Patent Application
20100261813
This invention generally relates to aqueous thickener polymer compositions, their method of manufacture and method of use.
Aqueous polymer systems, for example coatings containing emulsion polymer binders, typically use thickeners to obtain the desired degree of viscosity needed for the proper formulation and application of the aqueous system. One general type of thickener used in aqueous polymer systems is referred to in the art by the term “associative.” Associative thickeners are so called because the mechanism by which they thicken is believed to involve hydrophobic associations between the hydrophobic moieties in the thickener molecules and/or between the hydrophobic moieties in the thickener molecules and other hydrophobic surfaces. One type of commonly used associative thickener has a polymeric backbone constructed from one or more blocks of polymerized oxyalkylene units, typically polyethylene oxide or polypropylene oxide, with hydrophobic groups attached to or within the backbone. Another type of commonly used associative thickener utilizes a cellulosic backbone with hydrophobic groups attached to the backbone. Both of these types of associative thickeners can be characterized as polyether thickeners as they both have backbones comprising ether linkages. Known polyether associative thickeners are non-ionic thickeners, and their thickening efficiencies in aqueous systems are substantially independent of pH.
In addition to polyether segments, other types of segments can be incorporated into the backbone of a polyether associative thickener. Associative thickeners with polyurethane polyether backbone segments and containing hydrophobic groups comprising tertiary and secondary amine functionalities have been disclosed. U.S. Pat. No. 6,939,938 discloses associative polyurethane polyether thickeners with amine functional hydrophobic groups in which at least 85% of the amine functionality is converted to permanently cationic quaternary amine functionality. Because the quaternary amines are permanently cationic, the associative nature of the groups cannot be turned on and off readily by, for example, pH changes.
Most of the associative thickeners presently on the market are sold as pourable aqueous liquids. For ease of use, it is desirable for the viscosity (Brookfield at 6 rpm) of such thickener products to be less than 15,000 centipoise (cps), or even less than 5,000 cps, so that the product will readily drain from its storage container, and be readily incorporated into the aqueous system to which it is added. The viscosity of the aqueous thickener product can be decreased by reducing the active solids concentration, but this has the drawback of limiting formulation latitude in terms of weight solids of the aqueous system to be thickened by the product.
Other techniques for lowering polyether associative thickener viscosity are also unsatisfactory. Mixtures of polyether associative thickener and water with water miscible, organic co-solvents such as diethylene glycol monobutyl ether, triethylene glycol monobutyl ether, ethylene glycol, polyethylene glycol, propylene glycol or polypropylene glycol, have been used. However, use of these volatile organic solvents is contrary to the need to meet ever more stringent environmental regulations, including the reduction of Volatile Organic Content (VOC). Thus, although the organic co-solvents perform their intended role, they possess potential environmental, safety and health disadvantages. Another method to suppress the product viscosity of polyether associative thickeners is the admixture of surfactants with the aqueous associative thickener. However, the relatively high level of surfactant required can negatively impact the thickening efficiency of the thickener product in the aqueous system to be thickened, and it can degrade final dried coating properties. In addition, the surfactant adds cost to the product.
The admixture of cyclodextrin compounds with the aqueous thickener product to suppress viscosity has also been disclosed. The cyclodextrin suppresses the viscosity of the polyether thickener product until the product is added to an aqueous system containing levels of surfactant high enough to displace the thickener hydrophobe from the cyclodextrin cavity. The primary disadvantage of this method has been the high cost of cyclodextrin compounds.
High product viscosity KU building polyether thickeners can be blended with low product viscosity, ICI building polyether thickeners to provide a blend at an intermediate viscosity. However, when using this method, the flexibility to thicken to different KU and ICI viscosity targets in different coating formulations is compromised.
Another approach to providing an aqueous thickener at high active solids concentration in water is the use of hydrophobically modified alkali swellable or soluble emulsion (HASE) thickeners. HASE thickeners rely upon the insolubility of the polymer backbone itself at low pH to allow the thickener to be provided at low viscosity and at relatively high solids in the emulsion form. However, the substantially ionic backbone ultimately generates other problems related to water sensitivity in the applied coating.
A need in the art remains, therefore, for pourable associative thickeners with both low viscosity and the highest active thickener solids possible. A particular need exists for a cost-effective, environmentally friendly method to suppress the aqueous product viscosity of polyether associative thickeners with practical active solids concentration.
In a first aspect, there is provided an aqueous associative thickener polymer composition comprising (a) 1% to 60% by weight of an associative thickener having a backbone comprising a polyoxyalkylene, a polysaccharide, a polyvinyl alcohol, a polyvinyl alkyl ether, or a polyvinyl pyrrolidone, said associative thickener further comprising a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine, with the proviso that less than 80% of the total amine functionality is a quaternary amine; and wherein said hydrophobic group comprising the tertiary amine, or tertiary phosphine has a hydrocarbon radical bonded to the amine nitrogen atom or phosphine phosphorus atom, which hydrocarbon radical is pendant to the backbone and contains fewer than 10 carbon atoms; (b) sufficient acid to substantially protonate the tertiary amine, or the tertiary phosphine, or combination thereof; (c) 40% to 99% by weight of water; and (d) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof, as a viscosity-suppressing additive.
For each aqueous associative thickener polymer composition of the inventions described herein, there exists a preferred embodiment for which the associative thickener has a substantially non-ionic water soluble backbone. Preferably, the associative thickener has a non-ionic water soluble backbone.
Herein, a water soluble backbone is soluble in water under acidic, neutral and basic conditions, preferably pH=3 to pH=10. Backbones which are insoluble in water under either acidic or basic conditions are not water soluble backbones. The backbone has a solubility in water at 25° C. of at least 10% by weight.
In a second aspect, there is provided an aqueous associative thickener polymer composition comprising: (a) 1% to 60% by weight of an associative thickener comprising a substantially non-ionic water soluble backbone and a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine, with the proviso that less than 80% of the total amine functionality is a quaternary amine; and wherein said hydrophobic group comprising the tertiary amine, or tertiary phosphine has a hydrocarbon radical bonded to the amine nitrogen atom or phosphine phosphorus atom, which hydrocarbon radical is pendant to the backbone and contains fewer than 10 carbon atoms; (b) sufficient acid to substantially protonate the tertiary amine, or the tertiary phosphine, or combination thereof; (c) 40% to 99% by weight of water; and (d) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof, as a viscosity-suppressing additive.
In another aspect, there is provided an aqueous associative thickener polymer composition comprising: (a) 1% to 60% by weight of an associative thickener comprising a substantially non-ionic water soluble backbone comprising a polyoxyalkylene, a poly(meth)acrylamide, a polysaccharide, or a polyvinyl alcohol, or a copolymer comprising esters of (meth)acrylic acid, said associative thickener further comprising a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine, with the proviso that less than 80% of the total amine functionality is a quaternary amine; and wherein said hydrophobic group comprising the tertiary amine, or tertiary phosphine has a hydrocarbon radical bonded to the amine nitrogen atom or phosphine phosphorus atom, which hydrocarbon radical is pendant to the backbone and contains fewer than 10 carbon atoms; (b) sufficient acid to substantially protonate the tertiary amine, or the tertiary phosphine, or combination thereof; (c) 40% to 99% by weight of water; and (d) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof, as a viscosity-suppressing additive.
In a another aspect, there is provided a method to increase the viscosity of an aqueous polymer system, comprising (a) combining the aqueous polymer system with an aqueous thickener composition, wherein the aqueous thickener composition comprises: (i) 1% to 60% by weight of an associative thickener having a backbone comprising a polyoxyalkylene, a polysaccharide, a polyvinyl alcohol, a polyvinyl alkyl ether, or a polyvinyl pyrrolidone, said associative thickener further comprising a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine, with the proviso that less than 80% of the total amine functionality is a quaternary amine; and wherein said hydrophobic group comprising the tertiary amine, or tertiary phosphine has a hydrocarbon radical bonded to the amine nitrogen atom or phosphine phosphorus atom, which hydrocarbon radical is pendant to the backbone and contains fewer than 10 carbon atoms; (ii) sufficient acid to substantially protonate the tertiary amine, or the tertiary phosphine, or combination thereof; (iii) 40% to 99% by weight of water; and (iv) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof, as a viscosity-suppressing additive; and (b) adding an amount of a base sufficient to substantially deprotonate the protonated tertiary amine, or protonated tertiary phosphine, or combination thereof.
For each inventive method to increase the viscosity of an aqueous polymer system described herein, there exists a preferred embodiment of the method for which the associative thickener has a substantially non-ionic water soluble backbone. Preferably, the associative thickener has a non-ionic water soluble backbone.
In another aspect, there is provided a polymer composition, comprising in admixture, (a) an aqueous polymer system; and (b) an aqueous thickener composition comprising, based on the weight of the aqueous thickener composition: (i) 1% to 60% by weight of an associative thickener having a backbone comprising a polysaccharide, a polyvinyl alcohol, a polyvinyl alkyl ether, or a polyvinyl pyrrolidone, said associative thickener further comprising a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine, with the proviso that less than 80% of the total amine functionality is a quaternary amine; and wherein said hydrophobic group comprising the tertiary amine, or tertiary phosphine has a hydrocarbon radical bonded to the amine nitrogen atom or phosphine phosphorus atom, which hydrocarbon radical is pendant to the backbone and contains fewer than 10 carbon atoms; (ii) 40% to 99% by weight of water; and (iii) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof; wherein the tertiary amine, or the tertiary phosphine, or combination thereof, are substantially unprotonated.
In another aspect, there is provided a polymer composition, comprising in admixture, (1) an aqueous polymer system; and (2) an aqueous thickener composition comprising, based on the weight of the aqueous thickener composition: (a) 1% to 60% by weight of an associative thickener having a backbone comprising a polyoxyalkylene segment greater than 10 oxyalkylene units in length and one or more segments selected from (i) a urethane segment, (ii) a urea segment, (iii) an ester segment, (iv) an ether segment, (v) an acetal segment, (vi) a ketal segment, (vii) an aminoplast segment, (viii) a segment comprising the residue of the reaction of an epihalohydrin with an alcohol, an amine, or a mercaptan, and (ix) a segment comprising the residue of the reaction of a trihaloalkane with an alcohol, an amine, or a mercaptan, and (x) combinations of the foregoing, or wherein the associative thickener is a hydrophobically modified cellulosic polymer; said associative thickener further comprising a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine, with the proviso that less than 80% of the total amine functionality is a quaternary amine; and wherein said hydrophobic group comprising the tertiary amine, or tertiary phosphine has a hydrocarbon radical bonded to the amine nitrogen atom or phosphine phosphorus atom, which hydrocarbon radical is pendant to the backbone and contains fewer than 10 carbon atoms; (b) 40% to 99% by weight of water; and (c) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof; wherein the tertiary amine, or the tertiary phosphine, or combination thereof, are substantially unprotonated.
This invention describes a composition and method whereby the same group that is attached to or within the backbone of an associative thickener is reversibly switched between being hydrophilic and hydrophobic in nature. When the group that is attached to or within the backbone is rendered hydrophilic, the aqueous thickener is pourable and readily incorporated into aqueous polymer compositions. When this group is rendered hydrophobic, the thickener performs its thickening function efficiently. Switching is readily accomplished by adjusting the pH of the associative thickener composition and the aqueous polymer composition being thickened. The compositions and methods solve a long-standing need in the art for aqueous polymer thickener compositions that are readily pourable, capable of having a high solids content, and do not adversely affect the properties of the aqueous polymer compositions being thickened or the products formed thereby. Further, since there is no requirement for the addition of volatile organic solvents or costly additives such as cyclodextrin compounds, the compositions and methods are environmentally friendly and cost-effective.
The term “associative thickeners” is known in the art, and refers to thickeners that act via an associative mechanism. The associative mechanism enables the unique set of properties exhibited by the associative thickeners in particular. For example, in latex based coatings, polyether associative thickeners are known to provide improved flow and leveling and better film build compared to high molecular weight, non-associative thickeners.
It is believed in the art that the associative mechanism arises from the structure of associative thickener polymers, which contain distinct hydrophilic and hydrophobic groups. The hydrophilic groups impart overall water solubility to the polymer molecule. The hydrophobic groups associate with other hydrophobic groups on other thickener molecules or on latex particle surfaces to form a dynamic three-dimensional network structure of micelles containing thickener hydrophobic groups. Although the associations in this network are dynamic, interaction lifetimes can be long enough to provide viscosity to the system depending upon the applied shear rate.
As disclosed in U.S. Pat. No. 4,496,708, the “micellar bridging” theory is based upon the existence within the aqueous phase of intermolecular, micelle-like associations between the hydrophobic groups bonded to the water soluble polymer. In the broadest characterization, the term “micelle-like association” is intended to mean the approximate aggregation of at least two hydrophobic groups serving to exclude water. The greater effective lifetime of the micelle-like association yields a stronger network and a higher observed viscosity, that is, greater thickening efficiency. The duration of time that an individual micelle-like association exists is related to the chemical potential of the hydrophobic group as compared to its aqueous environment and steric factors, such as the proximity of one hydrophobic group to another, which aid the approach of two or more hydrophobic groups to each other. The chemical potential of the hydrophobic group as compared to its aqueous environment is directly related to the solubility parameter of the hydrophobic group in water. When the hydrophobic group is less soluble in water, there is a greater driving force for micelle-like association, and thus the network lifetime is greater and the observed viscosity is greater. When the hydrophobic group is more soluble in water, there is a reduced driving force for micelle-like association, and thus the network lifetime is shorter and the observed viscosity is less.
In the polymer compositions described herein, the water solubility parameters of select hydrophobic groups are modulated by controlling the pH of the thickener's aqueous environment. Many aqueous systems of commercial importance are supplied at pH values above about 8. The thickeners described herein deliver better thickening efficiency at pH values above about 8, i.e., the select hydrophobic groups exist in their least water soluble form at pH values above about 8. In the aqueous product as supplied at pH values less than about 6 and more than about 2.5, the thickener's efficiency is suppressed because the select hydrophobic groups exist in a more water soluble form. Thus, the novel associative thickener compositions are supplied at desirably low viscosities and at practical active solids concentrations. However, the compositions thicken aqueous systems very effectively if the pH of the aqueous system is adjusted to above about 8.
Most secondary and tertiary amines, as well as some tertiary phosphines, can be protonated at aqueous pH values below about 6. Primary amines, as components of hydrophobic groups, tend to require pH values well above about 8 to deprotonate from their acid form. Thus, primary amines can generally be characterized as too basic to be useful as a component of hydrophobic groups. Nitrogen atoms that are characterized as urea or urethanes tend to not be basic enough. That is, urea and urethane functionalities tend to require a pH value below about 2.5 to exist in the protonated form. At these low pH values, the associative thickener's polyether backbone is more prone to acid catalyzed degradation. Because of degradation during storage, polyether associative thickeners with pH values below about 2.5 are not desirable. Within the range of 2.5 to 6.0, a pH of 2.5 to 5.0 or 3.0 to 4.5 can be used.
The following discussion concerning pH and pKa is applicable to secondary amines, or tertiary amines, or tertiary phosphines. The concentration of the protonated secondary or tertiary amine, that is, the conjugate acid form of the amine, is defined as [HA+]. The concentration of the unprotonated secondary or tertiary amine, that is, the base form of the amine, is defined as [A]. The concentration of protons in solution is defined as [H+]. The acidity constant of the acid form of the amine, Ka, can be defined as follows (see, for example, Hendrickson, Cram and Hammond, Organic Chemistry, Third Edition, McGraw-Hill, pp 301-302, (1970)).
Ka=[H+][A]/[HA+]
Furthermore, the pKa of the secondary or tertiary amine and the pH of the aqueous associative thickener composition can be defined as follows.
pKa=−log Ka
pH=−log [H+]
A useful relationship is that when [HA+] equals [A], the pH of the solution will have a value equal to the pKa. Therefore, at pH values less than the amine's pKa, the concentration of the protonated form of the amine will exceed the concentration of the unprotonated form of the amine. The aqueous associative thickener composition must contain sufficient organic or inorganic acid to reduce the pH of the aqueous associative thickener composition below the value of the pKa of the secondary or tertiary amine functionalities which comprise the thickener's hydrophobic groups thereby substantially protonating said secondary or tertiary amines. When the aqueous associative thickener composition is added to the aqueous system to be thickened, the final pH value of the thickened system should be higher than the pKa of the secondary or tertiary amine group to substantially deprotonate the protonated hydrophobic amine groups. A method to increase the viscosity of an aqueous polymer composition comprises combining an aqueous polymer system with an aqueous associative thickener composition, said associative thickener further comprising a plurality of hydrophobic groups wherein one or more of said hydrophobic groups comprises a secondary amine, or a tertiary amine, or a tertiary phosphine, or combination thereof, and optionally a quaternary amine, with the proviso that less than 80% of the total amine functionality is a quaternary amine, and where the aqueous associative thickener composition is provided at a pH below that of the pKa of the secondary amine, or tertiary amine, or tertiary phosphine, or combination thereof; followed by the addition of an amount of base sufficient to raise the pH of the aqueous polymer composition above the pKa of the secondary amine, or tertiary amine, or tertiary phosphine, or combination thereof, to substantially deprotonate the protonated secondary amine, or protonated tertiary amine, or protonated tertiary phosphine, or combination thereof. The hydrophobic amine or phosphine groups of the associative thickener comprising the thickened aqueous polymer composition are substantially deprotonated when the pH of the thickened aqueous polymer composition exceeds the pKa of the secondary amine, or tertiary amine, or tertiary phosphine, or combination thereof, of the associative thickener. The alternative “or” expression also encompasses the “and” combination and is used interchangeably.
The pKa value of the amine or phosphine functionalities in the hydrophobic groups can be experimentally determined by the following method. Disperse 25 gms of thickener solids homogeneously in approximately 975 gms of water and sufficient phosphoric acid to provide 1000 gms of aqueous thickener composition of 2.5% weight thickener solids at pH=4. A mechanical stirrer, a pH meter probe, and a Brookfield viscometer can be simultaneously mounted over the vessel to provide agitation, pH measurement and viscosity measurement of the aqueous composition. Temperature should be 25° C. The stirrer should be turned off while pH measurements and viscosity measurements are recorded. The pH of the aqueous composition is adjusted stepwise upwards with 10% aqueous ammonia until a maximum pH of about 10.5 is obtained. After each aliquot of ammonia is added, the composition is stirred for 5 minutes, and then pH and viscosity are measured. Viscosity in centipoise is measured at 60 rpm and spindle #3, although more viscous titrations may require 60 rpm or lesser speeds with spindle #4 to keep the viscometer readout on scale. The viscosity is plotted on a linear scale versus the pH on a linear scale. At low and high pH values, the viscosity of the aqueous composition is relatively independent of pH. At the intermediate pH values, the viscosity is more dependent upon pH. The viscosity value at the high pH end of titration curve where the viscosity starts to become relatively independent of pH is assigned as the maximum viscosity value. The point on the titration curve corresponding to half of the maximum viscosity value is defined as the midpoint of the titration. The pKa for the amine or phosphine functionalities comprising the hydrophobic groups of the associative thickener is defined as the pH value associated with the midpoint of the titration.
Aqueous associative thickeners for use in the compositions and methods described herein comprise a hydrophilic backbone comprising a plurality of hydrophobic groups attached to or within the backbone, wherein at least one of the hydrophobic groups comprises a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine; and wherein said hydrophobic group comprising the tertiary amine, or tertiary phosphine has a hydrocarbon radical bonded to the amine nitrogen atom or phosphine phosphorus atom, which hydrocarbon radical is pendant to the backbone and contains fewer than 10 carbon atoms.
The hydrophilic backbone of the associative thickener can take a variety of forms, for example, the backbone can be linear, branched, or crosslinked. A variety of different types of backbones can be used, for example a polyether such as a polyoxyalkylene, a polyacrylamide, a polymethacrylamide, a polysaccharide, a polyvinyl alcohol, a polyvinyl alkyl ether, or a polyvinyl pyrrolidone. The polyacrylamide and polymethacrylamide may collectively be referred to as poly(meth)acrylamide. In one embodiment, the hydrophilic backbone comprises a (co)polymer comprising esters of acrylic acid or esters of methacrylic acid. Again, acrylic acid and methacrylic acid may collectively be referred to as (meth)acrylic acid and the related esters may collectively be referred to as esters of (meth)acrylic acid, or as (meth)acrylates. Preferably, the backbone is non-ionic. Examples of suitable esters of (meth)acrylic acid include hydroxyethyl(meth)acrylate, that is, HEA or HEMA.
In one embodiment the backbone is a polysaccharide based on a cellulosic backbone, for example a hydroxy ethyl cellulose backbone. Thus, the associative thickener may have a backbone comprising one or more saccharide segments greater than 10 saccharide units in length.
In another embodiment, a polyether associative thickener is based on building blocks of polyoxyalkylene segments, for example polyethylene glycol building blocks. For example, the associative thickener may have a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length. As used herein, the term “oxyalkylene” refers to units having the structure —(O-A)-, wherein O-A represents the monomeric residue of the polymerization reaction product of a C2-8 alkylene oxides. Examples of oxyalkylenes include, but are not limited to: oxyethylene with the structure —(OCH2CH2)—; oxypropylene with the structure —(OCH(CH3)CH2)—; oxytrimethylene with the structure —(OCH2CH2CH2)—; and oxybutylene with the general structure —(OC4H8)—. Polymers containing these units are referred to as “polyoxyalkylenes.” The polyoxyalkylene units can be homopolymeric or copolymeric. Examples of homopolymers of polyoxyalkylenes include, but are not limited to polyoxyethylene, which contains units of oxyethylene; polyoxypropylene, which contains units of oxypropylene; polyoxytrimethylene, which contains units of oxytrimethylene; and polyoxybutylene, which contains units of oxybutylene. Examples of polyoxybutylene include a homopolymer containing units of 1,2-oxybutylene, —(OCH(C2H5)CH2)—; and polytetrahydrofuran, a homopolymer containing units of 1,4-oxybutylene, —(OCH2CH2CH2CH2)—.
Alternatively, the polyoxyalkylene segments can be copolymeric, containing two or more different oxyalkylene units. The different oxyalkylene units can be arranged randomly to form a random polyoxyalkylene; or can be arranged in blocks to form a block polyoxyalkylene. Block polyoxyalkylene polymers have two or more neighboring polymer blocks, wherein each of the neighboring polymer blocks contain different oxyalkylene units, and each polymer block contains at least two of the same oxyalkylene units. Oxyethylene is the preferred oxyalkylene segment.
In still another embodiment, polyoxyalkylene segments are linked with non-polyoxyalkylene segments or linkages. When the polyoxyalkylene units are linked with a multi-functional isocyanate, a hydrophobically modified polyurethane polyether associative thickener is generated as is known in the art. These thickeners can also contain urea linkages, ester linkages or ether linkages other than those linking the polyoxyalkylene units. The multi-functional isocyanates can be aliphatic, cycloaliphatic, or aromatic; and can be used singly or in admixture of two or more, including mixtures of isomers. Examples of suitable organic polyisocyanates include 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 2,2,4-trimethyl-1,6-diisocyanatohexane, 1,10-decamethylene diisocyanate, 4,4′-methylenebis-(isocyanatocyclohexane), 1,4-cyclohexylene diisocyanate, 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane, m- and p-phenylene diisocyanate, 2,6- and 2,4-toluene diisocyanate, xylene diisocyanate, 4-chloro-1,3-phenylene diisocyanate, 4,4′-biphenylene diisocyanate, 4,4′-methylene diphenylisocyanate, 1,5-naphthylene diisocyanate, 1,5-tetrahydronaphthylene diisocyanate, hexamethylene diisocyanate trimer, hexamethylene diisocyanate biuret, and triphenylmethane-4,4′,4″-triisocyanate.
When the polyoxyalkylene segments are linked with a gem-dihalide reagent, hydrophobically modified polyacetal polyether and polyketal polyether associative thickeners are generated. Suitable gem-dihalide reagents include dihalogenomethanes, such as dibromomethane and dichloromethane; 1,1-dichlorotoluene, 1,1-dichloroethane, and 1,1-dibromomethane. When the polyoxyalkylene units are linked with an aminoplast reagent, a hydrophobically modified polyaminoplast polyether associative thickener is generated. When polyoxyalkylene units are linked with an epihalohydrin or trihaloalkane reagent, a hydrophobically modified polyEPI polyether associative thickener is generated, where EPI represents the residue of an epihalohydrin reagent's or a trihaloalkane reagent's reaction with amines, alcohols, or mercaptans. Thus, the associative thickener may have a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length and one or more segments selected from (i) a urethane segment, (ii) a urea segment, (iii) an ester segment, (iv) an ether segment, (v) an acetal segment, (vi) a ketal segment, (vii) an aminoplast segment, (viii) a segment comprising the residue of the reaction of an epihalohydrin with an alcohol, an amine, or a mercaptan, and (ix) a segment comprising the residue of the reaction of a trihaloalkane with an alcohol, an amine, or a mercaptan, and (x) combinations of the foregoing.
At least one of the hydrophobic groups attached to or within the thickener backbone contains a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine, that modulates the water solubility of the hydrophobic group, depending on the pH of the aqueous composition containing the thickener. Optionally, one or more hydrophobic group may comprise a secondary amine.
In a preferred embodiment, the hydrophobic group comprises a tertiary amine or tertiary phosphine and has a hydrocarbon radical bonded to the amine nitrogen atom or phosphine phosphorus atom, which hydrocarbon radical is pendant to the backbone and contains fewer than 10 carbon atoms.
Herein, a secondary amine is defined as a nitrogen with bonds to only one hydrogen and two carbons, wherein neither of the two adjoining carbons are classified as carbonyls or thionyls. Carbonyls are carbons with a double bond to oxygen. Thus, nitrogen that can be classified as part of amide, urethane or urea groups are not secondary amines. Thionyls are carbons with a double bond to sulfur. The two carbons adjoining the nitrogen radical may have other atoms or groups of atoms, including hydrogen and carbon, bonded to them, with the proviso that at least one of the groups of atoms includes a covalent bond to the thickener backbone. The groups of atoms bonded to the two carbons adjoining the nitrogen radical may connect forming a heterocyclic nitrogen moiety. Optionally, the amine group may be oxidized to the corresponding amine oxide.
Herein, a tertiary amine is defined as a nitrogen with bonds to only two or three carbons wherein the adjoining carbon atoms are not classified as carbonyls or thionyls. Thus, nitrogen that can be classified as part of an amide, urethane or urea group is not a tertiary amine. The two or three carbons adjoining the nitrogen may have other atoms or groups of atoms, including hydrogen and carbon, bonded to them, with the proviso that at least one of the groups of atoms includes a covalent bond to the thickener backbone. The groups of atoms bonded to the two or three carbons adjoining the nitrogen may connect forming a heterocyclic nitrogen moiety. Optionally, the amine group may be oxidized to the corresponding amine oxide.
A quaternary amine is defined as a nitrogen with bonds to four carbons.
Herein a tertiary phosphine is defined as any of several organic compounds having the structure of a tertiary amine as described above, but with phosphorus in place of nitrogen.
The associative mechanism requires a plurality of (i.e., two or more) hydrophobic groups on each hydrophilic backbone to participate in the network structure responsible for viscosity generation. It has been found that the presence of only a single tertiary amine, or tertiary phosphine, in the associative thickener is sufficient to decrease the thickening efficiency of the thickener at low pH. However, in one embodiment, at least 2, in another embodiment at least 3, and yet another embodiment at least 5 of the hydrophobic groups which comprise tertiary amines, or tertiary phosphines are present per thickener molecule. By “attached to or within the backbone” of the thickener, we mean these hydrophobic groups may be located within the backbone, pendant to the backbone and/or on chain termini. The term “hydrophobic group” means a group chosen from radicals and polymeric groups comprising at least one hydrocarbon-based chain chosen from linear and branched, saturated and unsaturated hydrocarbon-based chains, which optionally comprise one or more hetero atom, such as P, O, N and S, and radicals comprising at least one chain chosen from perfluoro and silicone chains. In one embodiment, when the term “hydrophobic group” means a group chosen from the hydrocarbon radicals, the hydrophobic group comprises at least 6 carbon atoms, preferably 10-24 carbon atoms. In another embodiment, when the term “hydrophobic group” means a group chosen from the hydrocarbon radicals, the hydrophobic group comprises fewer than 6 carbon atoms.
In the aqueous thickener composition, at least 10%, specifically at least 25%, more specifically at least 50%, and even more specifically at least 80% of the hydrophobic groups have one or more of a secondary amine or a tertiary amine, or a tertiary phosphine functionality.
Examples of reagents that can be used to generate hydrophobic groups comprising at least one secondary amine functionality include N-octylethylenediamine, N-dodecylethylene-diamine, N-octylaminoethanol, N-dodecylaminoethanol, and 2-(2,2,6,6-tetramethyl-4-piperidinyl)ethanol. Alternative routes to generate hydrophobic groups comprising at least one secondary amine functionality include the reaction of primary amines, such as octylamine, decylamine, and iso-tridecylamine, with an alkylhalide, epoxide, or aminoplast reagent.
Examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include 2-(dibutylamino)ethanol, 2-(dioctylamino)ethanol, 2-(diheptylamino)ethanol, 2-(dihexylamino)ethanol, 2-(diethylhexylamino)ethanol, 2-(dicocoamino)ethanol, 3-dibutylamino propylamine, N-benzyl, N-methyl ethanolamine, 1-(dibutylamino)-2-butanol, 2-amino-5-diethylaminopentane, 1-(bis(3-(dimethylamino)-propyl)amino)-2-propanol, N-benzyl 3-hydroxypiperidine, diphenylmethyl piperazine, 1-(1-alkylpiperazine), 1-(1-arylpiperazine), 1-(2-Aminoethyl)-4-benzyl-piperazine, 4-amino-1-benzyl-piperidine, 6-dipropylamino-1-hexanol, 1-dodecylisonipecotamide. Alkoxylated analogs of the di-alkylamino ethanol compounds are also suitable reagents. For example, 2-(dihexylamino)ethanol ethoxylated with 1 to 100 units of ethylene oxide are suitable reagents.
In an embodiment, the associative thickener has a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length and is a hydrophobically modified polyurethane polyether comprising the reaction product of a dialkylamino alkanol with a multi-functional isocyanate, a polyether diol, and optionally a polyether triol. Preferably, the polyether diol has a weight average molecular weight between 2,000 and 12,000, preferably between 6,000 and 10,000.
Alternative routes to generate hydrophobic groups comprising at least one tertiary amine functionality include the reaction of secondary amines with an alkylhalide, epoxide, or aminoplast reagent, where the alkyl groups on the secondary amine are C1 or higher, such as dimethylamine, diethylamine, dipropylamine, diisopropylamine, dibutylamine, diamylamine, dihexylamine, diheptylamine, dioctylamine, dibenzylamine, dicyclohexylamine, bis(2-ethylhexyl)amine, and higher homologues and where the alkyl groups of the secondary amine may be the same or different. These reagents would be used to provide hydrophobic groups on the ends of polymer chains. For example, these secondary amines can be reacted with alkylene oxides, such as ethylene oxide, propylene oxide, butylene oxide, higher homologues, and combinations thereof, to afford the corresponding amino alcohols that result from the ring opening of the alkylene oxide with the secondary amine providing compounds with the general formula,
wherein —(OA)- represents the oxyalkylene units described earlier; each of R1 and R2 are alkyl groups comprising one or more carbon atoms, which alkyl groups may be the same or different; and integer x is from 1 to 100.
Further examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include the corresponding amine oxides of the above, for example, 2-(dibutylamino)ethanol N-oxide, 2-(dioctylamino)ethanol N-oxide, and N-benzyl 3-hydroxypiperidine N-oxide.
Further examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include the amino alcohols derived from the reaction of secondary amines with glycidyl ether compounds, the amino alcohols having the general formula
wherein R1, R2, and R3 are alkyl groups comprising one or more carbon atoms, which alkyl groups may be the same or different. Representative alkyl groups for R1 and R2 include methyl, ethyl, isopropyl, butyl, amyl, hexyl, octyl, 2-ethylhexyl, decyl, benzyl, and cyclohexyl. Representative alkyl groups for R3 include allyl, methyl, butyl, isobutyl, tertiary-butyl, pentyl, hexyl, heptyl, 2-ethylhexyl, benzyl, decyl, undecyl, trityl, dodecyl, tridecyl, hexadecyl, phenyl, methylphenyl, alkylphenyl, furfuryl, and naphthyl.
Examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality where the nitrogen has bonds to two carbons only include pyridine derivatives, such as alkyl- or aryl-substituted hydroxypyridine derivatives, alkyl- or aryl-substituted aminopyridine derivatives, quinoline derivatives, such as hydroxyquinoline, aminoquinoline, 8-ethyl-4-quinolinol, and 6-amino-1,10-phenanthroline, pyrazole and pyrazoline derivatives, such as, 3-amino-5-phenylpyrazole and 5-aminoindazole, imidazole derivatives, such as 2-benzimidazole methanol, 2-butyl-4-hydroxymethylimidazole, and 2-mercapto-1-hexylimidazole, oxazole derivatives, such as, oxazol-2-yl-phenylmethanol, 2-amino-5-ethyl-4-phenyloxazole, 4-(5-methyl-1,3-benzoxazol-2-yl)phenylamine, and imine derivatives, such as alpha-(2-butylimino)-p-cresol, N-(benzylidene)ethanolamine, and 1-((2-hydroxyethyl)iminomethyl)naphthalene. Additional examples of suitable reagents are the corresponding amine oxides of any of the above compounds.
Further examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include the class of diols with the general formula
wherein —(OA)- represents the oxyalkylene units described earlier; R4 is a hydrophobic group containing at least 10 carbon atoms; and integers x and y are each at least 1, and the sum (x+y) is from 2 to about 100. The R4 group can be either linear or branched, saturated or unsaturated and aliphatic or aromatic in nature. Representative diols are available under the name Ethomeen™ from Akzo Nobel Chemicals B.V. (Amersfoort, Netherlands). Illustrative examples include bis(2-hydroxyethyl)cocoamine, bis(2-hydroxyethyl)cetylamine, bis(2-hydroxyethyl)stearyl-amine, bis(2-hydroxyethyl)tallowamine, bis(2-hydroxyethyl)soyaamine, bis(2-hydroxyethyl)isodecyloxypropylamine, bis(2-hydroxyethyl)isotridecyloxypropylamine, bis(2-hydroxyethyl) linear alkyloxypropylamine, and their alkoxylates. Other representative diols include bis(hydroxyethyl)decylamine, and bis(hydroxyethyl)dodecylamine. Additionally, any of the corresponding amine oxides of the above materials can be used. These reagents would be used to provide hydrophobic groups located within and pendant to the polymer chain.
Further examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include the class of diols derived from the reaction of secondary amines with glycidol to afford the corresponding 1,2-propanediol compounds. Representative examples include 3-(diethylamino)-1,2-propanediol, 3-(diisopropylamino)-1,2-propanediol, 3-(dibutylamino)-1,2-propanediol, 3-(diamylamino)-1,2-propanediol, 3-(dihexylamino)-1,2-propanediol, 3-(dioctylamino)-1,2-propanediol, 3-[bis(2-ethylhexyl)amino]-1,2-propanediol, 3-(dibenzylamino)-1,2-propanediol, and 3-(dicyclohexylamino)-1,2-propanediol.
Moreover, and surprisingly, it has been found that some hydrophilic small molecules with tertiary amine functionality can be used to link the diisocyanates to build up the hydrophobic groups within the HEUR backbone. Neither the diisocyanate itself nor those hydrophilic small molecules are hydrophobic enough to act as the hydrophobe for a thickener. However, the combined structure, formed by linking two or more diisocyanate units together with hydrophilic small molecules, is hydrophobic enough to provide the hydrophobes for HEUR thickeners. Since the hydrophilic small molecules do not contribute substantial hydrophobicity, the hydrophobicity of the diisocyanate is very important in this embodiment, the more hydrophobic diisocyanate being favored; for example, 4,4′-methylene bis(cyclohexyl isocyanate) (HMDI) is more hydrophobic than isophorone diisocyanate (IPDI), which is more hydrophobic than hexamethylene diisocyanate (HDI). The tertiary amine functionality on the hydrophilic small molecule can make the resulting hydrophobic group acid-suppressible, thereby allowing the thickener to be supplied with low as-is viscosity at low PH. This type of hydrophilic molecule should have two isocyanate-reactive groups (hydroxy, amine, or others) as well as at least one tertiary amine functionality. Examples of the hydrophilic small molecule having two isocyanate-reactive groups as well as at least one tertiary amine functionality include, for example, N-butyl diethanolamine, N-methyl diethanolamine, dimethylamino glycol, 3-(dimethylamino)-1,2-propanediol, 1-(2-hydroxy-ethyl)-piperazine (HEPZ), 1-(2-aminoethyl)-piperazine (AEPZ), and their homologues.
Accordingly, in one embodiment, examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include the class of diols with the general formula
wherein —(OA)- represents the oxyalkylene units described earlier; R4 is a hydrophobic group containing fewer than 10 carbon atoms; and integers x and y are each at least 1, and the sum (x+y) is from 2 to about 100. In another embodiment, R4 is a hydrophobic group containing fewer than 6 carbon atoms; and integers x and y are each at least 1, and the sum (x+y) is from 2 to about 100. In both cases, the R4 group can be either linear or branched, saturated or unsaturated and aliphatic or aromatic in nature.
Representative examples include alkoxylates of primary amines, where the alkoxylating agents include ethylene oxide, propylene oxide, butylene oxide and higher homologues, and where the primary amines include methylamine, ethylamine, propylamine, butylamine, pentylamine, hexylamine, heptylamine, octylamine, nonylamine, decylamine, and their isomers.
In a preferred embodiment, the associative thickener has a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length and is a hydrophobically modified polyurethane polyether comprising the reaction product of one or more alkyldialkanolamine with one or more multi-functional isocyanate, one or more polyether diol, and optionally one or more polyether triol. Preferably, the polyether diol has a weight average molecular weight between 2,000 and 12,000, preferably between 6,000 and 10,000. In one such embodiment, the alkyl group of the alkyldialkanolamine is a hydrocarbon radical containing fewer than 10 carbon atoms.
In another preferred embodiment, the associative thickener has a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length and is a hydrophobically modified polyurethane polyether comprising the reaction product of one or more alkyldialkanolamine and one or more dialkylamino alkanol with one or more multi-functional isocyanate, one or more polyether diol, and optionally one or more polyether triol. Preferably, the polyether diol has a weight average molecular weight between 2,000 and 12,000, preferably between 6,000 and 10,000. In one such embodiment, the alkyl group of the alkyldialkanolamine is a hydrocarbon radical containing fewer than 10 carbon atoms.
Thus, a preferred method to increase the viscosity of an aqueous polymer system comprises: (a) combining the aqueous polymer system with an aqueous thickener composition, wherein the aqueous thickener composition comprises: (i) 1% to 60% by weight of an associative thickener having a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length, said associative thickener further comprising a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine, with the proviso that less than 80% of the total amine functionality is a quaternary amine; and wherein said hydrophobic group comprising the tertiary amine, or tertiary phosphine has a hydrocarbon radical bonded to the amine nitrogen atom or phosphine phosphorus atom, which hydrocarbon radical is pendant to the backbone and contains fewer than 10 carbon atoms; and wherein the associative thickener is a hydrophobically modified polyurethane polyether comprising the reaction product of a dialkylamino alkanol, or an alkyldialkanolamine, or combination thereof, with a multi-functional isocyanate, a polyether diol having a weight average molecular weight between 2,000 and 12,000, preferably between 6,000 and 10,000, and optionally a polyether triol; (ii) sufficient acid to substantially protonate the tertiary amine, or the tertiary phosphine, or combination thereof; (iii) 40% to 99% by weight of water; and (iv) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof, as a viscosity-suppressing additive; and (b) adding an amount of a base sufficient to substantially deprotonate the protonated tertiary amine, or protonated tertiary phosphine, or combination thereof. In one such embodiment, the alkyl group of the alkyldialkanolamine is a hydrocarbon radical containing fewer than 10 carbon atoms.
Hydrophilic small molecules having more than two isocyanate-reactive groups as well as at least one tertiary amine functionality are also possible and can function to connect three or more isocyanate molecules (such as HMDI) to form one or more hydrophobic groups, and these hydrophilic small molecules include, for example, triethanolamine, tris(2-aminoethyl)amine, and their homologues.
Further examples of reagents that can be used to generate hydrophobic groups comprising at least one secondary and/or tertiary amine functionality include the class of diols prepared via the reaction of primary amines and/or secondary amines with mono- or di-glycidyl ether derivatives or other mono- or di-epoxy derivatives. Examples of suitable epoxy compounds include the mono- or di-glycidyl ethers of various diols, such as ethylene glycol, propylene glycol, polyethylene glycol, polypropylene glycol, 1,4-butanediol, 1,6-hexanediol, bisphenol A, bisphenol F, and cyclohexanedimethanol. Examples of suitable amines include hexylamine, octylamine, decylamine, dodecylamine, 3-octylamine, 1-isotridecylamine, diisopropylamine, dibutylamine, diamylamine, dicyclohexylamine, dihexylamine, dioctylamine, bis(2-ethylhexyl)amine, dibenzylamine, diphenylamine, and alkylaniline. For example, the reaction of 2 moles of dioctylamine with 1 mole of poly(ethylene glycol) diglycidyl ether affords the corresponding epoxy-amine adduct diol, bis[3-(dioctylamino)-2-hydroxypropyl]ether of poly(ethylene glycol). Further, the reaction of 1 mole of octylamine with 2 moles of butyl glycidyl ether affords the corresponding epoxy-amine adduct diol.
Thus, the associative thickener may have a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length and is a hydrophobically modified polyurethane polyether comprising the reaction product of an epoxy-amine adduct with a multi-functional isocyanate, and a polyether diol, said epoxy-amine adduct derived from the reaction of one or more primary amine with mono- or di-glycidyl ether derivatives or other mono- or di-epoxy derivatives, wherein the primary amine contains fewer than 10 carbon atoms. Preferably, the polyether diol has a weight average molecular weight between 2,000 and 12,000, preferably between 6,000 and 10,000.
Correspondingly, a preferred method to increase the viscosity of an aqueous polymer system comprises: (a) combining the aqueous polymer system with an aqueous thickener composition, wherein the aqueous thickener composition comprises: (i) 1% to 60% by weight of an associative thickener having a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length, said associative thickener further comprising a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine, with the proviso that less than 80% of the total amine functionality is a quaternary amine; and wherein said hydrophobic group comprising the tertiary amine, or tertiary phosphine has a hydrocarbon radical bonded to the amine nitrogen atom or phosphine phosphorus atom, which hydrocarbon radical is pendant to the backbone and contains fewer than 10 carbon atoms; and wherein the associative thickener is a hydrophobically modified polyurethane polyether comprising the reaction product of an epoxy-amine adduct with a multi-functional isocyanate, and a polyether diol having a weight average molecular weight between 2,000 and 12,000, preferably between 6,000 and 10,000, said epoxy-amine adduct derived from the reaction of one or more primary amine with mono- or di-glycidyl ether derivatives or other mono- or di-epoxy derivatives, wherein the primary amine contains fewer than 10 carbon atoms; (ii) sufficient acid to substantially protonate the tertiary amine, or the tertiary phosphine, or combination thereof; (iii) 40% to 99% by weight of water; and (iv) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof, as a viscosity-suppressing additive; and (b) adding an amount of a base sufficient to substantially deprotonate the protonated tertiary amine, or protonated tertiary phosphine, or combination thereof.
Further examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include the reaction products of an N-alkyl trimethylene diamine and an oxyalkylene, such as ethylene oxide, which are available under the name Ethoduomeen™ from Akzo Nobel Chemicals B.V.
Examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary phosphine functionality include 2-(dialkylphosphino)ethylamines, 3-(dialkylphosphino)propylamines, dialkylhydroxymethylphosphines, dialkylhydroxyethyl-phosphines, bis-(hydroxymethyl)alkylphosphines, bis-(hydroxyethyl)alkylphosphines, and the like. Specific examples include, 2-(diphenylphosphino)ethylamine, 3-(diphenylphosphino)-propylamine, 2-(dihexylphosphino)ethylamine, 2-(dioctylphosphino)-ethylamine, bis-(hydroxy-methyl)hexylphosphine, bis-(hydroxymethyl)octylphospine, and phosphine analogs of the above-described amines. For example, these reagents can be incorporated into polyurethane based associative thickeners.
Other examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary phosphine functionality include dialkylphosphines, such as dihexyl-phosphine, dioctylphosphine, dibenzylphosphine, diphenylphosphine, bis-(dodecyl)phosphine, and phosphine analogs of the above-described amines. For example, these reagents can be incorporated into associative thickener compositions via reaction with epoxy or alkyl halide functionality or via addition to double bonds.
Not all of the hydrophobic groups in the associative thickener are required to comprise secondary amines or tertiary amines or tertiary phosphines. Examples of reagents that can be used to form the hydrophobic groups not comprising secondary amines or tertiary amines or tertiary phosphines include branched or linear aliphatic alcohols, alkylaryl alcohols, aliphatic amines and p-alkylene glycol mono-alkyl ethers. Reagents may be mono-functional or multi-functional. Examples of suitable branched aliphatic alcohols include 2-butyl 1-octanol, 2-butyl 1-decanol, 2-hexyl 1-octanol, 2-hexyl 1-decanol, isononyl alcohol, isodecyl alcohol, and isoundecyl alcohol. Examples of suitable linear aliphatic alcohols include 1-hexadecanol, 1-tetradecanol, 1-dodecanol, 1-undecanol, 1-decanol, 1-nonanol, 1-octanol, 1-hexanol, 1,2-hexadecanediol, and 1,16-hexadecanediol. Examples of suitable alkyl aryl alcohols include nonyl phenol and tri-styryl phenol. Examples of suitable aliphatic amines include 1-decyl amine, 1-octyl amine, 1-hexyl amine, di-octyl amine, di-hexyl amine. Examples of suitable p-alkylene glycol mono-alkyl ethers include alkyl ethoxylates where the alkyl group ranges from 1 carbon to 24 carbons.
Organic or inorganic acids can be used for protonating the amine functionality in the associative thickener. Suitable acids include, for example, phosphoric acid, acetic acid, hydrochloric acid, sulfuric acid, citric acid, lactic acid, carbonic acid, ascorbic acid, glycolic acid, isoscorbic acid, adipic acid, succinic acid, oxalic acid, homopolymers and copolymers of acrylic acid, homopolymers and copolymers of methacrylic acid, homopolymers and copolymers of maleic anhydride, homopolymers and copolymers of styrenesulphonate, homopolymers and copolymers of 2-acrylamido-2-methylpropane sulfonic acid, polyphosphoric acid, homopolymers and copolymers of phosphoethylmethacrylate, alpha hydroxy acids and trans-cinnamic acid. Phosphoric acid, lactic acid, and polyacrylic acid with a molecular weight between 1000 and 5000 are preferred.
The thickener and acid are combined to provide an aqueous thickener composition. As used herein, the term “aqueous thickener composition” (or “aqueous thickener polymer composition” or “aqueous associative thickener composition”) refers to a composition that is provided predominantly in water rather than organic solvent, although a minor amount of a water-miscible organic solvent can be present. Preferably the aqueous thickener composition comprises less than 5 weight % water miscible solvent, more preferably less than 2 weight % water miscible solvent, and most preferably, less than 1 weight % water miscible solvent, based on the weight of the aqueous thickener composition. In one embodiment, no organic solvent is present in the aqueous thickener composition.
The aqueous thickener composition can further comprise other optional additives useful to decrease the viscosity of the composition. The embodiment is especially useful where the amine or phosphine functionalities are not completely protonated, that is, where it is desired to adjust the pH of the composition to be in the higher end of the pH range of 2.5 to 6. Suitable viscosity suppressing additives include, for example, surfactants such as dialkylsulfosuccinates, sodium lauryl sulfate, alkyl ethoxylates and alkylarylethoxylates; cyclodextrin compounds such as cyclodextrin (which includes α-cyclodextrin, β-cyclodextrin, and γ-cyclodextrin), cyclodextrin derivatives, cycloinulohexose, cycloinuloheptose, cycloinulo-octose, calyxarene, and cavitand. “Cyclodextrin derivatives” refer to α-cyclodextrins, β-cyclodextrins, and γ-cyclodextrins in which at least one hydroxyl group located on the rim of the cyclodextrin ring has been functionalized with a substituent group such as methyl, acetyl, hydroxypropyl, hydroxyethyl group. Cyclodextrin derivatives also include cyclodextrin molecules with multiple substituent groups including cyclodextrin molecules with more than one type of substituent group. Cyclodextrin derivatives do not include polymers with more than one attached cyclodextrin ring. Preferred cyclodextrin derivatives are methyl-β-cyclodextrin and hydroxypropyl-β-cyclodextrin, in particular methyl-β-cyclodextrin. Since surfactants degrade the effectiveness of the cyclodextrin compound in reducing viscosity, it is preferred that surfactants not be employed when a cyclodextrin compound is added to the aqueous thickener polymer composition.
In an embodiment for the preparation of the aqueous thickener composition, the associative thickener of the types described above is first dissolved or dispersed in water with no added acid; sufficient acid is then added such that the amount of acid is sufficient to adjust the pH of the aqueous thickener composition to a pH of 2.5 to 6. In another embodiment, the acid or some portion of the total acid is first pre-mixed with water, then the associative thickener polymer is subsequently dissolved or dispersed with stirring or agitation into the acid and water mixture, and if necessary, additional acid is added. Other additives, e.g., water miscible organic solvents or cyclodextrin compounds can be incorporated into the compositions at any point.
In an advantageous feature, the aqueous associative thickener compositions may be pourable at 25° C. The composition can have a viscosity of 500 cps to 15,000 cps, specifically less than 10,000 cps, even more specifically less than 5,000 cps. In a specific embodiment, the compositions are pourable without addition of any organic solvent and/or other viscosity-reducing additive, e.g., a cyclodextrin compound.
In still another advantageous feature, the aqueous associative thickener compositions can be formulated to contain a wide range of solids content. For example, the aqueous associative thickener composition can comprise 1 weight % to 60 weight % thickener solids, specifically 5 weight % to 40 weight % thickener solids, even more specifically 15 weight % to 25 weight % thickener solids, based on the total weight of the aqueous associative thickener compositions. The compositions further comprise 40 weight % to 99 weight % aqueous solution, specifically 60 weight % to 95 weight % aqueous solution, even more specifically 75 weight % to 85 weight % aqueous solution, based on the total weight of the aqueous associative thickener compositions. As stated above, the “aqueous solution” can comprise up to 5 weight percent of a water-miscible organic solvent. The optional additives used to further decrease the viscosity of the composition can be present in an amount of 0 weight % to 15 weight %, specifically 1 weight % to 10 weight %, even more specifically 1 weight % to 3 weight %, based on the total weight of the aqueous associative thickener compositions.
Mixing techniques to incorporate the aqueous associative thickener in the aqueous composition to be thickened include conventional mixing equipment such as mechanical lab stirrers, high speed dispersers, ball mills, sand mills, pebble mills, and paddle mixers. The aqueous associative thickener composition can be incorporated into aqueous polymer compositions in amounts from 0.005 weight % to 20 weight %, preferably from 0.01 weight % to 10 weight %, and most preferably from 0.05 weight % to 5 weight %, based on the weight of the aqueous composition.
Typical aqueous polymer systems in which the aqueous associative thickener compositions are added include paints, such as latex paints; dispersed pigment grinds; coatings, including decorative and protective coatings; wood stains; cosmetics, personal care items such as, for example, shampoos, hair conditioners, hand lotions, hand creams, astringents, depilatories, and antiperspirants; adhesives; sealants; inks; cementitious coatings; joint compounds and other construction materials; drilling fluids; topical pharmaceuticals; cleaners; fabric softeners; pesticidal and agricultural compositions; paper or paperboard coating formulations; textile formulations; and non-woven formulations.
In one embodiment, the aqueous polymer system to be thickened is a latex composition. A latex composition contains discrete polymer particles dispersed in an aqueous medium. Examples of such latex compositions include latex emulsion polymers, including but not limited to polymers that comprise (meth)acrylates, styrene, vinyl actetate or other ethylenically unsaturated monomers; latex paints; pre-blend formulations for paints or coatings; textile formulations; non-woven formulations; leather coatings; paper or paperboard coating formulations; and adhesives.
In another embodiment, the aqueous associative thickener polymer composition may be supplied at the lower pH, such that the amine or phosphine groups are protonated as described above, together with a latex emulsion polymer or other aqueous polymer system. The pH may be raised in a further formulating step, which may include, for example, the addition of an amount of base sufficient to substantially deprotonate the protonated amine or phosphine groups of the aqueous associative thickener polymer, and thereby effect an increase in viscosity. Thus, advantageously, a latex emulsion polymer is supplied together with the latent thickener, which is later formulated into an aqueous paint composition providing the desired increase in viscosity during formulation of the paint.
Optionally, the aqueous polymer compositions may comprise other components, such as pigments, fillers, and extenders such as, for example, titanium dioxide, barium sulfate, calcium carbonate, clays, mica, talc, and silica; surfactants; salts; buffers; pH adjustment agents such as bases and acids; biocides; mildewcides; wetting agents; defoamers; dispersants; pigments; dyes; colorants; water miscible organic solvents; anti-freeze agents; corrosion inhibitors; adhesion promoters; waxes; crosslinking agents; and other formulation additives known in the art.
The following examples are presented to illustrate the process and the composition of the invention. These examples are intended to aid those skilled in the art in understanding the present invention. The present invention is, however, in no way limited thereby.
The following abbreviations are used in the examples:
HMDI 4,4′-Methylene bis(cyclohexyl isocyanate)
IPDI Isophorone diisocyanate
HDI Hexamethylene diisocyanate
PEG polyethylene glycol
HEUR Hydrophobically modified ethylene oxide urethane polymer
SEC size exclusion chromatography
HPLC high pressure liquid chromatography
Mw weight average molecular weight
Mn number average molecular weight
The weight average molecular weights (Mw) of the associative thickeners were determined using size exclusion chromatography (SEC). The separations were carried out at room temperature on a liquid chromatograph consisting of an Agilent 1100 Model isocratic pump and autoinjector (Waldbronn, Germany), and a Polymer Laboratories ELS-1000 Model evaporative light scattering detector (Polymer Laboratories, International, Ltd., Church Stretton, UK). The detector was operated with a 140° C. nebulizer, a 180° C. evaporator, and a 1.5 liter2/minute gas flow rate. System control, data acquisition, and data processing were performed using version 3.0 of Cirrus® software (Polymer Laboratories, Church Stretton, UK). Samples were prepared in N,N-dimethylacetamide (DMAc, HPLC grade) at concentrations of 2 milligram/milliliter (mg/ml), shaken for 6 hours at 80° C., and filtered using 0.45 micron polytetrafluoroethylene (PTFE) filter. The SEC separations were performed in DMAc (HPLC grade) at 0.5 milliliter/minute (ml/min) using a SEC column set comprised of three PLgel™ columns (300×7.5 mm ID) packed with polystyrene-divinylbenzene gel (pore size marked as 100 Å, 103 Å and 104 Å, particle size 5 microns) purchased from Polymer Laboratories (Church Stretton, UK). The injection volume was 100 microliters (ul) of sample solution at a concentration of 2 mg/ml. The molar mass characteristics of the analyzed samples were calculated based on polyethylene glycol/oxide (PEG/PEO) standards also purchased from Polymer Laboratories (Church Stretton, UK).
A mixture of 200.0 g PEG (molecular weight 8000) and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 8.8 g HMDI and 0.2 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 3.4 g n-decanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after toluene evaporation. Mw was measured as 40,000.
A mixture of 200.0 g PEG (molecular weight 8000) and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 8.8 g HMDI and 0.2 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 3.1 g 1-decylamine was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 41,000.
A mixture of 200.0 g PEG (molecular weight 8000) and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 8.8 g HMDI and 0.2 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 4.7 g dioctylamine was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 41,000.
A mixture of 35.0 g PEG (molecular weight 8000) and 60.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 1.5 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 1.0 g di-n-octylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 41,000.
A mixture of 216 g PEG (molecular weight 8000) and 22.4 g Ethomeen™ 18/25 was heated to 115° C. under vacuum in a batch melt reactor for 2 hours. Ethomeen™ 18/25 is a bis(2-hydroxethyl)stearylamine with 25 total units of ethylene oxide. The mixture was cooled to 105° C., and 9.1 g IPDI and 0.5 g bismuth octoate solution (28%) were added. The mixture was then held at 105° C. with stirring for 20 min. The resulting molten polymer was removed from the reactor and cooled. Mw was measured as 21,000.
A mixture of 50.0 g PEG (molecular weight 8000) and 80.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 2.2 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 1.4 g di-2-ethylhexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 47,000.
A mixture of 50.0 g PEG (molecular weight 8000) and 100.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 5.0 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 7.7 g di-2-ethylhexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 14,000.
A mixture of 50.0 g PEG (molecular weight 8000) and 100.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 5.0 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 3.85 g di-2-ethylhexylaminoethanol and 3.1 g of di-hexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 43,000.
A mixture of 50.0 g PEG (molecular weight 8000) and 100.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 5.0 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 6.7 g di-2-ethylhexylaminoethanol and 0.4 g of hexanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 13,000.
A mixture of 50.0 g PEG (molecular weight 8000) and 100.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 5.0 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 6.2 g of di-hexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 36,000.
A mixture of 50.0 g PEG (molecular weight 8000) and 80.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 1.4 g HDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 1.4 g di-2-ethylhexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 35,000.
A mixture of 50.0 g PEG (molecular weight 8000) and 80.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 1.9 g IPDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 1.4 g di-2-ethylhexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 48,000.
A mixture of 52.8 g di-hexylamine and 74.9 g PEG-diglycidyl ether (Mn=526) was stirred under a nitrogen atmosphere for 4 hours at 80° C. followed by another 2 hours of stirring at 100° C. Nuclear magnetic resonance analysis of the resulting reactor contents showed approximately 94 weight % purity of the desired epoxy-amine adduct product, bis[3-(dihexylamino)-2-hydroxypropyl]ether of poly(ethylene glycol), resulting from the ring opening reaction of the oxiranes by the amine. A mixture of 150.1 g PEG (molecular weight 8000), 16.1 g epoxy-amine adduct described above, and 340.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 7.4 g HMDI and 0.2 g dibutyltin dilaurate were added. The mixture was then held at 90° C. with stirring for another 3 hours. The resulting solid polymer was isolated after precipitation with hexanes.
A mixture of 50.0 g PEG (molecular weight 8000) and 100.0 g toluene is dried by azeotropic distillation. The mixture is cooled to 90° C., and 5.0 g HMDI and 0.1 g dibutyltin dilaurate added. After 1 hour at 90° C. with stirring, 6.2 g 2-(diphenylphosphino)ethylamine is added. The mixture is then held at 90° C. with stirring for another hour. The resulting solid polymer is isolated after precipitation with hexanes.
Dispersions of thickener in water were produced by weighing solid dry polymer and water into 50 milliliter (mL) plastic centrifuge tubes. In some cases, glacial acetic acid was also added. The tubes were capped and mounted on a rotator for continuous tumbling over 48 hours. For each example, the highest pH sample was obtained by adding only water and solid dry polymer to the centrifuge tube. The pH value in the samples with added acetic acid varies depending upon how much acetic acid was added. Once homogeneous, the samples were equilibrated in a 25° C. water bath just prior to measuring pH and viscosity on a Brookfield DV-II+LV viscometer. Aqueous sample pH values were measured on a Corning pH Meter Model 430 (Corning Incorporated, Corning, N.Y., USA). The pH meter was calibrated with pH=7.0 and pH=4.0 buffer solutions from Fisher Scientific (Fair Lawn, N.J., USA).
In the following examples and comparative examples, the objective is to provide the thickener solution at low viscosity so that formulators can add it easily while maintaining a practical active solids concentration. That is, without excessive dilution.
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener do not comprise a secondary or tertiary amine functionality. The diisocyanate linker's reaction with the hydroxyl functionality on the decanol results in a urethane residue. At 20% thickener solids, the viscosity is too high to measure (at any pH). As shown in Table 1, the aqueous thickener solution viscosity does not decrease as solution pH is reduced with acid.
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener do not comprise a secondary or tertiary amine functionality. The diisocyanate linker's reaction with the amine functionality on the decylamine results in a urea residue. At 20% thickener solids, the viscosity is too high to measure (at any pH). As shown in Table 2, the aqueous thickener solution viscosity does not decrease as solution pH is reduced with acid. Thus, in this case, lowering the pH does result in a large viscosity change, but it is in the wrong direction.
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener do not comprise an amine functionality. The diisocyanate linker's reaction with the amine functionality on the dioctylamine results in a urea residue. At 20% thickener solids, the viscosity is too high to measure (at any pH). As shown in Table 3, the aqueous thickener solution viscosity does not decrease as solution pH is reduced with acid. Lowering the pH does result in a large viscosity change, but, again, it is in the wrong direction.
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener comprise a tertiary amine functionality. The diisocyanate linker's reaction with the hydroxyl functionality on the 2-(dioctylamino)-ethanol results in a urethane residue. This thickener is an example of the hydrophobic groups comprising tertiary or secondary amine functionality being located at the ends of backbone chains. The tertiary amine functionality is protonated as solution pH is reduced with added acid, in this case acetic acid. As shown in Table 4, aqueous thickener solution viscosity is suppressed at lower pH values.
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener comprise a tertiary amine functionality. The diisocyanate linker's reaction with the two hydroxyl functionalities on the Ethomeen™ 18/25 results in urethane residues. This thickener is an example of the hydrophobic groups comprising the tertiary or secondary amine functionality being located pendant to the backbone chain. The tertiary amine functionality is protonated as solution pH is reduced with added acid. As shown in Table 5, aqueous thickener solution viscosity is suppressed at lower pH values.
The hydrophobic groups in these hydrophobically modified polyurethane polyether associative thickeners comprise a tertiary amine functionality. The diisocyanate linker's reaction with the hydroxyl functionality on the 2-(diethylhexylamino)-ethanol results in a urethane residue. These thickeners are examples of the hydrophobic groups comprising the tertiary or secondary amine functionality being located at the ends of backbone chains. Samples were made at 20% thickener concentration, with and without added acetic acid. The samples containing either 20% Thickener Example 3 and no added acid or 20% Thickener Example 4 and no added acid were gel-like solids. Thus, the no added acid sample viscosities were too high to reliably measure pH or viscosity. The samples containing acetic acid were low enough in viscosity to measure viscosity and pH reliably. An active thickener concentration of 20% is a typical solids level in commercial pourable aqueous thickener compositions. Data are shown in Table 6.
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener comprise two different tertiary amine functionalities. The diisocyanate linker's reaction with the hydroxyl functionality on the 2-(diethylhexylamino)-ethanol and the 2-(dihexylamino)-ethanol results in urethane residues. Samples were made at 20% thickener concentration, with and without added acetic acid. The sample containing 20% Thickener Example 5 and no added acid was a gel-like solid. Thus, the no added acid sample viscosity was too high to reliably measure pH or viscosity. The sample containing acetic acid was low enough in viscosity to measure viscosity and pH reliably. Data are shown in Table 7.
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener comprise a tertiary amine functionality and a linear alkyl chain. Samples were made at 18% thickener concentration, with and without added Acumer™ 9932. Acumer™ 9932 is a polyacrylic acid with a molecular weight of approximately 3000, supplied by Rohm and Haas Company (Philadelphia, Pa., USA) at a solids content of 46%. An aqueous thickener composition was made by combining 9.00 g of the solid Thickener Example 6, 38.83 g of water and 2.17 g of Acumer™ 9932. The sample containing 18% Thickener Example 6 and no added acid was a gel-like solid. Thus, the no added acid sample viscosity was too high to reliably measure pH or viscosity. The sample containing Acumer™ 9932 was low enough in viscosity to measure viscosity and pH reliably. Data are shown in Table 8.
The pendant hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener comprise a tertiary amine functionality. Samples were made at 18% thickener concentration, with and without added Acumer™ 9932. An aqueous thickener composition was made by combining 9.00 g of the solid Thickener Example 10, 38.83 g of water and 2.17 g of Acumer™ 9932. The sample containing 18% Thickener Example 10 and no added acid was a gel-like solid. Thus, the no added acid sample viscosity was too high to reliably measure pH or viscosity. The sample containing Acumer™ 9932 was low enough in viscosity to measure viscosity and pH reliably. Data are shown in Table 9.
25 gms of Thickener Example 7 was dissolved in water, with sufficient phosphoric acid addition, to generate a 2.5% weight thickener solids solution at pH=4. Brookfield viscosity (#3 spindle, 60 rpm) was less than 8 cps. Concentrated ammonia was added in stepwise additions and pH and viscosity were measured following 5 minutes stirring. The viscosity versus pH titration curve was generated from the data shown in Table 10. The maximum viscosity value is 172 cps. Therefore, the pKa determined for Thickener Example 7 is 8.7.
The pKa was evaluated similarly for the Thickener Examples shown in Table 11.
The performance obtained by the use of associative thickeners comprising hydrophobic groups that comprise partially or wholly protonated secondary or tertiary amine functionality is demonstrated in a latex paint composition. A latex paint composition, Pre-paint #1, was prepared by combining the following components:
The formulated paint was obtained by adding thickener and water to 963.5 g of Pre-paint #1. To maintain constant solids of the fully formulated paint, the combined weight of added thickeners and water equals 49.5 g. The density of the fully formulated paint was 1013 pounds per 100 gallons (1.2 kilogram per liter). The pH of the fully formulated paints were in the range of 8.5 to 9.0.
Formulated paints were made by the following method. To 963.5 g Pre-paint #1, an amount of aqueous thickener dispersion and an amount of water were slowly added and stirred on a lab mixer for ten minutes. The total combined amount of aqueous thickener dispersions and water is 49.5 grams. In the following data presentation, thickener concentrations in the paint are described in terms of dry grams of thickener added even though the aqueous thickener composition was admixed into the paint. For example, a concentration of 3 dry grams of a thickener can be obtained in the paint by adding 15 grams of 20% solids thickener dispersion. Following a 24 hour equilibration at room temperature, the thickened paint was stirred for one minute on a lab mixer before measuring viscosity values.
“KU viscosity” is a measure of the mid-shear viscosity as measured by a Krebs viscometer. The Krebs viscometer is a rotating paddle viscometer that is compliant with ASTM-D562. KU viscosity was measured on a Brookfield Krebs Unit Viscometer KU-1+ available from Brookfield Engineering Labs (Middleboro, Mass., USA). “KU” shall mean Krebs unit.
“ICI viscosity” is the viscosity, expressed in units of poise, measured on a high shear rate, cone and plate viscometer known as an ICI viscometer. An ICI viscometer is described in ASTM D4287. It measures the viscosity of a paint at approximately 10,000 sec−1. ICI viscosities of paints were measured on a viscometer manufactured by Research Equipment London, Ltd (London, UK). An equivalent ICI viscometer is the Elcometer 2205 manufactured by Elcometer, Incorporated (Rochester Hills, Mich., USA). The ICI viscosity of a paint typically correlates with the amount of drag force experienced during brush application of the paint.
Thickener performance in the formulated latex paints was comparable to that of commercially available thickeners (Table 12).
The white paint formulated with Example 4 above was tinted by adding 35 g of red iron oxide colorant to 200 g of base paint followed by mixing on a paint shaker for 10 minutes. The red iron oxide colorant was obtained from the Sherwin Williams Company (Cleveland, Ohio, USA). KU, ICI, and Brookfield viscosities were measured one hour after tinting. The viscosity measurement was preceded by one minute of stirring on a mechanical mixer. The red iron oxide tinted paint exhibited KU, ICI, and Brookfield viscosities of 82, 0.6 and 3,800 cps, respectively, showing acceptable performance in formulations with added colorant.
Part B. Interior Hydrophobes by Linking Diisocyanates with Hydrophilic Small Molecules
A mixture of 200.0 g PEG (molecular weight 8200), 2.38 g N-methyldiethanolamine and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 9.90 g HMDI and 0.21 g bismuth octoate solution (28%) were added. After 2 hours at 90° C., the resulting solid polymer was isolated after removing toluene by rotoevaporation. Mw was measured as 51,000.
A mixture of 200.0 g PEG (molecular weight 8200), 3.21 g N-butyldiethanolamine and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 9.90 g HMDI and 0.21 g bismuth octoate solution (28%) were added. After 2 hours at 90° C., the resulting solid polymer was isolated after removing toluene by rotoevaporation. Mw was measured as 51,000.
1Acumer ™ 9932 (a polyacrylic acid polymer, available from the Dow Chemical Company, Midland, MI, USA; Mw of approximately 3,000) is a weak acid; lactic acid (LA) is a stronger acid.
Thickener Example 12 and Thickener Example 13 have only internal hydrophobes; they do not possess end-capping hydrophobes. The as-is viscosity of the 18% aqueous solutions show that these polymers function as thickeners. Further, the as-is viscosity can be suppressed by the addition of a small amount of acid, demonstrating that these thickeners are acid-suppressible thickeners.
A mixture of 200.0 g PEG (molecular weight 8200), 1.25 g diethylene glycol and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 12.78 g HMDI and 0.21 g bismuth octoate solution (28%) were added. After 1 hour at 90° C., with stirring, 3.49 g n-hexanol was added. The mixture was then held at 80° C. with stirring for another hour. The resulting solid polymer was isolated after removing toluene by rotoevaporation. Mw was measured as 39,000.
A mixture of 200.0 g PEG (molecular weight 8200), 1.40 g N-methyldiethanolamine and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 12.78 g HMDI and 0.21 g bismuth octoate solution (28%) were added. After 1 hour at 90° C., with stirring, 3.49 g n-hexanol was added. The mixture was then held at 80° C. with stirring for another hour. The resulting solid polymer was isolated after removing toluene by rotoevaporation. Mw was measured as 43,000.
1The same paint formulation shown earlier, using the thickeners in this table at a concentration of 8 dry grams.
2The compositions of the thickeners expressed in equivalents are: Comparative Thickener D: 0.55 PEG-8000/1.1 HMDI/0.265 diethylene glycol // 0.385 n-Hexanol
The two thickeners are compositionally similar (see footnote to Table 14) and have a similar rheology profile in terms of their ability to thicken paints. Each of the thickeners has both internal and end-capping hydrophobes. However, Thickener Example 14 is an acid-suppressible thickener and Comparative Example D is not an acid-suppressible thickener.
A mixture of 200.0 g PEG (molecular weight 8200) and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 8.79 g HMDI and 0.21 g bismuth octoate solution (28%) were added. After 1 hour at 90° C., with stirring, 5.59 g di-n-hexylaminoethanol was added. The mixture was then held at 80° C. with stirring for another hour. The resulting solid polymer was isolated after removing toluene by rotoevaporation. Mw was measured as 41,000.
A mixture of 200.0 g PEG (molecular weight 8200), 1.40 g N-methyldiethanolamine and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 11.32 g HMDI and 0.21 g bismuth octoate solution (28%) were added. After 1 hour at 90° C., with stirring, 5.04 g di-n-hexylaminoethanol was added. The mixture was then held at 80° C. with stirring for another hour. The resulting solid polymer was isolated after removing toluene by rotoevaporation. Mw was measured as 49,000.
A mixture of 200.0 g PEG (molecular weight 8200), 1.89 g N-butyldiethanolamine and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 11.32 g HMDI and 0.21 g bismuth octoate solution (28%) were added. After 1 hour at 90° C., with stirring, 5.04 g di-n-hexylaminoethanol was added. The mixture was then held at 80° C. with stirring for another hour. The resulting solid polymer was isolated after removing toluene by rotoevaporation. Mw was measured as 49,000.
1A similar paint formulation to that shown earlier (a zero VOC analog of the pre-paint #1), wherein the ethylene glycol and Texanol are replaced by Optifilm 400 (Eastman Chemicals, Kingsport, TN, USA), and using the thickeners in this table at a concentration of 7 dry grams. The ICI, KU and Brookfield viscosities are for the formulated paint.
2The compositions of the thickeners expressed in equivalents are:
The inventive acid suppressible thickeners of the present application, comprising both internal and end-capping hydrophobes, show advantage in the high shear viscosity range (ICI viscosity) compared to similar acid suppressible thickeners that comprise only end-capping hydrophobes.
Many formulated systems, including thickened aqueous paints, lack stability with respect to viscosity upon addition of commercial colorants. The drop in KU viscosity (AKU) upon color tinting is a well known problem for paint formulators. Colorant stability of the inventive thickener (Thickener Example 17) was studied in a deeptone paint composition (see below) and compared with commercial high efficiency KU build thickeners.
A mixture of 200.0 g PEG (molecular weight 8200), 3.93 g N-butyldiethanolamine and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 15.28 g HMDI and 0.21 g bismuth octoate solution (28%) were added. After 1 hour at 90° C., with stirring, 6.80 g di-n-hexylaminoethanol was added. The mixture was then held at 80° C. with stirring for another hour. The resulting solid polymer was isolated after removing toluene by rotoevaporation.
Bis(2-ethylhexyl)amine (200.0 grams) was heated to 110° C. under a nitrogen atmosphere in a round bottom flask equipped with a condenser, mechanical stirrer, and addition funnel. Glycidol (61.5 grams) was then added dropwise to the vigorously stirred amine over a 120 minute period. Upon completing the glycidol addition, the reaction mixture was stirred for an additional 1 hour. The epoxy-amine adduct diol product, 3-[bis(2-ethylhexylamino)]-1,2-propanediol, resulting from the ring opening reaction of glycidol by the amine, was isolated and purified via vacuum distillation (for use in preparing Comparative Example F).
Dihexylamine (200.0 grams) was heated to 100° C. under a nitrogen atmosphere in a round bottom flask equipped with a condenser, mechanical stirrer, and addition funnel. Glycidol (80.0 grams) was then added dropwise to the vigorously stirred amine over a 120 minute period. Upon completing the glycidol addition, the reaction mixture was stirred for an additional 1 hour. The epoxy-amine adduct diol product, 3-(dihexylamino)-1,2-propanediol, resulting from the ring opening reaction of glycidol by the amine, was isolated and purified via vacuum distillation (for use in preparing Comparative Example F).
PEG (molecular weight 8200; 1491.3 grams) was heated to 110° C. under vacuum in a batch melt reactor for 2 hours. 3-(Dihexylamino)-1,2-propanediol (17.98 grams) and 3-[bis(2-ethylhexylamino)]-1,2-propanediol (21.87 grams) were added to the reactor and allowed to mix for 5 minutes. IPDI (64.17 grams) was then added to the reactor and allowed to mix for 5 minutes. Bismuth octoate solution (28%, 3.73 grams) was then added to the reactor. The mixture was held at 110° C. with stirring for 20 minutes. The resulting molten polymer was removed from the reactor and cooled. The polymer is prepared as a 17.5 wt % solution in water containing 3% lactic acid (85%).
A Rhoplex™ VSR-1050 latex deeptone paint composition, Pre-paint #2, was prepared as follows. The following components were dispersed using a benchtop dispersator (Series 2000 Model 90, Premier Mill Corporation, Reading, Pa., USA) for 25 minutes to obtain an extender pre-mix.
Pre-paint #2 was prepared by combining 51.46 g of the Extender Pre-Mix prepared above with the following components, with benchtop mixing:
Each formulated VSR-1050 deeptone paint was obtained by adding thickener and water to 812.33 g of Pre-paint #2. To maintain constant solids of the fully formulated paint, the combined weight of thickener and water added to Pre-Paint #2 equals 70.0 g. The density of the fully formulated paint was 882.33 pounds per 100 gallons (1.06 kilogram per liter). The pH of the fully formulated paints were in the range of 9.0 to 9.2.
Formulated paints were made by the following method. To 812.33 g Pre-paint #2, an amount of aqueous thickener dispersion and an amount of water were slowly added and stirred on a lab mixer for ten minutes. The total combined amount of aqueous thickener dispersion and water is 70.0 grams. The target initial Stormer viscosity is 109 KU at 25° C. In the following data presentation, thickener concentrations in the paint are described in terms of dry grams of thickener added even though the aqueous thickener composition was admixed into the paint. For example, a concentration of 3 dry grams of a thickener can be obtained in the paint by adding 15 grams of 20% solids thickener dispersion. Following a 24 hour equilibration at room temperature, the thickened paint was stirred for one minute on a lab mixer before measuring viscosity values.
To obtain the brown tinted paint, 150 g of the thickened paint was mixed with 26.23 g of brown colorant. The brown colorant was obtained by blending universal colorants in the following proportions; 17.6 g lamp black, 58.9 g yellow iron oxide, 12.1 g red iron oxide, 11.4 g white.
Table 16, below, compares the effect of color tinting on the rheology profile of thickened paints for Thickener Example 17 and a commercial high efficiency KU build thickener (Acrysol™ SCT-275, available from Dow Chemical Company, Midland, Mich., USA). The drop in KU viscosity (ΔKU) upon color tinting is a well known problem for formulators of thickened aqueous compositions. This paint has a target Stormer KU viscosity of 109.
1The paint formulation, VSR-1050 Deeptone, created by adding thickener to Pre-paint #2, is described above.
2Acrysol ™ SCT-275 is a commercial high efficiency KU build thickener, available from Dow Chemical Company, Midland, MI, USA.
3The brown colorant is a combination of universal colorants: 17.6 g lamp black, 58.9 g yellow iron oxide, 12.1 g red iron oxide, 11.4 g white.
The hydrophobic groups of inventive Thickener Example 17 comprise a tertiary amine having a hydrocarbon radical bonded to the amine nitrogen atom, which hydrocarbon radical is pendant to the thickener backbone and contains fewer than 10 carbon atoms. The inventive acid suppressible thickener (Thickener Example 17) has better resistance to viscosity instability upon addition of colorant, as shown by a smaller drop in KU value (ΔKU) compared to that observed for Acrysol™ SCT-275 and Comparative F.
The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one skilled in the art. The endpoints of all ranges directed to the same component or property are inclusive of the endpoint and independently combinable. As used herein, the term “(meth)acrylic” encompasses both acrylic and methacrylic. Similarly, the term “poly(meth)acrylamide” encompasses both polyacrylamide and polymethacrylamide.
As described earlier herein, the associative thickener of this invention preferably has a non-ionic water soluble backbone. The addition of minor amounts of ionic groups in the backbone of the inventive associative thickener is also contemplated. Minor amounts of ionic groups are less than 20 weight percent, and more preferably less than 5 weight percent, of ionic monomer units based on the total weight of backbone monomer units. Thus, the associative thickener of this invention may have a substantially non-ionic water soluble backbone and still be considered a non-ionic water soluble backbone.
All cited documents are incorporated herein by reference.
This invention claims priority to U.S. Provisional Application No. 61/284,739 filed Dec. 23, 2009. Additionally, this application is a continuation-in-part of, and claims the benefit of the earlier filing dates of, the earlier filed U.S. patent application Ser. No. 11/974,071 filed Oct. 11, 2007 and its earlier provisional filing, U.S. Provisional Application No. 60/919,209 filed Mar. 21, 2007.
| Number | Date | Country | |
|---|---|---|---|
| 61284739 | Dec 2009 | US | |
| 60919209 | Mar 2007 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11974071 | Oct 2007 | US |
| Child | 12661856 | US |
