1. Introduction
Polyurethane-urea (PUU) materials are versatile polymers commonly used as adhesives and coatings [
1]. During the last few years, the development of eco-friendly polyurethane adhesives has become an important environmental and health concern. As compared to the conventional solvent-born polyurethane adhesives, waterborne polyurethane adhesives show lower levels of organic compounds and a lack of toxicity [
2].
Waterborne polyurethane-urea materials are obtained by reacting polyol, diisocyanate, internal emulsifier and chain extender, and they show segmented structures consisting of soft (SS) and hard (HS) segments, as well as ionic interactions [
3,
4,
5]. The hard and soft segments are thermodynamically incompatible, resulting in phase separation due to the formation of hard and soft microdomains in the PUUs, and the degree of phase separation determines their properties [
6]. The soft segments are made of polyol and provide flexibility to the PUU, whereas the hard segments are made by reaction of the diisocyanate and the chain extender, and they impart mechanical properties. The ionic interactions of the pendant groups of the internal emulsifier in different polymeric chains also contribute to the mechanical properties of the PUU. Furthermore, both hard and soft segments can be organized in either amorphous or crystalline ordered domains by formation of hydrogen bonds between them, and this also determines the PUU properties [
6].
Pressure-sensitive adhesives (PSAs) are polymeric materials which produce immediate physical bond to a substrate by the application of light pressure for a short time. PSAs are used in general in labels and tapes, post-its, packaging tapes, diapers, masking tapes, and medical bandages, etc. The requirements of the PSAs for these applications are good tack, adequate peel resistance, and high-shear resistance [
7]. During bonding of a substrate by a PSA, good wetting and adequate adhesion are needed, but the PSA also needs to resist de-bonding forces by high cohesion and energy dissipation without leaving residues on the substrate, i.e., high cohesion is necessary. In other words, the PSAs require a balance between their viscoelastic properties, i.e., at low strain rates they must flow for imparting adequate bonding and tack, and at high strain rates they must have a high cohesion and elasticity for de-bonding. It should be noted that the adhesion and cohesion properties are opposite properties and they must be adequate in PSAs.
The viscoelastic properties of the PSAs can be tailored by using copolymers with segmented structure in which the hard domains impart the elastic properties and the soft domains control the viscous properties. In this sense, the PUUs have a potential for manufacturing PSAs but they are rarely used because of their low tack and low peel adhesive strength, i.e., insufficient adhesion and cohesion properties. However, the PUUs show good temperature and solvent resistance, and have good low temperature performance—properties that are desirable in PSAs [
8].
Most PSAs are obtained from solvent-born formulations which, although effective, have environmental and health concerns, limiting their application in food and medical areas. Therefore, there is a need for developing waterborne-based PSAs. There are some previous studies on the development of waterborne polyurethane dispersions intended for PSAs, and the most of them are based on the use of hydroxyl-terminated polybutadiene (HTPB) polyols. Czech et al. [
9] synthesized water-dispersible polyurethane PSAs containing hydroxylated polybutadienes, and demonstrated that the addition of polypropylene glycol (PPG) of high molecular weight and dimethylolpropionic acid (DMPA), and an isocyanate cross-linking agent improved the mechanical properties of the PSAs. Lagiewczyk and Czech [
10] developed aqueous polyurethane PSAs containing hydroxylated polybutadiene (HTPB) as self-adhesives for protective films and they found that the increase of both HTPB and PPG amounts increased the viscosity and the thermal and the mechanical properties of the PSAs, which showed low tack, low adhesion and excellent cohesion after cross-linking with selected multifunctional isocyanates. In another study, Czech et al. [
11] synthesized waterborne polyurethane PSAs with HTPB, hydroxylated benzophenone, diisocyanates, high molecular weight PPG and dicarboxylic acids. Without crosslinker, the polyurethane PSAs exhibited low tack and peel adhesion, but the addition of small amounts of polycarbodiimide increased both tack and peel adhesion. On the other hand, waterborne polyurethane PSAs without crosslinker have been synthesized with PPGs of different molecular weights and hydroxyl-terminated polybutadienes [
12], and an increase of the storage modulus was found when the molecular weight of the PPG increased, and an increase in tack resulted when the amount of polybutadiene increased. In recent research, Akram et al. [
13,
14] have studied the influence of the isocyanate and the polyol on the adhesion properties of waterborne polyurethane PSAs made with HTPB and 1,4-butanediol chain extender.
In a different approach, Chen et al. [
15] have synthesized waterborne polyurethane PSAs intended for transdermal drug delivery by using the prepolymer method. Polyethylene glycol (PEG)-modified copolyether polyol and hexamethylene diisocyanate were used as reactants. They found that the holding power (related to the cohesion of the PSA), 180º peel strength and repeating peel-stick property increased as the NCO/OH ratio increased, but the tack property decreased. The optimal properties of the waterborne polyurethane PSAs, i.e., improved hydrophilicity, adhesion properties, and biocompatibility, were obtained by using NCO/OH ratios of 2.0–2.2.
Another approach used in the development of waterborne polyurethane PSAs consisted of the synthesis of hybrid acrylic/polyurethane PSAs. Lopez et al. [
16] synthesized acrylic/polyurethane hybrids with different diols chain extenders, and free radical miniemulsion polymerization was used. The authors concluded that the use of bisphenol A chain extender led to high-shear resistance PSAs with acceptable viscoelasticities. As outlined in a later publication, the same authors found an increase of the tack of the acrylic/polyurethane PSA by increasing the amount of the chain transfer agent (CTA), and this was explained to be a result of lower gel content and greater chain mobility [
17]. Degrandi-Contraires et al. [
18,
19] proposed a different strategy in the miniemulsion polymerization of hybrid acrylic/polyurethane PSAs which consisted of the grafting of the polyurethane prepolymer onto the acrylic backbone through a reactive monomer.
The existing literature on the synthesis of waterborne polyurethane PSAs is mainly based on the use of hydroxylated polybutadienes and polypropylene glycols, cross-linkers, or hybrid acrylic/urethane polymers. All those waterborne polyurethane PSAs showed insufficient cohesion and adhesion properties, i.e., the ones showing high tack and peel strength have poor cohesion, and the ones showing high cohesion have low tack and peel strength. In our previous study [
20], thermoplastic polyurethanes (TPUs) synthesized with 4,4′-diphenylmethane diisocyanate (MDI), 1,4-butanediol chain extender and mixtures of polypropylene glycols (PPGs) of different molecular weights have shown low glass transition temperatures, high tack, and low 180° peel strength, but poor cohesion. In a later study [
21], TPUs with pressure-sensitive adhesion and different hard segments content were synthesized. The TPUs with low hard segments content showed high tack and adequate de-bonding properties, whereas the ones with high hard segments content increased the cohesive strength but the tack was low.
There is a need of synthesizing new polyurethane PSAs with adequate tack, peel strength and cohesion, i.e., with improved cohesion and adhesion properties. In this study, the prepolymer method was used for synthesizing different waterborne polyurethane PSAs with isophorone diisocyanate, copolymer of ether and carbonate diol polyol and different amino-alcohols chain extenders. Apart from the novelty of the use of completely new reactants for synthesizing waterborne PSAs, in this study it has been demonstrated that the number of hydroxyl groups in the amino-alcohols and the degree of cross-linking during the chain extension step facilitate the design of PSAs with different tailored properties.
4. Conclusions
Different waterborne polyurethane-urea polymers made with amino-alcohols chain extenders with pressure-sensitive adhesive property have been synthesized. The pH values of the waterborne polyurethane-urea dispersions were near 9 except for the one made with AP chain extender. The mean particle sizes of the waterborne polyurethane-urea dispersions ranged between 51 to 78 nm, and they increased by increasing the number of OH groups in the amino-alcohol chain extender. The viscosities of the waterborne polyurethane-urea dispersions were low, and varied between 58 and 133 mPa·s.
The more important C=O species in the PUUs were the free and associated carbonates, and their percentages decreased by increasing the number of hydroxyl groups in the amino-alcohol. The PUU-2OH film showed higher percentage of hydrogen bonded urea groups and lower percentages of urethane groups than the rest, and the H-bonded urea groups appeared at lower wavenumber, indicating that its structure was different. In fact, according to the TGA experiments, the increase of the number of OH groups in the amino-alcohol displaced the decomposition of the urethane hard domains to lower temperature, and both the urea hard domains and the soft domains decomposed at lower temperatures. On the other hand, the polyurethane-urea films showed low Tg value, and they had cross-over temperatures between -8 and 68 °C depending on the number of OH groups in the chain extender.
According to Chang´s viscoelastic window, different types of PUU PSAs synthesized with different amino-alcohol chain extenders were obtained: PUU PSA synthesized with AP (one hydroxyl group) was a removable PSA, PUU PSA synthesized with HPA (two hydroxyl groups) was a general purpose PSA, and PUU PSA synthesized with THAM (three hydroxyl groups) was a high-shear PSA. All PUU PSAs showed adequate tack at 25 °C and the maximum tack was obtained in PUU-2OH PSA, the holding times of the PUU PSAs varied between 2 minutes and 5 days, and the 180° peel strength values ranged between 0.41 and 6.43 N/cm. The PUU PSAs synthesized with different amino-alcohol chain extenders have a potential for the development of new versatile waterborne polyurethane PSAs, the adhesion and cohesion properties of which can be tailored by selecting the number of OH groups in the amino-alcohol chain extender.