Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/16—Nitrogen-containing compounds
  • C08K5/21—Urea; Derivatives thereof, e.g. biuret
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24628—Nonplanar uniform thickness material
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31725—Of polyamide
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31786—Of polyester [e.g., alkyd, etc.]
  • Y10T428/31794—Of cross-linked polyester

Definitions

• the present invention relates to (hydroxyalkyl)urea crosslinking agents and the use thereof to replace formaldehyde-based crosslinking agents
• Synthetic polymers are used in a wide variety of applications In many applications, these synthetic polymers are crosslmked in order to achieve the required performance properties
• formaldehyde-based crosslinking agents Such crosslinking agents based on formaldehyde traditionally have provided an efficient and cost-effective means of curing a wide variety of materials
• formaldehyde-based crosslinking agents include melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde and acrylamide-formaldehyde adducts
• formaldehyde-based crosslinking agents include melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde and acrylamide-formaldehyde adducts
• formaldehyde-based crosslinking agents With growing toxicity and environmental concerns, there has been an ongoing search to replace formaldehyde-based crosslinking agents
• these alternative crosslmkers have suffered from significant deficiencies
• a particularly attractive crosslinking reaction involves the este ⁇ fication of a carboxylic acid functional polymer with a hydroxyl functional polymer This is an attractive reaction since water is the only product of the crosslinking reaction
• this reaction is difficult to conduct effectively since it is slow under conventional time and temperature conditions of cure Raising the temperature to force this curing reaction results in unacceptable color development and/or degradation, with the emission of unwanted volatile organic compounds.
• ⁇ -Hydroxyalkyl amide functionality was developed to facilitate the esterification crosslinking of carboxylic acid containing polymers.
• this technology still is deficient in crosslinking rate and crosslinking densities under conditions typically used for formaldehyde based crosslinking agents.
• the present invention relates to (hydroxyalkyl)urea crosslinking agents which are essentially free of formaldehyde and to compositions which utilize such crosslinking agents.
• the compositions comprise a poly-functional molecule comprising at least two functional groups selected from the group consisting of carboxyl, anhydride and amine; and the (hydroxyalkyl)urea crosslinking agent, present in amounts effective to provide crosslinked compositions.
• the crosslinking agent will comprise only a single urea group, at least two hydroxyl groups, and there must be at least two carbon atoms disposed between the urea group and each of the hydroxyl groups
• DESCRIPTION OF THE DRAWINGS Figure 1 is a thermogravimet ⁇ c analysis (TGA) thermogram comparing crosslinking properties of (hydroxyalkyl)urea (HAU) crosslinking agents to hydroxyalkyl amide (HAA) crosslinking agents
• compositions according to the present invention comprise a poly- functional molecule (PFM)
• PFM poly- functional molecule
• molecule includes non- polymeric molecules, low molecular weight polymers or o gomers, for instance having molecular weight of less than about 10,000, and higher molecular weight polymers, for instance having molecular weight of greater than about 10,000 to greater than 1 ,000,000
• the actual molecular weight of the molecule is not a limiting factor with respect to the use of the crosslinking agents of the present invention
• the PFM must contain at least two functional groups selected from the group consisting of carboxyl, anhydride and amine
• Exemplary molecules which may be used in the present invention include without limitation citric acid, 1 ,2,4-benzene t ⁇ carboxylic acid, 1 ,2,4,5-benzene tetracarboxy c acid, 1 ,2,3,4-butane tetracarboxyhc acid, poly(acryl ⁇ c acid), carboxy c-acid- functionalized polyester
• the crosslinking agents of the present invention are derived from urea, comprise only a single urea group, at least two hydroxyl groups, at least two carbon atoms disposed between the urea group and each of the hydroxyl groups, and may include any of those compounds represented by Structure (I).
• the two carbons disposed between the hydroxyl and urea groups may be in linear, branched or substituted configuration.
• R 2 is H or R 5
• R 3 is H or R 5
• R 4 is H, R 1 , or R 5 , where
• R 6 is H, CH 2 OH, CHCHOH, CHCHCHOH or C r C 4 alkyl
• R 6 is H, CH 2 OH, CHCHOH, CHCHCHOH or C r C 4 alkyl
• R 7 is H, CH 2 OH, CHCHOH, CHCHCHOH or C C 4 alkyl, where R 8 is H, methyl or ethyl, R 9 is H, methyl or ethyl, and R 10 is H, methyl or ethyl.
• HAU crosslinkers include, without limitation, N,N-bis(2- hydroxyethyl)urea, tetrakis(2-hydroxyethyl)urea, tris(2-hydroxyethyl)urea,
• N,N'-bis(2-hydroxyethyl)urea N,N'-bis(3-hydroxypropyl)urea, N,N'-bis(4- hydroxybutyl)urea and 2-urea-2-ethyl-1 ,3-propanediol.
• crosslinking agent and “crosslinker” are used interchangeably herein.
• the PFM may be generated in situ from starting molecules which do not comprise at least two functional groups selected from the group consisting of carboxyl, anhydride and amine
• functional groups will be generated such that the molecules comprise at least two functional groups selected from the group consisting of carboxyl, anhydride and amine
• the functional groups may be generated in situ by the addition of heat to the system or by chemical reaction with the starting molecules, For example, acid catalyzed hydrolysis of alkyl esters such as methyl or f-butyl, are very facile in generating carboxylic acid
• alkyl esters such as methyl or f-butyl
• HAU crosslinker when compared to other crosslinkers which contain at least two hydroxyl groups, the HAU systems exhibited dramatic improvement in crosslinking uncatalyzed systems, i e systems which comprise the PFM and the crosslinker, but do not contain a catalyst
• HAU, HAA and glycerol all containing two or more hydroxyl groups, are used to crosslink poly(acryl ⁇ c acid)
• the percent insolubles of the three systems are 42%, 3% and 0%, respectively, indicating that the urea group in combination with the two hydroxyl groups is critical in achieving desired crosslinking properties and that merely using a crosslinker with at least two hydroxy groups is not sufficient to realize the benefits afforded by the present invention
• the HAU and the HAA are used independently in combination with a catalyst such as sodium hypophosphite, the percent insolubles are 52% and 51 %, respectively
• the percent insolubles are 52% and 51 %, respectively
• the data indicate that the HAU and the HAA
• HAU crosslinking agents according to the present invention significantly enhance the crosslinking reaction rate, and thus the crosslinking efficiency, when compared to hydroxyalkyl amides (HAA) which may be used to crosslink molecules comprising at least two functional groups selected from carboxyl, amine and anhydride
• HAA crosslinker Sample 1
• HAU crosslinker Sample 2
• Sample 3 is the same HAA crosslinker which has been catalyzed with a phosphorus-containing catalyst The cure can be followed by the weight loss due to the release of water which is a byproduct of the cure
• the catalyst e.g., hydroxyalkyl amides
• the relative degree of crosslinking generated by HAU and HAA crosslinking agents may be observed by measuring the water and solvent resistance of the crosslinked molecule (via the determination of percent insolubles) As observed in Table 5, poly(acryl ⁇ c acid) Mw 90,000 was crosslinked both with HAU and HAA crosslinkers by curing at 240°C for ten minutes With respect to the degree of crosslinking, the HAU crosslinker was as efficient or better than the HAA crosslinkers (92% insolubles (HAU) vs 91 % and 74% insolubles, (HAA)s respectively)
• the PFM and the HAU crosslinking agent will be present in relative amounts such that the ratio of the sum total number of equivalents of the functional groups contained in the PFM to the number of equivalents of the hydroxyl groups contained in the HAU crosslinker ranges from about 1 1 to about 100 1
• Lewis acid and Lewis base catalysts may be used in combination with the crosslinking agent in order to further enhance crosslinking
• Such catalysts generally include clays, silica, including without limitation colloidal silica, organic amines, quaternized-ammes, metal oxides, metal sulfates, metal chlorides, urea sulfate, urea chloride and silicate-based catalysts
• Exemplary Lewis acid and Lewis base catalysts which may be used in the invention are set forth in Table 11
• Phosphorus-containing catalysts may be used in the present invention, including without limitation alkali metal hypophosphite salts, alkali metal phosphites, alkali metal polyphosphates, alkali metal dihydrogen phosphates, polyphosphonc acid and alkyl phosphmic acids
• Such catalysts, when used, are used in less than stoichiomet ⁇ c amounts as the maximum level allowed, and in minimum amounts effective to improve crosslinking compared to a non-catalyze
• the HAU and PFM are combined under conditions effective to induce crosslinking of the PFM
• Such conditions permit water to be removed from the system, thereby inducing crosslinking of the PFM
• These conditions may be provided by adjusting temperature and/or pressure
• one of the advantages of the crosslinkers of the present invention is that they are stable at elevated temperatures and therefore work particularly well in systems which must be cured at temperatures greater than 100°C Curing may occur at pressures where water may be removed from the system, for example at low pressures or under vacuum
• Both temperature and pressure be may be adjusted such that water may be removed from the system
• crosslinking may be induced by chemical reaction
• PFMs may be generated in situ Whether crosslinking be induced by heat transfer or by chemical reaction, the conditions must be effective to remove water from the system,
• compositions of the present invention may be used in preparing a number of compositions and articles of manufacture and may be applied to polymeric natural substrates, such as woven or non-woven cellulose, wood, leather, paper, cotton, wool, rayon and silk, and polymeric synthetic substrates, such as polyolefin, polyester, polyamide, polyvmyl chloride, polyviny dene chloride and polyimide
• substrates to which the compositions may be applied include glass, metal and composite substrates such as sand, ceramic, foundry sand and molds
• the compositions may be used in preparing coatings, such as automotive coatings, powder coatings, adhesive coatings, inks and paints
• the compositions also may be used as binders or sizing agents in the preparation of, for example, glass or cellulosic fibers, non-woven paper products, fiberglass insulation or batting, glass fiber rovings and molded fiberglass articles
• the compositions also may be used as binders in woven and nonwoven textiles and as backcoatmgs in
• crosslinking agents of the present invention and methods for making same are set forth below While one skilled in the art may be aware of other means of producing such compounds, the following examples are among the preferred methods for preparing the crosslinking agents
• Additional alkanolamines also may be used and include, without limitation, 2-am ⁇ no-2-methyl-1 ,3-propaned ⁇ ol, r ⁇ s(hydroxymethyl)am ⁇ no- methane, 2-methyl-3-am ⁇ no-1-propanol and 2-methylam ⁇ noethanol
• reaction also can be conducted effectively using refluxmg water as a means of removing evolved ammonia 105 g diethanolamine, 25 g water and 60 g urea were charged in a 1L flask equipped with heating mantle, thermometer and stirrer and allowed to react at 115°C for 8 hours
• Polymer poly(acrylic acid); 60,000 Mw
• NMA is N metholyl acrylamide
• HPA is hydroxypropyl acryiate
• DMHEA is N-(2,2-dimethoxy-1-hydroxy)ethyl acrylamide
• Polymer poly(acrylic acid); 90,000 Mw

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• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Organic Chemistry (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Wood Science & Technology (AREA)
• Life Sciences & Earth Sciences (AREA)
• Health & Medical Sciences (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
• Processes Of Treating Macromolecular Substances (AREA)
• Polyesters Or Polycarbonates (AREA)

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• 1997
  • 1997-01-07 US US08/783,350 patent/US5858549A/en not_active Expired - Lifetime
• 1998
  • 1998-01-07 CA CA 2248110 patent/CA2248110C/en not_active Expired - Fee Related
  • 1998-01-07 EP EP19980901789 patent/EP0888402B1/en not_active Expired - Lifetime
  • 1998-01-07 WO PCT/US1998/000590 patent/WO1998030627A1/en not_active Ceased
  • 1998-01-07 JP JP53123198A patent/JP2000508022A/ja not_active Ceased
  • 1998-01-07 DE DE69809639T patent/DE69809639T2/de not_active Expired - Lifetime
  • 1998-09-04 NO NO984074A patent/NO984074L/no not_active Application Discontinuation
  • 1998-10-28 US US09/181,192 patent/US6051646A/en not_active Expired - Lifetime

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