U.S. patent application number 17/128322 was filed with the patent office on 2021-04-15 for coating system.
This patent application is currently assigned to Elementis Specialties, Inc.. The applicant listed for this patent is Elementis Specialties, Inc.. Invention is credited to Yanhui CHEN, Prashant DESHMUKH, Maurice GRAY, Rajni GUPTA, James A. HECK, Wayne HOYTE, Wouter IJDO.
Application Number | 20210108088 17/128322 |
Document ID | / |
Family ID | 1000005291843 |
Filed Date | 2021-04-15 |
United States Patent
Application |
20210108088 |
Kind Code |
A1 |
GUPTA; Rajni ; et
al. |
April 15, 2021 |
COATING SYSTEM
Abstract
A coating composition containing a crosslinkable coating
composition. The coating system comprises: ingredient A that has at
least two protons that can be activated to form a Michael carbanion
donor; ingredient B that functions as a Michael acceptor having at
least two ethylenically unsaturated functionalities each activated
by an electron-withdrawing group; and a catalyst system. In one
embodiment, the catalyst system comprises diethyl carbonate,
quaternary ammonium hydroxide or quaternary ammonium alkoxide,
ethanol and 4-6 wt. % water. In another embodiment, the catalyst
system comprises carbon dioxide, quaternary ammonium hydroxide or
quaternary ammonium alkoxide, ethanol and 2-4 wt. % water. In
certain embodiments, the coating composition optionally further
comprising ammonium carbamate
(H.sub.2NR.sub.8R.sub.9+--OC.dbd.ONR.sub.8R.sub.9), wherein R.sub.8
R.sub.9 are each independently selected from hydrogen, a linear or
branched substituted or unsubstituted alkyl group having 1 to 22
carbon atoms; 1 to 8 carbon atoms; 1 to 3 carbon atoms.
Inventors: |
GUPTA; Rajni; (Princeton,
NJ) ; IJDO; Wouter; (Yardley, PA) ; CHEN;
Yanhui; (Princeton, NJ) ; DESHMUKH; Prashant;
(Plainsboro, NJ) ; HECK; James A.; (Robbinsville,
NJ) ; HOYTE; Wayne; (Parlin, NJ) ; GRAY;
Maurice; (Saint Albans, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Elementis Specialties, Inc. |
East Windsor |
NJ |
US |
|
|
Assignee: |
Elementis Specialties, Inc.
East Windsor
NJ
|
Family ID: |
1000005291843 |
Appl. No.: |
17/128322 |
Filed: |
December 21, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16007225 |
Jun 13, 2018 |
10894886 |
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17128322 |
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62518791 |
Jun 13, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08G 63/21 20130101;
A61K 2800/95 20130101; C08K 5/17 20130101; A61K 8/4986 20130101;
C08K 5/109 20130101; C09D 4/06 20130101; C09D 7/63 20180101; A61K
8/44 20130101; C09D 167/02 20130101; C09D 7/45 20180101; A61K 8/416
20130101; C08J 2367/02 20130101; A61K 8/494 20130101; A61K 8/33
20130101; A61K 8/85 20130101; A61Q 3/02 20130101; C08J 3/24
20130101; A61K 8/731 20130101; C09D 7/20 20180101 |
International
Class: |
C09D 4/06 20060101
C09D004/06; C09D 7/20 20060101 C09D007/20; C08G 63/21 20060101
C08G063/21; C08J 3/24 20060101 C08J003/24; C09D 167/02 20060101
C09D167/02; C09D 7/63 20060101 C09D007/63; C09D 7/45 20060101
C09D007/45; A61K 8/33 20060101 A61K008/33; A61K 8/41 20060101
A61K008/41; A61K 8/44 20060101 A61K008/44; A61K 8/49 20060101
A61K008/49; A61K 8/73 20060101 A61K008/73; A61K 8/85 20060101
A61K008/85; A61Q 3/02 20060101 A61Q003/02 |
Claims
1-38. (canceled)
39. A coating composition containing a crosslinkable coating
composition comprising: ingredient A that has at least two protons
that can be activated to form a Michael carbanion donor; ingredient
B that functions as a Michael acceptor having at least two
ethylenically unsaturated functionalities each activated by an
electron-withdrawing group; ammonium carbamate
(H.sub.2NR.sub.8R.sub.9+--OC.dbd.ONR.sub.8R.sub.9), wherein
R.sub.8, R.sub.9 are each independently selected from hydrogen, a
linear or branched substituted or unsubstituted alkyl group each
having a number of carbon atoms selected from the group consisting
of 1 to 22 carbon atoms; 1 to 8 carbon atoms; and 1 to 3 carbon
atoms; an additive selected from the group consisting of: wetting
agents, defoamers, rheological control agents, ultraviolet (UV)
light stabilizers, dispersing agents, flow and leveling agents,
optical brighteners, gloss additives, radical inhibitors, radical
initiators, adhesions promotors, gloss additives, radical
inhibitors, radical initiators, plasticizers and combinations
thereof; and a catalyst system selected from the group consisting
of (i) a catalyst system of diethyl carbonate, quaternary ammonium
hydroxide or quaternary ammonium alkoxide, ethanol and optionally
4-6 wt. % water relative to total weight of the crosslinkable
coating composition; and (ii) a catalyst system of carbon dioxide,
quaternary ammonium hydroxide or quaternary ammonium alkoxide,
ethanol and optionally 2-4 wt. % water relative to total weight of
the crosslinkable coating composition.
40. The coating composition according to claim 39, wherein
ingredient A is selected from the group consisting of compounds,
oligomers or polymers.
41. The coating composition according to claim 40, wherein the
ingredient A is independently selected from a malonate group
containing compound, a malonate group containing oligomer, a
malonate group containing polymer, an acetoacetate group containing
compound, an acetoacetate group containing oligomer, an
acetoacetate group containing polymer or combinations thereof.
42. The coating composition according to claim 41, wherein the
malonate group containing compound, malonate group containing
oligomer, malonate group containing polymer, an acetoacetate group
containing compound, acetoacetate group containing oligomer, or
acetoacetate group containing polymer are each selected from the
group consisting of: polyurethanes, polyesters, polyacrylates,
epoxy polymers, polyamides, polyesteramides or polyvinyl polymers,
wherein such compounds, oligomers or polymers have a malonate group
or acetoacetate group located in a main chain of such compound or
oligomer or polymer or a side chain of such compound or oligomer or
polymer.
43. The coating composition according to claim 42, wherein
ingredient B is selected from the group consisting of acrylates,
fumarates, maleates and combinations thereof.
44. The coating composition according to claim 43, wherein the
acrylate is independently selected from the group consisting of
hexanediol diacrylate, trimethylol propane triacrylate,
pentaerythritol triacrylate, di-trimethylolpropane tetraacrylate,
bis(2-hydroxyethyl acrylate), trimethylhexyl dicarbamate,
bis(2-hydroxyethyl acrylate) 1,3,3-trimethylcyclohexyl dicarbamate,
bis(2-hydroxylethyl acrylate) methylene dicyclohexyl dicarbamate
and combinations thereof.
45. The coating composition according to claim 42, wherein
ingredient B is independently selected from the group consisting of
polyesters, polyurethanes, polyethers and/or alkyd resins each
containing at least two pendant ethylenically unsaturated groups
each activated by an electron-withdrawing group.
46. The coating composition according to claim 42, wherein
ingredient B is independently selected from the group consisting of
polyesters, polyurethanes, polyethers and/or alkyd resins each
containing at least one pendant acryloyl functional group.
47. The coating composition according to claim 42, further
comprising an ingredient D having one or more reactive protons that
are more acidic than the two protons of ingredient A, with respect
to pKa.
48. The coating composition according to claim 47, wherein the one
or more reactive protons of ingredient D are less acidic than the
ammonium cation of the optional ammonium carbamate, with respect to
pKa.
49. The coating composition coating composition according to claim
42, further comprising an organic solvent.
50. The coating composition according to claim 49, wherein the
organic solvent is independently selected from the group consisting
of an alcohol, ester, ether, glycol ether, ketone, aromatic and
combinations thereof.
51. The coating composition according to claim 50, wherein the
alcohol is independently selected from the group consisting of
ethanol, iso-propanol, butanol, iso-butanol, t-butanol and
combinations thereof.
52. The coating composition according to claim 42, wherein the
catalyst system initiates Michael Addition to achieve crossing
linking when the crosslinkable coating composition is applied to a
surface.
53. The coating composition according to claim 42, wherein
ingredient A, ingredient B and the catalyst system are contained in
a container having two or more chambers, which are separated from
one another.
54. The coating composition according to claim 53, wherein
ingredient A and ingredient B are contained in separate chambers to
inhibit any reaction.
55. The coating composition according to claim 53, wherein the
catalyst system is contained in the chamber having ingredient A,
and optionally containing CO.sub.2.
56. The coating composition according to claim 53, wherein
ingredient A and ingredient B are contained in the same chamber and
the catalyst system is contained in a separate chamber to inhibit
any reaction and said separate chamber optionally containing
CO.sub.2.
57. The coating composition according to claim 42, wherein
ingredient A and ingredient B and catalyst system are contained in
a container having a single chamber, wherein the container
optionally (i) contains CO.sub.2.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority benefit from U.S.
Provisional Patent Application 62/518,791 filed Jun. 13, 2017 which
is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The invention provides for a coating composition containing
a carbonate catalyst system with water.
BACKGROUND
[0003] The coatings industry continues to develop new chemistries
as performance requirements for decorative and functional coatings
evolve. Drivers for change are varied and these can include:
regulatory controls to reduce VOC emissions, concerns about toxic
hazards of coating raw materials, a desire for cost reduction,
commitments to sustainability, and a need for increased product
effectiveness.
[0004] Highly crosslinked, durable coating compositions can be
achieved using Michael addition chemistry. The Michael addition
reaction involves the nucleophilic addition of a Michael donor,
such as a carbanion or another nucleophile to a Michael acceptor,
such as an .alpha.,.beta.-unsaturated carbonyl. As such, the base
catalyzed addition of activated methylene moieties to electron
deficient C.dbd.C double bonds are known in coatings applications.
Representative examples of suitable materials that can provide
activated methylene or methine groups are generally disclosed in
U.S. Pat. No. 4,871,822, which resins contain a methylene and/or
monosubstituted methylene group in the alpha-position to two
activating groups such as, for example, carbonyl, cyano, sulfoxide
and/or nitro groups. Preferred are resins containing a methylene
group in the alpha-position to two carbonyl groups, such as
malonate and/or acetoacetate group-containing materials, malonates
being most preferred. The .alpha.,.beta.-unsaturated carbonyl
typically is an acrylate material and representative materials have
been disclosed in U.S. Pat. No. 4,602,061. The Michael reaction is
fast, can be carried out at ambient temperatures and gives a
chemically stable crosslinking bond without forming any reaction
by-product.
[0005] A typical crosslinkable coating composition comprises a
resin ingredient A (Michael donor), a resin ingredient B (Michael
acceptor) and a base to start and catalyze the Michael addition
reaction. The base catalyst should be strong enough to abstract,
i.e. activate a proton from resin ingredient A to form the Michael
donor carbanion species. Since the Michael addition cure chemistry
can be very fast, the coating formulator is challenged to control
the speed of the reaction to achieve an acceptable balance of pot
life, open time, tack free time and cure time. Pot life is defined
as the amount of time during which the viscosity of a mixed
reactive system doubles. Working life or working time informs the
user how much time they have to work with a reactive two part
system before it reaches such a high state of viscosity, or other
condition, that it cannot be properly worked with to produce an
acceptable application result. Gel time is the amount of time it
takes for a mixed, reactive resin system to gel or become so highly
viscous that it has lost fluidity. The open time of a coating is a
practical measure of how much time it takes for a drying or curing
coating to reach a stage where it can no longer be touched by brush
or roller when applying additional coating material without leaving
an indication that the drying or curing coating and newly applied
coating did not quite flow together. These indications normally
take the form of brush or roller marks and sometimes a noticeable
difference in sheen levels. The tack free time is the amount of
time it takes for a curing or drying coating to be no longer sticky
to the touch, i.e. the time for a system to become hard to the
touch, with no tackiness. Cure time is the amount of time it takes
for a coating system to reach full final properties.
[0006] The Michael reaction starts the very moment when coating
resin ingredients A and B are mixed together with a suitable base.
Since it is a fast reaction, the material in a mixing pot starts to
crosslink and the fluid viscosity starts to rise. This limits the
pot life, working time and general use as a coating. A dormant
initiator that is essentially passive while coating material
remains in a mixing vessel but that activates the Michael addition
reaction upon film formation allows for longer pot life and working
time, yet would show good open time, tack free time and cure time.
Hence, the application of dormant initiator technology can provide
the formulator with tools to control the speed of the reaction in
order to achieve desirable cure characteristics.
[0007] U.S. Pat. No. 8,962,725 describes a blocked base catalyst
for Michael addition, which is based on substituted carbonate
salts. Preferred Michael donor resins are based on malonate and
Michael acceptor resins are acrylates. The substituted carbonates
can bear substituents, but these should not substantially interfere
with the crosslinking reaction between malonate and acrylate. The
carbonate salts release carbon dioxide and a strong base upon
activation by means of film formation. The base is either hydroxide
or alkoxide. Before practical pot life and gel times are achieved
with acceptable curing characteristics, the carbonate requires
presence of a certain amount of water in the coating formulation
for the blocking of the base to become effective. All disclosed
blocked carbonate examples utilize methanol and/or water. cl
SUMMARY OF INVENTION
[0008] In one embodiment, the present invention provides for a
coating composition containing a crosslinkable coating composition
comprising: ingredient A that has at least two protons that can be
activated to form a Michael carbanion donor; ingredient B that
functions as a Michael acceptor having at least two ethylenically
unsaturated functionalities each activated by an
electron-withdrawing group; and a catalyst system. In one
embodiment, the catalyst system comprises diethyl carbonate,
quaternary ammonium hydroxide or quaternary ammonium alkoxide,
ethanol and 4-6 wt. % water. In another embodiment, the catalyst
system comprises carbon dioxide, quaternary ammonium hydroxide or
quaternary ammonium alkoxide, ethanol and 2-4 wt. % water. In
certain embodiments, the coating composition optionally further
comprising ammonium carbamate
(H.sub.2NR.sub.8R.sub.9+--OC.dbd.ONR.sub.8R.sub.9), wherein R.sub.8
R.sub.9 are each independently selected from hydrogen, a linear or
branched substituted or unsubstituted alkyl group having 1 to 22
carbon atoms; 1 to 8 carbon atoms; 1 to 3 carbon atoms.
[0009] In one embodiment, the present invention provides a coating
composition wherein ingredient A is selected from the group
consisting of compounds, oligomers or polymers. In one such
embodiment, ingredient A is independently selected from a malonate
group containing compound, a malonate group containing oligomer, a
malonate group containing polymer, an acetoacetate group containing
compound, an acetoacetate group containing oligomer, an
acetoacetate group containing polymer or combinations thereof. In
another such embodiment, the malonate group containing compound,
malonate group containing oligomer, malonate group containing
polymer, an acetoacetate group containing compound, acetoacetate
group containing oligomer, or acetoacetate group containing polymer
are each selected from the group consisting of: polyurethanes,
polyesters, polyacrylates, epoxy polymers, polyamides,
polyesteramides or polyvinyl polymers, wherein such compounds,
oligomers or polymers have a malonate group or acetoacetate group
located in a main chain of such compound or oligomer or polymer or
a side chain of such compound or oligomer or polymer.
[0010] In one embodiment, the present invention provides a coating
composition wherein wherein ingredient B is selected from the group
consisting of acrylates, fumarates, maleates and combinations
thereof. In one such embodiment, the acrylate is independently
selected from the group consisting of hexanediol diacrylate,
trimethylol propane triacrylate, pentaerythritol triacrylate,
di-trimethylolpropane tetraacrylate bis(2-hydroxyethyl acrylate),
trimethylhexyl dicarbamate, bis(2-hydroxyethyl acrylate)
1,3,3-trimethylcyclohexyl dicarbamate, bis(2-hydroxyethyl acrylate)
methylene dicyclohexyl dicarbamate and combinations thereof.
[0011] In one embodiment, the present invention provides a coating
composition wherein ingredient B is independently selected from the
group consisting of polyesters, polyurethanes, polyethers and/or
alkyd resins each containing at least two pendant ethylenically
unsaturated groups each activated by an electron-withdrawing
group.
DETAILED DESCRIPTION
[0012] The invention disclosed here is a crosslinkable composition
comprising a resin ingredient A (Michael donor), a resin ingredient
B (Michael acceptor) and a catalyst system C. The invention
generally is useful as a coating composition.
[0013] Resin ingredient A (Michael donor): Resin ingredients A are
compounds, oligomers or polymers that contain functional groups
that have reactive protons that can be activated to produce a
carbanion Michael donor. In one embodiment, the functional group
can be a methylene or methine group and resins have been described
in U.S. Pat. Nos. 4,602,061 and 8,962,725 for example. In one
embodiment, resin ingredients A are those derived from malonic acid
or malonate esters, i.e. malonate. Oligomeric or polymeric malonate
compounds include polyurethanes, polyesters, polyacrylates, epoxy
resins, polyamides, polyesteramides or polyvinyl resins each
containing malonate groups, either in the main chain or the side
chain or in both.
[0014] In one embodiment, polyurethanes having malonate groups may
be obtained, for instance, by bringing a polyisocyanate into
reaction with a hydroxyl group containing ester or polyester of a
polyol and malonic acid/malonates, by esterification or
transesterification of a hydroxyfunctional polyurethane with
malonic acid and/or a dialkyl malonate. Examples of polyisocyanates
include hexamethylenediisocyanate, trimethylhexamethylene
diisocyanate, isophorone diisocyanate, toluene diisocyanate and
addition products of a polyol with a diisocyanate, such as that of
trimethylolpropane to hexamethylene diisocyanate. In one
embodiment, the polyisocyanate is selected from isophorone
diisocyanate and trimethyhexamethylene diisocyanate. In another
embodiment, the polyisocyanate is isophorone diisocyanate. In some
embodiments, hydroxyfunctional polyurethanes include the addition
products of a polyisocyanate, such as the foregoing
polyisocyanates, with di- or polyvalent hydroxy compounds,
including diethyleneglycol, neopentyl glycol, dimethylol
cyclohexane, trimethylolpropane, 1,3-propandiol, 1,4-butanediol,
1,6-hexanediol and polyether polyols, polyester polyols or
polyacrylate polyols. In some embodiments, the di- or polyvalent
hydroxy compounds include diethyleneglycol, 1,3-propanediol,
1,4-butanediol and 1,6-hexanediol. In other embodiments, the di- or
polyvalent hydroxy compounds include diethyleneglycol and
1,6-hexanediol.
[0015] In one embodiment, malonic polyesters may be obtained, for
instance, by polycondensation of malonic acid, an alkylmalonic
acid, such as ethylmalonic acid, a mono- or dialkyl ester of such a
carboxylic acid, or the reaction product of a malonic ester and an
alkylacrylate or methacrylate, optionally mixed with other di- or
polycarboxylic with one or more dihydroxy and/or polyhydroxy
compounds, in combination or not with mono hydroxy compounds and/or
carboxyl compounds. In some embodiments, polyhydroxy compounds
include compounds containing 2-6 hydroxyl group and 2-20 carbon
atoms, such as ethylene glycol, diethyleneglycol, propylene glycol,
trimethylol ethane, trimethylolpropane, glycerol, pentaerythritol,
1,4-butanediol, 1,6-hexanediol, cyclohexanedimethanol,
1,12-dodecanediol and sorbitol. In some embodiments, the
polyhydroxyl compounds include diethylene glycol, propylene glycol,
1,4-butanediol and 1,6-hexanediol. In other embodiments, the
polyhydroxyl compounds include propylene glycol and 1,6-hexanediol.
In certain embodiments, the polyhydroxy may be a primary alcohol
and in certain other embodiments, the polyhydroxy may be a
secondary alcohol. Examples of polyols with secondary alcohol
groups are 2,3-butanediol, 2,4-pentanediol and 2,5-hexanediol and
the like.
[0016] In one embodiment, malonate group-containing polymers also
may be prepared by transesterification of an excess of dialkyl
malonate with a hydroxy functional polymer, such as a vinyl
alcohol-styrene copolymer. In this way, polymers with malonate
groups in the side chains are formed. After the reaction, the
excess of dialkyl malonate may optionally be removed under reduced
pressure or be used as reactive solvent.
[0017] In one embodiment, malonate group or acetoacetate group
containing polymers may also be obtained from reaction with
malonate or acetoacetonate with polyols, such as those polyols that
are commercially sold for reaction with isocyanates to form
polyurethane coatings.
[0018] In one embodiment, malonic epoxy esters may be prepared by
esterifying an epoxy polymer with malonic acid or a malonic
monoester, or by transesterifying with a dialkylmalonate,
optionally in the presence of one or more other carboxylic acids or
derivatives thereof.
[0019] In one embodiment, polyamides having malonate groups may be
obtained in the same manner as polyesters, at least part of the
hydroxy compound(s) being replaced with a mono- or polyvalent
primary and/or secondary amine, such as cyclohexylamine, ethylene
diamine, isophorone diamine, hexamethylene diamine, or diethylene
triamine.
[0020] In some embodiments, such polyamide compounds can be
obtained when 12-hydroxystearic acid is reacted with a diamine such
as ethylenediamine. Such polyamides have secondary alcohol groups,
which can be esterified with malonic acid or malonate in a second
reaction step. In some embodiments, other diamines may also be used
in the reaction with 12-hydroxystearic acid, for example:
xylylenediamine, butylenediamine, hexamethylenediamine,
dodecamethylenediamine, and even dimer amine, which is derived from
dimer acid. Polyamines may also be used, but in a right
stoichiometric ratio as to avoid gelling of the polyamide in the
reactor. Lesquerolic acid may also be used in reactions with
polyamines to yield polyamides bearing secondary alcohol groups,
which can be used in reactions with malonate to form malonate
containing compounds. Reactions that yield malonamides are much
less desirable.
[0021] In some embodiments, the above mentioned malonate resins may
be blended together to achieve optimized coatings properties. Such
blends can be mixtures of malonate modified polyurethanes,
polyesters, polyacrylates, epoxy resins, polyamides,
polyesteramides and the like, but mixtures can also be prepared by
blending various malonate modified polyesters together. In some
other embodiments, various malonate modified polyurethanes can be
mixed together, or various malonate modified polyacrylates, or
malonate modified epoxy resins, or various malonate modified
polyamides, malonate modified polyesteramides.
[0022] In certain embodiments, malonate resins are malonate group
containing oligomeric esters, polyesters, polyurethanes, or epoxy
esters having 1-100, or 2-20 malonate groups per molecule. In some
such embodiments, the malonate resins should have a number average
molecular weight in the range of from 250 to 10,000 and an acid
number not higher than 5, or not higher than 2. Use may optionally
be made of malonate compounds in which the malonic acid structural
unit is cyclized by formaldehyde, acetaldehyde, acetone or
cyclohexanone. In some embodiments, molecular weight control may be
achieved by the use of end capping agents, typically monofunctional
alcohol, monocarboxylic acid or esters. In one embodiment, malonate
compounds may be end capped with one or more of 1-hexanol,
1-octanol, 1-dodecanol, hexanoic acid or its ester, octanoic acid
or its esters, dodecanoic acid or its esters, diethyleneglycol
monoethyl ether, trimethylhexanol, and t-butyl acetoacetate, ethyl
acetoacetate. In one such embodiment, the malonate is end capped
with 1-octanol, diethyleneglycol monoethyl ether, trimethylhexanol,
t-butyl acetoacetate and ethyl acetoacetate. In another such
embodiment, the malonate is end capped t-butyl acetoacetate, ethyl
acetoacetate and combinations thereof.
[0023] Monomeric malonates may optionally be used as reactive
diluents, but certain performance requirements may necessitate
removal of monomeric malonates from resin ingredient A.
[0024] In some embodiments, resin ingredients A include oligomeric
and/or polymeric acetoacetate group-containing resins. In some
embodiments, such acetoacetate group-containing resins are
acetoacetic esters as disclosed in U.S. Pat. No. 2,759,913,
diacetoacetate resins as disclosed in U.S. Pat. No. 4,217,396 and
acetoacetate group-containing oligomeric and polymeric resins as
disclosed in U.S. Pat. No. 4,408,018. In some embodiments,
acetoacetate group-containing oligomeric and polymeric resins can
be obtained, for example, from polyalcohols and/or
hydroxy-functional polyether, polyester, polyacrylate, vinyl and
epoxy oligomers and polymers by reaction with diketene or
transesterication with an alkyl acetoacetate. Such resins may also
be obtained by copolymerization of an acetoacetate functional
(meth)acrylic monomer with other vinyl- and/or acrylic-functional
monomers. In certain other embodiments, the acetoacetate
group-containing resins for use with the present invention are the
acetoacetate group-containing oligomers and polymers containing at
least 1, or 2-10, acetoacetate groups. In some such embodiments,
such acetoacetate group containing resins should have Mn in the
range of from about 100 to about 5000 g/mol, and an acid number of
about 2 or less. Resins containing both malonate and acetoacetate
groups in the same molecule may also be used.
[0025] In another embodiment, the above mentioned malonate group
containing resins and acetoacetate group-containing resins may also
be blended to optimize coatings properties as desired, often
determined by the intended end application.
[0026] Structural changes at the acidic site of malonate or
acetoacetate can alter the acidity of these materials and
derivatives thereof. For instance, pKa measurements in DMSO show
that diethyl methylmalonate (MeCH(CO.sub.2Et).sub.2) has a pKa of
18.7 and diethyl ethylmalonate (EtCH(CO.sub.2Et).sub.2) has a pKa
of 19.1 whereas diethyl malonate (CH.sub.2(CO.sub.2Et).sub.2) has a
pKa of 16.4. Resin ingredient A may contain such substituted
moieties and therewith show changes in gel time, open time, cure
time and the like. For example, resin ingredient A may be a
polyester derived from a polyol, diethyl malonate and diethyl
ethylmalonate.
[0027] Resin ingredient B (Michael acceptor): Resin ingredients B
(Michael acceptor) generally can be materials with ethylenically
unsaturated moieties in which the carbon-carbon double bond is
activated by an electron-withdrawing group, e.g. a carbonyl group
in the alpha-position. In some embodiments, resin ingredients B are
described in: U.S. Pat. Nos. 2,759,913, 4,871,822, 4,602,061,
4,408,018, 4,217,396 and 8,962,725. In certain embodiments, resin
ingredients B include acrylates, fumarates and maleates.
[0028] In some embodiments, resin ingredients B are the acrylic
esters of chemicals containing 2-6 hydroxyl groups and 2-20 carbon
atoms. These esters may optionally contain hydroxyl groups. In some
such embodiments, examples of such acrylic esters include
hexanediol diacrylate, trimethylolpropane triacrylate,
pentaerythritol triacrylate, di-trimethylolpropane tetraacrylate.
In one such embodiment, acrylic esters include trimethylolpropane
triacrylate, di-trimethylolproane tetraacrylate, dipentaerythritol
hexaacrylate, pentaerythritol ethoxylated (EO).sub.n tetraacrylate,
trimethylolpropane ethoxylated(EO).sub.n triacrylate and
combinations thereof. In another embodiment, acrylamides may be
used as a resin ingredient B.
[0029] In other embodiments, resin ingredients B are polyesters
based upon maleic, fumaric and/or itaconic acid (and maleic and
itaconic anhydride), and chemicals with di- or polyvalent hydroxyl
groups, optionally including materials with a monovalent hydroxyl
and/or carboxyl functionality.
[0030] In other embodiments, resin ingredients B are resins such as
polyesters, polyurethanes, polyethers and/or alkyd resins each
containing at least two pendant ethylenically unsaturated groups
each activated by an electron-withdrawing group. These include, for
example, urethane acrylates obtained by reaction of a
polyisocyanate with an hydroxyl group-containing acrylic ester,
e.g., an hydroxyalkyl ester of acrylic acid or a resins prepared by
esterification of a polyhydroxyl material with acrylic acid;
polyether acrylates obtained by esterification of an hydroxyl
group-containing polyether with acrylic acid; polyfunctional
acrylates obtained by reaction of an hydroxyalkyl acrylate with a
polycarboxylic acid and/or a polyamino resin; polyacrylates
obtained by reaction of acrylic acid with an epoxy resin; and
polyalkylmaleates obtained by reaction of a monoalkylmaleate ester
with an epoxy polymer and/or an hydroxy functional oligomer or
polymer. In certain embodiments, polyurethane acrylate resins may
be prepared by reaction of hydroxyalkyl acrylate with
polyisocyanate. Such polyurethane acrylate resins independently
include bis(2-hydroxyethyl acrylate) trimethylhexyl dicarbamate
[2-hydroxyethyl acrylate trimethylhexamethylene diisocyanate (TMDI)
adduct], bis(2-hydroxyethyl acrylate) 1,3,3-trimethylcyclohexyl
dicarbamate [2-hydroxyethyl acrylate
1,3,3-trimethylcyclohexyldiisocyanate/isophorone diisocyanate
(IPDI) adduct], bis(2-hydroxyethyl acrylate) hexyl dicarbamate
[2-hydroxyethyl acrylate hexamethylene diisocyanate (HDI) adduct],
bis(2-hydroxyethyl acrylate) methylene dicyclohexyl dicarbamate
[2-hydroxyethyl acrylate methylene dicyclohexyl diisocyanate (HMDI)
adduct], bis(2-hydroxylethyl acrylate) methylenediphenyl
dicarbamate [2-hydroxyethyl acrylate methylenediphenyl diisocyanate
(MDI) adduct], bis(4-hydroxybutyl acrylate)
1,3,3-trimethylcyclohexyl dicarbamate [4-hydroxybutyl acrylate IPDI
adduct], bis(4-hydroxybutyl acrylate) trimethylhexyl dicarbamate
[4-hydroxybutyl acrylate TMDI adduct], bis(4-hydroxybutyl acrylate)
hexyl dicarbamate [4-hydroxybutyl acrylate HDI adduct],
bis(4-hydroxybutyl acrylate) methylene dicyclohexyl dicarbamate
[4-hydroxybutyl acrylate HMDI adduct], bis(4-hydroxybutyl acrylate)
methylenediphenyl dicarbamate [4-hydroxybutyl acrylate MDI
adduct].
[0031] In other embodiments, resin ingredients B have unsaturated
acryloyl functional groups. In other certain embodiments, resin
ingredient B is independently selected from the group consisting of
polyesters, polyurethanes, polyethers and/or alkyd resins each
containing at least one pendant acryloyl functional group.
[0032] In certain embodiments, the acid value of the activated
unsaturated group-containing material (resin ingredient B) is
sufficiently low to not substantially impair the Michael addition
reaction, for example less than about 2, and further for example
less than 1 mg KOH/g.
[0033] As exemplified by the previously incorporated references,
these and other activated unsaturated group containing resins, and
their methods of production, are generally known to those skilled
in the art, and need no further explanation here. In certain
embodiments, the number of reactive unsaturated group ranges from 2
to 20, the equivalent molecular weight (EQW: average molecular
weight per reactive functional group) ranges from 100 to 2000, and
the number average molecular weight Mn ranges from 100 to 5000.
[0034] In one embodiment, the reactive part of resin ingredients A
and B can also be combined in one A-B type molecule. In this
embodiment of the crosslinkable composition both the methylene
and/or methine features as well as the .alpha.,.beta.-unsaturated
carbonyl are present in the same molecule, be it a monomer,
oligomer or polymer. Mixtures of such A-B type molecules with
ingredient A and B are also useful.
[0035] Each of the foregoing embodiments of resin ingredient A and
resin ingredient B may be combined with the various embodiments of
a catalyst system ingredient C, described below, to arrive at the
inventions described herein. In one embodiment, resin ingredient A
is a polyester malonate composition and resin ingredient B is a
polyester acrylate. In another embodiment, resin ingredient A is a
polyurethane malonate composition and resin ingredient B is a
polyester acrylate. In another embodiment, resin ingredient A is a
polyurethane malonate composition and resin ingredient B is a
polyester acrylate. In another embodiment, resin ingredient A is a
polyurethane malonate composition and resin ingredient B is a
polyurethane acrylate. In another embodiment, resin ingredient A is
a polyester malonate having acetoacetate end groups and resin
ingredient B is a polyester acrylate. In yet another embodiment,
resin ingredient A is a polyester malonate having acetoacetate end
groups and resin ingredient B is a polyurethane acrylate. In still
yet another embodiment, resin ingredient A is a polyester malonate
having acetoacetate end groups and resin ingredient B is a mixture
of polyester acrylate and polyurethane acrylate.
[0036] In the foregoing embodiments, the number of reactive protons
for resin ingredients A, and the number of
.alpha.,.beta.-unsaturated carbonyl moieties on resin ingredient B
can be utilized to express desirable ratios and ranges for resin
ingredients A and B. Typically, the mole ratio of reactive protons
of ingredient A that can be activated with subsequent carbanion
formation relative to the activated unsaturated groups on
ingredient B is in the range between 10/1 and 0.1/1, or between 4/1
and 0.25/1, or between 3.3/1 and 0.67/1. However, the optimal
amount strongly depends also on the number of reactive groups
present on ingredients A and/or B.
[0037] The amount of catalyst system used, expressed as mole ratio
of protons that can be abstracted to form an activated Michael
donor species (e.g. the methylene group of malonate can provide two
protons for reactions, while a methine group can provide one proton
to form an activated species) relative to catalyst, ranges from
about 1000/1 to 1/1, or from 250/1 to 10/1, or from 125/1 to 20/1
but the optimal amount to be used depends also on the amount of
solvent present, reactivity of various acidic protons present on
resin ingredients A and/or B.
Catalyst System C:
[0038] In one embodiment, the catalyst system comprises diethyl
carbonate, a quaternary ammonium hydroxide or a quaternary ammonium
alkoxide, ethanol and 4-6 wt. % water relative to total weight of
the crosslinkable composition.
[0039] In another embodiment, the catalyst system comprising carbon
dioxide, a quaternary ammonium hydroxide or a quaternary ammonium
alkoxide, ethanol and 2-4 wt. % water relative to total weight of
the crosslinkable composition.
[0040] Examples of a quaternary ammonium cations, either as
hydroxides or alkoxides, include dimethyl diethylammonium,
dimethyldipropyl ammonium, triethylmethylammonium,
tripropylmethylammonium, tributylmethylammonium,
tripentylmethylammonium, trihexylmethylammonium tetraethylammonium,
tetrapropyl ammonium, tetrabutylammonium, tetrapentylammonium,
tetrahexylammonium, benzyltrimethylammonium,
benzyltriethylammonium, benzyltripropylammonium,
benzyltributylammonium, benzyltripentyammonium, and
benzyltrihexylammonium. The alkoxide is a conjugate base of an
alcohol and examples of the alkoxide include ethoxide, isopropoxide
and tert-butoxide.
[0041] In some embodiments, the catalyst system further comprises
ammonium carbamate
(H.sub.2NR.sub.8R.sub.9+--OC.dbd.ONR.sub.8R.sub.9), wherein R.sub.8
R.sub.9 are each independently selected from hydrogen, a linear or
branched substituted or unsubstituted alkyl group having 1 to 22
carbon atoms; 1 to 8 carbon atoms; 1 to 3 carbon atoms.
[0042] In some embodiments, the ammonium carbamate is independently
selected from ammonium carbamate, methylammonium methylcarbamate,
ethylammonium ethylcarbamate, propylammonium propylcarbamate,
isopropylammonium isopropylcarbamate, butylammonium butylcarbamate,
isobutylammonium isobutylcarbamate, pentylammonium pentylcarbamate,
and hexylammonium hexylcarbamate. In other embodiments, the
ammonium carbamate is derived from carbamates independently
selected from dimethylammonium dimethylcarbamate, diethylammonium
diethylcarbamate, dipropylammonium dipropylcarbamate,
dibutylammonium dibutylcarbamate, diisobutylammonium
diisobutylcarbamate, dipentylammonium dipentylcarbamate,
dihexylammonium dihexylcarbamate, and dibenzylammonium
dibenzylcarbamate. In other embodiments, the ammonium carbamate is
derived from carbamates independently selected from
N-methylethylammonium methylethylcarbamate, N-methylpropylammonium
methylpropylcarbamate, and N-methylbenzylammonium
methylbenzylcarbamate. In some certain embodiments, the ammonium
carbamate is derived from carbamates independently selected from
dimethylammonium dimethylcarbamate, diethylammonium
diethylcarbamate, dipropylammonium dipropylcarbamate,
N-methylethylammonium methylethylcarbamate, and
N-methylpropylammonium methylpropylcarbamate.
[0043] The crosslinkable composition of this invention preferably
contains some solvent. The coating formulator may choose to use an
alcohol, or a combination of alcohols as solvent for a variety of
reasons. Other solvents like ethylacetate or butylacetate may also
be used, potentially in combination with alcohol solvents. Ethanol
is a preferred solvent. Isopropyl alcohol also is a potential
solvent. Methanol is not preferred as a solvent because of health
and safety risks. Other oxygenated, polar solvents such as ester or
ketones for instance, are also suitable and can be used,
potentially in combination with alcohol. Other organic solvents may
also be used.
[0044] The crosslinkable composition of this invention may also be
formulated without solvent in some cases. In other embodiments, the
crosslinkable coating contains typically at least 5 wt. % of
solvent, preferably between 5 wt. % and 45 wt. %, more preferable
between 5 wt. % and 35 wt. %, but preferable not more than 60 wt. %
because of VOC restrictions. In such embodiments, the organic
solvent is independently selected from the group consisting of an
alcohol, ester, ether, glycol ether, ketone, aromatic and
combinations thereof. In certain embodiments the alcohol is
independently selected from the group consisting of ethanol,
iso-propanol, butanol, iso-butanol, t-butanol and combinations
thereof.
[0045] The crosslinkable composition useful as a coating can be
formulated as a one component, a two component system or a three
component system. In an embodiment of a two component system,
catalyst system C is added to a mixture of ingredients A and B just
prior to use; ingredient D may optionally be added to the catalyst
system C or the mixture of ingredients A and B. In an alternative
embodiment, ingredients A and C are mixed, and ingredient B is
added prior to use ingredient; D may optionally be added to the
mixture of ingredient A and catalyst system C or ingredient B. In
yet another embodiment, ingredient A is added to a mixture of
ingredients B and catalyst system C prior to use; ingredient D may
optionally be added to ingredient A or the mixture of ingredient B
and catalyst system C. In certain embodiments, pot life, working
time and gel time can be adjusted by selection of the catalyst
system, the amount used in the crosslinkable composition, presence
of additional ammonium carbamate and to a certain extent the amount
of solvent and/or water. A gel time of hours, and even days can be
readily achieved, and gel times of weeks are possible. As such, the
catalyst system allows for an opportunity to formulate a three
component paint system. In such embodiment of a one component
system, ingredients A, B, C and D are mixed together, optionally
with other ingredients to formulate a paint, which is then canned
and stored until use. In certain embodiments, a one component
system can be enhanced by means of using excess carbon dioxide gas
over the crosslinkable composition as to further improve pot life
and gel time. For instance, a paint composition formulated
according to the invention may have a protective atmosphere of
carbon dioxide over the paint volume; and in yet another
embodiment, a container containing the crosslinkable composition
may even be pressurized with carbon dioxide. In another embodiment,
a one component system containing ingredients A, B and C are in a
container filled to capacity with essentially no space remaining
for other solids, liquid or gaseous ingredients and optionally
containing ammonium carbamate. In yet another embodiment,
additional ammonium carbamate may further enhance stability in such
one component coating formulations.
[0046] In another embodiment, the present invention provides for
the crosslinkable coating composition wherein ingredient A,
ingredient B and the catalyst system are contained in a container
having two or more chambers, which are separated from one another.
In one such embodiment, ingredient A and ingredient B are contained
in separate chambers to inhibit any reaction. In another such
embodiment, the catalyst system is contained in the chamber having
ingredient A, and optionally containing CO.sub.2 and/or ammonium
carbamate. In another such embodiment, the catalyst system is
contained in the chamber having ingredient B, and optionally
containing CO.sub.2 and/or ammonium carbamate.
[0047] In another embodiment, the present invention provides for
the crosslinkable coating composition such that ingredient A and
ingredient B are contained in the same chamber and the catalyst
system is contained in a separate chamber to inhibit any reaction
and said separate chamber optionally containing CO.sub.2 and/or
ammonium carbamate.
[0048] The number of reactive protons for ingredients A, and the
number of .alpha.,.beta.-unsaturated carbonyl moieties on resin
ingredient B can be utilized to express desirable ratio's and
ranges for ingredients A and B. Typically, the mole ratio of
reactive protons of ingredient A that can be activated with
subsequent carbanion formation relative to the activated
unsaturated groups on ingredient B is in the range between 10/1 and
0.1/1, preferably between 4/1 and 0.25/1, and more preferably 3.3/1
and 0.67/1. However, the optimal amount strongly depends also on
the number of such active functionalities present on ingredients A
and/or B. Although good tack free time may be obtained over a wide
ratio range, coatings properties, such as hardness for instance may
show a smaller preference range.
[0049] The crosslinkable composition of this invention comprising
ingredients A, B and C may optionally contain an additional
ingredient D, which once activated, can react with the Michael
acceptor. Ingredient D has one or more reactive protons that are
more reactive, i.e. more acidic than those of ingredient A (the pKa
of ingredient D is lower than that of ingredient A). The reactive
protons of ingredient D are present at a fraction based on the
reactive protons of ingredient A. The fraction ranges from 0 to
0.5, more preferably from 0 to 0.35, even more preferable between 0
and 0.15.
[0050] Examples of ingredient D include; succinimide, isatine,
ethosuximide, phthalimide, 4-nitro-2-methylimidazole,
5,5-dimethylhydantioin, phenol, 1,2,4-triazole, ethylacetoacetate,
1,2,3-triazole, ethyl cyanoacetate, benzotriazole, acetylacetone,
benzenesulfonamide, 1,3-cyclohexanedione, nitromethane,
nitroethane, 2-nitropropane, diethylmalonate,
1,2,3-triazole-4,5-dicarboxylic acid ethyl ester,
1,2,4-triazole-3-carboxylic acid ethyl ester,
3-Amino-1,2,4-triazole, 1H-1,2,3-triazole-5-carboxylic acid ethyl
ester, 1H-[1,2,3]triazole-4-carbaldehyde, morpholine, purines such
as purine, adenine, guanine, hypoxanthine, xanthine, theobromine,
caffeine, uric acid and isoguanine; pyrimidines, such as thymine
and cytosine; uracil, glycine, ethanimidamide, cysteamine,
allantoin, N,N-dimethylglycine, allopurinol, N-methylpyrrolidine,
benzeneboronic acid, salicyl aldehyde, 3-hydroxybenzaldehyde,
1-naphthol, methylphenidate and Vitamin E.
[0051] In another embodiments, ingredient D may be incorporated
into resin ingredient A. In such embodiments, substituted
succinimides, including hydroxyl group containing succinimide
derivatives, 3-hydroxy-2,5-pyrrolidinedione and
3-(hydroxymethyl)-2,5-pyrrolidinedione, or carboxylic acid group
containing succinimide derivative,
2,5-dioxo-3-pyrrolidinecarboxylic acid can undergo condensation
reactions with either acid/ester groups or hydroxyl groups at the
end of resin A polymer chain, where the succinimide moiety will be
incorporated into the polymer backbone as end cap.
[0052] The amount of catalyst system used, expressed as mole ratio
of protons that can be abstracted to form an activated Michael
donor species (e.g. the methylene group of malonate can provide two
protons for reactions, while a methine group can provide one proton
to form an activated species) relative to catalyst system, ranges
from about 1000/1 to 1/1, more preferably from 250/1 to 10/1, even
more preferable from 125/1 to 20/1 but the optimal amount to be
used depends also on the amount of solvent present, reactivity of
various acidic protons present on ingredient A and, if present,
ingredient D, on pigments or dyes present in the system, on the
number of active functionalities present on ingredients A and/or B
and the like. Hence, the optimal amount needs to be determined
experimentally to arrive at preferred curing characteristics.
[0053] Certain embodiments of the formulation may optionally
comprise resins that may act as film formers, adhesion promoters,
and aids to removal. These resins may also qualify as
solvent-dissolvable resins.
[0054] The cross-linkable coating composition of this invention can
comprise additives such as wetting agents, defoamers, rheological
control agents, ultraviolet (UV) light stabilizers, dispersing
agents, flow and leveling agents, optical brighteners, gloss
additives, radical inhibitors, radical initiators, adhesions
promotors, gloss additives, radical inhibitors, radical initiators,
plasticizers and combinations thereof. The selection of these
materials and additives will, of course, depend on the intended use
of the coating composition. However, all these materials need to be
carefully screened as some of these may react with the catalyst
system and therefore are not suitable for use in the crosslinkable
composition should such a reaction occur and significantly
interfere with the curing process. The above described materials
and additives are commonly used in the coatings industry and are
well known to one skilled in the art and need not be further
described here.
[0055] In certain embodiments, the crosslinkable composition of
this invention, ingredient A, ingredient B and the catalyst system
are contained in a container having two or more chambers, which are
separated from one another. In one such embodiment, ingredient A
and ingredient B are contained in separate chambers to inhibit any
reaction. In another embodiment, the catalyst system is contained
in the chamber having ingredient A, and optionally containing
CO.sub.2. In yet another embodiment, ingredient A and ingredient B
are contained in the same chamber and the catalyst system is
contained in a separate chamber to inhibit any reaction and said
separate chamber optionally containing CO.sub.2. In still yet
another embodiment, ingredient A and ingredient B and catalyst
system are contained in a container having a single chamber,
wherein the container optionally (i) contains CO.sub.2.
[0056] The following examples further describe and demonstrate
illustrative embodiments within the scope of the present invention.
The examples are given solely for illustration and are not to be
construed as limitations of this invention as many variations are
possible without departing from the spirit and scope thereof.
Coating Testing
[0057] Tack free time was evaluated by lightly pressing a gloved
index finger periodically onto the coating. The time when visible
marks in the film are no longer left by the pressed finger, was
then recorded as the tack free time.
[0058] Gel time was taken as the amount of time it takes for a
mixed, reactive resin system to gel or become so highly viscous
that it has lost fluidity. Typically, the various ingredients were
charged into a 4 ml vial and closed with headspace volume as
constant as possible to allow for comparison and the sample was
kept at room temperature and tilted at regular time intervals to
determine whether the material still flows. If no flow is observed
during tiling, the vial was held upside down and if no further flow
occurs the materials is gelled.
EXAMPLE 1
General Synthesis of Catalyst System from Diethylcarbonate
[0059] Most of the methanol solvent from a 40 g tetrabutylammonium
hydroxide (TBA OH) solution in methanol (1 M) was removed with a
rotary evaporator. The material was not allowed to become
completely dry without solvent as dry quaternary ammonium hydroxide
base is susceptible to decomposition. Next, 40 grams of ethanol was
added and most of the solvent was again removed. This procedure was
repeated at least two more times until the methanol effectively had
been replaced as determined by NMR. The solution strength is
determined by titration (typically 1.7 mmol base/g solution). Next,
a precise amount of the TBA OH in solution was mixed with diethyl
carbonate (DEtC) in a 1:5 molar ratio respectively and stirred for
1 hour at room temperature using magnetic stirrer. The final clear
catalyst system was analyzed by means of titration and NMR. In a
similar manner, clear solutions were obtained in 1-propanol and
2-propanol. A solution made using the TBA OH base in methanol
resulted in white precipitate which is removed by centrifuge
followed by filtration using 0.45.mu. syringe filter.
[0060] Transesterification reaction products were observed in the
NMR for all cases where the carbonate alkyl group was different
from the solvent, e.g. ethanol formation was observed when DEtC was
added to TBA OH in isopropanol and isopropyl groups associated with
carbonates were also observed.
EXAMPLE 2
Malonate Resin (I) Synthesis
[0061] A 500 ml reactor was charged with 149.8 g of Polyethylene
glycol (PEG 300), 100 g of diethyl malonate (DEM), 32.5 g of
1-octanol and 4-5 drops of titanium (IV) butoxide. The reactor was
equipped with a Dean-Stark apparatus, mechanical stirrer, nitrogen
flow and heating equipment. The mixture was heated to about
180.degree. C. with stirring under nitrogen atmosphere. During an
eight hour reaction time, about 70 ml of ethanol was collected. The
final product was a lightly yellow colored liquid with less than
0.15 wt. % of residual DEM as determined by gas chromatography
(GC). Gel permeation chromatography (GPC) analysis showed Mw/Mn
(PDI) of 4191/2818 (1.49) in gram/mole and a malonate methylene
equivalent molecular weight of 360 g/mole.
EXAMPLE 3
Blocked Catalyst Effectiveness
[0062] Diethylcarbonate (DEtC) derived catalysts were prepared in
methanol, ethanol, 1-propanol and 2-propanol in Example 1. Varying
amounts of water were added to the catalyst solutions. The catalyst
solutions were then tested in formulations prepared from malonate
resin (I) of Example 2 and trimethylolpropane triacrylate (TMPTA)
using a molar ratio for malonate methylene CH.sub.2 to TMPTA
acrylate to catalyst of 3:2:0.2 respectively. All the materials of
the formulation were mixed well prior to observing gel time and
applying a 3 mil test film on a polycarbonate substrate to test
curing behavior. Results are shown in Table 1. The amount of water
and alcohol solvent is expressed as percentage of the final
crosslinkable formulation. In the absence of water, the catalyst
solutions as synthesized per Example 1 are not active as a blocked
catalyst when the solvent is ethanol, 1-propanol or 2-propanol. No
tack free time could be measured because the resin--carbonate
catalyst mixture polymerized and cured immediately and an instant
gel was formed. A significant amount of water is needed before the
effect of a blocked catalyst can be observed. Only the methanol
based catalyst shows desirable gel times measured in hours, which
can be increased further when water is added to the
formulation.
TABLE-US-00001 TABLE 1 Solvent % Water % Solvent Tack free time
[sec] Gel time Methanol 0.0 14.4 <90 16 hrs 3.3 14.0 110 9 days
3.8 13.9 110 13 days 4.2 13.8 <120 >13 days 5.3 13.7 <120
>18 days Ethanol 0.0 14.4 -- <30 sec 3.3 14.0 -- <30 sec
3.8 13.9 -- <30 sec 4.2 13.8 <180 2 hrs 5.3 13.7 <180
>5 hrs 1-Propanol 0.0 14.4 -- <30 sec 3.3 14.0 -- <30 sec
3.8 13.9 <180 40 sec 4.2 13.8 <180 2 min 5.3 13.7 <180 2.0
hrs 2-Propanol 0.0 14.4 -- <30 sec 3.3 14.0 -- <30 sec 3.8
13.9 -- 1 min 4.2 13.8 -- <5 min 5.3 13.7 nm* 20 min *not
measured
EXAMPLE 4
General Synthesis of a Catalyst System by Reacting Base and Carbon
Dioxide
[0063] Tributylmethylammonium chloride (TBMA Cl), (10 g) was
dissolved in anhydrous ethanol (8.7 g) and mixed with a 20 wt. %
solution of potassium ethoxide in anhydrous ethanol (17.8 g) in 1:1
molar ratio. The mixture was allowed to mix under agitation for 30
min, and was then centrifuged at 5000 rpm for 15 min to remove
potassium chloride precipitate. The concentration of the
tributylmethylammonium quat ethoxide was determined
potentiometrically by titrating it against 0.1 N HCl solution. Dry
carbon dioxide gas was passed through the tributylmethylammonium
quat ethoxide solution with stirring for 1 hour as to obtain the
desired catalyst system. The tributylmethylammonium ethylcarbonate
(TBMA EC) solution in ethanol is light yellow in color and is
characterized by means of acid and base titrations (potentiometric
and with indicator) and NMR.
[0064] A tributylmethylammonium isopropylcarbonate (TBMA IPC)
catalyst solution was prepared in a similar manner.
Tributylmethylammonium chloride was reacted with potassium
tert-butoxide in isopropanol followed by centrifugation prior to
passing carbon dioxide through the solution. NMR analysis confirmed
isopropylcarbonate as the anionic species.
EXAMPLE 5
Malonate Resin (II) Synthesis
[0065] A 3 L reactor was charged with 700.0 g of diethyl malonate,
619.8 g of 1,6-hexanediol (HDO) and 227.5 g of ethyl acetoacetate
(EAA). The reactor was equipped with a Dean-Stark apparatus,
overhead mechanical stirrer, nitrogen flow and heating equipment.
The mixture was heated to about 120.degree. C. with stirring under
nitrogen and then 0.62 g of phosphoric acid was added. Temperature
was then increased to 145.degree. C. and ethanol started to distill
at this temperature. Temperature was then stepwise increased to
180.degree. C. and continued until ethanol distillation stopped. In
total, 588 ml of ethanol was collected. The reaction was then
cooled to 120.degree. C. and vacuum was applied for 4 hours while
driving molecular weight. The final product is clear with less than
0.1% of residual monomer. GPC analysis showed Mw/Mn (PD) of
4143/1792 (2.31) in g/mole.
EXAMPLE 6
Basic Clear Coating Formulation
[0066] The TBMA EC solution of Example 4 was tested as a catalyst
system. In a vial, 2.0 g of the malonate resin II of Example 5 was
mixed with 2.68 g of DTMPTA, 0.4 g of BA and then 0.80 g of the
TBMA EC solution was added. The complete formulation was mixed well
prior to observing gel time and applying a 3 mil test film on a
polycarbonate substrate to test coating curing behavior. A similar
test was carried out with the TBMA IPC catalyst using 0.90 g of the
TBMA IPC solution to keep molar amount of catalyst constant versus
the resin. Data in Table 2 shows that a notably shorter gel time
for the isopropanol based catalyst was observed.
TABLE-US-00002 TABLE 2 Catalyst Solvent Tack free time [sec] Gel
time [min] TBMA EC Ethanol 90 50 TBMA IPC 2-Propanol 120 25
EXAMPLE 7
[0067] The procedure as per Example 6 was repeated except that
varying amounts of dimethylammonium dimethylcarbamate (DMADMC) were
added to the TBMA EC solution prior to adding said solution to the
resin/DTMPTA solvent mix. The DMADMC was obtained from commercial
sources and purity was checked via NMR. DMADMC is the reaction
product between dimethylamine and carbon dioxide in a 2:1 molar
ratio, albeit small deviations from this stoichiometry are possible
in commercially available DMADMC materials. Such commercial
materials may also contain ammonium carbonates depending on source
purity. All ingredient amounts were kept the same and the DMADMC
amount is thus on top of the formulation. Only in experiment #4,
was DMADMC added to the resin/DTMPTA solvent mix rather than to the
catalyst solution. The complete formulation was mixed well prior to
observing gel time and applying a 3 mil test film on a
polycarbonate substrate to test coating curing behavior. The
ambient relative humidity was 48% while the temperature was
21.degree. C. The absolute humidity was 8.8 [g/m3]. Results in
Table 3 shows that addition of DMADMC greatly increases gel time
while the tack free time only marginally increases unless
significant amounts of DMADMC in excess to the catalyst are added.
No significant effect of DMADMC addition on film properties were
noted after cure.
TABLE-US-00003 TABLE 3 DMADMC/carbonate Tack free time # catalyst
(molar ratio) [m:s] Gel time 1 0 2:30 1 hr 2 0.5 2:20 12 hr 3 1
2:30 2 days 4 1 2:45 2 days 5 2 2:55 4 days 6 5 4:00 >4 days
EXAMPLE 8
[0068] The procedure as per Experiment 6 was repeated using the
TBMA EC catalyst solution of Example 4, except that varying amounts
of water were added to either the resin/DTMPTA solvent mix
(addition path I) or to the catalyst solution (addition path II).
Once water was added and well mixed, then the catalyst solution was
combined with the resin/DTMPTA solvent mix. The amount of water
added was chosen so that the overall water content of the total
formulation contained 0, 2, 4, 6, 8 or 10 wt. % water. The complete
formulations were mixed well. Gel time was tested and the tack free
time was determined after a 3 mil test film was applied on
polycarbonate substrates.
TABLE-US-00004 TABLE 4 Addition Wt. % Tack free time # path Water
[m:s] Gel time 1 I 0 2:40 1 hr 10 min 2 I 2 3:05 5 hr 3 II 2 3:30 4
hr 4 I 4 3:50 >9 hr, gelled O/N 5 II 4 4:20 >7 hrs, gelled
O/N 6 I 6 4:15 >33 hrs, gelled O/N 7 II 6 4:55 >31 hrs,
gelled O/N 8 I 8 4:45 >36 hrs, gelled O/N 9 I 10 5:20 4 days
LIST OF CHEMICAL ACRONYMS USED IN THE EXAMPLES
[0069] BA butylacetate [0070] DEM diethyl malonate [0071] DEtC
diethyl carbonate [0072] EAA ethyl acetoacetate [0073] HDO
1,6-hexanediol [0074] PEG 300 polyethylene glycol, Mw=300 [0075]
TBA OH tetrabutylammonium hydroxide [0076] TBMA Cl
tributylmethylammonium chloride [0077] TBMA EC
tributylmethylammonium ethylcarbonate [0078] TBMA IPC
tributylmethylammonium isopropylcarbonate [0079] TMPTA
trimethylolpropane triacrylate
[0080] The present disclosure may be embodied in other specific
forms without departing from the spirit or essential attributes of
the invention. Accordingly, reference should be made to the
appended claims, rather than the foregoing specification, as
indicating the scope of the disclosure. Although the foregoing
description is directed to the preferred embodiments of the
disclosure, it is noted that other variations and modification will
be apparent to those skilled in the art, and may be made without
departing from the spirit or scope of the disclosure.
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