Synthesis, Morphology, and Particle Size Control of Acidic Aqueous Polyurethane Dispersions

A range of charge-stabilized aqueous polyurethane (PU) dispersions comprising hard segments formed from hydrogenated methylene diphenyl diisocyanate (H₁₂MDI) with dimethylolpropionic acid (DMPA) and ethylenediamine, and soft segments of poly(tetramethylene oxide) of different molecular weights are synthesized. Characterization of the dispersions by mass spectrometry, gel permeation chromatography, small-angle X-ray scattering, atomic force microscopy, and infrared spectroscopy shows that they are composed of PUs self-assembled into spherical particles (primary population) and supramolecular structures formed by hydrogen-bonded H₁₂MDI and DMPA acid-rich fragments (secondary population). Analysis of the scattering patterns of the dispersions, using a structural model based on conservation of mass, reveals that the proportion of supramolecular structures increases with DMPA content. It is also found that the PU particle radius follows the predictions of the particle surface charge density model, originally developed for acrylic statistical copolymers, and is controlled by hydrophile (DMPA) content in the PU molecules, where an increase in PU acidity results in a decrease in particle size. Moreover, there is a critical fractional coverage of hydrophiles stabilizing the particle surface for a given polyether soft-segment molecular weight, which increases with the polyether molecular weight, confirming that more acid groups are required to stabilize a more hydrophobic composition.