A structured reactive latex

Field Of The Invention

0001The present invention relates to the copolymerizing of ethylenically unsaturated monomers with a mono unsaturated isocyanate via emulsion polymerization so that the sterically hindered or blocked isocyanate groups are distributed, generally, in the outer layer of the latex particles.

Background Of The Invention

0002In U.S. Pat. No. 4,439,616, there is disclosed a method for producing tertiary alkyl isocyanates, such as tetramethylxylylene diisocyanates (TMXDI), by thermal cracking of corresponding urethanes formed by addition of corresponding olefins and carbamic acid esters at moderate temperatures and in the presence of acid catalyst. Such process is particularly useful for producing the meta- and para-isomers of TMXDI and as the by-product thereof, substantial amounts of the corresponding vinyl isocyanate meta- or para-isomers, viz., meta-isopropenyl-α,α-dimethylbenzylisocyanate (m-TMI), respectively, are formed.

0003The meta-TMI or para-TMI by-products in such systems may be recycled within the process to improve the over-all yield of TMXDI therein, but such by-products have substantial utility per se as separate products due to their difunctional character, i.e., the presence of reactive isocyanate (-NCO) and vinyl groups. Thus, TMI may be homo- or co-polymerized to form polymers with isocyanate functionality which are cross-linkable with curatives containing a difunctional or polyfunctional amino or hydroxyl compound. Such cross-linkable compositions have film-forming properties and advantageously may be used for coatings, for example, on metal, wood and glass substrates, as well as having potential applicability for production of molded articles, such as by reaction injection molding (RIM).

0004U.S. Patent No. 3,290,350 discloses copolymerization of TMI by conventional methods using known addition polymerization initiators, such as those of the free radical type, e.g., persulfate, peroxy and azo initiators.

0005In U.S. Pat. No. 3,502,475, there is disclosed a method of forming a coating on polyolefin and polyester films, by application thereto of an aqueous dispersion of a copolymer of from about 1 to about 50 percent by weight of meta- or para-TMI.

0006The prior art teaches the art of making free or blocked isocyanate functional latexes of ethylenically unsaturated monomers which is conducted through conventional batch or semi-batch emulsion polymerization, and an uniform particle morphology is obtained. The functional groups which are buried inside the particles generally do not contribute to the surface reaction or crosslink where adhesion between surfaces are more important. For example, for the sizing of fiber glass, the adhesion between the sizing agent and the fiber is critical for both strand integrity and high composite strength.

0007Accordingly, it is an object of the invention to copolymerize the ethylenically unsaturated monomers with an unsaturated isocyanate monomer via a two-stage or one-stage seed emulsion polymerization.

0008Another object of the invention is to provide an isocyanate (NCO) distribution that generally is close to the surface of the emulsion polymer particles.

0009Other objects and advantages of the invention will be apparent from the ensuing disclosure and appended claims.

Summary Of The Invention

0010The present invention relates to a latex comprising a free radically polymerized product in the presence of a catalyst, said product comprising at least two ethylenically unsaturated monomers, at least one of said monomers being free of isocyanate functional groups and at least one of said monomers having an unsaturated isocyanate group which is sterically hindered or blocked, said latex comprising particles having a morphology with the isocyanate containing polymer being predominately located on the surface layer of said particle.

0011Suitable unsaturated monomers having a sterically hindered isocyanate group include dimethyl meta- or para-isopropenyl benzyl isocyanate (TMI). Other suitable unsaturated monomers having a blocked isocyanate group include acetone oxime blocked allyl isocyanate. Other isocyanates such as TDI, MDI, HDI, HMDI, TMXDI and IPDI can be reacted with hydroxy, carboxy and amines containing ethylenically unsaturated monomers to produce a reaction product of the unsaturated isocyanates. This reaction product can further be blocked to be used in the present invention. Suitable unsaturated monomers free of isocyanate functional groups include esters of acrylic or methacrylic acid, vinyl acetate and styrene.

0012The present invention further relates to a method of making a latex comprising polymerizing at least two ethylenically unsaturated monomers, at least one of said monomers having an isocyanate group which is sterically hindered or blocked and at least one other of said ethylenically unsaturated monomers being free of isocyanate functional groups, in an aqueous emulsion in the presence of a free-radical polymerization catalyst, in a manner such that the sterically hindered or blocked isocyanate groups distribute in the outer layer of the latex particle.

0013The present invention can be carried out in a one-stage or a two-stage seed emulsion polymerization process. In the process of copolymerizing the unsaturated monomers via seed emulsion polymerization, other optional ingredients such as defoamers, preservatives, pH adjusters, reducing agents and chain transfer agents can generally be used to adjust final properties. For example, polymerization conducted at pH less than 7 and using the redox initiator system enables the reaction at low temperature, so that less -NCO groups are lost during the polymerization process.

0014The emulsion can be used in applications such as fiber glass sizing and as a coating or adhesive on various substrates when properties such as increased adhesive strength and good composite strengths are important.

Brief Description Of The Drawings

0015Figure 1 shows the characteristic IR peaks corresponding to isocyanate groups in different latex films, given in Table III. It is shown by this figure that the conventional process caused significant loss in isocyanate groups.

0016Figure 2 and Figure 3 show the reaction of the isocyanate with Jeffamine ED-600, a diamine by Huntsman Corp., (Salt Lake City, UT). Films used for testing were cast from the mixture listed in Table IV.

0017Figure 2 shows the structured latex made from the current invention is further crosslinked, in contrast with the conventional latex, which is shown in Figure 3.

Detailed Description Of The Invention

0018The unsaturated isocyanate used in the present invention generally contains one or more carbon-carbon double bond and is a sterically hindered or blocked isocyanate. Generally, the steric hindrance or blockage reduces the reactivity of the isocyanate group with water so as to survive from the polymerization process and the storage period. Typically, this unsaturated isocyanate is TMI and preferably it is meta TMI, by Cytec Industries, Inc., (West Paterson, NJ). A preferred amount used in the present invention is about 0.1-20.0 wt-% of the total monomer weight, more preferably in an amount of about 1.0-10.0 wt-% of the total monomer weight and most preferably in an amount of about 3.0-5.0 wt-% of the total monomer weight. An example of the sterically hindered unsaturated isocyanate is meta TMI, and an example of the blocked unsaturated isocyanate is the acetone oxime blocked allyl isocyanate. Other isocyanates such as TDI, MDI, HDI, HMDI, TMXDI and IPDI can be reacted with hydroxy, carboxy and amines containing ethylenically unsaturated monomers to produce a reaction product of the unsaturated isocyanates. This reaction product can further be blocked to be used in the present invention.

0019The ethylenically unsaturated monomers co-polymerizable with the unsaturated isocyanate include C₁-C₈ alkyl acrylate and methacrylate, styrene, acrylonitrile, vinyl acetate and combinations thereof. The preferred combination of monomers are those that give a Tg, as measured by a DSC at the rate of 10°C per minute, of about -50 to about 85<img file="EP0808857A2_D0001.tif" />C. The preferred amount of the ethylenically unsaturated comonomers used in the present invention is about 20-60 wt-% of the latex, more preferred amounts of about 40-50 wt-% of the latex and most preferably in an amount of about 45 wt-% of the latex.

0020The free radical source may be thermal or redox systems. The preferred systems include azo compounds, hydroperoxide, persulfates and/or, in combination with salts of formaldehyde, sulfoxylate, bisulfite and erythorbic acid. The preferred amount is about 0.1-1.0 wt-% of the total monomer weight with a more preferred amount of about 0.1-0.5 wt-% and most preferably an amount of about 0.2-0.4 wt-%.

0021Chain transfer agents may be added to adjust the molecular weight of the emulsion polymers. They may be water soluble or oil soluble mercaptans or thiols. The preferred chain transfer agent is a normal or tertiary dodecyl mercaptans in a preferred amount of about 0.01-5.0 wt-% based on the total monomer weight, with a more preferred amount of about 0.01-2.0 wt-% based on the total monomer weight and most preferably in an amount of about 0.1-0.5 wt-% based on the total monomer weight.

0022The emulsifiers that may be present in the present invention may be ionic, nonionic, as well as polymeric, and mixtures thereof. The preferred composition includes alkyl polyethoxyethanol in an amount of about 0.5-5.0 wt-% of the total monomer weight, more preferably in an amount of about 0.5-3.0 wt-% of the total monomer weight and most preferably in an amount of about 1.0-2.0 wt-% of the total monomer weight.

0023The polymerization of the present invention is either a one-staged or a two-staged seed emulsion polymerization. In the one-stage seed process, heterogeneous latex particle morphology is obtained by forming the seed in situ followed by the polymerization of TMI. An example of the one-stage process is given in the following sequence of steps: <ul id="ul0001" list-style="none" compact="compact"><li>(1) forming an emulsion of the ethylenically unsaturated monomers in the presence of emulsifier(s);</li><li>(2) in a semi-batch, starved process polymerize the ethylenically unsaturated monomers to form a seed latex having average particle size about 0.05-0.5 microns.</li><li>(3) copolymerize TMI with or without other ethylenically unsaturated monomers on top of the pre-formed seed particles to further enlarge the particle and construct a surface layer composition different from the bulk composition.</li></ul>

0024In the two-staged seed process, a seed latex having no isocyanate functionality was present before the reaction and on which meta-TMI was polymerized again with or without other ethylenically unsaturated monomers.

0025Typically, the polymerization time of a one-stage process or two-stage process is about 2-5 hours. The resulting product may have particle size of about 0.1-1.0 microns, pH of about 2-5, viscosity of about 20-500 cps and solids of about 40-50%. The volume ratio of the bulk of the latex particle to the outer surface layer of the latex particle is preferably 5:95 - 99:1, more preferably 50:50 - 99:1 and most preferably 75:25 - 99:1. Generally, the latex contains particle sizes having morphologies ranging from a core and a surface layer which may or may not be continuous.

0026The preferred polymerization temperature is about 5-80°C, and most preferably, a polymerization temperature of about 35-65°C is useful. The resulting product has sterically hindered or blocked isocyanate groups distributed in the surface layer of the latex particles so that an efficient interfacial crosslinking can be achieved.

0027It is critical in some systems to carry the polymerization in the right pH level or in the presence of transition metal ions, such as Fe²⁺, to ensure the proper decomposition of the initiators. The preferred pH range is about 3-5 with a more preferred range of about 2-4. It is unique in the current invention that acetic acid was used to adjust the initial pH without using any salt form pH buffer. The intention of doing so is to obtain the desired pH level without negatively affecting the water resistance of the final product.

0028As one skilled in the art knows, functional groups buried inside the core of a latex particle are unable to achieve contact with the substrate surface or a post added crosslinking agent, especially when the particle is relatively large in size. Therefore, putting these reactive groups in the surface layer of the particle achieves a much higher efficiency of the interfacial crosslinking. In the current invention, this objective is achieved through the one-stage or two-stage emulsion polymerization process in which the distribution of the reactive isocyanate groups is controlled by the monomer feed schedule.

0029Copolymerizing the unsaturated isocyanate with other ethylenically unsaturated monomers introduces the reactive isocyanate groups into the copolymer. These isocyanate groups are capable of reacting with post added crosslinking agent containing, e.g., amine, hydroxyl or carboxyl, and/or with the functional groups on the surface of the substrate, so as to develop strong bonding or adhesion between the polymer and the substrate. Such a characteristic is appreciated by the applications where enhanced adhesion or compatibility are required, such as in surface coating adhesives.

0030The advantages of producing a latex made by the process of the present invention is demonstrated by an increase in its adhesive properties and the crosslinking efficiency of the reactive isocyanate groups. In fiber glass sizing for example, the reaction between the latex and the surface hydroxyl of the fiber glass creates good adhesion and thus good composite strength.

Examples:

0031The following examples are offered to further illustrate the various aspects and attributes of the present invention. They are, however, not intended to limit the scope of the present invention.

Example I

0032The following example describes the one-stage seed process for the preparation of the structured reactive latex containing sterically hindered isocyanate groups:

0033The pre-emulsion (PE) was made by charging 80 grams of deionized water and 6.65 grams of T-Det O-407, a surfactant from Harcros, (Kansas City, KS), a defoamer and mixed for 15 minutes. Under agitation the mixture of 155 grams of methyl methacrylate from ICI Americas, Inc., (Wilmington, DE), 155 grams of n-butyl acrylate from Hoechst Celanese Corp, (Somerville, NJ) and 0.93 grams of n-dodecyl mercaptan from Elf Atochem, (Philadelphia, PA) was added.

0034A jacketed reaction kettle was charged with 175 grams of deionized water and 0.1 grams of acetic acid. The reactor was placed under agitation and nitrogen purge. The temperature was raised to 60-65°C and 1 wt-% of the total pre-emulsion was started. The continuous feeding was started of the initiator solution containing 1.55 grams of t-butyl hydroperoxide from Aztec Chemicals, (Houston, TX) and 30 grams of deionized water, and the reducer solution containing 1.08 sodium formaldehyde sulfoxylate from Aldrich Chemical Co., Inc., (Milwaukee, WI) and 30 grams of deionized water. The system was reacted for 30 minutes before feeding the remaining pre-emulsion for 3 hours. Feeding started with 6 grams of m-TMI from Cytec, (W. Patterson, NJ) with the last 10% of the pre-emulsion. When all feeds were completed, the system was held at the same temperature for another hour to allow the full converting of monomers. After this the reactor was cooled ad the latex filtered through 200 mesh.

0035Using a similar procedure other latexes in Table I were prepared.

Example II - (Comparative)

0036The following example prepares the copolymer latexes using the continuous uniform feed of all the monomers.

0037The pre-emulsion (PE) was made by charging 80 grams of deionized water and 6.65 grams of T-Det 0-407, a surfactant from Harcros, (Kansas City, KS), a defoamer and mixing for 15 minutes. Under agitation the mixture of 155 grams of methyl methacrylate from ICI Americas, Inc., (Wilmington, DE), 155 grams of n-butyl acrylate from Hoechst Celanese Corp, (Somerville, NJ), 6 grams of m-TMI from Cytec, (W. Patterson, NJ), and 0.93 grams of n-dodecyl mercaptan from Elf Atochem, (Philadelphia, PA) was added.

0038A jacketed reaction kettle was charged with 175 grams of deionized water and 0.1 grams of acetic acid. The reactor was placed under agitation and nitrogen purge. The temperature was raised to 60-65°C and 1 wt-% of the total pre-emulsion was added. Continuous feeding of the initiator solution and reducer solution was started. The initiator solution contained 1.55 grams of t-butyl hydroperoxide from Aztec Chemicals, (Houston, TX), and 30 grams of deionized water, and the reducer solution contained 1.08 sodium formaldehyde sulfoxylate from Aldrich Chemical Co., Inc., (Milwaukee, WI) and 30 grams of deionized water. The system was left to react for 30 minutes before feeding the remaining pre-emulsion for 3 hours. After all feeds were completed, the system was held at the same temperature for another hour to allow the full converting of monomers. After this, the reactor was cooled and the latex filtered through 200 mesh.

0039Using a similar procedure other latexes in Table II were prepared.

Example III

0040The following example demonstrates, using FT-IR, the difference in crosslinking efficiency between the conventional latex in which the m-TMI is uniformly distributed in latex particles, and the structured latex in the current invention, in which the m-TMI is predominately distributed in the outer layer in latex particles.

0041Figure 1 shows the characteristic IR peaks corresponding to isocyanate group as indicated by the absorption at 2258 CM^-1 in different latex films, given in Table III. It is shown by this figure that the conventional process caused significant loss in isocyanate groups.

0042Figure 2 and Figure 3 show the reaction of the isocyanate with Jeffamine ED-600, a diamine (-NH₂ absorption at 3450 CM^-1) by Huntsman Corp., (Salt Lake City, UT). Films used for testing were cast from the mixture listed in Table IV.

0043Figure 2 shows the structured latex made from the current invention is further crosslinked, in contrast with the conventional latex, which is shown in Figure 3.

Example IV

0044The following example describes the two-stage seed process for the preparation of the structured reactive latex containing sterically hindered isocyanate groups:

0045The pre-emulsion (PE) was made by charging 105 grams of deionized water and 11.18 grams of T-Det O-407, a surfactant from Harcros, (Kansas City, KS), a defoamer and mixed for 15 minutes. Under agitation the mixture of 98.8 grams of methyl methacrylate from ICI America's, Inc., (Wilmington, DE), 130 grams of n-butyl acrylate from Hoehst Celanese Corp, (Somerville, NJ), 13 grams of meta-TMI from Cytec, (W. Patterson, NJ), and 5.2 grams of Monomer 238 from Sartomer Co., Inc., (West Chester, PA) was added.

0046A jacketed reaction kettle was charged with 577.2 grams of PN-3416-F latex from H.B. Fuller Co., (St. Paul, MN), which is a self-crosslinking acrylic latex, 270 grams of deionized water and 0.004 grams of ferrous sulfate. The reactor was placed under agitation and nitrogen purge. The temperature was raised to 60-65°C and continuous feeding began of pre-emulsion for 3 hours. Also fed was an initiator solution containing 0.39 grams of ammonium persulfate from Aldrich Chemical Co., (Milwaukee, WI) and 39 grams of deionized water, and a reducer solution containing 0.39 grams of sodium metabisulfite from Aldrich Chemical Co., (Milwaukee, WI), and 39 grams of deionized water. After all feeds were completed, the system was held at the same temperature for another hour to allow the full converting of monomers. After this the reactor was cooled and the latex filtered through 200 mesh.

0047Using a similar procedure other latexes in Table V were prepared.

Example V

0048To the samples prepared in and Example IV, different types and levels of post crosslinking agent may be added. In preparing the pre-crosslinked latexes, the crosslinking agent was added in deionized water dilution to the latexes in Example IV under agitation and room temperature. Table VI gives the examples of this kind of latexes. <tables id="tabl0001" num="0001"><img file="EP0808857A2_D0002.tif" /></tables><tables id="tabl0002" num="0002"><table frame="all"><title>TABLE III</title><tgroup cols="4" colsep="1" rowsep="1"><colspec colnum="1" colname="col1" colwidth="39.37mm" /><colspec colnum="2" colname="col2" colwidth="39.37mm" /><colspec colnum="3" colname="col3" colwidth="39.37mm" /><colspec colnum="4" colname="col4" colwidth="39.37mm" /><thead valign="top"><row rowsep="1"><entry namest="col1" nameend="col1" align="center"><u>Figure I</u> IR Spectrum Nos.</entry><entry namest="col2" nameend="col2" align="center">TMI Content (Gram)</entry><entry namest="col3" nameend="col3" align="center">Polymerization Process</entry><entry namest="col4" nameend="col4" align="center">-NCO Distribution</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="right">1</entry><entry namest="col2" nameend="col2" align="right">0</entry><entry namest="col3" nameend="col3" align="left">--</entry><entry namest="col4" nameend="col4" align="left">--</entry></row><row><entry namest="col1" nameend="col1" align="right">2</entry><entry namest="col2" nameend="col2" align="right">6</entry><entry namest="col3" nameend="col3" align="left">Current Invention</entry><entry namest="col4" nameend="col4" align="left">Outer Layer of Particle</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="right">3</entry><entry namest="col2" nameend="col2" align="right">6</entry><entry namest="col3" nameend="col3" align="left">Conventional</entry><entry namest="col4" nameend="col4" align="left">Uniform Within Particle</entry></row></tbody></tgroup></table></tables><tables id="tabl0003" num="0003"><table frame="all"><title>TABLE IV</title><tgroup cols="4" colsep="1" rowsep="1"><colspec colnum="1" colname="col1" colwidth="39.37mm" /><colspec colnum="2" colname="col2" colwidth="39.37mm" /><colspec colnum="3" colname="col3" colwidth="39.37mm" /><colspec colnum="4" colname="col4" colwidth="39.37mm" /><thead valign="top"><row rowsep="1"><entry namest="col1" nameend="col1" rowsep="0" align="center"><u>Figures II &amp; III</u> IR Spectrum Nos.</entry><entry namest="col2" nameend="col3" align="center">Composition</entry><entry namest="col4" nameend="col4" rowsep="0" align="center">Remarks</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" /><entry namest="col2" nameend="col2" align="center">Latex</entry><entry namest="col3" nameend="col3" align="center">Crosslinker</entry><entry namest="col4" nameend="col4" /></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="right">1</entry><entry namest="col2" nameend="col2" align="left">Example I</entry><entry namest="col3" nameend="col3" align="left">----</entry><entry namest="col4" nameend="col4" morerows="1" align="left">Latex made in Current Invention</entry></row><row><entry namest="col1" nameend="col1" align="right">2</entry><entry namest="col2" nameend="col2" align="left">Example I</entry><entry namest="col3" nameend="col3" align="left">ED-600</entry></row><row><entry namest="col1" nameend="col1" align="right">3</entry><entry namest="col2" nameend="col2" align="left">Example II</entry><entry namest="col3" nameend="col3" align="left">----</entry><entry namest="col4" nameend="col4" morerows="1" align="left">Conventional Latex</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="right">4</entry><entry namest="col2" nameend="col2" align="left">Example II</entry><entry namest="col3" nameend="col3" align="left">ED-600</entry></row></tbody></tgroup></table></tables><tables id="tabl0004" num="0004"><img file="EP0808857A2_D0003.tif" /></tables><tables id="tabl0005" num="0005"><table frame="all"><title>TABLE VI</title><tgroup cols="5" colsep="1" rowsep="1"><colspec colnum="1" colname="col1" colwidth="31.50mm" /><colspec colnum="2" colname="col2" colwidth="31.50mm" /><colspec colnum="3" colname="col3" colwidth="31.50mm" /><colspec colnum="4" colname="col4" colwidth="31.50mm" /><colspec colnum="5" colname="col5" colwidth="31.50mm" /><thead valign="top"><row rowsep="1"><entry namest="col1" nameend="col1" align="center">Sample No.</entry><entry namest="col2" nameend="col2" align="center">Polyamine (Jeffamine)</entry><entry namest="col3" nameend="col3" align="center">NCO/NH2 Molar Ratio</entry><entry namest="col4" nameend="col4" align="center">Maximum Tensile Strength (PSI)</entry><entry namest="col5" nameend="col5" align="center">Break Elongation (%)</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="right">1</entry><entry namest="col2" nameend="col2" align="left">---</entry><entry namest="col3" nameend="col3" align="left">---</entry><entry namest="col4" nameend="col4" align="right">1143</entry><entry namest="col5" nameend="col5" align="right">1208</entry></row><row><entry namest="col1" nameend="col1" align="right">2</entry><entry namest="col2" nameend="col2" align="left">T-403</entry><entry namest="col3" nameend="col3" align="left">1:0.7</entry><entry namest="col4" nameend="col4" align="right">1267</entry><entry namest="col5" nameend="col5" align="right">1170</entry></row><row><entry namest="col1" nameend="col1" align="right">3</entry><entry namest="col2" nameend="col2" align="left">T-3000</entry><entry namest="col3" nameend="col3" align="left">   "</entry><entry namest="col4" nameend="col4" align="right">1477</entry><entry namest="col5" nameend="col5" align="right">1239</entry></row><row><entry namest="col1" nameend="col1" align="right">4</entry><entry namest="col2" nameend="col2" align="left">T-5000</entry><entry namest="col3" nameend="col3" align="left">   "</entry><entry namest="col4" nameend="col4" align="right">1026</entry><entry namest="col5" nameend="col5" align="right">1249</entry></row><row><entry namest="col1" nameend="col1" align="right">5</entry><entry namest="col2" nameend="col2" align="left">ED-600</entry><entry namest="col3" nameend="col3" align="left">   "</entry><entry namest="col4" nameend="col4" align="right">1656</entry><entry namest="col5" nameend="col5" align="right">1211</entry></row><row><entry namest="col1" nameend="col1" align="right">6</entry><entry namest="col2" nameend="col2" align="left">ED-900</entry><entry namest="col3" nameend="col3" align="left">   "</entry><entry namest="col4" nameend="col4" align="right">1450</entry><entry namest="col5" nameend="col5" align="right">1242</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="right">7</entry><entry namest="col2" nameend="col2" align="left">ED-2001</entry><entry namest="col3" nameend="col3" align="left">   "</entry><entry namest="col4" nameend="col4" align="right">1120</entry><entry namest="col5" nameend="col5" align="right">1232</entry></row></tbody></tgroup></table></tables>