Pickering emulsion approach: A novel strategy to fabricate waterborne polyurethane with enhanced abradability and water-resistance comparable to that of solvent-based coating

The urgent requirement of replacement for solvent polyurethane (PU) makes waterborne polyurethane (WPU) coating more attractive and popular in many industrial areas. However, the simultaneous realization of good dispersion stability and high performance of the cured films especially water resistance remains challenging. Herein, we propose a novel and facile Pickering emulsion approach to fabricate WPU with enhanced abradability and water-resistance comparable to that of solvent-based PU coating. In this approach, the hydrophobic polyurethane synthesized by poly-addition reaction in ethyl acetate is directly dispersed into water with SiO2 nanoparticles as Pickering stabilizer followed by subsequent evaporation of the remaining solvent to obtain Pickering waterborne polyurethane dispersion (PWPU dispersion). The ability of SiO2 to stabilize emulsion can be modulated by hydrophobic modification with propyltriethoxysilane (PTS). SiO2 nanoparticles with an optimal PTS-grafting rate of 2.8 wt% enables the PWPU dispersion with excellent long-term, chemical, thermal, and freeze-thaw stability. The highly-transparent composite films with honeycomb structures are readily formed by casting PWPU dispersion at room temperature. The thermal and mechanical properties of PWPU films are comparable to or superior to solvent-borne polyurethane (SPU) and self-emulsifying waterborne polyurethane (SWPU) films. Moreover, the water absorption of the PWPU-5 film is approximately 20 times lower than that of SWPU, demonstrating the excellent water-resistance. We further validated the coating performance of PWPU for leather finishing. The hydrophobicity, abrasion resistance and water vapor permeability of PWPU-coated leather are superior to those of SPU and SWPU-coated leather.