Prepolymer catalysts

Advances in urethane processing involve changes in starting chemicals as well as improvements in processes. The chemicals have led to the use of low-cost polyether polyols, high-resilience (HR) "cold cure" foams, safer to handle than prepolymers, catalysts, and chain extenders. A major process improvement was the use of flat-top bun technology for low-density urethane foams. This technology... 

Reaction Injection Molding. RIM uses the anionic polymeri2ation of nylon-6 to carry out polymeri2ation in the mold. A commercial process involves the production of block copolymers of nylon-6 and a polyether by mixing molten caprolactam, catalyst, and polyether prepolymer, and reacting in a mold (27,28). 

Most general-purpose release agents have been developed for this market in part because of their low toxicity and chemical inertness and do not usually present health and safety problems. Some of the solvent dispersions require appropriate care in handling volatile solvents, and many supphers are offering water-based alternatives. Some of the sohds, particularly finely divided hydrophobic sohds, can also present inhalation problems. Some of the metallic soaps are toxic, although there is a trend away from the heavier, more toxic metals such as lead. The reactive type of release coating with monomers, prepolymers, and catalysts often presents specific handling difficulties. The potential user with health and safety questions is advised to consult the manufacturer directly. 

One-part urethane sealants (Table 3) are more compHcated to formulate on account of an undesirable side reaction between the prepolymer s isocyanate end and water vapor which generates carbon dioxide. If this occurs, the sealant may develop voids or bubbles. One way to avoid this reaction is to block the isocyanate end with phenol and use a diketamine to initiate cure. Once exposed to moisture, the diketamine forms a diamine and a ketone. The diamine reacts with the isocyanate end on the prepolymer, creating a cross-link (10). Other blocking agents, such as ethyl malonate, are also used (11). Catalysts commonly used in urethane formulations are tin carboxylates and bismuth salts. Mercury salt catalysts were popular in early formulations, but have been replaced by tin and bismuth compounds. 

The polyaddition reaction is influenced by the stmcture and functionaHty of the monomers, including the location of substituents in proximity to the reactive isocyanate group (steric hindrance) and the nature of the hydroxyl group (primary or secondary). Impurities also influence the reactivity of the system for example, acid impurities in PMDI require partial neutralization or larger amounts of the basic catalysts. The acidity in PMDI can be reduced by heat or epoxy treatment, which is best conducted in the plant. Addition of small amounts of carboxyHc acid chlorides lowers the reactivity of PMDI or stabilizes isocyanate terrninated prepolymers. 

In more recent years, molded flexible foam products are becoming more popular. The bulk of the molded flexible urethane foam is employed in the transportation industry, where it is highly suitable for the manufacture of seat cushions, back cushions, and bucket-seat padding. TDI prepolymers were used in flexible foam mol ding ia conjunction with polyether polyols. The introduction of organotin catalysts and efficient siHcone surfactants faciHtates one-shot foam mol ding, which is the most economical production method. 

Bismaleimides are best defined as low molecular weight, at least diftinctional monomers or prepolymers, or mixtures thereof, that carry maleimide terminations (Eig. 3). Such maleimide end groups can undergo homopolymerization and a wide range of copolymerizations to form a highly cross-linked network. These cure reactions can be effected by the appHcation of heat and, if required, ia the presence of a suitable catalyst. The first patent for cross-linked resias obtained through the homopolymerization or copolymerization of BMI was granted to Rhc ne Poulenc, Erance, ia 1968 (13). Shordy after, a series of patents was issued on poly(amino bismaleimides) (14), which are synthesized from bismaleimide and aromatic diamines. 

Heat-resistant resin compositions based on bismaleknide—epoxy blends are achieved by reaction of a BMI—y -aminophenol [591-27-5] (1 1) adduct with epoxy. This prepolymer is fully cured with an imida2ole catalyst (54). Blends of hydroxy-terminated BMI—aminophenol adducts can easily be B-staged, that is, prepolymerked, and subsequendy ground to provide a powder that can be molded by the appHcation of heat and pressure. 

The secondary hydroxyl groups of these poly(oxypropylene) glycol diols are less reactive than the primary hydroxyl groups of the earlier polyesters. At the time of the introduction of these polyethers, the catalysts then available were insufficiently powerful for one-shot processes to be practical and so these polymers have been used primarily in prepolymer processes. 

The first urethane reaction in Fig. 1 is used in two major ways in adhesives. In one case, a two-component adhesive usually employs a polyol and polyisocyanate with catalyst. This can react at room temperature to form the polyurethane. The second use of this reaction is to make an isocyanate-terminated prepolymer. Reacting a stoichiometric excess of isocyanate with polyol can produce an isocyanate-terminated prepolymer. A prepolymer is often made with an NCO/OH ratio of 2.0, as shown below, but the isocyanate ratio can range from 1.4 to over 8.0, depending upon the application ... 

Initially, the water slowly reacts with the isocyanate. However, the reaction can be catalyzed with an appropriate catalyst, such as dibutyltin dilaurate or a morpholine tertiary amine catalyst. The isocyanate will react with water to form a carbamic acid, which is unstable and splits off carbon dioxide, to produce a terminal amine end group (see p. 76 in [6]). This amine then reacts with more isocyanate-terminated prepolymer, as shown above, to form a polyurea. This process repeats itself, building up molecular weight and curing to become a polyurea-polyurethane adhesive. 

Catalysts serve a dual purpose in one-component moisture-curing urethanes. The first purpose is to accelerate the prepolymer synthesis. The second purpose is to catalyze the curing reaction of the adhesive with moisture. The most common catalysts used to promote both prepolymer formation (NCO/OH) and later the adhesive curing reaction (NCO/H2O) are dibutyltin dilaurate and DMDEE ((tertiary amine. A stabilizer such as 2,5-pentanedione is sometimes added when tin is used, but this specific stabilizer has fallen from favor in recent years, due to toxicity concerns. DMDEE is commonly used in many one-component moisture-curing urethanes. DMDEE is one of the few tertiary amines with a low alkalinity and a low vapor pressure. The latter... 

At moderately high molecular weights, the reaction mass becomes highly viscous, which limits heat transfer and evaporation of the condensation water. This high viscosity limits further melt polymerization in the bulk. In the literature, the melt polymerization stage is sometimes omitted and the prepolymers are condensed to high molecular weights in the solid state.6,28 41 The polymerizations can easily be carried out without a catalyst. 

Friedel-Crafts catalysts, 329, 331 Friedel-Crafts reaction, 297, 361 Front-end reactions, 235 FT Raman spectroscopy, 387 FTIR spectrometry. See Fourier transform infrared (FTIR) spectrometry Fuel cells, 272-273 Full prepolymers, 236, 237 Functionalized polyolefins, 459-460... 

Terminal-functionalized polymers such as macromonomers and telechelics are very important as prepolymer for construction of functional materials. Single-step functionalization of polymer terminal was achieved via lipase catalysis. Alcohols could initiate the ring-opening polymerizahon of lactones by lipase catalyst. The lipase CA-catalyzed polymerizahon of DDL in the presence of 2-hydroxyethyl methacrylate gave the methacryl-type polyester macromonomer, in which 2-hydroxyethyl methacrylate acted as initiator to introduce the methacryloyl group quanhtatively at the polymer terminal ( inihator method ).This methodology was expanded to the synthesis of oo-alkenyl- and alkynyl-type macromonomers by using 5-hexen-l-ol and 5-hexyn-l-ol as initiator, respechvely. 

Synthesis of Polyurethanes. In the "prepolymer method" employed in this study, MDI (2 equivalents) and PPG (1 equivalent) were reacted at 60°C in the presence of 1% dibutyltin dilaureate as catalyst, in the melt. The course of the polymerizations was followed spectroscopically by observing the intensity of the — NCO peak in the IR (Scheme III). 

As described in Section 9.1.2.2.3, several lanthanocene alkyls are known to be ethylene polymerization catalysts.221,226-229 Both (188) and (190) have been reported to catalyze the block copolymerization of ethylene with MMA (as well as with other polar monomers including MA, EA and lactones).229 The reaction is only successful if the olefin is polymerized first reversing the order of monomer addition, i.e., polymerizing MMA first, then adding ethylene only affords PMMA homopolymer. In order to keep the PE block soluble the Mn of the prepolymer is restricted to <12,000. Several other lanthanide complexes have also been reported to catalyze the preparation of PE-b-PMMA,474 76 as well as the copolymer of MMA with higher olefins such as 1-hexene.477... 

Figure 2.28 Dependency of the reaction progress on film thickness and time PET esterification product (prepolymer, Pn o = 2-3), with no catalyst added [8]...

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