POLYURETHANE ADHESIVE COMPOSITION FOR CARBON EMISSION REDUCTION AND METHOD OF PREPARING SAME

Abstract

A polyurethane adhesive composition for carbon emission reduction, and a method of preparing same, includes polyether polyol containing a carbonate linkage, thus exhibiting a carbon emission reduction effect and good or desirable adhesion performance. The polyurethane adhesive composition is obtained by mixing a polyol mixture including polyether polyol containing a carbonate linkage and polytetramethylene glycol with an isocyanate in appropriate amounts and allowing the resulting mixture to react.

Claims

1. A polyurethane adhesive composition, obtained by reacting: a polyol mixture comprising polyether polyol containing a carbonate linkage and polytetramethylene glycol; and an isocyanate.

2. The polyurethane adhesive composition of claim 1, comprising, based on 100 parts by weight of the polyol mixture, 20 to 60 parts by weight of the isocyanate, and wherein the polyol mixture comprises 60 to 70 wt % of the polyether polyol and 30 to 40 wt % of the polytetramethylene glycol.

3. The polyurethane adhesive composition of claim 1, further comprising, based on 100 parts by weight of the polyol mixture 0.5 to 5 parts by weight of a chain extender and 0.5 to 3 parts by weight of an additive.

4. The polyurethane adhesive composition of claim 3, wherein the chain extender comprises at least one selected from the group consisting of a diol, triol, tetraol, diamine, aminoalcohol, and combinations thereof.

5. The polyurethane adhesive composition of claim 3, wherein the additive comprises at least one selected from the group consisting of a halogen-based flame retardant, a phosphorus-based flame retardant, an inorganic flame retardant, and combinations thereof.

6. The polyurethane adhesive composition of claim 1, wherein the polyether polyol contains 5 to 15 wt % of the carbonate linkage.

7. The polyurethane adhesive composition of claim 1, wherein the polyether polyol is polyether carbonate polyol synthesized by copolymerizing carbon dioxide and propylene oxide.

8. The polyurethane adhesive composition of claim 1, wherein the polyether polyol has a hydroxyl group value of 40 to 80 mg KOH/g.

9. The polyurethane adhesive composition of claim 1, wherein the polyether polyol has a weight average molecular weight (Mw) of 1500 to 2500 g/mol.

10. The polyurethane adhesive composition of claim 1, wherein the polytetramethylene glycol has a weight average molecular weight (Mw) of 1900 to 2100 g/mol.

11. The polyurethane adhesive composition of claim 1, wherein the isocyanate comprises at least one selected from the group consisting of mono-isocyanate, diisocyanate, and combinations thereof.

12. The polyurethane adhesive composition of claim 1, wherein the isocyanate comprises methylene diphenyl diisocyanate represented by a chemical formula: ##STR00004##

13. The polyurethane adhesive composition of claim 1, wherein the isocyanate has 2.0 to 2.5 functional groups.

14. A method of preparing a polyurethane adhesive composition, the method comprising: preparing a polyol mixture comprising polyether polyol containing a carbonate linkage and polytetramethylene glycol; and obtaining a first reaction product by mixing the polyol mixture with an isocyanate.

15. The method of claim 14, wherein the obtaining of the first reaction product is performed at a temperature of 80 to 90° C.

16. The method of claim 14, wherein the obtaining of the first reaction product comprises mixing an alcohol group (—OH) of the polyol mixture and an isocyanate group (—NCO) of the isocyanate at a ratio of 1:0.5-1.8.

17. The method of claim 14, further comprising obtaining a second reaction product by mixing the first reaction product with a chain extender and an additive.

18. The method of claim 17, wherein the obtaining of the second reaction product is performed at a temperature of 90 to 100° C.

Description

DETAILED DESCRIPTION

[0033] The above and other objects, features, and advantages of the present disclosure should be more clearly understood from the following embodiments taken in conjunction with the accompanying drawings. However, the present disclosure is not limited to the embodiments disclosed herein and may be modified into different forms. These embodiments are provided to thoroughly explain the inventive concept and to sufficiently transfer the spirit of the present disclosure to those having ordinary skill in the art.

[0034] It should be further understood that the terms “comprise”, “include”, “have”, etc., when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components, or combinations thereof. Such terms do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

[0035] Unless otherwise specified, all numbers, values, and/or representations that express the amounts of components, reaction conditions, polymer compositions, and mixtures used herein are to be taken as approximations including various uncertainties affecting measurement that inherently occur in obtaining these values, among others. Thus, such numbers, values, and/or representations should be understood to be modified by the term “about” in all cases. Furthermore, when a numerical range is disclosed in this specification, the range is continuous, and includes all values from the minimum value of said range to the maximum value thereof, unless otherwise indicated. Moreover, when such a range pertains to integer values, all integers including the minimum value to the maximum value are included, unless otherwise indicated.

[0036] In the present specification, when a range is described for a variable, it should be understood that the variable includes all values within the stated range, including the end points. For example, the range of “5 to 10” should be understood to include any subranges, such as 6 to 10, 7 to 10, 6 to 9, 7 to 9 and the like, as well as individual values of 5, 6, 7, 8, 9 and 10. The range should also be understood to include any value between valid integers within the stated range, such as 5.5, 6.5, 7.5, 5.5 to 8.5, 6.5 to 9, and the like. Also, for example, the range of “10% to 30%” should be understood to include subranges, such as 10% to 15%, 12% to 18%, 20% to 30%, etc., as well as all integers including values of 10%, 11%, 12%, 13% and the like up to 30%. The range should also be understood to include any value between valid integers within the stated range, such as 10.5%, 15.5%, 25.5%, and the like.

[0037] A polyurethane adhesive composition according to the present disclosure is obtained by reacting a polyol mixture including polyether polyol containing a carbonate linkage and polytetramethylene glycol with an isocyanate.

[0038] Specifically, the polyurethane adhesive composition further includes a chain extender and an additive and may include 100 parts by weight of a polyol mixture, 20 to 60 parts by weight of an isocyanate, 0.5 to 5 parts by weight of a chain extender, and 0.5 to 3 parts by weight of an additive.

[0039] The individual components of the polyurethane adhesive composition according to the present disclosure are specified below.

[0040] (A) Polyol Mixture

[0041] A polyol mixture is included in an amount of 100 parts by weight in the polyurethane adhesive composition and may include polyether polyol and polytetramethylene glycol.

[0042] 1) Polyether Polyol

[0043] Polyether polyol contains a carbonate linkage and may be included in an amount of 60 to 70 wt % based on the total amount of the polyol mixture.

[0044] The polyether polyol may serve to facilitate processing in the polyurethane adhesive composition due to the low viscosity thereof.

[0045] The polyether polyol may have a hydroxyl group value of 40 to 80 mg KOH/g and an average molecular weight (Mw) of 1500 to 2500 g/mol.

[0046] The polyether polyol may contain 5 to 15 wt % of a carbonate linkage.

[0047] Specifically, the polyether polyol may be polyether carbonate polyol prepared by copolymerizing carbon dioxide and propylene oxide, as represented in Chemical Scheme 1 below.

##STR00002##

[0048] The polyether carbonate polyol may be a polyol in which a carbonate linkage is chemically contained in the chain structure of the polyether polyol by applying carbon dioxide in the synthesis step.

[0049] During the synthesis of polyether carbonate polyol, a polyol material is synthesized by adding carbon dioxide as a reactant. It is possible to reduce carbon dioxide emissions compared to conventional petroleum-based preparation in the synthesis method. The polyether carbonate polyol used in the present disclosure is a polyol including 20% of a carbon-dioxide-based material, and ultimately, the use of petrochemicals in the preparation process may be reduced by 20%. Here, in the polyether carbonate polyol, the synthesized material contains carbon dioxide, and the amount of propylene oxide that is conventionally used is decreased in proportion to the amount of carbon dioxide that is contained. Thus, there is an effect of reducing carbon dioxide emissions from the aspects of final products and synthesis processes.

[0050] 2) Polytetramethylene Glycol (PTMG)

[0051] Polytetramethylene glycol is a good, i.e., desirable or useful compound having a high elastic modulus, excellent low-temperature characteristics, low permanent compression strain, superior hydrolysis resistance, and an excellent surface tactile sensation.

[0052] The polytetramethylene glycol may be included in an amount of 30 to 40 wt % based on the total amount of the polyol mixture. Here, if the amount of polytetramethylene glycol is less than 30 wt %, hydrolysis resistance may be deteriorated. On the other hand, if the amount of polytetramethylene glycol exceeds 40 wt %, hydrolysis resistance may be increased, but mechanical properties may be comparatively deteriorated, which is undesirable.

[0053] The polytetramethylene glycol may have a weight average molecular weight (Mw) of 1900 to 2100 g/mol. When polytetramethylene glycol having a weight average molecular weight (Mw) in the above range is applied to a polyurethane adhesive, an adhesive having superior flexibility, low-temperature characteristics, and tensile strength may be manufactured.

[0054] (B) Isocyanate

[0055] An isocyanate may be included in an amount of 20 to 60 parts by weight, and, in one example, 30 to 50 parts by weight, based on 100 parts by weight of the polyol mixture in the polyurethane adhesive composition. Here, if the amount of the isocyanate is less than 20 parts by weight, the adhesion performance of the final material may be deteriorated. On the other hand, if the amount of the isocyanate exceeds 60 parts by weight, viscoelastic properties useful for an adhesive may not be exhibited due to the excessive chemical reaction and increased hardness.

[0056] The isocyanate is a component that is added in the preparation of polyurethane and serves to undergo a chemical reaction with the polyol.

[0057] The isocyanate may play a role in making the distribution of hard and soft segments in the polyurethane structure uniform through the chemical reaction involving the polyol.

[0058] The isocyanate may include at least one selected from the group comprising or consisting of mono-isocyanate, diisocyanate, and combinations thereof.

[0059] Specifically, the isocyanate may include methylene diphenyl diisocyanate (MDI) represented by Chemical Formula 1 below.

##STR00003##

[0060] The isocyanate has 2.0 to 2.5 functional groups (e.g. based on a proportion of mono-isocyanate, diisocyanate, or combinations thereof in the isocyanate) and may exist in a liquid state at room temperature.

[0061] (C) Chain Extender

[0062] A chain extender may be included in an amount of 0.5 to 5 parts by weight based on 100 parts by weight of the polyol mixture in the polyurethane adhesive composition. Here, if the amount of the chain extender is less than 0.5 parts by weight, the structure of the final material is unstable, so mechanical properties and durability may be deteriorated. On the other hand, if the amount of the chain extender exceeds 5 parts by weight, local variations in physical properties may occur due to excessive crosslinking, so uniform performance as an adhesive may be deteriorated.

[0063] The chain extender serves to extend the polyurethane chain and may include at least one selected from the group comprising or consisting of a diol, triol, tetraol, diamine, aminoalcohol, and combinations thereof.

[0064] Specifically, the chain extender in one example may be 1,4-butanediol.

[0065] (D) Additive

[0066] An additive serves to impart various functionalities to the polyurethane adhesive composition, and the additive may be used without any particular limitation within a range that does not impair the effects of the present disclosure.

[0067] The additive is used to increase the low flame retardancy of the polyurethane adhesive.

[0068] The additive may include a reactive flame retardant and an additive flame retardant. Specifically, it may include at least one selected from the group comprising or consisting of a halogen-based flame retardant, a phosphorus-based flame retardant, an inorganic flame retardant, and combinations thereof.

[0069] The additive may be included in an amount of 0.5 to 3 parts by weight based on 100 parts by weight of the polyol mixture in the polyurethane adhesive composition. Here, if the amount of the additive is less than 0.5 parts by weight, the resulting flame retardancy may not meet flame retardancy specifications for automobile interior materials. On the other hand, if the amount of the chain extender exceeds 3 parts by weight, the final product may be discolored due to excessive use of the flame retardant.

[0070] The method of preparing the polyurethane adhesive composition according to the present disclosure as described above includes preparing a polyol mixture including polyether polyol containing a carbonate linkage and polytetramethylene glycol and obtaining a first reaction product by mixing the polyol mixture with an isocyanate.

[0071] The method of preparing the polyurethane adhesive composition may further include obtaining a second reaction product by mixing the first reaction product with a chain extender and an additive.

[0072] The individual steps of the method of preparing the polyurethane adhesive composition according to the present disclosure are specified below.

[0073] First, in the step of preparing the polyol mixture, polyether polyol containing a carbonate linkage and polytetramethylene glycol may be mixed.

[0074] Here, the polyol mixture may be obtained by mixing 60 to 70 wt % of polyether polyol and 30 to 40 wt % of polytetramethylene glycol.

[0075] Next, in the step of obtaining the first reaction product, the first reaction product may be synthesized by mixing 100 parts by weight of the polyol mixture and 20 to 60 parts by weight of an isocyanate.

[0076] In the step of obtaining the first reaction product, the reaction may be carried out at 80 to 90° C. If the reaction temperature is lower than 80° C., the reaction may occur slowly, whereas if the reaction temperature is higher than 90° C., the reaction rate is too fast, making it difficult to form a uniform internal density through mixing.

[0077] Finally, in the step of obtaining the second reaction product, the second reaction product may be synthesized as a final reaction product by mixing 0.5 to 5 parts by weight of a chain extender and 0.5 to 3 parts by weight of an additive based on 100 parts by weight of the polyol mixture.

[0078] In the step of obtaining the second reaction product, the reaction may be carried out at 90 to 100° C. If the reaction temperature is lower than 90° C., the chemical reaction may be non-uniform, whereas if the reaction temperature is higher than 100° C., a chemical structure imbalance may occur in the final product due to the excessive reaction.

[0079] In the method of preparing the polyurethane adhesive composition according to the present disclosure, the first reaction product and the second reaction product are obtained through stepwise reactions at different temperatures. Thus, the distribution of the hard and soft segments in the polyurethane structure is made uniform and the internal density thereof is evenly distributed. As a result, a polyurethane adhesive composition having improved adhesion performance and durability may be obtained.

[0080] In the step of obtaining the second reaction product, the alcohol group (—OH) of the polyol mixture and the isocyanate group (—NCO) of the isocyanate may be mixed at a ratio of 1:0.5-1.8. In one example, the ratio of —OH to —NCO is 1:1.3-1.6. Here, if the ratio thereof is less than 1:0.5, excess polyol component is present. Thus, the surface may become very sticky due to high viscosity after formation of polyurethane and unreacted polyol may remain in the product, resulting in deteriorated adhesion performance. On the other hand, if the ratio thereof exceeds 1:1.8, excess unreacted isocyanate functional groups are present. Thus, performance and durability as an adhesive may be deteriorated.

[0081] The density of the polyurethane adhesive composition prepared by the method according to the present disclosure may be 30 to 140 kg/m.sup.3.

[0082] Meanwhile, the polyurethane adhesive composition is not limited with regard to the fields of use thereof but may be used as an adhesive material for automobile parts. In particular, it exhibits high adhesion performance for bonding of various materials and heterogeneous materials applied to automobiles and thus may be industrially useful.

[0083] A better understanding of the present disclosure may be obtained through the following examples. These examples are merely set forth to illustrate the present disclosure and are not to be construed as limiting the present disclosure.

[0084] The respective compositions of Examples 1 to 6 were prepared in the following manner using components in the amounts shown in Table 1 below.

Examples 1 to 3

[0085] Polyether carbonate polyol and polytetramethylene glycol were mixed under conditions of 1 atm and 30-32° C., after which the temperature was raised to 80-90° C. Then, methylene diphenyl diisocyanate was added thereto and the resulting mixture was stirred at 500 to 700 rpm using a stirrer to prepare a first reaction product.

[0086] Subsequently, the temperature was raised to 90-100° C. Then, 1,4-butanediol as a chain extender was added to the first reaction product and mixed therewith, whereby a second reaction product was prepared.

Examples 4 to 6

[0087] A second reaction product was prepared in the same manner as in Examples 1 to 3, with the exception that a flame retardant was further added when the chain extender was added.

TABLE-US-00001 TABLE 1 Classification (unit: wt %) Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Polyol Polyether 66.6 69 69.5 66.9 69 66.4 mixture carbonate polyol Polytetramethylene 33.4 31 30.5 33.1 31 33.6 glycol Classification (unit: parts by weight) Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Polyol mixture 100 100 100 100 100 100 Chain 1,4-butanediol 3 3 4 4 4 5 extender Flame Inorganic flame — — — 1.5 1.5 1.5 retardant retardant Isocyanate Methylene 50 50 50 50 50 50 diphenyl diisocyanate 1. Polyether carbonate polyol: Own synthesized product (Hyundai Motors) 2. Polytetramethylene glycol: Mitsubishi Chemical, Japan, PTMEG-2000 (molecular weight: 2,000 g/mol) 3. 1,4-butanediol: Sigma Aldrich 4. Methylene diphenyl diisocyanate: Sigma Aldrich

[0088] Also, the respective compositions of Comparative Examples 1 to 6 were prepared in the following manner using components in the amounts shown in Table 2 below.

Comparative Examples 1 to 3

[0089] A polyurethane adhesive composition was prepared in the same manner as in Examples 1 to 3, with the exception that a petroleum-based polyether polyol was used in lieu of the polyether polyol containing a carbonate linkage.

Comparative Examples 4 to 6

[0090] A polyurethane adhesive composition was prepared in the same manner as in Examples 4 to 6, with the exception that a petroleum-based polyether polyol was used in lieu of the polyether polyol containing a carbonate linkage.

TABLE-US-00002 TABLE 2 Classification Comparative Comparative Comparative Comparative Comparative Comparative (unit: wt %) Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Polyol Petroleum-based 66.6 69 69.5 66.9 69 66.4 mixture polyether polyol Polytetramethylene 33.4 31 30.5 33.1 31 33.6 glycol Classification Comparative Comparative Comparative Comparative Comparative Comparative (unit: parts by weight) Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Polyol mixture 100 100 100 100 100 100 Chain 1,4-butanediol 3 3 4 4 4 5 extender Flame Inorganic flame — — — 1.5 1.5 1.5 retardant retardant Isocyanate Methylene 50 50 50 50 50 50 diphenyl diisocyanate 1. Petroleum-based polyether polyol: Korea Polyol, FA-702 2. Polytetramethylene glycol: Mitsubishi Chemical, Japan, PTMEG-2000 (molecular weight: 2,000 g/mol) 3. 1,4-butanediol: Sigma Aldrich 4. Methylene diphenyl diisocyanate: Sigma Aldrich

Test Example

[0091] The physical properties of the samples of the polyurethane adhesive compositions according to Examples and Comparative Examples were measured through the following method. The results thereof are shown in Tables 3 and 4 below.

[0092] [Evaluation Method]

[0093] Adhesion Shear Test Method:

[0094] Two samples of each of stainless steel, aluminum, polycarbonate (PC), and polymethyl methacrylate (PMMA) were prepared to a size of 100 mm×25 mm×2 mm.

[0095] The two samples were then disposed such that an overlapping area (25 mm×12.5 mm) was formed therebetween.

[0096] Next, the polyurethane adhesive prepared according to the present disclosure was applied on the overlapping area, maintained at 110° C. for 30 minutes, and then left in an environment having a relative humidity of 50% for 7 days.

[0097] Finally, the adhesion shear strength was measured at a head speed of 5 mm/min using a universal tensile tester (ASTM D1002).

TABLE-US-00003 TABLE 3 Adhesion Adhesion Adhesion Adhesion shear shear shear shear strength test strength test strength test strength test (substrate: (substrate: (substrate: (substrate: steel) aluminum) PC) PMMA) Classification (MPa) (MPa) (MPa) (MPa) Example 1 3.9 3.7 4 4 Example 2 3.9 3.8 4.1 4 Example 3 3.9 3.7 4.1 4.1 Example 4 3.8 3.6 4 4 Example 5 3.9 3.9 4 4 Example 6 3.8 3.8 4 4

TABLE-US-00004 TABLE 4 Adhesion Adhesion Adhesion Adhesion shear shear shear shear strength test strength test strength test strength test (substrate: (substrate: (substrate: (substrate: steel) aluminum) PC) PMMA) Classification (MPa) (MPa) (MPa) (MPa) Comparative 3.5 3.3 3.4 3.4 Example 1 Comparative 3.4 3.3 3.4 3.5 Example 2 Comparative 3.4 3.3 3.2 3.5 Example 3 Comparative 3.5 3.3 3.4 3.4 Example 4 Comparative 3.5 3.3 3.3 3.5 Example 5 Comparative 3.4 3.2 3.4 3.4 Example 6

[0098] As is apparent from Table 3, Examples 1 to 6 using the polyol containing a carbonate linkage exhibited bonding strength of 3.8 to 3.9 MPa, 3.6 to 3.9 MPa, 4.0 to 4.1 MPa, and 4.0 to 4.1 MPa with steel, aluminum, polycarbonate, and polymethyl methacrylate, respectively, indicating high adhesion performance. Therefore, it can be concluded that the polyurethane adhesive composition according to the present disclosure, when prepared using individual components in appropriate amounts, exhibits excellent quality without variation within each sample.

[0099] In contrast, as is apparent from Table 4, Comparative Examples 1 to 6 not using the polyol containing a carbonate linkage exhibited bonding strength of 3.4 to 3.5 MPa, 3.2 to 3.3 MPa, 3.2 to 3.4 MPa, and 3.4 to 3.5 MPa with steel, aluminum, polycarbonate, and polymethyl methacrylate, respectively. Thereby, it was confirmed that Comparative Examples using the petroleum-based polyether polyol exhibited vastly inferior adhesion performance compared to the bonding strength of Examples according to the present disclosure.

[0100] Therefore, the polyurethane adhesive composition according to the present disclosure can exhibit good or desirable adhesion performance regardless of the type of material thereof by mixing a polyol mixture including polyether polyol containing a carbonate linkage and polytetramethylene glycol with an isocyanate in appropriate amounts and allowing the resulting mixture to react, unlike petroleum-based polyurethane adhesive compositions.

[0101] Although specific embodiments of the present disclosure have been described, those having ordinary skill in the art should appreciate that the present disclosure may be embodied in other specific forms without changing the technical spirit or features thereof. Thus, the embodiments described above should be understood to be non-limiting and illustrative in every way.