Automated parallel polyurethane dispersion synthesis and characterization

Abstract

The synthesis of waterborne polyurethane dispersions (PUDs) using an automated parallel reactor system was explored. Waterborne PUDs are an important class of polymer dispersion that can be used in many applications such as coatings for wood finishing, glass fiber sizing, adhesives, automotive topcoats, and other applications. Herein, we present the synthesis of aqueous PUDs using a Chemspeed Autoplant A100™ automated parallel reactor system. This is the first time a PUD has been synthesized using an automated parallel reactor system. The synthesis involves the formation of an isocyanate-terminated prepolymer followed by neutralization, dispersion in water, and chain extension. Details of the methodology are discussed with respect to the process of writing the program for the synthesis to synthesizing the PUD itself with the Chemspeed. It is demonstrated that an aqueous PUD can be synthesized with an automated parallel process and the unit-to-unit results are similar. Process variables such as agitator design, rate of neutralization, and rate of water dispersion are varied as these are the three major factors which lead to the desired end product property. The controlled addition of neutralizer, water, and chain extender is an added advantage with this automated technique and gave consistent results in all the units. The PUDs were characterized for their particle size, viscosity, and percent solids.