WO2013100634A1

WO2013100634A1 - Emulsifier for the preparation of microcellular polyurethane elastomers

Info

Publication number: WO2013100634A1
Application number: PCT/KR2012/011574
Authority: WO
Inventors: Jae Soo Yang; Hee Young Choi; Jeongmoo KIM; Joon Mo Lee
Original assignee: SKC Co Ltd
Current assignee: SKC Co Ltd
Priority date: 2011-12-27
Filing date: 2012-12-27
Publication date: 2013-07-04
Anticipated expiration: 2014-06-27
Also published as: KR101364550B1; KR20130075297A

Description

DESCRIPTION

EMULSIFIER FOR THE PREPARATION OF MICROCELLULAR POLYURETHANE ELASTOMERS

FIELD OF THE INVENTION

The present invention relates to a novel emulsifier, and, more particularly, to an emulsifier useful for preparing a polyurethane elastomer suitable for use in helper springs for bicycles, motorcycles, automobile suspension devices, furnitures or high- vibrating matrixes.

BACKGROUD OF THE INVENTION Due to superior vibration damping and impact absorption properties as well as excellent dynamic characteristics under high loads, durability and permanent deformation resistance, polyurethane elastomers having a rnicrocellular structure have been extensively used in helper springs for bicycles, motorcycles, automobile suspension devices, furnitures or high- vibrating matrixes. In particular, as polyurethane elastomers prepared by using naphthalene diisocyanate (NDI) have superior bending fatigue resistance, they are widely applied in cases where high durability is required, such as in helper springs for bicycles, motorcycles, automobile suspension devices, furnitures or high-vibrating matrixes.

Typical polyurethane elastomers are prepared by reacting a polyol with a diisocyanate-based material. Conventional methods of preparing polyurethane elastomers with using NDI are performed by, for example, reacting NDI alone, or in combination with 4,4-diphenylmethane diisocyanate (p-MDI), with a polyol to prepare a polyurethane prepolymer containing a termial isocyanate (NCO) group, followed by mixing the prepared polyurethane prepolymer containing a terminal NCO group with water, a catalyst, a surfactant, an antioxidant, a chain extender, etc. to obtain a prepolymer blend, and then foaming the prepolymer blend with a foaming machine to prepare a polyurethane elastomer.

Polyurethane elastomers contain water when prepared in accordance with conventional methods therefor. Increase of the amount of water present in polyurethane elastomers can provide superior tensile strength due to the promotion of forming a urea bond, while resulting in overall improved properties attributable to the formation of a cross-linked structure. However, if the amount of water increases, phase separation of a hyclrogen-containing composition may occur, thereby undesirably deteriorating the properties.

Therefore, it has been required to develop an emulsifier capable of preventing phase separation of the hydrogen-containing composition as well as increasing the amount of water in a polyurethane elastomer, and a polyurethane elastomer with superior properties prepared by using such emulsifier.

SUMMARY OF THE INVENTION

Accordingly, an object of the present invention is to provide an emulsifier for suppressing phase separation of a hydrogen-containing composition containing an excess of water during preparation of a microcellular polyurethane elastomer.

Another object of the present invention is to provide a method of preparing a polyurethane elastomer by using the emulsifier, and a microcellular polyurethane elastomer having a crystalline superstructure prepared by the method.

Still another object of the present invention is to provide a helper spring for bicycles, motorcycles, automobile suspension devices, furnitures or high-vibrating matrixes, manufactured by using the polyurethane elastomer.

In order to accomplish the above objects, the present invention provides an emulsifier which is a mixture of

(a) a compound selected from the group consisting of 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 2,4-diphenylmethane diisocyanate, 4,4'-diphenylmethane diisocyanate, hexamethylene diisocyanate, l,4'-cyclohexane diisocyanate and mixtures thereof, and

(b) a C₂-io hydrocarbon having a molecular weight of 500 or less with two to four hydroxyl groups, or mixtures thereof.

According to the present invention, the emulsifier can suppress phase separation of a hydrogen-containing composition containing an excess of water as a chain extender during the preparation of a microcellular polyurethane elastomer, thereby increasing processability of the method.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, the present invention will be described in detail.

An emulsifier according to the present invention is a mixture of (a) a compound selected from the group consisting of 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 2,4-diphenylmethane diisocyanate, 4,4'-diphenylmethane diisocyanate, hexamethylene diisocyanate, l,4'-cyclohexane diisocyanate and mixtures thereof, and (b) a C_2-io hydrocarbon having a molecular weight of 500 or less with two to four hydroxyl groups, or mixtures thereof.

The emulsifier functions to prevent phase separation when a large amount of water is used, in addition to providing an emulsification function. Particularly in the process of preparing a microcellular polyurethane elastomer, when a hydrogen- containing composition obtained by mixing water, the emulsifier and so on contains an excess of water, the emulsifier prevents from occurring phase separation of the hydrogen-containing composition.

The emulsifier has a weight ratio of component (a) to component (b) of 1 :20 to 1 :5, and preferably 1:13 to 1:7.

In the emulsifier, if the weight ratio of component (b) relative to component (a) is less than 5, side reactions may undesirably take place due to an excess of residual NCO group. In contrast, if the weight ratio thereof exceeds 20, side reactions may occur due to an excess of residual OH group, which undesirably deteriorates the properties.

An emulsifier according to the present invention may be used for preparing a microcellular polyurethane elastomer, and the microcellular polyurethane elastomer may be prepared by the method comprising (i) reacting naphthalene diisocyanate (NDI) with a polyol to obtain a prepolymer containing an isocyanate (NCO) group; (ii) adding a plasticizer and an additional amount of naphthalene diisocyanate to the prepolymer prepared in step (i) to introduce into the prepolymer a terminal free isocyanate (NCO) group having 5 to 30 wt% of an allophanate structure, based on the weight of the prepolymer; and (iii) mixing the prepolymer having a terminal free isocyanate (NCO) group obtained in step (ii) with water and an emulsifier and then foaming the prepolymer blend to prepare a polyurethane elastomer.

In step (i), the polyol influences the properties of a final microcellular polyurethane elastomer, and may be selected from the group consisting of polyester glycol, polyether glycol, polycarbonate glycol and polycaprolactone glycol. In particular, it is preferable to use polycaprolactone glycol that has excellent resistance to water, oil, solvent, chlorine and the like and is biodegradable to ensure eco-friendly properties.

The number average molecular weight (Mn) of the polyol is preferably 500 to 5,000, and more preferably 1,000 to 5,000. If the Mn is less than 500, the resulting microcellular polyurethane elastomer may show decreased flexibility, and thus easy to be broken. In contrast, if the Mn exceeds 5,000, the resulting microcellular polyurethane elastomer does not have sufficient hardness, and has high viscosity and is thus difficult to be handled. Particularly, in the case where this elastomer is applied to a helper spring for automobile suspension devices, sufficient strength cannot be ensured.

The molar ratio of NDI to polyol is 0.2 to 0.6: 1 , and preferably 0.3 to 0.5 : 1.

The amount of NCO contained in the prepolymer may be 2 to 15 wt%, and preferably 5 to 10 wt%.

The prepoloymer may contain a terminal free isocyanate (NCO) group having an allophanate structure, and the amount of the allophanate structure is preferably 5 to 30% based on the amount of the prepolymer.

The allophanate structure may be introduced by adding a plasticizer and an additional amount of NDI to the prepared prepolymer containing an NCO group.

In step (ii), the plasticizer is not particularly limited so long as it is typically usable in the preparation of polyurethane, and examples thereof may include diisobutyl phthalate, dioctyl phthalate, and diisononyl phthalate. The plasticizer may be added in an amount of 0.1 to 30 parts by weight, preferably 1 to 20 parts by weight, and more preferably 2 to 10 parts by weight, based on 100 parts by weight of the prepolymer. The additional amount of NDI may be used in an amount of 1 to 40 parts by weight, preferably 2 to 35 parts by weight, and more preferably 5 to 25 parts by weight, based on 100 parts by weight of the prepolymer prepared in step (i).

After preparation of the prepolymer having a terminal free isocyanate group through steps (i) and (ii), the prepolymer is subjected to step (iii), which includes mixing the prepolymer having a terminal free isocyanate (NCO) group obtained in step (ii) with water and an emulsifier and then foaming the prepolymer blend to prepare a polyurethane elastomer.

In the above step, water may produce carbon dioxide (CO₂) by the reaction with NDI and thus functions as a foaming agent. In addition, water may form a cross-linked body having a urea bond due to the allophanate structure of the prepolymer, which may form a large area of crystallization, thus effectively improving heat resistance and mechanical properties, in particular, durability.

The amount of water to be mixed is preferably 20 to 95 parts by weight, more preferably 30 to 85 parts by weight, and most preferably 50 to 80 parts by weight, based on 100 parts by weight of the prepolymer.

However, if water is used in an excessively large amount, phase separation may undesirably occur due to the use of a surfactant.

Accordingly, the use of the emulsifier according to present invention may prevent phase separation.

The emulsifier is preferably added in an amount of 5 to 15 parts by weight based on 100 parts by weight of the prepolymer. If the amount of the emulsifier is less than 5 parts by weight, a phase separation effect may not occur. In contrast, if the amount thereof exceeds 15 parts by weight, an excess of urethane group may be formed, thereby undesirably deteriorating heat resistance and durability. In step (iii) for preparing the polyurethane elastomer, the prepared prepolymer may be additionally mixed with a polyol, a chain extender, a cross-linking agent, a catalyst, a surfactant, or an antioxidant.

The polyol may be added as necessary, and preferred examples thereof may include the same kind of the polyol used in step (i). The above polyol may include a polyol which is the same as or different from the polyol used in step (i). The above polyol is preferably used in an amount of 0 to 90 parts by weight, and more preferably 0 to 30 parts by weight, based on 100 parts by weight of the prepolymer.

In the case where the polyol is additionally used in step (iii), the degree of crystallization of a soft segment may increase because of interactions between the polyol included in the prepolymer prepared in step (i) and the polyol additionally used in step (iii), thus improving dynamic elastic behavior. However, if the amount of the polyol additionally used in step (iii) exceeds 90 parts by weight based on 100 parts by weight of the prepolymer, the degree of crystallization of a hard segment may rather decrease, undesirably deteriorating durability.

The chain extender may be added as necessary, and may be a C_2-io hydrocarbon having a molecular weight of 500 or less with two to four hydroxyl groups, and is preferably used in an amount of 0 to 20 parts by weight, and more preferably 0 to 10 parts by weight, based on 100 parts by weight of the prepolymer.

The catalyst may include an organic metal compound, for example, a tin (II) salt of organic carboxylic acid, such as tin (II) dioctoate, tin (II) dilaurate, dibutyltin diacetate and dibutyltin dilaurate, a tertiary amine, such as tetramethylethylenediamine, N- methylmoφholine, diemylbenzylamine, triemylamine, dimemylcyclohexylamine, diazabicyclooctane, N,N'-dimethylpiperazine, N-methyl,N'-(4-N- dimemylaniino)butylpiperazine, Ν,Ν,Ν',Ν'',Ν''-pentamemyldiemylenetriainine and so on, an amidine, such as 2,3-o^emyl-3,4,5,6-tetrahydropyrirnidine, tris- (dialkylanimoalkyl)-s-hexahydrotriazine, in particular, tris-(N,N-dimemylaminopropyl)- s-hexahydrotriazine, a tetraalkylammonium hydroxide, such as tetramethyl ammonium hydroxide, an alkali metal hydroxide, such as sodium hydroxide, and an alkali metal alcoholate, such as sodium methylate and potassium isopropylate, and an alkali metal salt of a long-chain fatty acid having 10 to 20 carbons and any side OH group, and preferably 2,6-dimethylmoφholineethylether and tetramemylemylenediamine.

The catalyst is used in an amount of 0.5 to 3 parts by weight, based on 100 parts by weight of the prepolymer, depending on reactivity.

The surfactant decreases surface tension of the prepared polyurethane foamed body to grow foam, and may prevent breakdown of cells due to instability of foam upon increasing viscosity. Also, the surfactant may increase flowability of foam and chargeability at foaming mold and thus make uniform the density of a product. Preferably, a silicone surfactant may be used.

The surfactant may be used in an amount of 0.3 to 3 parts by weight, preferably 0.5 to 2.5 parts by weight, based on 100 parts by weight of the prepolymer. If the amount of the surfactant is less than 0.3 parts by weight, a non-uniform foamed body may result. In contrast, if the amount thereof exceeds 3 parts by weight, a foamed body may have decreased hardness or may shrink.

The antioxidant is not particularly limited so long as it is typically used in the art, and may include hindered phenol- or hindered arylamine-based antioxidants. The amount of the antioxidant may be 0.01 to 1.0 parts by weight based on 100 parts by weight of the prepolymer.

The foaming may be conducted by foaming the prepolymer blend comprising the prepolymer, water, an emulsifier and the like with a foaming machine. This foaming process may be carried out at 70 to 99 ^°C, and preferably at 80 to

85 ^°C.

If the foaming temperature is lower than 70 ^°C, viscosity may increase, undesirably deteriorating handleability. In contrast, if the foaming temperature is higher than 99 ^°C , it is not easy to handle the prepolymer blend due to high temperature.

The polyurethane elastomer thus prepared may have a crystalline superstructure. Such a crystalline superstructure enables the formation of giant hard segment crystals and thus plays an important role in supporting an external load.

A helper spring for bicycles, motorcycles, automobile suspension devices, furnitures or high-vibrating matrixes can be manufactured by using the polyurethane elastomer.

A better understanding of the present invention may be obtained via the following examples which are set forth to illustrate, but are not to be construed as limiting the present invention.

Preparation Example 1

An emulsifier was prepared by mixing toluene diisocyanate and 1,4-butanediol at a weight ratio of 1 : 13.

Preparation Example 2

An emulsifier was prepared by mixing toluene diisocyanate and 1,3 -propanediol at a weight ratio of 1 : 13.

Preparation Example 3

An emulsifier was prepared by mixing toluene diisocyanate and 1,4-butanediol at a weight ratio of 1 :7. Example 1

Naphthalene diisocyanate (NDI) and polycaprolactone glycol (PCL2000) having a number average molecular weight (Mn) of 2,000 as a polyol were used at a molar ratio of 0.3:1 to obtain a prepolymer having 5 wt% of NCO. 5 parts by weight of diisobutyl phthalate as a plasticizer and 20 parts by weight of NDI were added to 100 parts by weight of the prepolymer having 5 wt% of NCO to prepare a prepolymer containing a terminal NCO group having 20% of an allophanate structure relative to the prepolymer, which was then mixed with 85 parts by weight of water, 2 parts by weight of 2,6- d^nethylmo holmeethylether as a catalyst, 1.0 part by weight of a silicone surfactant as a surfactant, 0.2 parts by weight of butylated hydroxytoluene as an antioxidant, and 15 parts by weight of the emulsifier prepared in Preparation Example 1 to obtain a prepolymer blend.

The presence of the allophanate peak in the prepared prepolymer was observed by using FT-IR (NICOLET 380, available from Thermo Electron Corporation (USA)), and the amount of the allophanate was determined via peak segmentation.

The prepolymer blend was foamed at 80 ^°C by using a low-pressure foaming machine to prepare a microcellular polyurethane elastomer.

Example 2

A microcellular polyurethane elastomer was prepared in the same manner as in Example 1, with the exception that 1 parts by weight of the emulsifier prepared in Preparation Example 2 was used as the emulsifier. Example 3

A microcellular polyurethane elastomer was prepared in the same manner as in Example 1 , with the exception that the amount of the emulsifier was changed to 10 parts by weight.

Example 4

A microcellular polyurethane elastomer was prepared in the same manner as in Example 1, with the exception that 15 parts by weight of the emulsifier prepared in Preparation Example 3 was used as the emulsifier.

Comparative Example 1

Naphthalene diisocyanate (NDI) and polycaprolactone glycol (PCL2000) having a number average molecular weight (Mn) of 2,000 as a polyol were used at a molar ratio of 0.3:1 to obtain a prepolymer having 5 wt% of NCO. 5 parts by weight of diisobutyl phthalate as a plasticizer and 20 parts by weight of NDI were added to 100 parts by weight of the prepolymer having 5 wt% of NCO to prepare a prepolymer containing a terminal NCO group having 20% of an allophanate structure relative to the prepolymer, which was then mixed with 0.5 parts by weight of water, 10 parts by weight of 1,4- butanediol as a chain extender, 2 parts by weight of tetramemylemylenediamine as a catalyst, 1.0 part by weight of a silicone surfactant as a surfactant, and 0.2 parts by weight of butylated hydroxytoluene as an antioxidant to obtain a prepolymer blend.

The prepolymer blend was foamed at 100^°C by using a low-pressure foaming machine to prepare a microcellular polyurethane elastomer. Comparative Example 2

A polyurethane elastomer was prepared in the same manner as in Example 1, with the exception that 10 parts by weight of water was used to obtain the prepolymer blend.

Comparative Example 3

A polyurethane elastomer was prepared in the same manner as in Example 1, with the exception that 100 parts by weight of 1,4-butanediol was used as the chain extender and water was not added to obtain the prepolymer blend.

Comparative Example 4

A polyurethane elastomer was prepared in the same manner as in Example 1, with the exception that a mixture comprising toluene diisocyanate and 1,4-butanediol at a weight ratio of 1 :4 was used as the emulsifier.

Comparative Example 5

A polyurethane elastomer was prepared in the same manner as in Example 1, with the exception that a mixture comprising toluene diisocyanate and 1,4-butanediol at a weight ratio of 1 :25 was used as the emulsifier.

Test Example

The hardness, fracture tensile strength, fracture elongation and rate of change in thickness of the polyurethane elastomers obtained in the examples and comparative examples, and the durability of helper spring samples for automobile suspension devices manufactured by using the above polyurethane elastomers were evaluated as follows.

(1) Hardness

A polyurethane elastomer was sufficiently hardened at 80 to 99 ^°C for 48 hrs and then cooled to room temperature. Thereafter, the hardness thereof was measured with Shore C.

(2) Fracture tensile strength

This strength was measured according to ASTM D 3574 and was determined as an average of three measurements on the same sample.

(3) Fracture elongation

This elongation was measured according to ASTM D 3574 and was detenriined as an average of three measurements on the same sample.

(4) Rate of change in thickness (ΔΗ, %)

According to the following Equation 1, the height (H_t) of a sample after durability test relative to the height (H₀) of a sample before durability test was measured and expressed in percentage.

[Equation 1]

ΔΗ=((ΔΗο-ΔΗ /ΔΗ₍) *100 (5) Durability of helper spring sample for automobile suspension device

Helper spring samples for automobile suspension devices manufactured by using the polyurethane elastomers obtained in the examples and comparative examples were compressed under conditions of 5kN*2Hzx 500,000 times, after which whether external cracking was present was evaluated. The case where external cracking did not occur was indicated as ©, the case where the cracking occurred was indicated as ^x, and the case where the cracking did not occur but the rate of change in thickness exceeded 30% was indicated as Δ .

Table 1 below shows the results of hardness, fracture tensile strength, fracture elongation, and rate of change in thickness of the polyurethane elastomers obtained in the examples and comparative examples, and durability of the helper spring samples for automobile suspension devices manufactured by using the polyurethane elastomers.

[Table 1]

Comparative

62 32 330 X

Example 5

As is apparent from Table 1, the microcellular polyurethane elastomers prepared by the method of the invention were superior in hardness, fracture tensile strength, fracture elongation, and rate of change in thickness, compared to the polyurethane elastomers of Comparative Examples 1 to 5.

In Comparative Example 1, since a smaller amount of water was used to obtain the prepolymer blend, compared to Example 1, fracture strength and fracture elongation were inferior to those of Example 1.

In Comparative Example 2, as a larger amount of water was used, compared to Comparative Example 1, and the surfactant was used but the emulsifier was not used, phase separation of the hydrogen-containing composition occurred, thereby resulting in poor hardness, fracture tensile strength, fracture elongation, and durability of the polyurethane elastomer.

In Comparative Example 3, the use of 100 parts by weight of 1,4-butanediol as the chain extender resulted in fracture, thereby undesirably deteriorating durability. This is considered to be because urethane bonds are formed and then broken at about 100 to 120^°C , when 1,4-butanediol is used as the chain extender during preparation of the polyurethane elastomer.

Therefore, the helper spring samples for automobile suspension devices manufactured by using the microcellular polyurethane elastomers obtained in accordance with the method of the invention can be seen to exhibit superior durability, compared to the helper spring samples for automobile suspension devices manufactured by using the polyurethane elastomers of Comparative Examples 1 to 5.

Claims

WHAT IS CLAIMED IS:

1. An emulsifier which is a mixture of

(a) a compound selected from the group consisting of 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 2,4-diphenylmethane diisocyanate, 4,4'-diphenylmethane diisocyanate, hexamethylene diisocyanate, 1,4-cyclohexane diisocyanate and mixtures thereof, and

2. The emulsifier of claim 1, wherein a weight ratio of component (a) and component (b) is 1:20 to 1:5.

3. A method of preparing a microcellular polyurethane elastomer, comprising:

(i) reacting naphthalene diisocyanate (NDI) with a polyol to obtain a prepolymer containing an isocyanate (NCO) group;

(ii) adding a plasticizer and an additional amount of naphthalene diisocyanate to the prepolymer prepared in step (i) to introduce into the prepolymer a terminal free isocyanate (NCO) group having 5 to 30 wt% of an allophanate structure, based on the weight of the prepolymer; and

(iii) mixing the prepolymer having a terminal free isocyanate (NCO) group obtained in step (ii) with water and an emulsifier according to claim 1, and then foaming the prepolymer blend to prepare a polyurethane elastomer.

4. The method of claim 3, wherein in step (iii), water and the emulsifier are added in amounts of 20 to 95 parts by weight and 5 to 15 parts by weight, respectively, based on 100 parts by weight of the prepolymer.

5. The method of claim 3, wherein in step (iii), the prepolymer is additionally mixed with a polyol, a chain extender, a cross-linking agent, a catalyst, a surfactant, or an antioxidant.

6. A microcellular polyurethane elastomer having a crystalline superstructure, prepared by the method of any one of claims 3 to 5.

7. A helper spring for a bicycle, a motorcycle, an automobile suspension device, furniture or a high-vibrating matrix, manufactured by using the microcellular polyurethane elastomer of claim 6.