Ultra-high solid content polyurethane dispersion and a continuous process for producing ultra-high solid content polyurethane dispersions

1. A continuous process for producing an Ultra-high solid content polyurethane dispersion comprising the steps of:

providing a first stream, wherein said first stream comprises a first polyurethane prepolymer or a first polyurethane prepolymer emulsion;

providing a second stream, wherein said second stream is a seed latex consisting of a polyolefin dispersion, wherein said seed latex has a volume average particle size diameter from 0.05 to 5.0 microns;

continuously merging said first stream with said second stream in the presence of a chain extender and a surfactant, wherein the temperature is in the range of 10° C. to 70° C., the ratio of said first stream to said second stream is in the range of 0.1 to 0.6 and said surfactant is present in a concentration range of from 0.1 to 3% based on the total weight of said first stream, said second stream, and said surfactant;

thereby forming said ultra-high solid content polyurethane dispersion comprising at least two volume average particle size diameters, the ultra-high solid content polyurethane dispersion having a particle size distribution in the range of 1:2 to 1:20 based on the percent volume of a first volume average particle size diameter to a second volume average particle size diameter, and wherein said ultra-high solid content polyurethane dispersion has at least a solid content of at least 70 percent by weight of said solid excluding the weight of any filler, based on the total weight of said ultra-high solid content polyurethane dispersion, and a viscosity of less than 3500 cps at 20 rpm at 21° C. using spindle #4 with Brookfield viscometer.

2. The continuous process for producing an ultra-high solid content polyurethane dispersion according to claim 1 , wherein said first stream comprises first polymer resins and said second stream comprises second polymer resins, and wherein said first polymer resin and said second polymer resin have a volume average particle size ratio in the range of 1:5 to 1:2.

3. The continuous process for producing an ultra-high solid content polyurethane dispersion according to claim 2 , wherein said first polymer resin and said second polymer resin have a volume average particle size ratio in the range of about 1:3.

4. The continuous process for producing an ultra-high solid content polyurethane dispersion according to claim 1 , wherein said first stream comprises first polymer resins and said second stream comprises second polymer resins, and wherein said ultra-high solid content polyurethane dispersion comprises 20 to 40 percent by weight of said first polymer resins having a particle size in the range of 0.04 micron to 5.0 micron, and 60 to 80 percent by weight of said second polymer resins having a particle size in the range of 0.05 micron to 5.0 micron, based on the total weight of said first polymer resin and said second polymer resin.

5. The continuous process for producing an ultra-high solid content polyurethane dispersion according to claim 1 , wherein said seed latex is an oil phase emulsified in water.

6. An ultra high solid content polyurethane dispersion prepared according to the continuous process of claim 1 .

7. The continuous process for producing an ultra-high solid content polyurethane dispersion according to claim 1 , wherein said first polyurethane prepolymer is a reaction product of at least one polyisocyanate and at least one polyol.

8. The continuous process for producing an ultra-high solid content polyurethane dispersion according to claim 7 , wherein said polyisocyanate is aromatic or aliphatic.

9. The continuous process for producing an ultra-high solid content polyurethane dispersion according to claim 8 , wherein said polyol is selected tom the group consisting of polyether, polyester, polycarbonate, natural seed oil polyol, and combinations thereof.

10. The continuous process for producing an ultra-high solid content polyurethane dispersion according to claim 9 , wherein said first polyurethane prepolymer is ionic or non-ionic.

11. The continuous process for producing an Ultra-high solid content polyurethane dispersion according to claim 6 , wherein said first polyurethane prepolymer is isocyanate terminated or hydroxyl terminated.

12. A method for producing an article comprising the steps of:

providing a first stream, wherein said first stream comprising a first polyurethane prepolymer or a first polyurethane prepolymer emulsion;

providing a second stream, wherein second stream is a seed latex consisting of a polyolefin dispersion, wherein said seed latex has a volume average particle size diameter from 0.05 to 5.0 microns;

continuously merging said first stream with said second stream in the presence of a chain extender and a surfactant, wherein the temperature is in the range of 10° C. to 70° C., the ratio of said first stream to said second stream is in the range of 0.1 to 0.6 and said surfactant is present in a concentration range of from 0.1 to 3% based on the total weight of said first stream, said second stream, and said surfactant;

thereby forming said ultra-high solid content polyurethane dispersion, comprising at least two volume average particle size diameters, the ultra-high solid content polyurethane dispersion having a particle size distribution in the range of 1:2 to 1:20 based on the percent volume of a first volume average particle size diameter to a second volume average particle size diameter, and wherein said ultra-high solid content polyurethane dispersion has at least a solid content of at least 70 percent by weight of said solid excluding the weight of any filler, based on the total weight of said ultra-high solid content polyurethane dispersion, and a viscosity of less than 3500 cps at 20 rpm at 21° C. using spindle #4 with Brookfield viscometer;

applying the dispersion to a substrate;

drying the dispersion, and

thereby forming the article.

13. A method for producing an article comprising the steps of:

providing a first stream, wherein said first stream comprises a first polyurethane prepolymer or a first polyurethane prepolymer emulsion;

providing a second stream, wherein said second stream is a seed latex consisting of a polyolefin dispersion, wherein said seed latex has a volume average particle size diameter from 0.05 to 5.0 microns;

continuously merging said first stream with said second stream in the presence of a chain extender and a surfactant, wherein the temperature is in the range of 10° C. to 70° C., the ratio of said first stream to said second stream is in the range of 0.1 to 0.6 and said surfactant is present in a concentration range of from 0.1 to 3% based on the total weight of said first stream, said second stream, and said surfactant;

thereby forming said ultra-high solid content polyurethane dispersion, comprising at least two volume average particle size diameters, the ultra-high solid content polyurethane dispersion having a particle size distribution in the range of 1.2 to 1:20 based on the percent volume of a first volume average particle size diameter to a second volume average particle size diameter, and wherein said ultra-high solid content polyurethane dispersion has at least a solid content of at least 70 percent by weight of said solid excluding the weight of any filler, based on the total weight of said ultra-high solid content polyurethane dispersion, and a viscosity of less than 3500 cps at 20 rpm at 21° C. using spindle #4 with Brookfield viscometer;

frothing the dispersion;

thereby forming a foam;

drying the foam; and

thereby forming the article.

14. An article produced according to the method of either claim 12 or claim 13 .