Latent thiol mercaptan chain transfer agents and their use in the synthesis of polymers

Abstract: Latent thiol mercaptan chain transfer agents and their use in the synthesis of polymers are described. In addition, novel polymers and block copolymers formed using these latent thiol mercaptan chain transfer agents are described. The latent thiol mercaptan chain transfer agents comprise at least one thiol functional group and at least one protected thiol group. The polymers and coploymers are useful in adhesives, mastics or caulks or as compatibilizers for physical blends of at least two polymers.

Description: This invention relates to latent thiol mercaptan chain transfer agents and their use in the synthesis of polymers. In addition, this invention relates to novel polymers and block copolymers formed using these latent thiol mercaptan chain transfer agents. "Latent thiol mercaptan chain transfer agent," as used herein, is defined as compounds containing at least one thiol group and at least one protected thiol group. During use in a polymerization, the at least one thiol group reacts with a polymer chain being formed from at least one first ethylenically unsaturated monomer. This yields a polymer chain containing at least one protected thiol group, primarily at the terminal portion of the chain. This polymer formed can be used as is, or can be reacted further. The term "latent" refers to the fact that the protected thiol group does not react with the first ethylenically unsaturated monomer or monomers, but after the polymerization is conducted, the protected thiol group can be deprotected, for example by a cleaving reaction, to yield a terminal thiol group on the polymer chain. These terminal thiol groups can then react further, for example with at least one second ethylenically unsaturated monomer, forming a block copolymer. "Block copolymers" as used herein are defined as the "linear" macromolecules formed by attachment of different polymers or copolymers at their ends. The term linear as used herein, includes molecules which are perfectly linear and also those bearing side chains but are still predominantly linear. Due to the ability to chemically combine unlike polymeric segments in one molecule, block copolymers have unique properties, making them particularly useful for their surface active properties, such as for example in stabilizing physical blends of otherwise incompatible polymeric or monomeric compounds. US-A-4565854 and US-A-4699950 disclose nonaqueous processes for the formation of a polymer with terminal thiol groups and its use in forming block copolymers. Initially, a polymer is obtained by polymerizing at least one monomer capable of radical polymerization in the presence of a thiolcarboxylic acid. The thiolcarboxylic acid works as a chain transfer agent, with the thiol portion of the thiolcarboxylic acid reacting at the end of the polymer to form a thiolcarboxylic acid ester. Upon subjecting the polymer to alkali or acid, the thiolcarboxylic acid ester is decomposed, leaving a polymer with terminal thiol groups. This polymer can then react, via the thiol end groups, with vinyl monomers to form subsequent block copolymers via an aqueous solution polymerization. However, the aqueous solution polymerizations of US-A-4565854 and US-A-4699950 suffer from the drawback of forming solutions with low solids content when polymers with high molecular weights are prepared. Another problem with these techniques is that they are not an efficient process because thiolcarboxylic acids suffer from poor chain transfer efficiency. Furthermore, thiolacetic acid (CH₃COSH) has been found to be inefficient as a chain transfer agent and is therefore not a desirable latent thiol mercaptan chain transfer agent (see Comparative Example 4). US-A-4,797,223 discloses detergent compositions including water soluble polymers which serve as builders, lime soap dispersants, and antiredeposition agents. The polymer may be prepared using a mercaptan as a chain transfer agent. The present invention seeks to overcome the problems associated with the prior art. According to a first aspect of the present invention there is provided a latent thiol mercaptan chain transfer agent having the general formula; wherein: A is a polyvalent organic radical; x and y are positive integers such that x+y equals the valence of A; B is an organic acyl radical; and n and m are integers from 1 to 6. According to a second aspect of the present invention there is provided a polymer comprising polymerized units of an ethylenically unsaturated monomer and having a terminal thiol functional group derived from the latent thiol mercaptan chain transfer agent defined above. According to a third aspect of the present invention there is provided a block copolymer comprising (a) at least one first block of polymerized units of at least one first ethylenically unsaturated monomer and at least one latent thiol mercaptan chain transfer agent as defined above; and (b) at least one second block of polymerized units of at least one second ethylenically unsaturated monomer; wherein the first block has at least one terminal thiol functional group; and wherein the at least one second block is attached to the at least one first block via the at least one terminal thiol functional group. According to a fourth aspect of the present invention there is provided a method of making block copolymers comprising a) polymerizing in a first stage of a two stage emulsion polymerization at least one first ethylenically unsaturated monomer and reacting at least one latent thiol mercaptan chain transfer agent as defined above with the polymer chain formed wherein a polymer is formed having protected thiol functional groups; b) deprotecting the protected thiol functional groups to form thiol functional groups; and c) polymerizing at least one second ethylenically unsaturated monomer in the presence of said polymer formed in the first stage . According to a fifth aspect of the present invention there is provided a water-based coating containing an effective amount of a polymer according to the first aspect of the present invention, or a copolymer according to third aspect of the present invention, or a copolymer prepared by a method according to the fourth aspect of the present invention admixed with a suitable carrier or diluent, wherein the coating is an adhesive, a mastic or a caulk. According to a sixth aspect of the present invention there is provided a use of a copolymer according to third aspect of the present invention, or a copolymer prepared by a method according to the fourth aspect of the present invention as a compatibilizer for physical blends of at least two polymers. Preferably, in the formula for the latent thiol mercaptan chain transfer agent, A is a C₁ to C₆ hydrocarbon radical; B is an acetyl or acetoacetyl group; and n and m are positive integers from 1 to 2. Preferably, the latent thiol mercaptan chain transfer agent is selected from the group consisting of; mono-, bis- and tris-S-acetyl-pentaerythritol tetra-3-mercapto- propionate; mono-, bis-, and tris-S-acetoacetyl-pentaerythritol tetra-3-mercapto- propionate; mono- and bis-S-acetoacetyl-trimethylolpropane tri-3-mercapto- propionate; mono- and bis-S-acetyltrimethylolpropane tri-3-mercaptopropionate; 1-(S-acetyl-3-mercapto- propoxy)-3-mercapto-2-acetoxypropane; and 1-(S-acetyl-3-mercaptopropoxy)-3-mercapto-2-hydroxypropane. Preferably, the ethylenically unsaturated monomer is selected from the group consisting of acrylate esters and acids; methacrylate esters and acids; acrylonitrile; methacrylonitrile; acrolein; methacrolein; vinyl aromatic compounds; vinyl esters of organic acids; N-vinyl compounds; unsaturated halogenated compounds; acrylamide, methacrylamide and substituted acrylamides and methacrylamides; polymerizable sulfonic acids and salts thereof; and vinyl esters. Preferably, the block copolymer is composed of from about 5 to 95 (preferably 20 to 80, more preferably 40 to 60) weight percent of polymerized units of (a) and from about 5 to 95 (preferably 20 to 80, more preferably 40 to 60) weight percent of polymerized units of (b). Preferably, the at least one second ethylenically unsaturated monomer is selected from the group consisting of acrylate esters and acids; methacrylate esters and acids; acrylonitrile; methacrylonitrile; acrolein; methacrolein; vinyl aromatic compounds; vinyl esters of organic acids; N-vinyl compounds; unsaturated halogenated compounds; acrylamide, methacrylamide and substituted acrylamides and methacrylamides; polymerizable sulfonic acids and salts thereof; and vinyl. Preferably, the polymer composition has a solids concentration of from about 20 to about 60 percent, based on the total weight of the composition. Preferably, the copolymer is dispersed as particles having a size of less than 800 (preferably from about 50 to 200) nanometers. Preferably, in the composition dispersion, the copolymers are copolymers according to the third aspect of the present invention. Preferably, in the method, the latent thiol mercaptan chain transfer agent is present in the first stage of the emulsion polymerization at a concentration up to about 10 (preferably 5, more preferably 2) mole percent. It has been discovered that the block copolymer products of the present invention can be used directly in water-based emulsion coatings, elastomers, adhesives, caulks and mastics. Still further uses for these copolymers are as plastic additives for use as compatibilizers of polymer-polymer blends. As stated above, latent thiol mercaptan chain transfer agents are compounds containing at least one thiol group and at least one protected thiol group. During use in a polymerization, the at least one thiol group reacts with a polymer chain being formed from at least one first ethylenically unsaturated monomer, yielding a polymer chain containing at least one protected thiol group, primarily at the terminal portion of the chain. This polymer formed can be used as is, or can react further. For example, the protected thiol group can be deprotected to yield a terminal thiol group on the polymer chain. These terminal thiol groups can then react with at least one second ethylenically unsaturated monomer, forming a block copolymer. The latent thiol mercaptan chain transfer agents according to the present invention are compounds containing at least one thiol group and at least one protected thiol group. The latent thiol mercaptan chain transfer agents have the following structure; where A is a polyvalent organic radical; x and y are positive integers such that x+y equals the valence of A; B is an organic acyl radical; and n and m are integers from 1 to 6. It is preferable that A is a C₁ to C₆ hydrocarbon radical; B is an acetyl or acetoacetyl group; and n and m are 1 or 2. Specific examples of latent thiol mercaptan chain transfer agents include; mono-, bis- and tris-S-acetyl-pentaerythritol tetra-3-mercaptopropionate; mono-, bis-, and tris-S-acetoacetyl-pentaerythritol tetra-3-mercaptopropionate; mono- and bis-S-acetoacetyl-trimethylolpropane tri-3-mercaptopropionate; mono- and bis-S-acetyltrimethylolpropane tri-3-mercaptopropionate; 1-(S-acetyl-3-mercaptopropoxy)-3-mercapto-2-acetoxypropane; and 1-(S-acetyl-3-mercaptopropoxy)-3-mercapto-2-hydroxypropane. When the latent thiol mercaptan chain transfer agent is bis-S-acetyl-penta- erythritol tetra-3-mercaptopropionate, it may be prepared by the esterification of pentaerythritol with 3-mercaptopropionic acid to yield the tetra ester containing four free thiol groups. Some of the thiol groups can then be converted to thioacetates by reacting the tetra ester with acetic anhydride. Although a statistical mixture of partially acetylated thiols is obtained, the mono-, di-, and tri-materials act equivalently under the reaction conditions. If two or more free thiols are present in the same molecule, they undergo intramolecular chain transfer and therefore behave grossly like a monothiol. A similar procedure can be followed for bis-S-acetyl-trimethylolpropane tri-3-mercaptopropionate, except the pentaerythritol is replaced with trimethylolpropane. In the preparation of 1-(S-acetyl-3-mercaptopropoxy)-3-mercapto-2-hydroxypropane, thiolacetic acid is reacted with allyl glycidyl ether, in the presence of t-butylhydroperoxide, to yield a thioacetate epoxide. Additional thiolacetic acid is then reacted with the epoxide, in the presence of a base catalyst, to yield a bis-thioacetate. The bis-thioacetate can be treated with acid or base, preferably ammonia, triethylamine or p-toluenesulfonic acid and even more preferably p-toluenesulfonic acid to yield the product. The thioacetate adjacent to the hydroxyl group is more labile and is cleaved selectively. These latent thiol mercaptan chain transfer agents can be used in all types of reactions where the use of chain transfer agents is well known to those skilled in the art, for example in solution or emulsion polymerizations. To form the block copolymers of the present invention, it is preferable to use a two stage aqueous emulsion polymerization. In the first stage, the latent thiol mercaptan chain transfer agent is contained in the aqueous emulsion polymerization at a concentration up to about 10 mole percent, more preferably up to about 5 mole percent and even more preferably up to about 2 mole percent. During this first stage, the at least one thiol group reacts with a polymer chain being formed from at least one first ethylenically unsaturated monomer to form a polymer chain containing at least one protected thiol group, primarily at the terminal portion of the chain. The ethylenically unsaturated monomer useful in the first stage for the preparation of the block copolymer can be any ethylenically unsaturated monomer, for example; acrylate esters and acids; methacrylate esters and acids; acrylonitrile; methacrylonitrile; acrolein; methacrolein; vinyl aromatic compounds such as styrene, substituted styrene, vinyl pyridine and vinyl naphthalene; vinyl esters of organic acids, such as vinyl acetate; N-vinyl compounds such as N-vinyl pyrrolidone; unsaturated halogenated compounds such as vinyl chloride and vinylidene chloride; acrylamide, methacrylamide and substituted acrylamides and methacrylamides; polymerizable sulfonic acids and salts thereof such as styrene sulfonic acid, sodium vinyl sulfonate, sulfoethyl acrylate, sulfoethyl methacrylate and acryloamidopropanesulfonic acid (AMPS); vinyl ethers; or combinations thereof. The emulsion polymerization should be run such that the protected thiol group from the latent thiol mercaptan chain transfer agent remains substantially intact during the first stage polymerization. In addition, it is preferable to run the first stage emulsion polymerization reaction in an inert atmosphere, for example, in a nitrogen atmosphere. This polymer formed in stage one of the aqueous emulsion polymerization has, for example, the structure; where polymer(1) is the polymer formed from the at least one first ethylenically unsaturated monomer and R is a segment of polymer(1) with a degree of polymerization of from about 1 to 10. Once the polymer chain with terminal protected thiol groups has been formed in the first stage of the aqueous emulsion polymerization, the polymer can then be subjected to a deprotection reaction, for example a cleaving reaction or thermal heating, whereby the protected thiol groups (latent thiol groups) are deprotected, converting them into thiol groups. When the protected thiol group of the polymer chains produced in the first stage emulsion polymerization are deprotected using a cleaving reaction, for example when the protected thiol group is thioacetate, any cleaving technique well known to those skilled in the art may be used. However, it is preferable to cleave the thioacetate group with, for example, ammonia, hydroxylamine, N-propylamine, diethylamine, morpholine, dimethylaminoethanol, and hydrazine. The more preferred cleaving agents are ammonia, dimethylaminoethanol and hydrazine and the even more preferred is hydrazine. Generally, the cleaving reaction is run at a temperature of from about 15 to 95°C and more preferably from about 65 to 75°C. It is more preferable to form a stage one polymer using a latent thiol mercaptan chain transfer agent where the thiol group is protected as the thioacetoacetate. This allows for the deprotection reaction to be accomplished with more innocuous compounds, for example with tertiary amine or alkali, and in addition leads to less toxic by-products from the deprotection reaction. Once the protected thiol groups have been deprotected to form terminal thiol groups, the polymer chain produced in the first stage emulsion polymerization can be isolated, for example by spray drying, used as is, or stored for further reaction at a later time. After the deprotection reaction the polymers formed have, for example, the following structure; It is highly preferred that the second stage monomer emulsion be added directly to the polymer emulsion of stage one to form the block copolymer. One of the key advantages of this process is that the polymer of stage one does not have to be isolated before reacting in stage two, and stage two can take place simply by adding stage two monomer. In stage two of the aqueous emulsion polymerization at least one second ethylenically unsaturated monomer, preferably in the form of an aqueous emulsion, is added to a reaction mixture containing the polymer chain formed during the first stage of the aqueous emulsion polymerization. Because the polymer chain from the first stage is a chain transfer agent containing terminal thiol groups, it is preferable to add all of the second stage monomer together at one time. However, if the second stage monomer is gradually added, some non-block copolymer may form, yielding a mixture of block copolymer and polymer derived from second stage monomer. This mixture may have some beneficial uses. The at least one second ethylenically unsaturated monomer can be any of the ethylenically unsaturated monomers listed above for use as the at least one first ethylenically unsaturated first monomer. The block copolymers formed after the second stage of the aqueous emulsion polymerization have, for example, the following structures; where polymer(2) is the polymer formed from the at least one second ethylenically unsaturated monomer and R¹ is a segment of polymer(2) with a degree of polymerization of from about 1 to 10. The aqueous emulsion copolymerization technique of the present invention is based on a two stage polymerization where the mode of monomer addition in the first stage is not critical and a single addition of monomer in the second stage is preferred. The aqueous emulsion copolymerization techniques used in the present invention are well known to those skilled in the art. The temperature of the reaction in each of the two stages should be in the range of from about room temperature to about 150°C, more preferably from about 50°C to 90°C. An emulsifier can be used in the process of the present invention and can be of the general type of an anionic, cationic, or nonionic emulsifier. The more preferred emulsifiers are the anionic and the nonionic emulsifiers and the even more preferred are the anionic emulsifiers, such as sulfates and sulfonates, like sodium lauryl sulfate and sodium dodecyl benzene sulfonate. The amount of emulsifier used may be from about 0.05 to 10%, and more preferably from about 0.3 to 3%, based on the total weight of the monomers. Many other emulsifiers can be used and are well known in the emulsion polymerization art. The latex particle size is controllable to be as small as from about 50 to 200 nanometers (nm) to as large as 800 nm or more by adjusting the type and level of emulsifier used. The particle size is preferably less than 500 nm. It is advantageous to initiate and catalyze the reaction in each of the two stages in a conventional manner. Any commonly known free radical generating initiators can be used, such as persulfates, peroxides, hydroperoxides, peresters and azo compounds. Specific examples are benzoyl peroxide, tert-butyl hydroperoxide, azodiisobutyronitrile and sodium, potassium and ammonium persulfates. The more preferred are the sodium, potassium and ammonium persulfates which can be used by themselves, activated thermally, or in a redox system. When used in a redox system, reducing agents such as sodium formaldehyde sulfoxylate, isoascorbic acid and sodium bisulfite can be used along with a promoter, such as for example iron or others well known to those skilled in the art. Thermal initiation is more preferred. The amount of initiator will generally be in the range of from about 0.1 to 3.0% by weight, based on the total weight of the monomers. The reaction conditions used in the second stage are dependant on the method of deprotection of the protected thiol group. For example, if a cleaving reaction utilizing ammonia is used to deprotect the protected thiol group, it is preferable to initiate the second stage polymerization thermally using ammonium persulfate or with redox initiators of tert-butylhydroperoxide and sodium formaldehyde sulfoxylate or isoascorbic acid. If hydroxylamine is used to deprotect the protected thiol group via a cleaving reaction, it is preferable to neutralize the amine with, for example, acetic acid, prior to the second stage polymerization. If hydrazine is used to cleave the protected thiol group, it is preferable to complex the hydrazine with 2,4-pentanedione prior to the stage two emulsion polymerization. Additional initiator or catalyst systems may be added after stage two polymerization to reduce any residual monomer. Generally, the aqueous emulsion formed containing the block copolymer has a solids level of from about 20 to about 60%, based on the total weight of the aqueous composition. The block copolymer products of this aqueous emulsion polymerization can be isolated, for example by spray drying, coagulation or other techniques well known to those skilled in the art. However, it is preferable to use the aqueous emulsion containing the copolymer as is. The invention will now be illustrated by the following examples. Examples 1, 2 and 3: Preparation of Latent Thiol Mercaptan Chain Transfer Agents. EXAMPLE 1 Preparation of a Mixture of 1-(S-acetyl-3-mercaptopropoxy)-3-mercapto-2-hydroxypropane and 1-(S-acetyl-3-mercaptopropoxy)-3-mercapto-2-acetoxypropane STEP 1 Reagents for Example 1-Step 1 Allyl glycidyl ether 156 g. 1.37 mole Thiolacetic acid 104 g. 1.37 mole t-Butylhydroperoxide 10 g. To a 1 litre 4-neck flask fitted with reflux condenser, thermocouple, and addition funnel was added allyl glycidyl ether (156 g). Thiolacetic acid was added in approximately 20 g. aliquots and each aliquot was initiated by the addition of 0.5 g. of a 70% t-butylhydroperoxide solution. An exotherm of between 10-20°C was observed for each aliquot, with care being taken to keep the reaction temperature below 65°C. NMR analysis after the addition of one equivalent of thiolacetic acid showed 30-40% residual allyl glycidyl ether. Additional thiolacetic acid (40 g.) was then added in two portions, each portion initiated as above. NMR analysis showed >95% conversion of the allyl glycidyl ether. STEP 2 Reagents for Example 2-Step 2 Thiolacetic acid 104 g. 1.37 mole Triethylamine 1.5 g. Ethanol 250 g. The reaction product described in step 1 was allowed to cool to room temperature and then was diluted with 250 g. of ethanol. Thiolacetic acid was added, followed by catalytic triethylamine. An exotherm from room temperature to approximately 60°C over 1 hour was observed. STEP 3 A sample of the bis-thioacetate from step 2 was diluted with an equal volume of ethanol, and then 1% by weight p-toluenesulfonic acid (2 g.) was added. The mixture was heated to reflux for 4 hours. NMR analysis showed complete transformation of the thioacetate adjacent to the hydroxyl group with the formation of two products; 1-(S-acetyl-3-mercaptopropoxy)-3-mercapto-2-hydroxypropane and 1-(S-acetyl-3-mercaptopropoxy)-3-mercapto-2-acetoxypropane EXAMPLE 2 Preparation of Bis-S-acetyl-pentaerythritol tetra(3-mercaptopropionate) Reagents for Example 2 Pentaerythritol tetramercaptopropionate 50 g. acetic anhydride 20.89 g. 4-dimethylaminopyridine (DMAP) 0.1 g. methylene chloride 100 g. The tetraester was dissolved in methylene chloride containing DMAP. The acetic anhydride was added and a mild exotherm ensued. The mixture was heated to 40°C for 1 hour. NMR analysis showed conversion to the desired partially protected chain transfer agent. Silver nitrate titration for mercaptan showed ca. 90% capping efficiency. The major product was bis-S-acetylpentaerythritol tetra(3-mercaptopropionate) along with lesser amounts of the mono- and tris-acetyl compounds. EXAMPLE 3 Preparation of Pentaerythritol Tetramercaptopropionate Diacetoacetate. To a solution of 20.0 g. (0.041 mol) of pentaerythritol tetramercaptopropionate in 20 g. of acetonitrile was added 7.9 g. (0.094 mol. 2.3 equiv.) of diketene. Upon addition of triethylamine catalyst (30 mg) an exotherm of 17°C was observed. After 30 minutes the reaction mixture was warmed to 70°C for an additional 30 minutes to ensure complete reaction. Solvent was removed on a rotary evaporator. Silver nitrate titration for thiol showed 2.05 meq thiol/g material. The major product was bis-S-acetoacetyl-pentaerythritol tetra-3-mercaptopropionate along with lesser amounts of mono and tris-acetoacetyl compounds. Examples 4 and 5: Emulsion Polymerization Example 4 Stage One Preparation of emulsion copolymer of 99.5 parts Butyl acrylate/0.5 parts Methacrylic Acid with 2.24 weight percent based on the weight of the monomer of bis-S-acetyl pentaerythritol tetra-3-mercaptopropionate (degree of polymerization 200) To a 5 litre 4-necked flask equipped with mechanical stirrer, reflux condenser, and thermometer was added 1080 g. of water and 14 g. of a 2.3% aqueous solution of sodium dodecylbenzenesulfonate and the mixture was warmed to 85°C. A monomer emulsion was prepared consisting of 400 g. of water, 20 g. of a 23% aqueous solution of sodium dodecylbenzenesulfonate, 1393 g. of butyl acrylate, 7 g. of methacrylic acid, and 31.35 g. of bis-S-acetyl pentaerythritol tetra-3-mercaptopropionate from Example 2. A portion of the monomer emulsion (185 g.) was added to the flask at 85°C followed by 2 g. of ammonium persulfate dissolved in 68 g. of water. After the initial exotherm subsided (5 minutes) the remainder of the monomer emulsion was fed into the flask at 85°C over 2.5 hours. The mixture was maintained at 85°C for an additional 30 minutes and then cooled to 60°C. t-Butylhydroperoxide (0.3 g. of a 70% solution) in 10 ml of water and 0.2 g. of sodium formaldehyde sulfoxylate were added to the flask. The theoretical yield was 47.4% solids, the actual yield was 47.2% solids. Deprotection of Stage One Copolymer via a Cleavage Reaction The stage one latex prepared above, 99.5 parts butyl acrylate/0.5 parts methacrylic acid with 2.24% of bis-S-acetyl pentaerythritol tetra-3-mercaptopropionate, 400 g. solids, was placed in a 3 litre, 4-necked flask (8.96 g. chain transfer agent, 0.031 mole latent thiol groups present). The apparatus was flushed with nitrogen. Hydrazine (2.0 g., 0.0625 mole, 2 equiv.) was added and the mixture was heated to 70°C. After two hours, silver nitrate titration of a 0.25 g. solids aliquot showed essentially quantitative liberation of thiol. Then, 2,4-pentanedione (6.88 g., 0.06875 mole) was added to complex with the hydrazine. Stage Two Emulsion polymerization of 50 parts (99.5 butyl acrylate/0.5 methacrylic acid with 2.24% bis-S-acetyl pentaerythritol tetra-3-mercaptopropionate)/ /50 parts Methyl Methacrylate. Once deprotection was complete, the second stage monomer emulsion was prepared: MMA 400 g. dodecylbenzensulfonate (23%) 3 g. water 500 g. This emulsion was added to the latex and the temperature was allowed to return to 60°C. Ferrous sulfate/EDTA solutions (1 ml of 0.15% solution) were added and then a single shot polymerization was initiated by addition of 1.0 g. of 70% t-butylhydroperoxide in 10 g. of water followed by 1.37 g. of isoascorbic acid in 10 g. of water. An exotherm of 25.5°C was observed over a 15 minute period. The reaction was allowed to cool to 60°C and then solutions of 0.3 g. of t-BHP/5 g. water and 0.3 g. of sodium formaldehyde sulfoxylate/5 g. water were added twice. The theoretical yield was 45.1% solids, the actual yield was 44.8% solids. The MFT (minimum film forming temperature) of this block copolymer was found to be 3°C. A random copolymer of butyl acrylate and methyl methacrylate of the same composition and molecular weight had an MFT of 22°C. EXAMPLE 5 Stage One Preparation of emulsion copolymer of 99 parts Butyl Acrylate/1 part Methacrylic Acid with 2.57 weight percent based on the weight of the monomer of bis-S-acetoacetyl pentaerythritol tetra-3-mercaptopropionate (degree of polymerization 200). To a 3-litre 4-necked flask equipped with mechanical stirrer, reflux condenser, and thermometer was added 570 g. of water and 7.0 g. of a 2.3% aqueous solution of sodium dodecylbenzenesulfonate and the mixture was warmed to 85°C. A monomer emulsion was prepared containing 200 g. water, 10 g. of a 23% aqueous solution of sodium dodecylbenzenesulfonate, 693 g. butyl acrylate, 7.0 g. methacrylic acid, and 18.0 g. bis-S-acetoacetyl pentaerythritol tetra-3-mercaptopropionate from Example 3. A portion of the monomer emulsion (93 g.) was added to the flask at 85°C followed by the addition of 1.0 g. of ammonium persulfate dissolved in 34 g. water. After the initial exotherm subsided (5 minutes), the remainder of the monomer emulsion was fed into the flask at 85°C over 2.4 hours. The mixture was maintained at 85°C for an additional 30 minutes and was then cooled to 60° C. t-Butylhydroperoxide (0.2 g. of a 70% solution) in 10 ml of water and 0.2 g. of sodium formaldehyde sulfoxylate in 10 ml of water were then added to the flask. The theoretical yield was 45.1% solids, the actual yield was 44.9% solids. The particle size was 284 nm. Deprotection of Stage One Copolymer via a Cleavage Reaction The stage one latex prepared above, 99 parts butyl acrylate/1 part methacrylic acid with 2.57% bis-S-acetoacetyl pentaerythritol tetra-3-mercaptopropionate, 100 g. solids, was placed in a 1 litre, 4-necked flask. The apparatus was flushed with nitrogen. Dimethylaminoethanol (1.51 g., 0.017 mol, 2 equiv.) was added and the mixture was heated to 70°C. After 1 hour, silver nitrate titration showed essentially quantitative liberation of thiol. Aerosol® A-103 surfactant (3.0 g. of 33% aqueous solution) was added and the mixture was acidified to pH 7.8 using 15% aqueous acetic acid. Stage Two Emulsion polymerization of 50 parts (99 parts butyl acrylate/1 part methacrylic acid with 2.57% bis-S-acetoacetyl pentaerythritol tetra-3-mercaptopropionate)//50 parts methyl methacrylate. Once deprotection was complete, the second stage monomer emulsion was prepared: MMA (100 g) and dodecylbenzenesulfonate (23%) (0.6 g) and water (135 g) This emulsion was added to the latex in one portion and the temperature was allowed to return to 60°C. Ferrous sulfate/EDTA solutions (2 ml of 0.15% solution) were added and then a single shot polymerization was initiated by the addition of 0.5 g. of 70% t-butylhydroperoxide in 10 ml of water followed by 0.7 g. of isoascorbic acid in 10 ml of water. An exotherm of 21°C was observed over a 12 minute period. The reaction mixture was allowed to cool to 60°C and then solutions of 0.2 g. of t-BHP/10 g. water and 0.2 g. sodium formaldehyde sulfoxylate/10 g. water were added. The theoretical yield was 40.0% solids and the actual yield was 39.7% solids. The particle size was 358 nm. Example 6-Comparative The use of thiolacetic acid as a chain transfer agent was evaluated. Comparative data can be seen in Table 4, showing that, at a given concentration the thiolacetic acid is less effective in controlling molecular weight. Thiolacetic acid has been found to form significant amounts of mono-adducts with acrylate monomers. Upon deprotection, this material yields low molecular weight thiol which is unattached to polymer and therefore results in reduced yields of block copolymer. Comparison of Chain Transfer Agents Chain Transfer Agent Theoretical Mn Experimental Mn 1. thiolacetic acid 3650 3260 2. thiolacetic acid 1440 3540 3. thiolacetic acid 720 4360 4. thiolacetic acid 1440 5100 5. thiolacetic acid 3650 5650 6. thiolacetic acid 1500 2605 7. thiolacetic acid 4500 8300 8. butyl mercaptopropionate 4500 4390 9. thiolacetic acid 2500 >10,000 10. thiobenzoic acid 2500 7500 11. butyl mercaptopropionate 2500 2870 12. thiolacetic acid 10,000 17,500 13. butyl mercaptopropionate 10,000 10,200 Experimentation revealed that the samples according to the present invention display favourable properties when in compositions such as adhesives, mastics and caulks. Experimentation also showed that the samples according to the present invention are good compatibilisers for polymers.

Claims: A latent thiol mercaptan chain transfer agent having the general formula; wherein A is a polyvalent organic radical; x and y are positive integers such that x+y equals the valence of A; B is an organic acyl radical; and n and m are integers from 1 to 6. A latent thiol mercaptan chain transfer agent according to claim 1 wherein A is a C₁ to C₆ hydrocarbon radical; B is an acetyl or acetoacetyl group; and n and m are positive integers from 1 to 2. A polymer comprising polymerized units of an ethylenically unsaturated monomer and having a terminal thiol functional group derived from the latent thiol mercaptan chain transfer agent as defined in claims 1 or 2. A block copolymer comprising (a) at least one first block of polymerized units of at least one first ethylenically unsaturated monomer and at least one latent thiol mercaptan chain transfer agent as defined in claims 1 or 2; and (b) at least one second block of polymerized units of at least one second ethylenically unsaturated monomer; wherein the first block has at least one terminal thiol functional group; and wherein the at least one second block is attached to the at least one first block via the at least one terminal thiol functional group. A polymer composition comprising a block copolymer according to claim 4 dispersed in water. A method of making block copolymers comprising a) polymerizing in a first stage of a two stage emulsion polymerization at least one first ethylenically unsaturated monomer and reacting at least one latent thiol mercaptan chain transfer agent as defined in claims 1 or 2 with the polymer chain formed wherein a polymer is formed having protected thiol functional groups; b) deprotecting the protected thiol functional groups to form thiol functional groups; and c) polymerizing at least one second ethylenically unsaturated monomer in the presence of said polymer formed in the first stage. A method according to claim 6 wherein the copolymers are copolymers according to claim 4. A water-based coating containing an effective amount of a polymer according to claim 3, or a copolymer according to claim 4, or a composition dispersion according to claim 5, or a copolymer prepared by a method according to claims 6 or 7, admixed with a suitable carrier or diluent, wherein the coating is an adhesive, a mastic or a caulk. Use of a copolymer according to claim 4, or a composition dispersion according to claim 5, or a copolymer prepared by a method according to claims 6 or 7, as a compatibilizer for physical blends of at least two polymers.

Inventors: EMMONS WILLIAM DAVID, GROSS ANDREW WILLIAM, EMMONS, WILLIAM DAVID, GROSS, ANDREW WILLIAM
Applicants: ROHM & HAAS, ROHM AND HAAS COMPANY
Application year: 1992
Main classification: C08F2
IPC codes: C08F293, C08F2