Prepolymer reactions

To obtain the polyurethanes, typically a prepolymer was first prepared by reacting the diisocyanate with various diols in dimethylformamide or dimethylacetamide in a two to one molar ratio at 100-110°C for two hours under nitrogen atmosphere. A solution of chain extenders, such as BEP, was then added to the prepolymer reaction mixture and further reacted another three hours. The polymer was isolated by quenching the reaction mixture in cold water. Fine white powder was obtained with a typical yield of around 90%. 

A major problem is the exotherm that is given out in the reaction. The heat generated must be removed in the molding. The total amount of heat given out is the sum of the heat from the initial prepolymer reaction and the final chain extension stage. This leads the process to be used in relatively thin-walled products. 

Effective catalysts for preparing the polyformals were p-toluenesulfonic acid, camphorsulfonic acid, methanedisulfonic acid, and perchloric acid. Various other acidic compounds were evaluated as catalysts with tetramethylcyclobutanediol. In these experiments, 0.5 to 1.0 gram of acidic compound per mole of tetramethylcyclobutanediol was normally added. If insufficient water was obtained, more catalyst was added. If the prepolymer was obtained but an appreciable amount of brown color was present, less catalyst was then used. Compounds which did not catalyze the reaction (no water obtained) were phosphoric acid, zinc chloride, trifluoroacetic acid, and heptafluorobutyric acid. Incomplete reactions (insufficient water) took place with concentrated hydrochloric acid, concentrated nitric acid, zinc fluoroborate, or Amberlite IRC-50 ion exchange resin as catalyst. A prepolymer was obtained when boron trifluoride etherate was used, but buildup did not take place in the solid phase (catalyst probably too volatile). Brown or speckled-brown polymers (after solid-phase buildup) were obtained with catalysts containing sulfonic acid groups (benzenesulfonic, dodecylbenzenesulfonic, sulfo-acetic, methanetrisulfonic, sulfuric, p-toluenesulfonic, camphorsulfonic, and methanedisulfonic acids). To obtain white polymers from tetramethylcyclobutanediol it was necessary to treat the solvent and prepolymer reaction mixture as previously described. (White polyformals were obtained from the other diols without this treatment.)... 

POLYESTERAMIDE PREPOLYMER In the prepolymer reaction, the multifunctional acyllactam which normally acts as initiator for caprolactam polymerization, also functions to combine the polymeric polyol moeities. An excess of acyllactam is used so that the resulting prepolymer is terminated by acyllactam. The reaction occurs slowly with heat (13), but in the presence of an alkaline catalyst is completed within seconds. The prepolymer may be prepared in mass or in the presence of inert organic solvents, or in caprolactam as part of the total copolymerization reaction. See Reaction B. 

Figure 1-32. Prepolymer reaction, chain extension reaction.

Fig. 2.2. Prepolymer reaction sequence for elastomer synthesis (from AHport Janes, 1973).

Compound Metal (%) Gelation times (min at 7(fC) Prepolymer Reaction ... 

The initial step to prepare polyurethane polymers for solution wet or dry spinning includes reaction of 1000-3500 molecular weight macroglycol with a diisocyanate at molar ratios of between about 1 1.4 and 1 2.0. Reaction conditions must be carefully selected and controlled to minimize side reactions, eg, allophanate and biuret formation, which can result in trifunctional branched chains and ultimately to insoluble cross-linked poljuners. For the prepolymer reaction, poly(tetramethylene ether) glycol [25190-06-1] and bis(4-isocyanatophenyl) methane [101-68-8] are currently the most commonly used macroglycol and diisocyanate. Several types of polyester-based macroglycols are included in spandex producers product lines, but with the exception of Dorlastan, made by Bayer AG in Germany, the polyester-based products represent only a minor part of their spandex fiber production. 

FIG. 36 SEM micrographs of PER/PBNCO 90/10 mixture after rubber-prepolymer reaction and curing process at two different magnifications (a) 2500 x, (b) 5000 x. 

Stopping the polymer at this point requires the ratio of formaldehyde to phenol to be less than unity. Both methylene and ether bridges are known to be present. The reaction is either acid or base catalyzed, and branching is uncommon at this stage. The products are variously known as A stage resins, novolacs, or resole prepolymers. 

A large number of polymeric compounds have been investigated, but most modem propellants utilize prepolymers that ate hydroxy-functional polybutadienes (HTPB), carboxy-functional polybutadienes (CTPB), or a family of polyethylene oxides (PEGs) to form urethanes. Typical cure reactions... 

To produce a spandex fiber by reaction spinning, a 1000—3500 molecular weight polyester or polyether glycol reacts with a diisocyanate at a molar ratio of about 1 2. The viscosity of this isocyanate-terrninated prepolymer may be adjusted by adding small amounts of an inert solvent, and then extmded into a coagulating bath that contains a diamine so that filament and polymer formation occur simultaneously. Reactions are completed as the filaments are cured and solvent evaporated on a belt dryer. After appHcation of a finish, the fibers are wound on tubes or bobbins and rewound if necessary to reduce interfiber cohesion. 

Stabilizers and pigments are normally slurried with macroglycol and added to the polymeric glycol charge, prior to diisocyanate addition. Therefore, care must be taken to avoid additives that react significantly with diisocyanates or diamines under processing conditions. Also, stabilizers should be chosen that have no adverse catalytic effect on the prepolymer or chain-extension reactions. 

Following this work, the y -12F-diol was used for the direct reaction with hexamethylene-1,6-diisocyanate in the presence of dibutyltin dilaurate to produce a cross-linked elastomer or a reactive prepolymer which was terminated with either isocyanate or hydroxyl groups, depending on which reactant was in excess (142,143). 

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). 

Another significant use of 3-methylphenol is in the production of herbicides and insecticides. 2-/ f2 -Butyl-5-methylphenol is converted to the dinitro acetate derivative, 2-/ f2 -butyl-5-methyl-4,6-dinitrophenyl acetate [2487-01 -6] which is used as both a pre- and postemergent herbicide to control broad leaf weeds (42). Carbamate derivatives of 3-methylphenol based compounds are used as insecticides. The condensation of 3-methylphenol with formaldehyde yields a curable phenoHc resin. Since 3-methylphenol is trifunctional with respect to its reaction with formaldehyde, it is possible to form a thermosetting resin by the reaction of a prepolymer with paraformaldehyde or other suitable formaldehyde sources. 3-Methylphenol is also used in the production of fragrances and flavors. It is reduced with hydrogen under nickel catalysis and the corresponding esters are used as synthetic musk (see Table 3). 

Uretha.nes. Urethane elastomers are prepared by the reaction of an isocyanate molecule with a high molecular weight ester or ether molecule. The result is either an elastomeric mbber form or a Hquid prepolymer that can be vulcanised with an amine or a hydroxyl molecule (see Urethane POLYAffiRS). 

The first step in formulating a urethane sealant is to prepare what is commonly called the prepolymer, typically by reaction of a hydroxy-terrninated polyether with a stoichiometric amount of a diisocyanate. Each hydroxy group reacts with one end of every diisocyanate molecule. 

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. 

---