This application is a U.S. National-Stage entry under 35 U.S.C. § 371 based on International Application No. PCT/EP2019/055809, filed Mar. 8, 2019, which was published under PCT Article 21(2) and which claims priority to European Application No. 18161462.9, filed Mar. 13, 2018, which are all hereby incorporated in their entirety by reference.
The present disclosure relates to a solution comprising a dye. The invention also relates to a peroxide formulation comprising said solution.
Radically curable resins, such as unsaturated polyester (UP) resins, vinyl ester (VE) resins and (meth)acrylate resins, are usually cured by mixing the resin with an organic peroxide formulation. In addition, a cure accelerator may be added to allow the cure to proceed at lower temperature.
It is generally not visible whether or not the organic peroxide has already been added and if so, whether its dispersion in the resin is homogeneous. For that purpose, peroxide formulations have been developed that contain a dye. The dye indicates the presence of the organic peroxide formulation in the resin, and shows whether or not the formulation is homogeneously dispersed.
If a dye is used that loses its colour during the cure (probably due to radicals attacking the chromophoric group), it is possible to monitor the cure by the fading colour. In addition, the dye will not affect the colour of the cured product.
Suitable dyes for this purpose are solid and need to be dissolved before incorporation in the peroxide formulation. However, these dyes are very difficult to dissolve in many solvents.
Solvents presently used for dissolving such dyes are N-ethyl pyrrolidone and N-methylpyrrolidone. These solvents, however, are classified as reprotoxic.
This disclosure provides a solution comprising:
The following detailed description is merely exemplary in nature and is not intended to limit the disclosure or the application and uses of the subject matter as described herein. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description
The object of the present disclosure is therefore the provision of a suitable solvent for such dyes that poses less health risks.
This object has been met by a solvent mixture comprising cyclopentanone and dimethylsulphoxide in a weight ratio of about 60:40 to about 95:5.
The present disclosure therefore relates to a solution comprising:
In the above formulae, R1 and R2 are independently selected from —CxH2x+1, —CxH2x—C≡N, —CxH2x—OH, —CxH2x—O—C(═O)—O—CxH2x+1, —CxH2x—O—C(═O)—CxH2x+1, and —CxH2x—C(═O)—O—CxH2x+1, x being an integer in the range of about 1 to about 5, typically about 1 to about 2. Specifically preferred R1 groups are —CxH2x+1 and —CxH2x—C≡N, more typically —CH2CH3 and —CH2—CH2—C≡N.
Specifically preferred R2 groups are —CxH2x—O—C(═O)—O—CxH2x+1 and —CxH2x—O—C(═O)—CxH2x+1. Specifically preferred examples are —C2H4—O—C(═O)—O—C2H5 and —C2H4—O—C(═O)—CH3.
Specific examples of suitable dyes with formula
are:
Disperse Blue 79, i.e. 2-[5-acetamido-N-(2-acetyloxyethyl)-4-[(2-bromo-4,6-dinitrophenyl)diazenyl]-2-ethoxyanilino]ethyl acetate, in which Y=—NO2, R1=R2=—C2H4—O—C(═O)—CH3, R3=Br, R4=NO2, n=2, one R5 is —O—C2H5; the other is —N(H)—C(═O)—CH3, R6=H.
Disperse Brown 1, i.e. 2-[3-chloro-4-[(2,6-dichloro-4-nitrophenyl)diazenyl]-N-(2-hydroxyethyl)anilino]ethanol, in which Y=—NO2, R1=R2=—C2H4—OH, R3=R4=Cl, n=1, R5=Cl, R6=H.
Disperse Violet 24, i.e. 2-[[4-[2-(2-Bromo-4,6-dinitrophenyl)diazenyl]-3-methyl phenyl]butylamino]ethanol, in which Y=—NO2, R1=C4H9, R2=—C2H4—OH, R3=Br, R4=NO2, n=1, R5=CH3, R6=H.
Disperse Red 73, i.e. 2-[[4-[2-cyanoethyl(ethyl)amino]phenyl]diazenyl]-5-nitrobenzonitrile, in which Y=—NO2, R1=C2H5, R2=—C2H4—C≡N, R3=H, R4=—C≡N, n=0, R6=H.
Disperse Orange 25, i.e. 3-[N-Ethyl-4-(4-nitrophenylazo)phenylamino]propionitrile, in which Y=—NO2, R1=C2H5, R2=—C2H4—C≡N, R3=R4=H, n=0, R6=H.
Disperse Red 1, i.e. N-Ethyl-N-(2-hydroxyethyl)-4-(4-nitrophenylazo)aniline, in which Y=—NO2, R1=C2H5, R2=—C2H4—OH, R3=R4=H, n=0, R6=H.
Specific examples of suitable dyes with formula
are:
Disperse Blue 148, i.e. methyl N-ethyl-N-(4-((5-nitro-2,1-benzisothiazol-3-yl)azolphenyl)-beta-alaninate, in which Y=—NO2, R1=C2H5, R2=—C2H4—C(═O)—O—CH3, n=0
Disperse Red 177, i.e. 2-((2-cyanoethyl)(4-((6-nitrobenzothiazol-2-yl)azo)phenyl)amino)ethyl acetate, in which Y=—NO2, R1=—C2H4—C≡N, R2=—C2H4—O—C(═O)—CH3, n=0
Disperse Red 179, i.e. 3-[N-ethyl-[3-methyl-4-(6-nitrobenzothiazol-2-yl)diazenyl-phenyl]amino]propanenitrile, in which Y=—NO2, R1=C2H5, R2=—C2H4—C≡N, n=1, and R5=CH3
Disperse Red 145, i.e. 3-[N-ethyl-4-[(6-nitro-1,3-benzothiazol-2-yl)diazenyl]anilino]propanenitrile, in which Y=—NO2, R1=C2H5, R2=—C2H4—C≡N, n=0
Disperse Red 154, i.e. 2-[2-cyanoethyl][4-[6-nitrobenzothiazol-2-yl)azo]phenyl]amino]ethyl carbonate, in which Y=—NO2, R1=—C2H4—C≡N, R2=—CH2CH2—O—C(═O)—O—C2H5, n=0
Disperse Red 177, i.e. 3-[[2-(acetyloxy)ethyl][4-[2-(6-nitro-2-benzothiazolyl)diazenyl]phenyl]amino]propanenitrile, in which Y=—NO2, R1=—C2H4—C≡N, R2=—CH2CH2—O—C(═O)—CH3, n=0
The latter two dyes, i.e. Disperse Red 154 and Disperse Red 177, are the preferred dyes for use in the present disclosure. These dyes are the most compatible with organic peroxides and have the best discoloration properties.
The solution according to the present disclosure (“the dye-containing solution”) comprises about 1 to about 25 wt %, typically about 2 to about 20 wt %, and typically about 5 to about 15 wt % of the dye, dissolved in a mixture cyclopentanone and dimethylsulphoxide (DMSO).
Said mixture comprises cyclopentanone and dimethylsulphoxide in a cyclopentanone:dimethylsulphoxide weight ratio of about 60:40 to about 95:5, typically about 70:30 to about 90:10, typically about 70:30 to about 80:20.
Said solvent mixture typically includes solely of cyclopentanone and dimethylsulphoxide.
The present disclosure also relates to a peroxide formulation comprising:
Examples of suitable organic peroxides are ketone peroxides, organic hydroperoxides, peroxyesters, and combinations thereof.
Examples of ketone peroxides are acetylacetone peroxide (AAP), methyl ethyl ketone peroxide (MEKP), methyl isopropyl ketone peroxide (MiPKP), cyclohexanone peroxide, cyclopentanone peroxide, methyl isobutyl ketone peroxide (MiBKP), and combinations thereof. Ketone peroxides can have the formula
or the formula
These formulae represent methyl isopropyl ketone peroxide when R1 and R4 are methyl and R2 and R3 are isopropyl. They represent methyl ethyl ketone peroxide when R1 and R4 are methyl and R2 and R3 are ethyl. They represent methyl isobutyl ketone peroxide when R1 and R4 are methyl and R2 and R3 are isobutyl. They represent cyclohexanone peroxide when R1 and R2 are linked to form a cyclohexane ring and R3 and R4 are linked to form a cyclohexane ring. They represent cyclopentanone peroxide when R1 and R2 are linked to form a cyclopentane ring and R3 and R4 are linked to form a cyclopentane ring.
The first formula reflects a so-called type-4 (T4) ketone peroxide; the second formula a so-called type-3 (T3) ketone peroxide. Both types are generally present in ketone peroxide formulations, in addition to hydrogen peroxide.
Examples organic hydroperoxides are cumyl hydroperoxide (CHP), isopropyl cumyl hydroperoxide, 1,1,3,3-tetramethylbutyl hydroperoxide, tert-butyl hydroperoxide (TBHP), tert-amyl hydroperoxide, pinane hydroperoxide, para-menthane hydroperoxide, and combinations thereof.
Examples of peroxyesters are tert-butyl peroxybenzoate (TBPB), tert-butyl peroxy-2-ethylhexanoate, 2,5-dimethyl-2,5-di(2-ethylhexanoylperoxy)hexane, tert-butylperoxy-3,5,5-trimethylhexanoate, and combinations thereof.
In addition to the peroxide and the dye-containing solution, other compounds may be present in the peroxide formulation, such as an organic solvent other than cyclopentanone and dimethylsulphoxide. This solvent may serve as a diluent/phlegmatizer for the organic peroxide. Suitable solvents are compatible with cyclopentanone and dimethylsulphoxide and at the same time are able to stabilize organic peroxides. Examples of suitable solvents are phthalates, such as dimethyl phthalate or diisononyl phthalate, 2,2,4-trimethyl pentanediol diisobutyrate (TXIB), mineral spirits, diacetone alcohol, and methylbenzoate.
Furthermore, other materials such as diethyl acetoacetamide, 2,4-pentanedione, water, residual ketone, H2O2, and fillers (e.g. silica or clay) may be present in the peroxide formulation.
The disclosure further relates to a process for curing a radically curable resin using the peroxide formulation.
Suitable radically curable resins to be cured according to the disclosure include alkyd resins, unsaturated polyester (UP) resins, vinyl ester resins, and (meth)acrylate resins. Preferred resins are (meth)acrylate resins, UP resins, and vinyl ester resins. The radically curable resin may be combined with other types of resins, such as epoxy resins.
In the context of the present application, the terms “unsaturated polyester resin” and “UP resin” refer to the combination of unsaturated polyester resin and ethylenically unsaturated monomeric compound. The term “vinyl ester resin” refers to a resin produced by the esterification of an epoxy resin with an unsaturated monocarboxylic acid, and dissolved in an ethylenically unsaturated monomeric compound (e.g. styrene). UP resins and vinyl ester resins as defined above are well known and commercially available.
Suitable UP resins to be cured by the process of the present disclosure are so-called ortho-resins, iso-resins, iso-npg resins, and dicyclopentadiene (DCPD) resins. Examples of such resins are maleic, fumaric, allylic, vinylic, and epoxy-type resins, bisphenol A resins, terephthalic resins, and hybrid resins.
Acrylate and methacrylate resins without an additional ethylenically unsaturated monomeric compound like styrene are referred to in this application as (meth)acrylate resins.
Examples of suitable ethylenically unsaturated monomers to be present in UP and vinyl ester resins include styrene and styrene derivatives like α-methyl styrene, vinyl toluene, indene, divinyl benzene, vinyl pyrrolidone, vinyl siloxane, vinyl caprolactam, stilbene, but also diallyl phthalate, dibenzylidene acetone, allyl benzene, methyl methacrylate, methylacrylate, (meth)acrylic acid, diacrylates, dimethacrylates, acrylamides; vinyl acetate, triallyl cyanurate, triallyl isocyanurate, allyl compounds which are used for optical application (such as (di)ethylene glycol diallyl carbonate), chlorostyrene, tert-butyl styrene, tert-butylacrylate, butanediol dimethacrylate, and mixtures thereof. Suitable examples of (meth)acrylate reactive diluents are PEG200 di(meth)acrylate, 1,4-butanediol di(meth)acrylate, 1,3-butanediol di(meth)acrylate, 2,3-butanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate and its isomers, diethylene glycol di(meth)acrylate, triethylene glycol di(meth)acrylate, glycerol di(meth)acrylate, trimethylol propane di(meth)acrylate, neopentyl glycol di(meth)acrylate, dipropylene glycol di(meth)acrylate, tripropylene glycol di(meth)acrylate, PPG250 di(meth)acrylate, tricyclodecane dimethylol di(meth)acrylate, 1,10-decanediol di(meth)acrylate, tetraethylene glycol di(meth)acrylate, trimethylol propane tri(meth)acrylate, glycidyl (meth)acrylate, bismaleimides, biscitraconimides, bisitaconimides, monoitaconimides, monocitraconimides, monocitraconimides containing a functional group—e.g. an additional unsaturated functionality, for example n-allylcitraconimides—and mixtures thereof.
The amount of ethylenically unsaturated monomer to be used is typically at least about 0.1 wt %, based on the weight of the resin, typically at least about 1 wt %, and typically at least about 5 wt %. The amount of ethylenically unsaturated monomer is typically not more than about 50 wt %, typically not more than about 40 wt %, and typically not more than about 35 wt %.
The amount of peroxide formulation to be used in the curing process is typically at least about 0.1 wt %, typically at least about 0.5 wt %, and typically at least about 1 wt %, based on the weight of resin. The amount of peroxide formulation is typically not more than about 8 wt %, typically not more than about 5 wt %, typically not more than about 2 wt %, based on the weight of resin.
Other optional additives may be employed in the curing process according to the disclosure, such as cure accelerators, fillers, glass fibres, pigments, inhibitors, and promoters.
In the curing process of the present disclosure, the resin is first mixed with the monomer. The peroxide formulation can be added directly to the resulting mixture. However, it can also be first mixed with the monomer or resin.
The curing process can be carried out at any temperature from about −5° C. up to about 250° C. Typically, it is carried out at ambient temperatures commonly used in applications such as hand lay-up, spray-up, filament winding, resin transfer moulding, coating (e.g. gel-coat and standard coatings), button production, centrifugal casting, corrugated sheets or flat panels, relining systems, kitchen sinks via pouring compounds, etc. However, it can also be used in SMC, BMC, pultrusion techniques, and the like, for which temperatures up to about 180° C., typically up to about 150° C., typically up to about 100° C. are used.
1.0 gram of Disperse Red 154 powder was stirred for 30 minutes in 9.0 g solvent or solvent mixture. Samples of the resulting mixture were subsequently stored for at least about 12 hours at different temperatures: −15° C., 5° C., and 20° C.
After storage, the mixture was filtered. The residue was dried and its weight was determined.
1— = not analysed
2DEG = diethylene glycol
3TEP = triethyl phosphate
2.5 grams of Disperse Red 177 powder was stirred for 24 hours at room temperature in 22.5 grams of a CP/DMSO 80/20 mixture. Disperse Red 177 completely dissolved.
2.5 gram of Disperse Red 1 powder was stirred for 24 hours at room temperature, followed by 4 hours at 40° C., in 22.5 grams of a CP/DMSO 80/20 mixture. Disperse Red 1 completely dissolved.
Peroxide formulations were prepared by adding 0.2 g of a freshly made solution of 10 wt % Disperse Red 154 in 80/20 CP/DMSO to 100 g of different peroxide formulations.
The formulations were stored in 30 ml glass bottles for about 4 or 8 weeks at 30° C. or 40° C.
After storage, the decrease in total active oxygen content was determined by way of iodometric titration according to ASTM D2180-89(2008). Samples having a decrease in total active oxygen content of >10% after eight weeks storage at 40° C. are considered unstable.
A gelcoat was cured with Butanox M-50, with and without 0.2 wt % of the 10 wt % Disperse Red 154 in 80/20 CP/DMSO solution. The colour of the mold- and back side of the resulting gel coat was following in time using an X-rite Color I-5. It showed that red colour of the mould side disappeared completely during the curing reaction; the back side did retain some red colour after cure, which faded completely after one month of storage.
While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the various embodiments in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment as contemplated herein. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the various embodiments as set forth in the appended claims.
Number | Date | Country | Kind |
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18161462 | Mar 2018 | EP | regional |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2019/055809 | 3/8/2019 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2019/175040 | 9/19/2019 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
20060202158 | Chen et al. | Sep 2006 | A1 |
20070049650 | Araki | Mar 2007 | A1 |
Number | Date | Country |
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0989164 | Mar 2000 | EP |
2016153791 | Sep 2016 | WO |
Entry |
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EPO, International Search Report issued in International Application No. PCT/EP2019/055809, dated Jun. 24, 2019. |
Number | Date | Country | |
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20210017389 A1 | Jan 2021 | US |