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CN108884203A - 含有聚氨酯和潜在催化剂的层压粘合剂制剂 - Google Patents

含有聚氨酯和潜在催化剂的层压粘合剂制剂 Download PDF

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CN108884203A
CN108884203A CN201780020178.4A CN201780020178A CN108884203A CN 108884203 A CN108884203 A CN 108884203A CN 201780020178 A CN201780020178 A CN 201780020178A CN 108884203 A CN108884203 A CN 108884203A
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CN108884203B (zh
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D·文西
E·哈布朗特
T·施密特
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Dow Global Technologies LLC
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Abstract

公开了一种粘合剂制剂，其包含：a)聚氨酯组合物；和b)潜在催化剂，其是i)含脒化合物、含胍化合物或含胺化合物；ii)二氧化碳；和iii)水、醇、胺或硫醇的反应产物。

Description

含有聚氨酯和潜在催化剂的层压粘合剂制剂
相关申请的引用
本申请要求于2016年3月29日提交的美国临时申请第62/314,484号的权益。
技术领域
本发明涉及一种粘合剂制剂和其用于制造层压物的方法。具体地，它涉及具有潜在催化剂的无溶剂聚氨酯粘合剂制剂。
引言
无溶剂聚氨酯粘合剂是一类有用的层压粘合剂。这些是含有聚异氰酸酯和多元醇的液体组合物，可能还含有其它成分。所述粘合剂通常用于包装工业，特别用于制造食品包装。
然而，这些粘合剂往往具有较短的适用期(20至40分钟)，并且它们的固化时间可较长(对于低于2ppb和完全机械强度下的伯芳香胺(PAA)衰变长达10天)。无溶剂聚氨酯层压粘合剂的理想反应特征是具有在层压过程中较长的适用期但在层压后较高的反应性的组合。
一种解决方案是使用潜在的或延迟的催化剂来延长适用期。基于有机金属的催化剂已用作聚氨酯组合物的潜在催化剂。然而，这些催化剂中的大多数是基于锡的。众所周知并认识到基于锡的催化剂不推荐用于食品包装应用。此外，这些催化剂的活化条件(例如时间或温度)不适用于层压过程。因此，需要一种用于聚氨酯层压粘合剂的潜在催化剂，其可以在层压过程中活化并且不是基于有机金属的。
发明内容
在本发明的一个广泛的实施例中，公开了一种粘合剂制剂，其包含a)聚氨酯组合物；和b)潜在催化剂，它是i)含脒化合物、含胍化合物或含胺化合物；ii)二氧化碳；和iii)水、醇、胺或硫醇的反应产物。
在另一个实施例中，公开了前一实施例的粘合剂制剂，其中聚氨酯组合物包含以聚氨酯组合物总干重计为10至40重量％的异氰酸酯和60至90重量％的多元醇。
在另一个实施例中，公开了前述实施例中任一项的粘合剂制剂，其中催化剂选自由1,8-二氮杂双环十一碳-7-烯、1,1,3,3-四甲基胍(TMG)和叔丁基-1,1,3,3,四甲基胍组成的群组。
在另一个实施例中，公开了前述实施例中任一项的粘合剂制剂，其中催化剂以制剂的总干重计为0.0001至10重量％的量存在。
在另一个实施例中，公开了前述实施例中任一项的粘合剂制剂，其中聚氨酯组合物含有溶剂。
在另一个实施例中，公开了前述实施例中任一项的粘合剂制剂，其中聚氨酯组合物不含溶剂。
在另一个实施例中，公开了制备前述实施例中任一项的粘合剂制剂的方法，所述方法包含a)在形成聚氨酯组合物后将潜在催化剂加入聚氨酯组合物中；和
b)活化潜在催化剂。
在另一个实施例中，公开了前一实施例的方法，其中在步骤b)使用加热、机械力或辐射来活化潜在催化剂。
还公开了一种由前述实施例中任一项的粘合剂制剂制备的层压粘合剂，以及由这种层压粘合剂制备的柔性包装。
附图说明
图1是显示四个样品的粘度对时间的图。
具体实施方式
本发明的粘合剂制剂包含一种双组分聚氨酯粘合剂，以及包含脒或胍的催化剂。
粘合剂制剂可以是基于溶剂的或无溶剂的。如果粘合剂制剂不含溶剂，则它不含有机溶剂。在这些实施例中，粘合剂制剂以粘合剂制剂的总干重计，包含在各种实施例中小于4重量％，小于2重量％，和在各种其它实施例中小于1重量％的有机溶剂。
粘合剂制剂可以是需要碱催化剂的任何制剂。实例包括但不限于聚氨酯和环氧树脂。
在各种实施例中，粘合剂制剂是聚氨酯，其包含作为聚合单元的异氰酸酯和多元醇。可以使用的多元醇的实例是聚醚多元醇和聚酯多元醇。
异氰酸酯通常具有在各种其它实施例中小于500g/mol，小于300g/mol，和在各种其它实施例中小于275g/mol的分子量Mw。
异氰酸酯可以是单体芳族二异氰酸酯。单体芳族二异氰酸酯的实例包括但不限于二异氰酸亚甲基二苯酯(MDI)、甲苯二异氰酸酯(TDI)和其组合。TDI通常能够以任何常用的异构体分布使用。最常用的TDI具有80％2,4-异构体和20％2,6-异构体的异构体分布。也可以使用具有其它异构体分布的TDI。当使用MDI制备聚氨基甲酸酯预聚物时，其通常是纯4,4'-MDI或MDI异构体的任意组合。当使用4,4'-MDI与其它MDI异构体的组合时，4,4'-MDI的优选浓度是所有MDI异构体的25％至75％。
以聚氨酯预聚物的总干重计，单体芳香族二异氰酸酯通常以0至40重量％的范围存在于聚氨酯预聚物中。本文包括并公开了在0至40重量％之间的任何和所有范围；例如，二异氰酸酯可以12至38重量％或15至35重量％的范围存在于聚氨酯预聚物中。
在各种其它实施例中，聚醚多元醇和聚酯多元醇各自具有400至4000g/mol、750至3500g/mol，更优选800至3000g/mol的重均分子量Mw。在各种其它实施例中，聚醚多元醇和聚酯多元醇各自可具有1.8至10、1.9至3的官能度，并且在各种其它实施例中可具有2至2.5的官能度。
可使用的聚醚多元醇的实例包括并不限于环氧乙烷、环氧丙烷、四氢呋喃与环氧丁烷的加聚产物和接枝产物、多元醇的缩合产物和其任意组合。聚醚多元醇的具体实例包括并不限于聚丙二醇(PPG)、聚乙二醇(PEG)、聚丁二醇、聚四亚甲基醚二醇(PTMEG)和其任意组合。
在各种实施例中，以聚氨酯预聚物的总干重计，聚醚多元醇通常以0至99重量％的范围存在于聚氨酯预聚物中。本文包括并公开了在0至99重量％之间的任何和所有范围，例如，聚醚多元醇可以25至80重量％或30到75重量％的范围存在于聚氨酯预聚物中。
聚酯多元醇是二醇以及二羧酸和其衍生物的缩合产物或其衍生物。
二醇的具体实例包括并不限于乙二醇、丁二醇、二乙二醇、三乙二醇、聚烷二醇(诸如聚乙二醇、1,2-丙二醇、1,3-丙二醇、2-甲基-1,3-丙二醇、1,3-丁二醇、1,4-丁二醇、1,6-己二醇、新戊二醇、3-甲基-1,5-戊二醇和其任意组合)。为了实现大于2的多元醇官能度，也可以使用三醇和/或四醇。这种三醇的具体实例包括三羟甲基丙烷和丙三醇。这种四醇的具体实例包括赤藓醇和季戊四醇。
二羧酸选自芳香族酸、脂肪族酸和其组合。芳香族酸的合适实例是邻苯二甲酸、间苯二甲酸和对苯二甲酸；而脂肪酸的合适实例是己二酸、壬二酸、癸二酸、戊二酸、四氯邻苯二甲酸、马来酸、富马酸、衣康酸、丙二酸、辛二酸、2-甲基琥珀酸、3,3-二乙基戊二酸和2,2-二甲基琥珀酸。这些酸的酸酐同样也可以使用。为了本发明的目的，酸酐因此涵盖在术语“酸”的表述中。优选地，所述脂肪族酸和芳香族酸是饱和的，并且分别是己二酸和间苯二甲酸。例如苯甲酸和己烷羧酸的一元羧酸应降到最少或排除。
聚酯多元醇也可以通过内酯与二醇、三醇和/或四醇的加聚反应来制备。内酯的具体实例包括己内酯、丁内酯和戊内酯。二醇的具体实例是乙二醇、丁二醇、二乙二醇、三乙二醇、聚烷二醇例如聚乙二醇、1,2-丙二醇、1,3-丙二醇、2-甲基1,3-丙二醇、1,3-丁二醇、1,4-丁二醇、1,6-己二醇、新戊二醇、3-甲基1,5-戊二醇和其任意组合。三醇的具体实例包括三羟甲基丙烷和丙三醇。四醇的具体实例包括赤藓醇和季戊四醇。
在各种实施例中，以聚氨酯预聚物的总干重计，聚酯多元醇可以在0至99重量％的范围内存在于聚氨酯预聚物中。本文包括并公开了在0至99重量％之间的任何和所有范围，例如，预聚物可含有18至28重量％的聚酯多元醇，或20至25重量％的聚酯多元醇。
聚氨酯预聚物能够以所属领域的那些一般技术人员所熟知且包括缩聚反应的任何方式来制备。有机溶剂不用于制备聚氨酯预聚物。
将潜在催化剂在搅拌下添加到聚氨酯分散液中以形成稳定的混合物。
潜在催化剂是通过基于脒或胍的化合物与二氧化碳和水、醇、胺或硫醇的反应形成的络合物。可以使用任何醇，但在各种实施例中，使用1-乙醇、丙-2-醇、1-辛醇或乙二醇。
基于脒的化合物具有如下式I所示的一般结构。
其中R1、R2、R3和R4独立地选自由氢、甲基、乙基、丙基、异丙基、丁基、异丁基和环状结构组成的群组。
基于胍的化合物具有如下式II所示的一般结构。
其中R1、R2、R3、R4和R5独立地选自由氢、甲基、乙基、丙基、异丙基、丁基、异丁基和环状结构组成的群组。
基于脒的化合物的合适实例包括但不限于(1,8-二氮杂双环十一碳-7-烯)(DBU)。
基于胍的化合物的合适实例包括但不限于1,1,3,3-四甲基胍(TMG)和叔丁基-1,1,3,3,四甲基胍。
代替基于脒或胍的化合物，可以使用基于胺的化合物。基于胺的化合物的实例包括但不限于乙二胺、二亚乙基三胺和氨丙基三乙氧基硅烷。
潜在催化剂的通常用量以制剂的总重量计在0.0001至10重量％的范围内。本文包括并公开了在0.0001重量％与10重量％之间的任何和所有范围，例如，潜在催化剂可以0.1到5重量％或0.5到3重量％范围内的量存在。
在各种实施例中，制剂还可含有增粘剂、填料、粘合促进剂、染料和/或溶剂。但是，该制剂不能含有酸性化合物。
将粘合剂制剂施加到至少一个衬底的表面上。衬底通常选自由聚合物膜、金属化聚合物膜、箔、聚合物背衬金属箔、纸和其组合组成的群组。
包括金属箔、聚酯膜和尼龙膜。然后可以将第二衬底层压到第一衬底上。
当粘合剂制剂的催化剂涂覆在第一基底或第二基底上时可被活化。催化剂如何活化的实例包括但不限于加热(例如微波或红外加热)、机械力或辐射。如果使用加热，催化剂通常在30至200℃但在各种其它实施例中50至100℃的范围内的温度下活化。
层压物可以是包含附加衬底和附加粘合剂制剂的较厚层压物的一部分。附加的衬底可以与本发明的层压物中包含的膜相同或不同。附加粘合剂制剂可以与本发明的粘合剂制剂相同或不同，并且可以是层压工业中的任何常用粘合剂制剂。
实例
制备封闭的基于TMG的催化剂
将1,1,3,3-四甲基胍(TMG)和水的等摩尔混合物溶解在乙腈(1体积混合物/1体积乙腈)中并引入试管中。使通过滴落在碳酸钙上的磷酸反应产生的二氧化碳在试管中鼓泡。封闭反应在室温下进行1至2小时。在反应结束时，过滤不溶于乙腈的基于TMG的烷基碳酸盐，并用过量的乙腈洗涤。使盐在罩子下的滤纸中干燥过夜，并无需进一步纯化进行分析。活化温度范围确定为80至130℃。在90℃下的活化时间确定为30分钟。
通过粘度测量确定的粘度曲线用一般性能系统(MOR-FREE 698A+C79)运行。MOR-FREE 698A是基于纯4,4'-MDI和异构MDI的预聚物。C79是蓖麻油和聚醚三醇的共混物。
对于以下系统，活性曲线在40℃下运行1小时：
·参考：MOR-FREE 698A+C79 100/50
·无活性催化剂(CAT1)：MOR-FREE 698A+C79混合100/50+0.05重量％的无活性基于TMG的催化剂(如上制备)并搅拌1分钟
·活性催化剂(活化的CAT1)：MOR-FREE 698A+C79与0.05重量％活化的基于TMG的催化剂100/50混合搅拌1分钟
·TMG参考：MOR-FREE 698A+C79混合100/50+0.03重量％TMG搅拌约1分钟
通过在90℃下加热C79和催化剂的混合物1小时来活化基于TMG的催化剂。然后加入MOR-FREE 698A并测量最终共混物的粘度。
参见图1，CAT1在40℃下无活性1小时。活化后，CAT1显示出与TMG类似的催化活性。

Claims (10)

1.一种粘合剂制剂，其包含
a)聚氨酯组合物；和
b)潜在催化剂，其是
i)含脒化合物、含胍化合物或含胺化合物；
ii)二氧化碳；和
iii)水、醇、胺或硫醇的反应产物。
2.根据权利要求1所述的粘合剂制剂，其中所述聚氨酯组合物包含以所述聚氨酯组合物的总干重计为10至40重量％的异氰酸酯和60至90重量％的多元醇。
3.根据权利要求1或2中的任一项所述的粘合剂制剂，其中所述催化剂选自由1,8-二氮杂双环十一碳-7-烯、1,1,3,3-四甲基胍(TMG)和叔丁基-1,1,3,3,四甲基胍组成的群组。
4.根据前述权利要求中任一项所述的粘合剂制剂，其中所述催化剂是以所述制剂的总干重计为0.0001至10重量％范围内的量存在。
5.根据前述权利要求中的任一项所述的粘合剂制剂，其中所述聚氨酯组合物含有溶剂。
6.根据前述权利要求中的任一项所述的粘合剂制剂，其中所述聚氨酯组合物不含有溶剂。
7.一种制备根据前述权利要求中任一项所述的粘合剂制剂的方法，所述方法包含
a)在所述聚氨酯组合物形成后将所述潜在催化剂加入所述聚氨酯组合物中；和
b)活化所述潜在催化剂。
8.根据权利要求7所述的方法，其中在步骤b)使用加热、机械力或辐射来活化所述潜在催化剂。
9.一种由根据权利要求1-6中任一项所述的粘合剂制剂制备的层压粘合剂。
10.一种由根据权利要求9所述的层压粘合剂制备的柔性包装。
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