Cyclic carbonyl containing polymers

Abstract: The present invention relates to novel polymers which are adducts of an unsaturated hydrocarbon, wherein the novel polymers are produced by contacting cyclic carbonyl monomers with an unsaturated hydrocarbon to form novel cyclic carbonyl polymers having an Mn of about 500 to about 10⁷.

Description: The present invention relates to novel polymers which are adducts of cyclic carbonyl monomers or derivatives. Various unsaturated hydrocarbon polymers have been reacted with maleic anhydrides to form a variety of maleic anhydride adducts of unsaturated hydrocarbon polymers. The reactivity of maleic anhydride with many unsaturated hydrocarbon polymers is poor and in some instances, as for example with EPDM rubber, even employment of extensive heating is ineffective. Free radical reactions which graft maleic anhydride onto the unsaturated hydrocarbon polymer have been utilized as alternative routes. Free radical grafting leads to chain scission, crosslinking and solvent grafting if the solvent is sufficiently reactive. The present invention seeks to overcome these deficiencies. UK Patent GB-A-1 009 785 describes a synthetic ketone resin which is prepared by reacting a synthetic rubber such as polybutadiene or butadiene-styrene copolymer with a cyclic ketone such as methyl cyclohexanone and an aldehyde such as formaldehyde. The reaction is carried out in the presence of methyl-alcoholic alkali liquor. The present invention relates to novel polymers which are useful as solution viscosification agents. The novel polymers are produced by reacting a cyclic carbonyl monomer having ene-reactive carbonyl groups with an unsaturated hydrocarbon to form a novel cyclic carbonyl containing polymer having an Mn of about 500 to about 10⁷. The novel polymers of the present invention, which are adducts of cyclic carbonyl monomers or derivatives, with unsaturated organic molecules, are produced by contacting cyclic carbonyl monomers A and/or B with an unsaturated polymer to form the novel product. In particular the unsaturated polymer can be a polyolefin polymer ranging in molecular weight from about 500 to about 10,000,000. Typical reactions to produce these novel cyclic carbonyl polymers are represented by the equations: wherein Ra, Rb, Rc, Rd, and Re are independently selected from the group consisting of H, alkyl groups having 1 to 10⁷ carbon atoms, alkenyl groups having 3 to 10⁷ carbon atoms, wherein said alkyl and/or alkenyl groups can have one or more substituents selected from the groups consisting of alkoxy, aryloxy, Cl, CN, OH, acyl, aroyl, acyloxy, aryl, and HO(CH₂CH₂O) x where x=1-10; Q=H₂O, MeOH, EtOH, n-BuOH or any suitable alcohol; n=O,1,>1: and X or Y are independently selected from the group consisting of CH₂, C=O, C=NOH with the proviso that X and Y are not both CH₂; U, V and W are independently selected from the group consisting of CH₂, C=O, C=NH, C=N-alkyl, wherein alkyl group has 1 to 18 carbon atoms; O, NH, N-alkyl, S, C=S, CMe₂, CH-phenyl, CH-CHOH-CH₂OH; U + V = 1,2-phenylene,-1,8-naphthalene-diyl; 1,2-naphthalenediyl and 1,2-dihydroxyethylene-1,2- diyl. Typical monomers include alloxan, indantrione, tetralintrione, dehydroascorbic acid, rhodizonic and croconic acid, triquinoyl, leuconic acid and keto-Meldrum's acid (A wherein X = Y = C=O, U = W = O and V = CMe₂). The acylic carbonyl monomer is reacted at about 20°C to about 200°C, more preferably about 40 to about 180°C and most preferably about 60 to about 160°C. Heating is carried out at about 100°C under reflux conditions for about 4 to about 24 hours, preferably about 6 to about 18 hours, and most preferably about 8 to about 12 hours with an unsaturated hydrocarbon which is selected from the group consisting of EPDM terpolymers, EPR, polyisoprene, polybutadiene, butyl rubber, styrene-butadiene and styrene-isoprene "random" and block copolymers, polyisobutylene, hydrocarbon resins such as a Escorez® resins. Oligomers or polymers which have olefin functionality near the end of the chain are of interest. Such molecules include, but are not limited to, polyisobutene and polybutenes of various molecular weights. Vistanex®, Vistanex® J are examples of such polymers. Plastics such as polyethylene and polypropylene containing low levels of unsaturation are also suitable polyolefins. Olefins substituted with functionality like CN, HO, HO(CH₂CH₂O) x (x = 1-10), alkoxy, Cl, and other groups illustrated below are examples of useful reactants. wherein G = C, N; J = O, S, SO₂; and L is selected from the group consisting of OH; -OR₁; NR 1R2 ; R₁; wherein R has 1 to 18 carbon atoms, wherein R₂ is any alkyl and has 1 to 18 carbon atoms, -NR₃R₄ wherein R₃ and R₄ has 1 to 18 carbon atoms, OR₅ wherein R₅ is hydrogen or an alkyl group having 1 to 18 carbon atoms, -COOR₆ wherein R₆ is hydrogen or an alkyl group having 1 to 18 carbon atoms; and -SR₇, wherein R₇ is an alkyl group having 1 to 18 carbon atoms. The expression "butyl rubber" as employed in the specification and claims, is intended to include copolymers made from a polymerization reaction mixture having therein from 70 to 99.5% by weight of an isobutylene and about 0.5 to 30% by weight of a conjugated multi-olefin having from about 4 to 14 carbon atoms, e.g., isoprene. The resulting copolymer typically contains 85 to 99.8% by weight of combined isoolefin and 0.2 to 15% of combined multi-olefin. The EPDM terpolymers are low unsaturated polymers having about 0.5 to about 10.0 wt.% olefinic unsaturation, more preferably about 2 to about 8, most preferably about 3 to 7 defined accordingly to the definition as found in ASTM-1418-64 and is intended to mean terpolymers containing ethylene and propylene in the backbone and an olefin residue in the side chain as result of multi-olefin incorporation in the backbone. Illustrative methods for producing these terpolymers are found in U.S. Pat. No. 3,280,082, British Pat. No. 1,030,289 and French Pat. No. 1,386,600. The preferred polymers contain about 40 to about 75 wt.% ethylene and about 1 to about 10 wt.% of a diene monomer, the balance of the polymer being propylene. Preferably, the polymer contains about 45 to about 70 wt.% ethylene, e.g., 50 wt.% and about 2.6 to about 8.0 wt.% diene monomer, e.g., 5.0 wt.%. The diene monomer is preferably a nonconjugated diene. Illustrative of these nonconjugated diene monomers which may be used in the terpolymer (EPDM) are 1,4-hexadiene, dicyclopentadiene, 5-ethylidene-2-norbornene, 5-methylene-2-norbornene, 5-propenyl-norbornene, methyl tetrahydroindene and 4-methyl-5-methylene-2-norbornene. The EPDM terpolymers of this invention have a number average molecular weight (M n ) as measured by GPC of about 10,000 to about 200,000, more preferably of about 15,000 to about 100,000, most preferably of about 20,000 to about 60,000. The Mooney viscosity (ML, 1+8, 212°F) of the EPDM terpolymer is about 5 to about 60, more preferably about 10 to about 50, most preferably about 15 to about 40. The M v as measured by GPC of the EPDM terpolymer is preferably below about 350,000 and more preferably below about 300,000. The M w as measured by GPC of the EPDM terpolymer is preferably below about 500,000 and more preferably below about 350,000. Other suitable olefin polymers include polymers comprising a major molar amount of C₂ to C₅ mono-olefins, e.g., ethylene, propylene, butylene, isobutylene and pentene. The polymers may be homopolymers such as polyisobutylene, as well as copolymers of two or more such olefins such as copolymers of ethylene and propylene, butylene and isobutylene, propylene and isobutylene. The reaction of the cyclic carbonyl monomer with the unsaturated hydrocarbon polymer can occur in solution, in a melt and in polymer processing equipment such as a rubber mill, a Brabender, an extruder or a Banbury mixer. Typically, the polymer is dissolved in a suitable solvent, such as tetrahydrofuran, xylene or mineral oil and heated to temperatures ranging from about 40°C to about 140°C. The cyclic carbonyl monomer, as a hydrate or hemiketal of methanol or butanol or some suitable alcohol, is dissolved in a suitable solvent such as tetrahydrofuran, dioxane, butanol or a suitable alcohol, and added gradually to the heated polymer solution. The reaction mixture is heated, with stirring, until infrared and/or NMR analysis of the mixture indicates that the ene-addition of the carbonyl monomer to the unsaturated polymer is complete. Depending on temperature and concentration, reaction periods of about 4 to 40 hours are sufficient to achieve high conversions to ene adducts. Bulk reactions can be carried out at about 40°C to about 200°C for approximately 3 to 300 minutes depending upon polyolefin and carbonyl monomer reactivity. If necessary, products can be isolated by solvent removal by evaporation, or by adding the reaction mixture to a polar solvent such as acetone, which induces the precipitation of the functionalized polymer. If desired, ene additions of cyclic carbonyl monomers to unsaturated hydrocarbon polymers can be effected in the presence of acid catalysts selected from the group consisting of kaolin, montmorillonite, silicates, SnCl₄, AlCl₃, FeCl₃ and BF₃. Typically, 0.1 to 1 gram of acid catalyst per 0.01 to 1.0 moles of reactants would be employed. The following examples illustrate the present invention without, however, limiting the same hereto. Example 1 Ten grams of hot polyisobutylene, Mn=950, was poured into a nitrogen blanketed reactor fitted with a mechanical stirrer, thermometer, and condensor. The polyisobutylene was heated to about 150°C in an oil bath, and 1.6 grams of alloxan monohydrate dissolved in 20 ml of dioxane, was added dropwise to the stirred polymer over a four hour period. Heating the reaction mixture at 150°C was continued for about ten hours. When cool, the residue was dissolved in about 100 ml of cyclohexane, filtered through Celite, and concentrated by sparging with nitrogen overnight. The residue analyzed for 1.84% N, and featured an infrared spectrum with a dominant carbonyl absorption band at about 5.85 µm. UV-GPC analysis showed that the polyisobutylene polymer was uniformly substituted with alloxan, and the MW distribution of the polyisobutylene were unaffected by ene-modification. Example 2 Ten grams of poly co-ethylene propylene ethylidene norbornene terpolymer, Mn = 55,000, containing about 43 wt.% propylene, and 5 wt.% ethylidene norbornene, was dissolved in 90 grams of xylene, and poured into a nitrogen blanketed reactor fitted with a mechanical stirrer, and reflux condensor. Using a silicone oil bath, the reactor was heated to 120°C and 0.5 gram of alloxan hydrate dissolved in 30 ml dioxane was added all at once to the xylene solution of the terpolymer. The reaction mixture was stirred at 120°C for about eight hours. The functionalized polymer was precipitated by addition of the cooled reaction mixture to a liter of acetone. The dried polymer analyzed for 0.76% N, and featured an infrared spectrum (film) with an intense carbonyl absorption band at about 5.9 µm. GPC analysis showed that ene functionalization with alloxan, in contrast with conventional free radical processes, did not affect the MW distribution of the terpolymer. Example 3 Ten grams of polyisobutylene, MW=950, and two grams of indantrione hydrate were combined in a nitrogen blanketed reactor fitted with a mechanical stirrer and condensor. The stirred mixture was heated in an oil bath at 140-150°C for about 28 hours, then cooled, and dissolved in 100 ml of cyclohexane. The mixture was filtered through Celite®, and concentrated by evaporation using a stream of nitrogen. The residue analyzed for 3.96% O, and featured an infrared spectrum with an intense carbonyl absorption band at about 5.9 µm. Example 4 Ten grams of poly co-ethylene propylene ethylidene norbornene terpolymer, Mn=55,000 with 43% propylene and 5% ethylidene norbornene, were dissolved in 90 grams of xylene and charged into a nitrogen blanketed reactor equipped with a mechanical stirrer and condensor. The stirred mixture was heated to about 120°C in an oil bath, and then 0.5 gram of indantrione hydrate dissolved in 30 ml of 1,4-dioxane was added in one portion to the reactor. The reaction mixture was kept at 120°C for about six hours, then cooled, and a 10 ml portion added to 100 ml of acetone. The precipitated polymer was washed with acetone, and dried under high vacuum at about 40°C. The modified polymer analyzed for 1.74% O, and featured an infrared spectrum dominated by an intense carbonyl absorption at about 5.9 µm. In a similar manner, terpolymer modification with indantrione was also effected in other solvents such as tetrahydrofuran.

Claims: A cyclic carbonyl adduct of an unsaturated hydrocarbon polymer, the cyclic carbonyl constituent being selected from cyclic carbonyls characterized by the formulas: wherein X or Y are independently selected from CH₂, C=O, C=NOH with the proviso that X and Y are not both CH₂; U, V and W are independently selected from the group consisting of CH₂, C=O, C=NH, C=N-alkyl, wherein alkyl group has 1 to 18 carbon atoms, O, NH, N-alkyl, S, C=S, CMe₂, CH-phenyl, CHCHOH-CH₂0H; U + V = 1,2-phenylene, 1,8-naphthalene-diyl, 1,2-naphthalene-diyl; and 1,2-dihydroxyethylene-1,2-diyl. An adduct according to claim 1 wherein said unsaturated hydrocarbon polymer is selected from the group consisting of ethylene propylene terpolymers, ethylene propylene copolymers, polyisoprene, butyl rubber, polybutadiene, and styrene-butadiene, and styrene-isoprene random and block copolymers, polypropylenes and polyisobutylenes, as well as plastic polypropylene copolymers or polyethylene copolymers. An adduct according to claim 1 wherein said unsaturated hydrocarbon polymer contains substituents such as CN, HO, HO(CH₂CH₂O) x (x=1-10), alkoxy, Cl, and wherein G = C, N; J=O, S, SO₂; and L is selected from OH; -OR 1, NR1 R₂; R₁; wherein R has about 1 to about 18 carbon atoms, wherein R₂ is any alkyl and has about 1 to about 18 carbon atoms, -NR₃R₄ wherein R₃ and R₄ has about 1 to about 18 carbon atoms, OR₅ wherein R₅ is hydrogen or an alkyl group having about 1 to about 18 carbon atoms, -COOR₆ wherein R₆ is hydrogen or an alkyl group having about 1 to about 18 carbon atoms, and -SR₇, wherein R₇ is an alkyl group having about 1 to about 18 carbon atoms. The adduct of any preceding claim which is formed by contacting the unsaturated hydrocarbon polymer with a cyclic carbonyl compound selected from: wherein Q=H₂O, MeOH, EtOH, n-BuOH; n=0, 1, >1; X or Y are independently selected from CH₂, C=O, C=NOH with the proviso that X and Y are not both CH₂; U, V and W are independently selected from the group consisting of CH₂, C=O, C=NH, C=N=alkyl, wherein alkyl group has 1 to 18 carbon atoms, O, NH, N-alkyl, S, C=S, CMe₂, CH-phenyl, CHCHOH-CH₂0H; U + V = 1,2-phenylene, 1,8-naphthalene-diyl, 1,2-naphthalene-diyl; and 1,2-dihydroxyethylene-1,2-diyl. The adduct of any preceding claim which is formed in the presence of an acid catalyst selected from the group consisting of from kaolin, montmorillonite, silicates, SnCl₄, AlCl₃, FeCl₃ and BF₃.

Inventors: BROIS STANLEY JAMES, BROIS, STANLEY JAMES
Applicants: EXXON RESEARCH ENGINEERING CO, EXXON RESEARCH AND ENGINEERING COMPANY
Application year: 1991
Main classification: C08F8
IPC codes: C07C59, C07C69, C10L1, C07C49, C10M133, C07D239, C08C19, C08F8, C07C45, C07C235, C10M129, C10L10