CN111868135A

CN111868135A - Composition using polyuretdione resin

Info

Publication number: CN111868135A
Application number: CN201980021506.1A
Authority: CN
Inventors: A·埃金; A·D·布什迈尔; F·J·施坦普夫莱
Original assignee: Covestro Deutschland AG; Covestro LLC
Current assignee: Covestro Deutschland AG; Covestro LLC
Priority date: 2018-03-23
Filing date: 2019-03-21
Publication date: 2020-10-30
Also published as: CN112105666A; WO2019183308A1; EP3768750A1; CN111886272A; CN111886273A; WO2019180128A1; CN111886271A; CN112105665A; EP3768756A1; CN112105666B; EP3768745A1; EP3768755A1; CN111868131A; WO2019183319A1; EP3768757A1; WO2019180130A1; WO2019180129A1; WO2019183330A1; EP3768747A1; CN111886272B

Abstract

本发明提供了一种反应混合物，其包含基于第一异氰酸酯的脲二酮树脂和基于第二异氰酸酯的脲二酮树脂的热共混物、中和的多元醇和叔胺催化剂，以及任选的添加剂包，所述添加剂包选自流动控制添加剂、颜料（着色剂）、润湿剂和溶剂，其中第一异氰酸酯和第二异氰酸酯不同。已经热共混在一起的基于异氰酸酯的脲二酮生产涂料、胶粘剂、铸造材料、复合材料和密封剂，其显示出与由基于异氰酸酯的脲二酮成分单独生成的那些涂料、胶粘剂、铸造材料、复合材料和密封剂相比更好的性能性质（例如显微硬度）。The present invention provides a reaction mixture comprising a thermal blend of a first isocyanate-based uretdione resin and a second isocyanate-based uretdione resin, a neutralized polyol and a tertiary amine catalyst, and optional additives The additive package is selected from the group consisting of flow control additives, pigments (colorants), wetting agents and solvents, wherein the first isocyanate and the second isocyanate are different. Isocyanate-based uretdiones that have been thermally blended together to produce coatings, adhesives, foundry materials, composites, and sealants are shown to be comparable to those produced from the isocyanate-based uretdione components alone. Better performance properties (eg microhardness) of materials compared to sealants.

Description

Composition using polyuretdione resin

Technical Field

The present invention relates generally to polymers, and more particularly to polymers made with neutralized polyols, uretdiones, and tertiary amine catalysts. The resulting allophanate polymers are useful in the preparation of coatings, adhesives, casting materials (castings), composites and sealants.

Background

Polyurethane-forming compositions are widely used in a variety of commercial, industrial and domestic applications, such as in automotive clear coat and seating applications. Polyurethane systems employing isocyanates pre-reacted with monofunctional reagents to form relatively thermally unstable compounds are known as blocked isocyanates. Uretdiones are one type of blocked isocyanate. Uretdiones are typically prepared by dimerizing isocyanates to form one or more uretdiones having unreacted isocyanate end groups, which can then be extended with a polyol to form a polymeric material containing two or more uretdione groups in the polymer chain. Uretdiones are known in some literature as "1, 3-diaza-2, 4-cyclobutanone", "1, 3-bisacridine-2, 4-diones (1, 3-diazatidine-2, 4-diones)", "2, 4-dioxo-1, 3-diazetidine", "uretdiones" or "uretdiones". Generally, the polymers have few, if any, free isocyanate groups, which is achieved by controlling the stoichiometry of the polyisocyanate, polyol, and by using a blocking agent.

The reaction of uretdiones with polyols to form polyurethane coatings is well known in the art, particularly in polyurethane powder coatings. However, the formation of allophanates from uretdiones and polyols at ambient or low temperatures in the presence of tertiary amine catalysts has not been fully investigated in the literature. To the best of the inventors' knowledge, no one has developed a crosslinking process that uses neutralized polyols to promote the successful conversion of uretdiones to allophanates at ambient or low temperatures in the presence of tertiary amine catalysts.

Summary of The Invention

Uretdione-based resins can be crosslinked with polyols to form allophanate groups. Different isocyanate-based uretdiones can be reacted (thermally blended) in a flask with a polyol to achieve the desired molecular weight and functionality. Isocyanate-based uretdiones that have been blended together produce coatings, adhesives, foundry materials, composites, and sealants that exhibit better performance than those coatings, adhesives, foundry materials, composites, and sealants made from the isocyanate-based uretdione component alone.

Accordingly, the present invention seeks to alleviate the problems inherent in the art by providing such an alternative crosslinking process to obtain a composition having physical properties similar to those of a polyurethane composition. To increase the conversion of uretdiones and polyols to allophanate groups at ambient or low temperatures in the presence of tertiary amine catalysts, the acidity of the polyol, and more generally of the system, is minimized or eliminated. Accordingly, various embodiments of the process of the present invention relate to crosslinking polyuretdione resins with neutralized polyols in the presence of tertiary amine catalysts. The polyols can be neutralized by reaction with acid scavengers at temperatures ranging from room temperature (21 ℃ C. -24 ℃ C.) to 120 ℃ and the resulting allophanate polymers can be used to prepare coatings, adhesives, casting materials, composites and sealants.

These and other advantages and benefits of the present invention will be apparent from the detailed description of the invention below.

Detailed Description

The present invention will now be described for purposes of illustration and not limitation. Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities, percentages, and so forth, in the specification are to be understood as being modified in all instances by the term "about".

Any numerical range recited in this specification is intended to include all sub-ranges subsumed within that range with the same numerical precision. For example, a range of "1.0 to 10.0" is intended to include all sub-ranges between (and including) the recited minimum value of 1.0 and the recited maximum value of 10.0 (and including the recited minimum value of 1.0 and the recited maximum value of 10.0), i.e., having a minimum value equal to or greater than 1.0 and a maximum value of equal to or less than 10.0, such as, for example, 2.4 to 7.6. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, applicants reserve the right to amend this specification (including the claims) to specifically recite any sub-ranges subsumed within the ranges explicitly recited herein. All such ranges are intended to be inherently described in this specification such that revisions explicitly reciting any such sub-ranges will comply with the requirements of 35 u.s.c. § 112(a) and 35 u.s.c. § 132 (a).

Unless otherwise indicated, any patent, publication, or other disclosure material, in its entirety, is herein incorporated by reference into the specification, but only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this specification. Any conflicting material incorporated by reference herein is therefore, and to the extent necessary, replaced by explicit disclosure as set forth in this specification. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. Applicants reserve the right to amend this specification to specifically list any subject matter or portion thereof incorporated by reference herein.

Reference throughout this specification to "various non-limiting embodiments," "certain embodiments," or the like, means that a particular feature or characteristic may be included in an embodiment. Thus, the use of the phrases "in various non-limiting embodiments," "in certain embodiments," and the like, in this specification does not necessarily refer to the same embodiment, and may refer to different embodiments. Furthermore, the particular features or characteristics may be combined in any suitable manner in one or more embodiments. Thus, without limitation, particular features or characteristics illustrated or described in connection with various or some embodiments may be combined, in whole or in part, with features or characteristics of one or more other embodiments. Such modifications and variations are intended to be included within the scope of this specification.

As used herein, the grammatical articles "a", "an", and "the" are intended to include "at least one" or "one or more", even if "at least one" or "one or more" is explicitly used in some instances, unless otherwise indicated. Thus, the articles are used in this specification to refer to one or to more than one (i.e., "at least one") of the grammatical object of the article. For example and without limitation, "a component" refers to one or more components, and thus more than one component may be considered and employed or used in the practice of the described embodiments. Furthermore, unless the context of such usage requires otherwise, the use of a singular noun includes the plural, and the use of a plural noun includes the singular.

In various embodiments, the present invention provides a reaction mixture comprising a thermal blend of a first isocyanate-based uretdione resin and a second isocyanate-based uretdione resin; a neutralized polyol and a tertiary amine catalyst; and optionally, an additive package (additive package) selected from flow control additives, pigments (colorants), wetting agents, and solvents, wherein the first isocyanate and the second isocyanate are different.

In various non-limiting embodiments, the present invention further provides a method of preparing an allophanate polymer, which comprises thermally blending a first isocyanate-based uretdione resin and a second isocyanate-based uretdione resin to form a resin thermal blend, reacting the resin thermal blend with a neutralized polyol in the presence of a tertiary amine catalyst, optionally in the presence of an additive package selected from the group consisting of flow control additives, pigments (colorants), wetting agents and solvents, wherein the first isocyanate and the second isocyanate are different. The polyol can be neutralized by reaction with an acid scavenger at a temperature of room temperature (21 ℃ -24 ℃) to 120 ℃. Accordingly, the present invention provides a process for preparing an allophanate polymer by the following route:

in the blended uretdiones according to embodiments of the invention, R₁、R₂、R₃And R₄May independently be the same or different. This scheme shows the use of a compound from R₁And R₂To form an allophanateAn acid ester group. From R₄And R₅The second uretdione of (a) also forms an allophanate. Isocyanate-based uretdiones that have been heat blended together produce coatings, adhesives, foundry materials, composites, and sealants that exhibit better performance properties (e.g., microhardness) than each of the coatings, adhesives, foundry materials, composites, and sealants made from the isocyanate-based uretdione component alone.

The term "polymer" as used herein includes prepolymers, oligomers, and homopolymers and copolymers; the prefix "poly" refers herein to two or more. The term "molecular weight" as used herein, unless otherwise specified, is an index average molecular weight when used with respect to a polymer.

The term "polyol" as used herein refers to a compound comprising at least two free hydroxyl groups. Polyols include polymers containing lateral and terminal hydroxyl groups.

The term "coating composition" as used herein refers to a mixture of chemical components that will cure and form a coating when applied to a substrate.

The term "adhesive" or "adhesive compound" refers to any substance that can adhere or bond two items together. The concept that the composition or formulation is a combination or mixture of more than one species, component or compound is encompassed within the definition of "adhesive composition" or "adhesive formulation" and may include adhesive monomers, oligomers, and polymers, as well as other materials.

"sealant composition" refers to a composition that can be applied to one or more surfaces to form a protective barrier, for example, to prevent ingress or egress of solid, liquid, or gaseous materials, or to allow gases and liquids to pass through the barrier with selective permeability. In particular, it may provide a seal between surfaces.

"casting composition" refers to a mixture of liquid chemical components that is typically poured into a mold containing a hollow cavity of a desired shape and then allowed to cure.

"composite" refers to a material made from two or more polymers, optionally containing other kinds of materials. The composite material has properties that are different from the properties of the individual polymers/materials that make up it.

"cured", "cured composition" or "cured compound" refers to components and mixtures obtained from one or more original compounds or one or more mixtures thereof that are reactive curable, which have undergone chemical and/or physical changes to convert the original compound or compounds or mixture or mixtures into a solid, substantially non-flowing material. A typical curing process may involve crosslinking.

The term "curable" means that the original compound or compounds or composition material or materials can be converted to a solid, substantially non-flowing material by chemical reaction, crosslinking, radiation crosslinking, and the like. Thus, the compositions of the present invention are curable, but unless otherwise specified, the original compound or compounds or composition material or materials are uncured.

"thermally blended" or "thermal blending" as used in the context of the present invention means taking a first isocyanate-based uretdione-containing resin and a second isocyanate-based uretdione-containing resin and mixing them together in a flask, reactor or other vessel, reacting them with an appropriate polyol or polyols while heating to obtain a uretdione blend having a particular functionality and molecular weight. The resulting hot blend may be liquid when cooled to room temperature after the reaction is complete.

After the hot blend is made, coating, adhesive, casting, composite and sealant formulations are prepared by adding the appropriate polyols and catalysts to the blend.

The components used in the present invention include polyisocyanates. The term "polyisocyanate" as used herein refers to a compound comprising at least two unreacted isocyanate groups, such as three or more unreacted isocyanate groups. The polyisocyanate may include diisocyanates such as linear aliphatic polyisocyanates, aromatic polyisocyanates, cycloaliphatic polyisocyanates, and aralkyl polyisocyanates.

Particularly preferred in the present invention are those blocked isocyanates known as uretdiones. The uretdiones used in the present invention can be obtained by catalytic dimerization of polyisocyanates via methods known to those skilled in the art. Examples of dimerization catalysts include, but are not limited to, trialkylphosphines, aminophosphines, and aminopyrazines such as dimethylaminopyridine, and tris (dimethylamino) phosphine, as well as any other dimerization catalyst. The result of the dimerization reaction depends, in a manner known to the skilled worker, on the catalyst used, on the process conditions and on the polyisocyanate employed. It is possible in particular to form products which contain on average more than one uretdione group per molecule, the number of uretdione groups being distributed. The (poly) uretdiones may optionally contain isocyanurate, biuret, allophanate and iminooxadiazinedione groups in addition to the uretdione groups.

Uretdiones are NCO functional compounds and can undergo further reactions, such as blocking of free NCO groups or further reaction of NCO groups with NCO-reactive compounds having a functionality of 2 or greater to extend the uretdiones, thereby forming a polyuretdione prepolymer. This results in compounds containing uretdione groups and higher molecular weights, which, depending on the chosen ratio, may also contain NCO groups, be free of NCO groups or may contain blocked isocyanate groups.

Suitable blocking agents include, but are not limited to, alcohols, lactams, oximes, malonates, alkyl acetoacetates, triazoles, phenols, imidazoles, pyrazoles, and amines, such as butanone oxime, diisopropylamine, 1,2, 4-triazole, dimethyl-1, 2, 4-triazole, imidazole, diethyl malonate, ethyl acetoacetate, acetoxime, 3, 5-dimethylpyrazole, caprolactam, N-tert-butylbenzylamine, and cyclopentanone, including mixtures of these blocking agents.

Examples of NCO-reactive compounds having a functionality of 2 or greater include polyols. In some embodiments, the NCO-reactive compound is used in an amount sufficient to react with all free NCO groups in the uretdione. By "free NCO groups" is meant all NCO groups that are not present as part of uretdione, isocyanurate, biuret, allophanate and iminooxadiazinedione groups.

The resulting polyuretdione contains at least 2, such as 2 to 10, uretdione groups. More preferably, the polyuretdione contains 5% to 45% uretdione, 10% to 55% urethane and less than 2% isocyanate groups. The percentages by weight are based on the total weight of the uretdione, urethane and isocyanate containing resin.

Suitable polyisocyanates for preparing the uretdiones useful in embodiments of the present invention include organic diisocyanates represented by the formula

R(NCO)₂

Wherein R represents an organic group obtained by removing isocyanate groups from an organic diisocyanate having (cyclo) aliphatically bound isocyanate groups and a molecular weight of 112 to 1000, preferably 140 to 400. Preferred diisocyanates for use in the present invention are those represented by this formula wherein R represents a divalent aliphatic hydrocarbon group having 4 to 18 carbon atoms, a divalent cycloaliphatic hydrocarbon group having 5 to 15 carbon atoms or a divalent araliphatic hydrocarbon group having 7 to 15 carbon atoms.

Examples of organic diisocyanates particularly suitable for use in the present invention include 1, 4-tetramethylene diisocyanate, 1, 6-hexamethylene diisocyanate, 2, 4-trimethyl-1, 6-hexamethylene diisocyanate, 1, 12-dodecamethylene diisocyanate, cyclohexane-1, 3-and 1, 4-diisocyanate, 1-isocyanato-2-isocyanato-methylcyclopentane, 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), bis- (4-isocyanatocyclohexyl) methane, 1, 3-and 1, 4-bis (isocyanatomethyl) -cyclohexane, bis- (4-isocyanato-3-methyl-cyclohexyl) -methane, α, α, α ', α' -tetramethyl-1, 3-and 1, 4-xylylene diisocyanate, 1-isocyanato-1-methyl-4 (3) -isocyanato-methylcyclohexane and 2, 4-and 2, 6-hexahydrotoluylene diisocyanate, Toluene Diisocyanate (TDI), diphenylmethane diisocyanate (MDI), Pentane Diisocyanate (PDI) -biobased, and isomers of any of these; or a combination of any of these. Mixtures of diisocyanates may also be used. Preferred diisocyanates include 1, 6-hexamethylene diisocyanate, isophorone diisocyanate, and bis (4-isocyanatocyclohexyl) -methane because they are readily available and produce a relatively low viscosity polyuretdione polyurethane oligomer.

In some embodiments, the uretdione may constitute 35% to 85% of the resin solids (excluding solvents, additives, or pigments) in the compositions of the invention. In other embodiments from 50% to 85%, and in still other embodiments from 60% to 85%. Uretdione can constitute any amount of resin solids between any range of combinations of these values, inclusive of the recited values.

In various embodiments of the present invention, the reaction mixture containing the polyuretdione and the neutralized polyol can be heated to a temperature of 140 ℃ in the presence of a tertiary amine catalyst, and in other embodiments to a temperature of 20 ℃ to 140 ℃.

The polyols useful in the present invention may be low molecular weight (62-399 Da, as determined by gel permeation chromatography) or high molecular weight (400 to 10,000 Da, as determined by gel permeation chromatography) materials and in various embodiments will have an average hydroxyl number, as determined by ASTM E222-10, method B, of 1000 to 10, and preferably 500 to 50.

The polyols in the present invention include low molecular weight diols, triols and higher alcohols and polymeric polyols such as polyester polyols, polyether polyols, polycarbonate polyols, polyurethane polyols and hydroxyl-containing (meth) acrylic polymers.

The low molecular weight diols, triols and higher alcohols useful in the present invention are known to those skilled in the art. In many embodiments, they are monomeric and have hydroxyl numbers of 200 and higher, typically in the range of 1500 to 200. Such materials include aliphatic polyols, particularly alkylene polyols containing from 2 to 18 carbon atoms. Examples include ethylene glycol, 1, 4-butanediol, 1, 6-hexanediol; alicyclic polyols such as cyclohexanedimethanol. Examples of triols and higher alcohols include trimethylolpropane and pentaerythritol. Polyols containing ether linkages such as diethylene glycol and triethylene glycol are also useful.

In various embodiments, suitable polyols are polymeric polyols having a hydroxyl number of less than 200, such as from 10 to 180. Examples of the polymeric polyol include polyalkylene ether polyols, polyester polyols (including hydroxyl-containing polycaprolactones), hydroxyl-containing (meth) acrylic polymers, polycarbonate polyols, and polyurethane polymers.

Examples of polyether polyols include poly (oxytetramethylene) glycol, poly (oxyethylene) glycol, and the reaction products of ethylene glycol with mixtures of propylene oxide and ethylene oxide.

Polyether polyols formed by the alkoxylation of various polyols, for example, diols such as ethylene glycol, 1, 4-butanediol, 1, 6-hexanediol, and the like, or higher polyols such as trimethylolpropane, pentaerythritol, and the like, are also useful. One commonly used alkoxylation process is by reacting a polyol with an alkylene oxide, such as ethylene oxide, in the presence of an acidic or basic catalyst.

Polyester polyols may also be used as the polymeric polyol component in certain embodiments of the present invention. The polyester polyols can be prepared by polyesterification of organic polycarboxylic acids or anhydrides thereof with organic polyols. Preferably, the polycarboxylic acids and polyols are aliphatic or aromatic diacids and diols.

Diols that may be employed to prepare the polyesters include alkylene glycols, such as ethylene glycol and butylene glycol, neopentyl glycol, and other glycols, such as cyclohexanedimethanol, caprolactone glycols (e.g., the reaction product of caprolactone and ethylene glycol), polyether glycols, such as poly (oxytetramethylene) glycol, and the like. However, various types of other diols and higher functionality polyols, as shown, may also be used in various embodiments of the present invention. Such higher polyols may include, for example, trimethylolpropane, trimethylolethane, pentaerythritol, and the like, as well as higher molecular weight polyols, such as those made by alkoxylation of low molecular weight polyols. An example of such a high molecular weight polyol is the reaction product of 20 moles of ethylene oxide per mole of trimethylolpropane.

The acid component of the polyester consists essentially of monomeric carboxylic acids or anhydrides having from 2 to 18 carbon atoms per molecule. Among the acids that may be used are phthalic acid, isophthalic acid, terephthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid, adipic acid, azelaic acid, sebacic acid, maleic acid, glutaric acid, chlorendic acid, tetrachlorophthalic acid, and various types of other dicarboxylic acids. Higher polycarboxylic acids such as trimellitic acid and tricarballylic acid may also be employed (where acids are mentioned hereinabove, it is to be understood that anhydrides of those acids which form anhydrides may be used in place of the acids). Lower alkyl esters of acids, such as dimethyl glutamate, may also be used.

In addition to polyester polyols formed from polybasic acids and polyols, polycaprolactone-type polyesters may also be used. These products are formed from the reaction of cyclic lactones, such as caprolactone, with polyols having primary hydroxyl groups, such as those mentioned above. Such a product is described in U.S. patent No. 3,169,949.

In addition to polyether polyols and polyester polyols, (meth) acrylic polymers or (meth) acrylic polyols containing hydroxyl groups can also be used as the polyol component.

Among the (meth) acrylic polymers are polymers having from 2 to 20% by weight of vinyl monomers containing primary hydroxyl groups, such as hydroxyalkyl acrylates and methacrylates having from 2 to 6 carbon atoms in the alkyl group, and from 80 to 98% by weight of other ethylenically unsaturated copolymerizable materials, such as alkyl (meth) acrylates; weight percent is based on the total weight of the monomer charge.

Examples of suitable hydroxyalkyl (meth) acrylates are hydroxyethyl (meth) acrylate and hydroxybutyl (meth) acrylate. Examples of suitable alkyl acrylates and alkyl (meth) acrylates are lauryl methacrylate, 2-ethylhexyl methacrylate and n-butyl acrylate.

In addition to the acrylic and methacrylic esters, other copolymerizable monomers copolymerizable with the hydroxyalkyl (meth) acrylates include ethylenically unsaturated materials such as monoolefins and diolefins, halogenated monoolefins and diolefins, unsaturated esters of organic and inorganic acids, amides and esters of unsaturated acids, nitriles and unsaturated acids, and the like. Examples of such monomers include styrene, 1, 3-butadiene, acrylamide, acrylonitrile, alpha-methylstyrene, alpha-methylchlorostyrene, vinyl butyrate, vinyl acetate, alkyl chlorides, divinylbenzene, diallyl itaconate, triallyl cyanurate and mixtures thereof. These other ethylenically unsaturated materials are preferably used in admixture with the acrylates and methacrylates mentioned above.

In certain embodiments of the present invention, the polyol may be a polyurethane polyol. These polyols can be prepared by reacting any of the polyols mentioned above with a minor amount of polyisocyanate (OH/NCO equivalent ratio greater than 1: 1) such that free primary hydroxyl groups are present in the product. In addition to the high molecular weight polyols mentioned above, mixtures of high and low molecular weight polyols (such as those mentioned above) may also be used.

Suitable hydroxy-functional polycarbonate polyols may be those prepared by reacting monomeric diols, such as 1, 4-butanediol, 1, 6-hexanediol, di-, tri-or tetraethylene glycol, di-, tri-or tetrapropylene glycol, 3-methyl-1, 5-pentanediol, 4' -dimethylolcyclohexane and mixtures thereof, with diaryl carbonates, such as diphenyl carbonate, dialkyl carbonates, such as dimethyl carbonate and diethyl carbonate, alkylene carbonates, such as ethylene carbonate or propylene carbonate, or phosgene. Optionally, a smaller amount of higher functional monomeric polyol, such as trimethylolpropane, glycerol or pentaerythritol, may be used.

In various embodiments of the invention, the polyol is neutralized, for example, by the addition of an acid scavenger. The acid scavenger should be covalently bonded to the acidic groups in the polyol. In various embodiments, the acid scavenger can be selected from the group consisting of carbodiimides, anhydrides, epoxy resins, trialkyl orthoformates, amine compounds, and oxazolines. The inventors believe, without wishing to be bound by any particular theory, that these acid scavengers are covalently bonded to the carboxylic and acrylic acid groups within the polyol. Such compounds are commercially available from various suppliers, such as, for example, monomeric carbodiimides sold under the trade name STABAXOL by Rhein Chemie, and bis (2, 6-diisopropylphenyl) carbodiimide sold as EUSTAB HS-700 by eutec chemical co. In various embodiments, neutralization is carried out at any temperature from room temperature (21 ℃ -24 ℃) to 120 ℃, in other embodiments from room temperature (21 ℃ -24 ℃) to 80 ℃, and in certain embodiments at room temperature (21 ℃ -24 ℃).

In various embodiments of the present invention, the uretdiones based on the first and second isocyanates can be thermally blended in various ratios from 92:8 to 24: 76; in some embodiments the ratio may be 92:8 to 55: 45; in other embodiments the ratio may be 50:50, and in still other embodiments the ratio may be 92:8 to 65:35, depending on the first and second isocyanates themselves (identities).

Examples of suitable solvents include, but are not limited to, aliphatic and aromatic hydrocarbons, such as toluene, xylene, isooctane, acetone, butanone, methyl ethyl ketone, methyl amyl ketone, methyl isobutyl ketone, ethyl acetate, butyl acetate, amyl acetate, tetrahydrofuran, ethyl ethoxypropionate, N-methyl-pyrrolidone, dimethylacetamide, and dimethylformamide, solvent naphtha, solvasso 100 or hydrosol (aral), ethers, or mixtures thereof.

The compositions of the present invention may further comprise any of a variety of additives, such as defoamers, devolatilizers, surfactants, thickeners, flow control additives, colorants (including pigments and dyes), or surface additives.

The compositions of the present invention may be contacted with the substrate by any method known to those skilled in the art, including but not limited to spraying, dipping, flow coating, roll coating, brush coating, casting, and the like. In some embodiments, the compositions of the present invention may be applied in the form of coatings (paints) or lacquers (lacquers) to any compatible substrate, such as, for example, metals, plastics, ceramics, glass and natural materials. In certain embodiments, the compositions of the present invention are applied in the form of a monolayer. In other embodiments, the compositions of the present invention may be applied in multiple layers, as desired.

Examples

The following non-limiting and non-exhaustive examples are intended to further describe various non-limiting and non-exhaustive embodiments without limiting the scope of the embodiments described in this specification. All amounts given in "parts" and "percentages" are to be understood as being by weight, unless otherwise indicated. Although the present invention is described in the context of a coating in the present example, those skilled in the art will recognize that it is equally applicable to adhesives, casting materials, composites, and sealants.

The compositions of the examples were prepared using the following materials:

polyol a contains no aromatic, branched hydroxyl-containing polyester polyols, available as DESMOPHEN 775 XP from Covestro;

additive a is used as an active hydrolysis resistance agent for polyester polyurethanes, as an acid scavenger for acid groups in polyols, available as STABAXOL I from Rhein Chemie;

additive B polyacrylate-based surface additives for solvent-borne coating systems and printing inks, available as BYK 358N from BYK Chemie;

catalyst A1, 8-diazabicyclo [5.4.0] undec-7-ene (DBU), a tertiary amine catalyst, available as POLYCATDBU from Air Products; preparing a 10% catalyst a solution in butyl acetate;

Uretdione A uretdione prepolymer based on 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), a product patented by Covestro LLC, having a uretdione equivalent weight of 1,276 and a viscosity of 817 cPs in 50% butyl acetate;

uretdione B uretdione prepolymers based on 1, 6-Hexamethylene Diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), a product patented by Covestro LLC having a uretdione equivalent weight of 824 and a viscosity of 8,250 cPs in 30% butyl acetate;

uretdione C uretdione prepolymers based on 1, 6-Hexamethylene Diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), a product patented by Covestro LLC having a uretdione equivalent weight of 822 and a viscosity of 16,500 cPs in 30% butyl acetate;

uretdione D uretdione prepolymers based on 1, 6-Hexamethylene Diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), a product patented by Covestro LLC having an uretdione equivalent weight of 820 and a viscosity of 15,300 cPs in 30% butyl acetate;

Uretdione E uretdione prepolymers based on 1, 6-Hexamethylene Diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), a product patented by Covestro LLC having an uretdione equivalent weight of 814 and a viscosity of 8,680 cPs in 30% butyl acetate;

uretdione F uretdione prepolymers based on 1, 6-Hexamethylene Diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), a product patented by Covestro LLC having a uretdione equivalent weight of 812 and a viscosity of 22,500 cPs in 30% butyl acetate;

uretdione G uretdione prepolymers based on 1, 6-Hexamethylene Diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), a product patented by Covestro LLC, having a uretdione equivalent weight of 808 and a viscosity of 12,900 cPs in 30% butyl acetate;

uretdione H uretdione prepolymers based on 1, 6-Hexamethylene Diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), a product patented by Covestro LLC, having a uretdione equivalent weight of 809 and a viscosity of 9,220 cPs in 30% butyl acetate;

Uretdione I uretdione prepolymers based on 1, 6-Hexamethylene Diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), a product patented by Covestro LLC having a uretdione equivalent weight of 808 and a viscosity of 18,800 cPs in 30% butyl acetate;

uretdione J uretdione prepolymers based on 1, 6-Hexamethylene Diisocyanate (HDI), a product of the patent by Covestro LLC, having a uretdione equivalent weight of 871 and a viscosity of 10,800 cPs in 30% butyl acetate;

uretdione K uretdione prepolymers based on 1, 6-methylene diisocyanate (HDI), a product of the patent by Covestro LLC, have an uretdione equivalent weight of 624 and a viscosity of 31,200 cPs in 20% butyl acetate.

Formulations a to K in table I were prepared according to the same procedure. As an example, formulation a was prepared as follows. Polyol a has been reacted with additive a prior to formulation. In a 100 ml plastic container were placed 4.76 parts of the reaction mixture of polyol A and additive A, 0.19 parts of additive B, 0.98 parts of catalyst A (10% solution in butyl acetate (n-BA)), 1.70 parts of n-butyl acetate and 32.37 parts of uretdione A. The resulting mixture was mixed using a FLACKTEK flash mixer (speed mixer) for 1 minute and then applied using a squeegee (drawdown bar).

The test plates were tested using ACT B952, 3 "x 9" (7.62 cm x 22.9) treated with zinc phosphate. The coating thickness was 4 mils (100 μm) wet (2 mils (50 μm) dry). The resulting plate was used to test microhardness.

The film was cured at room temperature (21 ℃ C. -24 ℃ C.) for one day. In addition, the film was cured at 100 ℃ for 30 minutes and allowed to stand at room temperature for one day before testing.

Measurement of microhardness (Marten's hardness) was done using a FISCOPE HM2000 instrument according to the method described in DIN EN ISO 14577. Microhardness readings were taken at a test load of 20 mN for a maximum indentation depth of 5 μm within an application time of 20 seconds. The results reported are the average of three readings for each formulation.

In Table I, the numbers in parentheses after the uretdione indicate their functionality.

It will be appreciated by reference to Table I that examples A to K were prepared to determine the effect of blending different isocyanate uretdione resins on the properties of the coating formulations in terms of microhardness. Examples A, J and K are control formulations that were not formed by the resin blend. Examples B, C, D, E, F, G, H and I are thermal blend formulations. By comparing microhardness results, it will be apparent to those skilled in the art that coatings made from formulations made with resin blends have better microhardness properties than the corresponding control formulations.

The present description has been described with reference to various non-limiting and non-exhaustive embodiments. However, one of ordinary skill in the art will recognize that various substitutions, modifications, or combinations of any of the disclosed embodiments (or portions thereof) can be made within the scope of the present description. Thus, it is to be considered and understood that this specification supports additional embodiments that are not explicitly set forth herein. Such embodiments may be obtained, for example, by combining, modifying or recombining any of the disclosed steps, components, elements, features, aspects, characteristics, limitations, etc. of the various non-limiting embodiments described in this specification. Accordingly, the applicant reserves the right to amend the claims during the filing period to add features as variously described in the present specification, and such amendments comply with the requirements of 35 u.s.c. § 112(a) and 35 u.s.c. § 132 (a).

Various aspects of the subject matter described herein are set forth in the following numbered clauses:

1. a reaction mixture comprising a thermal blend of a first isocyanate-based uretdione resin and a second isocyanate-based uretdione resin; a neutralized polyol and a tertiary amine catalyst; and optionally, an additive package selected from the group consisting of flow control additives, pigments (colorants), wetting agents, and solvents, wherein the first isocyanate and the second isocyanate are different.

2. The reaction mixture according to clause 1, wherein the tertiary amine is an amidine.

3. The reaction mixture according to clause 1, wherein the tertiary amine is selected from the group consisting of 1, 8-diazabicyclo [5.4.0] undec-7-ene, 7-methyl-1, 5, 7-triazabicyclo [4.4.0] dec-5-ene, 1,4,5, 6-tetrahydro-1, 2-dimethylpyrimidine, 1,2, 4-triazole, sodium derivatives, and 2-tert-butyl-1, 1,3, 3-tetramethylguanidine, and combinations thereof.

4. The reaction mixture according to clause 1, wherein the neutralized polyol comprises the reaction product of a polyol and an acid scavenger.

5. The reaction mixture according to clause 4, wherein the acid scavenger is covalently bonded to an acidic group within the polyol and is selected from the group consisting of carbodiimides, anhydrides, epoxy resins, trialkyl orthoformates, amine compounds, oxazolines, and combinations thereof.

6. The reaction mixture according to clause 4, wherein the polyol is selected from the group consisting of a polyalkylene ether polyol, a polyester polyol, a hydroxyl-containing polycaprolactone, a hydroxyl-containing (meth) acrylic polymer, a polycarbonate polyol, a polyurethane polyol, and combinations thereof.

7. The reaction mixture according to one of clauses 1 to 6, wherein the first isocyanate and the second isocyanate are independently selected from the group consisting of 1, 4-tetramethylene diisocyanate, 1, 6-Hexamethylene Diisocyanate (HDI), 2, 4-trimethyl-1, 6-hexamethylene diisocyanate, 1, 12-dodecamethylene diisocyanate, cyclohexane-1, 3-and 1, 4-diisocyanate, 1-isocyanato-2-isocyanato-methylcyclopentane, 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), bis- (4-isocyanatocyclohexyl) methane, 1, 3-and 1, 4-bis- (isocyanatomethyl) -cyclohexane, bis- (4-isocyanato-3-methyl-cyclohexyl) -methane, α, α, α ', α' -tetramethyl-1, 3-and 1, 4-xylylene-diisocyanate, 1-isocyanato-1-methyl-4 (3) -isocyanato-methylcyclohexane and 2, 4-and 2, 6-hexahydrotoluylene diisocyanate, Toluene Diisocyanate (TDI), diphenylmethane diisocyanate (MDI), Pentane Diisocyanate (PDI) -biobased, and isomers of any of these.

8. The reaction mixture according to one of clauses 1 to 7, wherein the first isocyanate is 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI) and the second isocyanate is 1, 6-Hexamethylene Diisocyanate (HDI).

9. The reaction mixture according to clause 8, wherein the ratio of 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI) to 1, 6-Hexamethylene Diisocyanate (HDI) is between 92:8 and 65: 35.

10. One of a coating, an adhesive, a casting material, a composite material and a sealant comprising the reaction mixture according to one of clauses 1 to 9.

11. A method of applying a reaction mixture according to one of clauses 1 to 10 to a substrate, wherein the method comprises at least one of spraying, dipping, flow coating, roll coating, brush coating, and pouring.

12. A method of preparing an allophanate polymer, which comprises thermally blending a first isocyanate-based uretdione resin and a second isocyanate-based uretdione resin to form a resin thermal blend, reacting the resin thermal blend with a neutralized polyol in the presence of a tertiary amine catalyst, optionally in the presence of an additive package selected from flow control additives, pigments (colorants), wetting agents and solvents, wherein the first isocyanate and the second isocyanate are different.

13. The method according to clause 12, wherein the tertiary amine is an amidine.

14. The method according to clause 12, wherein the tertiary amine is selected from the group consisting of 1, 8-diazabicyclo [5.4.0] undec-7-ene, 7-methyl-1, 5, 7-triazabicyclo [4.4.0] dec-5-ene, 1,4,5, 6-tetrahydro-1, 2-dimethylpyrimidine, 1,2, 4-triazole, sodium derivatives, and 2-tert-butyl-1, 1,3, 3-tetramethyl-guanidine, and combinations thereof.

15. The method according to one of clauses 12 to 14, wherein the neutralized polyol comprises the reaction product of a polyol and an acid scavenger.

16. The method according to clause 15, wherein the acid scavenger is covalently bonded to an acidic group within the polyol and is selected from the group consisting of carbodiimides, anhydrides, epoxy resins, trialkyl orthoformates, amine compounds, oxazolines, and combinations thereof.

17. The method according to clause 15, wherein the polyol is selected from the group consisting of a polyalkylene ether polyol, a polyester polyol, a hydroxyl-containing polycaprolactone, a hydroxyl-containing (meth) acrylic polymer, a polycarbonate polyol, a polyurethane polyol, and combinations thereof.

18. The method of one of clauses 12 to 17, wherein the first isocyanate and the second isocyanate are independently selected from the group consisting of 1, 4-tetramethylene diisocyanate, 1, 6-Hexamethylene Diisocyanate (HDI), 2, 4-trimethyl-1, 6-hexamethylene diisocyanate, 1, 12-dodecamethylene diisocyanate, cyclohexane-1, 3-and 1, 4-diisocyanate, 1-isocyanato-2-isocyanato-methylcyclopentane, 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI), bis- (4-isocyanatocyclohexyl) methane, 1, 3-and 1, 4-bis (isocyanatomethyl) -cyclohexane, bis- (4-isocyanato-3-methyl-cyclohexyl) -methane, α, α, α ', α' -tetramethyl-1, 3-and 1, 4-xylylene diisocyanate, 1-isocyanato-1-methyl-4 (3) -isocyanato-methylcyclohexane and 2, 4-and 2, 6-hexahydrotoluylene diisocyanate, Toluene Diisocyanate (TDI), diphenylmethane diisocyanate (MDI), Pentane Diisocyanate (PDI) -biobased, and isomers of any of these.

19. The method of one of clauses 12 to 18, wherein the first isocyanate is 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI) and the second isocyanate is 1, 6-Hexamethylene Diisocyanate (HDI).

20. The process according to clause 19, wherein the ratio of 1-isocyanato-3-isocyanatomethyl-3, 5, 5-trimethylcyclohexane (isophorone diisocyanate or IPDI) to 1, 6-Hexamethylene Diisocyanate (HDI) is between 92:8 and 65: 35.

21. An allophanate polymer made by the process according to one of clauses 12 to 20.

22. One of a coating, an adhesive, a casting material, a composite material, and a sealant comprising the allophanate polymer prepared in accordance with one of clauses 12 to 21.

23. A method of applying an allophanate polymer prepared according to one of clauses 12 to 21 to a substrate, wherein the method comprises at least one of spraying, dipping, flow coating, roller coating, brushing and pouring.

Claims

1. A reaction mixture comprising:

A thermal blend of a first isocyanate-based uretdione resin and a second isocyanate-based uretdione resin;

neutralized polyols; and

tertiary amine catalyst,

optionally, an additive package selected from flow control additives, pigments (colorants), wetting agents and solvents,

wherein the first isocyanate and the second isocyanate are different.

2. The reaction mixture of claim 1, wherein the tertiary amine is an amidine.

3. The reaction mixture of claim 1, wherein the tertiary amine is selected from the group consisting of 1,8-diazabicyclo[5.4.0]undec-7-ene, 7-methyl-1,5,7 - Triazabicyclo[4.4.0]dec-5-ene, 1,4,5,6-tetrahydro-1,2-dimethylpyrimidine, 1,2,4-triazole, sodium derivatives and 2 - tert-butyl-1,1,3,3-tetramethylguanidine and combinations thereof.

4. The reaction mixture of claim 1, wherein the neutralized polyol comprises the reaction product of a polyol and an acid scavenger.

5. The reaction mixture of claim 4, wherein the acid scavenger is covalently bonded to acidic groups within the polyol and is selected from the group consisting of carbodiimides, anhydrides, epoxy resins, trioxane orthoformate base esters, amine compounds, oxazolines, and combinations thereof.

6. The reaction mixture of claim 4, wherein the polyol is selected from the group consisting of polyalkylene ether polyols, polyester polyols, hydroxyl-containing polycaprolactones, hydroxyl-containing (meth)acrylic polymers compounds, polycarbonate polyols, polyurethane polyols, and combinations thereof.

7. The reaction mixture of claim 1, wherein the first isocyanate and the second isocyanate are independently selected from 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate ( HDI), 2,2,4-trimethyl-1,6-hexamethylene diisocyanate, 1,12-dodecylene diisocyanate, cyclohexane-1,3- and 1,4-diisocyanate Isocyanates, 1-isocyanato-2-isocyanato-methylcyclopentane, 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane (isophorone diisocyanate or IPDI), bis-(4-isocyanatocyclohexyl)methane, 1,3- and 1,4-bis(isocyanatomethyl)-cyclohexane, bis- (4-Isocyanato-3-methyl-cyclohexyl)-methane, α,α,α',α'-tetramethyl-1,3- and 1,4-xylylenediisocyanate, 1-Isocyanato-1-methyl-4(3)-isocyanato-methylcyclohexane and 2,4- and 2,6-hexahydrotoluene diisocyanate, toluene diisocyanate (TDI), Diphenylmethane diisocyanate (MDI), pentane diisocyanate (PDI) – biobased, and isomers of any of these.

8. The reaction mixture of claim 1, wherein the first isocyanate is 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane (isofor Erone diisocyanate or IPDI) and the second isocyanate is 1,6-hexamethylene diisocyanate (HDI).

9. The reaction mixture of claim 8, wherein 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane (isophorone diisocyanate or IPDI ) to 1,6-hexamethylene diisocyanate (HDI) in a ratio between 92:8 and 65:35.

10. One of coatings, adhesives, foundry materials, composite materials and sealants comprising the reaction mixture of claim 1 .

11. A method of applying the reaction mixture of claim 1 to a substrate, wherein the method comprises at least one of spray coating, dip coating, flow coating, roll coating, brush coating, and casting.

12. A method of preparing an allophanate polymer comprising:

thermally blending the first isocyanate-based uretdione resin and the isocyanate B-based uretdione resin to form a resin thermal blend;

subjecting the resin thermal blend with neutralized polyol in the presence of a tertiary amine catalyst,

optionally reacted in the presence of an additive package selected from flow control additives, pigments (colorants), wetting agents and solvents,

wherein the first isocyanate and the second isocyanate are different.

13. The method of claim 12, wherein the tertiary amine is an amidine.

14. The method of claim 12, wherein the tertiary amine is selected from the group consisting of 1,8-diazabicyclo[5.4.0]undec-7-ene, 7-methyl-1,5,7- Triazabicyclo[4.4.0]dec-5-ene, 1,4,5,6-tetrahydro-1,2-dimethylpyrimidine, 1,2,4-triazole, sodium derivatives and 2- tert-Butyl-1,1,3,3-tetramethylguanidine and combinations thereof.

15. The method of claim 12, wherein the neutralized polyol comprises the reaction product of a polyol and an acid scavenger.

16. The method of claim 15, wherein the acid scavenger is covalently bonded to acidic groups within the polyol and is selected from the group consisting of carbodiimides, anhydrides, epoxy resins, trialkyl orthoformates Esters, amine compounds, oxazolines, and combinations thereof.

17. The method of claim 15, wherein the polyol is selected from the group consisting of polyalkylene ether polyols, polyester polyols, hydroxyl-containing polycaprolactones, hydroxyl-containing (meth)acrylic polymers , polycarbonate polyols, polyurethane polyols and combinations thereof.

18. The method of claim 12, wherein the first isocyanate and the second isocyanate are independently selected from 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate (HDI), 2,4-tetramethylene diisocyanate 2,4-trimethyl-1,6-hexamethylene diisocyanate, 1,12-dodecylene diisocyanate, cyclohexane-1,3- and 1,4-diisocyanate, 1-isocyanato Cyanato-2-isocyanato-methylcyclopentane, 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane (isophorone diisocyanate or IPDI), bis-(4-isocyanatocyclohexyl)methane, 1,3- and 1,4-bis(isocyanatomethyl)-cyclohexane, bis-(4-isocyanato acido-3-methyl-cyclohexyl)-methane, α,α,α',α'-tetramethyl-1,3- and 1,4-xylylene diisocyanate, 1-isocyanato Synthetic-1-methyl-4(3)-isocyanato-methylcyclohexane and 2,4- and 2,6-hexahydrotoluene diisocyanate, toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), pentane diisocyanate (PDI) – biobased, and isomers of any of these.

19. The method of claim 12, wherein the first isocyanate is 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane (isophor ketone diisocyanate or IPDI) and the second isocyanate is 1,6-hexamethylene diisocyanate (HDI).

20. The method of claim 19, wherein 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane (isophorone diisocyanate or IPDI) The ratio to 1,6-hexamethylene diisocyanate (HDI) is between 92:8 and 65:35.

21. An allophanate polymer made by the method of claim 12.

22. One of coatings, adhesives, casting materials, composites and sealants comprising the allophanate polymer made according to claim 12.

23. A method of applying the allophanate polymer made according to claim 12 to a substrate, wherein the method comprises spraying, dipping, flow coating, rolling, brushing and casting at least one of.