Michael Costello represented Stahl at the SusPolyurethanes Conference 5 and 6 October. He informed about the advances in bio-based polyurethanes for automotive interior coatings.

1. Advances in bio-based polyurethanes
(for automotive interior coatings)
SusPolyurethanes Conference
M. Costello, Oct 5-6, Amsterdam

2. ▪ Introduction
▪ Polyurethane Dispersions for coatings
▪ Renewables & Bio-Polyurethanes
▪ Processing & Performance
▪ Future
Agenda

3. 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)
Introduction
Stahl

4. Polyurethane
Dispersions

5. ▪ 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

6. Polyurethane Dispersions

7. Polyurethane Dispersions

8. 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

9. Typical Building BlocksTypical Formula
O
O
O
O
HO
O
O
O
O
OH
n
HO
O
O
O
O
OH
n
HO
O
O
O OH
O
O
O
n
Polyester
Polyether
Polycarbonate
Isocyanate N=C=O
Polyurethane Dispersions
Ingredients %
PolyolPolyolPolyolPolyol 60606060 ----80808080 (on solids)(on solids)(on solids)(on solids)
IsocyanateIsocyanateIsocyanateIsocyanate 10101010 ----15151515 (on solids)(on solids)(on solids)(on solids)
Solvent 5 – 10
Water 60 – 70
Additives 0 – 5 (on solids)

10. Renewables &
Bio-Polyurethanes

11. Polyurethane dispersions with 40% bio-content have already been achieved
with polyols derived from natural oils.
Cutting millions of years off lead times …

12. nOH
O
nOH
O
OH
O
n
Cat
nnOH
O
OH
O
OH OH
+
m
- H2O
nnO
O
O
O
OH
OH 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

13. Building BlocksTypical Formula
Bio-based Polyester:
Isocyanate N=C=O
Bio-based Polyurethane Dispersions:
Building Blocks
nnO
O
O
O
OH
OH m m
Ingredients %
PolyolPolyolPolyolPolyol 60606060 ----80808080 (on solids)(on solids)(on solids)(on solids)
IsocyanateIsocyanateIsocyanateIsocyanate 10101010 ----15151515 (on solids)(on solids)(on solids)(on solids)
Solvent 5 – 10
Water 60 – 70
Additives 0 – 5 (on solids)

14. Sourcing:
▪ Canada
▪ China
▪ India
▪ Europe
▪ Australia
Current Usage:
▪ Animal feed
▪ Vegetable oils
▪ Biodiesel fuel
Canola oil
Rapeseed example

15. Processing &
Performance

16. 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 Organic
Content
Polyurethane Dispersions
Co-solvent

17. Bio-based polyols contribute to a lower pre-polymer viscosity.
Volatile Organic
Content
Polyurethane Dispersions
Low Viscosity Pre-polymer Reduced co-solvent need.
Reduced V.O.C

18. ■ 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 Performance
Bio-Polyurethanes:

19. Bio-Polyurethanes: Film Performance after Hydrolysis
0
10
20
30
40
50
60
70
80
90
Retainded%ofOrigonalvalue
Retained UTS Retained MOD100
Test conditions: 50 C, 95% Humidity, 14 days
UTS : Ultimate Tesile Strength
MOD100 : Tensile strength at 100% modulus
PES: Polyester Polyurethane Dispersion
PE: Polyether Polyurethane Dispersion
PC: Polycarbonate Polyurethane Dispersion

20. Future

21. Bright Future
Bio-based Polyurethanes
■ Even higher performance
■ Higher % bio-content
How?
■ New bioNew bioNew bioNew bio----polyolspolyolspolyolspolyols (soy, linseed, palm…)
■ IsocyanatesIsocyanatesIsocyanatesIsocyanates (from biomass?)
■ CoCoCoCo----solventssolventssolventssolvents (plant-based becoming available)

22. Land use for bioplastics 2014 and 2019

23. Conclusions
Bio-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

24. If it can be imagined,
it can be created
Thank you