Abstract:
The liquid oligomeric compositions of this invention are made by the Michael addition reaction of acetoacetate functional donor compounds with multifunctional acrylate receptor compounds where the equivalent ratios of multifunctional acrylate to acetoacetate vary from ≧1:1 to ≧13.2:1 depending on the functionality of both multifunctional acrylate and acetoacetate. Unuseable gelled or solid oligomer products occur below the claimed ranges. The liquid oligomers of this invention are further crosslinked to make coatings, laminates and adhesives.

Description:
FIELD OF THE INVENTION 
     This invention relates to liquid oligomers containing unsaturation which can be crosslinked using ultraviolet light without adding costly photoinitators. Films made from the crosslinked oligomers of the inventions are used as protective or decorative coatings on various substrates. The oligomers can be added to other resins used in adhesives or composites. 
     BACKGROUND OF THE INVENTION 
     Acrylate, methacrylate and other unsaturated monomers are widely used in coatings, adhesives, sealants, and elastomers, and may be crosslinked by ultraviolet light radiation or peroxide initiated free radical cure. These are typically low molecular weight multifunctional compounds which may be volatile or readily absorbed through skin and can cause adverse health effects. Functionalized polymers may overcome some of these drawbacks; generally, polymers are nonvolatile compounds, not readily absorbed through skin. However, multistep syntheses may be required, low functionality may be detrimental to reactivity and final properties, and catalyst or initiator may be required to effect crosslinking. 
     The Michael addition of acetoacetate donor compounds to multiacrylate receptor compounds to make crosslinked polymers has been described in the literature. For example, Mozner and Rheinberger reported the Michael addition of acetoacetates having a β-dicarbonyl group to triacrylates and tetracrylates. Macromolecular Rapid Communications 16 135-138 (1995). The products formed were crosslinked gels. In one of the reactions, Mozner added one mole of trimethylol propane triacrylate (TMPTA) having 3 functional groups to one mole of polyethylene glycol (600 molecular weight) diacetoacetate (PEG600-DAA) having two functional groups. (Each &#34;acetoacetate functional group&#34; reacts twice, thus each mole of diacetoacetate has four reactive equivalents.) ##STR1## Mole Ratio of TMPTA: PEG 600 DAA=1:1 Ratio of acrylate: acetoacetate functional groups=3:2 
     Ratio of reactive equivalents=3:4 
     BROAD DESCRIPTION OF THE INVENTION 
     This invention is the discovery that certain soluble liquid uncrosslinked oligomers, made by one step Michael addition of acetoacetates to multi-acrylates, can be further crosslinked using ultraviolet light without using costly photoinitiators. 
     We have discovered that when precise proportions of multiacrylate acceptor compounds to acetoacetate donor compounds are combined using a basic catalyst, liquid oligomeric compositions are the product. If proportions below the claimed ranges are used, crosslinked gels or solid products are made which are not useful for the purposes of this invention because only un-gelled, uncrosslinked liquid oligomers will further crosslink without adding photoinitiators. In addition, the liquid oligomer compositions of this invention, since they are liquids, can readily be applied to various substrates using conventional coating techniques such as roll or spray prior to ultraviolet light cure. 
     The graph illustrates that ratios below the three curves were unuseable gelled materials outside the scope of the invention. Ratios on or above the curves are the liquid oligomers of this invention. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Among the multiacrylates used to make the oligomers of this invention are diacrylates, triacrylates, and tetraacrylates. 
     Useful diacrylates are: ##STR2## 
     Useful triacrylates are: ##STR3## 
     Useful acetoacetates having a reactive equivalent functionality of two are: ##STR4## 
     Useful acetoacetates having a reactive equivalent functionality of four are: ##STR5## Useful acetoacetates having a reactive equivalent functionality of six are: ##STR6## A useful acetoacetate having a reactive equivalent functionality of eight is: ##STR7## 
     The Michael addition reaction is catalyzed by a strong base; diazabicycloundecene (DBU) is sufficiently strong and readily soluble in the monomer mixtures. Other cyclic amidines, for example diazabicyclo-nonene (DBN) and guanidines are also suitable for catalyzing this polymerization. 
     Michael addition of a methacrylate functional β-dicarbonyl compound, 2-acetoacetoxyethyl methacrylate (AAEM), to diacrylate monomer yields liquid linear polyesters with reactive pendant methacrylate groups, which can be crosslinked in a subsequent curing reaction. As the acrylate and acetoacetate are mutually reactive and the methacrylate is inert under the conditions of the Michael addition, a highly functionalized (one methacrylate per repeat unit), liquid uncrosslinked polymer can be obtained in a one-step, ambient temperature, solventless reaction. The high selectivity of the Michael reaction permits the use of monomers such as styrene and methyl methacrylate as inert solvents to give low-viscosity systems that are easily incorporated into a variety of laminating resins. 
     In the following Examples all parts are by weight unless otherwise indicated. In addition, all references mentioned herein are specifically incorporated by reference. 
     A series of experiments defined the proportions of multi-acrylate to β-dicarbonyl acetoacetate which separate the liquid oligomer products of this invention from the gel or solid products of the prior art. 
    
    
     SYNTHETIC PROCEDURE 
     An example of resin synthesis is as follows. Trimethylolpropane triacrylate (TMPTA) 59.2 g and diazabicycloundecene (DBU) 0.4 g were weighed into a 500 ml 3-neck round bottom flask equipped with a mechanical stirrer and addition funnel. Ethyl acetoacetate (EAA) 13.0 g was weighed into the addition funnel. The TMPTA and DBU were mixed for 5 minutes prior to addition of the EAA. EAA was then added dropwise to the stirred TMPTA/DBU mixture over a 15 minute period. The solution warmed after addition of EM was complete. After the exotherm subsided a viscous yellow liquid was obtained which did not gel upon standing. 
     The same general procedure can be employed for a variety of combinations of acrylate and acetoacetate functional reactants, provided the equivalent ratio of acrylate: acetoacetate is sufficient to yield liquid, uncrosslinked products. For particularly exothermic or large scale reactions, controlled, gradual addition of acetoacetate and/or cooling of the reaction may be required to prevent premature, thermally initiated crosslinking of acrylate functional groups. 
     
                       TABLE 1______________________________________Acetoacetate/Acrylate Mixturesaceto-            f      mole equiv                              weight reactionacetate  acrylate ratio  ratio                         ratio                              ratio  product______________________________________A   ethyl    hexanediol                 2:2  1:1  2:2  36.5:63.5                                       viscous                                       liquid*B   ethyl    penta-   2:4  1:10 1:20 3.6:96.4                                       viscous        erythritol                     liquid*C   butanediol        hexanediol                 4:2  1:1  2:1  53.3:46.7                                       cross-                                       linked                                       gel**D   penta-   penta-   8:4  1:10 1:5  11.8:88.2                                       cross-    erythritol        erythritol                     linked                                       gel**______________________________________ *soluble in methyl ethyl ketone (MEK) at room temperature. **insoluble in refluxing methyl ethyl ketone. A and B made useful oligomers of the inventor. C and D made crosslinked gels which are outside the invention. 
    
     
                                           TABLE 2__________________________________________________________________________Reactions of diacrylate acceptor with acetoacetate-functional donors.       Functionality             Mole Equivalent                       Weight                             ReactionAcceptorDonor  ratio ratio                  ratio                       ratio product__________________________________________________________________________TRPGDAMeOAcAc       2:2   1:1  1:1  72.1:27.9                             solTRPGDAEtOAcAc       2:2   1:1  1:1  69.8:30.2                             solTRPGDAaceto- 2:2   1:1  1:1  62.9:37.1                             solacetanilideTRPGDAbutanediol       2:4   7.7:1                  3.9:1                       90:10 soldi-OAcAcTRPGDA      2:4   4.9:1                  2.4:1                       85:15 gelTRPGDA      2:4   3.44:1                  1.7:1                       80:20 gelTRPGDAcyclohexane       2:4   19.8:1                  9.9:1                       95:05 soldimethanol di-TRPGDAdi-OAcAc       2:4   13.8:1                  6.9:1                       93:7  solTRPGDA      2:4   9.4:1                  4.7:1                       90:10 gelTRPGDA      2:4   5.9:1                  2.95:1                       85:15 gelTRPGDA      2:4   4.2:1                  2.1:1                       80:20 gelTRPGDAneopentyl       2:4   8.2:1                  4.1:1                       90:10 solglycolTRPGDAdi-OAcAc       2:4   5.1:1                  2.6:1                       85:15 solTRPGDA      2:4   3.6:1                  1.8:1                       80:20 gelTRPGDATONE   2:6   16.6:1                  5.5:1                       90:10 sol0301 tri-OAcAcTRPGDA      2:6   10.4:1                  3.5:1                       85:15 gelTRPGDA      2:6   7.4:1                  2.5:1                       80:20 gelTRPGDAglycerin       2:6   10.3:1                  3.4:1                       90:10 soltri-OAcAcTRPGDA      2:6   6.5:1                  2.2:1                       85:15 gelTRPGDA      2:6   4.6:1                  1.5:1                       80:20 gelTRPGDApenta- 2:8   14.2:1                  3.5:1                       90:10 solerythritoltetra-OAcAcTRPGDA      2:8   8.9:1                  2.2:1                       85:15 gelTRPGDA      2:8   6.3:1                  1.6:1                       80:20 gel__________________________________________________________________________ Review of Table 2 shows that certain diacrylateacetoacetate equivalent ratios make sol or liquid oligomers of the invention. 
    
     
                                           TABLE 3__________________________________________________________________________Reactions of triacrylate acceptor with acetoacetate-functional donors.       Functionality             Mole Equivalent                       Weight                             ReactionAcceptorDonor  ratio ratio                  ratio                       ratio product__________________________________________________________________________TMPTAEtOAcAc       3:2   2:1  3:1  82:18 solTMPTAEtOAcAc       3:2   3:2  2.25:1                       77.4:22.6                             solTMPTAEtOAcAc       3:2   4:3  2:1  75.2:24.8                             gelTMPTAbutanediol       3:4   7.8:1                  5.9:1                       90:10 soldi-OAcAcTMPTA       3:4   4.9 1                  3.7:1                       85:15 gelTMPTA       3:4   3.5:1                  2.6:1                       80:20 gelTMPTAcyclohexane       3:4   9.5:1                  7.1:1                       90:10 soldimethanol di-TMPTAdi-OAcAc       3:4   6.0:1                  4.5:1                       85:15 gelTMPTA       3:4   4.2:1                  3.2:1                       80:20 gelTMPTAneopentyl       3:4   8.3:1                  6.2:1                       90:10 solglycolTMPTAdi-OAcAc       3:4   5.2:1                  3.9:1                       85:15 gelTMPTA       3:4   3.7:1                  2.8:1                       80:20 gelTMPTATONE   3:6   16.8:1                  8.4:1                       90:10 sol0301 tri-OAcAcTMPTA       3:6   10.6:1                  5.3:1                       85:15 gelTMPTAglycerin       3:6   14.3:1                  7.2:1                       92.5:7.5                             soltri-OAcAcTMPTA       3:6   10.5:1                  5.2:1                       90:10 gelTMPTApenta- 3:8   30.3:1                  11.4:1                       95:5  solerythritoltetra-OAcAcTMPTA       3:8   19.7:1                  7.4:1                       92.5:7.5                             solTMPTA       3:8   14.4:1                  5.4:1                       90:10 gel__________________________________________________________________________ Review of Table 3 shows that certain triacrylate:acetoacetate ratios make sol or liquid oligomers of the invention. 
    
     
                                           TABLE 4__________________________________________________________________________Reactions of tetracrylate acceptor with acetoacetate-functional donors.       Functionality             Mole Equivalent                       Weight                             ReactionAcceptorDonor  ratio ratio                  ratio                       ratio product__________________________________________________________________________PETA EtOAcAc       4:2   3.3:1                  6.6:1                       90:10 solPETA EtOAcAc       4:2   2:1  4.0:1                       84.4:15.6                             gelPETA EtOAcAc       4:2   1:1  2:1  73:27 gelPETA butanediol       4:4   13.9:1                  13.9:1                       95:5  soldi-OAcAcPETA        4:4   9.7 1                  9.7:1                       93:7  solPETA        4:4   6.6:1                  6.6:1                       90:10 gelPETA cyclohexane       4:4   16.8:1                  16.8:1                       95:5  soldimethanol di-PETA di-OAcAc       4:4   8.0:1                  8:1  90:10 gelPETA neopentyl       4:4   14.7:1                  14.7:1                       95:5  solglycolPETA di-OAcAc       4:4   10.3:1                  10.3:1                       93:7  solPETA        4:4   7.0:1                  7:1  90:10 gelPETA TONE   4:6   29.8:1                  19.9:1                       95:5  sol0301 tri-OAcAcPETA        4:6   20.8:1                  13.9:1                       93:7  solPETA        4:6   14.1:1                  9.4:1                       90:10 gelPETA glycerin       4:6   18.6:1                  12.4:1                       95:5  soltri-OAcAcPETA        4:6   12.1:1                  8:1  92.5:7.5                             gelPETA penta- 4:8   65.7:1                  32.9:1                       98:2  solerythritoltetra-OAcAcPETA        4:8   43.3:1                  21.7:1                       97:3  solPETA        4:8   32.2:1                  16.1:1                       96:4  solPETA        4:8   25.5:1                  12.7:1                       95:5  solPETA        4.8   17.8:1                  8.9:1                       93:7  gelPETA        4:8   12.1:1                  6:1  90:10 gel__________________________________________________________________________ Review of Table 4 shows that certain tetracrylate:acetoacetate ratios mak sol or liquid oligomers of the invention. 
    
     In order to demonstrate ultraviolet light crosslinking of these liquid oligomers, samples containing 1% (wt) Irgacure 500 photoinitiator and 0% photoinitiator were applied to release liner and spread to a thickness of 1.5 mil. Specimens were cured on a Fusion Systems Corp. uv curing unit, using an H-bulb and belt speed of 20-25 feet/minute; all formed transparent, flexible, nearly colorless films. Samples of each film were weighed, immersed in acetone (a good solvent for the uncured resins) at room temperature for 48 hours, blotted dry and re-weighed to determine solvent uptake. Specimens were then dried to constant weight in a vacuum oven at 80° C. to determine gel fractions; these values are listed in the table 5 below. 
     
                       TABLE 5______________________________________Solvent Uptake and Gel Fractions of UV Cured MethacrylateFunctional Polyesters.    Solvent             Solvent    Uptake, % Gel Fraction                        Uptake, %                                Gel Fraction    (Irgacure (Irgacure (No Photo-                                (No Photo-DIACRYLATE    500, 1%)  500, 1%)  initiator)                                initiator)______________________________________NPG      18        94%        9      96%PEG 200  19        96%       18      94%Hexanediol    12        96%        9      96%Triethylene    16        95%       19      96%glycol______________________________________ 
    
     These results confirm that the products are crosslinked and indicate no significant difference between products cured with or without added photoinitiator. This suggests that the pendant methyl ketone substituents serve as an internal or &#34;built in&#34; photoinitiator. To further demonstrate the role of methyl ketone substituents in the uv cure of these resins, three acrylate terminal resins were prepared from neopentyl glycol diacrylate and various b-dicarbonyl compounds in a 5:4 molar ratio. β-dicarbonyl compounds included acetylacetone (2 methyl ketones per molecule), ethyl acetoacetate (1 ketone/molecule) and diethyl malonate (no ketones). UV cure was performed as before, without added photoinitiator. Resins containing acetylacetone or ethyl acetoacetate cured to soft, tacky films. Such films are useful in protective or decorative coatings on wood, or metal substrates. The resin containing diethyl malonate failed to cure, remaining liquid.