Polyurethane diols

Fig. 9. Reaction scheme for the synthesis of PU elastomers with strictly monodisperse hard segments and narrow soft segment length distribution made with hydroxy-terminated polyurethanes Diol-n and polyethers POTM-n (see Figure 3) ... 

Diester/Ether Diol of Tetrabromophthalic Anhydride. This material [77098-07-8] is prepared from TBPA in a two-step reaction. First TBPA reacts with diethylene glycol to produce an acid ester. The acid ester and propylene oxide then react to give a diester. The final product, a triol having two primary and one secondary hydroxyl group, is used exclusively as a flame retardant for rigid polyurethane foam (53,54). 

Miscellaneous chemicals are used to modify the final properties of rigid polyurethane foams. Eor example, halogenated materials are used for flammabihty reduction, diols may be added for toughness or flexibiUty, and terephthalate-based polyester polyols may be used for decreased flammabiUty and smoke generation. Measurements of flammabihty and smoke characteristics are made with laboratory tests and do not necessarily reflect the effects of foams in actual fire situations. 

One of the first attempts to produce polyurethane was from the reaction of an intermediate polyol of 1,3- and l,4-bis(hydroxyhexa uoroisopropyl)benzene m- and -12F-diols) by reaction with epichlorohydrin. This polyol was subsequentiy allowed to react with a commercial triisocyanate, resulting in a tough, cross-linked polyurethane (129,135,139). ASTM and military specification tests on these polyurethanes for weather resistance, corrosion prevention, bUster resistance, and ease of cleaning showed them to compare quite favorably with standard resin formulations. 

The next approach to incorporate the 12F-diol into a polyurethane matrix was reaction of the y -12F-diol with aUphatic diacid chlorides (where a = 3 or 4) to give low molar mass polyesters (141) ... 

Acetylene is condensed with carbonyl compounds to give a wide variety of products, some of which are the substrates for the preparation of families of derivatives. The most commercially significant reaction is the condensation of acetylene with formaldehyde. The reaction does not proceed well with base catalysis which works well with other carbonyl compounds and it was discovered by Reppe (33) that acetylene under pressure (304 kPa (3 atm), or above) reacts smoothly with formaldehyde at 100°C in the presence of a copper acetyUde complex catalyst. The reaction can be controlled to give either propargyl alcohol or butynediol (see Acetylene-DERIVED chemicals). 2-Butyne-l,4-diol, its hydroxyethyl ethers, and propargyl alcohol are used as corrosion inhibitors. 2,3-Dibromo-2-butene-l,4-diol is used as a flame retardant in polyurethane and other polymer systems (see Bromine compounds Elame retardants). 

Much more important is the hydrogenation product of butynediol, 1,4-butanediol [110-63-4]. The intermediate 2-butene-l,4-diol is also commercially available but has found few uses. 1,4-Butanediol, however, is used widely in polyurethanes and is of increasing interest for the preparation of thermoplastic polyesters, especially the terephthalate. Butanediol is also used as the starting material for a further series of chemicals including tetrahydrofuran, y-butyrolactone, 2-pyrrohdinone, A/-methylpyrrohdinone, and A/-vinylpyrrohdinone (see Acetylene-DERIVED chemicals). The 1,4-butanediol market essentially represents the only growing demand for acetylene as a feedstock. This demand is reported (34) as growing from 54,000 metric tons of acetylene in 1989 to a projected level of 88,000 metric tons in 1994. 

In the second step, a papermaking method is also used for the fine fibers, less than 0.1 tex (1 den). This process is usually followed by a high pressure water jet process instead of the third step. In the fourth step, to obtain the required properties in specific appHcations, a polyurethane is selected out of the segmented polyurethanes, which comprises a polymer diol, a diisocyanate, and a chain extender (see Urethane polymers). A DMF—water bath for coagulation is also controlled to create the adequate pore stmcture in combination with fibers. 

Poly(propylene oxide) [25322-69-4] may be abbreviated PPO and copolymers of PO and ethylene oxide (EO) are referred to as EOPO. Diol poly(propylene oxide) is commonly referred to by the common name poly(propylene glycol) (PPG). Propylene oxide [75-56-9] and poly(propylene oxide) and its copolymers, with ethylene oxide, have by far the largest volume and importance in the polyurethane (PUR) and surfactant industry compared to all other polyepoxides. Articles reviewing propylene oxide (1), poly(propylene oxide) (2—4), other poly(aIkylene oxides) (4), and polyurethanes (5—7) are cited to lead the interested reader to additional detail not in the scope of this article. 

Step-growth polymerization is characterized by the fact that chains always maintain their terminal reactivity and continue to react together to form longer chains as the reaction proceeds, ie, a -mer + -mer — (a + )-mer. Because there are reactions that foUow this mechanism but do not produce a molecule of condensation, eg, the formation of polyurethanes from diols and diisocyanates (eq. 6), the terms step-growth and polycondensation are not exactly synonymous (6,18,19). 

Methylenedi(cyclohexyhsocyanate) (45) [5124-30-1] (MDCHl, Desmodur W) is the dominant derivative of MDCHA and is used in light-stable urethanes. Polyurethane physical properties are dependent on the diamine geometric isomer composition used for the derivative diisocyanate which reacts with diol (87). 

Until the mid-1960s, phenylenediamines were used primarily for oxidative purposes the para isomer was of major importance. Since then, the use of phenylenediamines to manufacture polymers has far exceeded their use for oxidative purposes. The y -phenylenediamines, (2,4 and 2,6)-toluenediamine, are widely used for the manufacture of polyurethanes. Phenylenediamines are dihinctional and react with other dihinctional compounds, such as dianhydrides, diacyl chlorides, dicarboxyHc acids, and disulfonyl chlorides to give polyamides. Phenylenediamines also give polymers with epoxides, diols, diacetals. 

Polyurethane foams are formed by reaction with glycerol with poly(propylene oxide), sometimes capped with poly(ethylene oxide) groups with a reaction product of trimethylolpropane and propylene oxide or with other appropriate polyols. A typical reaction sequence is shown below, in which HO—R—OH represents the diol. If a triol is used, a cross-linked product is obtained. 

Mesogenic diols, such as 4,4 -bis( CO-hydtoxyaLkoxy)biphenyls, ate used with 2,4-TDI or 1,4-diisocyanatobenzene (PPDI) to constmct Hquid crystalline polyurethanes (7). Partial replacement of the mesogenic diols by PTMG shows that the use of lower molecular weight flexible spacers form polymers that have a more stable mesophase and exhibit higher crystallinity (8). Another approach to Hquid crystal polyurethanes involves the attachment of cholesterol to the polyurethane chain utilizing the dual reactivity in 2,4-TDI (9). 

In addition, polyester polyols are made by the reaction of caprolactone with diols. Poly(caprolactone diols) are used in the manufacture of thermoplastic polyurethane elastomers with improved hydrolytic stabiHty (22). The hydrolytic stabiHty of the poly(caprolactone diol)-derived TPUs is comparable to TPUs based on the more expensive long-chain diol adipates (23). Polyether/polyester polyol hybrids are synthesized from low molecular weight polyester diols, which are extended with propylene oxide. 

Flame retardants (qv) are incorporated into the formulations in amounts necessary to satisfy existing requirements. Reactive-type diols, such as A/ A/-bis(2-hydroxyethyl)aminomethylphosphonate (Fyrol 6), are preferred, but nonreactive phosphates (Fyrol CEF, Fyrol PCF) are also used. Often, the necessary results are achieved using mineral fillers, such as alumina trihydrate or melamine. Melamine melts away from the flame and forms both a nonflammable gaseous environment and a molten barrier that helps to isolate the combustible polyurethane foam from the flame. Alumina trihydrate releases water of hydration to cool the flame, forming a noncombustible inorganic protective char at the flame front. Flame-resistant upholstery fabric or liners are also used (27). 

Water-borne polyurethane coatings are formulated by incorporating ionic groups into the polymer backbone. These ionomers are dispersed in water through neutrali2ation. The experimental 1,12-dodecane diisocyanate (C12DI Du Pont) is especially well suited for the formation of water-borne polyurethanes because of its hydrophobicity (39). Cationomers are formed from IPDI, /V-methyIdiethan olamine, and poly(tetramethylene adipate diol)... 

Polyurethane adhesives are known for excellent adhesion, flexibihty, toughness, high cohesive strength, and fast cure rates. Polyurethane adhesives rely on the curing of multifunctional isocyanate-terrninated prepolymers with moisture or on the reaction with the substrate, eg, wood and ceUulosic fibers. Two-component adhesives consist of an isocyanate prepolymer, which is cured with low equivalent weight diols, polyols, diamines, or polyamines. Such systems can be used neat or as solution. The two components are kept separately before apphcation. Two-component polyurethane systems are also used as hot-melt adhesives. 

Polyester and polyether diols are used with MDI in the manufacture of thermoplastic polyurethane elastomers (TPU). The polyester diols are obtained from adipic acid and diols, such as ethylene glycol, 1,4-butanediol, or 1,6-hexanediol. The preferred molecular weights are 1,000 to 2,000, and low acid numbers are essential to ensure optimal hydrolytic stabihty. Also, caprolactone-derived diols and polycarbonate diols are used. Polyether diols are... 

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). 

There is also growing interest in multi-phase systems in which hard phase materials are dispersed in softer polyether diols. Such hard phase materials include polyureas, rigid polyurethanes and urea melamine formaldehyde condensates. Some of these materials yield high-resilience foams with load deflection characteristics claimed to be more satisfactory for cushioning as well as in some cases improving heat resistance and flame retardancy. 

Poly(tetramethylene oxide) polyols (PTMEG) are high performance polyethers that are crystalline waxes at molecular weights above 650 and liquids at lower molecular weights. They are only available as diols, but they produce adhesives with good hydrolysis resistance and moisture resistance, which is why these adhesives are even used in medical devices, blood bags, catheters, and heart-assist devices [25]. Certain thermoplastic polyurethane adhesives and solvent-borne adhesives are also based on PTMEG s. 

Crystalline polyesters are highly important as adhesive raw materials. They are normally crystalline waxes and are highly symmetrical in nature, which can aid the crystallization process [26]. Poly(hexamethylene adipate) and poly(caprolactone), shown in Table 2, are only two of the many crystallizable backbones. Poly(ethylene adipate) and poly(letramethylene adipate) are also commonly used in urethane adhesives. The crystalline polyesters are used in curing hot melts, waterborne polyurethanes, thermoplastic polyurethanes, and solvent-borne urethane adhesives. The adipates are available mostly as diols. The poly(caprolactones) are available as diols and triols. 

In a second step, the prepolymer was then reacted with a low molecular weight difunctional alcohol, commonly referred to as a diol or a diamine, to connect the prepolymer oligomers into a high molecular weight polyurethane. This step was referred to as the chain extension , resulting in the use of the term chain extenders to describe the low molecular weight diols or diamines that reacted with the prepolymer oligomers. 

Technical Data Sheet — Polyester Diol S-105. Ruco Polymer Corporation, Oct. 1995. Trappe, G., In Buist, J. and Gudgeon, H. (Eds.), Advances in Polyurethane Technology. Maclaren, 1968, p. 80. 

Fatty acids, both saturated and unsaturated, have found a variety of applications. Brassilic acid (1,11-un-decanedicarboxylic acid [BA]), an important monomer used in many polymer applications, is prepared from erucic acid (Scheme 2), obtained from rapeseed and crambe abyssinica oils by ozonolysis and oxidative cleavage [127]. For example, an oligomer of BA with 1,3-butane diol-lauric acid system is an effective plasticizer for polyvinylchloride. Polyester-based polyurethane elastomers are prepared from BA by condensing with ethylene glycol-propylene glycol. Polyamides based on BA are known to impart moisture resistance. 

No by-product is formed from this reaction. Toluene diisocyanate (Chapter 10) is a widely used monomer. Diols and triols produced from the reaction of glycerol and ethylene oxide or propylene oxide are suitable for producing polyurethanes. 

Polyester polyurethanes are usually based on a blend of a quasi-prepolymer (polyester/MDl) and a diol/polyester suitable for spray-up operation. An alternative is to use a solvent-containing system using blocked curatives to give an extended pot-life of 2 to 3 hours enabling them to be brush, roller or spray applied. 

Polyether polyurethanes are often based on a quasi prepolymer/diol blend reacted with a carbodiimide modified M.D.I. suitable for automatic mix-dispensers. 

A urethane is typically prepared by nucleophilic addition reaction between an alcohol and an isocyanate (R—N = C=0), so a polyurethane is prepared by reaction between a cliol and a diisocyanate. The diol is usually a low-molecular-weight polymer (MW 1000 amu) with hydroxyl end-groups the diisocyanate is often toluene-2,4-diisocyanate. 

Polyurethane foams are generally made using a polyalcohol rather than a diol as the monomer, so the polymer has a high amount of three-dimensional cross-linking. The result is a rigid but very light foam suitable for use as thermal insulation in building construction and portable ice chests. 

Step-growth polymers, the second major class of polymers, are prepared by reactions between difunctional molecules, with the individual bonds in the polymer formed independently of one another. Polycarbonates are formed from a diester and a diol, and polyurethanes are formed from a diisocyanate and a diol. 

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