A novel method to prepare polyurethane dispersions (PUDs) is introduced in this article. Water dispersible polyurethane ionomer pellets were synthesized without solvent; these pellets were then dissolved in acetone and dispersed in water. Then PUDs were obtained after acetone was distilled off. Polyurethane ionomers were synthesized from polyether diol containing sulfonate as hydrophilic monomer and poly(1,4-butylene adipate glycol) with an average molecular weight of 3000 as soft segments, isophorone diisocyanate and 1,4-butanediol as hard segments, and dibutyltin dilaurate as catalyst. The properties of PUDs were measured by Laser particle size analyzer, Brookfield viscosity, and TEM analysis. High-solid content and low viscosity PUDs were obtained. Meanwhile, PUDs exhibited excellent stability and polydispersity according to the above analysis. Tensile tests and dynamic mechanical analysis showed good mechanical and thermodynamic properties of PUD films. Some typical characteristics of crystalline polymers were revealed in the tensile stress-strain curves of PUD films. Peel strength test (PVC/PVC) yielded a maximum initial peel strength value of 6 N/mm and T-peel strength value of 10 N/mm. (C) 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 127: 2823-2831, 2013