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Chemistry and Technology
of Polyols for Polyurethanes,
2nd Edition
Volume 1
Mihail Ionescu
Chemistry and
Technology of Polyols for
Polyurethanes, 2nd Edition
Volume 1
Mihail Ionescu
A catalogue record for this book is available from the British Library.
Every effort has been made to contact copyright holders of any material reproduced
within the text and the author and publishers apologise if
any have been overlooked.
iii
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
iv
A
cknowledgements
I thank you very much to my colleagues from Kansas Polymer Research Center:
Dr. Andy Myers, Dr. Ivan Javni, Xianmei Wan, Alisa Zlatanić, Dragana Radojčić,
Nikola Bilić and others for helpful discussions, for synthesis and characterisation of
new renewable polyols and of bio-based PU from these polyols.
v
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
vi
P
reface
PU have a history of slightly more than 75 years. They have become one of the
most dynamic groups of polymers. Their use covers practically all fields of polymer
application: foams, elastomers, thermoplastics, thermorigids, adhesives, coatings,
sealants, and fibres. Furniture, bedding, seating for cars, shoe soles, thermoinsulation
for refrigerators and buildings, wood substitutes, packaging, and coatings, are only
a few common examples of PU use in everyday life.
A large variety of chemical reactions for the synthesis of oligo-polyols are used to build
the chemical architecture of oligo-polyols. These include: ring-opening polymerisation
of cyclic monomers by anionic, cationic or coordinative mechanisms; polycondensation
reactions (polyesterification, transesterification, Mannich reactions, phenol-aldehydes
condensations); alkoxylation; radical polymerization; transformation of double-bonds
in hydroxyl groups (e.g., epoxydation-hydrolysis, hydroxylation, hydroformylation,
ozonolysis-reduction); oxidation; thiol-ene; amidation reactions. These varieties of
chemical reactions need deep knowledge of organic and macromolecular chemistry.
The author tries to explain, in a very simple and accessible manner, the very complex
phenomena involved in oligo-polyol fabrication.
vii
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
This book attempts to link, in a general, organized, and systematic manner, the
most important knowledge, data and information concerning the chemistry and
technology of oligo-polyols for PU. This general viewpoint results from the fact that
all oligo-polyols used for PU have many common features. In order not to provide
too much information and to avoid presentation of confidential data, the commercial
names of oligo-polyols are not mentioned. Thus, each oligo-polyol is identified by its
chemical structure or chemical name. Simultaneously and for identical reasons, the
names of companies that developed and produced the various types of oligo-polyols
are not mentioned. The commercial name and company name are specified only for
unanimously accepted and very important developments in oligo-polyols [e.g., Poly
Harnststoff dispersion (PHD)-polyols of Bayer (Germany)].
A decade has passed from the first edition of the book Chemistry and Technology of
Polyols for Polyurethanes. Due to the appreciable amount of new developments in
polyols for PU carried out in 2005–2015, the second edition of the book has been
divided into two volumes. Volume 1 is dedicated to polyols for elastic PU and volume
2 is dedicated to polyols for rigid PU.
Supplies of crude oil and petrochemical raw materials are limited and, in 50–100
years, may be finished. However, raw materials from natural resources have practically
infinite renewability.
Petrochemical polyols (polyethers and polyesters) remain stable and are the
most important polyols for elastic PU. Polyols for elastic PU, irrespective of their
structure, are characterised by high molecular weight (2,000-6,000 daltons) and low
functionality (2–3 hydroxyl groups/mol). Reaction of these long-chain polyols with
diisocyanates results in highly elastic PU.
Volume 1 of the second edition details the main knowledge regarding the synthesis
of the most important oligo-polyols for preparation of elastic PU (polyether polyols,
graft polyether polyls, PHD, polyisocyanate polyaddition polyols, polyester polyols,
polytetramethylene glycols, polybutadiene polyols, acrylic polyols, polysiloxane
polyols). New developments in petrochemical polyether polyols, such as the most
important polyols for elastic PU (e.g., synthesis of high solid content graft polyols;
continuous processes for the synthesis of polyether polyols with double metal cyanide
catalysts) are described.
Covering all aspects and describing all the oligo-polyol structures created from
companies, universities, research centers and institutes is not possible. Nevertheless,
the most important aspects of oligo-polyols for manufacture of elastic PU are
presented.
viii
Preface
I hope that the monograph will be the start of novel developments in oligo-polyols
for elastic PU. I hope that this will lead to creation of new oligo-polyols with new
designs and new chemical architectures, as well as new (and possibly unconventional)
manufacturing technologies. Good luck in your endeavours!
Mihail Ionescu
February 2016
ix
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
x
C
ontents
1. Polyols........................................................................................................ 1
1.1 Introduction..................................................................................... 1
xi
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
3.7 Reactivity....................................................................................... 49
3.8 Specific Gravity.............................................................................. 51
3.9 Viscosity........................................................................................ 51
3.10 Colour........................................................................................... 52
3.11 Acid Number................................................................................. 52
3.12 Renewable Content........................................................................ 53
xii
Contents
xiii
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
xiv
Contents
xv
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
Postface.............................................................................................................. 343
Abbreviations..................................................................................................... 345
xvi
1
Polyols
1.1 Introduction
OCONH R NHCOO R′
n
R N C O + HO R′ R NHCOO R′
Isocyanate Alcohol Urethane (1.1)
The first urethane was synthesised by this route as early as 1849 by Wurtz [6, 16,
22, 30]. In 1937, after very systematic and intensive research work at IG Farben
(Interessen-Gemeinschaft Farbenindustrie AG, Germany), Dr. Bayer synthesised the
first PU by reaction of a diisocyanate with a polyester having two terminal hydroxyl
1
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
n
n
O C N R N C O + HO OH
Diisocyanate Polyester diol
OCONH R NHCOO O
n
PU (1.2)
In slightly more than 75 years of the existence of PU, except for the global
financial recession during 2008–2010, the growth of PU was constant.
Predictions for the future are very optimistic due to the new markets opened in
Eastern Europe, Asia and South America [34–36]. China has become an important
‘player’ in the PU industry. In terms of worldwide polymer consumption,
China produces 35.5% of PU, 33.3% of 2,4-toluene diisocyanate, and 33.3%
of diphenylmethane diisocyanate, and has important capacities for production
of polyether polyols and polyester polyols [35, 36].
In Figure 1.1, one can see the growth of PU consumption between 2012 and 2014.
2
Polyols
22,000,000
20,000,000
18,000,000
16,000,000
14,000,000
Tonnes
12,000,000
10,000,000
8,000,000
6,000,000
4,000,000
2,000,000
0
2004 2012 2013 2014 2015
Thermosets
15% PU 5%
Other
thermoplastics Polyethylene
13% 29%
Polyvinyl Polypropylene
chloride 12%
Polystyrene 9%
17%
3
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
Figure 1.3 shows the worldwide consumption of polyether polyols and polyester
polyols for PU in 2012–2014 [35–37].
7,000
6,000
5,000
Kilo tonnes
4,000 Polyether
3,000 Polyester
2,000
1,000
0
2004 2012 2013 2014
4
Polyols
Figure 1.4 shows that most PU used worldwide are foams (flexible, semiflexible,
rigid foams), and ≈69–70% of total PU. In 2004–2014, worldwide production of
CASE (coatings, adhesives, sealants, elastomers, binders) surpassed the worldwide
production of rigid PU foams.
Adhesives
Coatings 4%
13% Flexible
foams
39%
Rigid
foams
26%
Binders
Elastomers Sealants 4%
12% 2%
Upon consideration of practical and applicative reasons, PU can be divided into two
main categories: elastic (e.g., flexible foams, elastomers, coatings, adhesives, fibres),
and rigid (e.g., rigid PU foams, structural foams, wood substitutes, solid PU). This
common classification of PU is based mainly on the oligo-polyol structure. Thus,
the general reaction for the PU synthesis is:
Reaction 1.3 shows the general reaction for synthesis of crosslinked PU:
5
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
Rigid
PU
Crosslink (28%) Rigid PU foams
density Structural foams
Wood substitute
Solid PU
Soft Hard
Stiffness
OH n
OCN R NCO HO
Diisocyanate +
HO
Oligo-polyol
OCOHN R NHCOO n
OCOHN R NHCOO
n = 0,1,2.......6
OCOHN R NHCOO
PU
6
Polyols
Polyols of low functionality, having ≈2–3 hydroxyl groups/mol and with a high-MW
of 2,000–12,000 Da, lead to an elastic PU. In contrast, a low-MW oligo-polyol of
300–1,000 Da with high functionality of ≈3–8 hydroxyl groups/mol leads to a rigid
crosslinked PU.
N C O
C N
H O
Hydrogen bonds
O H
O H
H O
C N
N C O N C O
H O
7
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
Hard domains
Soft
domain
A polyol of high-MW (3,000–6,500 Da) and with low functionalityof ≈2–3 hydroxyl
groups/mol, if reacted with a diisocyanate, leads to a low-crosslinked, flexible PU
structure. This structure is characteristic of flexible PU foams. The resulting
structure is crosslinked, s o the MW of the resulting PU is infinite in value. Only
linear PU have a finite and determinable MW.
In Figure 1.8, one can see a hypothetical crosslinked structure of a flexible PU foam
resulting from an oligo-triol with a MW of 3,000–6,500 Da and a diisocyanate
[3–16, 20].
The rigid structures of PU are created using low-MW polyols (150–1,000 Da)
that have high functionalities of ≈3–8 hydroxyl groups/mol. By reacting these
low-MW oligo-polyols of high functionality with a diisocyanate or polyisocyanate
(having 2–3 –NCO groups/mol), a hard, rigid PU structure is obtained (Figure
1.9). This high rigidity is an immediate consequence of the high crosslink density of
the resulting PU polymer [3–6, 10, 11, 14, 39]. Figure 1.9 shows a hypothetical,
highly crosslinked structure of a rigid PU.
8
Polyols
O O O O O
H H
= O C HN R NH C O or O C HN R N C N R NH C O
a b
9
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
Several general aspects of the profound influence the oligo-polyol structure has on
the properties of the resulting PU have been discussed briefly in this chapter. To
understand fully the role of the polyol structure on PU properties, the method of
chemical insertion of oligo-polyol into PU macromolecules will be discussed in
Chapter 2 with the most important aspects of PU chemistry. Then, the general
and common characteristics of oligo-polyols for PU will be presented. Subsequent
chapters will deal with a detailed presentation of the main types of oligo-polyols
for PU, as well as the chemistry and technology of these oligo-polyols (including
their manufacture). Oligo-polyols are presented in two main groups: oligo-polyols
for elastic PU and oligo-polyols for rigid PU. The final chapter details all knowledge
concerning oligo-polyols, and describes the relationship between oligo-polyol
structure and properties of the final PU.
References
4. The ICI Polyurethanes Book, 2nd Edition, Ed., G. Woods, John Wiley & Sons,
Chichester, UK, 1990.
10
Polyols
10. J.H. Saunders and K.C. Frisch in Polyurethanes: Chemistry and Technology,
Part I, Interscience Publishers, New York, NY, USA, 1962.
13. Plastic Foams, Eds., K.C. Frisch and J.H. Saunders, Marcel Dekker,
New York, NY, USA, 1972.
16. Flexible Polyurethane Foams, 2nd Edition, Eds., R. Herrington and K. Hock,
Dow Chemical Company, Midland, MI, USA, 1997.
17. H. Ulrich in Reaction Polymers, Eds., W.F. Gum, W. Riese and H. Ulrich,
Hanser Publishers, New York, NY, USA, 1992, p.50.
19. Analytical Chemistry of the Polyurethanes, Eds., D.J. David and H.B. Staley,
Wiley Interscience, New York, NY, USA, 1969, Volume 16, Part III, High
Polymers.
11
Chemistry and Technology of Polyols for Polyurethanes, 2nd Edition, Volume 1
24. A.F. Johnson, P.D. Coates and M.W.R. Brown in Reactive Processing of
Polymers, Rapra Review Report No. 73, Smithers Rapra Technology,
Shawbury, Shropshire, UK, 1994.
26. MDI and TDI: Safety, Health and the Environment - A Source Book and
Practical Guide, Eds., D.C. Allport, D.S. Gilbert and
S.M. Outterside, Wiley Publishers, Chichester, UK, 1998.
30. Houben Weyl: Methoden der Organische Chemie, Eds., E. Muller, O. Bayer,
H. Meerwein and K. Ziegler, Georg Thieme Verlag, Stuttgart, Germany,
1963, 14, 2, 57. [In German]
12
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to that time. Consult also Dreschfeld, Brain, July, 1884, and January, 1886.