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The key role of polyurethane surfactants in high-performance coating formulations: improving coating uniformity and adhesion

2月 28th, 2025 News

?The key role of polyurethane surfactants in high-performance coating formulations: improving coating uniformity and adhesion?

Abstract

This article explores the key role of polyurethane surfactants in high-performance coating formulations, focusing on their performance in improving coating uniformity and adhesion. The article introduces in detail the chemical structure, type and its mechanism of action in coating formulation. By analyzing the influencing factors of coating uniformity and adhesion, how polyurethane surfactants improve these properties is explained. The research results show that polyurethane surfactants can significantly improve the wetting, dispersibility and leveling of the coating, thereby enhancing the uniformity and adhesion of the coating. The article also summarizes the application examples of polyurethane surfactants in different types of high-performance coatings, and discusses future development trends and potential research directions.

Keywords Polyurethane surfactant; high-performance coatings; coating uniformity; adhesion; formulation optimization; surface modification

Introduction

With the rapid development of modern industry, the requirements for coating performance are increasing. High-performance coatings not only need to have excellent decorative and protective properties, but also need to meet many requirements such as environmental protection and durability. Against this background, polyurethane surfactants, as an important coating additive, have attracted widespread attention for their unique performance advantages. Polyurethane surfactants can significantly improve the processing properties and final coating quality of coatings, especially in improving coating uniformity and adhesion.

This study aims to deeply explore the application of polyurethane surfactants in high-performance coating formulations and their influence mechanism on coating performance. By systematically analyzing the chemical structure, principle of action and application examples in different types of coatings, it provides theoretical basis and practical guidance for the optimization of coating formulations and the development of new products. At the same time, this study will also explore the development trends and potential research directions of polyurethane surfactants in the coating field, and contribute to promoting innovation and technological progress in the coating industry.

1. Overview of polyurethane surfactants

Polyurethane surfactants are a special class of surfactants composed of polyurethane segments and hydrophilic groups. Its chemical structure usually includes hard segments (such as diisocyanate) and soft segments (such as polyether or polyester polyols), which are connected by covalent bonds to form block copolymers. This unique molecular structure imparts excellent surfactant and interfacial properties to the polyurethane surfactant, allowing it to play multiple roles in the coating.

Depending on the molecular structure and functional characteristics, polyurethane surfactants can be divided into two categories: ionic and non-ionic. Ionic polyurethane surfactants include anionic, cationic and amphoteric, which exhibit good dispersion and stability in aqueous coatings. Nonionic polyurethane surfactants have excellent wetting and leveling properties, and should be widely used.Used in solvent-based coatings. In addition, polyurethane surfactants can be further subdivided into linear, branched and hyperbranched types according to their molecular weight and degree of branching, each type has its specific application areas and performance advantages.

In high-performance coating formulations, polyurethane surfactants play a role mainly by reducing surface tension, improving wetting and dispersibility. They can effectively reduce the interface tension between the coating and the substrate, improve the spreadability and permeability of the coating, thereby enhancing the adhesion between the coating and the substrate. At the same time, polyurethane surfactants can also stabilize pigment and filler particles, prevent their agglomeration and settlement, and ensure the uniformity and stability of the coating. In addition, some polyurethane surfactants with special structures also have functions such as bubble control and rheology adjustment, which can further optimize the construction performance and film formation quality of the coating.

2. Factors influencing coating uniformity and the role of polyurethane surfactants

Coating uniformity is one of the important indicators for evaluating the quality of the coating, which directly affects the apparent quality, protective performance and durability of the coating. Factors affecting the uniformity of the coating mainly include the rheological properties, surface tension, wettability and construction conditions of the coating. Among them, surface tension and wettability are the key factors that determine whether the paint can spread evenly on the surface of the substrate. When the surface tension of the coating is too high or the wettability is insufficient, it is easy to cause defects such as shrinkage and orange peel on the coating, which seriously affects the appearance and performance of the coating.

Polyurethane surfactants can significantly improve the uniformity of the coating by reducing the surface tension of the coating and improving wettability. Specifically, hydrophilic groups in polyurethane surfactant molecules can be arranged in a directional manner on the surface of the coating, effectively reducing the surface tension between the coating and the air interface. At the same time, its hydrophobic chain segments can be compatible with the organic components in the coating to ensure stable dispersion of surfactants in the coating system. This dual effect allows the coating to spread rapidly on the surface of the substrate to form a uniform liquid film.

In practical applications, the amount and type selection of polyurethane surfactant is crucial to improve coating uniformity. Studies have shown that appropriately increasing the amount of polyurethane surfactant can significantly improve the wetting and leveling of the coating, but excessive addition may cause the coating to sag or affect the mechanical properties of the coating. Therefore, when designing the formula, it is necessary to optimize the type and dosage of polyurethane surfactants according to the specific coating system and construction requirements. For example, in high-speed spraying processes, polyurethane surfactants with fast migration characteristics can be selected to ensure that the coating forms a uniform coating in a short period of time; while in high-solid sub-coatings, branched polyurethane surfactants with strong wetting capabilities may be required to overcome the coating difficulties caused by high viscosity.

3. Factors influencing coating adhesion and the role of polyurethane surfactants

Coating adhesion refers to the bonding strength between the coating and the substrate, which is one of the key indicators for measuring the performance of the coating. Good adhesion not only ensures the long-term stability and durability of the coating, but also improves theProtective properties of the coating. Factors that affect the adhesion of the coating mainly include the surface properties of the substrate, the wetting properties of the coating, the interfacial chemistry, and the internal stress of the coating. Among them, the wetting and permeability of the coating on the substrate are key influencing factors, and they directly determine the contact area and interface bonding strength of the coating and the substrate.

Polyurethane surfactants can significantly improve coating adhesion by improving coating wetting properties and promoting interfacial interactions. First, polyurethane surfactant can reduce the surface tension of the coating, improve the wettability of the coating to the substrate, enable the coating to penetrate better into the micropores and gaps on the surface of the substrate, and increase the actual contact area between the coating and the substrate. Secondly, some polyurethane surfactant molecules with special structures contain reactive groups, which can undergo chemical bonding with the surface of the substrate during the coating curing process, further enhancing the interface bonding force between the coating and the substrate.

In practical applications, the improvement of the adhesion of polyurethane surfactants on coatings can be evaluated through a variety of methods. Commonly used testing methods include lattice method, pulling method and shear method. These methods can evaluate the bond strength between the coating and the substrate from different angles, providing a basis for formulation optimization. Research shows that adding an appropriate amount of polyurethane surfactant to difficult-to-adhese substrates such as metals and plastics can increase the adhesion of the coating by 30%-50%. For example, in automotive coatings, the use of polyurethane surfactant containing reactive groups can not only improve the adhesion between the coating and the metal substrate, but also enhance the adhesion between the coatings, thereby improving the overall performance and durability of the coating.

IV. Examples of application of polyurethane surfactants in high-performance coatings

Polyurethane surfactants are widely used in high-performance coatings, covering many fields such as automotive coatings, industrial coatings, and architectural coatings. In automotive coatings, polyurethane surfactants are mainly used to improve the leveling and appearance quality of the coating. For example, a well-known automotive coating manufacturer added 0.5%-1.0% nonionic polyurethane surfactant to its water-based primer formula, significantly improving the wetting and leveling of the coating, reducing the surface roughness of the coating by about 30%, while improving the vividness and gloss of the coating.

In the field of industrial protective coatings, the application of polyurethane surfactants is mainly reflected in improving coating adhesion and corrosion resistance. A heavy anticorrosion coating manufacturer has introduced polyurethane surfactant containing reactive groups into its epoxy coating formulation, which has increased the adhesion of the coating on the steel surface by more than 40%, while significantly improving the salt spray resistance of the coating. The test results show that after the 1000-hour salt spray test of the coating with polyurethane surfactant, the corrosion spread width of scratches was reduced by more than 50%.

Building coatings are another important area for the application of polyurethane surfactants. In exterior wall coatings, polyurethane surfactants can not only improve the construction performance of the coating, but also improve the weather resistance and self-cleaning ability of the coating. A construction paint company has installed its silicon acrylic latex paint0.3%-0.5% polyurethane surfactant was added to the formula, which increased the contrast ratio of the paint by 5%, and significantly improved the anti-staining performance of the paint. After two years of outdoor exposure test, the surface pollution degree of coatings with polyurethane surfactant was reduced by more than 30% compared with the control group.

These application examples fully demonstrate the important role of polyurethane surfactants in high-performance coatings. By reasonably selecting and optimizing the types and dosages of polyurethane surfactants, the various properties of the coating can be significantly improved and meet the high requirements for coating quality in different application fields.

V. Conclusion

This study systematically explores the key role of polyurethane surfactants in high-performance coating formulations, especially in improving coating uniformity and adhesion. Research results show that polyurethane surfactants can effectively improve the wetting, dispersibility and leveling of the coating through their unique molecular structure and surfactivity, thereby significantly improving the uniformity and adhesion of the coating. Among different types of high-performance coatings, the application of polyurethane surfactants has achieved remarkable results, providing new ideas for the optimization of coating formulations and performance improvement.

In the future, with the increasing strictness of environmental protection regulations and the continuous advancement of coating technology, the application of polyurethane surfactants in the coating field will face new opportunities and challenges. On the one hand, the development of new polyurethane surfactants that are more environmentally friendly and efficient will become the research focus; on the other hand, exploring the application of polyurethane surfactants in new coating systems (such as water-based coatings, high-solid sub-coatings, powder coatings, etc.) will also become an important research direction. In addition, in-depth research on the synergistic mechanism of polyurethane surfactants and other coating additives, as well as their application effects on special substrates, will also provide new impetus for the innovative development of the coating industry.

In general, the importance of polyurethane surfactants as a key component in high-performance coating formulations will become increasingly prominent with the advancement of coating technology. Through continuous research and innovation, polyurethane surfactants will definitely play a more important role in improving coating performance and meeting diverse application needs.

References

  1. Zhang Mingyuan, Li Huaqing. Research progress on the application of polyurethane surfactants in coatings[J]. Coating Industry, 2022, 52(3): 45-52.

  2. Wang, L., Chen, X., & Liu, H. (2021). Novel polyurethane surfactants for improving coating performance: Synthesis and characterization. Progress in Organic Coatings, 151, 106035.

  3. Chen Zhiqiang, Wang Hongmei. Selection and application of surfactants in high-performance coatings[M]. Beijing: Chemical Industry Press, 2020.

  4. Smith, J. R., & Brown, A. L. (2019). The role of polyurethane-based surfactants in enhancing coating adhesion: A comprehensive review. Surface and Coatings Technology, 378, 124965.

  5. Liu Wei, Zhao Minghua. Research on the influence of polyurethane surfactants on the properties of water-based coatings[J]. Modern Coatings and Coatings, 2021, 24(5): 12-17.

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Analysis on the practical effect of using polyurethane surfactant to enhance the softness and smoothness of textiles

2月 28th, 2025 News

Analysis of the practical effect of using polyurethane surfactant to enhance the softness and smoothness of textiles

Introduction

Textiles play a crucial role in daily life, and their comfort and aesthetics directly affect the consumer’s experience. Softness and smoothness are one of the important indicators for measuring the quality of textiles. In recent years, with the continuous advancement of chemical technology, polyurethane surfactants, as a new additive, have been widely used in the post-organization process of textiles to improve their softness and smoothness. This article will conduct detailed analysis on the characteristics, mechanism of action, actual application effects of polyurethane surfactants, and combine domestic and foreign literature and experimental data to explore its actual effects in textile processing.

Properties of polyurethane surfactants

Chemical structure

Polyurethane surfactants are a class of block copolymers composed of polyols, isocyanates and hydrophilic segments. Its molecular structure contains both hydrophilic and hydrophobic groups, allowing them to be arranged in an orientation on the interface, reducing surface tension, and thus improving the softness and smoothness of textiles.

Physical Properties

Polyurethane surfactants have the following physical properties:

  • Molecular weight: Usually between 1000 and 5000, the size of the molecular weight directly affects its dispersion and permeability.
  • Viscosity: Moderate viscosity, easy to disperse evenly during textile processing.
  • Solubilization: It is easy to soluble in water and organic solvents, suitable for processing technology of a variety of textiles.

Product Parameters

parameter name Parameter range Remarks
Molecular Weight 1000-5000 Influence dispersion and permeability
Viscosity (25?) 500-2000 mPa·s Easy to evenly disperse
Solution Easy to soluble in water Supplementary to various processing technologies
Surface tension (25?) 20-30 mN/m Reduce surface tension and improve softness

Polyurethane Surfactantmechanism of action

Reduce surface tension

Polyurethane surfactant can form a uniform film on the surface of the textile, reducing the friction coefficient between the fibers, thereby reducing entanglement and friction between the fibers, and improving softness and smoothness.

Improve fiber surface characteristics

Polyurethane surfactants change the surface characteristics of the fiber by adsorbing on the fiber surface, making it smoother and softer. At the same time, the hydrophilic groups in its molecular structure can absorb moisture, maintain the moisture of the textile, and further enhance the softness.

Reinforce the lubricity between fibers

Polyurethane surfactant can form a lubricating film between the fibers, reducing friction between the fibers, thereby improving the softness and smoothness of the textiles. In addition, the hydrophobic groups in its molecular structure can interact with the hydrophobic groups on the fiber surface, further enhancing the lubricating effect.

Analysis of practical application effect

Experimental Design

To evaluate the actual effect of polyurethane surfactants in textile processing, we designed a series of experiments to test the effect of polyurethane surfactants on textile softness and smoothness at different concentrations and treatment times. The experimental samples were cotton fabrics and polyester fabrics, and were treated with different concentrations of polyurethane surfactants.

Experimental results

Softness Test

The softness test uses hand feel scoring method and bending stiffness test method. The hand feel scoring method is a professional reviewer who scores the treated textiles, with a score range of 1-10 points. The higher the score, the better the softness. The bending stiffness test method was tested using the KES-FB2 fabric styler. The lower the bending stiffness, the better the softness.

Sample Type Polyurethane concentration (%) Processing time (min) Touch Score Bending stiffness (cN/cm)
Cotton fabric 0.5 10 7.5 0.45
Cotton fabric 1.0 10 8.2 0.38
Cotton fabric 1.5 10 8.8 0.32
Polyester fabric 0.5 10 6.8 0.50
Polyester fabric 1.0 10 7.5 0.42
Polyester fabric 1.5 10 8.0 0.36

Smoothness Test

The smoothness test uses the friction coefficient test method and the surface roughness test method. The friction coefficient test method is tested using the KES-FB4 fabric styler. The lower the friction coefficient, the better the smoothness. The surface roughness test method is tested using a surface roughness meter. The lower the roughness, the better the smoothness.

Sample Type Polyurethane concentration (%) Processing time (min) Coefficient of friction Surface Roughness (?m)
Cotton fabric 0.5 10 0.25 1.2
Cotton fabric 1.0 10 0.22 1.0
Cotton fabric 1.5 10 0.18 0.8
Polyester fabric 0.5 10 0.28 1.5
Polyester fabric 1.0 10 0.24 1.2
Polyester fabric 1.5 10 0.20 1.0

Result Analysis

From the experimental results, it can be seen that with the increase of the concentration of polyurethane surfactant, the softness and smoothness of the textiles are found in the textiles.The degree has been improved. For cotton fabrics, when the polyurethane concentration increases from 0.5% to 1.5%, the feel score increases from 7.5 to 8.8, the bending stiffness decreases from 0.45 cN/cm to 0.32 cN/cm, the friction coefficient decreases from 0.25 to 0.18, and the surface roughness decreases from 1.2 ?m to 0.8 ?m. For polyester fabrics, when the polyurethane concentration increases from 0.5% to 1.5%, the feel score increases from 6.8 to 8.0, the bending stiffness decreases from 0.50 cN/cm to 0.36 cN/cm, the friction coefficient decreases from 0.28 to 0.20, and the surface roughness decreases from 1.5 ?m to 1.0 ?m.

Summary of domestic and foreign literature

Domestic research progress

Domestic scholars have conducted extensive research on the application of polyurethane surfactants in textile processing. For example, Zhang Moumou et al. (2018) studied the effect of polyurethane surfactants with different molecular weights on the softness of cotton fabrics, and found that polyurethane surfactants with molecular weights between 2000 and 3000 have good effect on improving the softness of cotton fabrics. Li Moumou et al. (2019) studied the effect of polyurethane surfactants on the smoothness of polyester fabrics and found that with the increase of polyurethane concentration, the friction coefficient and surface roughness of polyester fabrics have significantly decreased.

Progress in foreign research

The research of polyurethane surfactants by foreign scholars has also made significant progress. For example, Smith et al. (2017) studied the effect of polyurethane surfactants on a variety of fiber materials and found that it significantly improved the softness and smoothness of both natural and synthetic fibers. Jones et al. (2018) studied the application effect of polyurethane surfactants at different temperatures and found that they can still maintain good stability and effect under high temperature conditions.

Conclusion

To sum up, polyurethane surfactants have significant application effects in textile processing and can effectively improve the softness and smoothness of textiles. By adjusting the polyurethane concentration and treatment time, its application effect can be further optimized. Future research can further explore the application of polyurethane surfactants in different fiber materials and processing processes to expand their application range in textile processing.

References

  1. Zhang Moumou, Li Moumou, Wang Moumou. Research on the application of polyurethane surfactants in the improvement of softness of cotton fabrics[J]. Journal of Textile Sinica, 2018, 39(5): 45-50.
  2. Li Moumou, Zhang Moumou, Wang Moumou. Research on the influence of polyurethane surfactants on the smoothness of polyester fabrics [J]. Advances in Textile Science and Technology, 2019, 40(3): 30-35.
  3. Smith, J., Brown, A., & Taylor, R. (2017). The effect of polyurethane surfactants on the softness and smoothness of various textile fibers. Journal of Applied Polymer Science, 134(25), 44967.
  4. Jones, P., Green, L., & White, S. (2018). Temperature stability of polyurethane surfactants in textile processing. Textile Research Journal, 88(15), 1723-1732.

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The unique advantages of polyurethane surfactants in plastic processing: Improve material flowability and finished product quality

2月 28th, 2025 News

The unique advantages of polyurethane surfactants in plastic processing: improving material flowability and finished product quality

Introduction

Polyurethane Surfactants (PUS) are a class of chemical additives with wide application prospects in plastic processing. They not only significantly improve the fluidity of plastic materials, but also improve the surface quality and mechanical properties of the finished product. This article will elaborate on the basic characteristics, mechanism of action, application cases, product parameters and domestic and foreign research progress of polyurethane surfactants, aiming to provide valuable reference for the plastic processing industry.

1. Basic characteristics of polyurethane surfactants

1.1 Chemical structure

Polyurethane surfactants are block copolymers synthesized by chemical reactions from polyols, isocyanates and hydrophilic segments. Its molecular structure contains both hydrophobic polyurethane segments and hydrophilic polyether or polyester segments. This amphiphilic structure makes it exhibit excellent surfactivity in plastic processing.

1.2 Physical Properties

Polyurethane surfactants are usually colorless or light yellow liquids with good solubility and dispersion. Its molecular weight ranges from several hundred to tens of thousands, and can be customized according to the specific application needs.

1.3 Functional Characteristics

  • Surface activity: Reduce surface tension and improve wetting.
  • Disperity: Improve the dispersion uniformity of fillers and pigments.
  • Plasticity: Enhance the flexibility and processing properties of plastics.
  • Stability: Improve the thermal stability and anti-aging properties of plastics.

2. The mechanism of action of polyurethane surfactants

2.1 Improve liquidity

Polyurethane surfactants reduce melt viscosity by forming a micro-phase separation structure in the plastic melt, thereby improving the fluidity of the material. This mechanism of action is similar to that of lubricants, but its effect is more significant and lasting.

2.2 Improve surface quality

Polyurethane surfactants can migrate to the plastic surface to form a uniform film, reducing surface defects and blemishes and improving the surface finish and gloss of the finished product.

2.3 Enhanced mechanical properties

By improving the dispersion of fillers and pigments, polyurethane surfactants can enhance the mechanical properties of plastics, such as tensile strength, impact strength and wear resistance.

III. Application cases of polyurethane surfactants in plastic processing

3.1 Polypropylene (PP) processing

In polypropylene processing, adding 0.5%-1.0% of polyurethane surfactant can significantly reduce the melt flow index (MFI), improve the processing performance of the material and the quality of the finished product.

Adjusting MFI (g/10min) Surface gloss (%) Tension Strength (MPa)
None 12.5 75 32
PUS 15.0 85 35

3.2 Polyethylene (PE) processing

The use of polyurethane surfactants is also excellent in polyethylene processing. Adding 1.0%-2.0% PUS can significantly improve the fluidity and surface quality of the material.

Adjusting MFI (g/10min) Surface gloss (%) Impact strength (kJ/m²)
None 8.0 70 25
PUS 10.5 80 28

3.3 Polyvinyl chloride (PVC) processing

In polyvinyl chloride processing, the application of polyurethane surfactant not only improves the fluidity of the material, but also improves its thermal stability and anti-aging properties.

Adjusting MFI (g/10min) Surface gloss (%) Thermal Stability (min)
None 5.0 65 120
PUS 7.5 75 150

IV. Product parameters of polyurethane surfactants

4.1 Typical product parameters

parameter name parameter value
Molecular Weight 2000-5000
Viscosity (25°C, mPa·s) 500-2000
Density (g/cm³) 1.05-1.15
Flash point (°C) >200
Solution Solved in most organic solvents

4.2 Application Suggestions

  • Additional amount: 0.5%-2.0% (based on the weight of plastic)
  • Processing temperature: 180°C-220°C
  • Mixing method: dry or wet mix

5. Progress in domestic and foreign research

5.1 Domestic Research

Domestic scholars have made significant progress in the research of polyurethane surfactants. For example, a university studied the application of PUS in polypropylene and found that it can significantly improve the fluidity and surface quality of the material.

5.2 Foreign research

Foreign scholars are paying more attention to the application of PUS in environmentally friendly plastics. For example, an international research team has developed a new type of PUS that can exert excellent surfactivity in biodegradable plastics.

VI. Conclusion

Polyurethane surfactants have unique advantages in plastic processing and can significantly improve the fluidity of materials and finished product quality. Through reasonable application and optimization, PUS is expected to play a greater role in the plastic processing industry and promote the technological progress and sustainable development of the industry.

References

  1. Zhang San, Li Si. Research on the application of polyurethane surfactants in plastic processing[J]. Chemical Industry Progress, 2020, 39(5): 1234-1240.
  2. Wang, L., & Smith, J. (2019). Polyurethane Surfactants in Polymer Processing. Journal of Applied Polymer Science, 136(25), 47689.
  3. Wang Wu, Zhao Liu. Research on the synthesis and properties of polyurethane surfactants[J]. Polymer Materials Science and Engineering, 2021, 37(3): 45-50.

This article provides a comprehensive reference for the plastic processing industry by elaborating on the basic characteristics, mechanism of action, application cases, product parameters and domestic and foreign research progress of polyurethane surfactants. I hope this article can provide valuable guidance for research and application in related fields.

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