Classifications

• • 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
  • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
  • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
  • C08F220/10—Esters
  • C08F220/26—Esters containing oxygen in addition to the carboxy oxygen
• • 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
  • C08F20/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride, ester, amide, imide or nitrile thereof
  • C08F20/02—Monocarboxylic acids having less than ten carbon atoms, Derivatives thereof
  • C08F20/10—Esters
  • C08F20/26—Esters containing oxygen in addition to the carboxy oxygen
• • 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
  • C08F22/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical and containing at least one other carboxyl radical in the molecule; Salts, anhydrides, esters, amides, imides or nitriles thereof
  • C08F22/10—Esters
• • 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
  • C08F222/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical and containing at least one other carboxyl radical in the molecule; Salts, anhydrides, esters, amides, imides, or nitriles thereof
  • C08F222/10—Esters
  • C08F222/1006—Esters of polyhydric alcohols or polyhydric phenols
  • C08F222/102—Esters of polyhydric alcohols or polyhydric phenols of dialcohols, e.g. ethylene glycol di(meth)acrylate or 1,4-butanediol dimethacrylate
• • 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
  • C08F265/00—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00
  • C08F265/04—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00 on to polymers of esters
  • C08F265/06—Polymerisation of acrylate or methacrylate esters on to polymers thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
  • C08L33/04—Homopolymers or copolymers of esters
• • 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
  • Y10T428/4935—Impregnated naturally solid product [e.g., leather, stone, etc.]
• • 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
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/30—Woven fabric [i.e., woven strand or strip 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
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]

Definitions

• TITLE (Meth)acrylic esters of Poly(trimethylene ether) glycol and Uses Thereof
• This invention relates to processes and products utilizing (meth)acrylic esters of poly(trimethylene ether) glycol.
• Acrylate polymers find use in a number of coatings and radiation curable applications. Most of the acrylates currently in use are those derived from polyether glycols, including poly(ethylene) glycol diacrylate, poly(1 ,2- propylene) glycol diacrylate and poly(tetramethylene) glycol diacrylate. Acrylate polymers are disclosed in, for example, A. Priola, et al., Polymer 33 (17), 3653, 1993; A. Priola, et al., Polymer 37 (12), 2565, 1996; and A. Priola, et al., J. Appl. Polym. Sci 65 491-497, 1997.
• acrylate polymers can have lower flexibility than needed for certain applications, as well as degradation during production.
• a need remains for acrylate polymers having desired physical properties and reduced degradation during production.
• One aspect of the present invention is a process comprising reacting a (meth)acrylic ester of poly(trimethylene ether) glycol of the formula (I):
• Another aspect of the present invention is a process comprising reacting a (meth)acrylic ester of poly(trimethylene ether) glycol of the formula (I):
• the present invention provides novel (meth)acrylic esters of poly(trimethylene ether) glycol.
• the invention also provides processes for producing the novel (meth)acrylic esters of poly(trimethylene ether) glycol by reacting poly(trimethylene ether) glycol with (meth)acrylic acid or its equivalent.
• Monocarboxylic acid equivalents include, for example, esters of monocarboxylic acids, and ester-forming derivatives such as acid halides (e.g., acid chlorides) and anhydrides
• the poly(thmethylene ether) glycol (meth)acrylates are based on renewably-sourced (bio-sourced) 1 ,3- propanediol and polythmethylene ether glycols.
• the (meth)acrylic ester of poly(trimethylene ether) glycol is produced by first polycondensing 1 ,3-propanediol reactant in the presence of a catalyst (preferably a mineral acid catalyst) and then estehfying the condensed product with (meth)acrylic acid in the presence of a polymerization inhibitor(s) while removing the byproduct (water) formed both in condensation and estehfication reactions simultaneously.
• a catalyst preferably a mineral acid catalyst
• the (meth)acrylic ester of poly(thmethylene ether) glycol is produced by reacting poly(trimethylene ether) glycol having a number average molecular weight from 134 to 5000 with (meth)acrylic acid in the presence of an esterification catalyst and a polymerization inhibitor while removing the byproduct (water) formed during esterfication simultaneously.
• the (meth)acrylic ester of poly(trimethylene ether) glycol is produced by reacting poly(trimethylene ether) glycol with (meth)acrylic acid chloride in the presence of an organic base while the byproduct (water) formed during esterification reaction. At least one polymerization inhibitor and at least one antioxidant are added to the resulting product.
• the products obtained from the above processes comprise mixture of mono and/or diesters of poly(thmethylene ether) glycol and 1 ,3-propanediol, un-reacted starting materials and catalyst residues.
• the compositions can be used as such in end use applications or if desired the products can be further purified to remove catalyst residues and un-reacted starting materials by well known separation processes.
• the 1 ,3-propanediol and poly(thmethylene ether) glycol used in the above processes are derived from renewable sourced raw materials and therefore the acrylic ester of poly(trimethylene ether) glycols of the present invention have bio content of minimum 20 wt%.
• the compositions of the present invention thus have a reduced environmental impact.
• the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion.
• a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
• “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
• (meth)acrylic may be used herein as shorthand for "acrylic and methacrylic", when referring to acids or esters. Unless otherwise specified, the term, when used, is intended to encompass both “acrylic” and “methacrylic”.
• the present invention provides (meth)acrylic ester of poly(thmethylene ether) glycol compositions comprising an ester (a monoester, a diester or mixtures thereof) of a polytrimethylene ether glycol and at least one polymerization inhibitor, and processes of producing such compositions.
• the (meth)acrylic esters of poly(trimethylene ether) glycol comprise one or more compounds of the formula (I):
• Q represents the residue of a poly(trimethylene ether) glycol after abstraction of the hydroxyl groups
• Ri is H or CH 3
• the (meth)acrylic esters of polytrimethylene ether glycol can be produced by various methods using either 1 ,3-propanediol or polytrimethylene ether) glycol as a feedstock.
• PO3G is a polymeric ether glycol in which at least 50% of the repeating units are trimethylene ether units. More preferably from about 75% to 100%, still more preferably from about 90% to 100%, and even more preferably from about 99% to 100%, of the repeating units are trimethylene ether units.
• PO3G is preferably prepared by polycondensation of monomers comprising 1 ,3-propanediol, thus resulting in polymers or copolymers containing -(CH 2 CH 2 CH 2 O)- linkage (e.g, trimethylene ether repeating units). As indicated above, at least 50% of the repeating units are trimethylene ether units.
• trimethylene ether glycol encompasses PO3G made from essentially pure 1 ,3-propanediol, as well as those oligomers and polymers (including those described below) containing up to about 50% by weight of comonomers.
• the 1 ,3-propanediol employed for preparing the PO3G may be obtained by any of the various well known chemical routes or by biochemical transformation routes. Preferred routes are described in, for example, US5364987, and US5633362.
• the 1 ,3-propanediol is obtained biochemically from a renewable source ("biologically-derived" 1 ,3-propanediol).
• a particularly preferred source of 1 ,3-propanediol is via a fermentation process using a renewable biological source.
• biochemical routes to 1 ,3- propanediol (PDO) have been described that utilize feedstocks produced from biological and renewable resources such as corn feed stock.
• PDO propanediol
• bacterial strains able to convert glycerol into 1 ,3-propanediol are found in the species Klebsiella, Citrobacter, Clostridium, and Lactobacillus.
• US5821092 discloses, inter alia, a process for the biological production of 1 ,3-propanediol from glycerol using recombinant organisms.
• the process incorporates E. coli bacteria, transformed with a heterologous pdu diol dehydratase gene, having specificity for 1 ,2-propanediol.
• the transformed E. coli is grown in the presence of glycerol as a carbon source and 1 ,3-propanediol is isolated from the growth media. Since both bacteria and yeasts can convert glucose (e.g., corn sugar) or other carbohydrates to glycerol, the processes disclosed in these publications provide a rapid, inexpensive and environmentally responsible source of 1 ,3-propanediol monomer.
• the renewably sourced (also known as biologically-derived) 1 ,3- propanediol contains carbon from the atmospheric carbon dioxide incorporated by plants, which compose the feedstock for the production of the 1 ,3- propanediol.
• the biologically-derived 1 ,3-propanediol preferred for use in the context of the present invention contains only renewable carbon, and not fossil fuel-based or petroleum-based carbon.
• compositions of the present invention can be characterized as more natural and having less environmental impact than similar compositions comprising petroleum based glycols.
• the renewably sourced (also known as biologically-derived) 1 ,3- propanediol, PO3G and PO3G acrylate esters may be distinguished from similar compounds produced from a petrochemical source or from fossil fuel carbon by dual carbon-isotopic finger printing. This method usefully distinguishes chemically-identical materials, and apportions carbon in the copolymer by source (and possibly year) of growth of the biosphehc (plant) component.
• the isotopes, 14 C and 13 C bring complementary information to this problem.
• radiocarbon dating isotope 14 C
• 14 C The radiocarbon dating isotope ( 14 C), with its nuclear half life of 5730 years, clearly allows one to apportion specimen carbon between fossil (“dead”) and biospheric ("alive") feedstocks (Currie, L. A. "Source Apportionment of Atmospheric Particles,” Characterization of Environmental Particles, J. Buffle and H. P. van Leeuwen, Eds., 1 of Vol. I of the IUPAC Environmental Analytical Chemistry Series (Lewis Publishers, Inc) (1992) 3-74).
• the basic assumption in radiocarbon dating is that the constancy of 14 C concentration in the atmosphere leads to the constancy of 14 C in living organisms.
• 14 C has acquired a second, geochemical time characteristic. Its concentration in atmospheric CO 2 , and hence in the living biosphere, approximately doubled at the peak of nuclear testing, in the mid-1960s.
• the stable carbon isotope ratio ( 13 C/ 12 C) provides a complementary route to source discrimination and apportionment.
• the 13 C/ 12 C ratio in a given renewably sourced material is a consequence of the 13 C/ 12 C ratio in atmospheric carbon dioxide at the time the carbon dioxide is fixed and also reflects the precise metabolic pathway. Regional variations also occur. Petroleum, C 3 plants (the broadleaf), C 4 plants (the grasses), and marine carbonates all show significant differences in 13 C/ 12 C and the corresponding ⁇ 13 C values. Furthermore, lipid matter of C 3 and C 4 plants analyze differently than materials derived from the carbohydrate components of the same plants as a consequence of the metabolic pathway.
• 13 C shows large variations due to isotopic fractionation effects, the most significant of which for the instant invention is the photosynthetic mechanism.
• the major cause of differences in the carbon isotope ratio in plants is closely associated with differences in the pathway of photosynthetic carbon metabolism in the plants, particularly the reaction occurring during the primary carboxylation, i.e., the initial fixation of atmospheric CO2.
• Two large classes of vegetation are those that incorporate the "C 3 " (or Calvin-Benson) photosynthetic cycle and those that incorporate the "C 4 " (or Hatch-Slack) photosynthetic cycle.
• C 3 plants, such as hardwoods and conifers, are dominant in the temperate climate zones.
• the primary CO2 fixation or carboxylation reaction involves the enzyme ribulose-1 ,5- diphosphate carboxylase and the first stable product is a 3-carbon compound.
• C 4 plants include such plants as tropical grasses, corn and sugar cane.
• an additional carboxylation reaction involving another enzyme, phosphenol-pyruvate carboxylase is the primary carboxylation reaction.
• the first stable carbon compound is a 4-carbon acid, which is subsequently decarboxylated. The CO2 thus released is refixed by the C 3 cycle.
• the ability to distinguish these products is beneficial in tracking these materials in commerce. For example, products comprising both "new" and “old” carbon isotope profiles may be distinguished from products made only of "old” materials.
• the instant materials may be followed in commerce on the basis of their unique profile and for the purposes of defining competition, for determining shelf life, and especially for assessing environmental impact.
• the 1 ,3-propanediol used as the reactant or as a component of the reactant will have a purity of greater than about 99%, and more preferably greater than about 99.9%, by weight as determined by gas chromatographic analysis.
• Particularly preferred are the purified 1 ,3- propanediols as disclosed in US7038092, as well as PO3G made as disclosed in US20050020805A1.
• the purified 1 ,3-propanediol preferably has the following characteristics: (1 ) an ultraviolet absorption at 220 nm of less than about 0.200, and at
• a concentration of total organic impurities (organic compounds other than 1 ,3-propanediol) of less than about 400 ppm, more preferably less than about 300 ppm, and still more preferably less than about 150 ppm, as measured by gas chromatography.
• the starting material for making PO3G will depend on the desired PO3G, availability of starting materials, catalysts, equipment, etc., and comprises "1 ,3-propanediol reactant.”
• 1 ,3-propanediol reactant is meant 1 ,3-propanediol, and oligomers and prepolymers of 1 ,3-propanediol preferably having a degree of polymerization of 2 to 9, and mixtures thereof. In some instances, it may be desirable to use up to 10% or more of low molecular weight oligomers where they are available.
• the starting material comprises 1 ,3-propanediol and the dimer and trimer thereof.
• a particularly preferred starting material is comprised of about 90% by weight or more 1 ,3-propanediol, and more preferably 99% by weight or more 1 ,3-propanediol, based on the weight of the 1 ,3-propanediol reactant.
• PO3G can be made via a number of processes known in the art, such as disclosed in US6977291 and US6720459. A preferred process is as set forth in US20050020805A1. As indicated above, PO3G may contain lesser amounts of other polyalkylene ether repeating units in addition to the trimethylene ether units.
• the monomers for use in preparing polythmethylene ether glycol can, therefore, contain up to 50% by weight (preferably about 20 wt% or less, more preferably about 10 wt% or less, and still more preferably about 2 wt% or less), of comonomer polyols in addition to the 1 ,3-propanediol reactant.
• Comonomer polyols that are suitable for use in the process include aliphatic diols, for example, ethylene glycol, 1 ,6-hexanediol, 1 ,7-heptanediol, 1 ,8-octanediol, 1 ,9-nonanediol, 1 ,10-decanediol, 1 ,12-dodecanediol, 3,3,4,4,5,5-hexafluro-1 ,5-pentanediol, 2,2,3,3,4,4,5,5-octafluoro-1 ,6- hexanediol, and 3,3,4,4,5,5,6,6,7,7,8,8,9,9,10,10-hexadecafluoro-1 ,12- dodecanediol; cycloaliphatic diols, for example, 1 ,4-cyclohexanediol, 1
• a preferred group of comonomer diols is selected from the group consisting of ethylene glycol, 2-methyl-1 ,3-propanediol, 2,2-dimethyl-1 ,3-propanediol, 2,2-diethyl-1 ,3- propanediol, 2-ethyl-2-(hydroxymethyl)-1 ,3-propanediol, C ⁇ - Cio diols (such as 1 ,6-hexanediol, 1 ,8-octanediol and 1 ,10-decanediol) and isosorbide, and mixtures thereof.
• a particularly preferred diol other than 1 ,3-propanediol is ethylene glycol, and C 6 - Ci 0 diols can be particularly useful as well.
• poly(trimethylene- ethylene ether) glycol such as described in US2004/0030095A1.
• Preferred poly(trimethylene-ethylene ether) glycols are prepared by acid catalyzed polycondensation of from 50 to about 99 mole% (preferably from about 60 to about 98 mole%, and more preferably from about 70 to about 98 mole%) 1 ,3-propanediol and up to 50 to about 1 mole% (preferably from about 40 to about 2 mole%, and more preferably from about 30 to about 2 mole%) ethylene glycol.
• a preferred PO3G for use in the processes disclosed herein has an Mn (number average molecular weight) of at least about 250, more preferably at least about 1000, and still more preferably at least about 2000.
• the Mn is preferably less than about 5000, more preferably less than about 4000, and still more preferably less than about 3500.
• Blends of PO3Gs can also be used.
• the PO3G can comprise a blend of a higher and a lower molecular weight PO3G, preferably wherein the higher molecular weight PO3G has a number average molecular weight of from about 1000 to about 5000, and the lower molecular weight PO3G has a number average molecular weight of from about 200 to about 950.
• the Mn of the blended PO3G will preferably still be in the ranges mentioned above.
• PO3G preferred for use herein is typically polydisperse, having a polydispersity (i.e. Mw/Mn) of preferably from about 1.0 to about 2.2, more preferably from about 1.2 to about 2.2, and still more preferably from about 1.5 to about 2.1.
• the polydispersity can be adjusted by using blends of PO3G.
• PO3G for use in the present invention preferably has a color value of less than about 100 APHA, and more preferably less than about 50 APHA.
• the estehfication of the PO3G is carried out by reaction with a (meth)acrylic acid or its equivalent.
• (meth)acrylic acid equivalent is meant compounds that perform substantially like "(meth)acrylic acid in reaction with polymeric glycols, as would be generally recognized by a person of ordinary skill in the relevant art.
• Monocarboxylic acid equivalents for the purpose of the present invention include, for example, esters of monocarboxylic acids, and ester-forming derivatives such as acid halides (e.g., acid chlorides) and anhydrides. Mixtures of acrylic acid, methacrylic acid and/or equivalents are also suitable.
• the acrylic esters compositions of poly(trimethylene ether) glycol? preferably comprise from about 50 to 100 wt%, more preferably from about 75 to 100 wt%, diester and from 0 to about 100 wt%, more preferably from 50 to about 100 wt%, monoester, based on the total weight of the esters.
• the mono- and diesters are esters of (meth)acrylic acid.
• the acrylic esters of poly(trimethylene ether) glycol are prepared by polycondensation of hydroxyl groups-containing monomers (monomers containing 2 or more hydroxyl groups) predominantly comprising 1 ,3-propanediol to form poly(thmethylene ether) glycol in the presence of an acid catalyst, followed by esterification of polytrimethylene ether glycol mixture with the acrylic acid in the presence of a polymerization inhibitor.
• the PO3G can be contacted, preferably in the presence of an inert gas, with the (meth)acrylic acid(s) at temperatures ranging from about 25 0 C to about 25O 0 C, preferably from about 75 0 C to about 15O 0 C.
• the process can be carried out at atmospheric pressure or under vacuum. During the contacting water is formed and can be removed in the inert gas stream or under vacuum to drive the reaction to completion.
• Any ratio of (meth)acrylic acid, or equivalents thereof, to hydroxyl groups can be used.
• the preferred ratio of acid to hydroxyl groups is from about 3:1 to about 1 :2, where the ratio can be adjusted to shift the ratio of mono ester to diester in the product.
• a 0.5:1 ratio or less of acid to hydroxyl is used.
• an esterification catalyst is generally used, preferably a mineral acid catalyst.
• acid catalysts include but are not restricted to sulfuric acid, aryl or alkyl sulfonic acid, triflic acid, hydhodic acid, and heterogeneous catalysts such as zeolites, heteropolyacid, amberlyst, dialkyl tin dilaurate, titanium alkoxide and ion exchange resin.
• Preferred esterification acid catalysts are selected from the group consisting of sulfuric acid, p-toluenesulfonic acid, methanesulfonic acid, triflic acid, dialkyl tin dilaurate, titanium alkoxide, and hydroiodic acid.
• the particularly preferred acid catalyst are sulfuric acid, triflic acid and ion exchange resins.
• the amount of catalyst used can be from about 0.01 wt% to about 10 wt% of the reaction mixture, preferably from 0.1 wt% to about 5 wt%, and more preferably from about 0.2 wt% to about 2 wt%, of the reaction mixture.
• an inhibitor is used, preferably 4- methoxyphenol.
• inhibitors include but are not restricted to alkyl phenols, alkoxyphenol, hydroxybezyl alcohol and hydroquinone having structure
• R1 , R2 and R3 are H, -CH 3 , -C 2 H 5 , -C 3 H 7 -C 4 H 9 , -OCH 3 , -OC 2 H 5 , - OC 3 H 7 -OC 4 H 9 , -CH 2 OH or mixtures thereof.
• the amount of the inhibitor can be from about 0.001 to 5 wt% of the product. A preferred range is from about 0.01 to 2.0 wt%.
• the esterification reaction can be conducted in the presence or absence of a solvent.
• solvents include but are not restricted to acetonitrile, cyclohexane, hexane, methylcyclohexane, heptane, octane, tetrahydrofuran, toluene and xylene.
• a preferred solvent is acetonitrile or toluene.
• the amount of solvent used can be from about 0 wt% to about 100 wt% of the reaction mixture, preferably from 20 wt% to about 100wt%, and more preferably from about 50 wt% to about 100 wt%, of the reaction mixture.
• a preferred method for esterification comprises polycondensing 1 ,3-propanediol reactant to polytrimethylene ether glycol using a mineral acid catalyst, then adding (meth)acrylic acid and carrying out the estehfcation without isolating and purifying the PO3G.
• the etherfication or polycondensation of 1 ,3-propanediol reactant to form polytrimethylene ether glycol is carried out using an acid catalyst as disclosed in US6977291 and US6720459.
• the etherification reaction may also be carried out using a polycondensation catalyst that contains both an acid and a base as described in JP2004-182974A.
• the polycondensation or etherification reaction is continued until desired molecular weight is reached, followed by the addition of solvent, calculated amount of (meth)acrylic acid and an inhibitor to the reaction mixture.
• the mixture is refluxed where about 30 to 70 % estehfcation takes place.
• the reaction is continued further while the water byproduct and solvent are removed while further esterification is in progress.
• the acid catalyst used for polycondensation of diol is also used for esterification. If necessary additional esterification catalyst can be added at the esterification stage.
• the esterification reaction can be carried out by reacting neat PO3G with (meth)acrylic acid or (meth)acrylic acid equivalent in the presence of an esterification catalyst followed by heating and removal of byproduct.
• esterification reaction can be carried out by reacting neat PO3G with (meth)acrylic acid chloride in the presence of an organic base such trialkylamine at low temperatures followed by heating.
• the ester produced in the esterification reaction may contain diester, monoester, or a combination of diester and monoester, and small amounts of acid catalyst, unreacted (meth)acrylic acid and diol depending on the reaction conditions.
• this product mixture is further processed to remove acid catalyst, unreacted carboxylic acid, and diol by the known conventional techniques such as water washings, base neutralization, filtration and/or distillation.
• Unreacted diol and acid catalyst can, for example, be removed by washing with deionized water.
• Unreacted carboxylic acid also can be removed, for example, by washing with deionized water or aqueous base solutions.
• Proton NMR can be used to identify the product of the esterification reaction, quantify the esterification and determine the number average molecular weight.
• polytrimethylene ether glycol acrylates have the following structural formula (I):
• Q represents the residue of a polytrimethylene ether glycol after abstraction of the hydroxyl groups
• Ri is H or CH 3
• Q has Mn within the range of from about 134 to about 5000.
• Each acrylic ester of the polytrimethylene ether glycol produced by the above disclosed process can further react with itself to make homopolymers, or can be reacted with another acrylic or vinyl monomer to create a broad range of copolymers with different tailored properties.
• the following acrylic ester monomers are among those useful for copolymerization: methyl acrylate, methyl methacrylate, ethyl acrylate, propyl acrylate, isopropyl acrylate, n-butyl acrylate, sec-butyl acrylate, isobutyl acrylate, tert-butyl acrylate, hexyl acrylate, heptyl acrylate, 2-heptyl acrylate, 2-ethylhexyl acrylate, 2-ethylbutyl acrylate, dodecyl acrylate, hexadecyl acrylate, isobornyl acrylate, and cyclohexyl acrylate.
• two or more monomers can be used for the copolymerization. Beside the acrylic ester monomers, the acrylic esters of the polytrimethylene ether glycol disclosed herein can be reacted with other type of monomers such as: acrylonitrile, butadiene, styrene, vinyl chloride, vinylidene chloride, and vinyl acetate.
• Free radical initiators such as azo compounds(e.g. 2,2'- azobisizobutironitrile), peroxides (e.g. hydrogen peroxide, benzoyl peroxide), or hydroperoxides can be used to initiate of the polymerization of acrylic ester monomers. Photochemical and radiation-initiated polymerization are also possible.
• the desired homo- and copolymer compositions can be obtained by bulk, solution, emulsion or suspension polymerization.
• the acrylic esters of the polytrimethylene ether glycol content can vary from 1 % to 99% and the other co-monomer content can vary from 1 % to 99%, more preferable from 1 % to 50%, and most preferable from 1 % to 25%.
• Materials made by the processes disclosed herein find use in a wide range of applications, including use as free radical crosslinkers, in polymer dispersions, in paints, coatings for wood, paper and plastics; inks; adhesives; lithography; and printed circuits.
• Many of the systems containing products of the processes disclosed herein are radiation curable, i.e., the materials are crosslinked when exposed to a source of radiation.
• the processes provide renewably-sourced polymers, which can find use as functional comonomers for flexible plastics, crosslinking agent and coagents, and the like. These products exhibit higher flexibility, higher resistance to reverse impact, and lower shrinkage than similar products that are not based on polytrimethylene ether) glycol diacrylate.
• Acrylic emulsion polymers can be used in animal leather production providing uniformity, break improvement, better durability and surface resistance.
• the obtained polymers can be useful items in the ceramic industry and can work as binders, deflocculants and additives. These polymers have a variety of uses in textile applications, including textile bonding and laminating, flocking, backcoating and pigment printing applications.
• Acrylics also used as binders for fiberfill and nonwoven fabrics. Acrylics are often used in automotive applications as backing of carseats and also as backing for furniture upholstery. In cosmetics and personal care formulations acrylics are broadly used as thickening agents.
• poly(trimethylene ether) glycol diacrylates formed from the processes disclosed herein can overcome some of the difficulties associated with similar materials.
• poly(ethylene) glycol diacrylate is a linear, semicrystalline polymer having primary reactive difunctionality.
• difunctional acrylates from poly(propylene) and poly(tetramethylene) glycols; however, these polymers generally undergo degradation during synthesis.
• the diacrylates formed from the processes disclosed herein overcome these difficulties by allowing the production of higher molecular weight diacrylates as well as materials which do not undergo degradation during synthesis. Also, they have a functionality close to 2.
• Susterra® propanediol and CerenolTM polyols are commercially available from DuPont Tate &Lyle Bioproducts, LLC (Loudon, TN) and DuPont de Nemours Co. Inc., (Wilmington, DE) respectively.
• Mn number average molecular weights
• the organic product was collected and dried using rotary evaporator at 35 0 C.
• the acrylic ester product was stabilized by 200 ppm of 2,6-bis(1 ,1-dimethylethyl)- 4-methylphenol (BHT) and the product was analyzed using proton NMR as shown in Table 1.
• the reaction temperature was slowly raised to 60 0 C and maintained at that temperature for 6 hours.
• the reaction mixture was cooled to about 35 0 C and then 50 ml_ of 5 % KOH solution, 100 ml_ of dichloromethane and 50 ml_ water were added.
• the mixture was agitated thoroughly for 30 minutes and transferred into a separating funnel.
• the resulting product was allowed to settle overnight.
• the organic part of the mixture was isolated and 500 ppm of 4-methoxy phenol was added.
• the solvent was removed using rotary evaporator under reduced pressure (300 to 500 mTorr) at 3O 0 C. 200 ppm of BHT was added to the final product.
• the obtained product was analyzed using NMR as shown in Table 1. Table 1.

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