High-gravity-assisted emulsification for continuous preparation of waterborne polyurethane nanodispersion with high solids content

doi:10.1007/s11705-019-1895-z

Front. Chem. Sci. Eng.

2020, Vol. 14

Issue (6) : 1087-1099 https://doi.org/10.1007/s11705-019-1895-z

RESEARCH ARTICLE

High-gravity-assisted emulsification for continuous preparation of waterborne polyurethane nanodispersion with high solids content

Weihong Zhang^1,², Dan Wang¹(

), Jie-Xin Wang^1,², Yuan Pu²(

), Jian-Feng Chen^1,²

¹. State Key Laboratory of Organic-Inorganic Composites, Beijing University of Chemical Technology, Beijing 100029, China
². Research Centre of the Ministry of Education for High Gravity Engineering and Technology, Beijing University of Chemical Technology, Beijing 100029, China

Download: PDF(3675 KB) HTML
Export: BibTeX | EndNote | Reference Manager | ProCite | RefWorks

Abstract

In this work, we developed a continuous preparation strategy for the production of high-solids-content waterborne polyurethane (WPU) emulsions via high-gravity-assisted emulsification in a rotating packed bed (RPB) reactor. By adjusting the experimental parameters and formula, WPU emulsions with a high solids content of 55% and a low viscosity were prepared. Preliminary applications of the high-solids-content WPU as a thermally insulating material were demonstrated. RPB emulsification is an economical and environmentally friendly production strategy because of the low energy consumption, short emulsification time, and effective devolatilization. This study demonstrated an effective method for preparation of high-solids-content WPU, moving toward commercialization and industrialization.

Keywords waterborne polyurethane rotating packed bed emulsification nanodispersion high solids content

Corresponding Author(s): Dan Wang,Yuan Pu

Just Accepted Date: 27 December 2019 Online First Date: 06 March 2020 Issue Date: 11 September 2020

Cite this article:

Weihong Zhang,Dan Wang,Jie-Xin Wang, et al. High-gravity-assisted emulsification for continuous preparation of waterborne polyurethane nanodispersion with high solids content[J]. Front. Chem. Sci. Eng., 2020, 14(6): 1087-1099.

URL:

https://academic.hep.com.cn/fcse/EN/10.1007/s11705-019-1895-z
https://academic.hep.com.cn/fcse/EN/Y2020/V14/I6/1087

Fig.1 Scheme 1 Preparation process of MDI-WPU.

Fig.2 Schematic diagram of experimental setup for WPU emulsification. 1: Nitrogen cylinder; 2: pre-polymerization reactor; 3, 7: valve; 4, 8: pump; 5, 9: flow meter; 6: emulsion storage tank; 10: RPB.

Fig.3 Specific design structure of the RPB reactor.

Fig.4 (a) Sketch of the first step of the mixing process in the RPB; (b) the liquid flow distribution simulated by CFD with respect to the pre-polymer flow rate at 50 and 100 rpm; (c) the Z-average size obtained with various pre-polymer flow rates; (d) sketch of the second step of the mixing process in the RPB; (e) the liquid flow distribution simulated by CFD with respect to the circulating flow rate at 100 and 250 rpm; (f) the Z-average size obtained with various circulating flow rates.

Fig.5 (a) Particle sizes distribution of WPU particles obtained after various numbers of cycles; (b) the Z-average size and PDI of WPU particles obtained after various numbers of cycles; (c) the contrast in PSD between 45 cycles in the RPB and STR reactors.

Fig.6 (a) PSD of WPU particles obtained at various high-gravity levels; (b) the Z-average size and PDI of WPU particles obtained at various high-gravity levels; (c) the comparison of PSDs between STR and RPB with 430g.

Fig.7 (a) TEM image of WPU for 50g; (b) TEM image of WPU for 135g; (c) TEM image of WPU after 15 cycles; (d) TEM image of WPU after 75 cycles.

Fig.8 Schematic diagram of coalescence and breakup in RPB.

Fig.9 (a) Relationship between solids content and viscosity of different WPU emulsions; (b) the schematic diagram of different dispersions of emulsions by RPB and STR; (c) TEM morphology of monodisperse particles by RPB; (d) TEM morphology of WPU flocculation.

Fig.10 (a) Digital photograph of WPU emulsion prepared with different emulsification times; (b) two series of digital photographs for WPU coating films with solids contents of 53% and 30% at different times; (c) the relationship between relative weight and time during drying of the WPU coating films.

1	S Wang, X S Du, Y X Jiang, J H Xu, M Zhou, H B Wang, X Cheng, Z L Du. Synergetic enhancement of mechanical and fire-resistance performance of waterborne polyurethane by introducing two kinds of phosphorus-nitrogen flame retardant. Journal of Colloid and Interface Science, 2019, 537: 197–205 https://doi.org/10.1016/j.jcis.2018.11.003
2	J Q Hu, K M Peng, J S Guo, D Y Shan, G B Kim, Q Y Li, E Gerhard, L Zhu, W P Tu, W Z Lv, et al. Click cross-linking-improved waterborne polymers for environment-friendly coatings and adhesives. ACS Applied Materials & Interfaces, 2016, 8(27): 17499–17510 https://doi.org/10.1021/acsami.6b02131
3	J Leng, J Chen, D Wang, J X Wang, Y Pu, J F Chen. Scalable preparation of Gd2O3: Yb3+/Er3+ upconversion nanophosphors in a high-gravity rotating packed bed reactor for transparent upconversion luminescent films. Industrial & Engineering Chemistry Research, 2017, 56(28): 7977–7983 https://doi.org/10.1021/acs.iecr.7b02262
4	Q Yan, H Dong, J Su, J Han, B Song, Q Wei, Y Shi. A review of 3D printing technology for medical applications. Engineering, 2018, 4(5): 729–742 https://doi.org/10.1016/j.eng.2018.07.021
5	D J Yang, S Y Wang, R S Zhong, W F Liu, X Q Qiu. Preparation of lignin/TiO2 nanocomposites and their application in aqueous polyurethane coatings. Frontiers of Chemical Science & Engineering, 2018, 13(1): 59–69 https://doi.org/10.1007/s11705-018-1712-0
6	C P Chai, Y F Ma, G P Li, Z Ge, S Y Ma, Y J Luo. The preparation of high solid content waterborne polyurethane by special physical blending. Progress in Organic Coatings, 2018, 115: 79–85 https://doi.org/10.1016/j.porgcoat.2017.10.021
7	D K Chattopadhyay, K V S N Raju. Structural engineering of polyurethane coatings for high performance applications. Progress in Polymer Science, 2007, 32(3): 352–418 https://doi.org/10.1016/j.progpolymsci.2006.05.003
8	H Y Liang, S W Wang, H He, M Q Wang, L X Liu, J Y Lu, Y Zhang, C Q Zhang. Aqueous anionic polyurethane dispersions from castor oil. Industrial Crops and Products, 2018, 122: 182–189 https://doi.org/10.1016/j.indcrop.2018.05.079
9	H Honarkar, M Barmar, M Barikani. Synthesis, characterization and properties of waterborne polyurethanes based on two different ionic centers. Fibers and Polymers, 2015, 16(4): 718–725 https://doi.org/10.1007/s12221-015-0718-1
10	C Philipp, S Eschig. Waterborne polyurethane wood coatings based on rapeseed fatty acid methyl esters. Progress in Organic Coatings, 2012, 74(4): 705–711 https://doi.org/10.1016/j.porgcoat.2011.09.028
11	J Feng, Q H Lu, W M Tan, K Q Chen, P K Ouyang. The influence of the NCO/OH ratio and the 1,6-hexanediol/dimethylol propionic acid molar ratio on the properties of waterborne polyurethane dispersions based on 1,5-pentamethylene diisocyanate. Frontiers of Chemical Science and Engineering, 2019, 13(1): 80–89 https://doi.org/10.1007/s11705-018-1763-2
12	P Król. Synthesis methods, chemical structures and phase structures of linear polyurethanes. Properties and applications of linear polyurethanes in polyurethane elastomers, copolymers and ionomers. Progress in Materials Science, 2007, 52(6): 915–1015 https://doi.org/10.1016/j.pmatsci.2006.11.001
13	S J Peng, Y Jin, X F Cheng, T B Sun, R Qi, B Z Fan. A new method to synthesize high solid content waterborne polyurethanes by strict control of bimodal particle size distribution. Progress in Organic Coatings, 2015, 86: 1–10 https://doi.org/10.1016/j.porgcoat.2015.03.013
14	X Zhou, C Q Fang, W Q Lei, J Du, T Y Huang, Y Li, Y L Cheng. Various nanoparticle morphologies and surface properties of waterborne polyurethane controlled by water. Scientific Reports, 2016, 6(1): 6 https://doi.org/10.1038/srep34574
15	I D A Mariz, J C de la Cal, J R Leiza. Control of particle size distribution for the synthesis of small particle size high solids content latexes. Polymer, 2010, 51(18): 4044–4052 https://doi.org/10.1016/j.polymer.2010.07.001
16	I D A Mariz, J R Leiza, J C de la Cal. Competitive particle growth: A tool to control the particle size distribution for the synthesis of high solids content low viscosity latexes. Chemical Engineering Journal, 2011, 168(2): 938–946 https://doi.org/10.1016/j.cej.2011.02.023
17	L J Hou, Y T Ding, Z L Zhang, Z S Sun, Z H Shan. Synergistic effect of anionic and nonionic monomers on the synthesis of high solid content waterborne polyurethane. Colloids and Surfaces a-Physicochemical and Engineering Aspects, 2015, 467: 46–56
18	M Li, F Liu, Y Li, X H Qiang. Synthesis of stable cationic waterborne polyurethane with a high solid content: Insight from simulation to experiment. RSC Advances, 2017, 7(22): 13312–13324 https://doi.org/10.1039/C7RA00647K
19	S K Lee, B K Kim. High solid and high stability waterborne polyurethanes via ionic groups in soft segments and chain termini. Journal of Colloid and Interface Science, 2009, 336(1): 208–214 https://doi.org/10.1016/j.jcis.2009.03.028
20	J L Salager, A Forgiarini, L Marquez, A Pena, A Pizzino, M P Rodriguez, M Rondo-Gonzalez. Using emulsion inversion in industrial processes. Advances in Colloid and Interface Science, 2004, 108: 259–272 https://doi.org/10.1016/j.cis.2003.10.008
21	A Perazzo, V Preziosi, S Guido. Phase inversion emulsification: Current understanding and applications. Advances in Colloid and Interface Science, 2015, 222: 581–599 https://doi.org/10.1016/j.cis.2015.01.001
22	H Liu, T Hu, D Wang, J Shi, J Zhang, J X Wang, Y Pu, J F Chen. Preparation of fluorescent waterborne polyurethane nanodispersion by high-gravity miniemulsion polymerization for multifunctional applications. Chemical Engineering and Processing-Process Intensification, 2019, 136: 36–43 https://doi.org/10.1016/j.cep.2018.12.012
23	D Wenzel, A Gorak. Review and analysis of micromixing in rotating packed beds. Chemical Engineering Journal, 2018, 345: 492–506 https://doi.org/10.1016/j.cej.2018.03.109
24	X He, Z Wang, Y Pu, D Wan, R Tang, S Cui, J X Wang, J F Chen. High-gravity-assisted scalable synthesis of zirconia nanodispersion for light emitting diodes encapsulation with enhanced light extraction efficiency. Chemical Engineering Science, 2019, 195: 1–10 https://doi.org/10.1016/j.ces.2018.11.036
25	X He, R Tang, Y Pu, J X Wang, Z Wang, D Wang, J F Chen. High-gravity-hydrolysis approach to transparent nanozirconia/silicone encapsulation materials of light emitting diodes devices for healthy lighting. Nano Energy, 2019, 62: 1–10 https://doi.org/10.1016/j.nanoen.2019.05.024
26	D Wang, Z Wang, Q Zhan, Y Pu, J X Wang, N R Foster, L Dai. Facile and scalable preparation of fluorescent carbon dots for multifunctional applications. Engineering, 2017, 3(3): 402–408 https://doi.org/10.1016/J.ENG.2017.03.014
27	Y Pu, J Leng, D Wang, J X Wang, N R Foster, J F Chen. Process intensification for scalable synthesis of ytterbium and erbium co-doped sodium yttrium fluoride upconversion nanodispersions. Powder Technology, 2018, 340: 208–216 https://doi.org/10.1016/j.powtec.2018.09.035
28	Y Liu, W Jiao, G Qi. Preparation and properties of methanol-diesel oil emulsified fuel under high-gravity environment. Renewable Energy, 2011, 36(5): 1463–1468 https://doi.org/10.1016/j.renene.2010.11.007
29	S M Modarres-Gheisari, R Gavagsaz-Ghoachani, M Malaki, P Safarpour, M Zandi. Ultrasonic nano-emulsification—a review. Ultrasonics Sonochemistry, 2019, 52: 88–105 https://doi.org/10.1016/j.ultsonch.2018.11.005
30	G W Cui, J P Wang, X C Wang, W Li, X Zhang. Preparation and properties of narrowly dispersed polyurethane nanocapsules containing essential oil via phase inversion emulsification. Journal of Agricultural and Food Chemistry, 2018, 66(41): 10799–10807 https://doi.org/10.1021/acs.jafc.8b02406
31	J F Chen, M Y Zhou, L Shao, Y Wang, J Yun, N Y K Chew, H K Chan. Feasibility of preparing nanodrugs by high-gravity reactive precipitation. International Journal of Pharmaceutics, 2004, 269(1): 267–274 https://doi.org/10.1016/j.ijpharm.2003.09.044
32	K Wu, H R Wu, T C Dai, X Z Liu, J F Chen, Y Le. Controlling nucleation and fabricating nanoparticulate formulation of sorafenib using a high-gravity rotating packed bed. Industrial & Engineering Chemistry Research, 2018, 57(6): 1903–1911 https://doi.org/10.1021/acs.iecr.7b04103
33	S Y Kang, Z X Ji, L F Tseng, S A Turner, D A Villanueva, R Johnson, A Albano, R Langer. Design and synthesis of waterborne polyurethanes. Advanced Materials, 2018, 30(18): 1706237 https://doi.org/10.1002/adma.201706237
34	C Tan, M C Lee, A Abbaspourrad. Facile synthesis of sustainable high internal phase emulsions by a universal and controllable route. ACS Sustainable Chemistry & Engineering, 2018, 6(12): 16657–16664 https://doi.org/10.1021/acssuschemeng.8b03923
35	A Guyot, F Chu, M Schneider, C Graillat, T F McKenna. High solid content latexes. Progress in Polymer Science, 2002, 27(8): 1573–1615 https://doi.org/10.1016/S0079-6700(02)00014-X
36	Y Cui, H Gong, Y Wang, D Li, H Bai. A thermally insulating textile inspired by polar bear hair. Advanced Materials, 2018, 30(14): 1706807 https://doi.org/10.1002/adma.201706807
37	Y J Wu, C F Xiao, H L Liu, Q L Huang. Fabrication and characterization of novel foaming polyurethane hollow fiber membrane. Chinese Journal of Chemical Engineering, 2019, 27(4): 935–943 https://doi.org/10.1016/j.cjche.2018.09.016

[1]	Yichen Liu, Yongli Li, Andreas Hensel, Juergen J. Brandner, Kai Zhang, Xiaoze Du, Yongping Yang. A review on emulsification via microfluidic processes[J]. Front. Chem. Sci. Eng., 2020, 14(3): 350-364.
[2]	Dongxiang ZHANG, Yuanping LIN, Anmei LI, V. V. TARASOV. Emulsification for castor biomass oil[J]. Front Chem Sci Eng, 2011, 5(1): 96-101.

Viewed

Full text

Abstract

Cited

Shared

Discussed