Waterborne one component non-isocyanate polyurethane epoxy hybrid coatings

1 . A method of preparing a composition for a one-package (1 K) waterborne non-isocyanate polyurethane epoxy hybrid coating, the method comprising steps of

combining a cyclic carbonate with one or more of 3,3′-diamino-N-methyldipropylamine (DMDPA) and norspermidine as an internal emulsifier and a diamine to thereby obtain a non-isocyanate polyurethane (NIPU) prepolymer, where the internal emulsifier also provides hard segments to an eventual neutralized NIPU polymer;

subjecting the NIPU prepolymer to chain extension by combining the NIPU prepolymer with an epoxy resin, to thereby obtain a chain extended NIPU polymer;

subjecting the chain extended NIPU polymer to neutralization by combining the chain extended NIPU polymer with a neutralizing agent, to thereby obtain the neutralized NIPU polymer; and

dispersing the neutralized NIPU polymer in water to thereby provide a waterborne NIPU liquid dispersion as a one-package (1 K) composition.

2 . The method of claim 1 , wherein the step of providing the cyclic carbonate includes synthesizing the cyclic carbonate by combining a starting material with carbon dioxide and a catalyst, wherein the catalyst is selected from tetrabutylammonium bromide (TBAB), quaternary ammonium salt modified amberlyst (D296), Bu 4 NBr, and metal-organic frameworks (MOFs).

3 . The method of claim 2 , wherein the starting material is a difunctional epoxy.

4 . The method of claim 2 , wherein the starting material is selected from bisphenol A diglycidyl ether (DGEBA), ethylene glycol diglycidyl ether (EGDE), and glycol diglycidyl ether (GDE).

5 . The method of claim 1 , wherein the diamine is a fatty acid diamine.

6 . The method of claim 1 , wherein the diamine is selected from diethyl enetriamine, triethylenetetramine, tetraethylenepentamine, pentaethylenehexamine, propylenediamine, dipropylenetriamine, 2,4,4-trimethylhexamethylenediamine, 3,3′-diamino-N-methyldipropylamine, 1,4-bis-(3′-aminopropyl)-piperazine, N,N-bis-(3-aminopropyl)-ethylenediamine, neopentanediamine, 2-methyl-1,5-pentanediamine, 1,3-diaminopentane, and hexamethylenediamine.

7 . The method of claim 1 , wherein the cyclic carbonate, the internal emulsifier, and the diamine are dissolved in a solvent during the step of combining, wherein the solvent is a water soluble solvent including one or more of ethanol, methanol, and methyl ethyl ketone (MEK), further comprising a step of removing the solvent in connection with the dispersing the neutralized NIPU polymer in the water.

8 . The method of claim 1 , wherein the epoxy resin includes an epoxy with functionality of 2-4.

9 . The method of claim 1 , wherein the epoxy resin is selected from bisphenol A diglycidyl ether (DGEBA), trimethylolpropane triglycidyl ether (TTE), and 4,4′-methylenebis (N,N-diglycidylaniline) (MBDA).

10 . The method of claim 1 , wherein the waterborne NIPU liquid dispersion has a solid content of from about 10 wt. % to about 40 wt. %.

11 . The method of claim 1 , further comprising a step of allowing the waterborne NIPU liquid dispersion to dry by allowing evaporation of the water therefrom, to thereby form a waterborne NIPU coating film including the neutralized NIPU polymer.

12 . The method of claim 11 , wherein, prior to the evaporation, a wet waterborne NIPU coating has a wet film thickness of from about 25 μm to about 500 μm.

13 . The method of claim 11 , wherein the waterborne NIPU coating has a dry film thickness of from about 5 μm to about 300 μm.

14 . The waterborne NIPU coating made by the method of claim 11 .

15 . The waterborne NIPU liquid dispersion made by the method of claim 1 .

16 . The method of claim 7 , further comprising, after the dissolving the cyclic carbonate, the internal emulsifier, and the diamine in the solvent as a mixture and prior to the subjecting the NIPU prepolymer to chain extension, heating the mixture to a temperature of from about 60° C. to about 80° C. for about 6 hours to about 12 hours.

17 . The method of claim 1 , further comprising applying the waterborne NIPU liquid dispersion onto a substrate to form a wet film, and allowing the water of the wet film to evaporate to thereby form a waterborne NIPU coating film including the neutralized NIPU polymer.