduce viscosity or otherwise improve the suitability of the one-part adhesive for these applications.
In certain embodiments no catalyst is used. In certain embodiments, a catalyst is included in the formulation to increase the reaction rate of free isocyanate and water.
In certain embodiments, hydroxyethyl acrylate groups may be included in the aliphatic polycarbonate polyols, other polyols, and/or derivatized prepolymers to impart uv curing characteristics.
In certain embodiments, fatty acid groups and/or other molecules having unsaturated functionality may be included in the aliphatic polycarbonate polyol, other polyols, and/or derivatized prepolymers to enable crosslinking by oxidation.
In certain embodiments, the 1-component adhesive mixture forms a final cured polyurethane adhesive having the following composition:
1 to 80 parts by weight of one or more isocyanate components or prepolymers based on isocyanate components as described hereinabove and in the specific embodiments and examples herein;
20 to 99 parts by weight of a polyol component or a polyol-based prepolymer component, wherein the polyol component comprises from about 5 to 100 weight percent of one or more aliphatic polycarbonate polyols as described above and in the specific embodiments and examples herein;
0 to 1 parts by weight of one or more catalysts as described above and in the specific embodiments and examples herein;
0 to 20 parts by weight of one or more chain extenders, wherein said chain extender molecules are substantially as described hereinabove and in the specific embodiments and examples herein; and
0 to 10 parts by weight of one or more additives, wherein the additives are selected from: fillers, clays, blocking agents, stabilizers, thixotropic materials, plasticizers, compatibilizers, colorants, UV stabilizers, or flame retardants as described above and in the specific embodiments and examples herein.
B. Reactive 2-component polyurethane adhesives
In one aspect, the present invention encompasses a reactive two-part adhesive composition. In certain embodiments, such two-part adhesive compositions are derived from mixtures containing one or more aliphatic polycarbonate polyols as defined above and in the embodiments and examples herein.
In certain embodiments, the two-part adhesive comprises a prepolymer derived from one or more aliphatic polycarbonate polyols. These prepolymers can be produced using excess isocyanate and/or excess hydroxyl content and then mixed with one or more of the isocyanates described above, the aliphatic polycarbonate polyols, the other polyols, and the other components described above.
In certain embodiments, the two-part adhesive is formulated to have an isocyanate coefficient of 90 to 150. In certain embodiments, an isocyanate coefficient greater than 100 is used to increase the hardness of the adhesive and improve adhesion to substrates, especially those having hydroxyl groups on their surface. In certain embodiments, an isocyanate coefficient of less than 100 is used to produce a softer and more flexible adhesive.
In certain embodiments, MDI is the preferred isocyanate for forming the two-part adhesive. In certain embodiments, TDI is the preferred isocyanate for forming two-part adhesives. In certain embodiments, these isocyanates have a functionality greater than 2 and are polymerizable. Other isocyanates are used in certain embodiments, including aliphatic isocyanates where resistance to ultraviolet light is desired.
In certain embodiments only a single aliphatic polycarbonate polyol is used in the formation of the two-part adhesive. In certain embodiments, one or more polycarbonate polyols are mixed with one or more additional polyols as described above. In certain embodiments, these polyols have a molecular weight of from 200g/mol to 10,000g/mol, preferably from 300g/mol to 5,000 g/mol.
In certain embodiments, the two-part adhesive is formulated with an isocyanate and/or a polyol having a functionality of 2.0 or less. In certain embodiments, the adhesive is formulated with an isocyanate and/or a polyol having a functionality greater than 2.0 (in other words, a degree of branching) to introduce crosslinking in the cured two-part adhesive. In certain embodiments, the overall level of crosslinking is relatively high to produce an adhesive with high modulus, high hardness, and good tensile, shear stress, and peel strength properties. In certain embodiments, the overall level of crosslinking is lower to produce an adhesive with greater elasticity.
In certain embodiments, the two-part adhesive is applied as 100% solids. In certain embodiments, the two-part adhesive may be dissolved, dispersed, and/or emulsified in a solvent or water to reduce viscosity or otherwise improve its suitability. In certain embodiments, solvents such as acetone, methyl ethyl ketone, ethyl acetate, toluene, or xylene are preferred.
In certain embodiments, no filler is present in the two-part adhesive. In other embodiments, calcium carbonate, talc, clay, and the like are added as fillers to control rheology, reduce shrinkage, reduce cost, and/or for other reasons. In certain embodiments, the two-part adhesive includes thixotropic agents, flow agents, film-forming additives, and/or catalysts to achieve desired in-process and finished adhesive properties.
In certain embodiments, the 2-component adhesive mixture forms a final cured polyurethane adhesive having the following composition:
10 to 40 parts by weight of one or more isocyanate components or prepolymers based on isocyanate components as described above and in the specific embodiments and examples herein;
60 to 90 parts by weight of a polyol component or a polyol-based prepolymer component, wherein the polyol component comprises from about 5 to 100 weight percent of one or more aliphatic polycarbonate polyols as described above and in the specific embodiments and examples herein;
0 to 1 parts by weight of one or more catalysts as described above and in the specific embodiments and examples herein;
0 to 20 parts by weight of one or more chain extenders, wherein said chain extender molecules are substantially as described hereinabove and in the specific embodiments and examples herein; and
0 to 10 parts by weight of one or more additives, wherein the additives are selected from: fillers, clays, blocking agents, stabilizers, thixotropic materials, plasticizers, compatibilizers, colorants, UV stabilizers, or flame retardants as described above and in the specific embodiments and examples herein.
In certain embodiments, the present invention encompasses adhesives formulated from a polyol blend comprising one or more aliphatic polycarbonate polyols as described above and one or more commercially available polyester or polyether polyols. In certain embodiments, the aliphatic polycarbonate content of such blends ranges from about 10% to about 90%. Such blends may be formulated to provide a range of hardness or elasticity as shown in fig. 8. In certain embodiments, the present invention encompasses adhesive compositions derived from a polyol blend comprising about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, or about 80% aliphatic polycarbonate polyol, with the remainder comprising polyester polyol. In certain embodiments, such blends comprise poly (butylene adipate) glycol as the polyester polyol. In certain embodiments, the present invention encompasses adhesive compositions derived from a polyol blend comprising about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, or about 80% aliphatic polycarbonate polyol, with the remainder comprising polyether polyol. In certain embodiments, such blends comprise polyethylene glycol or polypropylene glycol as the polyether polyol component.
C. Hot melt polyurethane adhesive
In one aspect, the invention encompasses reactive hot melt adhesives. In certain embodiments, such reactive hot melt adhesive compositions are derived from mixtures containing one or more aliphatic polycarbonate polyol compositions as defined above and in the embodiments and examples herein.
In certain embodiments, the hot melt adhesive comprises a prepolymer derived from one or more aliphatic polycarbonate polyols. These prepolymers can be produced using excess isocyanate and/or excess hydroxyl content and then mixed with one or more of the isocyanates described above, the aliphatic polycarbonate polyols, the other polyols, and the other components described above. In certain embodiments, the molar ratio of isocyanate to polyol is from 1.5:1 to 4:1, preferably from 1.9:1 to 3:1, and is typically very close to 2: 1.
In certain embodiments, MDI is the preferred isocyanate to react with one or more aliphatic polyols and possibly one or more other polyols as described above. In certain embodiments requiring unique hot melt adhesive performance characteristics, TDI and/or aliphatic isocyanates are used in place of or in addition to MDI.
In certain embodiments, the reactive hot melt adhesive prepolymer is produced by reacting an excess of isocyanate with a higher molecular weight polyol. These prepolymers therefore have excess isocyanate or "free" isocyanate groups which react with atmospheric moisture to improve the finished properties of the reactive hot melt adhesive. In certain embodiments, the amount of free isocyanate is from about 1 to 5 weight percent.
In certain embodiments, the polyol, isocyanate, and/or prepolymer comprising the primary component of the reactive hot melt adhesive is formulated such that the viscosity of the adhesive formulation is sufficiently low at the application temperature to enable effective application to a substrate. The reactive hot melt viscosity increases as it cools to provide good bonding characteristics quickly.
In certain embodiments, the reactive hot melt polyurethane adhesive mixture forms a final cured polyurethane adhesive having the following composition:
5 to 40 parts by weight of one or more isocyanate components or prepolymers based on isocyanate components as described above and in the specific embodiments and examples herein;
60-95 parts by weight of a polyol component or a polyol-based prepolymer component, wherein the polyol component comprises about 5 to 100 weight percent of one or more aliphatic polycarbonate polyols as described above and in the specific embodiments and examples herein;
0 to 1 parts by weight of one or more catalysts as described above and in the specific embodiments and examples herein;
0 to 20 parts by weight of one or more chain extenders, wherein said chain extender molecules are substantially as described hereinabove and in the specific embodiments and examples herein; and
0 to 10 parts by weight of one or more additives, wherein the additives are selected from: fillers, clays, blocking agents, stabilizers, thixotropic materials, plasticizers, compatibilizers, colorants, UV stabilizers, or flame retardants as described above and in the specific embodiments and examples herein.
D. Non-reactive solvent-borne polyurethane adhesives
In another aspect, the present invention encompasses non-reactive solvent-based adhesives. In certain embodiments, such solvent-borne adhesive compositions are derived from one or more aliphatic polycarbonate polyol compositions as defined above and in the embodiments and examples herein.
In certain embodiments, solvent-borne adhesives are produced by reacting one or more aliphatic polycarbonate polyols with one or more isocyanates, and possibly with one or more additional polyols and/or all of the other additives described above, to produce higher molecular weight prepolymers and/or polyurethane adhesives. These high molecular weight polyurethanes are then dissolved in one or more solvents for application to various substrates. In these embodiments, the solvent-based adhesive is described as a one-component system. Additional fillers and performance enhancing additives may be included in the formulation.
In certain embodiments, solvent-based crosslinkers are added to the solvent-based polyurethane adhesives described above to improve the strength and resistance of the finished adhesives. The cross-linking agent may be any combination of the above aliphatic polycarbonate polyols, additional polyols and isocyanates, and may also be other types of thermosetting components. In these embodiments, the solvent-based adhesives are described as two-part reactive systems, and thus in embodiments (where these systems are dissolved in one or more solvents) are similar and/or identical to the two-part reactive adhesives described above.
In certain embodiments, the non-reactive solvent-based adhesive mixture forms a final cured polyurethane adhesive having the following composition:
5 to 30 parts by weight of one or more isocyanate components or prepolymers based on isocyanate components as described above and in the specific embodiments and examples herein;
70-95 parts by weight of a polyol component or a polyol-based prepolymer component, wherein the polyol component comprises from about 5 to 100 weight percent of one or more aliphatic polycarbonate polyols as described above and in the specific embodiments and examples herein;
0 to 1 parts by weight of one or more catalysts as described above and in the specific embodiments and examples herein;
0 to 20 parts by weight of one or more chain extenders, wherein said chain extender molecules are substantially as described hereinabove and in the specific embodiments and examples herein; and
0 to 10 parts by weight of one or more additives, wherein the additives are selected from: fillers, clays, blocking agents, stabilizers, thixotropic materials, plasticizers, compatibilizers, colorants, UV stabilizers, or flame retardants as described above and in the specific embodiments and examples herein.
E. Non-reactive water-based adhesives
In one aspect, the invention encompasses reactive water-based adhesives. In certain embodiments, such water-based adhesive compositions are derived from mixtures containing one or more aliphatic polycarbonate polyol compositions as defined above and in the embodiments and examples herein.
In certain embodiments, the aqueous binder is produced by reacting one or more aliphatic polycarbonate polyols with one or more isocyanates and possibly with one or more additional polyols and/or all of the other additives described above to produce a higher molecular weight prepolymer and/or polyurethane binder that is then dispersed in water and referred to as a polyurethane dispersion (PUD). In certain embodiments, they may contain low levels of solvent to help stabilize the polymer in water.
In certain embodiments, the solids content of the final PUD binder ranges from 25 to 75%, with a preferred range of 35 to 50%. In certain embodiments, water-based adhesives are formulated to very high or very low values within these ranges, depending on viscosity requirements, other processing considerations, and desired finished adhesive properties.
In certain embodiments, a water-based cross-linker is added to the water-based PUDs as described above to improve the properties of the finished adhesive. The cross-linking agent may be any combination of the above aliphatic polycarbonate polyols, additional polyols and isocyanates, and may also be other types of thermosetting components. In these embodiments, the water-based adhesive is similar to the two-component reaction system described above in the embodiments (except that it is dispersed in a water system), where these systems are dispersed or emulsified in water.
In certain embodiments, the non-reactive water-based adhesive mixture forms a final cured polyurethane adhesive having the following composition:
20 to 50 parts by weight of one or more isocyanate components or prepolymers based on isocyanate components as described above and in the specific embodiments and examples herein;
50 to 80 parts by weight of a polyol component or a polyol-based prepolymer component, wherein the polyol component comprises from about 5 to 100 weight percent of one or more aliphatic polycarbonate polyols as described above and in the specific embodiments and examples herein;
0 to 1 parts by weight of one or more catalysts as described above and in the specific embodiments and examples herein;
0 to 20 parts by weight of one or more chain extenders, wherein said chain extender molecules are substantially as described hereinabove and in the specific embodiments and examples herein; and
0 to 10 parts by weight of one or more additives, wherein the additives are selected from: fillers, clays, blocking agents, stabilizers, thixotropic materials, plasticizers, compatibilizers, colorants, UV stabilizers, or flame retardants as described above and in the specific embodiments and examples herein.
F. Non-reactive hot melt adhesive
In one aspect, the invention encompasses non-reactive hot melt adhesives. In certain embodiments, such non-reactive hot melt adhesive compositions are derived from mixtures containing one or more aliphatic polycarbonate polyol compositions as defined above and in the embodiments and examples herein.
In certain embodiments, the non-reactive hot melt adhesive is produced by reacting one or more aliphatic polycarbonate polyols with one or more isocyanates and possibly with one or more additional polyols and/or all of the other additives described above to produce a higher molecular weight polymer and/or polyurethane adhesive. Additional fillers and performance enhancing additives may be included in the formulation.
In certain embodiments, the polyol, isocyanate, prepolymer and/or polyurethane adhesive comprising the major component of the non-reactive hot melt adhesive is formulated such that the viscosity of the adhesive formulation is sufficiently low at the application temperature to enable effective application to a substrate. The non-reactive hot melt viscosity increases as it cools to provide good bonding characteristics quickly. In certain applications, they may be formulated to have a melt viscosity of 25,000 to 500,000 mPa-s, more preferably 50,000 to 250,000 mPa-s.
In certain embodiments, the non-reactive hot melt adhesive mixture forms a final cured polyurethane adhesive having the following composition:
1 to 80 parts by weight of one or more isocyanate components or prepolymers based on isocyanate components as described hereinabove and in the specific embodiments and examples herein;
20 to 99 parts by weight of a polyol component or a polyol-based prepolymer component, wherein the polyol component comprises from about 5 to 100 weight percent of one or more aliphatic polycarbonate polyols as described above and in the specific embodiments and examples herein;
0 to 1 parts by weight of one or more catalysts as described above and in the specific embodiments and examples herein;
0 to 20 parts by weight of one or more chain extenders, wherein said chain extender molecules are substantially as described hereinabove and in the specific embodiments and examples herein; and
0 to 10 parts by weight of one or more additives, wherein the additives are selected from: fillers, clays, blocking agents, stabilizers, thixotropic materials, plasticizers, compatibilizers, colorants, UV stabilizers, or flame retardants as described above and in the specific embodiments and examples herein.
G. Mixing system
In certain embodiments, any of the above-described reactive and non-reactive binder formulations are combined with other binder chemicals in a mixing system. In certain embodiments, the finished binder is a urethane acrylic system that can take a variety of forms including the use of an aqueous system of water dispersible isocyanate with PUD and acrylic emulsion polymer, the mixing of acrylic and hydroxyl polyols to form copolymeric resins, and the like. In certain embodiments, vinyl terminated acrylic polymers are used to improve impact resistance. In certain embodiments, polyurethanes with acrylic functionality are also used in anaerobic or radiation cured adhesives to improve toughness. In certain embodiments, the polyurethane and epoxy compound are combined using an amine curing system to produce a fast curing adhesive for structural and heavy duty applications.
Adhesives with improved properties
The adhesives provided by the present invention have unique and unexpected properties. As mentioned above, epoxide-CO-based compositions incorporating the binders of the invention2Unlike existing commercial polycarbonate polyols having more than two bound carbon atoms between adjacent carbonate linkages. Without being bound by theory or thereby limiting the scope of the invention, one possibility is a higher density of carbonate functions/based on CO than the existing polycarbonate polyols2The unit chain length of the polyol(s) results in an unexpected increase in desirable properties such as adhesion, high temperature strength, and solvent resistance.
A. Improved high temperature strength
In certain embodiments, the present invention encompasses compositions comprising a CO-derived polymer2And one or more epoxy-copolymerized polyols and characterized in that the cured adhesive has unexpectedly high strength at elevated temperatures. High strength at elevated temperatures can be demonstrated by measuring the cured adhesive strength on a metal substrate using the ASTM D1002 lap shear test at ambient temperature followed by the same measurements at one or more elevated temperatures.
In certain embodiments, the adhesive of the present invention (i.e., any of the adhesive compositions described above) is characterized by a strength retention of the cured adhesive at 50 ℃ measured using ASTM D1002 that is at least 60% of the strength measured at 25 ℃ using the same method. In certain embodiments, the adhesive of the present invention is characterized by a strength of the cured adhesive measured at 50 ℃ that is at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 92%, at least 95%, or at least 98% of the strength measured at 25 ℃ using the same method. In certain embodiments, the adhesives of the invention are characterized by a strength of the cured adhesive measured at 50 ℃ that is 50% to 100% of the strength measured at 25 ℃ using the same method. In certain embodiments, the adhesive of the invention is characterized by a strength of the cured adhesive measured at 50 ℃ that is 50% to 80%, 70% to 80%, 60% to 80%, 70% to 100%, or 80% to 100% of the strength measured at 25 ℃ using the same method. In certain embodiments, the intensity of the above comparison is made by a method selected from the group consisting of: load at the time of destruction; tensile breaking energy; yield stress; and a measure of yield strain.
In certain embodiments, the adhesive of the present invention (i.e., any of the adhesive compositions described above) is characterized by a strength of the cured adhesive as indicated by load at failure measured at 50 ℃ using ASTM D1002 that is at least 60% of the load at failure measured at 25 ℃ using the same method. In certain embodiments, the adhesives of the invention are characterized by a load at failure, measured at 50 ℃, of the cured adhesive of at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 92%, at least 95%, or at least 98% of the load at failure, measured using the same method at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a load at failure of the cured adhesive measured at 50 ℃ that is 50% to 100% of the load at failure measured using the same method at 25 ℃. In certain embodiments, the adhesive of the invention is characterized by a load at failure of the cured adhesive measured at 50 ℃ of 50% to 80%, 70% to 80%, 60% to 80%, 70% to 100%, or 80% to 100% of the load at failure measured using the same method at 25 ℃.
In certain embodiments, the adhesive of the present invention (i.e., any of the adhesive compositions described above) is characterized by a strength of the cured adhesive as indicated by tensile energy to break measured at 50 ℃ using ASTM D1002 that is at least 60% of the tensile energy to break measured at 25 ℃ using the same method. In certain embodiments, the adhesives of the invention are characterized by a tensile energy to break of the cured adhesive measured at 50 ℃ of at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 92%, at least 95%, or at least 98% as measured using the same method at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a tensile energy to break of the cured adhesive measured at 50 ℃ of from 50% to 100% of the tensile energy to break measured at 25 ℃ using the same method. In certain embodiments, the adhesives of the invention are characterized by a tensile energy to break of the cured adhesive measured at 50 ℃ of from 50% to 80%, 70% to 80%, 60% to 80%, 70% to 100%, or 80% to 100% of the tensile energy to break measured at 25 ℃ using the same method.
In certain embodiments, the adhesive of the present invention (i.e., any of the adhesive compositions described above) is characterized in that the strength of the cured adhesive as indicated by the yield stress or strain, measured at 50 ℃ using ASTM D1002, is at least 60% of the yield stress or strain, measured at 25 ℃ using the same method. In certain embodiments, the adhesives of the invention are characterized by a yield stress or strain of the cured adhesive measured at 50 ℃ that is at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 92%, at least 95%, or at least 98% of the yield stress or strain of the cured adhesive measured using the same method at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a yield stress or strain of the cured adhesive measured at 50 ℃ that is 50% to 100% of the yield stress or strain measured at 25 ℃ using the same method. In certain embodiments, the adhesives of the invention are characterized by a yield stress or strain of the cured adhesive measured at 50 ℃ that is 50% to 80%, 70% to 80%, 60% to 80%, 70% to 100%, or 80% to 100% of the yield stress or strain measured at 25 ℃ using the same method.
In certain embodiments, the adhesive of the present invention (i.e., any of the adhesive compositions described above) is characterized by a strength of the cured adhesive measured at 50 ℃ using ASTM D1002 that is greater than the strength at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a strength of the cured adhesive measured at 50 ℃ using ASTM D1002 that is at least 10% greater than the strength measured at 25 ℃ using the same method. In certain embodiments, the adhesive of the present invention is characterized by a strength of the cured adhesive at 50 ℃ that is at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 150% greater than a strength measured using the same method at 25 ℃. In certain embodiments, the adhesive of the present invention is characterized by a strength of the cured adhesive measured at 50 ℃ that is 100% to 200%, 100% to 150%, 120% to 180%, 120% to 150%, or 100% to 120% of the strength measured at 25 ℃ using the same method. In certain embodiments, the intensity of the above comparison is made by a method selected from the group consisting of: load at the time of destruction; tensile breaking energy; yield stress; and a measure of yield strain. In certain embodiments, the intensity of the above comparison is made by a method selected from the group consisting of: load at the time of destruction; tensile breaking energy; and a measure of yield strain.
In certain embodiments, the adhesive of the present invention (i.e., any of the adhesive compositions described above) is characterized by a cured adhesive strength as indicated by load at failure measured at 50 ℃ using ASTM D1002 that is greater than the load at failure at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a load at failure, as measured at 50 ℃ using ASTM D1002, that is at least 10% greater than the load at failure, as measured at 25 ℃ using the same method. In certain embodiments, the adhesive of the present invention is characterized by a load at failure of the cured adhesive at 50 ℃ that is at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 150% greater than the load at failure at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a load at failure, measured at 50 ℃, of the cured adhesive of from 100% to 200%, 100% to 150%, 120% to 180%, 120% to 150%, or 100% to 120% of the load at failure, measured using the same method at 25 ℃.
In certain embodiments, the adhesive of the present invention (i.e., any of the adhesive compositions described above) is characterized by a cured adhesive strength as indicated by tensile energy to break measured at 50 ℃ using ASTM D1002 that is greater than the tensile energy to break at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a tensile energy to break of the cured adhesive, as measured at 50 ℃ using ASTM D1002, that is at least 10% higher than the tensile energy to break, as measured at 25 ℃ using the same method. In certain embodiments, the adhesives of the invention are characterized by a tensile energy to break of the cured adhesive at 50 ℃ that is at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 150% greater than the tensile energy to break of the adhesive at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a tensile energy to break of the cured adhesive measured at 50 ℃ of 100% to 200%, 100% to 150%, 120% to 180%, 120% to 150%, or 100% to 120% of the tensile energy to break of the adhesive at 25 ℃.
In certain embodiments, the adhesive of the present invention (i.e., any of the adhesive compositions described above) is characterized by a strength of the cured adhesive as indicated by yield strain at 50 ℃ measured using ASTM D1002 that is greater than the yield strain at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a yield strain of the cured adhesive measured at 50 ℃ using ASTM D1002 that is at least 10% higher than the yield strain measured at 25 ℃ using the same method. In certain embodiments, the adhesives of the invention are characterized by a yield strain of the cured adhesive at 50 ℃ that is at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 150% greater than the yield strain of the adhesive at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a yield strain of the cured adhesive measured at 50 ℃ of 100% to 200%, 100% to 150%, 120% to 180%, 120% to 150%, or 100% to 120% of the yield strain of the adhesive at 25 ℃.
In certain embodiments, the adhesive of the present invention (i.e., any of the adhesive compositions described above) is characterized by a strength retention of the cured adhesive at 70 ℃ measured using ASTM D1002 that is at least 40% of the strength measured at 25 ℃ using the same method. In certain embodiments, the adhesive of the present invention is characterized by a strength of the cured adhesive measured at 50 ℃ that is at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, or at least 80% of the strength measured at 25 ℃ using the same method. In certain embodiments, the adhesives of the invention are characterized by a strength of the cured adhesive measured at 70 ℃ that is from 40% to 100% of the strength measured at 25 ℃ using the same method. In certain embodiments, the adhesive of the present invention is characterized by a strength of the cured adhesive measured at 70 ℃ that is 40% to 80%, 40% to 60%, 50% to 80%, 50% to 70%, or 70% to 90% of the strength measured at 25 ℃ using the same method. In certain embodiments, the intensity of the above comparison is made by a method selected from the group consisting of: load at the time of destruction; tensile breaking energy; yield stress; and a measure of yield strain.
In certain embodiments, the adhesive of the present invention (i.e., any of the adhesive compositions described above) is characterized by a strength of the cured adhesive as indicated by yield strain at 70 ℃ as measured using ASTM D1002 that is greater than the yield strain at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a yield strain of the cured adhesive, as measured using ASTM D1002 at 70 ℃, that is at least 10% higher than the yield strain measured using the same method at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a yield strain of the cured adhesive at 70 ℃ that is at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 150% greater than the yield strain of the adhesive at 25 ℃. In certain embodiments, the adhesives of the invention are characterized by a yield strain of the cured adhesive measured at 70 ℃ of 100% to 200%, 100% to 150%, 120% to 180%, 120% to 150%, or 100% to 120% of the yield strain of the adhesive at 25 ℃.
In certain embodiments, the present invention encompasses epoxy-CO-based adhesives comprising the following characteristics characterized in that the cured adhesive has the following properties when measured by ASTM D10022Adhesive composition of polyol of (a): -a load at 50 ℃ failure that is 75% to 200% of the load at 25 ℃ failure; and
-a tensile energy to break at 50 ℃ exceeding the tensile energy to break at 25 ℃.
In certain embodiments, the present invention encompasses epoxy-CO-based adhesives comprising the following characteristics characterized in that the cured adhesive has the following properties when measured by ASTM D10022Binder composition of polyol (b):
-a yield strain at 50 ℃ that is at least 60% of the yield strain at 25 ℃; and
-a yield strain at 50 ℃ exceeding the yield strain at 25 ℃.
In certain embodiments, the present invention encompasses epoxy-CO-based adhesives comprising the following characteristics characterized in that the cured adhesive has the following properties when measured by ASTM D10022Binder composition of polyol (b):
-a load at 50 ℃ failure that is 75% to 200% of the load at 25 ℃ failure;
-a tensile energy to break at 50 ℃ exceeding the tensile energy to break at 25 ℃;
-a yield strain at 50 ℃ that is at least 60% of the yield strain at 25 ℃; and
-a yield strain at 50 ℃ exceeding the yield strain at 25 ℃.
In certain embodiments, the present invention encompasses epoxy-CO-based adhesives comprising the following characteristics characterized in that the cured adhesive has the following properties when measured by ASTM D10022Binder composition of polyol (b):
-a load at 50 ℃ failure in excess of the load at 25 ℃ failure;
-a tensile energy to break at 50 ℃ exceeding the tensile energy to break at 25 ℃; and
-a yield strain at 70 ℃ equal to or greater than the yield strain at 25 ℃.
B. Improved transparency
In another aspect, the present invention encompasses compositions comprising epoxy-CO-based adhesives characterized by a high degree of transparency of the cured adhesive2-a polyol binder composition. Such transparent properties are unexpected because similar binders formulated with commercially available polycarbonate polyols (e.g., those having more than two bound carbon atoms between adjacent carbonate bonds) fog (hazy) upon curing (see, e.g., fig. 7).
In certain embodiments, the adhesive compositions of the present invention comprise epoxy-CO based adhesives2And further characterized in that they have a total light transmission of greater than 85% when measured using ASTM D1003-00. In certain embodiments, the adhesive compositions of the present invention are further characterized in that they have a light transmission of greater than 90%, greater than 95%, greater than 96%, greater than 97%, greater than 98%, or greater than 99% when measured using ASTM D1003.
In certain embodiments, the adhesive compositions of the present invention comprise epoxy-CO based adhesives2And further characterized in that they have a total light transmission of greater than 85% when measured using ASTM D1003 (corrected for reflection). In certain embodiments, the adhesive compositions of the present invention are further characterized in that they have a light transmission of greater than 90%, greater than 95%, greater than 96%, greater than 97%, greater than 98%, or greater than 99% when measured using ASTM D1003.
In certain embodiments, the adhesive compositions of the present invention comprise a ring-basedoxide-CO2And further characterized in that they have a haze value of less than 20% when measured using ASTM D1003-92. In certain embodiments, the adhesive compositions of the present invention are further characterized in that they have a haze value of less than 15%, less than 10%, less than 7%, less than 6%, less than 5%, or less than 3% when measured using ASTM D1003-92.
C. Improved solvent resistance
In another aspect, the invention encompasses compositions comprising epoxy-based-CO characterized by a high resistance of the cured adhesive to solvents2The polyol binder composition of (1). Such solvent resistance is unexpected because similar adhesives formulated with commercially available polycarbonate polyols (e.g., those having more than two tethered carbon atoms between adjacent carbonate bonds) are more degraded by solvents than the adhesives of the present invention. (see, e.g., fig. 5).
In certain embodiments, the adhesive compositions of the present invention comprise epoxy-CO based adhesives2And also characterized in that they have excellent resistance to hydrocarbon solvents. In certain embodiments, the adhesive compositions of the present invention are characterized by their excellent resistance to aromatic hydrocarbons. In certain embodiments, the invention comprises an epoxide-CO based polymer characterized by a mass gain of less than 5% when immersed in an aromatic hydrocarbon liquid for 1 week2The polyol of (1). In certain embodiments, the mass gain is less than 5% when submerged in toluene for 1 week. In certain embodiments, the mass gain is less than 1% when immersed in xylene for 1 week.
D. Flexible adhesive with low tensile set
In another aspect, the invention encompasses compositions comprising epoxy-CO-based adhesives characterized by very low tensile set of the cured adhesive after stretching2The polyol binder composition of (1). Such low tensile set characteristics are unexpected because similar binders formulated with commercially available polycarbonate polyols (e.g., those having more than two tethered carbon atoms between adjacent carbonate bonds) cannot demonstrateSuch low tensile set.
In certain embodiments, the adhesive compositions of the present invention comprise epoxy-CO based adhesives2And further characterized in that they have a tensile set of less than 2% after being stretched at least 500%. In certain embodiments, the tensile set is less than 1% or less than 0.5% after being stretched to 500%. In certain embodiments, the tensile set after being stretched to 1000% is less than 2%, less than 1%, or less than 0.5%.
Adhesives based on polyol blends
Such improvements in adhesive properties are highly desirable in certain applications. However, based only on epoxide-CO2The adhesive properties of the derivatized polyols are not suitable for various applications. For example, while PPC-based adhesives are extremely strong, the adhesives do not have particular flexibility. This is not desirable in certain adhesive applications, such as those in which the bonded portions must be flexible or move relative to each other. Fortunately, the inventors have also found that the catalyst may be based on epoxide-CO2Novel adhesives formulated with mixtures of polyols with conventional polyurethane polyols, such as polyester polyols and polyether polyols. The use of blends allows for the formulation of adhesives that span a continuous range from very high tensile strength but rigid adhesives to very soft and flexible adhesives. Surprisingly, even when formulated into highly flexible adhesives, the epoxy CO2The incorporation of polyols imparts significant toughness.
In certain embodiments, the invention encompasses CO derived from the above2-an adhesive formulated from a combination of an epoxide derived polycarbonate polyol and a polyether or polyester polyol. In certain embodiments, the polyether or polyester polyol comprises from about 5% to about 50% of the polyol present in the adhesive formulation. Incorporation of polyether or polyester polyols in this range provides better results than the epoxide CO alone2Those of polyols are softer binders.
In certain embodiments, the present invention encompasses adhesives comprising a mixture of one or more polyester polyols and one or more aliphatic polycarbonate polyols described above and in the classes, subclasses, and examples herein. In certain embodiments, the polyol component of such adhesives comprises from 5% to about 10%, from 10% to about 25%, or from 20% to about 50% of a polyester polyol and the remainder comprises aliphatic polycarbonate polyols of any formula P2a to P2r-a (or mixtures of two or more thereof). In certain embodiments, the polyester polyols present comprise diol and diacid based materials (e.g., polymers based on Adipic Acid (AA); sebacic acid (SBA); Succinic Acid (SA); dodecanedioic acid (DDA); isophthalic acid (iPA); azelaic acid (Az); Ethylene Glycol (EG); Propylene Glycol (PG); 1, 3-propanediol; 1, 4-Butanediol (BDO); 1, 6-Hexanediol (HID); diethylene glycol (DEG); neopentyl glycol (NPG); 3-methyl-1, 5-pentanediol (MPD); examples of these include, but are not limited to:
AA-EG polyesters having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
AA-EG/BDO polyesters having molecular weights of 500, 1,000, 2,000, or 3,000 g/mol;
AA-PG polyesters having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
AA-BDO polyesters having molecular weights of 500, 1,000, 2,000 or 3,000 g/mol;
AA-BDO/HID polyesters with molecular weights of 500, 1,000, 2,000 or 3,000 g/mol;
AA-DEG polyesters having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
AA-NPG polyesters having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
AA-NPG/HID polyesters having molecular weights of 500, 1,000, 2,000 or 3,000 g/mol;
an AA-HID polyester having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
AA-MPD polyesters having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
SEA-HID polyester with molecular weight of 2,000, 3,000, 4,000 or 5,000 g/mol;
DDA-HID polyesters having molecular weights of 2,000, 3,000, 4,000 or 5,000 g/mol;
Az-EG polyesters having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
Az/iPA-EG/NPG polyester with molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
SA-EG polyesters having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
SA-DEG polyesters having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
SA-NPG polyesters having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
SA-PG polyesters having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol;
in certain embodiments, the polyester polyol is formed by ring-opening polymerization of caprolactone or propiolactone. For example, polycaprolactone having a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol; or polypropiolactone with a molecular weight of 500, 1,000, 2,000 or 3,000 g/mol.
In certain embodiments, the present invention encompasses polyurethane adhesives derived from the reaction of a polyisocyanate with a polyol composition, wherein the polyol composition is characterized in that it contains from 50 to 95 weight percent of a polyol selected from the group consisting of poly (propylene carbonate); poly (ethylene carbonate); and poly (ethylene-co-propylene carbonate) and 5 to 50% by weight of a polyester polyol. In certain embodiments, the polyurethane adhesive is further characterized by the aliphatic polycarbonate polyol having an Mn of about 500g/mol to 10,000 g/mol; or about 500 to 5,000 g/mol; or about 500 to 3,000g/mol, or about 500 to 1,500g/mol, or about 1,000 to 2,500g/mol, or about 3,000 to 7,000 g/mol. In certain embodiments, the polyurethane adhesive is further characterized by the aliphatic polycarbonate polyol having a functionality of 2; or the aliphatic polycarbonate polyol has a functionality greater than 2. In certain embodiments, the polyurethane adhesive is further characterized in that the polyester comprises a polyester derived from one or more of: adipic Acid (AA); sebacic acid (SBA); succinic Acid (SA); dodecanedioic Acid (DDA); isophthalic acid (iPA); azelaic acid (Az); ethylene Glycol (EG); propylene Glycol (PG); 1,3 propylene glycol; 1, 4-Butanediol (BDO); 1, 6-Hexanediol (HID); diethylene glycol (DEG); neopentyl glycol (NPG); and 3-methyl-1, 5-pentanediol (MPD). In certain embodiments, such adhesive formulations are also characterized in that they have a yield strain (i.e., as measured using ASTM D1002) of greater than 5%. In certain embodiments, the adhesive formulations are further characterized in that they have a yield strain of greater than 10%. In certain embodiments, such adhesive formulations are also characterized in that they have an elongation at break (i.e., as measured using ASTM D412) of greater than 100%. In certain embodiments, the adhesive formulations are further characterized in that they have an elongation at break of greater than 200%, greater than 300%, or greater than 500%.
In another aspect, the present invention provides adhesive compositions and formulations comprising mixtures of the aliphatic polycarbonate polyols described above with other commonly used polyols. In certain embodiments, the present invention comprises a strength-enhancing additive for a polyurethane adhesive, wherein the additive comprises a CO-derived polymer derived from CO2And one or more epoxide co-derived polycarbonate polyols. In certain embodiments, the additive has a primary repeat unit having the structure:
wherein each R is1、R2、R3And R4As defined above and within classes and subclasses herein.
In certain embodiments, the additive comprises from about 1% to about 40% of the polyol present in the adhesive formulation. In certain embodiments, the additive comprises 2% to 5% of the polyol present in the adhesive formulation and an aliphatic polycarbonate polyol derived from the copolymerization of carbon dioxide and one or more epoxides. In certain embodiments, the additive is used in an amount of 1% to 5%, 5% to 10%, 10% to 20%, 20% to 30%, or 30% to 40% of the polyol present.
In this regard, the present invention also provides a process for the preparation of a polymer by reacting an epoxide with CO2A method of using a derivatized polyol to replace a portion of the polyol in a base formulation to improve the strength of a polyurethane adhesive.
In certain embodiments, the method comprises modifying a base polyurethane adhesive formulation, wherein the base formulation comprises a polyester polyol. Modification is carried out by substituting a portion of the polyester polyols with an aliphatic polycarbonate polyol derived from the copolymerization of carbon dioxide and one or more epoxides and having a main repeating unit of the structure:
wherein each R is1、R2、R3And R4As defined above and within classes and subclasses herein.
In certain embodiments, the substituted polyester polyol portion is from about 2% to about 50%. In certain embodiments, the method comprises replacing 2% to 5% of the polyester polyol in the binder formulation with an aliphatic polycarbonate polyol derived from the copolymerization of carbon dioxide and one or more epoxides. In certain embodiments, 5% to 10%, 10% to 20%, 20% to 30%, or 30% to 50% of the polyester polyols in the formulation are substituted.
In certain embodiments, the method comprises modifying a base polyurethane adhesive formulation, wherein the base formulation comprises a polyether polyol. Modification is carried out by replacing a portion of the polyether polyol with an aliphatic polycarbonate polyol derived from the copolymerization of carbon dioxide and one or more epoxides and having a primary repeat unit of the structure:
wherein each R is1、R2、R3And R4As defined above and within classes and subclasses herein.
In certain embodiments, the substituted polyether polyol portion is from about 2% to about 50%. In certain embodiments, the method comprises replacing 2% to 5% of the polyether polyol in the adhesive formulation with an aliphatic polycarbonate polyol derived from the copolymerization of carbon dioxide and one or more epoxides. In certain embodiments, from 5% to 10%, from 10% to 20%, from 20% to 30%, or from 30% to 50% of the polyether polyol in the formulation is substituted.
In certain embodiments of the above process, the aliphatic polycarbonate polyol has substantially the same OH # (where it is substituted) as the polyester or polyether polyol. In certain embodiments, the aliphatic polycarbonate polyol has substantially the same functionality as the polyester or polyether polyol (where it is substituted). In certain embodiments, the aliphatic polycarbonate polyol has an OH # (where it is substituted) that is substantially different from the polyester or polyether polyol (e.g., by more than 5%, by more than 10%, or by more than 25%), and the method includes the additional steps of: the amount of isocyanate included in the adhesive formulation is adjusted to accommodate the differences in the resulting blend polyol OH # associated with the base formulation.
The present application includes, but is not limited to, the following embodiments:
wherein R is1、R2、R3And R4Independently at each occurrence in the polymer chain, selected from-H, fluorine, optionally substituted C1-40Aliphatic radical, optionally substituted C1-20Heteroaliphatic and optionally substituted aryl, wherein R1、R2、R3And R4Any two or more of (a) may optionally form, together with intervening atoms, one or more optionally substituted rings optionally containing one or more heteroatoms.
Item 6. the polyurethane adhesive composition of
Item 7 the polyurethane adhesive composition of
Item 9 the polyurethane adhesive composition of
wherein R is1、R2、R3And R4Independently at each occurrence in the polymer chain, selected from-H, fluorine, optionally substituted C1-30Aliphatic radical and optionally substituted C1-20Heteroaliphatic and optionally substituted C6-10Aryl, wherein R1、R2、R3And R4Any two or more of (a) may optionally form, together with intervening atoms, one or more optionally substituted rings optionally containing one or more heteroatoms;
y, at each occurrence, is independently-H or a site linked to any chain extension moiety described in the classes and classifications herein;
n, at each occurrence, is independently an integer from about 3 to about 1,000;
x and y are each independently integers from 0 to 6, wherein the sum of x and y is from 2 to 6.
Item 11 the polyurethane adhesive composition of
Item 12 the polyurethane adhesive composition of item 11, wherein
Item 13 the polyurethane adhesive composition of item 11, wherein y is 0 and x is greater than 2.
Item 14. the polyurethane adhesive composition of
wherein t is an integer of 1 to 12 inclusive, and RtIndependently at each occurrence is-H or-CH3。
Item 16, the polyurethane adhesive composition of
Item 17 the polyurethane adhesive composition of item 16, further comprising 0.01 to 20 parts by weight of one or more chain extenders.
Item 18. the polyurethane adhesive composition of item 16, further comprising 0 to 20 parts by weight of one or more reactive small molecules, wherein the reactive small molecules comprise a functional group selected from the group consisting of hydroxyl, amine, thiol, and carboxylic acid.
Item 19 the polyurethane adhesive composition of item 18, wherein the reactive small molecule comprises a diol.
Item 20 the polyurethane adhesive composition of item 16, further comprising 0 to 10 parts by weight of one or more additives, wherein the additives are selected from the group consisting of: fillers, clays, blocking agents, stabilizers, thixotropic materials, plasticizers, compatibilizers, colorants, UV stabilizers, or flame retardants.
Item 21. the polyurethane adhesive composition of
Item 22 the polyurethane adhesive composition of
Item 23. the adhesive composition of any one of
Item 24 the adhesive composition of item 23, wherein the cured bond formed by the adhesive retains at least 50% of its room temperature strength when heated to a temperature of 60 ℃ or when heated to a temperature of 70 ℃.
Item 26. an adhesive composition according to any one of
Item 27. an adhesive formulation that cures to form the adhesive composition of any one of
Item 28 the adhesive formulation of item 27, wherein the formulation is a one-part adhesive comprising a polyurethane prepolymer synthesized from the aliphatic polycarbonate polyol.
Item 29 the adhesive formulation of item 27, wherein the formulation is a two-component formulation comprising a first component and a second component, wherein the first component comprises one or more of the aliphatic polycarbonate polyols and the second component comprises one or more isocyanates.
Item 31. a method of joining two substrates, the method comprising the steps of applying the adhesive formulation of any one of items 27 to 30 to at least one substrate, arranging the substrates so that both substrates are in contact with the adhesive formulation, and curing the adhesive formulation.
Item 32. a method of improving the high temperature strength of a polyurethane adhesive, the adhesive comprising a polyol component and an isocyanate component, the method comprising the step of replacing a portion of the polyol component with an aliphatic polycarbonate polyol derived from the copolymerization of carbon dioxide and one or more epoxides.
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