Polymerisation Polyurethane

The unsaturation present at the end of the polyether chain acts as a chain terminator ia the polyurethane reaction and reduces some of the desired physical properties. Much work has been done ia iadustry to reduce unsaturation while continuing to use the same reactors and hoi ding down the cost. In a study (102) usiag 18-crown-6 ether with potassium hydroxide to polymerise PO, a rate enhancement of approximately 10 was found at 110°C and slightly higher at lower temperature. The activation energy for this process was found to be 65 kj/mol (mol ratio, r = 1.5 crown ether/KOH) compared to 78 kj/mol for the KOH-catalysed polymerisation of PO. It was also feasible to prepare a PPO with 10, 000 having narrow distribution at 40°C with added crown ether (r = 1.5) (103). The polymerisation rate under these conditions is about the same as that without crown ether at 80°C. 

Step-Growth Gopolymerization. A sample of a block copolymer prepared by condensation polymerisation is shown in equation 30 (37). In this process, a prepolymer diol (HO—Z—OH) is capped with isocyanate end groups and chain extended with a low molecular-weight diol (HO—E—OH) to give a so-called segmented block copolymer, containing polyurethane hard blocks and O—Z—O soft blocks. 

The third approaeh to synthetic polymers is of somewhat less commereial importance. There is in fact no universally accepted deseription for the route but the terms rearrangement polymerisation and polyaddition are commonly used. In many respects this process is intermediate between addition and condensation polymerisations. As with the former teehnique there is no moleeule split out but the kinetics are akin to the latter. A typical example is the preparation of polyurethanes by interaction of diols (di-alcohols, glycols) with di-isocyanates Figure 2.7). 

Chemical reactions of polymer intermediate during polymerisation and/or cross-linking. This is important with polyurethanes. 

An important development of polymerisation casting is that of reaction injection moulding. Developed primarily for polyurethanes (and discussed further in Chapter 27), the process has also found some use with polyamides and with epoxide resins. 

Reaction injection moulding techniques, developed primarily for polyurethanes (see Chapter 27), have also been adapted for nylon 6 in what must be considered as a variation of the polymerisation casting technique. 

The basic RIM process is illustrated in Fig. 4.47. A range of plastics lend themselves to the type of fast polymerisation reaction which is required in this process - polyesters, epoxies, nylons and vinyl monomers. However, by far the most commonly used material is polyurethane. The components A and B are an isocyanate and a polyol and these are kept circulating in their separate systems until an injection shot is required. At this point the two reactants are brought together in the mixing head and injected into the mould. 

This system was slightly modified by R J. Flory, who placed the emphasis on the mechanisms of the polymerisation reactions. He reclassified polymerisations as step reactions or chain reactions corresponding approximately to condensation or addition in Carother s scheme, but not completely. A notable exception occurs with the synthesis of polyurethanes, which are formed by reaction of isocyanates with hydroxy compounds and follow step kinetics, but without the elimination of a small molecule from the respective units (Reaction 1.3). 

The factors which influence pre-gel intramolecular reaction in random polymerisations are shown to influence strongly the moduli of the networks formed at complete reaction. For the polyurethane and polyester networks studied, the moduli are always lower than those expected for no pre-gel intramolecular reaction, indicating the importance of such reaction in determining the number of elastically ineffective loops in the networks. In the limit of the ideal gel point, perfect networks are predicted to be formed. Perfect networks are not realised with bulk reaction systems. At a given extent of pre-gel intramolecular... 

These high energy species are extremely reactive, with themselves and with nucleophiles, and can generate runaway exotherms. With water, rapid evolution of carbon dioxide results. Some instances are reported [1], A compound of this class was resposible for the worst chemical industry accident to date. Di-isocyanates are extensively employed, with polyols, to generate polyurethane polymers. The polymerisation temperature should be held below 180°C or decomposition may occur which, in the case of foams, may induce later autoignition. 

Two series of polyether polyurethanes (PU) based on hydroquinone bis (P-hydroxyethyl) ether (HQEE) or 1,4-butanediol (BDO) as a chain extender were prepared by the one step bulk polymerisation process. By varying the mole ratio of poly tetra methylene oxide (PTMO) extender (with Mn = 1000 and Mn = 2000) and 4,4 -diphenylene methane diisocyanate (MDI) the two series of HQEE (PUlOOOHj, PU 1000H2, PU2000Hj,... 

Polymers Unsaturated fatty-acid chains offer opportunities for polymerisation that can be exploited to develop uses in surface coatings and plastics manufacturing. Polyunsaturated fatty acids can be dimerised to produce feedstocks for polyamide resin (nylon) production. Work is also ongoing to develop polyurethanes from vegetable oils through manipulation of functionality in the fatty-acid chains, to produce both rigid foams and elastomers with applications in seals, adhesives and moulded flexible parts (see Chapter 5 for more information). 

Epoxidised oils (with isolated double bonds), such as epoxidised soybean are used as plasticisers. The natural occurrence of epoxidised fatty acids could be exploited to reduce processing costs on the pathway to polymerisation. For example, seed oils derived from Vernonia galamensis and Euphorbia lagascae both contain significant proportions (60-80%) of the epoxy acid vemolic acid, with interesting applications in greases and polyurethane applications (Turley et al., 2000). 

PVC can be blended with numerous other polymers to give it better processability and impact resistance. For the manufacture of food contact materials the following polymerizates and/or polymer mixtures from polymers manufactured from the above mentioned starting materials can be used Chlorinated polyolefins blends of styrene and graft copolymers and mixtures of polystyrene with polymerisate blends butadiene-acrylonitrile-copolymer blends (hard rubber) blends of ethylene and propylene, butylene, vinyl ester, and unsaturated aliphatic acids as well as salts and esters plasticizerfrec blends of methacrylic acid esters and acrylic acid esters with monofunctional saturated alcohols (Ci-C18) as well as blends of the esters of methacrylic acid butadiene and styrene as well as polymer blends of acrylic acid butyl ester and vinylpyrrolidone polyurethane manufactured from 1,6-hexamethylene diisocyanate, 1.4-butandiol and aliphatic polyesters from adipic acid and glycols. 

Fig. 21.8. Sensitivity pattern to pyrene of 100 nm layers of polyurethane imprinted with various ratios of pyrene/naphthalene and polymerised at different temperatures.

Fig. 21.12. Sensitivity pattern of QCM coated with a p-xylene imprinted polyurethane to 0.1% solvent pulses. Other templates for the polymerisation results in increased sensitivity to the corresponding analyte and to sterically comparable neutral molecules.

The growing commercial use of polymer colloids whose preparation involves step polymerisations, hybrid systems and/or new routes to dispersion of polymers has not yet spawned an equivalent level of activity in academic studies. The success of the Avecia ex Zeneca Resins) technology for preparation of polyurethane dispersions is a good example of the importance of such developments. There also is the attraction of using conventional solvent-borne coating vehicles e.g., alkyd resins) in aqueous media and hybrid systems... 

Liquid polyurethane waterproofing systems are coal-tar modified products. Two-component materials are catalysed curing systems, and one-component materials are cured by exposure to moisture. Both the materials exhibit comparable properties on complete curing. Two-component materials require on-site mixing of the components. One-component materials can be applied directly, but the problem with this type is polymerisation of the product inside the container if it is improperly sealed. Such products are purged with an inert gas when the pack is sealed. 

Phosgene is very commonly employed in polymerisation reactions. Its role in the synthesis of polyurethanes and of polycarbonates has been described in Chapter 4, and reactions in which polymers are modified by post-treatment with COCl have been described in Chapter 10 (under the Section most appropriate to the type of functional group involved). This Section is mainly concerned with the reactions of phosgene to give novel polymers. 

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