Polyamide ester rheological additive, a solution containing the additive and thickened compositions containing the additive

Abstract: A polyamide (or oligomeric amide) ester rheological additive especially for organic solvent-based compositions comprises the reaction product of a defined polycarboxylic acid, a diamine, an alkoxylated polyol and a capping agent. The additive exhibits excellent efficiency and ease of dispersibility and is especially effective when first predispersed in an organic solvent. Organic solvent-based compositions which may be thickened by using the rheological additive are aliphatic, aromatic, and some moderately polar solvent-based compositions.

Description: BACKGROUND AND SUMMARY OF THE INVENTION The present invention relates to a polyamide or oligomeric amide ester rheological additive, a solution containing the additive and also a thickened composition containing the additive. The rheological additive art has constantly sought materials which may be used to control the rheological properties of various compositions. For example, thickeners and other thixotropising agents are used for improving the spreadability of a coating on a surface during application, for preventing coatings which are applied to vertical surfaces from sagging, and for inhibiting pigments and other heavy fillers from separating or settling during storage of the coating composition. One type of material which has been shown to be useful to thicken various organic compositions is an organomodified clay. Different kinds of organically modified (otherwise known as organophilic) clays are described in U.S. Patent Nos. 4,081,496; 4,105,578; 4,116,866; 4,193,806; 4,208,218; 4,216,135; 4,287,086; 4,391,637; 4,410,364; 4,412,018; 4,434,075; 4,434,076; 4,450,095 and 4,517,112. Additional types of thickeners and thixotroprising agents which have been used in the past for organic coating compositions may include finely powdered or fumed silica or organic compositions such as castor wax products, modified unsaturated polyesters, polymeric amides, polyurethanes and polyester amides as disclosed, for example, in U.S. Patent No, 4,462,926. Certain types of polyamides have also been employed as rheological additives. A polyamide thixotropic agent is referred to in U.S. Patent No. 3,131,201 which describes a resinous composition which is the reaction product of an alkyl diamine having from 2 to 6 carbon atoms and two terminal primary amines with a copolymer formed by the reaction of a glyceride of a polyunsaturated fatty acid having an iodine value above 130 and a conjugated alicyclic diene hydrocarbon monomer. Thixotropic agents comprising polyamides which are paint compositions containing the thixotropic agents, and a process for incorporating the thixotropic agents in the form of a concentrated solution into a paint or a hardener or both also useful for thickening paint compositions are described in British Patent Nos. 2,177,411A and 2,177,412A. The thixotropic agents are produced by the reaction of (i) xylylene diamine or C 4 -C 8 diamine, and (ii) hydroxy-substituted C 1 -C 11 carboxylic acid (or the equivalent lactone), and (iii) polymer fatty acids. The molar ratio of (ii) to (i) is from 1:1 to 2:3 and the ratio of amine groups in (i) to acid groups in (ii) + (iii) is about 1:1. A polyamide rheological additive especially for organic solvent-based compositions which comprises the reaction product of a defined polycarboxylic acid, an active hydrogen compound and a capping agent described as a monocarboxylic acid having olefinic unsaturation or hydroxyl group and containing 16-22 carbon atoms is disclosed in U.S. Patent No. 4,778,843. The additive exhibits excellent efficiency and dispersability and is effective when first predispersed in an organic solvent. Organic solvent-based compositions which may be thickened using the rheological additive are aromatic, aliphatic and some moderately polar solvent-based compositions. Certain types of polyamide esters have also been used as rheological additives. Thus, for example, previously mentioned U.S. Patent No. 4,462,926 discloses a thixotropic agent for unsaturated polyester resins consisting of at least one cyclohexylamide of a saturated fatty acid which contains at least 10 carbon atoms and one or more oligomeric ester amides which have an average molecular weight of from 600 to 3,000, a content of carboxylic acid amide groups of from 1.5 to 15% by weight and a content of carboxylate groups of from 2 to 13% by weight. U.S. Patent No. 4,026,850 discloses thixotropic urethane alkyd resins in which fatty acid modified dimeric fatty acid polyester amides have been incorporated, obtainable by reacting mixtures of: (a) OH-containing partial esters of polyhydric alcohols and long chain unsaturated fatty acids and/or OH-containing oligoesters of polyhydric alcohols, long chain unsaturated fatty acids and polybasic carboxylic acids; (b) OH-containing fatty acid modified dimeric fatty acid polyester amides; with (c) diisocyanates. It is, however, necessary to have unreacted hydroxyl groups reacted with the NCO-containing crosslinker to form resinous material. The fatty acid modified polyester amides which contain OH-groups are obtained by reacting mixtures of dimeric fatty acid polyamides, fatty acid partial esters and/or mixtures of fatty acid esters with polyhydric alcohols. British Patent No. 1,252,282 discloses polyester resins suitable for use in flexographic and gravure ink vehicles and in the formulation of thixotropic vehicle compositions. It was found that if a portion of a poly-functional amine is replaced by certain dihydric alcohols, the product does not gel certain aliphatic alcohols which are used as carrier solvents. In particular, polyesteramide material which comprises the condensation product of a polyamine, an ethoxylated diphenylolpropane, and a polymeric fatty acid is disclosed. The polyesteramide thixotrope is formed by the reaction of (a) diamine, (b) a particular dihydric alcohol where diphenylpropane is ethoxylated/propoxylated with 2 to 4 moles of ethylene oxide and/or propylene oxide. Although capping agents in the form of a monofunctional carboxylic acid are not specifically required, it is contemplated that a monobasic carboxylic acid which functions as a chain terminator can be used optionally, although not required and not used as a modifier to a rheological additive. European Patent Application No. 302,690 discloses a polyoxyalkylene polyamide thickener consisting of the reaction products of a diamine, an aminopropyl polyoxyethylene ether and a dimer acid. British Patent Application No. 2,188,330 discloses compositions which contain a polyether-amide derived from an aliphatic diamine, an ether mono-, di-, or triamine and optionally another monoamine and a dicarboxylic acid, optionally together with a monocarboxylic acid. The polyether-amides may be used to impart thixotropy to, or thicken, a wide variety of organic liquids and solvents, especially coating compositions. European Patent Application No. 239,419 discloses thixotropic compositions which comprise a film forming resin and a polyether-amide derived from an aliphatic diamine, an ether mono-, bi-, or triamine and optionally a different monoamine, and an organic dicarboxylic acid, optionally together with a monocarboxylic acid. A wide variety of organic liquid materials may be thickened by the polyetheramides, including thermoplastic and thermosetting acrylic polymers, by simple dissolution without heating. U.S. Patent No. 2,410,788 describes fatty amide polymers which are suitable for modifying the properties of textile fibers and not as a rheological additive. The disclosed polymers are resinous or semi-resinous materials of very large molecular weights in which dialcohol substituted carboamido compounds carrying side chains containing polyamino acid amide radicals are linked together by reaction with polybasic acids. Despite the numerous types of known rheological additives, an ongoing search has been made for new rheological additives which are highly efficient and are readily dispersible in the composition to be thickened. The earlier organic thixotropic agents were based on castor wax products which have restrictions on processing temperatures when being incorporated into organic based compositions, in particular aliphatic, aromatic and some moderately polar solvent-based paint compositions. Tight processing temperature ranges are required for these additives between minimum and maximum limits for acceptable performance. Too low a processing temperature leads to an incomplete rheological development. Excessively high processing or storage temperatures may partially solubilize the organic rheological additives thereby leading to a loss of rheological structure and the formation of soft gel particles or "seeds" upon cool down. The polyamide thixotropic agents described in U.S. Patent No. 4,778,843 have a minimum processing temperature with no upper processing temperature limit. For a proper development of rheology, a minimum temperature should be reached; however, because there is not an upper processing temperature limit, organic-based compositions and paints containing these additives do not "seed" or lead to the formation of soft gel particles on cool down. The main drawback with the use of these polyamide thickeners is that the minimum activation temperatures required for incorporation in an aliphatic paint system are quite high at 160-180°F compared to normal paint preparation processing temperatures of 120-150°F. It is accordingly an object of the present invention to provide an improved rheological additive for organic compositions which reduces minimum activation temperatures required for incorporation of a polyamide thixotrope in an aliphatic paint system by the inclusion of an alkoxylated moiety that contains at least two active hydrogen moieties in a polyamide ester composition. It is a more specific object of the present invention to provide a polyamide ester rheological additive which is efficient in thickening organic compositions. It is a further object of the present invention to provide a polyamide ester rheological additive that can be readily dispersed in the organic composition to be thickened. It is a further object of the present invention to provide a polyamide ester rheological additive that can be readily dispersed in the organic composition to be thickened at low activation temperatures. It is a further object of the present invention to provide a solution of the polyamide ester rheological additive in an organic solvent, which solution enhances a further improvement in efficiency. It is a still further object of the present invention to provide an organic solvent solution of a polyamide ester rheological additive which exhibits improved efficiency and remains fluid in storage at ambient temperatures. It is a still further object of the present invention to provide an organic solvent solution of a polyamide ester rheological additive which is easy to handle and which can readily be incorporated into organic compositions. It is a yet further object of this invention to provide an efficient rheological additive for organic solvent-based systems which, once dispersed in the system, will remain so, and thus will not form "seeds" (large agglomerates) due to storage of the organic solvent-based system. The present invention provides a rheological additive according to claim 1. The present invention also provides a solution formed by dissolving the polyamide ester rheological additive in an organic solvent and a thickened organic composition containing the polyamide ester rheological additive. Further advantages and features of the invention, as well as the scope, nature and utilization of the invention will become apparent to those skilled in the art from the description of the preferred embodiments of the invention set forth below. DESCRIPTION OF THE PREFERRED EMBODIMENTS As stated hereinabove, one aspect of the present invention relates to a polyamide ester rheological additive comprising the reaction product of polycarboxylic acid, active hydrogen compound, alkoxylated active hydrogen compound, and monocarboxylic acid capping agent. The polycarboxylic acid has at least 5 carbon atoms, preferably from 6 to 36 carbon atoms and most preferably from 16 to 20 carbon atoms per carboxylic acid group. While polycarboxylic acids having more than 2 carboxylic acid groups may be employed, the amount of such acids should be limited to avoid extensive cross linking which would render the reaction product insoluble in the intended organic composition. This typically means that less than 80 percent by weight, preferably less than 20 percent by weight, and most preferably less than 5 percent by weight of the total amount of polycarboxylic acid should have three or more carboxylic acid groups. Illustrative polycarboxylic acids include sebacic acid, poly(butadiene)dioic acids, dodecane dicarboxylic acid and mixtures thereof. Especially preferred polycarboxylic acids are oligomers of fatty acids having a carbon chain of from 16 to 22 carbon atoms, preferably 16 to 18 carbon atoms. Exemplary fatty acids are those derived from soybean oil, castor oil, tall oil, corn oil, cottonseed oil, kapok seed oil, linseed oil and mixtures thereof. Even further preferred are oligomers of fatty acids which are substantially comprised of the dimerized fatty acid. Typically, the dimerized fatty acid constitutes at least 20% by weight of the oligomerized fatty acid, preferably at least 80% by weight of the oligomerized fatty acid. The oligomerized fatty acid preferably also has a low monomer content such as less than 10% by weight and more preferably less than 4% by weight. Preparation of the oligomerized fatty acid, including the described low monomer content oligomer, is well known in the art and is disclosed, for example, in U.S. Patent Nos. 2,793,219 and 2,955,121. Additionally, suitable oligomerized fatty acids are commercially available such as certain oligomerized fatty acids available under the name "Empol" from Emery Industries, a division of National Distillers & Chemical Corporation and "Sylvadym" available from Arizona Chemical Company. The active hydrogen compound has the general formula X m -R-Y n wherein R represents a group containing from 2 to 12 carbon atoms and which may contain non-reactive groups, such as ether, alkoxy or halogen groups, X and Y are independently selected from primary amino, secondary amino and hydroxyl and m and n are at least 1, the sum of (m+n) is at least 2, and preferably m and n are each 1. At least 90%, preferably at least 95%, and most preferably all of the X and Y groups participating in the reaction are primary amino, secondary amino or a mixture thereof. Preferably, R represents a group containing from 6 to 12 carbon atoms, and more preferably R represents a group containing from 6 to 8 carbon atoms, although R can represent a group containing from 2 to 12 carbon atoms which may contain an alkoxy non-reactive group. As stated above with respect to the polycarboxylic acid, and as is apparent from the general formula, the active hydrogen compound can have 3 or more active groups. However, the amount of active hydrogen compound having 3 or more active groups should not be selected such that the reaction produce is cross-linked to an extent such that it is insoluble in the environment of the organic composition in which it is to be used. Typically, this means that the amount of active hydrogen compound having 3 or more active hydrogen groups should be less than 20 mole percent, preferably less than 2 mole percent and most preferably it is substantially absent. Illustrative active hydrogen compounds include polyamines, such as 1,2-diaminoethane, 1,2- and 1,3-diaminopropane, 1,4-diaminobutane, 1,6-diaminohexane, 1,8-diaminooctance, 1,12-diaminododecane, 3,3-diaminopropyl-N-methyl-amine, N-alkyl-1,3-diaminopropanes wherein the alykl group is a long carbon chain such as coco or tallow alkyl, soya alkyl, oleyl, stearyl and mixtures thereof, and amino alcohols, such as ethanolamine, 6-aminohexanol, aminoethylethanolamine and mixtures thereof. Diols which may constitute a portion of the active hydrogen compound are exemplified by 1,2-ethanediol, 1,2- and 1,3-propane diol, 1,4-butane diol, 1,6-hexanediol, diethylene glycol, triethylene glycol and mixtures thereof. However, as discussed above, the amount of diol must be limited such that of the total active hydrogen groups participating in the reaction, at least 90 mole percent must be primary and/or secondary amino. Preferred active hydrogen compounds are diamines, especially diamines having from 6 to 12 carbon atoms with the most preferred diamine being 1,6-diaminohexane. The alkoxylated active hydrogen compound is a polyether segment (alkoxylated) moiety with at least 2 active hydrogen groups. The alkoxylated active hydrogen compound must have an active amine or hydroxyl moiety at each termini of the polyether chain and/or have an end of the polyether chain linked to a central molecular fragment having at least one additional amine or hydroxyl moiety and/or polyether chain attached thereon. This definition includes alkoxylated polyols (polyalkylene glycols or polyalkylene diols) that have two hydroxyl end groups and contain ethylene, propylene, or butylene oxide units such as polyethylene glycol, polypropylene glycol or polybutylene glycol, respectively, with molecular weights of about 250 to 2000. Additionally adducts of an alkylene oxide and a difunctional reactant such as an alkanolamine (e.g., ethanolamine) are also useful; such adducts are also known as diol ethers or alkanol amine ethers. Also, suitable compounds which provide polyether segments include amine-terminated polyoxyethylenes of the formula: H 2 N(CH 2 CH 2 O) x H and H 2 N(CH 2 CH 2 ) x CH 2 CH 2 NH 2 where x ranges from about 10 to 50 and such compounds are commercially available under the tradename "Jeffamine." Also, the alkoxylated active hydrogen compound includes alkoxylated aliphatic nitrogen-containing compounds. The alkoxylated aliphatic nitrogen-containing compound can have a chemical structure represented by the formula: where R 1 is a straight or branched chain aliphatic alkyl group having 6 to 30 carbon atoms, R can be a hydrogen, methyl, or ethyl group, both q and r are at least 1, s is zero or 1, and the sum of q+r is from 2 to 50. Illustrative alkoxylated aliphatic nitrogen-containing compounds represented by formula (I) include those tertiary amines having one fatty alkyl group derived from various fatty sources having 12 to 18 carbon atoms and at least two polyoxyethylene or polyoxypropylene groups attached to the nitrogen. Polyethoxylated aliphatic amine olyols are commercially available and marketed by Akzo Chemicals, Inc. under the tradename "Ethomeen" while polyethoxylated aliphatic amides are available from the same company under the tradename "Ethomid". As stated above with respect to the polycarboxylic acid and active hydrogen compound, the alkoxylated active hydrogen compound can also have 3 or more active groups. However, the amount of alkoxylated active hydrogen compound having 3 or more active groups should not be selected such that the reaction product is crosslinked to an extent such that it is insoluble in the environment of the organic composition in which it is to be used. Typically, this means that the amount of active hydrogen compound having 3 or more active hydrogen groups should be less than about 10 mole percent, preferably less than about 2 mole percent and most preferably it is substantially absent. An example of on alkoxylated active hydrogen compound having 3 or more active groups can be represented by an alkoxylated aliphatic nitrogen-containing compound which has a chemical structure represented by the following formula: wherein R 2 is a straight or branched chain aliphatic alkyl group having 6 to 30 carbon atoms, the value of p can range from 1 to 20, and R has the same meaning used with respect to formula (I). The values of x, y and z are independently selected and can be zero or an integer greater than zero with the sum of x+y+z being from 1 to 50. Illustrative alkoxylated aliphatic amines represented by formula (II) include those amines obtained from N-alkyl trimethylene diamines and having two polyoxyethylene groups attached to one nitrogen group. Such polyalkoxylated aliphatic diamines are commercially available and marketed by Akzo Chemicals, Inc. under the tradename "Ethoduomeen". Preferred alkoxylated hydrogen compounds are polyethylene oxide glycols with molecular weights ranging from 100-1000 and alkoxylated aliphatic nitrogen-containing compounds of the chemical structure represented by formula (I) wherein R 1 is 12 to 22 carbon atoms, R is a methyl group, s=0, and the sum of q+r is 2 to 15. Most preferably, alkoxylated hydrogen compounds are alkoxylated nitrogen-containing compounds of the chemical structure represented by formula (I) wherein R 1 is a fatty alkyl having 12 to 18 carbon atoms, such as coco, soya, tallow hydrogenated tallow, oleyl, octadecyl, and mixtures thereof, R is a methyl group, s is 0, and the sum of q+r is 2 to 10. The capping agent is used to terminate the reaction product of the polycarboxylic acid, the active hydrogen compound and the alkoxylated active hydrogen compound and is a monocarboxylic acid which is at least one of unsaturated and hydroxylated. The monocarboxylic acid generally has from 8 to 22 carbon atoms. While monocarboxylic acids having fewer carbon atoms may be used to achieve certain benefits in environments such as organic solvent-based coatings, such smaller monocarboxylic acid should be limited to less than 20 mole percent, preferably less than 10 mole percent of the total capping agent employed and most preferably are absent. It is preferred to have a monocarboxylic acid capping agent containing both unsaturation and hydroxylation. Further preferred is a monocarboxylic acid capping agent with a single point of unsaturation (if aliphatic) or a single hydroxyl moiety. Most preferred is a monocarboxylic capping agent with a single point of unsaturation (if aliphatic) and a single hydroxyl moiety. The capping agent may also have a straight or branched chain and may also contain groups, such as tertiary amino, alkoxy, halo, keto, etc., which do not react with the other components used to prepare the rheological additive. Illustrative unsaturated aliphatic acids include linoleic acid, linolenic acid, oleic acid, monocarboxylic acids derived from dehydrated castor oil, undecylenic acid, tall oil fatty acids, soya fatty acids, and mixtures thereof. Aromatic acids, such as benzoic acid, salicylic acid and mixtures thereof may also be employed as a portion of the total capping agent. Hydroxylated monocarboxylic acids include ricinoleic acid, 12-hydroxystearic acid, 12-hydroxydodecanoic acid, and mixtures thereof. The preferred capping agent is ricinoleic acid. A portion of the capping agent may be composed of a compound which is not a monocarboxylic acid which is unsaturated and/or hydroxylated. For example, a portion of the capping agent may be composed of at least one non-hydroxylated, saturated aliphatic monocarboxylic acid such as octanoic acid, nonanoic acid, dodecanoic acid, octadecanoic acid, docosanoic acid, hydrogenated tallow acids, stearic acid and mixtures thereof. However, to obtain significant advantageous results imparted by the described monocarboxylic acid capping agent at least 25 mole percent, preferably at least 50 mole percent and most preferably at least 90 mole percent of the capping agent actually reacted should be the described unsaturated and/or hydroxylated monocarboxylic acid. From the foregoing discussion, it can be understood that an especially preferred aspect of the present invention is a polyamide ester rheological additive which is the reaction product of oligomer of fatty acid having a carbon chain of from 16 to 18 carbon atoms, diamine having from 6 to 12 carbon atoms, an ethoxylated C 12 -C 18 alkyl amine having 2 to 10 ethoxylated units, and unsaturated and hydroxylated monocarboxylic acid having from 8 to 22 carbon atoms as the capping agent, with the most preferred capping agent being ricinoleic acid. It can also be understood that while additional groups and/or components can be present, the presence of such material should not be present to substantially adversely affect the ability of the rheological additive to function in its intended environment and in this respect the reaction product consists essentially of the defined components. Two presently preferred compositions are: Ricinoleic acid (2)/1,6-hexamethylene diamine (3)/C-36 dimer acid (3)/Ethoxylated [5] octadecylamine (1), and Ricinoleic acid (2)/1,6-hexamethylene diamine (3)/C-36 dimer acid (3)/polyethylene oxide glycol M.W. 400 (1), where the numbers in parenthesis are molar equivalents and the numbers in brackets are units of ethylene oxide. Laboratory experiments have defined the following compositional limits for the alkoxylated active hydrogen compound. H-(OCH 2 CH 2 ) n -OH wherein n = 4-50, and where q+r = 2-50 and R 1 is a long chain alkyl group C 12 -C 22 and R can be hydrogen, metkhyl or ethyl. Consequently, if the number of alkoxylated units is 2 to 4 (i.e., ≤ 4), then a long chain (C 12 -C 22 ) alkyl group must be present. The polyamide ester rheological additive is believed to function via a pigment-rheological additive interaction of an associative nature. The presence of the polar alkoxy moieties increases the pigment-rheological additive interaction in a coatings system, thereby increasing the ease of dispersion and lower the energy (i.e., temperature) requirements for rheological incorporation into the coatings system. The specific types and amount of the reactants are selected so as to obtain a non-resinous reaction product which can be dispersed in the intended organic composition and which will function as a rheological additive. Thus, the amount of active hydrogen compound reacted to form the reaction product is in the range of from 0.25 to 2.0, preferably from 0.5 to 2.0 and most preferably from 0.75 to 1.175 moles per mole of the reacted polycarboxylic acid. The amount of alkoxylated active hydrogen compound reacted to form the reaction product is in the range from 0.10 to 1.5, preferably from 0.25 to 0.75, and most preferably from 0.25 to 0.50 moles per mole of the reacted polycarboxylic acid. The amount of capping agent selected is sufficient to cap the ends of the reaction product upon completion of the reaction. Typically, the amount of capping agent reacted to form the reaction product is in the range of from 0.1 to 4.0, preferably from 0.17 to 2.0 and most preferably from 0.3 to 2.0 moles per mole of the reacted polycarboxylic acid. As should be apparent to those skilled in the art, the molar amounts of the components in the reaction mixture may be different than that of the formed polyamide ester rheological additive. That is, one or more of the reactants may be employed in excess. Typically, for instance, it has been found advantageous to use a 2-10% molar excess of the active hydrogen compound (e.g., diamine) which accelerates the reaction and makes up for that amount lost by co-distillation with the water of reaction. The average molecular weight of the reaction product, which can, for instance, be determined from an acid value analysis, ranges from 600 to 15,000, preferably from 1,400 to 10,000 and most preferably from 2,000 to 5,000. It can therefore be understood from this discussion that the polyamide ester rheological additive is not a polymeric resin, but is instead a relatively low molecular weight compound. The polyamide ester rheological additive may be prepared according to known techniques. For example, the reactants may be charged to a suitable reaction vessel which is equipped with a mechanical stirrer, a thermometer, a Dean-Stark trap equipped with a Bartlett modification and a nitrogen inlet. The vessel can be heated with stirring under a nitrogen blanket. After completion of the reaction, which can be determined by acid number (e.g., preferably less than about 20), the polyamide ester is cooled and is discharged. If amenable to grinding, which is dependent on the melting point of the particular polyamide ester rheological additive, the polamide ester can then be ground to a fine particle size. The polyamide ester rheological additives of the present invention are a substantial improvement over known additives. In contrast to some particulate-type rheological additives, which are exemplified by organomodified clays and finely divided (fumed) silica, the polyamide ester rheological additives of the present invention can have excellent flow and leveling properties, as well as excellent efficiency and easy dispersing characteristics. Additionally, coating compositions containing the polyamide ester rheological additives of the present invention may be prepared such that large agglomerates (sometimes referred to as "seeds") which sometimes form during storage of coating compositions containing prior art thixotropes can be avoided. Furthermore, in addition to being "seed"-resistant, the polyamide ester rheological additive of the present invention can be incorporated at lower activation temperatures in aliphatic alkyd coating systems compared to recent polyamide rheological additives disclosed in the art. The polyamide rheological additive of the present invention may be used to thicken a variety of organic solvent-based compositions and it is believed that the rheological additive can also be used in some solvent-free compositions. The additive is particularly useful, for example, in thickening aliphatic solvent-based compositions and, while not as efficient, may also be used in certain aromatic solvent-based and moderately polar (e.g., ketones and alcohols) based compositions. Illustrative organic solvent-based compositions include aliphatic alkyd paints such as Trade Sales solvent-based paints and varnishes, aromatic solvent-based paints based on acrylic, alkyd and polyester binders, such as standard quality industrial paints which include appliance enamels, equipment enamels, and automotive refinish enamels, and certain sealants. It should also be understood that the amount of polyamide ester rheological additive used in a specific instance is determined by numerous factors including the reactants used in the preparation of the additive, the type of organic solvent-based composition to be thickened, and the level of thickening desired. However, a general range is from 1.5 to 30 pounds per hundred gallons of composition. On a weight basis, the amount of polyamide ester rheological additive is generally from 0.1 to 5% by weight, preferably from 0.1 to 3% by weight and most preferably from 0.2 to 1% by weight. To further improve the efficiency and handling of the polyamide ester rheological additive in the organic composition and/or to effectively use those polyamide esters which may not be amenable to grinding, the polyamide esters can be first pre-dispersed in a compatible organic solvent, especially at a slightly elevated temperature. Preferably, the solvent contains at least about 50% by weight of an alcohol such as methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, isobutanol, isoamyl alcohol, cyclohexanol and mixtures thereof with the preferred alcohol being cyclohexanol. By using an alcohol solution of the rheological additive, greater latitude can be employed in selecting the amounts of the reactants used to prepare the rheological additive. For example, the amount of groups participating in the reaction from the active hydrogen compound can be reduced from 90% amino to at least 50% amino groups. Even in this instance, however, it is preferred to employ more amino groups and that accordingly it is preferred that at least 75% of the groups participating in the reaction from the active hydrogen compound are primary and/or secondary amino groups. The remaining portion of the solvent can be any organic solvent, which, with the alcohol, will provide a fluid solution of the polyamide rheological additive and which will be compatible with the intended application of the additive. Preferred cosolvents are aromatic solvents, such as benzene, toluene, xylenes, or ethyl benzene and mixtures thereof, and aliphatic solvents such as mineral spirits, mineral oil, hexanes, heptanes and mixtures thereof with the most preferred cosolvents being toluene and xylenes. The preferred combination of solvents is cyclohexanol and Aromatic 150 (an aromatic solvent available from Exxon Chemical Company) in a weight ratio of from 1:1 to 9:1 and most preferably from 1:1 to 2:1. Such a combination with the rheological additive provides a solution which remains fluid on storage at ambient temperatures and functions as an efficient rheological additive or thixotrope when used in an organic solvent based application. The amount of polyamide ester rheological additive which can be pre-dispersed in the solvent understandably varies depending on several factors, but generally is in the range of from 5 to 75% by weight, preferably from 20 to 50% by weight. The invention will be further clarified by the following examples which are intended to be purely exemplary of the invention and should not be construed as limiting the invention. PREPARATION OF RHEOLOGICAL ADDITIVE A one liter resin flask, equipped with a mechanical stirrer, a thermometer, a Dean-Stark trap-Bartlett modification and a nitrogen inlet is charged with (a) molten or liquid active hydrogen compound, (b) molten or liquid alkoxylated active hydrogen compound, (c) polycarboxylic acid, and (d) capping agent. The mixture is heated with stirring under a nitrogen blanket. Water begins to be evolved at approximately 150-155°C. After two hours at 180-195°C, aliquots are removed hourly and analyzed for acid number and the reaction is continued until the acid number reaches a minimum or falls below 8. The reaction product is cooled to 140-145°C and is discharged into a stainless steel tray and allowed to cool overnight. If the solid form of the product is used for evaluation and is amenable to grinding, the product is cooled with liquid nitrogen and ground cryogenically to a fine powder using a Brinkmann centrifugal mill. If a solution form of the solid product is desired, the rheological additive is then predispersed in an organic solvent by dissolving with slight heating (usually at 50°C) in varying amounts in organic solvents. EXAMPLE 1 C 36 Dimer Acid - 1,6-hexamethylene diamene - Ethoxylated (5) octadecylamine capped with Ricinoleic Acid. A mixture of 54.70 g (0.471 moles) of molten 1,6-hexamethylenediamine, 75.46 g (0.154 moles) of an ethoxylated [5] octadecylamine (Ethomeen 18/15 commercial available from Akzo Chemicals, Inc.), 271.74 g (0.463 moles) of a C 36 dimer acid with a molecular weight of 586.9 Sylvadym T-18 commercially available from Arizona Chemicals), and 91.99 g (0.309 moles) of ricinoleic acid was added to a one liter resin flask equipped with a mechanical stirrer, a thermometer, a Dean-Stark trap-Bartlett modification, and a nitrogen inlet. The reaction mixture is heated with stirring under a nitrogen blanket. Water beings to be evolved at approximately 150-155°C. After two hours at 190-195°C, aliquots are removed hourly and analyzed for acid number and the reaction is Continued until the acid number reaches a value of 14-15. The reaction product is cooled to 140°C and is discharged into a stainless steel tray and allowed to cool to room temperature overnight. The product is then cooled with liquid nitrogen, dried and ground cryogenically to a fine powder using a Brinkmann centrifugal mill. EXAMPLE 2 C 36 Dimer Acid - 1,6-hexamethylene diamine - polyethylene glycol (PEG) capped with Ricinoleic Acid. A mixture of 62.71 g (0.540 moles) of molten 1,6-hexamethylene diamine, 70.78 g (0.176 moles) of a polyethylene glycol with an approximate molecular weight of 400 (PEG 400), 311.52 g (0.531 moles) of a C 36 dimer acid (Sylvadym T-18 commercial available from Arizona Chemicals), and 105.46 g (0.354 moles) of ricinoleic acid was added to a one liter resin flask equipped with a mechanical stirrer, a thermometer, and a nitrogen inlet. The reaction mixture is heated with stirring under a nitrogen blanket. Water begins to be evolved at approximately 150-155°C. After two hours at 190-195°C, aliquots are removed hourly and analyzed for acid number and the reaction is continued until the acid number reaches a value of 17. The reaction product is cooled to 140°C and is discharged into a stainless steel tray and allowed to cool to room temperature overnight. The product is then cooled with liquid nitrogen, dried and ground cryogenically to a fine powder using a Brinkmann centrifugal mill. COMPARATIVE EXAMPLE A C 36 Dimer Acid - 1,6-hexamethylene diamine - capped with Ricinoleic Acid. A mixture of 101.2 g (0.871 moles) of molten 1,6-hexamethylene diamine, 371.5 g (0.641 moles) of a C 36 dimer acid with a molecular weight of 580.0 (Sylvadym T-18 commercial available from Arizona Chemicals), and 127.3 g (0.427 moles) of ricinoleic acid was added to a one liter resin flask equipped with a mechanical stirrer, a thermometer, a Dean-Stark trap-Bartlett modification and a nitrogen inlet. The reaction mixture is heated with stirring under a nitrogen blanket. Water begins to be evolved at approximately 150-155°C. After two hours at 190-195°C, aliquots are removed hourly and analyzed for acid numbers and the reaction is continued until the acid number reaches a value of 4. The reaction product is cooled to 140°C and is discharged into a stainless steel tray and allowed to cool to room temperature overnight. The product is then cooled with liquid nitrogen, dried and ground cryogenically to a fine powder using a Brinkmann centrifugal mill. RHEOLOGICAL ADDITIVE REACTANTS AND CHARACTERISTICS Various reactants were used to prepare the rheological additives in Examples 3-19 in Table I below in accordance with the procedure set forth above. The reactants, the molar amounts thereof, the acid value as determined by titration, and the melting point are set forth below in Table I. In Table I: (a) Sylvadym 1-18 is dimerized fatty acid available from Arizona Chemicals and contains 82% dibasic acid, 18% polybasic acids, and (1% monobasic acid. (b) Ethomeen 18/15 is a polyoxyethylene (5) octadecylamine available from Akzo Chemicals, Inc. (c) Ethomeen C/15 is a polyoxyethylene (5) cocoamine available from Akzo Chemicals, Inc. (d) Ethomeen 18/12 is a bis(2-hydroxyethyl)octadecylamine available from Akzo Chemicals, Inc. (e) Varonic U205 Is a PEG 5 cetyl/stearylamine available from Sherex Chemical Company, Inc. PREPARATION OF PREDISPERSED RHEOLOGICAL ADDITIVE IN ORGANIC SOLVENT To evaluate the solution form of the solid rheological additive predispersed in organic solvent, samples of the additive which were prepared in the manner previously described were dissolved in varying amounts in organic solvents. The rheological additives and solvent solutions are set forth in Table II. Example No. Solid Rheological Additive (Ex. No.) Solvent and Weight % of Rheological Additive 20 1 41.8% in cyclohexanol 21 2 39.8% in cyclohexanol Comp. B Comp. A 30.0% in cyclohexanol: Aromatic 150 (1:1 weight ratio of solvent) 22 3 40.8% in cyclohexanol 23 4 40.2% in cyclohexanol 24 5 25 6 27 8 28 9 30 11 31 12 40.0% in cyclohexanol 32 13 39.2% in cyclohexanol 33 14 39.9% in cyclohexanol 34 15 40.0% in cyclohexanol 35 16 40.1% in cyclohexanol 36 17 40.0% in cyclohexanol 37 18 41.9% in cyclohexanol 38 19 36.2% in cyclohexanol EVALUATION OF RHEOLOGICAL ADDITIVES A number of the previously described samples were incorporated into a standard aliphatic alkyd gloss enamel at a loading of 3 pounds on the basis of solids per hundred gallons and a number of tests conducted to demonstrate the ease of dispersion and effectiveness of the rheological additive. The aliphatic alkyd gloss enamel paint was prepared by mixing the ingredients set forth in Formulation A in the order listed. The ingredients were mixed using a one horsepower Premier high speed dispersator equipped with a 1-5/8" diameter Cowles sawtooth blade. FORMULATION A: LONG OIL ALKYD ENAMEL Ingredient Generic Name Manufacturer [Pounds ] kg Aroplaz 1266 M70 Long Oil Soya Alkyd, 70% N.V. Reichhold Chemicals [105.76] 47.97 Mineral Spirits 66/3 Solvent Ashland Chemical [70.60] 32.02 Mix 5 minutes at 3000 rpm, then add TITANOX 2101 Rheological Additive Titanium Dioxide Kronos, Inc. [325.00] 147.42 Grind at 5,000 rpm for 15 minutes while maintaining the temperature at 43 - 49°C [110-120°F], unless otherwise indicated. Cool the paint to 57°C [135°F] and mix at 2,000 rpm while adding the following: Aroplaz 1266 M70 Long Oil Soya Alkyd, 70% N.V. Reichhold Chemicals [445.90] 202.26 6% Zirconium Nuxtra Drier Hüls [10.30] 4.67 6% Cobalt Nuxtra Drier Hüls [3.42] 1.55 Exkin #2 Anti-skinning Agent Hüls [2.00] 0.91 Mineral Spirits 66/3 Solvent Ashland Chemical [54.70] 24.83 Mix for 10 minutes at low speed Total (without rheological additive) [ 1017.68 ] 461.63 After the paints were allowed to equilibrate to room temperature overnight, the paint properties such as fineness of grind (indicative of dispersibility), Brookfield viscosity, Stormer viscosity, sag resistance, and gloss were measured. The fineness of grind was measured in Hegman units using a Hegman gauge in accordance with ASTM D1210-79. Brookfield viscosities at 10 and 100 rpm were measured with a Brookfield Viscometer Model RVT in accordance with ASTM D2196-81. From viscosity data, a Thixotropic Index (TI) was obtained as follows: Stormer viscosities were measured in Krebs Units (KU) with a Thomas Stormer Instrument, Model #09730-G15, in accordance with ASTM D562-81. Sag resistance was measured in mils using a Leneta Sag Multinotch applicator at room temperature in accordance with ASTM D4400-84. In some instances, gloss measurements were measured at 60° in accordance with ASTM D523-80. Drawdowns were prepared of paints prepared according to Formulation A, and the 60° gloss determined after curing the films for 24 hours at room temperature. The results of the tests are set forth in Table III below. COMPARATIVE EXAMPLE C A long oil aliphatic alkyd gloss enamel paint was prepared according to the procedures described in Formulation A without the addition of a rheological additive. The paint properties were evaluated and are set forth in Table III. Exam No. Fineness of Grind Brookfield Visc (cP) Thixotropic Index Stormer Visc (KU) Sag (mils) 60° Gloss 10 rpm 100 rpm 1 2 Comp A 20 6.5A 4160 1704 2.44 93 12 87 21 6A 2960 1316 2.25 86 9 -- Comp B 3A 2880 1500 1.92 90 7.5 87 22 6A 3560 1384 2.57 88 11 -- 23 5B 3320 1412 2.49 88 11 -- 24 25 27 28 30 31 6A 2840 1216 2.34 85 7.5 -- 32 6.5A 2280 1116 2.04 85 5 -- 33 6.5A 1440 948 1.52 82 3 -- 34 6.5A 1440 896 1.61 82 3 -- 35 6A 2760 1280 2.28 86 6 -- 36 6A 1320 924 1.43 84 3 -- 37 5.5A 1000 864 1.16 83 4 86 38 6.5A 880 760 1.16 80 3 -- Comp C 7A 650 670 0.97 78 3 90 A sample of the polyamide ester rheological additive of the present invention was evaluated for fineness of grind (ease of dispersibility), Brookfield viscosities, sag control and gloss using the procedures previously described in an aromatic alkyd gloss paint. The aromatic alkyd gloss paint was prepared by mixing the ingredients set forth in Formulation B in the order listed. The ingredients were mixed using a one horsepower Premier high speed dispersator equipped with a 1-5/8" diameter Cowles sawtooth blade. The rheological additive loading was equivalent to three pounds per hundred gallons on a solids basis. FORMULATION B: AROMATIC ALKYD GLOSS ENAMEL Ingredient Generic Name Manufacturer [Pounds ] Kg Duramac 2434 Medium Oil Alkyd Resin McWhorter, Inc. [212.0] 96.2 Xylene Solvent Ashland Chemical [60.0] 27.2 While stirring, slowly add: Rheological additive Mix for 5 minutes at 3000 rpm. Reduce speed and add: BYK 1045 Byk-Mallinckrodt Mallinckrodt, Inc. [10.0] 4.54 TITANOX 2101 Titanium Dioxide KRONOS, Inc. [280.0] 127.0 Grind at 5,000 rpm for 15 minutes while maintaining the temperature at 49°C [120°F]. Reduce speed to 2,000 rpm and add: Letdown: Duramac 2434 Medium Oil Alkyd Resin NcWhorter, Inc. [388.0] 176.0 Xylene Solvent Ashland Chemical [73.5] 33.34 6% Cobalt Drier Hüls [4.0] 1.81 Exkin #2 Anti-Skinning Agent Hüls [1.0] 0.45 Mix at low speed while cooling to 26.7°C [80°F]. Total (without rheological additive) [ 1028.5 ] 466.54 The paint properties were evaluated and are set forth in Table IV which shows the general use in other coating systems of the rheological additives of the present invention. Example No. Fineness of Grind Brookfield Visc (cP) Thixotropic Index Sag (mils) 60° Gloss 10 rpm 100 rpm 20 6.5A 2240 1132 1.98 11 90 Comp B 6.5A 2720 1184 2.30 14 90 A sample of the polyamide ester rheological additive of the present invention was evaluated for fineness of grind (ease of dispersibility), Brookfield viscosities, sag control and gloss using the procedures previously described in a high solids air dry aliphatic alkyd enamel paint. The high solids air-dry aliphatic enamel paint was prepared by mixing the ingredients set forth in Formulation C in the order listed. The ingredients were mixed using a one horsepower Premier high speed dispersator equipped with a 1-5/8" diameter Cowles sawtooth blade. The rheological additive loading was equivalent to three pounds per hundred gallons on a solids basis. FORMULATION C: HIGH SOLIDS AIR-DRY ALIPHATIC ENAMEL Ingredient Generic Name Manufacturer [Pounds ] Kg Beckosol 92-839 Alkyd Resin Reichhold Chemicals [200.00] 90.7 Mineral Spirits 66/3 Solvent Ashland Chemical [25.00] 11.3 Mix well: 6% Calcium Nuxtra Drier Hüls [5.84] 2.65 KRONOS 2101 Titanium Dioxide KRONOS, Inc. [381.50] 173.05 Rheological Additive Disperse at 5400 rpm for 15 minutes while maintaining the temperature at 52°C [125°F]. Then add: Letdown: Aromatic 100 Solvent Exxon Chemical [20.10] 9.12 Beckosol 92-839 Alkyd Resin Reichhold Chemicals [331.91] 150.55 Mineral Spirits 66/3 Solvent Ashland Chemical [102.60] 46.54 12% Cobalt Nuxtra Drier Hüls [1.95] 0.88 18% Zirconium Nuxtra Drier Hüls [9.84] 4.46 Exkin #2 Anti-Skinning Agent Hüls [0.50] 0.23 Total (without rheological additive) [ 1079.24 ] 489.5 The paint properties were evaluated and are set forth in Table V. Example No. Fineness of Grind Brookfield Visc (cP) Thixotropic Index Sag (mils) 60° Gloss 10 rpm 100 rpm 20 7A 4080 1330 3.07 20 86 Comp A 3.5A 840 582 1.44 3 89 A sample of the polyamide ester rheological additive of the present invention was evaluated for fineness of grind (ease of dispersibility), Brookfield viscosities, sag control and gloss using the procedures previously described in a high solids air-dry aromatic gloss enamel paint. The high-solids air-dry aromatic paint was prepared by mixing the ingredients set forth in Formulation D in the order listed. The ingredients were mixed using a one horsepower Premier high speed dispersator equipped with a 1-5/8" diameter Cowles sawtooth blade. The rheological additive loading was equivalent to three pounds per hundred gallons on a solids basis. FORMULATION D: HIGH SOLIDS AIR-DRY AROMATIC ENAMEL Ingredient Generic Name Manufacturer [Pounds ] Kg Aroplaz 6440-A4-85 Alkyd Resin Reichhold Chemicals [200.00] 90.7 Xylene Solvent Ashland Chemical [30.00] 13.6 Nuospere 700 Dispersant Hüls [5.00] 2.27 KRONOS 2101 Titanium Dioxide KRONOS, Inc. [350.00] 158.7 Rheological Additive Disperse at 5400 rpm for 15 minutes while maintaining the temperature at 52°C [125°F]. Then add: Letdown: Aroplaz 6440-A4-85 Alkyd Resin Reichhold Chemicals [300.00] 136 Xylene Solvent Ashland Chemical [190.00] 86.2 6% Zirconium Nuxtra Drier Hüls [8.00] 3.63 6% Calcium Nuxtra Drier Hüls [8.00] 3.63 6% Cobalt Nuxtra Drier Hüls [4.00] 1.81 Exkin #2 Anti-Skinning Agent Hüls [1.00] 0.45 Total (without rheological additive) [ 1096.00 ] 497 The paint properties were evaluated and are set forth in Table VI Exam No. Fineness of Grind Brookfield Visc (cP) Thixotropic Index Stormer Visc (KU) Sag (mils) 60° Gloss 10 rpm 100 rpm 20 7A 2960 1100 2.69 -- 12 89 Comp B 7A 2320 1012 2.29 -- 8 89 EFFECT OF INCORPORATION TEMPERATURE ON EFFECTIVENESS OF RHEOLOGICAL ADDITIVE To evaluate the effect of incorporation temperature on ease of dispersibility (as measured by fineness of grind) and thickening capabilities and paint sag control, the rheological additive of Example 21 was incorporated into Formulation A where the grind step was maintained at temperatures varying from 120 to 160°F. The rheological additive loading was equivalent to three pounds per hundred gallons on a solids basis. The paint properties were evaluated and are set forth in Table VII. Exam No. Incor. Temp. (°F) FOG Brookfield Visc (cP) T.I. Stormer Visc (KU) Sag (mils) 60° Gloss 10 rpm 100 rpm 21 120 6.5A 4640 1940 2.39 97 14 87 130 6.5A 5200 2112 2.46 98 14 87 140 6.5A 5440 2240 2.43 100 16 87 150 6.5A 6800 2568 2.64 102 18 85 160 6.5A 7360 2704 2.72 102 20 85

Claims: A rheological additive comprising the reaction product of: a) polycarboxylic acid; b) an active hydrogen compound having the formula X m -R-Y n , wherein R represents a group containing from 2 to 12 carbon atoms, X and Y are independently selected from primary amino, secondary amino and hydroxyl and m and n are at least 1 and the sum of (m+n) is at least 2 with the proviso that at least 25 % of the X and Y groups participating in the reaction are primary amino, secondary amino or a mixture thereof; c) an alkoxylated compound containing at least two active hydrogen groups, wherein the alkoxylated compound is selected from the group consisting of: (1) alkoxylated polyols that have two hydroxyl end groups and contain ethylene, propylene, or butylene oxide units, and (2) wherein q+r is 2 to 50, both q and r are at least 1, R 1 is a C 12 -C 22 alkyl group and R is hydrogen, methyl or ethyl, and d) a capping agent containing at least 25 mole percent of unsaturated and/or hydroxylated monocarboxylic acid, wherein, to form the reaction product, the amount of the active hydrogen compound reacted is from 0.25 to 2.0 moles per mole of the reacted polycarboxylic acid, the amount of the alkoxylated compound is from 0.1 to 1.5 mole per mole of the reacted polycarboxylic acid, with the proviso that less than 90 mole percent of the total active hydrogen groups are provided by primary and/or secondary amino groups, said reaction product having a molecular weight of from 600 to 15000. The rheological additive according to claim 1, wherein the polycarboxylic acid has from 5 to 20 atoms per carboxylic acid group. The rheological additive according to claim 1 or 2, wherein less than 5 percent by weight of a total amount of the polycarboxylic acid have three or more carboxylic acid groups. The rheological additive according to any of the claims 1 to 3, wherein the polycarboxylic acid is selected from the group consisting of oligomers of fatty acids of dimerized fatty acid, sebacic acid, poly(butadiene)dioic acids, dodecane dicarboxylic acid and mixtures thereof. The rheological additive according to any of the claims 1 to 4, wherein the active hydrogen compound having the formula X m -R-Y n is selected from the group consisting of polyamines including 1,2-diaminoethane, 1,2- and 1,3-diaminopropane, 1,4-diaminobutane, 1,6-diaminohexane, 1,8-diaminooctane, 1,12-diaminododecane, 3,3-diaminopropyl-N-methyl-amine, N-alkyl-1,3-diaminopropanes, wherein said alkyl group is coco or tallow alkyl, soya alkyl, oleyl, stearyl and mixtures thereof, and amino alcohols, including etanolamine, 6-aminohexanol, aminoethylethanolamine and mixtures thereof. The rheological additive according to any of the claims 1 to 5, wherein the reaction product is a reaction product of oligomer of fatty acid having a carbon chain of from 16 to 18 carbon atoms, diamine having from 6 to 12 carbon atoms, an ethoxylated C 12 -C 18 alkyl amine having 2 to 10 ethoxylated units, and unsaturated and hydroxylated monocarboxylic acid having from 8 to 22 carbon atoms as the capping agent. The rheological additive according to any of the claims 1 to 6, wherein the amount of the capping agent is from 0.3 to 2.0 moles per mole of the reacted polycarboxylic acid. The rheological additive according to any of the claims 1 to 7, wherein the capping agent is ricinoleic acid. A pre-dispersed mixture of a rheological additive as claimed in any of the claims 1 to 8 in an organic solvent. The pre-dispersed mixture of claim 9, wherein the organic solvent contains at least 50% by weight of an alcohol. The pre-dispersed mixture of claim 10, wherein the alcohol is cyclohexanol. The organic composition containing 0.1 to 5% by weight of a rheological additive as claimed in any one of the claims 1 to 8 or a pre-dispersed mixture according to any one of the claims 9 to 14. An organic composition according to claim 12 containing the rheological additive in an amount sufficient to prevent formation of large agglomerates which will develop during storage in the absence of said rheological additive. The organic composition according to claim 12 or 13 which contains aliphatic alkyd paints and aromatic solvent-based paints based on acrylic, alkyd, and polyester binders.

Inventors: COOPERMAN MURRAY C, REICHERT WILLIAM W, COOPERMAN, MURRAY C., REICHERT, WILLIAM W.
Applicants: RHEOX INT, RHEOX INTERNATIONAL, INC.
Application year: 1992
Main classification: C08G69
IPC codes: C09D7, C09K3, C08G69