Abstract:
This invention relates to copolymerizable ultraviolet light monomers which are acrylate esters of 2-hydroxy, alkoxy, methylolbenzophenones having the formula: ##STR1## where R is alkyl C 1  -C 8 , 
     n is 1 or 2, and 
     Y is a copolymerizable radical selected from acryloyl and alkylacryloyl.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to copolymerizable light absorber monomers, and, more particularly to acrylate esters of 2-hydroxy, alkoxy, methylolbenzophenones, which can copolymerize with various monomers to provide copolymer materials having improved resistance to degradation by light. 
     2. Description of the Prior Art 
     Various organic compounds exhibit the power to absorb electromagnetic radiation and can be incorporated in various plastic materials such as transparent sheet which act as filters for all the radiation passing through and will transmit only such radiations as are not absorbed by the sheet and/or the absorbing agent. Such filters find use in many technical and commercial applications. 
     Numerous acrylic compounds have been suggested as absorbents for the range of radiations described above. For specific compounds, see U.S. Pat. Nos. 3,081,380; 3,373,810; 3,644,466; 3,356,312 and 3,215,724. These ultraviolet absorbers are mechanically mixed with the plastic materials to prevent discoloration and degradation of the material. However, it has been observed that such absorbers sometimes fail or are baked out of the plastic under adverse weather conditions before the lifetime of the protected material. Another disadvantage of these ultraviolet absorbers is the high amount of absorber needed for protection of some materials. 
     Hydroxy, alkoxybenzophenone compouns are known to be effective ultraviolet light absorbers and stabilizers. For example, in U.S. Pat. No. 4,186,151, there is disclosed in detail literature and patent references relating to such compounds and derivatives thereof. Additionally, in U.S. Pat. No. 4,177,122 there is described the preparation of ultraviolet light sensitive compounds obtained by reacting a hydroxybenzophenone with an alkylene oxide and esterifying with an unsaturated end group, which are useful particularly in making printing inks. 
     CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     Ser. No. 153,107, filed May 23, 1980, by the same inventors and assigned to the same assignee as herein, describes and claims intermediates useful in making the copolymerizable compounds of this invention. 
     Ser. No. 168,224, filed July 10, 1980, by the same inventors and assigned to the same assignee as herein, describes and claims related monomers made which are α,β-dicarboxylic acid half-esters of said intermediate methylol compounds. 
     SUMMARY OF THE INVENTION 
     What is provided herein are improved, novel copolymerizable ultraviolet light absorber compounds of the formula: ##STR2## where R is alkyl, C 1  -C 8 , 
     n is 1 or 2, and 
     Y is a copolymerizable radical selected from acryloyl and alkylacryloyl. 
     Representative Y groups are ##STR3## 
     In the preferred embodiments of the invention, R is a lower alkyl group; C 1  -C 3  in the 4-position, n is 1, Y is acryloyl or methacryloyl, and --CH 2  OY is located at the 3- or 5-position of the phenyl ring. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The intermediate compounds used in the invention are made by formylation of a 2-hydroxy, alkoxybenzophenone starting material having the formula: ##STR4## where R is alkyl C 1  -C 8 , with formaldehyde in aqueous alkaline solution at a pH of about 12-13, and at a temperature of less than 40° C., preferably at room temperature, using a water-miscible organic solvent to keep the benzophenone in solution. 
     An alkyl group is defined herein as being either straight chain or branched, including methyl, ethyl, propyl, butyl, octyl, isopropyl, isobutyl and the like. 
     During the formylation reaction, an excess of formaldehyde in the reaction mixture prevents side reactions from occurring, thus increasing the yield of the desired methylol product. Accordingly, when the molar ratio of benzophenone to formaldehyde is adjusted to 1:1, a yield of about 70% of predominately the 5-monomethylol intermediate is obtained during a 24-hour reaction period. On the other hand, by using a ratio with an excess of formaldehyde, e.g., about 1:3, the mixture of the 5- and 3-monomethylol compounds, in about a 60:40 ratio of each, and some 3,5-dimethylol compound, during a 51/2 hour reaction period. Still higher ratios may be used, too, but the substantial excess of formaldehyde must be separated from the reaction products, which is undesirable. 
     The concentration of the reactants is not critical. Generally they are made low enough to keep them in solution but sufficiently high to enable the reaction to proceed at a reasonable reaction rate. Usually the benzophenone is present at a concentration of about 30% by weight, and the formaldehyde about 10% by weight of the solution. The alkali is present at a concentration of about 10%. 
     After the methylol intermediate is formed, the reaction product mixture is acidified and washed with water. Then unreacted formaldehyde, which is present in the organic phase, is removed under vacuum. The resultant oily organic product is dried overnight over molecular sieves to remove residual traces of water. 
     The intermediate product may be isolated as an individual compound or compounds, or kept as a mixture of several compounds. Either form may be immediately converted to the desired copolymerizable ultraviolet light absorber compounds by esterification with an acryloyl halide. The esterification reaction is carried out in an inert solvent, suitably in an aromatic or aliphatic hydrocarbon or halogenated hydrocarbon, such as toluene, benzene, chloroform or ethylene dichloride, in methylethylketone, or in acetone, at a suitable temperature, generally ranging from 30°-40° C., in presence of a molecular sieve, having small pores, such as Linde 3A, which can absorb the acid by-product of the reaction. Suitably the molar ratios of the reactants are controlled to provide at least a 1:1 molar ratio of, e.g., the acryloyl halide to the 2-hydroxy, alkoxy, methylolbenzophenone. Preferably an excess of acryloyl chloride is used. The reaction is run for about 1-5 hours at the stated temperatures. 
     The presence of the primary methylol group on the phenyl ring of the benzophenone intermediate enables the preparation of monoesters of these unsaturated acids with relative ease. The monomers of the invention are characterized by nuclear magnetic resonance ( 1  H,  13  C) and ultraviolet spectroscopy. 
     The copolymerizable ultraviolet light absorber monomers then are copolymerized with unsaturated monomers, generally by emulsion, suspension or solution polymerization, to provide copolymer materials having ultraviolet absorber protection built into the molecule. Suitable monomers for this purpose include styrene, butadiene, and their mixtures, vinyl pyrrolidone, and the like. 
    
    
     The following non-limiting examples will illustrate the invention more particularly. 
     EXAMPLE 1 
     Preparation of 2-Hydroxy-4-Methoxy-5-Methylolbenzophenone Acrylate 
     A. 2-Hydroxy, alkoxy, methylolbenzophenone 
     Into a 100 ml. 3-necked flask equipped with thermometer, dropping funnel and magnetic stirrer is charged 2-hydroxy-4-methoxybenzophenone (65.3 g., 0.286 moles) dissolved in 11.44 g. of sodium hydroxide in 115 g. of distilled water, and 64 ml. of tetrahydrofuran is added to produce a clear solution. The 27% solution of formaldehyde (64.0 g., 0.789 moles) is added with stirring at room temperature and the reaction is allowed to proceed for 51/2 hours. Thereafter the reaction product mixture is acidified to a pH of 5-6, using a 50% acetic acid solution, and washed several times with distilled water. Then the unreacted formaldehyde present in the organic phase is removed by rotating the mixture on a Rotavac in vacuum. The organic phase is dried overnight over molecular sieves. The yield is 60.0 g. of a mixture of the desired intermediate products which may be used as such for the subsequent esterification reaction with the unsaturated anhydride or acid halide. The 5-methylol intermediate is about  58 parts, the 3-methylol intermediate about 38 parts and the 3,5-dimethylol intermediate about 4 parts of the mixture. 
     B. The reaction product of A (40 g.) is dissolved in anhydrous methylethylketone (15 ml.) and powdered molecular sieve (Linde type 3A, 5.0 g.) and hydroquinone (0.1 g.) is added. Then acryloyl chloride (5 g.) is added dropwise at 40° C. over 30 minutes. The reaction mixture then is stirred at 35° C. for an additional 5 hours, cooled to room temperature, filtered to remove the molecular sieve, and methylbutylketone (50 ml.) is added. The solution then is washed several times with water, dilute sodium carbonate, again several times with water, and finally the desired monomer product is dried over molecular sieves. 
     EXAMPLE 2 
     Preparation of 2-Hydroxy-4-Methoxy-5-Methylolbenzophenone Methacrylate 
     The procedure of Example 1 is repeated with methacryloyl chloride in place of acryloyl chloride to provide the desired monomer. 
     EXAMPLE 3 
     Preparation of Copolymers 
     The monomer of Example 1 is copolymerized with styrene under emulsion polymerization conditions to provide a useful copolymer having enhanced, built-in ultraviolet light stability. 
     The following materials are used. 
     
         ______________________________________No.  Ingredient              Amount (g.)______________________________________1    Distilled water         322.02    Siponate DS-10 - Surfactant                        6.03    Styrene                 47.664    2-Hydroxy-4-Methoxy-5-Methylolbenzo-phenone Acrylate        8.15    Ammonium persulfate (in 10.0 g. distilledwater)                  1.56    Styrene                 181.2______________________________________ 
    
     Ingredient No. 2 is dissolved in No. 1 and the solution is charged into a 1 l. kettle. Then No. 4 in No. 3 is added with stirring. The contents are alternatively evacuated and repressurized to 25 psi. with N 2  three times and heated to 75° C. while stirring is continued. At 75° C., No. 5 is added; then No. 6 is charged during a period of 1 hour. The reaction mixture then is held at 75°±2° C. for 41/2 hours, cooled to room temperature and discharged. The resulting latex is coagulated and the copolymer obtained is purified by exhaustive extraction with acetone using a Soxhlet extractor. The presence of the comonomer as a part of the polymer is identified by ultraviolet spectroscopy. 
     Stability of the copolymer to ultraviolet light is determined by comparing films of the copolymer with films of polystyrene, the latter being synthesized in a similar manner as the copolymer but without using comonomer No. 4. A standard Weatherometer test for 100 hours is used (carbon arc, 40° dry). The test results show that the polymer containing the comonomer changes only very slightly in appearance whereas the polystyrene is noticeably yellowed. 
     EXAMPLE 4 
     The monomer of Example 1 is copolymerized with styrene and butadiene under emulsion polymerization conditions to provide another useful copolymer which also has enhanced, built-in ultraviolet light stability. The following materials are used: 
     
         ______________________________________No.   Ingredient             Amount (g.)______________________________________1     Distilled water        935.12     Kemplex - 100 (42%)    2.23     Monawet MB-45 (45%)    10.664     Seed latex (42%)       57.105     2-Hydroxy-4-Methoxy-5-Methylolbenzo- phenone Acrylate       24.306     Itaconic acid          18.07     Distilled water        50.08     Ammonium persulfate    2.49     Styrene                684.010    Butadiene              480.011    t-Dodecyl mercaptan    4.812    Distilled water        200.013    Sodium hydroxide (20%) 18.014    Ammonium persulfate    6.015    Monawet MB-45 (45%)    21.3______________________________________ 
    
     Ingredient Nos. 1 through 6 are charged at room temperature into a 1-gallon pressure reactor, and alternately evacuated and purged with N 2  three times while agitating at 300 rpm. Then the temperature of the contents is raised to 180° F., and the solution of No. 8 in No. 7 is added. Then Nos. 9 through 11 and Nos. 12 through 15 are added separately and continuously to the reactor during a period of 4 hours. After the addition has been completed, the temperature is increased to 190° F. and the contents are held at this temperature for 2 hours. The reaction mass then is cooled and discharged. 
     This reaction product also is tested for ultraviolet light stability in a standard Weatherometer test. Accordingly films are cast from the latex prepared above with and without the comonomer, No. 5. The polymer prepared above, with the comonomer present integrally therein, was far superior with respect to yellowing than the latex without the comonomer.