Viscous conjugated diene block copolymers.

0001This invention relates to viscous conjugated diene block copolymers. Further, the invention relates to cross-linked epoxidized polymers made from such block copolymers and adhesive, coating, and sealant compositions made therefrom.

0002Curing of hot melt adhesives based on conjugated dienes and, optionally, vinyl aromatics has increased the range of service properties for such adhesives. Radiation curing and chemical curing are known. This curing causes covalent cross-linking of the polymerized conjugated dienes which is evidenced by a high gel content of the cross-linked polymer. Before cross-linking, the polymers are melt processable but after cross-linking, the gel cannot be processed as melts. Cross-linking therefore enhances solvent resistance and improves elevated temperature shear properties. The compositions can therefore be applied to a substrate in a melt and then cross-linked to form a superior adhesive. However, improvements in the adhesives, coatings and sealants could be made if the adhesives could be processed at lower temperatures and cured at lower dosages of radiation.

0003Radiation curing and chemical curing of these polymers to make coatings and sealants is known. Before cross-linking, the polymers are processable in solvent solution but after cross-linking, the gel cannot be processed as a solution. The cross-linking therefore enhances solvent resistance and improves toughness and cohesion. The compositions can therefore be applied to a substrate from solvent solution and then cross-link to form a superior coating or sealant. However, improvements in the coatings and sealants could be made if the coatings and sealants could be processed at higher solids content and cured at lower dosages of radiation or at lower temperatures in chemical cure.

0004Further, the known curable adhesives, sealants and coatings which are based on conjugated diene block copolymers do not have particularly good long term heat, weather and ultraviolet stability due to the need to utilize unhydrogenated polymers having one residual aliphatic double bond per polymerized unit. The known vinyl aromatic-conjugated diene block copolymer based adhesives, coatings and sealants which are curable are unhydrogenated polymers. Hydrogenation is known to improve long term heat, weather and ultraviolet stability, but it removes the double bonds which are needed to effect the curing. Such curing methods are not effective when the polymers are hydrogenated. The requirement for this unsaturation is particularly evident when typical tackifiers are present in the compositions because their presence generally inhibits ratidation cross-linking of the hydrogenated polymer.

0005It is therefore an object of the present invention to provide a cross-linked polymer which is melt processable before cross-linking and has a high gel content after cross-linking.

0006It is also an object of the present invention to provide a block copolymer which can be modified so that it can be cross-linked preferably by radiation and which is easily melt processable before cross-linking but has a high gel content after cross-linking.

0007The viscous block copolymers of the present invention have the formula:         (A-B-A_p)_n-Y_r-(A_q-B)_m wherein Y is a coupling agent or coupling monomers or a multi functional initiator, and wherein A and B are polymer blocks which may be homopolymer blocks of conjugated diene monomers, copolymer blocks of conjugated diene monomers or copolymer blocks of diene monomers and monoalkenyl aromatic hydrocarbon monomers. Also, the B blocks may be homopolymer or copolymer blocks of monoalkenyl aromatic hydrocarbon monomers. The A blocks have a greater number of di- and/or tetra-substituted unsaturation sites per unit block mass than do the B blocks and the number of tertiary unsaturation (TU) sites in the A blocks is lower than or equal to that number of the B blocks, where a TU site is defined to be an aliphatic double bond (ADB) between a tertiary carbon atom and either a primary or secondary carbon atom.

0008The A blocks have a molecular weight of from 100 to 3,000 and the B blocks have a molecular weight of from 1000 to 15,000. n is greater than 0, r is 0 or 1, m is greater than or equal to 0, and n + m ranges from 1 to 100. p and q may be 0 or 1. When either p or q or both are 1, extra highly substituted ADB sites are available in the interior of the polymer chain.

0009The block copolymers of the present invention may be partially hydrogenated, epoxidized or both partially hydrogenated and epoxidized. When these polymers are partially hydrogenated, it is recommended that they be hydrogenated to the extent that only from 0.1 to 3 milliequivalents of aliphatic double bonds per gram of polymer (0.1 to 3 Meq ADB/g) remain in the polymer. When these polymers are epoxidized, whether they are hydrogenated or not, it is preferred that the epoxidation take place only to the extent that 0.1 to 3 milliequivalents of epoxide per gram of polymer (0.1 to 3 Meq epoxide/g) are generated. Hence, the preferred epoxidized polymer has an epoxide equivalent weight of between 10,000 and 333. When both partial hydrogenation and epoxidation are used, it is preferred that the amount of aliphatic double bonds in the polymer should be reduced to 0.5 Meq/g or less by the combination of the two processes. The polymers may then be cross-linked through at least some of the epoxy functionality, preferably, by radiation.

0010Polymers containing ethylenic unsaturation can be prepared by copolymerizing one or more polyolefins, particularly a diene, by themselves or with one or more alkenyl aromatic hydrocarbon monomers. The copolymers may be random, tapered, block or a combination of these, as well as linear, star or radial.

0011The polymers containing ethylenic unsaturation or both aromatic and ethylenic unsaturation may be prepared using anionic initiators or polymerization catalysts. Such polymers may be prepared using bulk, solution or emulsion techniques. In any case, the polymer containing at least ethylenic unsaturation will, generally, be recovered as a solid such as a crumb, a powder, a pellet or the like, but it also may be recovered as a liquid such as in the present invention. Polymers containing ethylenic unsaturation and polymers containing both aromatic and ethylenic unsaturation are available commercially from several suppliers.

0012In general, the polymers containing ethylenic unsaturation or both aromatic and ethylenic unsaturation may be prepared by any method known in the art, such as those described in e.g. U.S. patents Nos. 3,231,905; 3,390,207; 3,263,765; 3,639,521; 3,598,887; 4,219,627 and 4,208,356.

0013Conjugated dienes which may be polymerized include those containing from about 4 to about 24 carbon atoms such as 1,3-butadiene, isoprene, piperylene, methylpentadiene, phenylbutadiene, 3,4-dimethyl-1,3-hexadiene, 4,5-diethyl-1,3-octadiene and the like. Isoprene and butadiene are the preferred conjugated diene monomers for use in the present invention because of their low cost and ready availability.

0014Alkenyl aromatic hydrocarbons which may be copolymerized include vinyl aromatic compounds such as styrene, various alkyl-substituted styrenes, alkoxy-substituted styrenes, vinyl naphthalene, alkyl-substituted vinyl naphthalenes and the like.

0015As described above, in general, the advantages of the present invention are achieved by utilizing an A block which contains more highly substituted aliphatic double bonds than the B blocks which should contain less highly substituted double bonds. One preferred specific example of this is the case where the A blocks are formed from isoprene monomer polymerized to give mostly cis-1,2-di-substituted residual ADB and the B blocks are formed from butadiene monomer. However, another special case is the situation wherein the A blocks are formed from 1,4-polybutadiene monomer addition (providing 1,2-disubstituted ADB) and the B blocks are formed from 1,2-polybutadiene monomer addition (providing mono-subsituted ADB). Another special case is wherein the A blocks are formed from 2,3-dimethyl butadiene (tetra-substituted residual ADB after 1,4 addition) and the B blocks are formed from either isoprene or butadiene.

0016The present invention also encompasses polymers which have midblocks formed of monoalkenyl aromatic hydrocarbon monomers, preferably styrene (a minor amount, less than 50%, of a conjugated diene may be in this midblock). In this situation, the external (A) blocks would be conjugated dienes containing di- and/or tetra-substituted aliphatic double bonds and the internal (B) blocks would be formed of the monoalkenyl aromatic hydrocarbon. This type of polymer is not a rubbery polymer, but rather is a hard and friable solid. This type of polymer can be cured in situ to give a material with a hard reinforcing phase.

0017In general, any of the solvents known in the prior art to be useful in the preparation of such polymers may be used. Suitable solvents, then, include straight- and branched chain hydrocarbons such as pentane, hexane, heptane, octane and the like, as well as, alkyl-substituted derivatives thereof; cycloaliphatic hydrocarbons such as cyclopentane, cyclohexane, cycloheptane and the like, as well as alkyl-substituted derivatives thereof; aromatic and alkyl-substituted derivatives thereof; aromatic and alkyl-substituted aromatic hydrocarbons such as benzene, naphthalene, toluene, xylene and the like; hydrogenated aromatic hydrocarbons such as tetralin, decalin and the like; linear and cyclic ethers such as dimethyl ether, methylethyl ether, diethyl ether, tetrahydrofuran and the like.

0018In a preferred embodiment, the polymers of the present invention are made by the anionic polymerization of conjugated diene monomers and alkenyl aromatic hydrocarbon monomers in a hydrocarbon solvent at a temperature between 0 and 100°C using an alkyl lithium initiator. The living polymer chains are usually coupled by addition of divinyl monomer to form a star polymer. Additional monomers may or may not be added to grow more branches or to terminally functionalize the polymer. The living chain ends are quenched with a proton source.

0019As stated above, the molecular weight of the A blocks varies from 100 to 3,000 because this molecular weight provides an adequate number of di- and/or tetra-substituted carbon to carbon double bonds that resist hydrogenation and/or allow easier functionalization, such as epoxidation, and subsequent cross-linking. The molecular weights of the B blocks range from 1,000 to 15,000 to provide flexible, short polymeric chains that limit the viscosity and especially the elasticity of the final uncured polymer. The B blocks are relatively easy to hydrogenate and/or more difficult to functionalize, such as by epoxidation, and, hence, they tend to remain more flexible than the A blocks after cross-linking. Polymers with monoalkenyl aromatic hydrocarbon monomer blocks are a special case and are hard at room temperature instead of flexible. Preferred versions of the block polymers of the present invention have A block molecular weights between 300 and 2,000, most preferably between 600 and 1,200, because the tighter ranges tend to provide the best balance of cross-linking site availability and viscosity control. The preferred B block molecular weight is between 2,000 and 10,000, most preferably between 3,000 and 7,000, to minimize the polymer viscosity. In most cases, polymers which fall within the preferred molecular weight ranges are viscous liquids at room or slightly elevated temperatures as compared to most commercial conjugated diene-monoalkenyl aromatic hydrocarbon block copolymers or the copolymers of U.S. 3,607,982, which are relatively high molecular weight visco-elastic solids.

0020Molecular weights of linear polymers or unassembled linear segments of polymers such as mono-, di-, triblock, and etc., arms of star polymers before coupling are conveniently measured by Gel Permeation Chromatography (GPC). A good method to use for a star shaped polymer is to measure the weight average mocular weight by light scattering techniques, as described in e.g. <ul id="ul0001" list-style="none"><li>1. <u>Modern Size-Exclusion Liquid Chromatography</u>, W. W. Yau, J. J. Kirkland, D. D. Bly, John Wiley &amp; Sons, New York, NY, 1979.</li><li>2. <u>Light Scattering from Polymer Solution</u>, M. B. Huglin, ed., Academic Press, New York, NY, 1972.</li><li>3. W. Kaye and A. J. Havlik, <u>Applied Optics</u>, <u>12</u>, 541 (1973).</li><li>4. M. L. McConnell, <u>American Laboratory</u>, 63, May, 1978.</li></ul>

0021Especially preferred polymers are those that have a value of n greater than 10. These polymers can be made especially reactive even when using low levels of epoxidation, such as 0.1 to 1.5 Meq epoxy/g, (polymers with epoxide equivalent weights of between 10,000 and 667), because the number of epoxidized crosslinkable sites per polymer molecule is still relatively high. Also especially useful are polymers where the number of di- and/or tetra-substituted double bonds per unit of block mass on the A blocks exceeds that on the B blocks by a ratio of at least 3:1, more preferably at least 8:1, and most preferably by at least 20:1, because this allows the polymer to be cross-linked in local regions with relatively uncross-linked regions and spaced in between to provide flexibility if the polymer has been partially hydrogenated and epoxidized. When the end use for the polymer is for pressure sensitive adhesives or flexible coatings, it is often useful for the B block to contain little or no di- and/or tetra-substituted double bonds.

0022There are a wide variety of coupling agents that can be employed. Any polyfunctional coupling agent which contains at least two reactive sites can be employed. Examples of the types of compounds which can be used include the polyepoxides, polyisocyanates, polyimines, polyaldehydes, polyketones, polyanhydrides, polyesters, polyhalides, and the like. These compounds can contain two or more types of functional groups such as the combination of epoxy and aldehyde groups, isocyanate and halide groups, and the like. Many suitable types of these polyfunctional compounds have been described in U.S. Patent Nos. 3,595,941; 3,468,972, 3,135,716; 3,078,254; 4,096,203 and 3,594,452 which are herein incorporated by reference. When the coupling agent has two reactive sites such as dibromoethane, the polymer will have a linear ABA structure. When the coupling agent has three or more reactive sites, such as silicon tetrachloride, the polymer will have a branched structure, such as (AB)_nY. Coupling monomers are coupling agents where several monomer units are necessary for every chain end to be coupled. Divinylbenzene is the most commonly used coupling monomer and results in star polymers.

0023The epoxidized copolymers of this invention can be prepared by the epoxidation procedures as generally described or reviewed in the <u>Encyclopedia of Chemical Technology</u><u>19,</u> 3rd ed., 251-266 (1980), D.N. Schulz, S.R. Turner, and M.A. Golub, <u>Rubber Chemistry and Technology,</u><u>5,</u> 809 (1982), W.K. Huang, G-H. Hsuie, and W-H. Hou, Journal of Polymer Science, Part A: Polymer Chemistry, <u>26,</u> 1867 (1988) and, K.A. Jorgensen, Chemical Reviews, <u>89</u>, 431 (1989).

0024For instance, epoxidation of the base polymer can be effected by reaction with organic peracids which can be preformed or formed in situ. Suitable preformed peracids include peracetic and perbenzoic acids. In situ formation may be accomplished by using hydrogen peroxide and a low molecular weight fatty acid such as formic acid. Alternatively, hydrogen peroxide in the presence of acetic acid or acetic anhydride and a cationic exchange resin will form a peracid. The cationic exchange resin can optionally be replaced by a strong acid such as sulphuric acid or p-toluenesulfonic acid. The epoxidation reaction can be conducted directly in the polymerization cement (polymer solution in which the polymer was polymerized) or, alternatively, the polymer can be redissolved in an inert solvent such as toluene, benzene, hexane, cyclohexane, methylenechloride and the like and epoxidation conducted in this new solution or can be epoxidized neat. Epoxidation temperatures on the order of 0 to 130 °C and reaction times from 0.1 to 72 hours may be utilized. When employing hydrogen peroxide and acetic acid together with a catalyst such as sulphuric acid, the product can be a mixture of epoxide and hydroxy ester. The use of peroxide and formic acid in the presence of a strong acid may result in diolefin polymer blocks containing both epoxide and hydroxy ester groups.

0025Due to these side reactions caused by the presence of an acid, it is preferred to carry out the epoxidation at the lowest possible temperature and for the shortest time consistent with the desired degree of epoxidation. Epoxidation may also be accomplished by treatment of the polymer with hydroperoxides or oxygen in the presence of transition metals such as Mo, W, Cr, V and Ag.

0026Epoxy functionality may also be created by direct oxidation of ehtylenic unsaturation by oxygen in the presence of tetra cyano ethylene. A temperature of 150 °C and an oxygen partial pressure of 58 atmospheres is suitable for this reaction.

0027When the polymers of the present invention are partially hydrogenated, they are preferably, hydrogenated such that from 0.1 to 3 Meq/g of the aliphatic double bonds remain in the polymer because less than 0.1 does not give enough cross-linking and more than 3 gives too much without cost benefit. If unhydrogenated polymer or the partially hydrogenated polymer is to be epoxidized, then it is preferred that 0.1 to 3 Meq/g of double bonds be consumed providing 0.1 to 3 Meq/g of epoxy functionality. It is preferred that the extent of the epoxidation be from about 0.5 Meq/g to 1.5 Meq/g because this is the best compromise between lower cost and having sufficient epoxy groups for good cross-linking.

0028Partial hydrogenation is diene selective. Generally, the rate of hydrogenation is slower for more highly substituted residual aliphatic double bonds than for less substituted aliphatic double bonds. The rate of epoxidation of carbon-carbon double bonds is generally just the opposite. Tetra-substituted and tertiary carbons promote epoxidation with peroxyacids better than secondary carbons, which in turn are better than primary carbons. Thus, polymers of the present invention are especially suitable for the sequential use of both processes on the polymer. Use of partial hydrogenation alone on the present invention preferentially leaves a greater number per unit of weight of residual diene double bonds in the A blocks than the B blocks. Partial hydrogenation can be more selective to diene monomer type than epoxidation. For this reason, it is often better to partially hydrogenate first and epoxidize last when both processes are used on the present polymers.

0029The polymers of this invention are preferably cured by ultraviolet or electron beam radiation, but radiation curing utilizing a wide variety of electromagnetic wavelength is feasible. Either ionizing radiation such as alpha, beta, gamma, X-rays and high energy electrons or non-ionizing radiation such as ultraviolet, visible, infrared, microwave and radio frequency may be used.

0030The presence of water in the polymeric composition during the radiation cross-linking is very undesirable due to the tendency of water to terminate the cross-linking. The radiation curing is therefore generally more effective if the polymeric composition is at a temperature near or above the boiling point of water at the time of the radiation curing.

0031The amount of radiation necessary for high gel formation varies with the thickness of the polymeric mass being irradiated, the amount of epoxy functionality, the extent to which the epoxy functionality is concentrated in specific regions within the polymeric mass and the type of radiation utilized. When electron beam radiation is utilized, radiation doses of 0.1 Mrads to 10 Mrads are acceptable and from 0.1 Mrads to 5 Mrads are preferred because of equipment cost and possible damage to substrate material.

0032When using non-ionizing radiation it is necessary to employ a photoinitiator to initiate the cross-linking reaction. Useful photoinitiators include diaryliodonium, alkoxy-substituted diaryliodonium, triarylsulfonium, dialkylphenacylsulfonium, and dialkyl-4-hydroxyphenylsulfonium salts. The anions in these salts generally possess low nucleophilic character and include SbF₆-, BF₄-, PF₆- and AsF₆-. Specific examples include (4-octyloxyphenyl)-phenyl-iodonium hexafluoroantimonate, UVI-6990 (from Union Carbide), and FX-512 (3M Company). Bis(dodecylphenyl)iodonium hexafluoroantimonate, UV 9310 C (GE), and, UVI-6974 (Union Carbide), are especially effective. The onium salts can be used alone or in conjunction with a photosensitizer to respond to long wave length UV and visible light. Examples of photosensitizers include thioxanthone, anthracene, perylene, phenothiazione, 1,2-benzathracene coronene, pyrene and tetracene. The photoinitiator and photosensitizer are chosen to be compatible with the polymer being cross-linked and the light source available.

0033Radiation induced cationic curing may also be done in combination with free radical curing. Free radical curing can be further enhanced by the addition of additional free radical photoinitiators and photosensitizers for them.

0034Reactive (radiation curable) diluents that can be added to the polymer include alcohols, vinyl ethers, epoxides, acrylate and methacrylate monomers, oligomers and polymers. They may also be blended with other diene-based polymers. Examples of epoxides include bis(2,3-epoxy cyclopentyl)ether vinyl cyclohexene dioxide, limonene dioxide, epoxidized soya and linseed oils and fatty acids, vernonia oil, and UVI 6110 (Union Carbide).

0035The polymers may also be cured without the use of radiation by addition of a cationic initiator. Suitable initiators include the halides of tin, aluminum, zinc, boron, silicon, iron, titanium, magnesium and antimony, and the fluroborates of many of these metals. BF₃ complexes such as BF₃-ether and BF₃-amine are included. Also useful are strong Bronsted acids such as trifluoromethanesulfonic acid (triflic acid) and the salts of triflic acid such as FC-520 (3M Company). The cationic initiator is chosen to be compatible with the polymer being cross-linked, the method of application and cure temperature. The epoxy-containing polymers may also be cross-linked by the addition of multifunctional carboxylic acids and acid anhydrides and in general by the curing methods described in U.S. 3,970,608. Radiation cross-linking is preferred for adhesives because reactive ingredients do not come in contact with warm adhesives.

0036The cross-linked materials of the present invention are useful in adhesives (including pressure sensitive adhesives, contact adhesives, laminating adhesives and assembly adhesives), sealants, coatings, films (such as those requiring heat and solvent resistance), etc. However, it may be necessary for a formulator to combine a variety of ingredients together with the polymers of the present invention in order to obtain products having the proper combination of properties (such as adhesion, cohesion, durability, low cost, etc.) for particular applications. Thus, a suitable formulation might contain only the polymers of the present invention and the curing agent. However, in most coating and sealant applications, suitable formulations would also contain various combinations of resins, plasticizers, fillers, solvents, stabilizers and other ingredients such as asphalt. The following are some typical examples of formulations for coatings and sealants.

0037In coatings and sealant applications, as well as in adhesives applications, it may be necessary to add an adhesion promoting or tackifying resin that is compatible with the polymer. A common tackifying resin is a diene-olefin copolymer of piperylene and 2-methyl-2-butene having a softening point of 95°C. This resin is available commercially under the tradename Wingtack 95 (Wingtack is a trade mark) and is prepared by the cationic polymerization of 60% piperylene, 10% isoprene, 5% cyclo-pentadiene, 15% 2-methyl-2-butene and 10% dimer, as taught in U.S. Patent No. 3,577,398. Other tackifying resins may be employed wherein the resinous copolymer comprises 20-80 weight percent of piperylene and 80-20 weight percent of 2-methyl-2-butene. The resins normally have ring and ball softening points as determined by ASTM method E28 between 80°C and 115°C.

0038Aromatic resins may also be employed as tackifying agents, provided that they are compatible with the particular polymer used in the formulation. Normally, these resins should also have ring and ball softening points between 80°C and 115°C although mixtures of aromatic resins having high and low softening points may also be used. Useful resins include coumarone-indene resins, polystyrene resins, vinyl toluene-alpha methylstyrene copolymers and polyindene resins.

0039Other adhesion promoting resins which are also useful in the compositions of this invention include hydrogenated rosins, esters of rosins, polyterpenes, terpenephenol resins and polymerized mixed olefins, lower softening point resins and liquid resins. An example of a liquid resin is Adtac LV (Adtac is a trade mark) resin from Hercules. To obtain good thermo-oxidative and color stability, it is preferred that the tackifying resin be a saturated resin, e.g., a hydrogenated dicyclopentadiene resin such as Escorez (Escorez is a trade mark) 5000 series resin made by Exxon or a hydrogenated polystyrene or polyalphamethylstyrene resin such as Regalrez (Regalrez is a trade mark) resin made by Hercules. The amount of adhesion promoting resin employed varies from 0 to 400 parts by weight per hundred parts rubber (phr), preferably between 20 to 350 phr, most preferably 20 to 150 phr. The selection of the particular tackifying agent is, in large part, dependent upon the specific polymer employed in the respective adhesive composition.

0040A composition of the instant invention may contain plasticizers, such as rubber extending plasticizers, or compounding oils or organic or inorganic pigments and dyes. Rubber compounding oils are well-known in the art and include both high saturates content oils and high aromatics content oils. Preferred plasticizers are highly saturated oils, e.g. Tufflo 6056 (Tufflo is a trade mark) and 6204 oil made by Arco and process oils, e.g. Shellflex 371 (Shellflex is a trade mark) oil made by Shell. The amounts of rubber compounding oil employed in the invention composition can vary from 0 to 500 phr, preferably between 0 to 100 phr, and most preferably between 0 and 60 phr.

0041Optional components of the present invention are stabilizers which inhibit or retard heat degradation, oxidation, skin formation and color formation. Stabilizers are typically added to the commercially available compounds in order to protect the polymers against heat degradation and oxidation during the preparation, use and high temperature storage of the composition.

0042Various types of fillers and pigments can be included in the coating or sealant formulation. This is especially true for exterior coatings or sealants in which fillers are added not only to create the desired appeal but also to improve the performance of the coatings or sealant such as its weatherability. A wide variety of fillers can be used. Suitable fillers include calcium carbonate, clays, talcs, silica, zinc oxide, titanium dioxide and the like. The amount of filler usually is in the range of 0 to 65%w based on the solvent free portion of the formulation depending on the type of filler used and the application for which the coating or sealant is intended. An especially preferred filler is titanium dioxide.

0043If the coating or sealant will be applied from solvent solution, the organic portion of the formulation will be dissolved in a solvent or blend of solvents. Aromatic hydrocarbon solvents such as toluene, xylene, or Shell Cyclo Sol 53 are suitable. Aliphatic hydrocarbon solvents such as hexane, naphtha or mineral spirits may also be used. If desired, a solvent blend consisting of a hydrocarbon solvent with a polar solvent can be used. Suitable polar solvents include esters such as isopropyl acetate, ketones such as methyl isobutyl ketone, and alcohols such as isopropyl alcohol. The amount of polar solvent used depends on the particular polar solvent chosen and on the structure of the particular polymer used in the formulation. Usually, the amount of polar solvent used is between 0 and 50%w in the solvent blend.

0044Antioxidants can be added to the formulations to protect the products against degradation by oxidation during preparation and use of the compositions. Combinations of primary and secondary antioxidants are preferred. Such combinations include sterically hindered phenolics with phosphites or thioethers, such as hydroxyphenylpropionates with aryl phosphates or thioethers, or amino phenols with aryl phosphates. Specific examples of useful antioxidant combinations include 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate)methane (Irganox 1010 (Irganox is a trade mark) from Ciba-Geigy) with tris(nonylphenyl)phosphite (Polygard HR (Polygard is a trade mark) from Uniroyal), Irganox 1010 with bis(2,4-di-t-butyl)pentaerythritol diphosphite (Ultranox 626 (Ultranox is a trade mark) from Borg-Warner).

0045Additional stabilizers known in the art may also be incorporated into the composition. These may be for protection during the life of the article against, for example, oxygen, ozone and ultra-violet radiation. However, these additional stabilizers should be compatible with the essential stabilizers mentioned hereinabove and their intended function as taught herein.

0046All adhesive, coating and sealant compositions based on the epoxidized polymers of this invention will contain some combination of the various formulating ingredients disclosed herein. No definite rules can be offered about which ingredients will be used. The skilled formulator will choose particular types of ingredients and adjust their concentrations to give exactly the combination of properties needed in the composition for any specific adhesive, coating or sealant application.

0047The only two ingredients that will always be used in any adhesive, coating or sealant are the epoxidized polymer and the curing agent, although, as discussed above, there are many types of curing agents from which to choose. Beyond these two ingredients, the formulator will choose to use or not to use among the various resins, fillers and pigments, plasticizers, reactive oligomers, stabilizers and solvents.

0048Adhesives are frequently thin layers of sticky compositions which are used in protected environments (adhering two substrates together). Therefore, unhydrogenated epoxidized polymers will usually have adequate stability so resin type and concentration will be selected for maximum stickiness without great concern for stability, and pigments will usually not be used.

0049Coatings are frequently thin, non-sticky, pigmented compositions applied on a substrate to protect or decorate it. Therefore, hydrogenated epoxidized polymers may be needed to give adequate durability. Resins will be selected to assure maximum durability and minimum dirt pick-up. Fillers and pigment will be selected carefully to give appropriate durability and color. Coatings will frequently contain relatively high solvent concentration to allow easy application and give a smooth dry coating.

0050Sealants are gap fillers. Therefore, they are used in fairly thick layers to fill the space between two substrates. Since the two substrates frequently move relative to each other, sealants are usually low modulus compositions capable of withstanding this movement. Since sealants are frequently exposed to the weather, the hydrogenated epoxidized polymers are usually used. Resins and plasticizers will be selected to maintain low modulus and minimize dirt pick-up. Fillers and pigment will be selected to give appropriate durability and color. Since sealants are applied in fairly thick layers, solvent content is as low as possible to minimize shrinkage.

0051A formulator skilled in the art will see tremendous versatility in the epoxidized polymers of this invention to prepare adhesives, coatings and sealants having properties suitable for many different applications.

0052The adhesive, coating and sealant compositions of the present invention can be prepared by blending the components at an elevated temperature, preferably between 50°C and 200°C, until a homogeneous blend is obtained, usually less than three (3) hours. Various methods of blending are known to the art and any method that produces a homogenous blend is satisfactory. The resultant compositions may then be used in a wide variety of applications. Alternatively, the ingredients may be blended into a solvent.

0053The adhesive compositions of the present invention may be utilized as many different kinds of adhesives, for example, laminating adhesives, pressure sensitive adhesives, tie layers, hot melt adhesives, solvent borne adhesives and waterborne adhesives in which the water has been removed before curing. The adhesive can consist of simply the epoxidized polymer or, more commonly, a formulated composition containing a significant portion of the epoxidized polymer along with other known adhesive composition components. A preferred method of application will be hot melt application at a temperature around or above 100°C because hot melt application above 100°C minimizes the presence of water and other low molecular weight inhibitors of cationic polymerization. The adhesive can be heated before and after cure to further promote cure or post cure. Radiation cure of hot adhesive is believed to promote faster cure than radiation cure at lower temperatures.

0054Preferred uses of the present formulation are the preparation of pressure-sensitive adhesive tapes and the manufacture of labels. The pressure-sensitive adhesive tape comprises a flexible backing sheet and a layer of the adhesive composition of the instant invention coated on one major surface of the backing sheet. The backing sheet may be a plastic film, paper or any other suitable material and the tape may include various other layers or coatings, such as primers, release coatings and the like, which are used in the manufacture of pressure-sensitive adhesive tapes. Alternatively, when the amount of tackifying resin is zero, the compositions of the present invention may be used for adhesives that do not tear paper and molded goods and the like.

0055Coating compositions of this invention can be used in many applications, depending on the hardness, adhesion, durability and cure conditions chosen by the formulator. A fairly soft coating formulated for low adhesion could be used as a protective strippable coating. A fairly soft coating formulated for high adhesion could be useful as a shatter retentive coating for glass bottles for carbonated beverages. A fairly hard coating formulated for high adhesion and long durability could be used as a corrosion protective coating for metals such as lawn equipment, automobiles, etc.

0056Sealant compositions of this invention can be used for many applications. Particularly preferred is their use as gap fillers for constructions which will be baked (for example, in a paint baking oven) after the sealant is applied. This would include their use in automobile manufacture and in appliance manufacture. Another preferred application is their use in gasketing materials, for example, in lids for food and beverage containers.

0057Asphalt is another common material which can advantageously be combined with the polymers of the present invention. The asphalt may comprise a bituminous component which may be a naturally occurring bitumen or derived from a mineral oil. Also, petroleum derivatives obtained by a cracking process, pitch and coal tar can be used as the bituminous component as well as blends of various bituminous materials. Examples of suitable components include distillation or "straight-run bitumens," precipitation bitumens, e.g. propane bitumens, blown bitumens and mixtures thereof. Other suitable bituminous components include mixtures of one or more of these bitumens with extenders such as petroleum extracts, e.g. aromatic extracts, distillates or residues, or with oils. Compatible asphalts are preferred for use herein. Compatible asphalts are those which will give a blend which does not phase separate upon standing. The amount of asphalt used in the formulation can vary widely depending on the performance requirements of the particular application. However, asphalt will generally be in the formulation at 0-95%w, more preferably 0-70%w and most preferably 0-30%w.

Example 1

0058A star polymer with a divinylbenzene core was prepared as follows.

00594410 grams of cyclohexane were charged into a reactor. 90 grams of 2,3-dimethyl-1,3-butadiene (DMB) were added and mixed at 500 rpms and 30°C. 74 milliliters of butyllithium was injected into the reactor. The temperature was slowly raised to 50°C over 4 minutes and then the temperature was allowed to stabilize. Over period of 12 minutes, the temperature was increased to 80°C and the reaction was allowed to continue.

00604140 grams of the polymer cement (the polymer in the cyclohexane solvent) was transferred to a second reactor and the temperature was set at 30°C. 360 grams of isoprene was added to the reactor along with 2 milliliters of butyllithium. The temperature was increased to 50°C and the reaction was allowed to proceed.

0061After the reaction was complete, 35 milliliters of divinylbenzene was added to the reactor and the temperature was increased to 65°C. This coupling reaction was allowed to go on for one hour. After that time, the polymerization was terminated with 3.6 milliters of methanol.

0062The polymer cement wash removed from the reactor and the solvent taken off. GPC analysis indicated that a star polymer with a divinylbenzene core was produced having DMB/isoprene arms wherein the isoprene blocks were on the inside attached directly to the divinylbenzene core. The molecular weight as determined by gel permeation chromatography of the DMB blocks was 1000 and the molecular weight of the isoprene blocks was 5000.

Examples 2

0063A second star polymer with a divinylbenzene core was prepared as follows. 1,3 butadiene was polymerized in cyclohexane via 1,4-polymerization to a block molecular weight of 1000. Then 1,3-butadiene was polymerized via 1,2-polymerization on the ends of the 1,4 blocks. The 1,2 blocks had a molecular weight of 5000. These arms were then coupled with divinylbenzene to produce a star block copolymer having 1,4-/1,2-polybutadiene arms wherein the 1,2 arms were on the inside coupled directly to the core.

0064The polymer was then hydrogenated at 600 psig using a nickel catalyst. Subsequently, the polymer was acid and water washed.

0065The hydrogenated polymer was then epoxidized by placing 565 grams of the polymer in 1085 grams of cyclohexane and adding 46.4 grams of peracetic acid. When the reaction was complete, the polymer was washed with a 50 percent sodium hydroxide solution and then washed several times with distilled water.

0066The epoxy content of the polymer was determined by NMR. The polymer was determined to have 0.93 to 0.95 milliequivalents of epoxy per gram of polymer.