Resorcinol-blocked isocyanate compositions are derived from the reaction between a resorcinol compound and at least two different isocyanate compounds. The resorcinol-blocked isocyanate compositions may have two or more unblocking temperatures and/or melting characteristics that may provide some unique properties, such as improved adhesion of rubber reinforcing materials to rubber materials or compounds. The resorcinol-blocked isocyanate compositions can be used in fabric dipping formulations and/or rubber compositions with improved properties.
Description
BRIEF DESCRIPTION OF THE FIGURE
FIG. 1 depicts the DSC curves of Examples 1, 2 and 7.
Claims
1) A resorcinol-blocked isocyanate composition comprising:
(a) a first compound having Formula (IIA):
2) The resorcinol-blocked isocyanate composition of claim 1, wherein each of X and Y is independently a divalent radical having one of the following formulae:
3) The resorcinol-blocked isocyanate composition of claim 1 further comprising a third compound having Formula (IIB):
4) The resorcinol-blocked isocyanate composition of claim 3 further comprising a fourth compound having Formula (IIIB):
5) The resorcinol-blocked isocyanate composition of claim 4 further comprising a fifth compound having Formula (IIC):
6) The resorcinol-blocked isocyanate composition of claim 5, wherein the resorcinol-blocked isocyanate composition comprises Compounds (1)-(5) having the formulae:
7) The resorcinol-blocked isocyanate composition of claim 6, wherein each of Compounds (1)-(5) is optionally substituted.
8) The resorcinol-blocked isocyanate composition of claim 1, wherein the resorcinol-blocked isocyanate composition has at least two melting temperatures.
9) The resorcinol-blocked isocyanate composition of claim 1, wherein the resorcinol-blocked isocyanate composition has at least two unblocking temperatures.
10) The resorcinol-blocked isocyanate composition of claim 1, wherein the mole ratio of Formula (IIA) to Formula (IIIA) is from about 10:90 to about 90:10.
11) The resorcinol-blocked isocyanate composition of claim 1, wherein the mole ratio of Formula (IIA) to Formula (IIIA) is from about 35:65 to about 65:35.
12) A process for preparing a resorcinol-blocked isocyanate composition comprising reacting at least two different isocyanate compounds with a resorcinol compound of Formula (I):
13) The process of claim 12, wherein the reaction occurs in the absence of a solvent.
14) The process of claim 12, wherein the reaction occurs in the presence of a catalyst.
15) The process of claim 14, wherein the catalyst is 3-methyl-1-phenyl-2-phospholene-1-oxide or dibutyltin dilaurate.
16) The process of claim 12, wherein the resorcinol compound is resorcinol.
17) The process of claim 12, wherein the at least two isocyanate compounds have the formulae O═C═N—X—N═C═O and O═C═N—Y—N═C═O wherein X and Y are different and each of X and Y is alkylene, cycloalkylene, arylene, alkarylene, cycloalkarylene, aralkylene, heterocyclylene, heteroarylene or a combination thereof.
18) The process of claim 17, wherein each of X and Y is independently a divalent radical having one of the following formulae:
19) The process of claim 12, wherein the reaction temperature is above the melting point of the resorcinol compound.
20) The process of claim 12, wherein at least a portion of the resorcinol compound of Formula (I) is replaced with a different blocking agent.
21) The process of claim 20, wherein the blocking agent is caprolactam, a phenol compound or a combination thereof.
22) The process of claim 21, wherein the phenol compound has Formula (IA):
23) A vulcanizable rubber composition comprising or obtainable from a mixture comprising a rubber material, a methylene donor and a methylene acceptor comprising the resorcinol-blocked isocyanate composition of claim 1.
24) The vulcanizable rubber composition of claim 23, wherein the rubber material is a natural or synthetic rubber.
25) The vulcanizable rubber composition of claim 23 further comprising a rubber reinforcement material.
26) The vulcanizable rubber composition of claim 25, wherein the rubber reinforcement material is in the form of fibers, filaments, fabrics or cords.
27) The vulcanizable rubber composition of claim 25, wherein the rubber reinforcing material is made of a polyester, a polyamide, carbon, glass, steel, polybenzoxazole or rayon.
28) The vulcanizable rubber composition of claim 27, wherein the reinforcing material is steel.
29) The vulcanizable rubber composition of claim 23 further comprising a vulcanizing agent.
30) The vulcanizable rubber composition of claim 23 further comprising at least an additive, wherein the additive is carbon black, zinc oxide, silica, an antioxidant, a stearate, an accelerator, an adhesion promoter, a cobalt salt, stearic acid, a filler, a plasticizer, a wax, a processing oil, a retarder, an antiozonant or a combination thereof.
31) A dipping formulation comprising the resorcinol-blocked isocyanate composition of claim 1.
32) The dipping formulation of claim 31 further comprising a solvent.
33) The dipping formulation of claim 31 further comprising an additive.
34) The dipping formulation of claim 33, wherein the additive is an epoxy-containing compound, a thickener, an antifoam or a combination thereof.
35) The dipping formulation of claim 31 further comprising a poly(vinyl pyridine/butadiene/styrene) latex.
36) The dipping formulation of claim 31 further comprising a resin solution.
37) The dipping formulation of claim 36, wherein the resin solution is a resorcinol-formaldehyde solution.
38) The dipping formulation of claim 37 further comprising an additive.
39) The dipping formulation of claim 38, wherein the additive is an antifoam.
40) A fabricated article comprising a rubber material and a rubber reinforcing material treated with the dipping formulation of claim 31.
41) The fabricated article of claim 40, wherein the rubber material is a natural or synthetic rubber.
42) The fabricated article of claim 40, wherein the rubber reinforcing material is in the form of fibers, filaments, fabrics or cords.
43) The fabricated article of claim 40, wherein the rubber reinforcing material is made of a polyester, a polyamide, carbon, glass, steel, a polybenzoxazole or rayon.
44) The fabricated article of claim 40, wherein the fabricated article is a tire, power transmission belt, conveyor belt, V-belt, hose printing roll, rubber shoe heel, rubber shoe sole, automobile floor mat, truck mud flap or ball mill liner.
45) A coating comprising a resin prepared by curing Formula (B), (B′), (C) or a combination thereof:
46) The coating of claim 45, wherein the curing occurs in the presence of an initiator.
47) The coating of claim 45 further comprising an additive.
48) The coating of claim 47, wherein the additive is a filler, rheology modifier, thickener, surfactant, wetting agent, cross-linking agent, coupling agent, colorant, lubricant, leveling agent, antioxidant, UV stabilizer, plasticizer or a combination thereof.
49) A coating comprising a resin prepared by curing Formula (B), (E) or a combination thereof:
50) The coating of claim 49 further comprising an additive.
51) The coating of claim 50, wherein the additive is a filler, rheology modifier, thickener, surfactant, wetting agent, cross-linking agent, coupling agent, colorant, lubricant, leveling agent, antioxidant, UV stabilizer, plasticizer or a combination thereof.
52) A resorcinol-blocked isocyanate composition comprising a compound having Formula (IIC):
53) The resorcinol-blocked isocyanate composition of claim 52, wherein the resorcinol-blocked isocyanate composition has at least two melting temperatures.
54) The resorcinol-blocked isocyanate composition of claim 52, wherein the resorcinol-blocked isocyanate composition has at least two unblocking temperatures.
55) The resorcinol-blocked isocyanate composition of claim 52 further comprising Formula (IIA), Formula (IIIA), Formula (IIB), Formula (IIIB):
56) The resorcinol-blocked isocyanate composition of claim 55, wherein the resorcinol-blocked isocyanate composition comprises Formula (IIC), Formula (IIA) and Formula (IIIA).
57) The resorcinol-blocked isocyanate composition of claim 56, wherein each of R11, R12, Ra, Rb, Rc and Rd is hydrogen.
58) The resorcinol-blocked isocyanate composition of claim 57, wherein X is a divalent radical having Formula (C) and Y is a divalent radical having Formula (D):
Patent Application
20070205393
