Green Synthesis of Castor Oil-Modified Waterborne Polyurethanes via a Solvent-Free Approach

The conventional production of waterborne polyurethane (WPU) typically relies on organic solvents to regulate viscosity; additionally, traditional ionic WPU systems still utilize volatile neutralizers, raising environmental and health concerns. To overcome these limitations and reduce dependence on petrochemical resources, this study presents a solvent-free approach for WPU synthesis using isophorone diisocyanate (IPDI), polytetrahydrofuran (PTMG), and the nonionic PEG derivative Ymer^TM A-130. In addition, castor oil (CO), a renewable and hydroxyl-rich bio-based material, was incorporated as a partial substitute for PTMG to improve both sustainability and material performance. The effects of varying substitution ratios of castor oil on the physical properties of the resulting dispersions, dried films, and coatings were initially investigated. The results indicate that increasing the castor oil content from 0 wt% to 11.8 wt% led to an enhancement in tensile strength, rising from 1.45 MPa to 2.40 MPa. Concurrently, the temperature at 5% weight loss (Td_5%) shifted upward from 263.84 °C to 285.36 °C, indicating a favorable trend in thermal stability. Furthermore, the preliminary solvent resistance, surface wetting characteristics, and environmental durability of the prepared coatings were evaluated and discussed.