WO1998033825A2 - Process for preparing viscoelastic compositions having reduced reactive monomer content - Google Patents
Process for preparing viscoelastic compositions having reduced reactive monomer content Download PDFInfo
- Publication number
- WO1998033825A2 WO1998033825A2 PCT/US1998/007413 US9807413W WO9833825A2 WO 1998033825 A2 WO1998033825 A2 WO 1998033825A2 US 9807413 W US9807413 W US 9807413W WO 9833825 A2 WO9833825 A2 WO 9833825A2
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- WO
- WIPO (PCT)
- Prior art keywords
- viscoelastic composition
- viscoelastic
- monomer
- reactive monomer
- ethylenically unsaturated
- Prior art date
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F6/00—Post-polymerisation treatments
- C08F6/006—Removal of residual monomers by chemical reaction, e.g. scavenging
Definitions
- This invention relates to preparing viscoelastic compositions.
- One particularly useful bulk polymerization process involves exposing an essentially solvent-free, pre- viscoelastic composition containing reactive monomers to a source of transmissive energy such as ultraviolet radiation or thermal conduction to cause the monomers to react and form the viscoelastic composition.
- the invention features a process for preparing a viscoelastic composition that includes the steps of: (a) exposing an essentially solvent-free, pre- viscoelastic composition that includes a reactive monomer to transmissive energy to form a viscoelastic composition that includes an amount of reactive monomer; and (b) exposing the viscoelastic composition to a dose of gamma radiation sufficient to reduce the amount of reactive monomer.
- the transmissive energy includes ultraviolet radiation, thermal conduction, or a combination thereof.
- the dose of gamma radiation preferably is greater than about 5 kGy and less than about 60 kGy.
- Examples of preferred viscoelastic compositions include adhesive compositions such as pressure sensitive adhesive compositions, hot melt adhesive compositions, and vibration damping materials.
- the pre-viscoelastic composition and the viscoelastic composition are preferably essentially free of crosslinking agents.
- Suitable pre-viscoelastic compositions include one or more monomers selected from the following: (a) an acrylic or methacrylic acid ester of a non-tertiary alcohol having between 4 and 14 carbon atoms, inclusive (e.g., isooctyl acrylate, 2-ethyl hexyl acrylate, butyl acrylate, and combinations thereof); (b) a polar ethylenically unsaturated monomer (e.g., acrylic acid, methacrylic acid, itaconic acid, acrylamide, methacrylamide, lower alkyl-substituted acrylamides, N- vinyl pyrollidone, and combinations thereof); and (c) a hydrophilic, ethylenically unsaturated monomer different from the polar monomer (e.g., an aery late- terminated poly(alkylene oxide), a methacrylate-terminated poly(alkylene oxide), or a combination thereof).
- the invention provides viscoelastic compositions having a reduced reactive monomer content. Such compositions are useful in a variety of settings, including medical applications (e.g., adhesive bandages and wound dressings).
- the method is useful for producing a variety of viscoelastic compositions having a reduced reactive monomer content.
- viscoelastic compositions which can be prepared include pressure sensitive adhesives, hot melt adhesives, hot melt processable sealants, vibration damping materials, and gels (e.g., for medical applications).
- the viscoelastic composition may be in the form of a microemulsion, as described in Dietz et al., WO 95/20634.
- Such polymerized microemulsions are derived from concurrent polymerization of a free-radically polymerizable hydrophilic or amphiphilic monomer or oligomer in the aqueous phase of a microemulsion and a free-radically polymerizable hydrophobic monomer in the organic phase of the microemulsion.
- the viscoelastic compositions are prepared by exposing an essentially solvent-free, reactive monomer-containing, pre-viscoelastic composition to a source of transmissive energy.
- the transmissive energy may be selected from ultraviolet radiation, visible radiation, thermal radiation, or thermal conduction, with ultraviolet radiation and thermal conduction being preferred.
- the reactive monomers contain at least one ethylenically unsaturated functional group. Upon exposure to transmissive energy, the monomers react with each other through the ethylenically unsaturated functional group to form a viscoelastic composition.
- One group of reactive monomers which may be used includes acrylic and methacrylic acid ester monomers prepared by reacting acrylic or methacrylic acid with alcohols such as 1-butanol, 2-butanol, 1-pentanol, 2-pentanol, 3-pentanol, 2-methyl-l-butanol, 1-hexanol, 2-hexanol, 2-methyl-l-pentanol, 3-methyl-l- pentanol, 2-ethyl-l-butanol, 3,5,5-trimethyl-l-hexanol, 3-heptanol, 1-octanol, 2- octanol, isooctyl alcohol, 2-ethyl-l-hexanol, 1-decanol, 1-dodecanol, 1-tridecanol, 1 -tetradecanol, and the like, as well as combinations thereof.
- Particularly preferred ester monomers include isooctyl acrylate,
- a second group of suitable monomers particularly where the viscoelastic composition is an adhesive designed for incorporation in an adhesive bandage or wound dressing, includes ethylenically unsaturated hydrophilic monomers such as free radically reactive hydrophilic oligomers (a polymer having a low number of repeating units, generally 2 to 20) and/or polymers including poly(alkylene oxides) (e.g., poly(ethylene oxide)), poly(vinyl methyl ether), poly(vinyl alcohol), cellulose derivatives, and mixtures thereof.
- hydrophilic monomers such as free radically reactive hydrophilic oligomers (a polymer having a low number of repeating units, generally 2 to 20) and/or polymers including poly(alkylene oxides) (e.g., poly(ethylene oxide)), poly(vinyl methyl ether), poly(vinyl alcohol), cellulose derivatives, and mixtures thereof.
- ethylenically unsaturated hydrophilic monomers include macromonomers, e.g., acrylate-terminated poly(ethylene oxide), methacrylate-terminated poly(ethylene oxide), methoxy poly(ethylene oxide) methacrylate, butoxy poly(ethylene oxide) methacrylate, p-vinyl benzyl-terminated poly(ethylene oxide), acrylate-terminated poly(ethylene glycol), methacrylate-terminated poly(ethylene glycol), methoxy poly(ethylene glycol) methacrylate, butoxy poly(ethylene glycol) methacrylate, p- vinyl benzyl-terminated poly(ethylene glycol), poly(ethylene oxide) diacrylate, poly(ethylene oxide) dimethacrylate, and combinations thereof.
- macromonomers e.g., acrylate-terminated poly(ethylene oxide), methacrylate-terminated poly(ethylene oxide), methoxy poly(ethylene oxide) methacrylate, butoxy poly(ethylene oxide) methacrylate, p-vinyl benz
- Particularly preferred ethylenically unsaturated hydrophilic monomers include acrylate and methacrylate esters prepared from mono-hydroxyl-terminated poly (lower alkylene oxides) such as polyethylene and polypropylene glycols commercially available under the trade designation Carbowax from Union Carbide Corp. in a variety of molecular weights (e.g., Carbowax 350, Carbowax 550, Carbowax 750, Carbowax 2000, and Carbowax 5000).
- An example of a preferred acrylate-terminated polyethylene glycol is commercially available from Shin-Nakamura Chemical Co., Ltd., Japan, under the designation "NK Ester AM-90G.”
- Suitable reactive monomers includes polar monomers such as acrylic acid, methacrylic acid, itaconic acid, acrylamide, methacrylamide, lower alkyl-substituted acrylamides (e.g., methyl, ethyl and t-butyl-substituted acrylamides), N-vinyl-pyrollidone, and combinations thereof.
- polar monomers such as acrylic acid, methacrylic acid, itaconic acid, acrylamide, methacrylamide, lower alkyl-substituted acrylamides (e.g., methyl, ethyl and t-butyl-substituted acrylamides), N-vinyl-pyrollidone, and combinations thereof.
- the preferred polar monomer is acrylic acid.
- the pre-viscoelastic composition is essentially free of multifunctional crosslinking monomers.
- multifunctional refers to crosslinking monomers which have two or more free radically polymerizable, ethylenically unsaturated groups.
- Useful multi-functional crosslinking monomers include acrylic or methacrylic esters of diols such as butanediol diacrylate, triols such as glycerol, and tetraols such as pentaerythritol.
- multifunctional crosslinking monomers include polymeric multifunctional (meth)acrylates, e.g., poly(ethylene oxide) diacrylate or poly(ethylene oxide) dimethacrylate; polyvinylic crosslinking agents such as substituted and unsubstituted divinylbenzene; and difunctional urethane acrylates such as "EBECRYL” 270 and "EBECRYL” 230 (1500 weight average molecular weight and 5000 weight average molecular weight acrylated urethanes, respectively—both available from Radcure Specialties), and combinations thereof.
- polymeric multifunctional (meth)acrylates e.g., poly(ethylene oxide) diacrylate or poly(ethylene oxide) dimethacrylate
- polyvinylic crosslinking agents such as substituted and unsubstituted divinylbenzene
- difunctional urethane acrylates such as "EBECRYL” 270 and "EBECRYL” 230 (1500 weight average molecular weight and 5000 weight average molecular weight acryl
- the pre-viscoelastic composition may also include an initiator.
- a photoinitiator is included in the pre-viscoelastic composition.
- Useful photoinitiators include substituted acetophenones such a benzyl dimethyl ketal and 1 -hydroxycyclohexyl phenyl ketone, substituted alpha-ketols such as 2-methyl-2- hydroxypropiophenone, benzoin ethers such as benzoin methyl ether, benzoin isopropyl ether, substituted benzoin ethers such as anisoin methyl ether, aromatic sulfonyl chlorides, and photoactive oximes.
- the amount of photoinitiator typically ranges from about 0.001 to about 5.0 parts by weight per 100 parts of total monomer, preferably from about 0.01 to about 5.0 parts by weight, and more preferably from about 0.1 to about 0.5 parts by weight.
- thermal initiator For thermal polymerization, a thermal initiator is included.
- Useful thermal initiators include azo, peroxide, persulfate, and redox initiators.
- Suitable azo initiators include 2,2'-azobis(2,4-dimethylvaleronitrile) (VAZOTM 52); 2,2'-azobis(isobutyronitrile) (VAZOTM 64); 2,2'-azobis-2- methylbutyronitrile (VAZOTM 67); and (l,l'-azobis(l-cyclohexanecarbonitrile) (VAZOTM 88), all of which are available from DuPont Chemicals, and 2,2'- azobis(methyl isobutyrate) (V-601) and 2,2'-azobis(2-amidinopropane) dihydrochloride (V-50) available from Wako Chemicals. Also suitable is 2,2'- azobis(4-methoxy-2,4-dimethylvaleronitrile), formerly available from DuPont Chemicals as VAZOTM 33.
- Suitable peroxide initiators include benzoyl peroxide, acetyl peroxide, lauroyl peroxide, decanoyl peroxide, dicetyl peroxydicarbonate, di(4-t- butylcyclohexyl) peroxydicarbonate (PERKADOXTM 16S, available from AKZO Chemicals), di(2-ethylhexyl) peroxydicarbonate, t-butylperoxypivalate (LupersolTMl 1 , available from Atochem), t-butylperoxy-2-ethylhexanoate
- Suitable persulfate initiators include potassium persulfate, sodium persulfate, and ammonium persulfate.
- Suitable redox (oxidation-reduction) initiators include combinations of the above persulfate initiators with reducing agents such as sodium metabisulfite and sodium bisulfite; systems based on organic peroxides and tertiary amines (for example, benzoyl peroxide plus dimethylaniline); and systems based on organic hydroperoxides and transition metals, for example, cumene hydroperoxide plus cobalt naphthenate.
- Other useful initiators include materials such as tetraphenyl 1,1,2,2- ethanediol.
- Preferred thermal free-radical initiators are selected from the group consisting of azo compounds and peroxides, e.g., LupersolTM 11 and PerkadoxTM 16, and mixtures thereof.
- the thermal initiator is generally used in an amount ranging from about 0.01 to about 5.0 parts by weight per 100 parts of total monomer, preferably from 0.025 to 2 weight percent.
- thermo and photoinitiators may be included in the pre-viscoelastic composition.
- the pre-viscoelastic composition may polymerized, e.g., in a reactive extruder, to a certain conversion using a thermal initiator, the resulting composition (still in a pre-viscoelastic state) combined with a photoinitiator, and the polymerization completed upon exposure to ultraviolet radiation.
- the initial polymerization may be initiated by a photoinitiator, and the polymerization subsequently completed using a thermal initiator.
- the thermal and photoinitiator may also be used together, rather than being added sequentially.
- chain transfer agents for controlling molecular weight (e.g., carbon tetrabromide, sulfur compounds such as isooctylthioglycolate ("IOTG"), or alcohols), tackifiers, plasticizers (e.g., polyethylene glycol, polypropylene glycol, or glycerin), perfumes, deodorants, antioxidants, hydrophobic or hydrophilic silica, pigments, glass or polymeric bubbles or beads (which may be expanded or unexpanded), fibers, reinforcing agents, calcium carbonate, toughening agents, fire retardants, antioxidants, finely ground polymeric partricles such as polyester, nylon, and polypropylene, stabilizers, and pharmacologically active ingredients such as drugs, antibiotics, and anti-microbial agents.
- Polymeric microspheres e.g., as described in Silver, U.S. 3,691,140 and Baker et al., U.S. 4,166
- the polymerization may be effected in a variety of ways.
- the pre-viscoelastic composition may be coated onto a backing and thereafter exposed to a source of transmissive energy.
- the pre-viscoelastic composition may be partially or completely surrounded by a packaging material, and the resulting package (e.g., in the form of a pouch) exposed to a source of transmissive energy.
- suitable packaging materials include flexible thermoplastic polymeric films such as ethylene-vinyl acetate, ethylene-acrylic acid, polypropylene, polyethylene, polybutadiene, and ionomeric films.
- Thermal polymerization can be effected by immersing the packaged composition in a heat exchange medium at temperatures between about 40°C and 100°C for a time sufficient to polymerize the composition.
- the heat exchange medium may be a forced or impinged gas or a liquid such as water, perfluorinated liquids, glycerine, or propylene glycol.
- the heat necessary for thermal polymerization may also be provided by a metal platen, heated metal rolls, or microwave energy.
- the temperature at which the polymerization occurs depends upon the activation temperature of the initiator.
- polymerization using VAZOTM64 a commercially available initiator from DuPont Company can be carried out at about 80°C
- VazoTM52 also available from DuPont Company
- a suitable liquid heat exchange medium is water, heated to the desired reaction temperature.
- Commercially available heat transfer fluids may also be used.
- Polymerization can also be effected by exposure to ultraviolet (UV) radiation as described in U.S. Patent No. 4,181,752 (Martens et al.).
- the polymerization may be carried out with UV black lights having over 60 percent, and preferably over 75 percent of their emission spectra between 280 to 400 nanometers (nm), with an intensity between about 0.1 to about 25 mW/cm 2 , under conditions such that the total energy ranges from 200 to 3000 mj/cm 2 .
- the temperature of the pre-viscoelastic composition can be controlled by blowing cooling air around the packaged composition, by running the packaged composition over a cooled platen, or by immersing the packaged composition in a water bath or a heat transfer fluid during polymerization.
- the packaged compositions are immersed in a water bath, with water temperatures between about -o-
- the viscoelastic product is exposed to gamma radiation to reduce the amount of unreacted monomer in the composition.
- the extent of reduction can be measured using, e.g., gas chromatography.
- the particular radiation dosage required is a function of the composition. In general, however, the dosage is greater than about 5 kGy and less than about 60 kGy.
- Examples 1-4 illustrate the effect of exposure to gamma radiation on the amount of unreacted isooctyl acrylate monomer for various isooctyl acrylate - acrylic acid-polyethylene oxide acrylate ("IOA/AA/EOA”) polymers.
- the polymers were prepared as follows.
- a vial was charged with isooctyl acrylate, after which 0.04% by weight photoinitiator (benzyl dimethyl ketal) was added and stirred until dissolution.
- Acrylic acid and, if present, polyethylene glycol acrylate ("NK Ester ⁇ AM-90G" from Shin-Nakamura Chemical Co., Ltd., Japan) were then added to the solution and the resulting solution reacted to form a syrup of coatable viscosity by exposing the solution to ultraviolet radiation.
- a second portion of photoinitiator was added to the syrup, after which the syrup was coated between two release liners; the total amount of photoinitiator used was 0.4% by weight of the total monomer weight.
- One of the release liners was a clear, silicone-coated polyethylene terephthalate film and the other liner was either silicone-coated paper or a second silicone-coated polyethylene terephthalate film.
- the caliper was set at 1.01 - 1.14 mm (40-45 mils) for each sample during the coating process.
- the sample was cured by exposure to a source of ultraviolet radiation (Sylvania Corp.) having over 80%) of its emissions between 280 and 400 nm, with a maximum at 350 nm, for a time sufficient to achieve a total energy of 1136 mj/cm 2 , as measured by a UVIMAPTM UM 365 L-S -y-
- 0.5 g of sample was placed in a clean vial to which 4.5 g of a stock solution (acetone containing 0.5 wt.% meta-xylene) was then added.
- 0.5 microliters of the resultting solution was then injected into a Hewlett-Packard gas chromatograph (model HP5890) equipped with a DB5 column and a flame ionization detector maintained at 300°C.
- the column had a length of 30 meters, an inner diameter of 0.25 mm, and was equipped with a 0.25 micron film.
- the sample was injected while maintaining the column at 50°C.
- the column was held at 50°C for 5 minutes following injection, after which the temperature was raised to 300°C in increments of 12.5°C/min.
- Examples 5-16 illustrate the effect of varying the gamma radiation dosage on the amount of unreacted isooctyl acrylate monomer for various IOA/AA/EOA polymers, prepared with and without an isooctyl thioglycolate ("IOTG") chain transfer agent.
- the polymers were prepared and analyzed following the procedure used in Examples 1 -4, with the exception that in the case of Examples 6, 7, 10, 12, 13, 15, and 16, an IOTG chain transfer agent was included in the reaction mixture as well.
- the total exposure energy in each example was 1048 mj/cm 2 .
- Table II All amounts are given in weight percent.
- Examples 17-24 illustrate the effect of exposure to gamma radiation on the amount of unreacted isooctyl acrylate monomer for various IO A/AA/EOA microemulsions.
- the microemulsions were prepared as follows. Acrylic acid, crosslinking agent, and polyethylene glycol acrylate ("NK
- Ester ⁇ AM-90G from Shin-Nakamura Chemical Co., Ltd., Japan
- isooctyl acrylate was then dissolved in the solution, followed by the addition of surfactant.
- the surfactants used were "Brij 76TM,” “BrijTM 98,” and “Tergitol 15-S-12” commercially available from ICI.
- an aqueous solution containing 4% by weight KCl was added to form a microemulsion.
- the resulting microemulsion was then cast in the form of a film having a thickness of 0.38 mm onto a silicone-treated paper substrate (polyethylene coated, moisture resistant Kraft paper #56) and covered with a silicone-treated polyester film about 0.05 mm thick.
- the microemulsion was then photopolymerized in air using a source of ultraviolet radiation (Sylvania Corp.) having over 80% of its emissions between 280 and 400 nm, with a maximum at 350 nm, for a time sufficient to achieve a total energy of 1229 mJ/cm 2 , as measured by a UVIMAPTM UM 365 L-S radiometer (Electronic Instrumentation & Technology, Inc., Sterling, VA).
- EOA Polyethylene glycol acrylate PI — Photoinitiator
- NNMBA N,N-Methylenebisacrylamide
- HDDA Hexanedioldiacrylate
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Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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AU71143/98A AU7114398A (en) | 1997-02-03 | 1998-01-20 | Process for preparing viscoelastic compositions having reduced reactive monomer content |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US79457397A | 1997-02-03 | 1997-02-03 | |
US08/794,573 | 1997-02-03 |
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WO1998033825A2 true WO1998033825A2 (en) | 1998-08-06 |
WO1998033825A3 WO1998033825A3 (en) | 1998-11-05 |
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PCT/US1998/007413 WO1998033825A2 (en) | 1997-02-03 | 1998-01-20 | Process for preparing viscoelastic compositions having reduced reactive monomer content |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2007120705A2 (en) | 2006-04-11 | 2007-10-25 | E. I. Du Pont De Nemours And Company | Process for preparation of swellable and deformable microspheres |
US7838035B2 (en) | 2006-04-11 | 2010-11-23 | E. I. Du Pont De Nemours And Company | Microsphere powder of high density, swellable, deformable, durable occlusion-forming microspheres |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4330383A (en) * | 1978-07-18 | 1982-05-18 | Polymer Technology Corporation | Dimensionally stable oxygen permeable hard contact lens material and method of manufacture |
GB2088390A (en) * | 1980-11-28 | 1982-06-09 | Coopervision Uk | Preparation of hydrogel materials |
US4376021A (en) * | 1980-03-24 | 1983-03-08 | Japan Atomic Energy Research Institute | Process for producing a water-soluble vinyl polymer |
US4737577A (en) * | 1986-12-31 | 1988-04-12 | Minnesota Mining And Manufacturing Company | Method for removing monomer from an acrylate adhesive by reaction with a scavenger monomer |
-
1998
- 1998-01-20 AU AU71143/98A patent/AU7114398A/en not_active Abandoned
- 1998-01-20 WO PCT/US1998/007413 patent/WO1998033825A2/en active Application Filing
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4330383A (en) * | 1978-07-18 | 1982-05-18 | Polymer Technology Corporation | Dimensionally stable oxygen permeable hard contact lens material and method of manufacture |
US4376021A (en) * | 1980-03-24 | 1983-03-08 | Japan Atomic Energy Research Institute | Process for producing a water-soluble vinyl polymer |
GB2088390A (en) * | 1980-11-28 | 1982-06-09 | Coopervision Uk | Preparation of hydrogel materials |
US4737577A (en) * | 1986-12-31 | 1988-04-12 | Minnesota Mining And Manufacturing Company | Method for removing monomer from an acrylate adhesive by reaction with a scavenger monomer |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2007120705A2 (en) | 2006-04-11 | 2007-10-25 | E. I. Du Pont De Nemours And Company | Process for preparation of swellable and deformable microspheres |
WO2007120705A3 (en) * | 2006-04-11 | 2007-12-06 | Du Pont | Process for preparation of swellable and deformable microspheres |
US7794755B2 (en) | 2006-04-11 | 2010-09-14 | E.I. Du Pont De Nemours And Company | Process for preparation of swellable and deformable microspheres |
US7838035B2 (en) | 2006-04-11 | 2010-11-23 | E. I. Du Pont De Nemours And Company | Microsphere powder of high density, swellable, deformable, durable occlusion-forming microspheres |
Also Published As
Publication number | Publication date |
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WO1998033825A3 (en) | 1998-11-05 |
AU7114398A (en) | 1998-08-25 |
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