Advances in bio-based polyurethanes (for automotive interior coatings)

SusPolyurethanes ConferenceM. Costello, Oct 5-6, Amsterdam

▪ Introduction

▪ Polyurethane Dispersions for coatings

▪ Renewables & Bio-Polyurethanes

▪ Processing & Performance

▪ Future

Agenda

� Leading chemical supplier for leather processing

▪ Key player in the specialty coatings market

▪ 1800 employees

▪ 9 R&D Centres

▪ 38 applications labs/centres of excellence

▪ €600+ Million sales

▪ 6 Business units (4 in leather, 2 for coatings)

IntroductionStahl

Polyurethane Dispersions

▪ Polyurethanes (water- and solvent-based)

▪ Nitrocellulose (topcoats, non automotive)

▪ Acrylic emulsions

▪ Butadiene (basecoats)

▪ Casein

Polyurethanes are typically used in high performance coatings

▪ Durability

▪ Cold crack

▪ Weather resistance

Polymers for automotive leather and interior plastics

Polyurethane Dispersions

Polyurethane Dispersions

HO-R-OH + OCN-R’-NCO HO-R [-O-C-N]-R’-NCO

OH

Polyol PolyurethaneDiisocyanate

■ Prepolymer phase:

- Polyol + DMPA + Diisocyanate

- Build polymeric structure

■ Dispersion phase:

- Neutralization

- Water dispersion

- Diamine extension (build molecular weight)

Manufacturing Process

Polyurethane Dispersions

Typical Building Blocks Typical Formula

OO

O

O

HOO

O

O

OOH

n

HOO

OO

OOH

n

HOO

O

O OHO

O

O

n

Polyester

Polyether

Polycarbonate

Isocyanate N=C=O

Polyurethane Dispersions

Ingredients %

PolyolPolyolPolyolPolyol 60 60 60 60 ----80808080 (on solids)(on solids)(on solids)(on solids)

IsocyanateIsocyanateIsocyanateIsocyanate 10 10 10 10 ----15 15 15 15 (on solids)(on solids)(on solids)(on solids)

Solvent 5 – 10

Water 60 – 70

Additives 0 – 5 (on solids)

Renewables & Bio-Polyurethanes

Polyurethane dispersions with 40% bio-content have already been achieved

with polyols derived from natural oils.

Cutting millions of years off lead times …

nOH

O

nOH

OOH

On

Cat

nnOH

OOH

OOH OH

+

m

- H2O

nnO

OO

O

OHOH

m m

The unsaturated fatty acid from the (eg: rapeseed) oil is dimerized:

Then polymerized with a diol, yielding a polyester with renewable content:

Renewable Resources

Building Blocks Typical Formula

Bio-based Polyester:

Isocyanate N=C=O

Bio-based Polyurethane Dispersions: Building Blocks

nnO

OO

O

OHOH

m m

Ingredients %

PolyolPolyolPolyolPolyol 60 60 60 60 ----80808080 (on solids)(on solids)(on solids)(on solids)

IsocyanateIsocyanateIsocyanateIsocyanate 10 10 10 10 ----15 15 15 15 (on solids)(on solids)(on solids)(on solids)

Solvent 5 – 10

Water 60 – 70

Additives 0 – 5 (on solids)

Sourcing:

▪ Canada

▪ China

▪ India

▪ Europe

▪ Australia

Current Usage:

▪ Animal feed

▪ Vegetable oils

▪ Biodiesel fuel

Canola oilRapeseed example

Processing & Performance

HO-R-OH + OCN-R’-NCO HO-R [-O-C-N]-R’-NCO

OH

Polyol Polyurethane(with Co-solvent)

Diisocyanate

■ Prepolymer phase:

- Polyol + DMPA + Diisocyanate

- Build polymeric structure

Pre-polymer viscosity is critical in determining the co-solvent

Amount in the final product.

Volatile OrganicContent

Polyurethane Dispersions

Co-solvent

Bio-based polyols contribute to a lower pre-polymer viscosity.

Volatile OrganicContent

Polyurethane Dispersions

Low Viscosity Pre-polymer Reduced co-solvent need.

Reduced V.O.C

■ With the latest advances in biotechnology, improved properties have

been achieved for bio-based Polyurethane Dispersions

■ Touch, feel, appearance

■ Film durability performance after hydrolysis

Higher PerformanceBio-Polyurethanes:

Bio-Polyurethanes: Film Performance after Hydrolysis

0

10

20

30

40

50

60

70

80

90

Re

tain

de

d %

of

Ori

go

na

l v

alu

e

Retained UTS Retained MOD100

Test conditions: 50 C, 95% Humidity, 14 daysUTS : Ultimate Tesile StrengthMOD100 : Tensile strength at 100% modulus

PES: Polyester Polyurethane DispersionPE: Polyether Polyurethane DispersionPC: Polycarbonate Polyurethane Dispersion

Future

Bright FutureBio-based Polyurethanes

■ Even higher performance

■ Higher % bio-content

How?

■ New bioNew bioNew bioNew bio----polyolspolyolspolyolspolyols (soy, linseed, palm…)

■ Isocyanates Isocyanates Isocyanates Isocyanates (from biomass?)

■ CoCoCoCo----solventssolventssolventssolvents (plant-based becoming available)

Land use for bioplastics 2014 and 2019

ConclusionsBio-based Polyurethanes

■ Performance is driving the introduction of bio-polymer technology

■ Bio-based polyurethane technology is advancing rapidly

■ Oil price fluctuations can temporarily cloud the long term reality

If it can be imagined, it can be created

Thank you