FREE-RADICAL ADDITION COPOLYMERS OF META- OR PARA-ISOPROPENYL-ALPHA,ALPHA-DIMETHYLBENZYLISOCYANATE

Abstract: Aromatic solvent-soluble substantially linear copoly­ mers of meta- or para-isopropenyl-α,α-dimethylbenzyliso­ cyanate substantially free of unsaturation and cross-linking are disclosed. Such copolymers are made by solution poly­ merization of the monomers under free-radical poly­ merization addition conditions.

Description: FREE-RADICAL INITIATED COPOLYMERS OF META- OR PARA- ISOPROPENYL- a, a-DIMETHYLBENZYLISOCYANATE BACKGROUND OF THE INVENTION This invention relates to copolymers of metaor para-isopropenyla,a-dimethylbenzylisocyanate and to a method of making same. In U.S. Patent 4,439,616 issued March 27, 1984, there is disclosed a method for production of tertiary aralkyl isocyanates, such as tetramethyl xylylene diisocyanate (TMXDI), by thermal cracking of corresponding urethanes formed by addition of corresponding olefins and carbamic acid esters at moderate temperatures and in the presence of acid catalyst. Such process is particularly useful in producing the meta- or paraisomers of TMXDI and as the by-product thereof, substantial amounts of the corresponding vinyl isocyanate meta- or para-isomers (i.e., meta-isopropenyl-a,a dimethylbenzylisocyanate (m-TMI) or para-isopropenyl-a,a¯ dimethylbenzylisocyanate (p-TMI), respectively), are formed. The m-TMI or p-TMI by-product in such systems may be recycled within the process to improve the overall yield of TMXDI therein, but has substantial utility per se as a separate product due to its difunctional character, viz., the presence of reactive isocyanato ( NCO) and vinyl groups. Thus, TMI may be homo- or copolymerized to form polymers with isocyanate functionality which are cross-linkable with curatives containing a difunctional or polyfunctional amino or hydroxyl compound. Such cross-linkable compositions have filmforming properties and advantageously may be used for coatings as for example on metal, wood and glass substrates, as well as having potential applicability for production of molded articles, such as by reaction injection molding (RIM). In general, it is desirable that the TMI homopolymers and copolymers be light stable in character and cross-linkable with diols, triols, polyols and oligomeric hydroxyl-containing compounds. Such homo- or copolymers of TMI further should be soluble in common coatings solvents for coatings end-use applications (i.e., solvents such as benzene, toluene, xylene, hexane, methylene chloride, cellosolve acetate, etc.) and should be free of toxicity problems associated with conventional isocyanates used heretofore. U.S. Patent No. 3,290,350 discloses the copolymerization of TMI by conventional methods using known addition polymerization initiators, such as those of the free radical type such as peroxy and azo initiators. More specifically, this patent discloses copolymerization of m-TMI in a solution of benzene containing l,l-azodicyclohexane carbonitrile with ethylene, introduced into the reaction system as a gas at elevated pressure, the polymerization being carried out at a temperature of 115 to 1250C. The resulting copolymer is precipitated from benzene solution at ambient temperature, as a result of its insolubility in benzene at ambient temperature. Such TMI/ethylene copolymer is not light stable in character. The insolubility of the TMI-copolymer produced by the above procedure in benzene and similar aromatic solvents, e.g., toluene and benzene is a severe disadvantage, in view of desirable end-use applications such as coatings and reaction injection molding wherein it is desired to dissolve or disperse the homopolymer in such aromatic solvents. Further, the presence of any significant cross linking in the resultant copolymer is destructive of the linear structure thereof and may result in premature gela ion of the copolymer when cinpi oyed in end-use applications such as coatings. It is an object of this invention to provide a method of making TMI copolymers which does not require isolation or purification of the copolymerization reaction product, which uses anhydrous copolymerization media, and which yields a substantially monomer-free copolymer product (thereby avoiding the toxicity concerns otherwise associated with the unreacted isocyanate monomer). It is another object of the present invention to provide aromatic solvent-soluble substantially linear copolymers of m-TMI or p-TMI which are substantially free of unsaturation and cross-linking. It is a further object of the invention to provide copolymers of the above type which have high molecular weights, e.g., on the order of 2,000 to 200,000. The present invention relates to a substantially linear, organic solvent-soluble copolymer substantially free of unsaturation and cross-linking of meta- or para-isopropenyl-a,a-dimethylbenzylisocyanate and at least one other ethylenically unsaturated comonomer polymerizable therewith. The at least one other ethylenically unsaturated monomer suitably may be selected from the group consisting of methyl methacrylate, butyl acrylate, styrene, a-methylstyrene, ethyl acrylate, methyl acrylate, p-methylstyrene and p-methyl-amethylstyrene. In another aspect, the invention relates to a method of forming a copolymer of the above-described type, comprising solution polymerizing the meta- or para-isopropenyl-a,a-dimethylbenzylisocyanate and the at least one other ethylenically unsaturated comonomer' in an aromatic hydrocarbon solvent and in the presence of a free radical initiator, or alternatively, under irradiation by ultraviolet radiation or electron beam irradiation. The free-radical initiator in the method above-described suitably may comprise t-butylperbenzoate, benzyl peroxide, or mixtures thereof. In a particularly preferred method aspect of the invention, free-radical addition polymerization is carried out by the following steps: (a) forming a reaction volume comprising the aromatic hydrocarbon solvent, free-radical initiator, port ions of all of the comonomers except such one thereof as has the highest reactivity thereof, such one of the monomers being fully present in the reaction volume in an amount to be incorporated into the copolymer; and (b) adding remaining portions of each apportioned comonomer to the reaction volume under polymerization reaction conditions while maintaining a substantially constant monomer composition in the reaction volume, to form the copolymer with a substantially homogeneous polymeric composition. The foregoing method also results in essentially 100% conversion of monomers, to yield a reaction product which is substantially free of monomeric reactants. The copolymers of the present invention usefully may be employed as cross-linkable compositions having utility for forming molded objects, such as by reaction injection molding, or in coatings. Such cross-linkable compositions may employ resin component containing a copolymer according to the invention and a cross-linkingly effective amount of a curing component containing a curative with free hydroxyl or amine functionalities, such as trimethylol propane, ethylene diamine ketimine, diethylene glycol; and 1,2,6-hexane-triol. Such compositions when used for coatings applications may be applied directly to the substrate, e.g. wood, metal or plastic, and Lhe applied film cured at ambient conditions with exposure to atmospheric humidity. As used herein, "aromatic solvent-soluble" means that the copolymer is soluble at ambient temperature, inter--alia, in toluene, xylene and benzene. As also used herein, "substantially free of unsaturation and cross-linking" means that the copolymer contains less than one percent by weight of ethylenically unsaturated groups. As indicated hereinabove, the presence of significant levels of unsaturation content and crosslinking in TMI copolymers which renders such polymers non-linear structurally and aromatic solvent insoluble. Such deficiencies are overcome in the copolymers of meta-TMI or para-TMI according to the present invention, in accordance with which copolymers are produced which are substantially linear, aromatic solvent-soluble, substantially monomer-free, and substantially free of unsaturation and cross-linking. These unexpected characteristics of the copolymers of the present invention are achieved by forming the copolymer by solution polymerization in an aromatic hydrocarbon solvent of the meta- or para-TMI and other ethylenically unsaturated comonomers selected from the group consisting of methyl methacrylate, butyl acrylate, styrene, a-methylstyrene, ethyl acrylate, methyl acrylate, p-methylstyrene and p-methyl-a-methylstyrene, in the presence of a free-radical initiator such as t-butylperbenzoate, benzoyl peroxide, and mixtures thereof. Alternatively, in place of the free-radical initiators mentioned, the free-radical addition polymerization reaction may be carried out under irradiation by ultraviolet (UV) radiation or electron beam irradiation. Copolymerization under these conditions tends to promote highly efficient polymerization, yielding product characterized by substantial absence of any cross-linking or residual unsaturation, with high molecular weights, e.g., on the order of from about 2,000 to about 200,000, with high isocyanate (-NCO) content, i.e., isocyanate mole percent contents of ten percent and higher are readily achievable in the practice of the present invention. In preferred practice, the substantially linear, organic solvent-soluble copolymer of the invention contains from about one to about eighty mole percent repeating units derived from meta- or para-TMI and from about 20 to about 99 mole percent repeating units derived from the at least one other ethylenically unsaturated comonomer polymerizable therewith selected from the group consisting of methyl methacrylate, butyl acrylate, styrene, a-methylstyrene, ethyl acrylate, methyl acrylate p-methylstyrene and p-methyl-a-methylstyrene. For TMI/styrene or styrene derivative copolymers to be employed in enduse applications where light stability is essential, it generally is desirable to limit the content of the styrene or styrene derivative monomer to not more than about 30 mole percent in the product copolymer. Particularly useful copolymer compositions include copolymers containing from about 10 to about 30 mole percent repeating units derived from meta- or para-TMI, from about 20 to about 50 mole percent repeating units derived from methyl methacrylate, from about 35 to about 45 mole percent repeating units derived from butyl acrylate, and from about 0 to about 25 mole percent repeating units derived from styrene. Aromatic hydrocarbon solvents may be used in the copolymerization reaction to form the copolymers of the present invention such as toluene, xylene, benzene and chlorobenzene. Other solvents usefully may be employed, such as methylene chloride, etylene dichloride and the like. Such solution polymerization may be carried out tltchwise or in continuous fashion, depending on the production requirellients of the given application. In a preferred method (hereinafter denoted "continuous addition method") for carrying out the copolymerization, a reaction volume is formed comprising the aromatic hydrocarbon solvent, free-radical initiator, portions of all of the comonomers to be employed in the reaction except such one thereof as has the highest reactivity of the comonomers, such one being fully present in the reaction volume in an amount to be incorporated into the copolymer product. The remaining portions of each of the apportioned comonomers is then added to the reaction volume under polymerization reaction conditions while maintaining a substantially constant monomer composition in the reaction volume, to form copolymer product having a substantially homogeneous polymeric composition. In practice, the copolymerization reaction may be conducted with a temperature of from about 500C to about 1200C for a reaction time of from about 5 to about 10 hours. Another preferred copolymer according to the present invention is a terpolymer containing from about 10 to about 30 mole percent repeating units derived from meta- or para-TMI, from about 30 to about 50 mole percent repeating units derived from methyl methacrylate, and from about 35 to about 55 mole percent repeating units derived from butyl acrylate, wherein the copolymerization is carried out by the aforementioned method wherein only the full amount of the comonomer having the lowest reactivity is fully present in the reaction volume, with the other comonomers being added while maintaining substantially constant monomer composition in the reaction volume. For such mode of polymerization, the monomer fully present in the reaction volume is butyl acrylate, and the reaction volume contains from about 25 to about 50 percent of the total amount of methyl methacrylate and butyl acrylate monomers to be incorporated into the copolymer product. Another preferred copolymer contains from about 30 to about 80 weight percent repeating units derived from meta- or para-TMI and from about 20 to about 70 weight percent repeating units derived from styrene. Such copolymer may be readily formed by solution polymerization in the presence of a free-radical mixture comprising benzyl peroxide and t-butyl perbenzoate. In one application of the invention, a substantially linear, organic solvent-soluble copolymer substantially free of unsaturation and cross-linking containing from about 30 to about 80 weight percent of repeating units of the formula: EMI8.1 wherein the (l-amino-l-methylethyl-) group is a meta- or para- substituent, and from about 20 to about 70 weight percent of repeating units of the formula: EMI8.2 may be formed fror b copolymer of meta- or para-TMl and styrene formed ls described immediately above, by hydrolyzing such copolymer in an aqueous solution of hydrochloric acid yield a hydrolyzed reaction mixture, which then is neutralized with a base, and from which (base-neutralized mixture) the aforementioned amino group-containing copolymer (hereinafter "TMA copolymer") is recovered. The base used in such neutralization following hydrolysis may be sodium hydroxide or any other suitable base and the hydrolysis usefully may be carried out at a temperature of from about 25 to about 1500C. The TMA copolymer formed as described above has utility in paper sizing applications, wherein paper, such as formed by a wet web process, is contacted with a solution of the TMA copolymer in dilute aqueous acetic acid. The copolymers of the present invention also have utility as film-forming components of coatings, and suitably may be employed in curable film-forming compositions comprising a resin component containing a copolymer according to the invention and a cross-linkingly effective amount of a curing component, such as curatives selected from the group consisting of trimethylol propane, ethylene diamine ketimine, diethylene glycol, 1,2,6-hexanetriol, and oligomeric (low molecular weight) polyols. Such film-forming composition may be employed to form a coating on a substrate by application thereto, of a film of the composition, which then may be cured by exposure to moisture (atmospheric humidity) to assist the cross-linking cure of the coating. Particularly useful for such coatings applications are copolymers containing from about 5 to about 40 mole percent repeating units derived from meta- or para-TMI, from about 30 to about 50 mole percent repeating units derived from methyl methacrylate and from about 35 to about 45 mole percent repeating units derived from butyl acrylate. The curing of such film-forming compositions is advantageously carried out under conditions where the molar ratio of'co- polymeric isomeric cyanate groups to curing component hy droxyl or mine groups is approximately 1:1. In the broad practice of the present invention, both meta- and para-TMI can be co-polymerized with various acrylates, e.g., methyl methacrylate, butyl methacrylate, ethyl acrylate, methyl acrylate and the like, as well as styrene, a-methylstyrene, pmethyl-a-methyl-styrene, and p-methylstyrene and acrylonitrile at various concentrations to give product copolymers of varying compositions and properties. Where styrene, p-methylstyrene or acrylonitrile are employed as comonomers, the amounts thereof should be limited, generally to not more than 30 mole percent in the product copolymer, to insure that such product copolymer is light stable in character, where light stability is necessary and/or desired. The free radical-initiated addition polymerization may be carried out in bulk or in solution, depending on the monomer reactivities and the anticipated end-use. In some free-radical copolymerizations wherein comonomers of significantly different reactivity are employed, conversions close to 100 percent may be achieved by using the continuous addition method hereinabove described, wherein the monomer having the lowest reactivity is fully contained in the reaction volume together with portions of all other monomers, with the unadded portions being added under polymerization reaction conditions while maintaining substantially constant monomer composition in the reaction volume. Product copolymer molecular weights may be controlled by the use of chain transfer agents such as thiols or mercaptans or by the use of high levels of the free-radical initiator. The preferred content of TMI in the product copolymer is from about one percent up to about 80 percent. The application of the invention is more fully illustrated by the following examples, wherein all parts and percentages are by weight, unless otherwise indicated. Example I In this Example, a copolymer of m-Thil, methyl methacrylate (MMA), butyl acrylate (BA) and styrene (ST) was prepared by free-radical polymerization in accordance with the method of the present invention. Three polymers were prepared at 50% weight solids content in toluene using 1.3 weight percent t-butyl perbenzoate, based on the weight of monomers present, at a reaction temperature of 114-1150C, having the compositions shown in Table I below. Table I Polymer Composition (mole %) Reference m-TMI MMA BA Styrene 1 15 45 40 0 2 15.36 37.92 38.39 8.36 3 15.47 23.43 38.54 22.55 Table II below shows for the polymers identified in Table I the polymerization reaction time, percent conversion, glass transition temperature Tg and molecular weight (for polymer 1 only) as determined by gel permeation chromatography (GPC). Table IT Polymer Refer- ization Conversion Tg Mol. Wt. ence Time (mins) (mole %) (oC) by GPC 1 430 98.4 25 17,400 2 392 97.9 29 3 406 97.2 29.5 As shown by the Table II data, reactions for these tetra copolymers were substantially complete' in 6.5-7 hours; Each of the. copolymer products was a clear, viscous permeable liquid having a glass transition temperature at approximately ambient temperature levels. Example II A m-ThI/lA/BA terpolymer was prepared by the "continuous addition" method described earlier herein, to provide continuous addition of m-TMI and MMA monomers to the reaction volume and yield a substantially homogeneous product terpolymer. To a flask was added 48.15 grams MMA, 85.26 grams BA and 21.84 grams m-Th1. A syringe was prepared containing 26.88 grams MMA and 27.86 grams m-TMI. The monomers in the flask were mixed with 210 gms toluene and 2.80 gms t-butyl perbenzoate and the re sulting reaction volume was deaerated with nitrogen and heated rapidly in an oil bath to 110-1140C. Monomer (m-TMI and MMA) from the syringe was added slowly, at a rate which maintained a constant monomer composition in the flask, as measured by gas chromato graphy of sample: (0.30 mls in 5 mls acetone). Monomer was added at the rate of about 0.6 mls/minute during the first 164 minutes of the reaction, and at the rate of 0.06 mls/minute during the final 260 minutes of the reaction. An extra 1 ml. of the initiator (t-butyl perbenzoate) was added after 272 minutes of reaction. After 424 minutes, the reaction was substantially complete at a conversion of 98.5 mole percent. Example III Solution polymerization of m-TMI/MMA/BA (15/45/40 mole percent, respectively was carried out in toluene at a temperature of 110-114 C, by batch reaction at decreasing levels of initiator with increasing concentrations of monomers in the polymerization solution. The initiator employed was t-butyl perbenzoate in all cases. Data for the various reactions are set out in Table III below: Table III Concentration Initiator Concentration Time to Of Monomers Reaction Start (1) Levels Total (2) 95% Con- Molecular Refer- In Solution Tempera- (% by weight based on version Weight GPC (3) Tg viscosence (% by weight) ture ( C) monomer) (Minutes) (Daltons) ( C) ity (4) 4 20 111.5 3.33 8.33 425 6.400 20 Thin 5 30 112 2.22 4.44 420 11,000 13? Slightly Viscous 6 40 113 1.67 2.50 380 15,100 22.5 Viscous 7 50 114-115 1.43 1.43 340 17,400 21.5 Viscous Pourable (1), (2) In some cases incremental addition of initiator during reaction was carried out, so that the initiator level is then greater than at the start. (3) Polystyrene standards (4) Visual appearance: all were water-white (transparent) solution. Polymer was soluble in acetone, toluene, methylene chloride; insoluble in d-alkanes. As seen by the data, an increasing concentration of monomer solids allows less initiator to be used, yields increased polymerization rates and results in higher copolymer product molecular weights. An isocyanate assay for each of the copolymers identified in Table III is contained in Table IV below, showing that the copolymers of the present invention are characterized by high content of free isocyanate (-NCO) groups. Table IV -NCO Content by Calculated Infra-red Titration with -NCO Con- Analysis Dibutylamine tent -NCO/NCO+-C=O Reference (meqig) (meqig) 4 0.87, 0.87 - No NH 0.35 5 0.74, 0.74 - No NH 0.45 6 0.54, 0.54 0.56 No NH 0.34, 0.36 7 0.65, 0.64 0.64 No NH 0.41, 0.45 0.40 Example IV The continuous monomer addition method was employed to prepare a terpolymer of homogeneous composition containing 15/45/40 mole percent m-TMI/MMA/BA. The copolymerization reaction was carried out at 110-114 C. and 50% monomer solids (final concentration), with t-butyl perbenzoate as the initiator Reaction data and product molecular weight'and viscosity information are set out in Table V below Table V Initiator Time to Molecular Levels Reach 95% Weight By Temp. Start Finish Conv. (min.) GPC Reference ( C) (% by weight based on monomer) (Daltons) Viscosity* 8 114 1.42 2.13 420 15,800 Viscous, pourable 9 110 1.40 1.90 390 15,800 Viscous, pourable * Determined also by Brookfield viscosity as 570 cps (30 rpm Spindle 2, LVT, at 50% weight solids in toluene) The glass transition temperature (Tg) of Sample 9 was 250C (Tg of Sample 8 was not measured). Isocyanate assay information for these samples is contained in Table VI below. Table VI -NCO content by Calculated Infra-red titration with -NCO content Analysis dibutylamine -NCO/-NCO + C=0 Reference (meq 1 gm) (meq 1 gm) (meq/gm) 8 0.66, 0.63 0.64 -NH 9 0.57, 0.58 0.59 1 -NH 0.40 Example V A series of copolymers of m-TMI and styrene containing 30% to 80% by 'weight of m-TMI were prepared by charging to the reaction vessel the m-ThI, styrene, hexadecane (used as an internal standard) and initiator(s), to thereby form a reaction volume. The reaction volume then is deaerated and heated in an oil bath at polymerization temperature for the time necessary to complete polymerization. Copolymers were analyzed by sampling 0.30 mls. of the polymerization product and determining the free monomer concentration thereof by GPC. Analysis of the copolymers is shown in Table VII below. The copolymers were then hydrolyzed to form styrens/TMA copolymers (TMA = hydrolysis product of TMI wherein the isocyanate group is hydrolyzed to amino). The starting TMI copolymers were clear solutions when warm, but white, semisolids when cold. The temperature at which the change occurred increased with the proportion of styrene in the polymer. Hydrolysis of each TMI copolymer was effected by stirring same at 90oC in toluene solvent in the presence of 38% aqueous solution of hydrochloric acid for 1 112 hours. During hydrolysis, the copolymer mixture became more viscous and CO2 was evolved. Hydrolysis was continued until I.R. indicated zero - NCO remained. The hydrolyzed mixture then was neutralized with 10% NaOH until it remained alkaline. The organic phase was washed by shaking with water and solvent was removed by rotary evaporation. Clear viscous polymers were obtained, which solidified to white opaque materials on cooling. These copolymers were found to be soluble in dilute aqueous acetic acid (as well as acetone, toluene and methylene chloride). The 40% by weight m-TMI (hydrolyzed to TMA) copolymer required warming to produce a solution, and the 30% by weight m-TMI (hydrolyzed) sample was marginally soluble on heating to 700C. See Table VII. The TMA polymers produced as above then were utilized in dilute acetic acid solutions for sizing of paper. Qualitative paper sizing tests were carried out using filter papers impregnated with acetic acid solutions of the TMA polymers and dried at 1050C. As shown in Table VII, optimum sizing against Tappi blue ink and green dye was obtained at about 40% m-TMI (hydrolyzed to TMA) in the copolymer. Table VII STYRENE/m-TMI COPOLYMERS A. Copolymerization Polymer Reference 10(1) 11 12 13 14 m-TMI in comonomers (% by weight) 30 40 50 60 80 m-TMI in Copolymer (% by weight) - 38.1 48.1 53.9 75.8 Total monomer conversion (mole %) - 84.3 80.3 64.0 83.2 Initiator: type A/B A A A B % by weight based on monomers 4/2 6.0 6.0 6.0 5.0 Temperature ( C.) 115 110 110 110 110 Molecular weight GPC (peak) - lost lost 11K 3K-9K B. Hydrolysis and Solubility Hydrolysis time &commat; 90 C (minutes) 90 120 120 50 60 Extent of hydrolysis by IR (%) 100 100 100 100 100 Solubility in dilute HAC (cold) st. sol. sol. sol. sol. sol. C. Sizing Effect on Filter Paper To Tappi blue ink some good 2 hr(2) good) slight none > 1 hr.) To "green water" some good 2 hr slight none none Example VI Curing Studies were conducted on a 15/40/45 mole percent m-TMI/BA/MMA terpolymer, using the following as curatives (crosslinkers): Curative Compound W Ethylenediamine ketimine X Diethylene Glycol Y Trimethylolpropane Z 1,2,6-hexanetriol For overall cure response at both elevated and at ambient temperature, the TMI terpolymer/curative Y system was the best. Solvent resistant films were obtained on cure schedules as low as 20'/800C and within 4-7 days at ambient temperature. The curative X system showed good advancement of cured panels at ambient temperature and ambient cured films developed good solvent resistance within 7 days (200+ MEK rubs). The curative Z system exhibited sluggish initial cure response and did not show good subsequent ambient room temperature advancement. Like curative Z, the curative W system also showed a sluggish cure response, and ambient cure response was also sluggish. Even after 7 days it developed only marginal solvent resistance (120 MEK rubs). The foregoing characterizations were based on films of the terpolymer/curative compositions at 1:1 molar ratio of terpolymer-NCO groups to the curative functionality (-NH2 or -OH), and 45% net volatiles in toluene in the coating compositions, as applied to substrate panels of 12005 aluminium. The terpolymer contained 2.42% NCO based on an equivalent weight of 1735.5(0.575 meq/gm of solution; 51.8% NV in toluene). The equivalent weights of curatives W, Y and X were 30, 44 and 53, respectively. Data are shown in Tables VIII-X below. Table VIII TMI Copolymers - Dry Film Characteristics CURATIVE CROSSLINKING AGENT) W X Y Z 20'/1250C THICK. 1.2 1.2 KNOOP 12.7 12.0 MEK, MAR - 150 REMOVE 200+ 200 20'/100"0 THICK. 1.2 1.2 1.2 1.2 KNOOP 10.4 13.0 12.5 10.6 MEK, MAR 90 90 -- 50 REMOVE 150 190 200+ 90 201/800C THICK. 1.2 1.2 1.2 1.2 KNOOP 10.5 9.8 11.4 7.5 MEK, MAR 40 50 150 10 REMOVE 80 110 200 35 TABLE IX TMI TERPOLYMER ADVANCEMENT AT ROOM TEMPERATURE CROSSLINKING AGENT W X Y Z AFTER 1 DAY 20'/1000C THICK. 1.2 MEK, MAR/ 90/150 REMOVE 20'/80 C THICK. 1.2 1.2 MEK, MAR/ 40/110 200+ REMOVE AFTER 2 DAYS 20'/1000C THICK. 1.2 1.2 MEK, MAR/ 150/200 90/130 REMOVE 20'/800C THICK. 1.2 1.2 MEK, MAR/ 80/140 20/70 REMOVE R.T.* THICK. 1.2 1.2 MEK, MAR/ 80/140 10/40 REMOVE AFTER 4 DAYS 20'/100 C THICK. 1.2 MEK, MAR/ 110/120 REMOVE 20'/800C THICK. 1.2 MEK, MAR/ 50/140 REMOVE R.T. THICK.. 1.2 1.2 MEK, MAR/ 40/110 50/180 REMOVE AFTER 7 DAYS R.T. THICK. 1.2 1.2 1.2 1.2 MEK, MAR/ 50/120 100/180 200+ 20/60 * RT = room temperature TABLE X TMI COPOLYMER - CURATIVE Y* DRY FiLM CHARACTERISTICS % NCO 2.42 20'/1000C FILM THICK. (MILS) 1.2 KNOOP HARDNESS 12.5 MEK, MAR/REMOVE 200+ 20'/300C FILM THICK. (MILS) 1.2 KNOOP HARDNESS 11.4 MEK, MAR/REMOVE 150/200 ADVANCEMENT AT RO()4 TEMP. AFTER 3 DAYS 20'/1000C FILM THICK. (MILS) KNOOP HARDNESS MEK, MAR/REMOVE 20'/800C FILM THICK. (MILS) KNOOP HARDNESS MEK, MAR/REMOVE R.T. FILM THICK. (MILS) KNOOP HARDNESS MEK, MAR/REMOVE AFTER 4 DAYS R.T. FILM THICK. (MILS) 1.2 MEK, MAR/REMOVE 50/180 * 33Z NV in cellosolve acetate Example VII Small scale copolymerizations of m-Tt11 with various comonomers were carried out to determine their relative reactivity. Copolymerization reactions were carried out for n-butylacrylate, methyl methacrylate, ethyl acrylate (all at 80 mole %) and styrene at 32, 45 and 56 mole qlq. Both n-butyl and ethyl acrylate were found to be incorporated more rapidly than m-TMI, methyl methacrylate was incorporated at a similar rate to m-TMI, but styrene was incorporated much more rapidly than m-TMI. The reactivities with m-TMI increase in the order: n-butyl # < MMA # m-TMI < styrene. Example VIII Solution copolymers of m-TMI were made in toluene at 1000C or 110 C Using peroxide free-radical initiators. Initiators, co-monomers, reaction parameters and molecular weight of the product copolymers are set out in Table XI below. TABLE XI SOLUTION COPOLYMERIZATION OF m-TMI EMI24.1 <tb> = <SEP> Mole <SEP> S <SEP> Initietor <SEP> Solvent/non-So1vnt <SEP> 11LflLt <SEP> 100 <SEP> Cfl.rsi)n <tb> ence <SEP> m-TMI <SEP> Type <SEP> L <SEP> Comononet <SEP> L <SEP> added <SEP> to <SEP> manomer) <SEP> Time <SEP> Temp <SEP> leo! <SEP> ': :1 <SEP> 'Wi <tb> <SEP> II <SEP> S <SEP> "- <SEP> 1 <tb> <SEP> 15 <SEP> 100 <SEP> BzO2 <SEP> 6.0 <SEP> m-TMI <SEP> 50 <SEP> hexedecont <SEP> 78 <SEP> 100 <SEP> 12 <SEP> 6 <SEP> 40)-Ia <tb> <SEP> C <tb> <SEP> 16 <SEP> 20 <SEP> Bz02 <SEP> 5.0 <SEP> Ethyl <SEP> Acrylate <SEP> 100 <SEP> toliene <SEP> 120 <SEP> 100 <SEP> C <SEP> S <SEP> 2 <tb> <SEP> L <tb> <SEP> <SEP> t <SEP> rs <SEP> sr <SEP> o1 <SEP> N <SEP> C <SEP> uo <SEP> fir <tb> <SEP> 17 <SEP> 20 <SEP> B <SEP> Z02 <SEP> a <SEP> Methyl <SEP> methecrylate <SEP> 100 <SEP> toluene <SEP> 300 <SEP> 100 <SEP> 72 <SEP> <SEP> > <SEP> OIhT <tb> <SEP> 18 <SEP> 20 <SEP> B <SEP> z02 <SEP> 5.0 <SEP> n-butyl <SEP> acrylate <SEP> 100 <SEP> toluene <SEP> 120 <SEP> 100 <SEP> 9? <SEP> 2 <SEP> (K <tb> <SEP> 19 <SEP> 20 <SEP> o <SEP> Z02 <SEP> O <SEP> c <SEP> o <SEP> c <SEP> " <SEP> toluene <SEP> ^ <SEP> min) <SEP> 100 <SEP> o <SEP> C.'! <tb> <SEP> <SEP> EO <SEP> O <SEP> O <SEP> O <SEP> C <SEP> O <SEP> O <SEP> C <SEP> C <SEP> O <SEP> ¯ <SEP> ¯ <SEP> ¯ <tb> <SEP> fJ <SEP> 1.0 <SEP> LI <SEP> I <SEP> <SEP> r <SEP> 16 <SEP> BZ2 <SEP> O <SEP> C <SEP> C <SEP> f <SEP> O <SEP> r <SEP> S <SEP> 0 <SEP> 0 <SEP> = <SEP> C <tb> <SEP> <SEP> eE <SEP> C <SEP> X <SEP> s <SEP> o <SEP> C <SEP> . <SEP> O <SEP> vrt <SEP> O <SEP> O <SEP> O <SEP> ¯ <SEP> C <tb> <SEP> 21 <SEP> Z <SEP> 8Z02 <SEP> 4.0 <SEP> | <SEP> rs <SEP> r4 <SEP> C <SEP> 100 <SEP> toluene <SEP> 255 <SEP> 100 <tb> <SEP> CV <SEP> F <SEP> N <SEP> N <SEP> N <SEP> P- <SEP> PI <tb> <SEP> 22 <SEP> 80 <SEP> B <SEP> Z02 <SEP> 4.0 <SEP> OIlED <SEP> 100 <SEP> 160 <SEP> 10(1 <SEP> ' <SEP> flu <tb> <SEP> C <SEP> ¯ <SEP> I <tb> <SEP> cE <SEP> : <tb> <SEP> > 3 <tb> <SEP> n <SEP> X <tb> <SEP> e <SEP> D <SEP> Q <SEP> C <SEP> C <SEP> 6.0 <SEP> Styrene <SEP> X <SEP> Ç <tb> <SEP> 3u <SEP> 0 <SEP> a <SEP> 0 <SEP> 8 <SEP> O <SEP> Y <SEP> Y <SEP> C <SEP> CC <tb> <SEP> C <SEP> r <SEP> : : <tb> <SEP> * <SEP> Xl <SEP> t.b.pb <SEP> r <SEP> 50 <SEP> toluene <SEP> 760 <SEP> o <SEP> o <SEP> x <SEP> r4 <SEP> IlK <tb> <SEP> C <SEP> u <SEP> LI <SEP> LI <SEP> L1 <SEP> LI <SEP> Y <SEP> 0 <SEP> 00 <tb> <SEP> 25 <SEP> X <SEP> oO.oO <SEP> r <SEP> Styrene <SEP> 50 <SEP> tolucne <SEP> S <SEP> u <SEP> Q <SEP> (13 <tb> <SEP> ot <SEP> =:1 <SEP> ¯ <SEP> S <SEP> Lss <SEP> Q <SEP> ¯ <tb> <SEP> > <SEP> 1x1 <SEP> O <SEP> CO <SEP> 0 <SEP> <SEP> 0 <SEP> 0 <SEP> 2 <SEP> 0 <SEP> 0 <SEP> 0 <SEP> 0 <SEP> 0 <tb> <SEP> 26 <SEP> 67 <SEP> 8Z02 <SEP> - <SEP> Styrene <SEP> so <SEP> toltione <SEP> 200 <SEP> 110 <SEP> .0 <tb> <SEP> wq <SEP> ¯ <tb> <SEP> r <tb> <SEP> ¯ <SEP> t <SEP> r <tb> <SEP> 1 <SEP> rw <SEP> :+ <tb> <SEP> > <SEP> : :N <SEP> > <SEP> u <tb> <SEP> e <SEP> ¯ <SEP> zQs <SEP> E <SEP> c <SEP> X <tb> <SEP> Ï <SEP> ¯ <SEP> S <SEP> a <SEP> s <SEP> zi <SEP> t <tb> <SEP> -¯ <SEP> c <SEP> S <SEP> o <SEP> - <SEP> c: <SEP> ri <SEP> X <SEP> :Y <SEP> z <SEP> ¯ <tb> <SEP> v <SEP> ss <SEP> > <SEP> ¯ <SEP> fi <SEP> [q <SEP> Qq <tb> <SEP> E <SEP> 1S <SEP> X: <SEP> e <SEP> X <SEP> a <SEP> c <SEP> a <SEP> ce <tb> <SEP> ; <SEP> o <SEP> o <SEP> o <tb> <SEP> o^ <SEP> o <SEP> o <SEP> o <SEP> o <SEP> o <SEP> o <SEP> o <SEP> o <SEP> o <SEP> . <tb> <SEP> a <SEP> vO <SEP> ffi <SEP> rb <SEP> o <SEP> ¯ <SEP> < <tb> <SEP> F <SEP> H <tb> <SEP> SL <SEP> (3 <SEP> o4 <SEP> ,r4 <SEP> ,rs <SEP> r4 <SEP> ,r4 <SEP> ,rv <SEP> ,rs <SEP> rs <SEP> ,rx <SEP> . <SEP> . <SEP> r4 <tb> <SEP> ¯ <SEP> -¯ <SEP> O <SEP> O <SEP> O <SEP> O <SEP> O <SEP> O <SEP> O <SEP> O <SEP> O <SEP> n <SEP> S <SEP> O <tb> <SEP> tS <SEP> t,S <SEP> IS <SEP> IS <SEP> tS <SEP> IS <SEP> st <SEP> IS <SEP> IS <SEP> . <SEP> . <SEP> st <tb> <SEP> Q <SEP> D: <SEP> t <SEP> ts <SEP> sq <SEP> 15 <SEP> a <SEP> U <SEP> CCt <tb> <SEP> tH <tb> <SEP> ¯ <SEP> > : <SEP> O <SEP> O <SEP> O <SEP> O <SEP> O <SEP> sO <SEP> 0 <SEP> O <SEP> O <SEP> o <SEP> N <SEP> b <tb> <SEP> E <SEP> = <SEP> cs <SEP> r4 <SEP> bt <SEP> c <SEP> 4 <SEP> ¯ <SEP> ¯ <SEP> I <SEP> .5 <SEP> o <SEP> s0 <SEP> s0 <tb> <SEP> CX <SEP> X <tb> <SEP> w <SEP> u <SEP> uo <SEP> o4 <SEP> X <tb> <SEP> a <SEP> C <SEP> ¯ <SEP> ¯ <SEP> ¯ <SEP> ¯ <SEP> ¯ <SEP> c4 <SEP> > 4 <SEP> r4 <SEP> r4 <SEP> c <SEP> 4 <SEP> v <SEP> 4 <SEP> r4 <tb> 1 ethylene glycol dimethacrylate 2 B2O2 = Benzoyl peroxide 3 t.b. pb = t-butyl perbenzoate 4 DVB = divinyl benzene 5 DIPEB = diisopropenylbenzene

Claims: \J11i11' l.S CLAIMED IS: 1. A substantially linear. aromatic solventsoluble copolymer, substantially free of unsaturation and cross-linking, of meta- or para-isopropenyl-a,a-dimethyl- benzylisocyanate and at least one other ethylenically unsaturated comonomer polymerizable therewith. 2. A copolymer according to Claim 1 wherein said at least one other ethylenically unsaturated comonomer is selected from the group consisting of methyl methacrylate, butyl acrylate, styrene, methyl styrene, ethyl acrylate, methyl acrylate, p-methylstyrene and p-methyl-a-methylstyrene. 3. A copolymer according to Claim 1 having a molecular weight of about 2000 to about 200,000. 4. A copolymer according to Claim 1 containing from about 1 to about 80 mole percent repeating units derived from meta- or para-isopropenyl-à,a-dimethyli- socyanate and from about 20 to about 99 mole percent repeating units derived from said at least one other ethylenically unsaturated comonomers. 5. A copolymer according to Claim 1 containing from about 5 to about 40 mole percent repeating units derived from meta-isopropenyl-a,a-dimethylbenzylisocyan- ate, from about 20 to about 50 mole percent repeating units derived from methyl methacrylate, from about 35 to about 45 mole percent repeating units derived from butyl acrylate, and from 0 to about 25 mole percent repeating units derived from styrene. 6. A method of forming a copolymer according to Claim 1, comprising solution polymerizing said metaor para-isopropenyl-ct,a-dimethylbenzylisocyanate and said at least one other ethylenically unsaturated comonomer in the presence of a free- radical initiator. 7. A method of forming a copolymer according to Claim 6, comprising solution polymerizing said metaor para-isopropenyl-a, a-dimethylbenzylisocyanate and said at least one other ethylenically unsaturated comonomer in an aromatic hydrocarbon solvent under irradiation by ultraviolet radiation or electron beam irradiation. 8. A method according to Claim 1 wherein said free-radical initiator is butyl perbenzoate, benzoyl peroxide, or mixtures thereof and said copolymerization is conducted in an aromatic hydrocarbon solvent of toluene, xylene, benzene, or chlorobenzene. 9. A method according to Claim 6, Claim 6 comprising: (a) forming a reaction volume comprising said aromatic hydrocarbon solvent, free-radical initiator, portions of all said comonomers except such one of said monomers having the highest reactivity thereof, said one of said monomers being fully present in said reaction volume in an amount to be incorporated into said copolymer; and (b) adding remaining portions of each apportioned comonomer to said reaction volume under polymerization reaction conditions while maintaining a substantially constant monomer composition in said reaction volume, to form said copolymer with a substantially homogeneous polymeric composition. 10. A method according to Claim 9 wherein said copolymer is a terpolymer containing from about 5 to about 40 mole percent repeating units derived from metaor para-isopropenyl-a,a-dimethylbenzylisocyanate, from about 30 to about 50 mole percent repeating units derived from methyl methacrylate, and from about 35 to about 55 mole percent repeating units derived from butyl acrylate, wherein said one of said monomers fully present in said reaction volume is butyl acrylate, and said reaction volume in step (a) contains from about 25 to about 50 percent of the total amount of the methyl methacryrlate and butyl acrylate monomers to be incorporated into said copolymer. 11. A copolymer according to Claim 1 containing from about 30 to about 80 weight percent repeating units derived from meta or par;S-isol)ropenyl-aea-dimethyl- benzylisocyanate and from about 20 to about 70 weight percent repeating units derived from styrene. 12. A method of forming the copolymer of Claim 11, comprising bulk polymerizing a comonomer mixture containing from about 30 to about 80 weight percent metaor para-isopropenyl-&alpha;,&alpha;-dimethylbenzylisocyanate and from about 20 to about 70 weight percent styrene in the presence of a free-radical initiator mixture comprising benzyl peroxide and t-butyl perbenzoate. 13. A method according to Claim 12 wherein said bulk polymerization is conducted at a temperature of from 900C to about 1200C for a reaction time of from about 5 to about 10 hours. 14. A curable film-forming composition comprising a resin component containing a copolymer according to Claim 1 and a cross-linkingly effective amount of a curing component consisting of trimethylolpropane, ethylenediamine ketimine, diethylene glycol, 1,2,6-hexanetriol or low molecular weight oligomeric polyols. 15. A method of forming a coating on a substrate, comprising applying to said substrate a film of a curable film-forming composition according to Claim 14, and curing same by exposure to moisture. 16. A method according to Claim 15 wherein said copolymer contains from about 10 to about 30 mole percent repeating units derived from meta- or para-isopropenyl-a,a-dimethylbenzylisocyanate, from about 30 to about 50 mole percent repeating units derived from methyl methacrylate and from about 35 to about 45 mole percent repeating units derived from butyl acrylate. 17. A method according to Claim 15 wherein the molar ratio of copolymer isocyanate groups to curing component hydroxyl or amine groups is approximately 1:1. 18. A free-radical addition polymerization reaction product of meta- or para-isopropenyl-a,-dimeth- ylbenzyl isocyanate and at least one other ethylenically unsaturated comonomer polymerizable therewith, which is substantially free of monomeric reactants.

Inventors: DEXTER, ROBIN WILLIAM, FORGIONE, PETER SALVATORE, SINGH, BALWANT
Applicants: AMERICAN CYANAMID COMPANY
Application year: 1984
Main classification: C08F246
IPC codes: C08G18, C08F212, C08F2, C09D133, C09D175, C08F246, C08F12, C09D125, C08F220