COMPOSITIONS OF EPOXYSILANE EMULSION ADDITIVES IN WATERBASED REACTIVE POLYMER DISPERSIONS AND METHODS OF PREPARATION

Abstract: The present invention provides stable epoxy silane emulsions and methods for the preparation of a stable epoxy-silane emulsions comprising: (I) a water insoluble or slightly soluble epoxysilane; (II) an emulsifier; (III) water; and (IV) a water dispersible polymer containing a functional group with an active hydrogen. Also provided are two part systems such that an epoxysilane emulsion comprising components (I)-(III) are combined and the component (IV) may be added upon use of components (I) to (III). Moreover, additional components (V), such as catalysts and pH buffers may be added. Said compositions may be used for, among other things, coatings, adhesives and sealants. The water dispersible or slightly soluble epoxy functional silane for use herein are of the general structure R<1>aR<2>bSi(OR<3>)4-a-b where R<1> is an epoxy substituted alkyl or aralkyl group, where the alkyl may have from four to thirty carbon atoms, R<3> is an alkyl or alkoxy-substituted alkyl, aryl or aralkyl group having from two to ten carbon atoms, R<2> is an alkyl group or alkoxy substituted alkyl, aryl or aralkyl group having from one to ten carbon atoms, a is one to three, and b is zero to two, with the proviso that a+b is 1, 2, or 3. R<1>, R<2>, and R<3> group may be cyclic, branched or linear.

Description: Compositions of Epoxysilane Emulsion Additives in Waterbased Reactive Polymer Dispersions and Methods of Preparation BACKGROUND OF THE INVENTION Conventional organic solvent based polymer compositions have become disfavored due to problems associated with environmental pollution, conservation of resources and providing a safe working environment. Instead, aqueous solution or dispersion type coating compositions have been proposed as alternatives. In particular, much attention has been paid to reactive polymer emulsions and dispersions because of the ease with which they provide improved properties such as water and solvent resistance. The use of combinations of polymers, aqueous emulsions and dispersions (latices) and epoxy resins or compounds is well known in the art. For example, U.S. Patent No. 4,049,869 to Long taught a composition including a high acid acrylic latex (5 to 20% by weight), a crosslinking agent (1 to 10%) and an ultraviolet absorber for use in preserving porous inorganic substrates. The crosslinking agent can include an epoxy resin. Water-soluble silanes as additives in latex systems have also been disclosed in the prior art. For example, U.S. Patent No. 5,017,632 to Bredow disclosed coating compositions for Portland cement or metal. The coating composition thereof can be mixed from a pair of storage stable components; a dry mix including a fine particle size filler, an epoxy resin and optionally, a coarse aggregate, and a wet mix including a polymer latex, an amine-functional epoxy curing agent, and a water-soluble epoxy- or amino-silane. U.S. Patent No. 5,100,955 to Pons disclosed coating and adhesive compositions based on aqueous dispersions of addition polymers of one or more olefinically unsaturated monomers, emulsion stabilizers and/or emulsifiers and a water-soluble epoxysilane. The water-soluble epoxysilane is added preferably after the polymerization of the addition polymer. The shelf life, however, of such compositions is only from two to three days. EP Patent No. 401,496 to Hahn disclosed aqueous silicon-modified plastic dispersions as adhesives by epoxysilane-treatment of a dispersion of emulsion copolymers containing carboxylic acid, amide and sulfonic acid groups. Water soluble epoxysilanes of the formula RιR 2 R 3 R Si are disclosed with Ri = (cyclo)alkyl with reactive oxirane group; R 2 = (cyclo)alkoxy, (cyclo)alkyl, aryl or aralkyl; R 3 , R 4 = (cyclo)alkoxy, or OH. However, the composition of the synthetic latex is specific. Furthermore, the neat epoxysilane is added directly to the polymer. In addition to these coating technologies, emulsions of trialkoxysilanes have been previously reported used as waterproofing agents. For example, buffered aqueous silane emulsions are disclosed in U.S. Pat. Nos. 4,877,654 and 5,393,330. Alkylalkoxysilanes are also emulsified with nonionic and anionic emulsifiers for water repellency properties in U.S. Pat. No. 5,226,954. SUMMARY OF THE INVENTION The present invention provides shelf stable compositions comprised of water-insoluble or slightly soluble epoxysilanes, emulsifier and a water dispersible or emulsifiable organic polymer which contains a functional group with an active hydrogen. The method of the present invention for the preparation of a shelf stable composition comprises: (a) dispersing a water insoluble or slightly soluble epoxysilane compound in an aqueous solution with emulsifier to yield an aqueous emulsion, and (b) adding the silane emulsion to a water dispersed or emulsified organic polymer which contains a functional group with an active hydrogen. Another aspect of the present invention is to provide an article coated and cured with the reactive, aqueous dispersion. The compositions of the present invention are stable for at least about six (6) months. Moreover, improved properties such as solvent resistance, adhesion, smoothness, hardness and mar resistance are achieved with compositions of the present invention. DETAILED DESCRIPTION OF THE INVENTION The present invention provides stable epoxy silane containing compositions and methods for the preparation of stable epoxy-silane containing compositions comprising: (I) a water insoluble or slightly soluble epoxysilane; (II) emulsifier; (III) water; and (IV) water dispersible or emulsified polymer containing a functional group with an active hydrogen. Also provided are two part systems such that an epoxysilane emulsion comprising components (I)-(III) are combined and the component (IV) may be added upon use of components (I) to (III). Moreover, additional components, (V), such as catalysts and pH buffers may be added. Contemplated herein are also compositions for the preparation of the above compositons, namely the silane (I) and the emulsifier (II). The present invention provides highly stable epoxysilane containing compositions that do not seed or gel during storage. Generally, they are stable for at least two to three weeks and more preferably two to three months. In fact, these compositions containing less than twenty weight percent epoxysilane last longer than six months of storage. This compares favorably with the prior art which taught silane/polymer compositions which would lose properties, such as adhesion, or even gel after two-three weeks. (I) SILANES The water insoluble or slightly soluble epoxy functional silane for use herein are of the general structure R a R Si(OR ) 4-a-b where R is an epoxy substituted alkyl or aralkyl group, where the alkyl may have from four to thirty carbon atoms,, R is an alkyl or alkoxy-substituted alkyl, aryl or aralkyl group having from two to ten carbon atoms, R 2 is an alkyl group or alkoxy substituted alkyl, aryl or aralkyl group having from one to ten carbon atoms, a is one to three, and b is zero to two, with the proviso that a+b is 1, 2, or 3. Each R group may be cyclic, branched or linear. The term water insoluble or slightly soluble silanes includes silanes with solubilities between 0.1 and 8.0 weight percent in water. Water insoluble epoxy silanes are preferred. However, water soluble silanes are specifically excluded from these silanes because compositions made with such silanes are not stable for extended periods of time, i.e., more than two to three days at ambient conditions. The preferred epoxy functional silanes include: where: R is (CH 2 ) m , where m has a value of zero to six; R is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from one to ten carbon atoms; R 3 is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from two to ten carbon atoms; R 4 , R 5 , R 6 or R 7 are each hydrogen or an alkyl group having from one to six carbon atoms; R 8 is an alkyl group having from one to four carbon atoms or aralkyl or aryl group having six to ten carbon atoms; R 9 is RSi(OR 3 ) 3 . n R 2 n n has a value of zero, one or two; c, d and e each have a value of zero or one; and f has a value of zero, one or two. More specifically, R 2 denotes a substituted or unsubstituted monovalent hydrocarbon group exemplified by alkyl groups (e.g., methyl, ethyl, isobutyl,, and octyl groups), alkenyl groups (e.g., vinyl and allyl groups), aryl groups (e.g., phenyl, tolyl and naphthyl groups), and aralkyl groups (e.g., benzyl and 2-phenylethyl groups), as well as those substituted groups obtained by the replacement of one or more of the carbon atoms in the above named hydrocarbon groups with various kinds of atoms and/or groups including sulfur and oxygen, and/or replacement of one or more of the hydrogen atoms in the above named hydrocarbon groups with various kinds of groups, including, but not limited to, halogen atoms, epoxy ^ methacryloxy, acryloxy, carboxyl, ester, cyano, and polyoxyalkylene groups. R 3 are alkyl, alkoxyalkyl, aryl or aralkyl radicals such as ethyl, n-propyl, n- butyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, n-decyl, and cyclo radicals such as cyclopentyl, cyclohexyl, cycloheptyl, and cyclooctyl. Illustrative of suitable branched chain hydrocarbon radicals for R 2 are alkyl radicals such as isopropyl, isobutyl, sec-butyl, isobutyl, sec-amyl, and 4-methyl-2-pentyl. Alkoxyalkyl groups may be exemplified by n-botoxy ethyl and methoxy propyl. Aryl groups may be exemplified by phenyl and aralkyl groups may be exemplified by benzyl or ethyl phenyl. R 4 , R 5 , R 6 or R 7 are hydrogen atoms or monovalent hydrocarbon groups having 1 to 6 carbon atoms exemplified by alkyl groups (e.g., methyl, ethyl, propyl, isopropyl, n-butyl and isobutyl groups), alkenyl groups (e.g., vinyl and allyl groups), and aryl groups (e.g., phenyl group). These hydrocarbon groups may be substituted by halogen atoms and functional groups, including cyano and epoxy, for a part or all of the hydrogen atoms therein. Examples of epoxy functional silanes used in accordance with the present invention include, but are not limited to, those silanes described by Brison and Lefort in French Patent No. 1,526,231. Specific examples are 2-(3 ,4-epoxycyclohexyl) ethyltriethoxysilane, 4-(methyldiethoxysilyl)-l,2-epoxycyclohexane, 3-(3, 4-epoxycyclohexyl) propyl tri(isobutoxy) silane, 3-(2,3-epoxybutoxy)propyltriethoxysilane, and [2.2.1] bicycloheptane 2,3-epoxy-5-(2-triethoxysilyl)ethyl. The silane(s) is present at 0.1 to 30 percent by weight of the total composition [(I) -(IV)]. The preferred concentration is about 0.1 to 10 percent of the weight of the total composition. In preparing the precursor epoxy silane emulsion, as defined by components (I)-(III), the silane(s) is present at 0.1 to 60 weight percent. (II) EMULSIFIER The emulsifiers for use herein include nonionic, anionic and cationic surfactants or mixtures of nonionic with anionic or cationic surfactants. Examples of the nonionic surfactants include polyoxyethylene alkyl ethers, polyoxyethylene alkyl phenyl ethers, polyoxyethylene fatty acid esters, sorbitan fatty acid esters, and polyoxyethylene sorbitan fatty acid esters. Examples of the anionic surfactants include fatty acid salts, alkyl sulfate ester salts, alkyl benzene sulfonate, alkyl phosphate, alkylallyl sulfate ester salt, and polyoxyethylene alkylphosphate ester. Examples of the cationic surfactants include quaternary ammonium salts such as long chain alkyl trimethylammonium salts, long chain alkyl benzyl dimethyl ammonium salts, and di(long chain alkyl) dimethyl ammonium salts. A further listing of surfactants useful in the present invention may be those described in 1994 McCutcheon's Vol. 2: Functional Materials, North American Edition (The Manufacturing Confectioner Publishing Co., Glen Rock) 1994, which is incorporated herein by reference. The emulsifier(s) should be present in the range of 0.05 to 30 weight percent based on weight of the total composition of (I) - (IV) and preferably 0.2 to 20 weight percent of the total composition. In the precursor epoxysilane emulsion, the emulsifier should be present at 0.1 to 50 weight percent of the epoxy silane (I). The appropriate HLB (hydrophilic-lipophilic balance) of the surfactants is chosen to correspond to the HLB of the specific epoxy silane being emulsified. The method for selecting the optimum HLB for a substance is well known to one skilled in the art and described in "The HLB System" by ICI Americas Inc. Because the reactive polymer emulsion, as defined by components (II) - (IV), may be prepared prior to the addition of the precursor epoxy silane emulsion, emulsifiers of the type described above can be used in preparing these precursor compositions. Again, the emulsifiers are chosen so that the appropriate HLB is chosen to correspond to the HLB of the specific reactive polymer being emulsified with the proviso that the emulsifier(s) chosen to emulsify the reactive polymer are compatible with the emulsifier(s) used to make the precursor epoxysilane emulsion. In the precursor reactive polymer emulsion, the emulsifier should be present at 1 to 50 weight percent of the reactive polymer. (III) WATER The water may be present in an amount ranging from 29.85 to 99.75 weight percent of the total composition (I) - (IV). When a precursor silane emulsion is made without the polymer, about 39 to 99.75% water should be present. (IV) POLYMERS The reactive polymers of the present invention are those which have an active hydrogen thereon, preferably in the form of a carboxylic group. Exemplary of such polymers are those which contain teπninal or pendant carboxyl groups (- COOH), some of which may be in its neutralized salt form (e.g., -COOK). These reactive polymers have molecular weights between 500 and 10 gms/mole. The preferred reactive polymer contains a carboxylic acid group in an amount sufficient to have an acid number, as determined by ASTM D669, between 1 and 780, and preferably, between, 10 and 280. The polymers may be added as dispersions, with no emulsifier, or as emulsions, with emulsifiers therein. Examples of reactive polymers which can be used in the present invention include carboxylic acid modified polymers chosen from the following: polyethylene, polypropylene, polyethylene propylene copolymer, urethanes, epoxies, polystyrenes and urethane acrylic polymers. Also useful herein are acrylic homopolymers, vinyl acrylic polymers, methacrylic polymers, styrene acrylic copolymers, and polyesters. These reactive polymers may also contain other organic functional groups, including hydroxyl, amide, vinyl and halogens are contemplated as being within the scope of reactive polymers. Specific examples of preferred reactive polymers which can be used in accordance with this invention include commercially available styrene acrylic emulsion polymers, such as JONCRYL ® s 554, 540,77, and 95, and SCX 2500, all commercially available from SC Johnson Polymer of Racine, WI. Other specific examples of commercially available preferred reactive polymers materials which can be used include NEOCRYL ® acrylic emulsions, NEOREZ ® water-borne urethane polymers and NEOPAC ® water-borne urethane acrylic copolymers, available from ZENECA Resins of Wilmington, MA, and UCAR ® acrylic and vinyl acrylic, latexes available from Union Carbide Corporation of Danbury, CT. Polymer dispersions, which contain no emulsifiers, may also be used herein. The polymer should be present at 0.1 to 70 weight percent of the total composition. (V) OPTIONAL INGREDIENTS The composition of the present invention may additionally contain crosslinking agents, such as urea and melamine resins which are methylolated and/or alkoxylated, epoxy resins, aziridines and carbodiimides. Such agents may be present at 0.1 to 20 weight percent of the total composition, as long as they do not destabilize the composition during storage. The compositions of the present invention optionally may comprise water soluble/emulsifiable/dispersible curing catalysts, which are hydrolytically stable, to modulate the curing conditions. Examples of such catalysts are organotitanate, organotin, chelated titanium, aluminum and zirconium compounds, and combinations thereof. Examples of chelated titanates are dihydroxy bis [2- hydroxypropanato (2-)-θ',0 2 ] (2-) titanate, mixed titanium ortho ester complexes, acetylacetonate chelate, bis(ethyl-3-oxobutanolato-θ',0 3 ] bis(2-propanolato) titanium, isopropoxy(triethanolaminato) titanium and alkanolamine complex of titanium. Examples of organotin catalysts are FOMREZ ® UL-1, UL-22, and UL-32 from Witco of Greenwich CT and dibutyltin bis(l-thioglycerol). The catalyst can be used in an amount of 0.01 to 20 percent, preferably 0.1 to 10 parts, based on reactive polymer component (IV). The pH of the total composition may impact upon its hydrostability. High alkalinity or high acidity of the composition catalyzes the hydrolysis and condensation of the alkoxysilyl group of the epoxy silane. The closer the pH of the composition is to neutral (pH = 7), the better the stability of the emulsion. Therefore, the preferred range of pH of the total composition is 5.5 to 8.5. Substances which can be used to adjust the pH are organic or inorganic buffers including sodium acetate, sodium citrate, sodium carbonate, sodium bicarbonate, sodium hydrogen phosphate, sodium dihydrogen phosphate, and the corresponding potassium salts. Other optional ingredients for inclusion herein are fillers, thixotropes, pigments, plasticizers, coalescing agents, biocides and fungicides as are commonly known and used in the art. METHOD OF PREPARATION AND USE The precursor epoxysilane emulsions of the present invention are prepared by first mixing the emulsifier (II) with the epoxy functional silane (I). Water (III) is added and the mixture is stirred to provide a white, milky emulsion. The pH of the resulting emulsion is adjusted, if necessary, to pH 7.0 ± 1.5. The precursor epoxysilane emulsion is added to the reactive polymer (IV) or to a reactive polymer emulsion [Components (II) - (IV)] to provide a stable composition. The method employed to mix these components is not critical and any commonly used low shear equipment, such as a blade or paddle mixer, is suitable. The optional ingredients (V) may be added at any time, although in some cases catalysts should be added last. The emulsions may be used as two component systems, i.e., components (I) - (III) and component (IV), mixed in shortly before use, but have sufficient stability when mixed to be used as one-component systems. The composition of components (I) - (IV) form uniform aqueous dispersions or emulsions. Many uses of these compositions require drying under ambient conditions or at elevated temperatures (e.g., baking). The resulting dried material has excellent solvent resistance, chemical resistance, hardness, mar resistance, adhesion, water resistance, durability or weatherability. The compositions made according to the present invention may be used as industrial and architectural coatings, sealants, wood coating, adhesives and in mastics, i.e., generally in any application where the polymer would be used. For example, in textile print paste applications, the composition of the present invention would provide crock resistant colorfast applications. In wood coating, the present compositions would provide stain resistance, mar resistance and block resistance between latex surfaces in storage. As to architectural coatings, the present composition would provide scrub resistance and other improved properties. . In sealants, the present composition would provide adhesion to inorganic surfaces. As is clear to one of ordinary skill in the art, there is vast array of applications of the present invention in coating, sealant, adhesives, masonry sealers, fiberglass binders and sizes, inks and other water-borne polymer systems. EXAMPLES 1. Preparation of a 40% β 3,4-epoxycyclohexyl) ethyl triethoxysilane (Silane A) emulsion with 5% surfactants - Into a beaker were added 3.85 grams of SPAN® 60 surfactant (ICI Americas) and 3.65 grams of TWEEN® 40 surfactant (ICI Americas) which were heated together in a hot water bath to melt the solid materials. 60.0 grams of Silane A were added and the mixture was stirred with a mechanical stirrer. 82.5 grams of water were added and the mixture was stirred vigorously for approximately five minutes to provide a white, stable emulsion containing 40% by weight of Silane A. 2. Preparation of a 20% Silane A emulsion with 5% surfactants - Into a beaker were added 3.5 grams of SPAN® 60 and 1.5 grams of TWEEN® 40 which were mixed and heated together in a hot water bath to melt the solid materials. 20.0 grams of Silane A were added and the mixture was stirred with a mechanical stirrer. 75.0 grams of water were added and the mixture was stirred vigorously for approximately five minutes to provide a white, stable emulsion containing 20% by weight of Silane A. 3. Preparation of a 40% Silane A emulsion with 8% surfactants - Into a beaker was added 2.18 grams of SPAN® 80 surfactant (ICI America) and 2.22 grams of TWEEN® 40 which were mixed together. To the surfactant mixture was added 22.0 grams of Silane A and the mixture was stirred with a mechanical stirrer. 28.6 grams of water were added and the mixture was stirred vigorously for approximately five minutes to provide a white, stable emulsion containing 40% by weight of Silane A. 4. Preparation of a 40% Silane A emulsion with 10% surfactants - Into a beaker was added 2.73 grams of SPAN® 80 and 2.77 grams of TWEEN® 40 which were mixed together. To the surfactant mixture was added 22.0 grams of Silane A and the mixture was stirred with a mechanical stirrer. 27.5 grams of water were added and the mixture was stirred vigorously for approximately five minutes to provide a white emulsion containing 40% by weight of Silane A. 5. Pre p aration of a 40% γ-glycidoxypropylmethyldiethoxysilane (Silane B) emulsion with 8% surfactants - 1.93 grams of SPAN® 60 surfactant (ICI Americas) and 2.87 grams of Myrj® 52S surfactant (ICI Americas) were mixed together in a beaker and heated together in a hot water bath in order to melt the solid materials. 24.0 grams of Silane B were added and the mixture was stirred with a mechanical stirrer. 31.2 grams of water were added and the mixture was stirred for approximately thirty minutes to provide a white emulsion containing 40% by weight of Silane B. The epoxy silane emulsion was metastable and gelled within one month. 6. Preparation of 40% of γ-glvcidoxypropyltri-(isobutoxy) silane (Silane D) with 6 weight percent surfactants - 2.72 grams of SPAN® 60 surfactant and 1.18 grams of TWEEN® 40 were mixed together in a beaker and heated together in a hot water bath to melt the solid materials. 26.0 grams of D were added and the mixture was stirred with a Barhart Mixer for 20 minutes. 35.1 grams of water were added and the mixture was stirred for approximately thirty minutes to provide a white, stable emulsion containing 40% by weight of Silane D. 7. Preparation of 40% β- (3,4 - epoxycvclohexyllethyl tri-(isobutoxy) silane (Silane E) emulsion with 6% surfactant - 2.36 gms of SPAN® 60 and 1.04 grams of TWEEN® 40 were mixed together in a beaker and heated together in a hot water bath to melt the solid material. 26.0 grams of Silane E were added and the mixture was stirred with a mechanical stirrer for 10 minutes. 35.1 grams of water were added and the mixture was stirred for approximately ten minutes. Giv-Gard DXN (Givaudan-Roure), a preservative, was added. 8 - 33. Preparation of stable epoxy silane containing compositions - Stable epoxy silane containing compositions were prepared by adding various amounts of precursor epoxy silane emulsion (i.e., Components I- III), as prepared according to procedures described in Examples 1-7 to varying amounts of acid modified polymer dispersions (Components III-IV) or emulsions (Components II-IV). The mixtures of precursor epoxy silane emulsions and acid modified polymer dispersions or emulsions were stirred for approximately 10 minutes. The descriptions and amounts of each component of stable epoxy silane compositions are reported in Table I. Comparative Examples I - XLIV - Comparative examples of epoxy silane acid modified polymer dispersions or emulsions were prepared by mixing various amounts of the epoxy silanes A-E and Z with varying amounts of commercially available acid modified polymer dispersions or emulsions, (see Table 1 for definition of silanes). The comparative example of alkylsilane U-W and diepoxy resin X were prepared by making an emulsion of the alkylsilanes or diepoxy resins according to procedures similar to those described in Examples 1-7, and then mixing various amounts of these alkyl silanes or diepoxy resin emulsions with varying amounts of commercially available acid modified polymer dispersions or emulsions. For example, the precursor diepoxy resin emulsion was prepared by charging into a beaker 2.44 grams of SPAN® 60 and 0.91 grams of MYRJ® 52S. The solids were melted by heating in a warm water bath with stirring. 18.2 grams of water were added to the mixture and stirred vigorously. 3.5 grams of 3,4 epoxycyclohexylmethyl 3,4 epoxycyclohexylcarboxylate (Union Carbide ERL-4221) were added and the mixture was stirred vigorously to yield a viscous paste. 28.7 grams of water were added and the stirring was continued for fifteen minutes to yield a white emulsion. The descriptions and amounts of each comparative example is reported in Table I. TABLE I Compositions of present invention (precursor epoxy emulsions and carboxylic acid modified polymers) and comparative examples. Example No. Silane % Surfactant 1 % Polymer 2 % Water % 8 SPAN 60 0.035 JONCRYL 554 46.53 53.22 TWEEN40 0.015 (Acid No.54) 9 SPAN 60 0.087 JONCRYL 554 45.83 53.55 TWEEN 40 0.037 10 SPAN 60 0.175 JONCRYL 554 44.66 54.09 TWEEN 40 0.075 11 SPAN60 0.192 JONCRYL 554 44.65 52.97 H 1 TWEEN 40 0.182 12 SPAN 60 0.485 JONCRYL 554 41.08 52.94 TWEEN 40 0.459 13 SPAN 60 0.087 JONCRYL 540 42.91 56.47 TWEEN 40 0.037 (Acid No. 49) 14 0.998 SPAN 60 0.175 JONCRYL 540 41.81 56.94 TWEEN 40 0.075 15 5.035 SPAN 60 0.485 JONCRYL 540 38.46 55.56 TWEEN 40 0.459 16 2.00 SPAN 60 0.192 JONCRYL 77 45.00 54.46 TWEEN 40 0.182 (Acid No. 55) UCAR Latex 154 52.45 41.57 (Acid No.16) UCAR Latex 154 45.71 41.95 UCAR Latex 163 50.70 43.32 (Acid No.15) UCAR Latex 163 44.19 43.47 JONCRYL 77 43.7 53.90 JONCRYL 95 28.50 69.10 Surfactant % Polymer % Water % NONE JONCRYL 554 47.00 53.00 NONE SCX 2500 43.00 57.00 NONE JONCRYL 77 46.00 54.00 NONE JONCRYL 540 44.00 56.00 NONE JONCRYL 95 30.00 70.00 SPAN 60 0.146 JONCRYL 540 43.12 54.63 MYRJ 52S 0.104 M NONE JONCRYL 77 44.83 53.17 NONE JONCRYL 77 44.83 53.17 NONE JONCRYL 77 44.83 53.17 NONE JONCRYL 77 44.83 53.17 NONE JONCRYL 77 44.83 53.17 NONE JONCRYL 77 44.83 53.17 XIII U 2.00 ARQUAD 2C75 0.100 JONCRYL 77 43.70 54.10 ARMEEN DMCD 0.100 XIV V 2.00 XV W 2.00 XVI XVII XVIII XIX XX XX! XXII XXIII XXIV XXV XXVI XXVII XLIV X 1.00 SPAN 60 0.073 JONCRYL 540 43.05 55.8 MYRJ 52S 0.051 A = (3,4-epoxycyclohexyl)ethyltriethoxysilane B = 3-glycidoxypropyldiethoxymethylsilane C = 3-glycidoxypropyltriethoxysilane D = 3-giycidoxypropyltri-(isobutoxy)siiane E = (3,4-epoxycyclonexyl)ethyltri-(isobutoxy)silane ro 4 U = octyltriethoxysilane V = 1 -triethoxysiIyl-2-methyldiethoxysilylethane W = amyltriethoxysilane X = (3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexyicarboxylate Z = 3-glycidoxypropyltrimethoxysilane 1 does not include the surfactants that may be in commercial acid modified polymer emulsion 2 polymer weight is based upon solids in commercial products. 34-84. Shelf Life Stability - The shelf life stability of the stable epoxy silane emulsions" containing acid modified polymer dispersions or emulsions containing acid modified polymer dispersions or emulsions (Components I-IV) and the comparative examples were determined by measuring the viscosity of these compositions at various times after preparation. The viscosity was visually monitored for flow properties by titling a bottle containing the compositions back and forth or by measuring the viscosity of the compositions at 25°C using a Brookfield viscometer. The stabilities of the compositions are reported in Table II. These examples show that the stable epoxy emulsions containing acid modified polymers (Components I-IV) are shelf stable for a period greater than 12 weeks provided that the pH of the composition is relatively neutral. For example, Example 27 has 10 weight percent Silane A and UCAR latex 100 and at a pH = 6, had a viscosity of 1300cP after storing at room temperature for 12 weeks. The compositions of comparative examples XXXIII and XXXV, where 10 percent of the Silane A was simply mixed with UCAR latex 100 showed an increase in viscosity, as shown in Examples 38 and 39, respectively. Comparative example XXXIII had an increase in viscosity to 3000 cP after storing at room temperature for 12 weeks. Comparative example XXXV gelled within 12 weeks. The shelf life of the stable epoxy emulsions is important to the end use properties. For example, compositions described in Example 24 were stable for a period of 12 weeks and form a film with a smooth surface upon drying as shown in Example 67. Comparative Example XXVIII, although it did not show a change in viscosity after 12 weeks, produced a poor quality film, as shown in Example 68. This ~ film had a cracked surface and fish eyes. The source of the surface defects was attributed to the hydrolysis and condensation of the epoxy silane to form microgels and oils. The pH of the compositions can have a pronounced effect on the stability of the compositions. For example, the viscosity of compositions set forth by Example 22 gradually increased and finally gelled after 24 weeks, as shown in Example 75. The increase in viscosity was attributed to the alkalinity of the composition. The pH of the composition was 8.6. These compositions may be useful as a two-component system where long pot time is required. The stability of Example 32 was observed to be poor, as shown in Example 53. Silane B is slightly soluble in water and the water solubility of this silane makes the preparation of a stable precursor epoxy emulsion difficult. The precursor epoxy silane emulsion described in Example 3 gelled within one month. Lowering the water solubility of Silane B by changing the alkoxy groups attached to the silicon atom can significantly improve the stability of the precursor epoxy silane emulsion. For example, the precursor silane emulsion described in Example 6 was stable. Of note, Silane D is insoluble in water. TABLE II Data showing that the compositions of present invention (I-IV) form more stable mixtures than simple addition of epoxy silane or additive to aqueous emulsion or dispersion of an acid modified polymers and produce good film quality. The table also shows the effect of pH on the stability of the compositions of the present invention. Viscosity of mixture (visual observation or measured τι temperature 24 Film Quality TABLE ll (cont.) Viscosity of mixture (visual observation or measured Example No Cmpstn pH Level viscosity in cP at 25° C) after storage at room temperature for various periods of time (weeks) Film Quality Q 1 2 4 12 24 50 XLI 4.0 Thin 1300 51 XLIII 4.0 Thin 1500 52 16 8.5 Thin 53 32 8.5 Thin 54 IX 8.5 Thin 55 X 8.5 Thin Gel 56 XI 8.5 Thin 57 VI 8.5 Thin t 58 18 8.5 Thin CO 59 33 8.5 Thin 60 XVI 8.5 Thin 61 XVII 8.5 Thin 62 XVIII 8.5 Thin 63 XXI 8.5 Thin 64 23 8.0 Thin 65 XXVI 8.0 Thin 66 XXVII 8.0 Thin 67 24 8.0 Thin 68 XXVIII 8.0 Thin TABLE II (cont.) pH level Viscosity of mixture (visual observation or measured Example No Composition (space) viscosity in cP at 25° C) after storage at room temperature for various periods of time (weeks) 0 12 24 weeks Film Quality Cratered surfac 69 XXIX 8.0 Smooth surface 70 25 8.0 71 XXX 8.0 Fish eyes 72 XXXI 8.0 Fish eyes ro 73 20 8.5 63 74 21 8.5 75 75 22 8.6 gel 76 8.5 45 77 13 8.6 400 78 14 8.6 440 79 15 8.6 gel 80 IV 8.6 240 81 9 8.4 260 82 10 8.5 930 83 12 8.5 gel 84 8.5 520 85-111. Solvent Resistance - The stable epoxy silane emulsions containing acid modified polymers are useful in improving the solvent resistance of films cast from them. The solvent resistance was determined by methyl ethyl ketone (MEK) double rubs. The tests were conducted according to ASTM D4752-87. Films were cured at 23°C and 50% relative humidity for seven days or cured at 121°C for 20 minutes and then 23°C at 50% relative humidity for 7 days. The results of solvent resistance is reported in Table III. The solvent resistance of films cast from compositions of the present invention was significantly better than films cast from the acid modified polymers alone. For example, the number of MEK double rubs of a film cast from compositions described in Example 16 and shown in Example 90 and cured at 121°C for 20 minutes was 130 rubs. Comparative Example III, a film of JONCRYL 77 withstood only 1 1 MEK rubs, as shown in Example 91. Simple mixtures of Silane A and JONCRYL 77, Comparative Example VIII, withstood only 34 rubs. In some cases, simple blends of epoxy silanes and polymers, such as Comparative Example XI, yield solvent resistant films shown in Example 94, but the shelf life of these compositions is poor. For example, Comparative Example XI gelled in two weeks, as shown in Example 56/ TABLE III Data showing that the compositions of present invention have improved solvent resistance, a demonstrated by MEK double rubs MEK double rubs Cured at 23° C at 50% Cured at 121 ° C for 20 min. and then relative humidity for 7 days23° C at 50% relative humidity for 7 days Example No. Compositiion 85 8 29 39 86 9 - 40 87 10 26 88 11 50 89 I 14 9 90 16 41 130 91 III 14 1 1 92 IX 41 169 93 XII 110 171 94 XI 87 127 OJ 95 VI 8 9 96 VII 45 97 VIII 34 98 XIII - 1 1 99 XIV - 9 100 XV - 9 101 18 19 182 102 V 8 7 MEK double rubs Cured at 23° C at 50% Cured at 121° C for 20 min. and then relative humidity for 7 days23° C at 50% relative humidity for 7 days 2 22 57 241 22 12 22 46 51 14 13 8 1. Film had craters. 112-115. Mar Resistance. The compositions of the present invention have improved ~ mar resistance when cast as films. The mar resistance was measured using an AATCC crockmeter, Atlas Electric Devices Company, model CM-5. Films were cast into Bonderite treated cold-rolled steel panels using a draw down bar and cured at 121°C for 20 minutes and 23°C and 50%> relative humidity for seven days. The gloss values were determined according to ASTM D 523. The results of the mar resistance of these films are reported in Table IV. Films cast from compositions of the present invention demonstrated an improvement in mar resistance for compositions freshly prepared and aged 6 months (Examples 1 12 and 1 13) as compared to compositions from Comparative Examples XLIV and IV (Examples 1 14 and 115). TABLE IV. Data showing that the mar resistance of films cast from compositions of present inventions are better than simple mixture of epoxy silane and acid modified polymers Exam le No. Com osition Initial Gloss (60°) Gloss after 10 cycles % loss 1 film cast immediately after preparation of composition 2 film cast 6 months after preparation of composition. ) 116 -125. Hardness - Films cast from the compositions of the present invention had an increase in hardness while maintaining other film properties, such as gloss, and adhesion, as indicated in Table V. Pencil hardness was measured according to ASTM D 3363-74. The gloss was measured according to ASTM-D 523. Crosscut tape adhesion was measured according to ASTM 3359-90. Wet adhesion of the film to E-coat steel panel was measured according to Method 6301 of US Federal Standard Test Method 14 IB. The films were prepared using a draw down bow. The dry film thickness was 2 mils. The films were cured at 121°C for 20 minutes and 23°C and 50%> relative humidity for 7 days. Table V. Data showing that composition of present invention give a good balance of film properties after curing at 121° C for 2 minutes and 23° for 7 days 10 10 10 10 10 10 C A dramatic illustration of the usefulness of the composition of the present invention is presented for a filled latex sealant. The sealant formulations are set forth in Table VI. The sealants were prepared by charging UCAR latex polymer 105 and TRITON X-405 into a mixing vessel and stirring for five minutes. A solution of NUOCEPT 95 preservative, TRITON X-405 surfactant and water was added to the mixing vessel and stirred for five minutes. The ethylene glycol, TEMOL 850 dispersing agent, ASE 60 thickener, KTPP potassium tripolyphosphate, and SANTICISER 160 plasticizer were added and mixed using a high speed mixing propeller. Mineral spirits, precursor epoxy silane emulsion or silicone additive and ammonium hydroxide were added and mixed using a spatula. A MOLTINI PLANAMAX mixer was used to stir the mixture for 20 minutes under a nitrogen atmosphere. The Ti0 2 and DMDEE (2,2- dimorpholino diethyl ether) catalysts were added and mixed for five minutes , . The mixture was degassed under reduced pressure for five minutes. The sealant was stored in a plastic sealant tube. The sealants were cured at 23 °C and 50% relative humidity for three weeks in an environmental chamber and 1 week at ambient conditions. The physical properties of the cured sealants were measured according to ASTM D 412C (percent elongation, tensile strength and modulus), ASTM 624 (tear strength), C-661 (shore A hardness) and C-794 (adhesion in peel). The sealants were heat aged at 50°C for 4 weeks. The physical properties of the sealant are reported in Table VI. The compositions of the present invention, when fully formulated into a filled acrylic latex (Example 129), had excellent adhesion while maintaining high elongation and low modulus, especially after aging for 4 weeks at 50°C. The comparative examples 126-28, 130-31 had either poor adhesion " after heat aging or dramatic loss of percent elongation. TABLE VI Data showing that the compositions of the present invention give a good balance of properties in a filled latex selant LATEX SEALANT FORMULATIONS 1. FILLED FORMULATION Components Parts Source UCAR® Latex Polymer 105 TRITON® X -405 (70% Active Surfactant) NUOSEPT® 95 (Preservative) TRITON® X - 405 Distilled Water Ethylene Glycol TEMOL® 850 (Dispersing Agent) ASE® 60 (Thickener) KTPP (Potassium Tripolyphosphate) SANTICISER® 160 (Plasticizer) Mineral Spirits Orgaπofuπctional Silane or precursor epoxy emulsion Ammonium Hydroxide (28% Soln) DRIKALITE® (Treated Calcium Carbonate) Titanium Dioxide R-901 DMDEE (Catalyst) PHYSICAL PROPERTIES" FOR FILLED ACRYLIC LATEX SEALANT FORMULATION Example Silane 126 None Initial Aged" 127 Z Initial Aged 128 Initial Aged 129 Example Initial Aged 130 W Initial Aged 131 T Initial 253 53.2 26.9 26.9 28 9 1 100% Aged 219 39.1 20.2 20.2 21 8.0 20% a) Physical properties measurements obtained in accordance with accepted ASTM lest specifications; b) Samples were aged for four (4) weeks at 50°C; A=(3.4-epoxycyclohexyl)ethyltrιethoxysιiane T= 3-amιnopropyisιloxanes in water Z= 3-glycιdoxypropyltrιmethoxysιlane Example 1. Precursor epoxy silane emulsion prepared in Example 1 = amyltriethoxysilane. (The silane was added as an emulsion prepared by mixing 40 grams of amyltriethoxysilane. 4.1 1 grams of SPAN60 and 3.87 grams of TWEEN 40 and 52 grams of water )

Claims: We claim: 1. A stable emulsion comprising a water insoluble or slightly soluble epoxy silane, water and an emulsifier which is shelf stable for at least two months. 2. An emulsion according to claim 1 wherein the epoxy silane is of the formula: R 1 a R 2 bSi(OR 3 ) . a-b . where R 1 is an epoxy substituted alkyl or aralkyl group, where the alkyl may have from four to thirty carbon atoms, R 3 is an alkyl or alkoxy-substituted alkyl, aryl or aralkyl group having from two to ten carbon atoms, R 2 is an alkyl group or alkoxy substituted alkyl, aryl or aralkyl group having from one to ten carbon atoms, a is one to three, and b is zero to two, with the proviso that a+b is 1 , 2, or 3. 3. An emulsion according to claim 2 wherein the epoxy silane is, selected from the group consisting of: where: R is (CH 2 ) m , where m has a value of zero to six; R is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from one to ten carbon atoms; R is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from two to ten carbon atoms; R 4 , R 5 , R 6 or R 7 are each hydrogen or an alkyl group having from one to six carbon atoms; R is an alkyl group having from one to four carbon atoms or aralkyl or aryl group having six to ten carbon atoms; R 9 is RSi(OR 3 ) 3-n R 2 n n has a value of zero, one or two; c, d and e each have a value of zero or one; and f has a value of zero, one or two. 4. The emulsion according to claim 3 wherein the emulsifier is selected from the group consisting of: polyoxyethylene alkyl ethers, polyoxyethylene alkyl phenyl ethers, polyoxyethylene fatty acid esters, sorbitan fatty acid esters, polyoxyethylene sorbitan fatty acid esters, fatty acid salts, alkyl sulfate ester salts, alkyl" benzene sulfonate, alkyl phosphate, alkylallyl sulfate ester salt, polyoxyethylene alkylphosphate ester, quaternary ammonium salts, alkyl trimethylammonium salts, alkyl benzyl dimethyl ammonium salts, and dialkyl dimethyl ammonium salts. 5. An emulsion according to claim 1 additionally comprising a water dispersible polymer containing a functional group with an active hydrogen. 6. A composition according to claim 3 wherein the silane is silane (I) and n=2. 7. A composition according to claim 3 wherein the silane is silane (III) and n=2. 8. An emulsion comprising : (I) 0.1 to 20 weight percent of a water insoluble or slightly soluble epoxysilane; (II) 0.1 to 25 weight percent of an emulsifier; (III) 10 to 80 weight percent of water; and (IV) 25 to 60 weight percent of a polymer containing a functional group with an active hydrogen. 9. An emulsion according to claim 8 wherein the silane is of the formula: R' a R 2 b Si(OR 3 ) 4-a - b . where R 1 is an epoxy substituted alkyl or aralkyl group, where the alkyl may have from four to thirty carbon atoms, R 3 is an alkyl or alkoxy-substituted alkyl, aryl or aralkyl group having from two to ten carbon atoms, R is an alkyl group or alkoxy substituted alkyl, aryl or aralkyl group having from one to ten carbon atoms, a is one to three, and b is zero to two, with the proviso that a+b is 1 , 2, or 3. 10. An emulsion according to claim 8 wherein the epoxy silane is selected from the group consisting of: or where: R is (CH 2 ) m , where m has a value of zero to six; R is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from one to ten carbon atoms; R 3 is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from two to ten carbon atoms; R 4 , R 5 , R 6 or R 7 are each hydrogen or an alkyl group having from one to six carbon atoms; R is an alkyl group having from one to four carbon atoms or aralkyl or aryl group having six to ten carbon atoms; R 9 is RSi(OR 3 ) 3-n R 2 n n has a value of zero, one or two; c, d and e each have a value of zero or one; and f has a value of zero, one or two. 11. A coating made from the emulsion of claim 8. 12. An emulsion according to claim 8 additionally comprising a pH buffer. 13. An emulsion according to claim 8 additionally comprising a cure catalyst. 14. An emulsion according to claim 8 wherein the polymer has pendant carboxylic acid groups. 15. A method of preparing a coating or sealant comprising mixing together: (I) 0.05 to 30 weight percent of a water insoluble or slightly soluble epoxysilane; (II) 0.05 to 30 weight percent of an emulsifier; (III) 29.85 to 99.75 weight percent of water; and (IV) 0.1 to 70 weight percent of a polymer containing a functional group with an active hydrogen. 16. The use of water insoluble or slightly soluble epoxy silanes to coat a surface. 17. The method according to claim 16 wherein the silane is applied in an emulsion. 18. The method according to claim 17 wherein the epoxy silane is selected from the group consisting of: P 2 n R4R5 C ^CR6-CH 2 -(OR8) c RSi(OR3)( 3 . n ) (II) or where: R is (CH 2 ) m , where m has a value of zero to six; R 2 is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from one to ten carbon atoms; R 3 is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from two to ten carbon atoms; R 4 , R 5 , R 6 or R 7 are each hydrogen or an alkyl group having from one to six carbon atoms; R 8 is an alkyl group having from one to four carbon atoms or aralkyl or aryl group having six to ten carbon atoms; R 9 is RSi(OR 3 ) 3-n R 2 n n has a value of zero, one or two; c, d and e each have a value of zero or one; and f has a value of zero, one or two. 19. The method according to claim 18 wherein the silane is silane (I) and n=2 20. The method according to claim 18 wherein the silane is silane (II) and and n=2. 21. The method according to claim 18 wherein the silane is Silane (III) and n=2. 22. A composition for the preparation of a shelf-stable epoxy-silane composition comprising: (a) an emulsifier; and (b) an epoxy silane selected from the group consisting of: P 2 n R4R5 C — CR6-CH -(OR8) c RSi(OR3)( 3 . n ) (II) ; 0400or where: R is (CH 2 ) m , where m has a value of zero to six; R is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from one to ten carbon atoms; R is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from two to ten carbon atoms; R , R , R 6 or R 7 are each hydrogen or an alkyl group having from one to six carbon atoms; R 8 is an alkyl group having from one to four carbon atoms or aralkyl or aryl group having six to ten carbon atoms; R 9 is RSi(OR 3 ) 3-n R 2 n n has a value of zero, one or two; c, d and e each have a value of zero or one; and f has a value of zero, one or two. AMENDED CLAIMS [received by the International Bureau on 21 February 1997 (21.02.97) original claims 1-22 replaced by new,claims 1-9 (4 pages)] 1. An emulsion comprising (a) a water insoluble or slightly soluble epoxy silane, (b) water, (c) an organic polymer containing one or more terminal or pendant carboxylic groups and (d) an emulsifier, which is shelf stable for at least two months and wherein the epoxy silane is of the formula: where : R is (CH j ). p where m has a value of zero to R 2 is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from one to ten carbon atoms ; R is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from two to ten carbon atoms; and n has a value of zero, one or two. 2. The emulsion according to claim l wherein the emulsifier is selected from the group consisting of: polyoxyethylene alkyl ethers. polyoxyethylene alkyl phenyl ethers r polyoxyethylene fatty acid esters, sorbitan fatty acid esters, polyoxyethylene sorbitan fatty acid esters, fatty acid salts, alkyl sulfate ester salts, alkyl benzene sulfonate, alkyl phosphate, alkylallyl sulfate ester salt, polyoxyethylene alkylphosphate eeter, quaternary ammonium salts, alkyl trimethylammonium salts, alkyl benzyl dimethyl ammonium salts, and dialkyl dimethyl ammonium salts . 3. A composition according to claim 1 wherein n=2. 4. An emulsion comprising; {I) 0.1 to 20 weight percent of a water insoluble or slightly soluble epoxysilane; (IX) 0.1 to 25 weight percent of an emulsifier; (III) 10 to 8C weight percent of water; and (IV) 25 to 60 weight percent of an organic polymer containing one or more terminal or pendant carboxylic groups wherein the epoxy silane is of the formula: wherein n has a value of zero, one or two, R is (CH;,)^ where has a value of sero to six; R 2 is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from one to ten carbon atoms; and R 3 is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from twc to ten carbon atoms. 5. A coating made f om the emulsion of claim 4 - 6. An emulsion according to claim 4 additionally comprising a ph buffer. 7. An emulsion according to claim 4 additionally comprising a cure catalyst. S . A method of preparing a coating or sealant comprising mixing together: (I) 0.05 to 30 weight percent of a water insoluble or slightly soluble epoxysilane: (II) 0.05 to 30 weight percent of an emulsifier; (III) 29.85 to 99.75 weight percent of water; and (IV) 0.1 to 70 weight percent of an organic polymer containing one or more terminal or pendant carboxylic groups wherein the epoxysilane is of the formul : wherein n has a value of zero, one or two, R is (CH 2 ) Hι where has a value of zero to six.; R z is an alkyl, alk∞ty-substituted alkyl, aryl or aralkyl group, each of said groups having from one to ten carbon atoms; and R 3 is an alkyl, alkoxy-substituted alkyl, aryl or aralkyl group, each of said groups having from two to ten carbon atoms. 9. The method according to claim 8 wherein n=2.

Inventors: CHAVES ANTONIO, CHEN MING J, OSTERHOLTZ FREDERICK D, POHL ERIC R, CHAVES, ANTONIO, CHEN, MING, J., OSTERHOLTZ, FREDERICK, D., POHL, ERIC, R.
Applicants: OSI SPECIALTIES INC, OSI SPECIALTIES, INC.
Application year: 1996
Main classification: C08K5
IPC codes: C08K5, C09D133, C09D183