Aqueous peroxy carbamyl group containing polymer systems and methods of their production and use

Abstract: High performance polymer systems based on water dispersed polyurethanes obtained from the reaction of NCO terminated prepolymers with a peroxide compound containing at least one active hydrogen atom, methods of making such polymer systems and their use as hydrolytically stable flexible substrate bonding agents are disclosed. Flexible packages, e.g, retortable laminate pouches, are formed by bonding together sections of films, foils or like flexible substrates using such as adhesives.

Description: This invention broadly relates to polymer systems used in converting processes, methods for their preparation, methods of using them and packages formed therewith. Polymer systems of the invention find particular applications as adhesives. Their use in making flexible packages from films, foils or like flexible sheet materials, particularly, retortable pouches and like flexible packages also forms part of the invention. In the flexible packaging industry, many types of polymer systems are employed, e.g., adhesives, coatings, primers, binders, inks, etc. This invention provides new, improved polymer systems usable as adhesives, coatings, primers, binders, inks, or the like in converting or other processes. A number of adhesive systems that are solvent-based and a select few water-based systems are being used in the production of laminates and other materials used in the packaging of food, non-food and medical products. While solvent-based adhesives have dominated this market for a number of years due to economical and ecological reasons, there is a growing need for competitive, high performance water borne adhesives systems. Although a number of water-based adhesive systems claim to fulfil the various needs of the packaging industry, they all exhibit various disadvantages. This is due to the fact that the lamination process used in making packaging laminates, so-called converting, is complicated and involves many requirements for any acceptable adhesive system. Thus, usable adhesive systems should be machinable, compatible with a wide variety of printing inks, fast drying at very high coating speeds and devoid of foam or other undesirable problems. Further, the adhesive systems should be capable of bonding a host of different type films, paper products and foil to one another, yet provide very good initial and final bonding of such materials to give clear laminated end products. Depending on the product that packages made for such laminates are to hold, a number of other requirements must be addressed, e.g., retortable packages (see below) used for food or medical products should be able to withstand high retort temperatures and/or pressures. A wide range of monolayer materials and multilayer structures are used in the flexible packaging industry for the containment of food, medical and other products. To meet the required compatibility of the packaging materials to the contents of the resulting packages, a variety of different flexible materials are used. e.g., papers, films, foils, metalized films and metalized papers. For the sake of brevity, all such materials will be referred to herein as flexiblele substrates. Also, the term flexible packages as used herein encompasses packages made entirely of flexible materials, e.g. pouches, as well as semirigid containers that lave at least one flexible body wall or lid. One important class of flexible packages extensively used to contain food and medicinals are called retortable packages, i.e., packages capable of withstanding thermal processing in a pressure autoclave at temperatures in excess of 100°C. (see "Retortable Flexible and Semirigid Packages", pps. 568-571, Willey Encyclopedia of Packaging Technology by Marilyn Bakker). Retortable packages must maintain their material integrity as well as their required barrier properties during product-to-package handling, thermal processing and subsequent shipping and handling. In the case of shelf stable food packages, the flexible substrate used must be retortable and still maintain extended barrier characteristics. In making such retortable packages, flexible substrates have been sealed together by adhesives that are solvent-based systems. The processing of such adhesives takes a number of days, e.g., up to 13, to complete. In addition to this drawback, the solvent system adhesives present environmental and economic problems so there is an ever growing need for aqueous system adhesives capable of replacing solvent system adhesives. This invention helps to fulfill this need with new forms of polyurethane aqueous dispersions. Aqueous polyurethane systems that are ionomeric in nature are a known class of product, see U.S. patents 4,598,121; 4,540,633 and 4,240,942, Canadian patent 837,176, German patent AS2624442 and references cited therein, the disclosures of which are incorporated herein by reference for their teachings concerning formation of polyurethane prepolymers that are converted into an ionomer containing free NCO groups which are then reacted with a diol or other difunctional reagent to give chain extended polymers. This invention uses this known prior art with a new combination of reagents to produce new forms of polyurethane aqueous dispersions that have been discovered to possess unique adhesive properties. Patents DE 1 246 247 and UK 1 021 931 disclose the reaction in organic solvents of hydroperoxide compounds, e.g., cumeme peroxide with compounds containing one or more isocyanate groups e.g., 2,4-toluene diisocyanate or polyether prepolymers containing terminal isocyanate groups, to form peroxy carbamates. Such peroxy materials are used to initiate free radical polymerization of compounds containing at least one ethylene unsaturation, e.g. styrene, methyl methacrylate, etc. According to a first aspect of the present invention there is provided an aqueous dispersion of a polyurethane polymer containing -NH-CO-O-O- groups. Advantageously the polyurethane polymer is the polyurethane reaction product of an -NCO terminated prepolymer and a peroxide containing at least one active hydrogen atom. Preferably, the adhesive has a solids content of between 20 and 50% by weight based on the total weight of the aqueous adhesive. In a third aspect, the invention provides a flexible package comprising a joint between a plurality of sections of flexible substrate bonded together by a layer comprising a dispersion according to the first or second aspect of the invention. The present invention also provides, in a fourth aspect, a method of forming a flexible package comprising: providing an aqueous adhesive comprising an aqueous dispersion of a polyurethane containing -NH-CO-O-O- groups. providing at least one flexible substrate; applying a layer of the adhesive to a section of the substrate; and forming a joint between the said section of the substrate and another section of the same or a different substrate by sandwiching the adhesive layer therebetween. In a fifth aspect, the invention provides a method of forming a flexible package comprising: providing an aqueous adhesive comprising an aqueous dispersion of a polyurethane reaction product of an -NCO terminated prepolymer and at least one peroxide compound containing at least one hydroperoxide group; providing at least one flexible substrate; applying a layer of the adhesive to a section of the substrate; and forming a joint between the said section of the substrate and another section of the same or a different substrate by sandwiching the adhesive layer therebetween. In a sixth aspect, the invention provides a method of producing an aqueous adhesive for bonding together flexible substrates comprising: preparing a prepolymer containing free -NCO groups by reacting a 6 to 15 carbon atom aromatic, aliphatic or cycloaliphatic diisocyanate with a diol of molecular weight between 2000 and 3000 and an ionisable group-containing organic compound; forming an ionomer by reacting the resulting prepolymer with a tertiary amine; and forming an aqueous dispersion of a polyurethane polymer containing -NH-CO-O-O- groups by reacting the ionomer in the presence of water with at least one peroxide compound containing at least one hydroperoxide group. In a preferred method according to the sixth aspect of the invention, the ionisable group-containing compound is dimethylol propionic acid and the tertiary amine is triethylamine added in sufficient amount to neutralize the anionic groups contained in the prepolymer may be prepared in the absence of an inert organic solvent in an amount of from 1 to 10% by weight based on the combined weight of the solvent and the prepolymer forming reagents. The invention also provides, in a seventh aspect, an aqueous dispersion of a polyurethane polymer containing -NH-CO-O-O- groups comprising 20 to 50% by weight based on the total weight of the dispersion of the reaction product of (1) a prepolymer containing free -NCO groups formed by reacting a 6 to 15 carbon atom aliphatic or cycloaliphatic diisocyanate with a diol of molecular weight between about 2000 to 3000 and an ionisable group-containing organic compound and (2) at least one peroxide compound containing at least one hydroperoxide group. In the methods of the prior art cited above, the reaction of an amine R¹NH₂ with an isocyanate RNCO, the resulting compound contains a urea linkage: or if the reaction is with a diamine H₂N-R¹-NH₂, two urea linkages (diurea) : However, when the reaction of the isocyanate is with a peroxide containing at least one active hydrogen atom, e.g., R²OOH where R² is preferably C1-C10 alkyl, cycloalkyl or aryl, in accordance with the invention, a peroxy carbamyl group compound is formed: In the case of hydrogen peroxide, which has two active hydrogen atoms, peroxy dicarbamyl group compounds containing O,O-dicarbamyl peroxide linkages are formed: It has been discovered as a result of this invention that these peroxy carbamyl groups in aqueous polyurethane dispersions bestow some unusual adhesive properties on the dispersions. Thus, such dispersions exhibit critically improved bonding to most film and foil combinations used in the flexible packaging industry. Further, the resulting bonds are retained even under harsh testing environments used in retortable applications. DESCRIPTION OF THE PREFERRED EMBODIMENTS To produce an aqueous system adhesive of the invention, first a prepolymer based on a di/poly isocyanate, di/polyol and an ionic group containing organic compound, particularly an ionic diol, is prepared using reactant proportions so that the resulting prepolymer contains free NCO groups. The di/polyfunctional isocyanate used is selected from the class of aromatic, aliphatic or cycloaliphatic diisocyanates, preferably those containing 6 to 15 carbon atoms. Examples of commercially available useable isocyanates include "Desmodur-W" (4,4′-methylene bisdicyclohexyl diisocyanate) and isophorene diisocyanate. Adducts of the class isocyanates with di/polyols described below and oligomers of the class isocyanates can also be used. The di/polyols used in the invention are selected from dihydroxy compounds of molecular weight between about 2000 and 3000. Such diols can be condensation products of commercially available dicarboxylic acids and diols. Also, polyether diols based on ethylene or propylene oxide can be used. Commercially available diols of this class include the "Formerez" series and "ED" series of polyols marketed by Witco Chemical Co. The ionic group containing compounds used are carboxylic or sulfonic acids containing up to 10 carbon atoms and two hydroxyl groups. A preferred compound is dimethylolpropanoic acid. Other useable compounds include 1,3 diamino-2-propanoic acid, and 1,3 diamino alkylene sulfonic acids. The prior art patents referenced above contain numerous examples of polyisocyanates, polyols and methods of reacting them with water dispersable groups. Alternatively, polyols carrying pendant carboxyl groups can be used. U.S. Patent 4,460,738 discloses methods of making such polyols and such disclosure is incorporated herein by reference. Since these polyols have groups that can be converted into an ionic group, a separate reaction with a compound such as dimethylol propionic acid is not necessary. Also, mixtures of polyols with pendant groups that are ionizable and polyols that do not have such groups may be used. A catalyst, e.g., dibutyltin dilaurate, is advantageously used in forming the prepolymer. Also, small amounts, e .g., 1 to 10% by weight, of inert solvent may be used if viscosity of the prepolymer presents processing problems, e.g. , problems is disbursing the prepolymer in water. Examples of useable solvents include N-methyl pyrrolidone, commercially available as "M-Pyrole" from BASF, 1,4-dioxane, DMF and ethylene glycol dimethylether. Also useable are monomers or polymers that do not participate in the reaction under the prevailing conditions. Examples of such materials acting as inert solvents are alkyl acrylate, alkyl methacrylates, vinyl group containing monomers and/or polymers. The prepolymer is then converted into an ionomer by reaction with a tertiary amine, typically a trialkylamine, e.g., triethylamine. Following this, the ionomer is slowly added with agitation to a water solution of peroxide compound containing at least one active hydrogen atom to produce the final polyurethane aqueous dispersion. Hydrogen peroxide is a preferred peroxide compound for use in producing the new polymer systems of the invention. Other useable peroxide reagents containing one or more active hydrogen atoms include t-butyl hydroperoxide, cumene hydroperoxide, tetralin hydroperoxide and similar alkyl, cycloalkyl and aryl mono or poly hydroperoxides. Mixtures of one or more peroxide compounds may be used. Also, instead of using such reagents per se, materials that give rise to such peroxides in an aqueous system may be used. For example, instead of using hydrogen peroxide pre se, alkali metal peroxides, e.g., NaOONa, KOOK, alkaline earth metal peroxides or the like may be used as the peroxide reagent precusor. The prepared dispersion per se may be used as a polymer system in accordance with the invention or it may be compounded with up to 15% by weight, preferably 5 to 15%, of commercially available melamine resins, e.g., "Cymel 301" from American Cyanamid, or epoxy resins, e.g. , "Epon 828" from Shell Chemical Co. The dispersions may also be compounded with up to 15% by weight of vinyl-type compounds, e.g., vinyl acetate, methyl acrylate, styrene, etc., and vinyl group containing polymers. Typically, the new polymer systems of the invention, when used as adhesives, are applied, e.g, by use of a drawdown bar, to a film, foil or other flexible substrate to give a coating weight of about 0.5 to 1kg, especially 0.5 to 0.7 kg, per 2700 square meters (1 to 2 pounds, especially 1 - 1.5 pounds, per 3000 square yards) of substrate surface. The coated substrate is dried to remove substantially all the water. The tacky surface is then bonded to a second same or different substrate by application of pressure to give good contact. Example 1 Into a three neck flask provided with a thermometer, mechanical stirrer and drying tubes, was placed 63 grams of "Desmodur-W" diisocyanate (Mobay) 197 g of "ED-3000" diol (WitcO) , a drop of dibutyltin dilaurate. Then, 20 ml of "M-pyrole" solvent were added. The contents were heated to 80° C for an hour and 17.2 g of dimethylol propionic acid were added plus another drop of DBTDL, after which the heating was continued for 5.5 hours. At the end of this reaction period, 12.9 g of triethylamine were added and stirring was continued for 15 minutes to form the ionomer. The resulting ionomer was slowly added over a period of 15 minutes to a vigorously stirred solution of 5.4 g of 30% hydrogen peroxide dissolved in 500 ml of water. The stirring was continued for an hour to complete the formation of the polyurethane dispersion which was stored for 24 hours before being tested for adhesive Properties. The resulting dispersion contained about 32% solids and had a pH of about 7.4. Example 2 The procedure of Example 1 was repeated except that "Formerez 55-56", a 2000 molecular weight polyester diol, was used in the place of "ED-2000". The dispersions of Examples 1 & 2 were mixed with 15% by weight of epoxy resin ("Epon 828") containing a small amount of surfactant and coated on a variety of substrates by means of a drawbar to five a coating weight of 0.5 to 0.7kg per 2700 square meters (1 - 1.5 pounds/3000 sq. yd.). The coated substrates were air dried using a hair dryer to remove all water. The resulting tacky surface of each specimen was then bonded to a second film or foil and hand-pressed using a 2kg (4.5 pound) roller to give good contact. Then, the resulting laminates were heated in a commercial, temperature controlled hot place device; ("Sentinel" marketed by Packaging Industries Group Inc.) for 0.5 sec. at 82°C (180°F) at 100 psi. Finally, bond strengths were measured at the initial time, after 24 hrs. and after 3 days in an oven at 54°C (130°F). Also, the laminates kept for 3 days were heated in an autoclave at 127°C (260°F) for 20 minutes at 0.16 N/mm² (23 psi) to simulate a retortable environment and then dried. Bond strengths were measured using ASTM (American Standard Testing Methods) D1876 method for adhesion peel values. The resulting test data are reported in Table I. Example 3 Example 1 was repeated, except instead of hydrogen peroxide, 12.8 g of 70% t-butyl hydroperoxide was used. Exp. Laminates Initial 72Hrs. 130 F After Retort I II 1 Polyester Foil 300 D D Foil PP 350 D D 2 Polyester Foil 300 D D Foil PP 37S D D Further, destruct bonds (one or both of the substrates destruct before the adhesive fails) have been obtained in 3 days when stored at 54°C (130°F). The same results have also been obtained for a 10-day storage at room temperature. With the SOlvent based adhesives that are used for retort applications, the lamination of polyester/foil takes 3 days when stored at 54°C (130°F), while foil/polypropylene lamination. Storage of 10 days at 54°C (130°F). The data of Table I shows that when hydrogen peroxide is used in accordance with the invention, the laminates withstand the retortability test destructed before the adhesive fails, have been obtained in 3 days when stored at 54°C (130°F). The same result has also been obtained with 10 day storage at room temperature. With solvent system adhesives that are used for retort applications, the laminates of polyester/foil takes 3 days when stored at 54°C (130°F) but the foil/pp laminations require storage of 10 days at 54°C (130°F). Thus, the aqueous system adhesives of the invention save much time in required bond formation, avoid use of costly solvents and the use of unreacted "free isocyanates" that is the key component of the solvent system adhesives. Another major feature of the new adhesives is their ability to form required bond strength to withstand retorting by simply being stored for 10 days at room temperature. This is particularly useful in connection with film that cannot withstand 54°C heating, e.g., polyethylene films used in snack packaging. Typical bond strengths obtained with 10 days storage at room temperature with a number of films to polyethylene film laminations when the adhesive was the Example 1 disperson to which was added 15% "Epon 828" epoxy resin (Shell Chemical Co.) are reported in Table II. Initial 20 Hrs. 72 Hrs. 1 Week PE/Polyethylene 250 500 950 D PE/polypropylene 200 525 675 D PE/polyester 275 450 D D PE/nylon 300 500 650 D PE/metal foil 325 500 625 D PE = Polyethylene. Table III shows bond strength obtained using the product of Example 3 as the adhesive system. Initial 24 Hrs. 72 Hrs. 1 Week Polypropylene/Polypropylene 250 400 600 D Polyester/Foil 250 300 350 D

Claims: An aqueous dispersion of a polyurethane polymer containing -NH-CO-O-O- groups. An aqueous dispersion according to claim 1 of a polyurethane polymer containing -NH-CO-O-O-CO-NH- groups. An aqueous dispersion according to claim 1 or 2 in which the polyurethane polymer is the polyurethane reaction product of an -NCO terminated prepolymer and a peroxide containing at least one active hydrogen atom. A dispersion according to claim 3 in which the peroxide is hydrogen peroxide. A flexible package comprising a joint between a plurality of sections of flexible substrate bonded together by a layer comprising the dispersion of any preceding claim. A method of forming a flexible package comprising: providing an aqueous adhesive comprising an aqueous dispersion of a polyurethane containing -NH-CO-O-O- groups. providing at least one flexible substrate; applying a layer of the adhesive to a section of the substrate; and forming a joint between the said section of the substrate and another section of the same or a different substrate by sandwiching the adhesive layer therebetween. A method according to claim 6 in which the said groups are -NH-CO-O-O-CO-NH- groups. A method of forming a flexible package comprising: providing an aqueous adhesive comprising an aqueous dispersion of a polyurethane reaction product of an -NCO terminated prepolymer and at least one peroxide compound containing at least one hydroperoxide group; providing at least one flexible substrate; applying a layer of the adhesive to a section of the substrate; and forming a joint between the said section of the substrate and another section of the same or a different substrate by sandwiching the adhesive layer therebetween. A method of producing an aqueous dispersion of a polyurethane polymer containing -NH-CO-O-O- groups comprising: preparing a prepolymer containing free -NCO groups by reacting a 6 to 15 carbon atom aromatic, aliphatic or cycloaliphatic diisocyanate with a diol of molecular weight between 2000 and 3000 and an ionisable group-containing organic compound; forming an ionomer by reacting the resulting prepolymer with a tertiary amine; and forming an aqueous dispersion of a polyurethane polymer containing -NH-CO-O-O- groups by reacting the ionomer in the presence of water with at least one peroxide compound containing at least one hydroperoxide group. A method according to claim 9 in which the quantity of hydrogen peroxide reacted with the ionomer is in excess of the stoichiometric requirement for total reaction with the free -NCO groups in the ionomer. A method according to claim 9 or 10 in which the ionisable group-containing compound is dimethylol propionic acid and the tertiary amine is triethylamine added in sufficient amount to neutralise the ionic groups in the prepolymer. A method according to any of claims 9 to 11 in which the prepolymer is prepared in the presence of an inert organic solvent or diluent in the amount of from 1 to 10% by weight based on the combined weight of the solvent and the prepolymer forming reagents. A method according to claim 12 in which the solvent is N-methylpyrrolidone. A method according to any of claims 8 to 13 in which the peroxide compound is hydrogen peroxide. An aqueous adhesive prepared by the method of any of claims 6 to 14 having a solids content of between 20 and 50% by weight based on the total weight of the aqueous adhesive. An aqueous dispersion of a polyurethane polymer containing -NH-CO-O-O- groups comprising 20 to 50% by weight based on the total weight of the dispersion of the reaction product of (1) a prepolymer containing free -NCO groups formed by reacting a 6 to 15 carbon atom aliphatic or cycloaliphatic diisocyanate with a diol of molecular weight between about 2000 to 3000 and an ionisable group-containing organic compound and (2) at least one peroxide compound containing at least one hydroperoxide group. An aqueous dispersion according to claim 16 in which the peroxide compound is an organic hydroperoxide. An aqueous dispersion according to claim 16 or 17 in which the peroxide compound is an alkyl hydroperoxide. An aqueous dispersion according to claim 16 in which the peroxide compound is supplied by a precursor capable of forming at least one peroxide compound containing at least one hydroperoxide group in the aqueous reaction system. An aqueous dispersion according to claim 17 in which the peroxide compound is hydrogen peroxide.

Inventors: RAMALINGHAM BALASUBRAMANIAM
Applicants: CENTURY INTERNATIONAL ADHESIVE, CENTURY INTERNATIONAL ADHESIVES AND COATINGS CORPORATION
Application year: 1988
Main classification: C08G18
IPC codes: C08G18, C08L75, B65D65, B32B7, C09J175, C09J161