Patent ID: 8821983

Claim:
A continuous process for producing an Ultra-high solid content polyurethane dispersion comprising the steps of: providing a first stream, wherein said first stream comprises a first polyurethane prepolymer or a first polyurethane prepolymer emulsion; providing a second stream, wherein said second stream is a seed latex consisting of a polyolefin dispersion, wherein said seed latex has a volume average particle size diameter from 0.05 to 5.0 microns; continuously merging said first stream with said second stream in the presence of a chain extender and a surfactant, wherein the temperature is in the range of 10° C. to 70° C., the ratio of said first stream to said second stream is in the range of 0.1 to 0.6 and said surfactant is present in a concentration range of from 0.1 to 3% based on the total weight of said first stream, said second stream, and said surfactant; thereby forming said ultra-high solid content polyurethane dispersion comprising at least two volume average particle size diameters, the ultra-high solid content polyurethane dispersion having a particle size distribution in the range of 1:2 to 1:20 based on the percent volume of a first volume average particle size diameter to a second volume average particle size diameter, and wherein said ultra-high solid content polyurethane dispersion has at least a solid content of at least 70 percent by weight of said solid excluding the weight of any filler, based on the total weight of said ultra-high solid content polyurethane dispersion, and a viscosity of less than 3500 cps at 20 rpm at 21° C. using spindle #4 with Brookfield viscometer.