Viscosity conditioner

Abstract: A viscosity conditioner is disclosed which comprises a compound structured to have a group of the following formula (1) where R is a hydrocarbyl group, R' is a branched or secondary hydrocarbyl group, and n ranges from 1 to 500. The specified viscosity conditioner is conducive to reduced temperature dependence and hence constant viscosity in a certain range suited for all environmental conditions and good coatability at all seasons. Also disclosed are an emulsion composition and an emulsion paint composition, each of which include of the viscosity conditioner.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to novel viscosity conditioners as well as to an emulsion composition and an emulsion paint composition utilizing such a viscosity conditioner. 2. Description of the Related Art A wide variety of viscosity builders are commonly known which are natural, semi-synthetic (carboxymethyl cellulose e.g.) or synthetic in character. Also, there are many known reaction products obtained by reaction of polyoxyethylene glycol derivatives with aliphatic acid esters or epoxides. Various other viscosity builders are also known as disclosed for instance in Japanese Patent Publication No. 52-25840, Japanese Patent Laid-Open No. 58-213074, Japanese Patent Publication No. 1-55292, Japanese Patent Publication No. 3-9151, Japanese Patent Publication No. 3-52766 and Japanese Patent Publication No. 4-55471. US Patent No. 4079028 discloses latex compounds containing polyurethane thickeners. The compounds disclosed in this document differ from those of the present invention in the nature of the terminal hydrocarbyl groups hereinafter defined as R'. Such known viscosity builders, however, pose the problem that their viscosities are liable to change under ambient temperatures. For example, a paint formulated with a viscosity conditioner and a viscosity builder is necessarily susceptible, if by nature dependent on temperature, to varying viscosities at the time it is coated in summer and in winter. Especially in a geographical area like Japan where the four seasons are clearly vary, the maximum temperature difference is frequently 30 to 40 °C between winter and summer seasons, so such viscosity changes with the seasons cause problems in the workability of the paint. The present applicant's EP-A-761779, which was published after the filing date of the present application, discloses viscosity conditioners and compositions containing the same. The viscosity conditioners of the present invention fall within the general disclosure of this document. However, EP-A-761779 does not disclose the specific viscosity conditioners of the present invention. SUMMARY OF THE INVENTION The present invention, therefore, has for its primary object to provide a viscosity conditioner which is less dependent on temperature, and thus, is highly capable of maintaining a constant range of viscosities suited for all environmental conditions and is adequately coatable throughout the year. Another object of the invention resides in the provision of an emulsion composition and of an emulsion paint composition, each of which include the above viscosity conditioner. To cope with the foregoing problems of the prior art, the present inventors have as a result of intensive research, developed a unique viscosity conditioner that has reduced temperature dependence, constant viscosity in a certain range to suit all environmental conditions and excellent coatability all the year round, coupled with an emulsion composition and an emulsion paint composition which each include of such viscosity conditioner. In one aspect, the present invention provides a viscosity conditioner comprising a compound represented by the formula (3) wherein: R and R 2 are each a hydrocarbylene group; R 3 is a hydrocarbyl group; R 1 is a hydrocarbylene group which may contain a urethane linkage; R' is a branched alkyl group of the following formula (4) where R 4 and R 5 are each a hydrocarbyl group and R 6 is a hydrocarbylene group, or a secondary alkyl group of the following formula (5) where R 7 and R 8 are each a hydrocarbyl group; n and k each range from 1 to 500; m is not less than 2; and h is not less than 1. In another aspect, the invention provides an emulsion composition including such viscosity conditioner. In a further aspect, the invention provides an emulsion paint composition including such viscosity conditioner. DETAILED DESCRIPTION OF THE INVENTION The viscosity conditioner according to the present invention is comprised of a compound represented by the formula (3) below. The formula (3) is as follows: where R and R 2 are each a hydrocarbylene group, R 3 is a hydrocarbyl group, R' is a branched alkyl group of formula (4), as defined above, or a secondary alkyl group of formula (5), as defined above, R 1 is a hydrocarbylene group which may have a urethane linkage, n and k each range from 1 to 500, m is not less than 2, and h is not less than 1. The viscosity conditioner of the formula (3) according to the present invention can be derived from reaction of one or more polyether polyols of formula R 3 -[(O-R 2 ) k -OH] m , one or more polyisocyanates of formula R 1 -(NCO) h+1 and one or more polyether monoalcohols of formula R'-(O-R) n -OH. To conduct such reaction, the groups R, R', R 1 , R 2 and R 3 are determined by the compounds of formulae R 3 -[(O-R 2 ) k -OH] m , R 1 -(NCO) h+1 and R'-(O-R) n -OH to be used. Though not restrictive with respect to the ratio of the three such compounds to be fed, it is preferred that the ratio between polyether polyol-induced and polyether monoalcohol-induced hydroxyl groups and a polyisocyanate-induced isocyanate group be set to range from 0.8 : 1 to 1.4 : 1 in terms of NCO/OH. In preparing the viscosity conditioner of the formula (3) according to the present invention, the polyether polyol compounds of formula R 3 -[(O-R 2 ) k -OH] m are not particularly limited insofar as they are composed of polyethers of m -valent alcohols. Such a compound can be prepared from addition polymerization of a polyol of valence m with an alkylene oxide such as ethylene oxide, propylene oxide, butylene oxide or epichlorohydrin, a styrene oxide. Polyols useful for that reaction are those of from divalence to octavalence, and their examples include divalent alcohols such as ethylene glycol, propylene glycol, butylene glycol, hexamethylene glycol and neopentyl glycol, trivalent alcohols such as glycerin, trioxyisobutane, 1,2,3-butanetriol, 1,2,3-pentanetriol, 2-methyl-1,2,3-propanetriol, 2-methyl-2,3,4-butanetriol, 2-ethyl-1,2,3-butanetriol, 2,3,4-pentanetriol, 2,3,4-hexane-triol, 4-propyl-3,4,5-heptanetriol, 2,4-dimethyl-2,3,4-pentanetriol, pentamethylglycerin,pentaglycerin, 1,2,4-butanetriol, 1,2,4-pentanetriol, trimethylolethane and trimethylolpropane, tetravalent alcohols such as pentaerythritol, 1,2,3,4-pentanetetrol, 2,3,4,5-hexane-tetrol, 1,2,4,5-pentanetetrol and 1,3,4,5-hexanetetrol, pentavalent alcohols such as adonite, arabite and xylite, heptavalent alcohols such as dipenta-erythritol, sorbite, mannite and idite, and octavalent alcohols such as sucrose. The group R 2 is determined by the kind of alkylene oxides or styrene oxides to be bonded. Alkylene oxides or styrene oxides of 2 to 4 carbon atoms are particularly preferable since they are easily available and highly conducive to excellent viscosity modification of the finished viscosity conditioner. The alkylene oxide or styrene oxide may be bonded to the group R 2 in conventional fashion by a mode of homopolymerization, or of block or random polymerization of two or more such oxides. The polymerization degree k is usually from 1 to 500, preferably from 1 to 200, more preferably from 10 to 200. The proportion of the ethylene group to be occupied in the group R 2 ranges preferably from 50 to 100% by weight, more preferably from 65 to 100% by weight, based on the total weight of the group R 2 so that excellent viscosity modification is attainable. The compounds of formula R 3 -[(O-R 2 ) k -OH] m preferably have a molecular weight of 500 to 50,000, more preferably of 1,000 to 20,000. In preparing the viscosity conditioner of the formula (3) according to the present invention, the polyisocyanates of formula R 1 -(NCO) h+1 are not particularly limited provided that they have two or more isocyanate groups in their molecules. These polyisocyanates are typified by aliphatic diisocyanates, aromatic diisocyanates, alicyclic diisocyanates, biphenyl diisocyanates, phenylmethane diisocyanates, triisocyanates and tetraisocyanates. Aliphatic diisocyanates used herein are chosen from methylene diisocyanate, dimethylene diisocyanate, trimethylene diisocyanate, tetramethylene diisocyanate, pentamethylene diisocyanate, hexamethylene diisocyanate, dipropylether diisocyanate, 2,2-dimethylpentane di-isocyanate, 3-methoxyhexane diisocyanate, octamethylene diisocyanate, 2,2,4-trimethylpentane diisocyanate, nona-methylene diisocyanate, decamethylene diisocyanate, 3-butoxyhexane diisocyanate, 1,4-butylene glycol dipropyl-ether diisocyanate, thiodihexyl diisocyanate, meta-xylylene diisocyanate, para-xylylene diisocyanate and tetramethylxylylene diisocyanate. Eligible aromatic diisocyanates include meta-phenylene diisocyanate, para-phenylene diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, di-methylbenzene diisocyanate, ethylbenzene diisocyanate, isopropylbenzene diisocyanate, tolidine diisocyanate, 1,4-naphthalene diisocyanate, 1,5-naphthalene diisocyanate, 2,6-naphthalene diisocyanate and 2,7-naphthalene diisocyanate. Eligible alicyclic diisocyanates include hydrogenated xylylene diisocyanate and isophorone diisocyanate. Eligible biphenyl diisocyanates include biphenyl diisocyanate, 3,3'-dimethylbiphenyl diisocyanate and 3,3'-dimethoxybiphenyl diisocyanate. Phenylmethane diisocyanates used herein are exemplified by diphenylmethane-4,4'-diisocyanate, 2,2'-dimethyldiphenylmethane-4,4'-diisocyanate, diphenyldimethylmethane-4,4'-diisocyanate, 2,5,2',5'-tetramethyl-diphenylmethane-4,4'-diisocyanate, cyclohexylbis(4-isocyanatophenyl)methane, 3,3'-dimethoxydiphenylmethane-4,4'-diisocyanate, 4,4'-dimethoxydiphenylmethane-3,3'-diisocyanate, 4,4'-diethoxydiphenylmethane-3,3'-diisocyanate, 2,2'-dimethyl-5,5'-dimethoxydiphenylmethane-4,4'-diisocyanate, 3,3'-dichlorodiphenyldimethylmethane-4,4'-diisocyanate and benzophenone-3,3'-diisocyanate. Triisocyanates used herein are chosen from 1-methyl-benzene-2,4,6-triisocyanate, 1,3,5-trimethylbenzene-2,4,6-triisocyanate, 1,3,7-naphthalene triisocyanate, biphenyl-2,4,4'-triisocyanate, diphenylmethane-2,4,4'-tri-isocyanate, 3-methyldiphenylmethane-4,6,4'-triisocyanate, triphenylmethane-4,4',4"-triisocyanate, 1,6,11-undecane triisocyanate, 1,8-diisocyanate-4-isocyanatemethyloctane, 1,3,6-hexamethylene triisocyanate, bicycloheptane tri-isocyanate and tris(isocyanatephenyl)thiophosphate. The polyisocyanate compounds exemplified above may be by nature dimeric or trimeric (isocyanurate-linked), or in the form of a biuret derived from reaction with an amine. Urethane linkage-containing polyisocyanate compounds may also be suitably employed which are obtained by reaction of a polyisocyanate selected from among the above listed polyisocyanates with a given polyol. Eligible polyols used here are those configured to be from divalent to octavalent in nature and are preferably selected from divalent alcohols such as ethylene glycol, propylene glycol, butylene glycol, hexamethylene glycol and neopentyl glycol, trivalent alcohols such as glycerin, trimethylolethane and trimethylolpropane, tetravalent alcohols such as pentaerythritol, pentavalent alcohols such as adonite, arabite and xylite, heptavalent alcohols such as dipentaerythritol, sorbite, mannite and idite, and octavalent alcohols such as sucrose, and oligomers thereof, adducts thereof with alkylene oxides and adducts thereof with caprolactones. Such an urethane-linked poly-isocyanate is preferable when a trivalent or higher polyvalent polyisocyanate is suitable as R 1 -(NCO) h+1 . In preparing the viscosity conditioner of the formula (3) according to the present invention, the polyether monoalcohols of formula R'-(O-R) n -OH are not particularly restricted provided that they are polyethers induced from branched or secondary monovalent alcohols of formula (4') or (5') below. Such a compound can be derived from addition polymerization of a branched or secondary monovalent alcohol with an alkylene oxide such as ethylene oxide, propylene oxide, butylene oxide or epichlorohydrin, a styrene oxide. The branched alcohol stated above is represented by the following formula (4'). The above secondary alcohol is represented by the following formula (5'). It is noted, therefore, that the group R' denotes the residue formed by removing a hydroxyl group from each of the compounds of formulae (4') and (5'). In the formulae (4) and (5), R 4 , R 5 , R 7 and R 8 are each a hydrocarbyl group selected for example from an alkyl group, an alkenyl group, an alkylaryl group, a cycloalkyl group and a cycloalkenyl group, and R 6 is a hydrocarbylene group, for example, an alkylene group, an alkenylene group, an alkylarylene group, a cycloalkylene group and a cycloalkenylene group. Alkyl groups eligible for the present invention are chosen among from methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tertiary butyl, pentyl, isopentyl, neopentyl, tertiary pentyl, hexyl, heptyl, octyl, 2-ethylhexyl, nonyl, decyl, undecyl, dodecyl, tridecyl, isotridecyl, myristyl, palmityl, stearyl, eicosyl, docosyl, tetracosyl, triacontyl, 2-octyldodecyl, 2-dodecylhexadecyl, 2-tetra-decyloctadecyl and monomethyl branched-isostearyl groups. Suitable alkenyl groups include vinyl, allyl, propenyl, isopropenyl, butenyl, isobutenyl, pentenyl, isopentenyl, hexenyl, heptenyl, octenyl, nonenyl, decenyl, undecenyl, dodecenyl, tetradecenyl and oleyl groups. Suitable alkylaryl groups include phenyl, toluyl, xylyl, cumenyl, mesityl, benzyl, phenethyl, styryl, cinnamyl, benzhydryl, trityl, ethylphenyl, propylphenyl, butylphenyl, pentylphenyl, hexylphenyl, heptylphenyl, octylphenyl, nonylphenyl, alpha-naphthyl and beta-naphthyl groups. Cycloalkyl and cycloalkenyl groups used herein are exemplified by cyclopentyl, cyclohexyl, cycloheptyl, methylcyclopentyl, methylcyclohexyl, methylcycloheptyl, cyclopentenyl, cyclohexenyl, cycloheptenyl, methyl-cyclopentenyl, methylcyclohexenyl and methylcycloheptenyl groups. In the formula (4), the group R 6 is a hydrocarbylene group such as, for example, an alkylene group, an alkenylene group, an alkylarylene group, a cycloalkylene group or a cycloalkenylene group. A group -CH 2 - is particularly suitable for use in the group R 6 since an alcohol branched at its 2-position is less dependent in viscosity on temperature. R' is a branched or secondary alkyl group of formula (4) or (5) above. The carbon number in the R' group totals preferably from 8 to 36, more preferably from 12 to 24. More specifically, each of the groups R 4 , R 5 , R 7 and R 8 in the formulae (4) and (5) should preferably have 4 or more carbon atoms, thereby rendering the viscosity of the resultant branched or secondary alcohol less dependent on temperature. The alkylene oxide or styrene oxide may be bonded by homopolymerization, or by random or block poly-merization of two or more such oxides. In this instance, any known method is suitable. The polymerization degree n is in the range of 1 to 500, preferably of 1 to 200, more preferably of 10 to 200. The proportion of the ethylene group to be occupied in the group R is preferably from 50 to 100% by weight, more preferably from 65 to 100% by weight, based on the total weight of the group R, and strict observance of this proportion leads to enhanced performance in viscosity modification. The compound of the formula (3) can be prepared as is usually done with the reaction of a polyether with an isocyanate. For example, reaction temperatures may be at 80 to 90°C with reaction times of 1 to 3 hours. In the case where the polyether polyol (a) of formula R 3 -[(O-R 2 ) k -OH] m , the polyisocyanate (b) of formula R 1 -(NCO) h+1 and the polyether monoalcohol (c) of formula R'-(O-R) n -OH are allowed to react with one another, some by-products tend to be formed which deviate from the structural formula (3). For example, use of a diisocyanate leads to the production of a compound of a c-b-a-b-c form as a main or desired product of the formula (3), often entailing formation of by-products such as a c-b-c form type compound and a c-b-(a-b) x -a-b-c form compound. In that instance, the compound of the formula (3) does not need to be isolated from the resultant reaction mixture containing such by-products; that is, the reaction mixture may be applied as produced and as a viscosity conditioner contemplated under the present invention. The viscosity conditioner of the present invention, comprised of a compound represented by the formula (3), provides those physical properties which have not been achieved with the foregoing viscosity builders of the prior art. For example, the viscosity conditioner of the invention is by nature nonionic, and though relatively low in molecular weight, it shows good viscosity increase even when added in a smaller amount to aqueous systems. It is moreover stable to water and to alcohol. In particular, upon application to emulsion paints, such viscosity conditioner is highly capable not only of bringing about a sufficient viscosity increase, but also of contributing in most cases to excellent fluidity and leveling properties and to outstanding performance of viscosity modification under both low- and high-sheared conditions. Also, the viscosity conditioner of the present invention advantageously offers a specific property of temperature sensitivity that the prior art viscosity builders have failed to gain. Owing to the temperature sensitivity, the viscosity conditioner is less dependent on temperature, fully constant in a certain range of viscosities held for all environmental conditions and adequately coatable in all seasons. These advantages are peculiar to the present invention and due to the fact that the group R' in the formula (3) is specifically defined as a branched or secondary alkyl group of formula (4) or (5), namely, to the fact that a branched or secondary alcohol of formula (4') or (5') is selectively used as a starting material in providing the group R' of the formula (3). The viscosity conditioner of the present invention is applicable to aqueous systems such as emulsions, latices and dispersible fluids (such as suspensions and dispersions). Polymeric emulsions of a vinyl acetate type are chosen for example from homopolymer emulsions of a vinyl acetate monomer, and copolymer emulsions of a vinyl acetate monomer with a comonomer such as ethylene, vinyl chloride, acrylic acid, acrylate ester, methacrylic acid, methacrylate ester, beova, maleic acid or maleate ester. Suitable polymeric emulsions of an acrylic type include homopolymer emulsions of a monomer such as acrylic acid, acrylate ester, methacrylic acid, methacrylate ester or acrylonitrile, copolymer emulsions of two or more such monomers, and copolymer emulsions of one such monomer with styrene. Suitable polymeric emulsions of a vinylidene type include homopolymer emulsions of a vinylidene chloride monomer, and copolymer emulsions of a vinylidene chloride monomer with a comonomer such as acrylic acid, acrylate ester, methacrylic acid, methacrylate ester, acrylonitrile or vinyl chloride. Included in other suitable polymeric emulsions are urethane resin emulsions, silicone resin emulsions, epoxy resin emulsions and fluorine resin emulsions. Eligible latexes are exemplified for example by SBR latex, SB latex, ABS latex, NBR latex, CR latex, VP latex, BR latex, MBR latex and IR latex. When dissolved or dispersed in water, the viscosity conditioner of the present invention can produce its effects of viscosity modification and may be used usually in an amount of 0.01 to 10%, preferably of 0.01 to 5%, based on the solid content of a given polymeric emulsion or on the total weight of a given latex. To the emulsion or latex may be added the viscosity conditioner as it is, or after it is diluted to a suitable viscosity with water or solvent. For use in emulsion paints, the viscosity conditioner of the invention may be incorporated as an aqueous solution in ethyl alcohol at a kneading stage or at a modifying stage of such an emulsion paint, whereby workability is facilitated with the viscosity conditioner added in an amount of 0.01 to 5%. The polymeric emulsions stated above can be prepared by the use of one or more anionic, cationic or nonionic emulsifiers. Two or more emulsifiers may be employed as admixed with one another irrespective of their types. The amount of the emulsifier to be used is from about 0.1 to 6% by weight based on the total weight of a selected monomer and may in some cases be larger than 6% by weight. Frequently, where an initiator of a persulfate salt type is employed, no emulsifiers may be needed. The average molecular weights of those emulsion polymers are generally from 1x10 5 to 1x10 7 and mostly above 5x10 5 . The viscosity conditioner of the present invention is nonionic in nature and thus effective also for polymeric emulsions of an alkaline class. Such viscosity conditioner may be added to such an emulsion together with a defoamer, a pigment dispersant and a surfactant. The viscosity conditioner may also contain or may subsequently be mixed with various other additives such as antioxidants, ultraviolet absorbers, water-proofing agents, anti-septic agents, bactericides, dispersants, anti-foaming agents, deodorizers, perfumes, extenders, dyes and pigments. Other aqueous systems suitable for the viscosity conditioner of the present invention are aqueous paint compositions for use in the paper, leather and textile industries, detergents, adhesives, waxes, polishing agents, cosmetics and toiletry goods, pharmaceuticals, agricultural chemicals and agricultural compositions. As discussed hereinabove, a novel viscosity conditioner, an emulsion composition and an emulsion paint composition each including such a viscosity conditioner are provided in accordance with the present invention. Now, the viscosity conditioner of the formula (3) according to the present invention will be illustrated with reference to Production Examples 10 to 24 and Examples 5 to 8 together with Comparative Production Examples 4 to 8. Production Example 10 Into a 4-necked flask of 1,000 ml in volume equipped with a thermometer, a nitrogen inlet and a stirrer were charged 480 parts by weight of polyethylene glycol (PEG) 6000 (molecular weight: 6,000), and 198 parts by weight of an adduct of the formula formed by reacting a branched alcohol of the formula with 20 mols of ethylene oxide (EO). The reactive system was dehydrated in vacuo (below 10 mm Hg) at 90 to 100°C for 3 hours until the moisture in the system was reduced to 0.03%. On subsequent cooling of the reactive system to 80 °C, 29.6 parts by weight of hexamethylene diisocyanate (HMDI) was placed in the flask. Reaction was then effected in a nitrogen stream at 80 to 90°C for 2 hours, after which the isocyanate content was confirmed to be nil. Thus, a reaction product of the invention was obtained which was a pale yellowish solid at normal temperature. This product is hereunder called Viscosity Conditioner 10 (R: ethylene group; R': 2-octyldodecyl group; R 1 : hexamethylene group; R 2 : ethylene group; R 3 : ethylene group; h=1; m=2; k=67; n=20). Production Example 11 The process for Production Example 10 was followed except that 522 parts by weight of PEG 6000, 145 parts by weight of an adduct of the formula formed by reacting a branched alcohol of the formula with 10 mols of EO, and 32.2 parts bt weight of HMDI were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 11 (R: ethylene group; R': 2-decyltetradecyl group; R 1 : hexamethylene group; R 2 : ethylene group; R 3 : ethylene group; h=1; m=2; k=67; n=10). Production Example 12 The process for Production Example 10 was followed except that 580 parts by weight of PEG 20000, 109 parts by weight of an adduct of the formula formed by reacting a branched alcohol of the formula with 35 mols of EO, and 11.1 parts by weight of tolylene di-isocyanate (TDI) were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 12 (R: ethylene group; R': 2-hexyldecyl group; R 1 : tolylene group; R 2 : ethylene group; R 3 : ethylene group; h=1; m=2; k=226; n=35). Production Example 13 The process for Production Example 10 was followed except that 360 parts by weight of PEG 6000, 303 parts by weight of an adduct of a secondary alcohol of 11 to 14 carbon atoms with 50 mols of EO, and 22.2 parts by weight of HMDI were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 13 (R: ethylene group; R': compound of the formula R 1 : hexamethylene group; R 2 : ethylene group; R 3 : ethylene group; h=1; m=2; k=67; n=50). Production Example 14 The process for Production Example 10 was followed except that 120 parts by weight of PEG 2000, 315 parts by weight of an adduct of a secondary alcohol of 11 to 14 carbon atoms with 100 mols of EO, and 18.5 parts by weight of tetramethylene diisocyanate were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 14 (R: ethylene group; R': same group as in Production Example 13; R 1 : tetramethylene group; R 2 : ethylene group; R 3 : ethylene group; h=1; m=2; k=22; n=100). Production Example 15 The process for Production Example 10 was followed except that 550 parts by weight of PEG 10000, 133 parts by weight of an adduct of the formula formed by reacting a branched alcohol of the formula with 50 mols of EO, and 20.4 parts by weight of HMDI were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 15 (R: ethylene group; R 1 : hexamethylene group; R 2 : ethylene group; R 3 : ethylene group; h=1; m=2; k=112; n=50). Production Example 16 The process for Production Example 10 was followed except that 367 parts by weight of an adduct of trimethylolpropane with 100 mols of EO, 286 parts by weight of an adduct of the formula formed by reaction of a branched alcohol of the formula with 20 mols of EO, and 40.8 parts by weight of HMDI were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 16 (R: ethylene group; R': 2-octyldodecyl group; R 1 : hexamethylene group; R 2 : ethylene group; R 3 : trimethylolpropane moiety; h=1; m=3; k=100; n=20). Production Example 17 The process for Production Example 10 was followed except that 603 parts by weight of a compound of the formula HO-(C 2 H 4 O) 80 -(C 3 H 6 O) 30 -(C 2 H 4 O) 80 -H 82.7 parts by weight of a compound of the formula and 11.3 parts by weight of HMDI were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 17 (R: ethylene group; R': 2-decyl-tetradecyl group; R 1 : hexamethylene group; (O-R 2 ) k : (C 3 H 6 O) 15 -(C 2 H 4 O) 80 ; R 3 : propylene group; h=1; m=2; n=20). Production Example 18 The process for Production Example 10 was followed except that 429 parts by weight of an adduct of pentaerythritol with 50 mols of EO, 226 parts by weight of an adduct of the formula formed by reaction of a branched alcohol of the formula with 20 mols of EO, and 36.5 parts by weight of xylylene diisocyanate were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 18 (R: ethylene group; R': 2-octyldodecyl group; R 1 : xylylene group; R 2 : ethylene group; R 3 : pentaerythritol moiety; h=1; m=4; k=50; n=20). Production Example 19 The process for Production Example 10 was followed except that 435 parts by weight of an adduct of dipentaerythritol with 35 mols of EO, 257 parts by weight of an adduct of a branched alcohol of the formula formed by reaction of a branched alcohol of the formula with 10 mols of EO, and 48.6 parts by weight of TDI were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 19 (R: ethylene group; R': 2-hexadecyloctadecyl group; R 1 : tolylene group; R 2 : ethylene group; R 3 : dipentaerythritol moiety; h=1; m=6; k=35; n=10). Production Example 20 The process for Production Example 10 was followed except that 431 parts by weight of an adduct of trimethylolpropane with 100 mols of EO and also with 50 mols of propylene oxide (PO), 214 parts by weight of a compound of the formula and 30.6 parts by weight of TDI were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 20 (R: ethylene group; R': 2-butyloctyl group; R 1 : tolylene group; (O-R 2 ) k : (C 2 H 4 O) 100 -(C 3 H 6 O) 50 ; R 3 : trimethylolpropane moiety; h=1; m=3; k=100, 50; n=10, 5). Production Example 21 The process for Production Example 10 was followed except that 540 parts by weight of a compound of the formula HO-(C 2 H 4 O) 110 -(C 3 H 6 O) 43 -(C 2 H 4 O) 110 -H 133 parts by weight of a compound of the formula and 18.6 parts by weight of 1,3,6-hexamethylene triisocyanate were used. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 21 (R: ethylene group; R': 2-octyldodecyl group; R 1 : hexanetriyl group; (O-R 2 ) k : (C 3 H 6 O) 21 -(C 2 H 4 O) 110 ; R 3 : propylene group; h=2; m=2; n=10). Production Example 22 The process for Production Example 10 was followed except that use was made of 420 parts by weight of PEG 6000, 283 parts by weight of an adduct of the formula formed by reaction of a branched alcohol of the formula with 20 mols of EO, and 72.7 parts by weight of a triisocyanate prepared from 1 mol of trimethylolpropane and 13 mols of HMDI. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 22 (R: ethylene group; R': 2-decyltetradecyl group; R 1 : trimethylolpropane-HMDI moiety; R 2 : ethylene group; R 3 : ethylene group; h=2; m=2; k=67; n=20). Production Example 23 The process for Production Example 10 was followed except that use was made of 43.5 parts by weight of an adduct of trimethylolpropane with 35 mols of EO, 578 parts by weight of an adduct of the formula formed by reaction of a branched alcohol of the formula with 50 mols of EO, and 64.9 parts by weight of a tetraisocyanate derived from 1 mol of pentaerythritol and 4 mols of TDI. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 23 (R: ethylene group; R 1 : pentaerythritol-TDI moiety; R 2 : ethylene group; R 3 : trimethylolpropane moiety; h=3; m=3; k=35; n=50). Production Example 24 The process for Production Example 10 was followed except that use was made of 200 parts by weight of PEG 20000, 464 parts by weight of an adduct formed by reaction of a branched alcohol of the formula with 100 mols of EO, and 24.4 parts by weight of a hexaisocyanate derived from 1 mol of dipentaerythritol and 6 mols of HMDI. Thus, a pale yellowish solid product was obtained. This product is called Viscosity Conditioner 24 (R: ethylene group; R': 2-hexyldecyl group; R 1 : dipentaerythritol-HMDI moiety; R 2 : ethylene group; R 3 : ethylene group; h=5; m=2; k=226; n=100). Comparative Production Example 4 Into a 4-necked flask of 1,000 ml in volume equipped with a thermometer, a nitrogen inlet and a stirrer were charged 534 parts by weight of PEG 6000, and 133 parts by weight of an adduct of stearyl alcohol with 10 mols of EO. The reactive system was dehydrated in vacuo (below 10 mm Hg) at 90 to 100 °C for 3 hours until the moisture in the system was lowered to 0.03%. Upon cooling of the reactive system to 80°C, 32.8 parts by weight of HMDI was placed in the flask. Reaction was then effected in a nitrogen stream at 80 to 90 °C for 2 hours, after which the isocyanate content was confirmed to be nil. Thus, a comparative reaction product was obtained which was a pale yellowish solid at normal temperature. This product is hereunder called Comparative Product 4. Comparative Production Example 5 The process for Comparative Production Example 4 was followed except that 580 parts by weight of PEG 20000, 107 parts by weight of an adduct of nonylphenol with 35 mols of EO, and 11.1 parts by weight of TDI. Thus, a pale yellowish solid product was obtained. This product is called Comparative Product 5. Comparative Production Example 6 The process for Comparative Production Example 4 was followed except that 168 parts by weight of PEG 6000, 505 parts by weight of an adduct of nonylphenol with 200 mols of EO, and 9.4 parts by weight of HMDI were used. Thus, a pale yellowish solid product was obtained. This product is called Comparative Product 6. Comparative Production Example 7 The process for Comparative Production Example 4 was followed except that 441 parts of a compound of the formula HO-(C 2 H 4 O) 80 -(C 3 H 6 O) 30 -(C 2 H 4 O) 80 -H 292 parts by weight of an adduct of lauryl alcohol with 50 mols of EO and also with 10 mols of PO, and 16.5 parts by weight of HMDI were used. Thus, a pale yellowish solid product was obtained. This product is called Comparative Product 7. Comparative Production Example 8 The process for Comparative Production Example 4 was followed except that 397 parts by weight of an adduct of trimethylol-propane with 50 mols of EO, 241 parts by weight of an adduct of stearyl alcohol with 10 mols of EO, and 59.8 parts by weight of TDI were used. Thus, a pale yellowish solid product was obtained. This product is called Comparative Product 8. An amount of 40 parts by weight of each of Viscosity Conditioners 10 to 24 according to the present invention and of Comparative Products 4 to 8 was mixed in uniform condition with 10 parts by weight of butyl cellosolve and 50 parts by weight of water, whereupon there was provided a transparent liquid composition, namely each of Compositions 10 to 24 and of Comparative Compositions 4 to 8. The viscosities of these test compositions are indicated below. (1 cP = 1 mPa.s) Composition 10 about 4,500 cPs Composition 11 about 4,000 cPs Composition 12 about 7,500 cPs Composition 13 about 5,000 cPs Composition 14 about 5,500 cPs Composition 15 about 5,000 cPs Composition 16 about 4,000 cPs Composition 17 about 4,500 cPs Composition 18 about 5,500 cPs Composition 19 about 5,500 cPs Composition 20 about 4,000 cPs Composition 21 about 5,500 cPs Composition 22 about 4,500 cPs Composition 23 about 6,000 cPs Composition 24 about 7,000 cPs Comparative Composition 4 about 2,000 cPs Comparative Composition 5 about 2,500 cPs Comparative Composition 6 about 6,000 cPs Comparative Composition 7 about 4,500 cPs Comparative Composition 8 about 3,000 cPs Example 5: Evaluation with Emulsions Formulation: emulsion (for gloss coating; acrylate ester type; commercially available) 100.0 g viscosity conditioner (each of inventive and comparative products; aqueous solution of 10% in solid content) 0.5 g anti-foaming agent (Adekanate B-940; mineral oil type; Asahi Denka Kogyo K.K.) 0.2 g The above formulation was hand-stirred for 5 minutes, followed by mechanical stirring (at 1,000 rpm). After being allowed to stand for 2 hours at each of three selected temperatures (5, 25 and 40 °C), the resulting emulsion compositions, inventive compositions 10 to 24 and comparative compositions 4 to 8, were measured in respect of their viscosities. The measurement was made under a set of conditions given below: viscometer: BM viscometer rotor: No. 4 revolution: 12 rpm The results are shown in Table 6. viscosity conditioner 5°C (cPs) 25 °C (cPs) 40 °C (cPs) 40 °C/5 °C Composition 10 11,000 9,200 8,000 0.73 Composition 11 11,500 10,200 10,200 0.89 Composition 12 8,500 7,400 6,000 0.71 Composition 13 6,800 6,800 6,700 0.99 Composition 14 7,900 7,500 6,900 0.87 Composition 15 15,400 13,500 13,000 0.84 Composition 16 6,000 5,800 5,500 0.92 Composition 17 4,000 3,800 3,700 0.93 Composition 18 7,100 6,900 6,500 0.92 Composition 19 9,800 9,800 9,700 0.99 Composition 20 3,500 3,400 3,400 0.97 Composition 21 10,000 9,700 9,000 0.90 Composition 22 3,300 3,100 3,100 0.94 Composition 23 12,800 12,800 12,000 0.94 Composition 24 5,600 5,500 5,100 0.91 Comparative Composition 4 8,300 5,100 3,100 0.37 Comparative Composition 5 9,700 6,000 4,200 0.43 Comparative Composition 6 11,000 6,000 2,500 0.23 Comparative Composition 7 7,500 3,000 1,300 0.17 Comparative Composition 8 6,500 1,000 530 0.08 The above testing was repeated with the exception of use of a different emulsion for use in elastic coating (styrene-acrylate ester type; commercially available) and a different grade of anti-foaming agent (Adekanate B-190; silicone type; Asahi Denka Kogyo K.K.). The results are listed in Table 7. viscosity conditioner 5°C (cPs) 25 °C (cPs) 40 °C (cPs) 40 °C/5 °C Composition 10 26,000 25,700 23,100 0.89 Composition 11 19,800 19,000 17,100 0.86 Composition 12 20,200 19,800 17,200 0.85 Composition 13 23,300 23,000 22,400 0.96 Composition 14 23,000 22,800 22,600 0.98 Composition 15 38,400 38,400 37,000 0.96 Composition 16 41,000 38,200 38,000 0.93 Composition 17 48,000 48,000 47,100 0.98 Composition 18 27,500 27,000 25,500 0.93 Composition 19 55,300 53,800 53,300 0.96 Composition 20 21,000 20,800 19,900 0.95 Composition 21 43,300 42,800 42,500 0.98 Composition 22 62,100 61,600 60,900 0.98 Composition 23 51,300 50,500 50,500 0.98 Composition 24 33,200 32,500 32,400 0.98 Comparative Composition 4 27,800 12,300 10,000 0.36 Comparative Composition 5 31,200 10,600 3,300 0.11 Comparative Composition 6 35,300 21,000 9,500 0.27 Comparative Composition 7 41,000 13,000 3,500 0.09 Comparative Composition 8 38,300 22,000 5,900 0.15 Example 6: Evaluation with Elastic Paints Formulation: water 90 parts by weight viscosity conditioner (each of inventive and comparative products) 70 parts by weight pigment dispersant (25% polycarboxylic acid type) 10 parts by weight anti-freeze agent (ethylene glycol) 20 parts by weight anti-foaming agent (Adekanate B-940; Asahi Denka Kogyo K.K.) 2 parts by weight titanium oxide 140 parts by weight calcium carbonate 160 parts by weight The mixture thus formulated was stirred for 24 hours and eventually used as a mill base. This base was then formulated as below. Formulation: mill base 493 parts by weight emulsion (for elastic coating; styrene-acrylate ester type; available in commerce) 410 parts by weight anti-foaming agent (Adekanate B-190) 3 parts by weight Stirring was done for 5 hours, and each of the finished paints was let to stand for 2 hours at three different temperatures (5, 25 and 40°C) and then checked for viscosities under the following set of conditions: viscometer: BM viscometer rotor: No. 4 revolution: 30 rpm The results are shown in Table 8. viscosity conditioner 5°C (cPs) 25 °C (cPs) 40 °C (cPs) 40 °C/5 °C Composition 10 41,000 39,300 36,500 0.89 Composition 11 25,200 24,600 22,100 0.88 Composition 12 39,300 29,200 27,500 0.70 Composition 13 15,100 14,800 14,000 0.93 Composition 14 22,100 21,900 19,800 0.90 Composition 15 33,500 32,000 30,800 0.92 Composition 16 65,300 65,000 65,000 1.00 Composition 17 72,100 70,000 68,800 0.95 Composition 18 55,300 53,300 53,300 0.96 Composition 19 66,800 65,000 63,200 0.95 Composition 20 48,200 48,200 47,900 0.99 Composition 21 76,800 75,600 75,500 0.98 Composition 22 35,800 35,800 34,500 0.96 Composition 23 91,500 90,800 89,600 0.98 Composition 24 44,300 43,500 42,900 0.97 Comparative Composition 4 21,700 15,900 7,600 0.35 Comparative Composition 5 32,300 23,000 12,300 0.38 Comparative Composition 6 45,100 30,000 16,000 0.35 Comparative Composition 7 41,800 22,000 9,500 0.23 Comparative Composition 8 62,200 28,500 11,100 0.18 As evidenced from Examples 5 and 6 above, Viscosity Conditioners 10 to 24 of the present invention produce those emulsions which are less susceptible to viscosity changes with temperature. This is because such viscosity conditioners were produced by the use of a selected class of branched or secondary alcohols as starting materials with eventual chemical attachment of a branched chain or a secondary hydrocarbon chain to the group R'. By contrast, Comparative Products 4 to 8 in common use involved great changes in viscosity with temperature since the products were prepared by the use of straight alcohols as starting materials and thus were configured to be terminated by a straight hydrocarbon chain. Example 7: Color Toning and Water Resistance with Emulsions Furthermore, the following testing was performed to evaluate performance of the viscosity conditioner of the present invention when used for an emulsion paint. Formulation: emulsion (acrylate ester type) 40.0 g black pigment 0.8 g anti-foaming agent (Adekanate B-940) 0.1 g Hand mixing of this formulation was done for 1 minute, followed by homogenization through mechanical stirring with a large turbine impeller for 10 to 20 minutes at 1,000 to 2,000 rpm. The resultant emulsion was coated over a slate plate. Color toning was adjudged in respect of any appreciable color changes at three points of the emulsion, i.e., (1) wet-on-wet coating, (2) coated surface texture upon finger rubbing and (3) coat sagging, as compared to the coated surface obtained with a single coating. Water resistance was determined by inspecting the state of the coat after being immersed in a warm water of 50°C for 24 hours. The results are listed in Table 9 in which the symbol "o" is taken as "not different", "_" as "slightly different" and "x" as "largely different". Viscosity Conditioner color tone water resistance point 1 point 2 point 3 Composition 10 ○ ○ ○ not different Composition 11 ○ ○ ○ not different Composition 12 ○ ○ ○ not different Composition 13 ○ ○ ○ not different Composition 14 ○ ○ ○ not different Composition 15 ○ ○ ○ not different Composition 16 ○ ○ ○ not different Composition 17 ○ ○ ○ not different Composition 18 ○ ○ ○ not different Composition 19 ○ ○ ○ not different Composition 20 ○ ○ ○ not different Composition 21 ○ ○ ○ not different Composition 22 ○ ○ ○ not different Composition 23 ○ ○ ○ not different Composition 24 ○ ○ ○ not different Comparative Composition 4 ― ○ × slightly blistered Comparative Composition 5 × ― ○ greatly blistered Comparative Composition 6 × × ― greatly blistered Comparative Composition 7 × ― × slightly blistered Comparative Composition 8 ○ ― × greatly blistered Example 8: Color Toning and Water Resistance with Paints Formulation: paint used in Example 6 40.0 g black pigment 0.8 g anti-foaming agent (Adekanate B-940) 0.1 g Hand mixing of this formulation was done for 1 minute, followed by homogenization through mechanical stirring with a large turbine impeller for 10 to 20 minutes at 1,000 to 2,000 rpm. The resultant emulsion was coated over a slate plate. Color toning was adjudged in respect of any appreciable color changes at three points of the emulsion, i.e., (1) wet-on-wet coating, (2) coated surface texture upon finger rubbing and (3) coat sagging, as compared to the coated surface obtained with a single coating. Water resistance was determined by inspecting the state of the coat after being immersed in a warm water of 50°C for 24 hours. The results are listed in Table 10 in which the symbol "o" is taken as "not different", "_" as "slightly different" and "x" as "largely different". Viscosity Conditioner color toning water resistance point 1 point 2 point 3 Composition 10 ○ ○ ○ not different Composition 11 ○ ○ ○ not different Composition 12 ○ ○ ○ not different Composition 13 ○ ○ ○ not different Composition 14 ○ ○ ○ not different Composition 15 ○ ○ ○ not different Composition 16 ○ ○ ○ not different Composition 17 ○ ○ ○ not different Composition 18 ○ ○ ○ not different Composition 19 ○ ○ ○ not different Composition 20 ○ ○ ○ not different Composition 21 ○ ○ ○ not different Composition 22 ○ ○ ○ not different Composition 23 ○ ○ ○ not different Composition 24 ○ ○ ○ not different Comparative Composition 4 × ― ○ slightly blistered Comparative Composition 5 ― × × slightly blistered Comparative Composition 6 ○ × × greatly blistered Comparative Composition 7 ― × ― slightly blistered Comparative Composition 8 × × ○ greatly blistered As is apparent from Examples 7 and 8 above, Viscosity Conditioners 10 to 24 of the present invention are physically excellent for use in emulsion paints.

Claims: A viscosity conditioner comprising a compound represented by the following formula (3): wherein: R and R 2 are each a hydrocarbylene group; R 3 is a hydrocarbyl group; R 1 is a hydrocarbylene group which may contain a urethane linkage; R' is a branched alkyl group of the following formula (4) where R 4 and R 5 are each a hydrocarbyl group and R 6 is a hydrocarbylene group, or a secondary alkyl group of the following formula (5) where R 7 and R 8 are each a hydrocarbyl group; n and k each range from 1 to 500; m is not less than 2; and h is not less than 1. The viscosity conditioner according to claim 1, wherein R and R 2 may each be identical or different and are an alkylene group of 2 to 4 carbon atoms or a phenylethylene group. The viscosity conditioner according to claim 1, wherein the group R 1 is a residue of polyisocyanate of formula R 1 -(NCO) h+1 . The viscosity conditioner according to claim 3, wherein the polyisocyanate of formula R 1 -(NCO) h+1 results from the reaction of a divalent to octavalent polyol and a divalent to tetravalent polyisocyanate and has a urethane linkage in its molecule. The viscosity conditioner according to claim 1, wherein the group R 3 is a residue of a polyol of formula R 3 -(OH) m , wherein R 3 and m are as defined in claim 1. The viscosity conditioner according to claim 1, wherein the groups R 4 , R 5 , R 7 and R 8 are each a hydrocarbyl group having a carbon number of 4 or greater, and R 6 is -CH 2 -. A viscosity conditioner resulting from the reaction of at least one polyether polyol of formula R 3 -[(O-R 2 ) k -OH] m , at least one polyisocyanate of formula R 1 -(NCO) h+1 and at least one polyether monoalcohol of formula HO-(R-O) n -R', wherein R 1 , R 2 , R 3 , R, R', h, k, m and n are as defined in claim 1. The viscosity conditioner according to claim 7, wherein three different starting materials for use as the polyether polyol, polyisocyanate and polyether monoalcohol are fed in an NCO/OH ratio of 0.8 : 1 to 1.4 : 1. An emulsion composition comprising, as an essential component, the viscosity conditioner of any one of claims 1 to 8. An emulsion paint composition comprising, as an essential component, the viscosity conditioner of any one of claims 1 to 8.

Inventors: KOMIYA KAORU, YOSHIOKA TOYOTARO, KOMIYA, KAORU, YOSHIOKA, TOYOTARO, KOMIYA, KAORU, C/O ASAHI DENKA KOGYO K.K., Yoshioka, Toyotaro, c/o Asahi Denka Kogyo K.K.
Applicants: ASAHI DENKA KOGYO KK, ASAHI DENKA KOGYO KABUSHIKI KAISHA
Application year: 1996
Main classification: C09D7
IPC codes: C09D7, C08G18