CUMYLPHENOL DERIVATIVES AND THEIR USE IN SYNTHETIC RESIN COMPOSITIONS

Abstract: New cumylphenol derivatives are described which are useful as reactive diluents, plasticizers and impact modifiers for polymeric materials. The derivatives include alkenyl esters of monocarboxylic acids, esters of polycarboxylic acids, and the esters of boric acid, and alkenyl and aralkyl esters. The borate ester of cumylphenol is particularly useful as impact modifiers with flame retardant properties.

Description: CUMYLPHENOL DERIVATIVES Cumylphenol and certain of its derivatives have been described in the prior art. See particularly Tsivunin et a'., Biol. Alcliv. Soidin. 1968, 172-5 (Russ.). Finding a use for such materials has been particularly desirable since they are readily available as byproducts from commerdal processes such as the making of phenol from cumene. Similarly, it has long been desired to improve the properties of polymeric material and reactive diluents, plasticizers and impact modifiers which serve such functions at low costs have long been sought. Though numerous materials are brown to satisfy these needs, - they are frequently deficient because of their costs or because of incompatibility with the particular polymer. The invention concerns derivatives of cumylphenol and their use in polymeric materials. More specifically, the invention describes alkenyl, monocarboxylic acid esters of cumylphenol; polycarboxylic acid esters of cumylphenol; inorganic esters of cumylphenol; and alkenyl and aralkyl ethers of cumylphenol. These materials are useful as reactive diluents in epoxy, phenolic, and urethane compounds; effective as plasticizers in polyvinyl chloride, polystyrene and urethane; and useful as impact modifiers in styrene-acrylonitrile, polystyrene, phenolic and polyvinyl chloride resins. Additionally, the borate ester has flame retardant properties. While not each and every cumylphenol derivative is effective in all of the aforesaid applications, these compounds all exhibit useful properties within certain of the aforesaid fields. Cumylphenol and derivatives thereof have been found useful as reactive diluents for a variety of resins, e. g ., epoxy, furan, phenolic, urethane, polyester and acrylate resins. The alkenyl esters are useful in polyesters and acrylates. These compounds are new compositions of matter and provide a low cost replacement for conventionally employed co-monomeric materials. In certain instan-ces, their use improves the chemical and physical properties of the cured resins. In still another embodiment of the invention, it has been found that esters of cumylphenol are useful as non-reactive plasticizers for polyurethanes. Here again the cost of the finished resin may be markedly reduced. In a further embodiment of the invention, the borate, benzyl, and glutarate esters and the benzyl and allyl ethers of cumylphenol have been found to be useful impact modifiers for polystyrene, styrene-acrylonitrile, phenolic and vinyl chloride resins. The derivatives of cumylphenol which are useful in the invention may be represented by the following formula: EMI3.1 wherein R is an acyl group, EMI3.2 an alkenyl group having from 3 to 12 carbon atoms, or an aralkyl group having from 7 to 12 carbon atoms; and wherein the R' above is an alkenyl group having 2 to 12 carbon atoms. When R is an alkenyl, the preferred radicals are allyl and methallyl; and when it is aralkyl, the preferred radical is benzyl. Most preferably, R' is a phenyl, vinyl or isopropenyl group. Still another group of derivatives are the cumylphenol esters of polyfunctional acids. The compounds may be based on both organic and inorganic acids. These materials may be readily pre pared by reacting, for each mole of acid, a number of moles of cumylphenoi equal to the functionality of the acid. The organic acids are novel and may have two or three carboxylic acid groups and from 2 to 8 additionaL carbon groups per molecule. Such compounds may be saturated or unsaturated, aliphatic or aromatic. Most preferred is the derivative of glutwic add, i.e., dicumyl phenyl glutarate. Other compounds include the derivatives of cinnamic acid, crotonic acid, sorbic acid, phthalic acid, lsophthalic acid, terephthalic acid, maleic acid, succinic acid, fumaric acid. Half esters of these acids may also be used, in which case only sufficient cumylphenol is reacted to combine with the unesterified carboxyl group. With respect to the esters of inorganic compounds, these include the novel borate ester. Where the cumylphenol derivatives are used as reactive dilu ents, they may be present in from about 10 to about 200 parts per 100 parts of the resin, preverably from about 20 to about 50 parts. In non-reactive plasticizer applications, from 15 to 60 wt. %, preferably from 20 to 40 wt. %, of the appropriate ester of the cumylphenol is used based on total weight of resin. As an impact modifier, from 0.5 to 30 wt. %, preferably from 1 to 10, of the cumylphenol derivative should be used for each part of the resin in question. In the applications of the invention where the cumylphenols are used as reactive diluents or non-reactive plasticizers, the cumyl phenol compound is initially blended with the appropriate resin along with other desired components. The blend Is fed to the polymerizing reactor and the resin polymerized in accordance with known techniques for the particular resin. The resins which are cured and formed in the practice of the invention include those generically referred to as "liquid thermoset resins." By this term is meant resins which are in the liquid state under conditions of application and include casting resins, i.e., liquid monomer or incompletely polymerized polymers, usually con taining catalysts or curing agents, capable of becoming hard after they are cast in molds; and coating resins, i.e., liquid monomers or incompletely polymerized polymers, optionally in a solvent or non solvent extender, which are capable of application by casting, potting, brushing, rolling, spraying or dipping. These include paints, varnishers, enamels, lacquers, and casting and potting resins. Of these resins, those of particular interest in the instant invention are furans, phenolics and urethanes. These may briefly be described as follows: The- furan resins are thermosetting resins obtained primarily by the condensation polymerization of furfural alcohol in the pres ence of a strong acid, sometimes in combination with formaldehyde or furfural. The term also includes resins made by condensing phenol with furfuryl alcohol or furfural, and furfuryl-ketone poly mers. Phenolic resins are a family of thermoset resins made by the reaction of phenols with aldehydes such as formaldehyde, acetalde hyde, or furfural in the presence of either acidic or basic cata lysts. For casting, B-stage resins are generally used. Examples of the phenols are di- and trivalent phenols such as cresol, resorci nol and cardanol. In casting resin applications, a large excess of formaldehyde is generally used with sodium hydroxide as the catalyst. The reaction is usually carried out at about 640C. The polyurethanes are a family of resins produced by reacting diisocyantes with organic compounds containing two or more active atoms to form polymers having free isocyanate groups. A detailed description of these resins is given in U.S. Patent 3,060,137, Issued October 23, 1962. These groups, under the influence of heat or catalyst, will react with each other or with water, glycols, etc., to form thermosetting materials. Rigid polyvinyl chloride resins optionally contain extenders, pigments, stabilizers and a small proportion of plasticizers wherein the proportion of plasticizer Is insufficient to reduce tensile modulus below about 2,000 psi. Polystyrene resins are thermoplastic resins prepared by the polymerization of high purity styrene generally in the presence of free radical producing catalysts. They may be made by any of the conventional polymerization methods. Styrene-acrylonitrile polymers are readily prepared by copolymerizing styrene and acrylonitrile in the presence of a free radical catalyst. See Teach, W. C., et al., HPolystyrene", Plastics Application Series, Reinhold Publishing Corp., New York, 1960. The following examples show specific embodiments of the invention: Example A: Preparation of Cumylphenyl Benzyl Ether The cumylphenyl benzyl ether was prepared as follows: a 3-liter flask equipped with a mechanical stirrer, thermometer, addition funnel, and external heating and cooling devices was charged sequentially with 1 liter of benzene, 1 liter af 4.5 wt. % aqueous sodium hydroxide and 1 mole of cumylphenol. The cumyl phenol salt dispersion formed after mixing was cooled to 10-150C., mixed and maintained at 10-15 C. during the addition of 1.1 moles of benzyl chloride over a four hour period. After the addition of the benzyl chloride, the reaction mix was refluxed for two hours. The two phases which formed were separated and the water phase discarded. The organic phase was thrice washed with cold water and the residual organic material fractionated. The yield of the benzyl ether was 74 mole% and the product had a boiling point of 218 to 2210C. at lmm Hg. The cumylphenyl benzyl ether has the following properties: Appearance: Waxy Solid/Heavy Liquid Specific Gravity 1.04 Wt./Gal., libs. 8.66 Viscosity at 93 C, cps 25 + 5 Flash point (COC), Min., 00. 176 Vapor Pressure (mm Hg.), Max. 93 C. 1 Pour Point, Max. C. 66 tsupercools easily) Minimum Assay by gas chromatograph (GC) X 85 This compound is useful as an impact modifier for styrene resins, e.g., ABS and SAN, polyphenylene oxide and polyphenylene sulfide. It is also effective in making cellulose compatible with styrenic resins and. styrenic resins compatible with nylon and polyester. Example B: Preparation of Cumyiphenyl Alkyl Ether The apparatus and procedure of Example A was used to prepare the allyl ether, except that allyl chloride was used in place of the epichlorohydrin. A yield of 84 mole % was obtained. The allyl ether had a boiling point of 1860 to 1900 C. at 1 mm Hg. The cumylphenyl allyl ether has the following properties: Appearance: Moderate Viscosity Yellow Liquid Specific Gravity 1.02 Wt./Gal., libs. 8.60 Viscosity at 24 C., cps 130 t 15 Flash Point CO0O)-, Nin. C. 93 Vapor Pressure at 24 C., tsm Hg.) flax. I Pour Point, Nax. 00. -18 Min. Assay by GC, % 85 This compound is useful as a reactive diluent for unsaturated polyesters and as a peroxide reactive plasticizer for vinyls and ink applications. Example C: Preparation of Tri(cumyl phenyl) Borate This ester was prepared by refluxing for two hours equal molar amounts of cumylphenol with tri-n-butyl borate. About 93% of by-product butanol was then recovered by fractionation. The residue boiled at over 1500C. at 1 mm Hg. Elemental analysis showed a boron content of 1.7%, substantially the same as the calculated value. The tri(cumyl phenyl) borate has the following properties: Appearance: White-tan crystalline solid Specific Gravity 1.10 Wt./Gal., libs. 9.16 Viscosity at 150 C., cps 70 + 10 Flash Point (COC), C., Min. 316 Acid Number, Meg./100g. flax. 0.5 Melting Range, C. 96-109 This compound is useful as a flame retardant in resins and the like and as a plasticizer for cellulose zithers and esters. Example D: Preparation of Dicumylphenyl Glutarate This compound was prepared by reacting 1 mole of dimethyl glutarate with 1 moles of cumylphenyl acetate in the presence of 0.5 wt. Z of sulfuric acid as catalyst During the reaction, acetic acid was distilled overhead until the bottoms product boiled over 150 C. at 1 mm Hg. Thereafter, the product was neutralized with calcium carbonate, filtered and recrystallized from toluene. The product obtained was a hard, white, wary solid. The yield was 83% of theory. The dicumylphenyl glutarate has the followin & properties: Appearance: Hard White Wax Specific Gravity 1.13 Wt./Gal., lbs. 9.41 Viscosity at 176 C., cps 140. t 15 Flash Point (COC)r Mien. OC. 371 Vapor Pressure (mm Hg.), flax. 930C. 1 Melting Range, C. 121-138 Acid Number, Meq./100g flax. 0.5 This compound is useful as a process aid in polyacrylate and polyacrylonitrile extrusion and molding operations. Example E: Preparation of Cumylphenyl Acrylate Cumylphenyl acrylate was prepared in the apparatus described in Example A. On mole of cumylphenol and 2 moles of calcium carbonate were slurried in the presence of 1 liter of toluene solvent. During a period of 2 hours1 one mole of acryl chloride was added to the solution while the temperature was maintained at 40 to 500 C. The reaction mixture was filtered and the filtrate distilled at 5 mm Hg. to produce a pale yellow oil boiling at 198 to 2030C. The yield was 84%. Gas chromatographic assay indicated that less than 3% of unreacted cumyl phenol was reatined in the product. The cumylphenyl acrylate has the following properties: Appearance: Pale Yellow Oil Specific Gravity 1.07 Wt./Gal-., libs. 8.91 Viscosity at 240C., cps 105 + 10 Flash Point (COC), min. 00. 150 Vapor Pressure at 240C. (mm Hg) I Acid Number, Meq. llOOg. Max. 0.5 Pour Point, Max. OC, -18 This compound is useful as a co-monomer in peroxide cured acrylates, polyesters and alkyl resin formulations. It also imparts greater impact strength and higher curing rates as compared with conventional co-monomers, e.g., phenyl acrylate. Example F: Preparation of Cumylphenyl Methacrylate The methacrylate ester was prepared by the procedure described in Example G, except that methacryl chloride was used in place of acryl chloride. The yield was 84%. The cumylphenyl methacrylate has the following properties: Appearance: Pale Yellow Oil Specific Gravity - 1.06 Wt./Gal., ibs 8.83 Viscosity at 240C., cps 110 + 15 Flash Point (coy), Min. C. 149 Boiling Range, C. at 5mm 213-222 Acid Number, Meq./100g. max. 0.5. Pour Point, Max C. -8 This compound is useful for the same application as the cumylphenyl acrylate. It is often superior, however, in enhancing impact strength, but it does not as effectively enhance the cure rate. Example 1 In this example an acrylonitrile-styrene copolymer (Bakelite RMD 4420, a trademark of Union Carbide Corp.) was admixed with 3 parts per 100 parts by weight of the cumylphenol derivative shown in the table below. The elongation, tensile strength, and notched Izod impact strength obtained in each case was compared with the acrylonitrile composition control. Table I Notched Izod Tensile Impact Strength Strength Additive Elongation: psi ft.lb./in. None 2.3 10,000 0.45 Cumylphenyl borate 2.8 13,500 0.60 Cumylphenyl glutarate 3.2 10,500 0.60 Cumylphenyl benzyl ether 7.4 12,800 -'0.90 The above table shows that each of the cumlyphenol derivatives evaluated increased the elongation, tensil strength and impact strength of the acrylonitrile-styrene copolymer. The benzyl ether was the most effective in enhancing elongation while the borate ester improved the tensile strength by about 35%. Impact strength was improved in all cases with the greatest increase being shown with the benzyl ether. Example 2 In this example, 100 parts of polystyrene (Dylene, a trademark of Arco Chemical Company) were admixed in a drum tumbler with 2 parts of the cumylphenol derivative shown in the following table. Input samples were prepared by profile extrusion at 1900F. in a non-vented Hartig extruder using a general purpose mixing screw, L/D ration of 24:1. The following Table shows the results obtained: Table II Notched Izod Tensile Impact Ultimate \ Strength Strength Additive Elongation, 5 psi ft.lb./in. None 1.8 6,700 0.35 Cumylphenyl benzyl ether 5.2 8,600 0.80 Cumylphenyl 3.1 7,400 0.55 allyl ether The above table clearly shows that the elongation, tensile strength, and notched impact strength are improved by the addition of the cumylphenol derivatives. The benzyl ether is the most outstanding in improving the physical properties. Example 3 In this example, the effect of the cumylphenol derivatives on the tensile and impact strength of unfilled phenolic resins is shown. The resin used was a Bakelite Resin 2620 (trademart of Union Carbide Corp.). For each 100 parts of resin, 3 parts of additive (shown in the table below) along with 0.2 parts of p-toluenesulfonic acid were admixed in a high shear Cowles mixer at 600 to 700F. The material was thereafter cast into test specimes, 6" x ?p" X q", in a Teflon coated steel mold and cured at 1500 F. for 2 hours. Table III Notched Izod Impact tensile Additive ft.lb./in. Strength, psi None 0.55 7,200 Cumylphenyl borate 0.62 8,900 Cumylphenyl benzyl ether 1.05 7,400 Example 4 In this example, 100 parts of an unfilled polyvinyl chloride resin Bakelite QSAP-7 (a trademark of Union Carbide Corp.) was compounded at a temperature of 1500F. in a twin screw Anger extruder (L/Lj=24:1) with 2 parts of microcrystalline wax, 1 part of calcium stearate, 1 part of lead diphthalate, and 3 parts of the cumylphenyl derivative shown in the following table. The extruder has a PVC screw and X-alloy coated barrel. Prior to extrusion the components were blended in a Wellex high shear mixer. Test samples were profile extruded at a temperature of 1500F into " square rods and cut into pieces 6" long. The following results were obtained: Table IV Notched Izod Impact Tensile Additive ft.lb.jin. Strength, psi None 0.65 5,800 Cumylphenyl borate 0.85 5,900 Cumylphenyl benzyl ether 1.15 7,400 Dicumyiphenyl glutarate 1.05 7,200 The above table shows that the cumyiphenol derivatives improved the notched Izod impact without lessening the tensile strength of the unfilled polyvinyl chloride. The benzyl ether and the glutarate ester were particularly outstanding since not only did they result in the greatest improvement in impact strenght, but they also gave the greatest improvement in tensile strength. These additives did not affect the clarity of the polyvinyl cholride, though the material became a light tan color.

Claims: Claims: 1. A cumylphenol derivative characterised in that the derivative is (A) a compound of the formula: EMI12.1 wherein R is an acyl group having the formula EMI12.2 an alkenyl group having from 3 to 12 carbon atoms or an aralkyl group having from 7 to 12 carbon atoms, and R' is an alkenyl group having 2 to 12 carbon atoms, (8) a derivative of a polyfunctional organic acid wherein the acid has 2 or 3 functional groups, or (C) a derivative of boric acid. 2. A cumylphenol derivative according to claim 1 characterised in that R is an acyl group and R' is a phenyl group, a vinyl group or an isopropenyl group. 3. A cumylphenol derivative according to claim 1 characterised in that R is an allyl, methalll)ilor benzyl. 4. A cumylphenol derivative according to claim 1 characterised in that the polyfunctional acid is an organic dicarboxylic acid having from 4 to 8 carbon atoms per molecule. 5. A cumylphenol derivative according to claim 4 characterised in that the dicarboxylic acid is unsaturated or aromatic. 6. A cumylphenol derivative according to claim 4 charactensed in that the dicarboxylic acid is glutaric acid. 7. A thermoplastic resin composition characterised in that it contains from 0.5 to 20 parts by weight of a cumylphenol derivative as claimed in any of the preceding claims. 8. A composition according to claim 7 characterised in that the resin is polyvinyl chloride, polystyrene or a copolymer of acrylonitrile and styrene. 9. A thermosetting resin composition characterised in that it contains from I to 25 parts by weight of a cumylphenol derivative as claimed in any of claims 1 to 6. 10. A composition according to claim 9 characterised in that the resin is an unfilled phenolic resin.

Inventors: MONTE, SALVATORE J., SUGERMAN, GERALD
Applicants: KENRICH PETROCHEMICALS, INC.
Application year: 1979
Main classification: C07C43
IPC codes: C08K5, C07F5, C07C69, C08L27, C07C67, C07C43, C08L33, C07C41, C08L1