IMPROVED CHEMICAL CURING OF EPOXIDIZED DIENE POLYMERS USING AROMATIC ANHYDRIDE CURING AGENTS

Abstract: The invention relating to a process for curing an epoxidized diene polymer for use in adhesives, sealants, and coatings which comprises contacting the polymer with an aromatic anhydride curing agent at a polymer/aromatic anhydride molar ratio from 0.5/1 to 2.0/1.0, and optionally from 0.1 to 10 phr of an accelerator, at a temperature of from 100 to 200 DEG C for a period of 10 minutes to six hours. The invention further relates to a cross-linked epoxidized polydiene polymer and to adhesive, sealant or coating compositions.

Description: IMPROVED CHEMICAL CURING OF EPOXIDIZED DIENE POLYMERS USING AROMATIC ANHYDRIDE CURING AGENTS This invention relates to a process for curing epoxidized diene polymers which may be used in sealant, coatings, and adhesives applications. More particularly, the present invention relates to such process in which an aromatic anhydride curing agent is used. The use of an aromatic anhydride curing agent provides a high level of crosslinking and enhanced mechanical properties in the cured polymer. The chemical curing of epoxidized diene polymers is of interest for sealant, coatings, and adhesives applications. U.S. Patent 5,229,464 describes low molecular weight epoxidized diene block copolymers and states that they may be crosslinked by the addition of multifunctional carboxylic acids and acid anhydrides. U.S. Patents 5,478,885 and 5,461,112 describe similar polymers which are used as toughening modifiers for epoxy resins. These epoxidized diene polymers are shown to be curable with carboxylic acid or anhydride curing agents. In this latter application, partially and fully saturated aliphatic carboxylic acids or anhydrides have been found to be very useful and to allow the production of very good products. However, a number of problems have been encountered when the same partially or fully saturated aliphatic carboxylic acids or anhydrides have been used as curing agents to cure the epoxidized diene polymers when epoxy resins are not present in the compositions to be cured. Such is the case when these polymers are used in sealant, coatings, and adhesive applications. I have discovered that when such carboxylic acid anhydrides are used to cure these epoxidized diene polymers alone, bubbles form in the crosslinked product. Relatively low conversion levels are achieved with these curing agents and the products exhibit low strength because of both a low level of crosslinking conversion of the epoxy and defects introduced into the product as bubbles. It has been found that the bubbles are produced as a result of the evolution of carbon dioxide during the decarboxylation of the anhydride. This side reaction competes with the desired crosslinking reaction and the kinetics are such that it takes up enough of the epoxy groups to significantly lessen the total curing while producing CO2 bubbles in the product. This problem does not occur to any noticeable extent m the epoxy resm impact modification as described in U.S. patents 5,478,885 and 5,461,112 above because the reaction of the anhydride with the epoxy resin is much faster than the reaction between the epoxidized diene polymer and the anhydride and also because in that patent, the majority of the composition is the epoxy resin. It is clear from the above that when there is a desire for a high strength, defect free sealant, coating, or adhesive utilizing an epoxidized diene polymer, a curing agent different from the partially and fully saturated aliphatic carboxylic acid anhydrides is needed. There are other types of curing agents which can be used, but acid anhydride curing agents are preferable in the curing of epoxidized diene polymers because amines will not rapidly cure such polymers without an epoxy resm present. The Applicant here has found that certain aromatic acid anhydride curing agents are capable of curing epoxidized diene polymers to a h gh degree of cure and high strength without the formation of bubbles, especially when used in a certain molar ratio relative to the epoxidized diene polymers. This invention is a method for chemically curing epoxidized diene polymers for use in sealants, coatings, and adhesives applications. The method involves curing said epoxidized diene polymers with aromatic anhydrides, preferably aromatic carboxylic acid anhydrides. The curing process generally takes place at elevated temperatures, 100 to 200°C, for a period of 10 minutes to 6 hours, preferably 30 minutes to 6 hours, and is often referred to as "bake cure." Preferred aromatic carboxylic acid anhydrides are chosen from phthalic anhydride and alkyl-substituted phthalic anhydrides. The alkyl-substituted phthalic anhydrides may be mono-, di- or tri- substituted phthalic anhydrides. More preferably, the aromatic carboxylic acid anhydride is chosen from phthalic anhydride and mono-alkyl substituted phthalic anhydride. The alkyl substituents may contain from 1 to 18 carbon atoms, preferably from 1 to 12 carbon atoms, even more preferably from 1 to 4 carbon atoms. Of the alkyl substituents, linear substituents are most preferred. The most preferred aromatic carboxylic acid anhydride curing agents for use in the present invention are phthalic anhydride and 4-methyl-phthalic anhydride. The process may be accelerated by using a curing accelerator. Polymers containing ethylenic unsaturation can be prepared by copolymerizing one or more olefins, particularly diolefins, by themselves or with one or more alkenyl aromatic hydrocarbon monomers. The copolymers may, of course, be random, tapered, block or a combination of these, as well as linear, star or radial. - 4 - In general, when solution anionic techniques are used, copolymers of conjugated diolefins, optionally with vinyl aromatic hydrocarbons, are prepared by contacting the monomer or monomers to be polymerized simultaneously or sequentially with an anionic polymerization initiator such as group IA metals, preferably lithium, their alkyls, amides, silanolates, napthalides, biphenyls or anthracenyl derivatives. The polydienes are synthesized by anionic polymerization of conjugated diene hydrocarbons with these lithium initiators. This process is well known as described in U.S. Patents Nos. 4,039,593 and Re. 27,145. Polymerization commences with a monolithium initiator which builds a living polymer backbone at each lithium site. Specific processes for making the preferred polymers for use herein are described in detail in International PCT Application No. WO 96/11215 and U.S. Patent 5,461,112. Conjugated diolefins which may be polymerized anionically include those conjugated diolefins containing from 4 to 24 carbon atoms such as 1, 3-butadiene, isoprene, piperylene, methylpentadiene, phenyl-butadiene, 3, 4-dimethyl-l, 3-hexadιene, 4, 5-dιethyl-l, 3-octadiene and the like. Preferably, conjugated diolefins containing from 4 to 8 carbon atoms are used. Isoprene and butadiene are the preferred conjugated diolefins for use in the present invention because of their low cost and ready availability. Alkenyl (vinyl) aromatic hydrocarbons which may be copolymerized include vinyl aryl compounds such as styrene, various alkyl-substituted styrenes, alkoxy-substituted styrenes, vinyl napthalene, alkyl-substituted vinyl napthalenes and the like, the alkyl and alkoxy groups typically comprising from 1 to 6, preferably from 1 to 4 carbon atoms. Epoxidized polymers which may be cured in accordance with the present invention are those described in U.S. Patents 5,229,464, 5,247,026. For instance, the following block copolymers, preferably containing from 0.1 to 7.0 milliequivalents (meq) of epoxy per gram of polymer, may be used: (A-B-A p ) n -Y r - (A q -B) m wherein Y is a coupling agent, coupling monomers or an initiator, and wherein A and B are polymer blocks which may be homopolymer blocks of conjugated diolefin monomers, copolymer blocks of conjugated diolefin monomers or copolymer blocks of conjugated diolefin monomers and monoalkenyl aromatic hydrocarbon monomers, and wherein the A blocks have a greater number of di-, tri- and tetra-substituted unsaturation sites per unit of block mass than do the B blocks, and wherein the A blocks have a weight average molecular weight from about 100 to about 3000 and the B blocks have a weight average molecular weight from about 1000 to about 15,000, and wherein p and q are 0 or 1 and n >0, r is 0 or 1, m 0 and n + m ranges from 1 to 100. The most highly preferred polymers for use herein are epoxidized diblock polymers which fall within the scope of the formula: (HO) X -A-S z -B- (OH) y wherein A and B are polymer blocks which may be homopolymer blocks of conjugated diolefin monomers, copolymer blocks of conjugated diolefin monomers, or copolymer blocks of diolefin monomers and monoalkenyl aromatic hydrocarbon monomers. These polymers may contain up to 60% by weight of at least one vinyl aromatic hydrocarbon, preferably styrene. Generally, it is preferred that the A blocks should have a greater concentration of more highly substituted aliphatic double bonds than the B blocks have. Thus, the A blocks have a greater concentration of di-, tri-, or tetra-substituted unsaturation sites (aliphatic double bonds) per unit of block mass than do the B blocks. This produces a polymer wherein the most facile epoxidation occurs in the A blocks. The A blocks have a weight average molecular weight of from 100 to 6000, preferably 500 to 4,000, and most preferably 1000 to 3000, and the B blocks have a weight average molecular weight of from 1000 to 15,000, preferably 2000 to 10,000, and most preferably 3000 to 6000. S is a vinyl aromatic hydrocarbon block which may have a weight average molecular weight of from 100 to 10,000. x and y are 0 or 1. Either x or y must be 1, but only one at a time can be 1. z is 0 or 1. The overall weight average molecular weight of such diblocks may range from 1500 to 15000, preferably 3000 to 7000. Either of the blocks in the diblock may contain some randomly polymerized vinyl aromatic hydrocarbon as described above. For example, where I represents isoprene, B represents butadiene, S represents styrene, and a slash (/) represents a random copolymer block, the diblocks may have the following structures : I-B-OH I-B/S-OH I/S-B-OH I-I/B-OH or B/I-B/S-OH B-B/S-OH I-EB-OH I-EB/S-OH or I-S/EB-OH I/S-EB-OH HO-I-S/B HO-I-S/EB where EB is hydrogenated butadiene, -EB/S-OH means that the hydroxyl source is attached to a styrene mer, and -S/EB-OH signifies that the hydroxyl source is attached to a hydrogenated butadiene mer. This latter case, -S/EB-OH, requires capping of the S/EB "random copolymer" block with a mini EB block to compensate for the tapering tendency of the styrene prior to capping with ethylene oxide. These diblocks are advantageous in that they exhibit lower viscosity and are easier to manufacture than the corresponding triblock polymers. It is preferred that the hydroxyl be attached to the butadiene block because the epoxidation proceeds more favorably with isoprene and there will be a separation between the functionalities on the polymer. Epoxidation of the base polymer can be effected by reaction with organic peracids which can be preformed or formed in situ. Suitable preformed peracids include peracetic and perbenzoic acids. In situ formation may be accomplished by using hydrogen peroxide and a low molecular weight acid such as formic acid. These and other methods are described in more detail in U. S. Patents 5,229,464, 5,247,026, 5,478,885, and 5, 461, 112. The epoxidized polymers to be used in the process according to invention preferably contains from 0.1 to 7.0 meq of epoxy per gram of polymer depending upon the desired end use for the product. The molecular weights of linear polymers or unassembled linear segments of polymers such as mono-, di-, triblock, etc., arms of star polymers before coupling are conveniently measured by Gel Permeation Chromatography (GPC) , where the GPC system has been appropriately calibrated. For anionically polymerized linear polymers, the polymer is essentially monodisperse (weight average molecular weight/number average molecular weight ratio approaches unity) , and it is both convenient and adequately descriptive to report the "peak" molecular weight of the narrow molecular weight distribution observed. Usually, the peak value is between the number and the weight average, but for monodisperse polymers, all three are very similar. The peak molecular weight is the molecular weight of the ma species shown on the chromatograph. For polydisperse polymers the weight average molecular weight should be calculated from the chromatograph and used. For materials to be used in the columns of the GPC, styrene-divinyl benzene gels or silica gels are commonly used and are excellent materials. Tetrahydrofuran is an excellent solvent for polymers of the type described herein. A refractive index detector may be used. Measurement of the absolute molecular weight of a polymer is not as straightforward or as easy to make using GPC. A good method to use for absolute molecular weight determination is to measure the weight average molecular weight by light scattering techniques. The sample is dissolved in a suitable solvent at a concentration less than 1.0 gram of sample per 100 milliliters of solvent and filtered using a syringe and porous membrane filters of less than 0.5 microns pore sized directly into the light scattering cell. The light scattering measurements are performed as a function of scattering angle, polymer concentration and polymer size using standard procedures. The differential refractive index (DRI) of the sample is measured at the same wave length and in the same solvent used for the light scattering. The following references relate to this subject: 1. Modern Size-Exclusion Liquid Chromatography, M. . Yau, J. J. Kirkland, D. D. Bly, John Wiley and Sons, New York, New York, 1979. 2. Light Scattering From Polymer Solutions, M. B. Huglm, ed., Academic Press, New York, New York, 1972. 3. W. K. Kai and A. J. Havlik, Applied Optics, 12, 541 (1973) . 4 . M . L . McConnel l , American Laboratory, 63 , Ma y, If desired, these block copolymers can be partially hydrogenated. Hydrogenation may be effected selectively as disclosed in U.S. Patent Reissue 27,145. The hydrogenation of these polymers and copolymers may be carried out by a variety of well established processes including hydrogenation in the presence of such catalysts as Raney Nickel, nobel metals such as platinum and the like, soluble transition metal catalysts and titanium catalysts as in U.S. Patent 5,039,755. The polymers will have different diene blocks and these diene blocks may be selectively hydrogenated as described in U.S. Patent 5,229,464. U.S. Patents 5,478,885 and 5,461,112 describe anhydride curing agents as commonly used to cure the epoxidized diene polymers described above. Anhydrides are used herein because a bake cure system is desired. Mine curing agents, which work well in compositions containing epoxy resins as described in said patent, will not cure epoxidized diene polymers. The anhydride curing agents described as useful m said patents may be any compound containing one or more anhydride functional groups and specific examples given include phthalic anhydride, substituted phthalic anhydrides, hydrophthalic anhydrides (which are not aromatic compounds because they are hydrogenated) , substituted hydrophthalic anhydrides, succinic anhydride, substituted succinic anhydrides, halogenated anhydrides, multifunctional carboxylic acids, and polycarboxylic acids. Because of their ease of handling, saturated or partially saturated anhydrides, such as hydrophthalic anhyαπdes and substituted hydrophthalic anhydrides, are regularly used in this type of curing. I have founc that, unknown to those skilled in the art, these anhycrides cause problems when used to cure epoxidized diene polymers by themselves (as opposed to in combination with epoxy resins as described U.S. Patents 5,478,885 and 5,461,112) . Specifically, carbon dioxide generated during the reaction of the epoxidized 5 polymer and the curing agent creates bubbles m the cured product and causes the product to have diminished physical properties. «, I have found that it is necessary to use an anhydride curing agent which is aromatic in nature to 10 achieve a good bake cure without the formation of bubbles in the product. Carbon dioxide is not generated in the reaction of an epoxidized diene polymer and an aromatic anhydride curing agent. According to my invention, the aromatic anhydride is 15 combined with the epoxidized diene polymer such that a suitable epoxidized diene polymer/aromatic anhydride molar ratio is achieved. This ratio should range from 0.5/1.0 to 2.0/1.0, preferably 0.8/1.0 to 1.2/1.0, and most preferably about 1/1, to achieve sufficient 20 crosslinking to produce a product with desirable physical properties. The crosslinking occurs through the epoxy groups and aromatic anhydride such that aromatic ester linkages are formed. Typically, the aromatic anhydride cures are conducted at elevated 25 temperatures - temperatures of from 100 to 200°C are possible but 130 to 180°C is the preferred operating range - for a period of 10 minutes to 6 hours, and are often referred to as "bake cures." The anhydride bake cures can be accelerated by 30 using a curing accelerator and accelerators are highly recommended for practical operation. Suitable curing accelerators include trialkyl amines, hydroxyl -containing compounds and imidazoles. Benzyldimethylam e (BDMA) , 2-ethyl -4-methylιmιdazole 3 (EMI,, triphenylphosphine (TPP), and BF3 amine complexes have been found to work well in curing the blends of the present invention. The accelerator is used in an amount of 0.1 to 10, preferably about 1 part of accelerator per 100 parts of polymer. The crosslinked materials of the present invention are useful in adhesives (including pressure sensitive adhesives, contact adhesives, laminating adhesives, assembly adhesives and structural adhesives), sealants, coatings, films (such as those requiring heat and solvent resistance), etc. However, it may be necessary for a formulator to combine a variety of ingredients together with the polymers of the present invention in order to obtain products having the proper combination of properties (such as adhesion, cohesion, durability, low cost, etc.) for particular applications. Thus, a suitable formulation might contain only the polymers of the present invention and the aromatic anhydride curing agent. This is especially true for coatings, sealants, and structural adhesives. However, in applications such as pressure sensitive adhesives, suitable formulations would also contain various combinations of resins, plasticizers, fillers, solvents, stabilizers and other ingredients such as asphalt. In particular, a suitable pressure sensitive formulation would comprise the epoxidized diene polymers, the aromatic anhydride curing agent and a tackifying resin. The following are some typical examples of formulating ingredients for adhesives, coatings and sealants. In adhesive applications, as well as in coatings and sealants, it may be necessary to add an adhesion promoting or tackifying resm that is compatible with the polymer. A common tackifying resm is a diene-olefm copolymer of piperylene and 2-methyl-2-butene having a softening point of about 95°C. This resin is available commercially under the tradename Wmgtack 95 and is prepared by the cationic polymerization of 60% piperlene, 10% isoprene, 5% cyclo-pentadiene, 15% 2-methyl-2-butene and about 10% dimer, as taught in U.S. Patent No. 3,577,398. Other tackifying resms may be employed wherein the resinous copolymer comprises 20-80 weight percent of piperylene and 80-20 weight percent of 2-methyl-2-butene. The resms normally have ring and ball softening points as determined by ASTM method E28 between about 80°C and 115°C. To obtain good thermo-oxidative and color stability, it is preferred that the tackifying resm be a saturated resm, e.g., a hydrogenated dicyclopenta- diene resin such as Escorez 5000 series resm made by Exxon or a hydrogenated polystyrene or polyalphamethyl- styrene res such as Regalrez resin made by Hercules. The amount of tackifying resm employed typically varies from 0 to 400 parts by weight per hundred parts rubber (phr) , preferably between 20 to 350 phr, most preferably 20 to 150 phr. The selection of the particular tackifying agent is, in large part, dependent upon the specific polymer employed in the respective adhesive composition. Resms, m particular aromatic resins, may also be employed as reinforcing agents, provided that they are compatible with the particular polymer used m the formulation. Normally, these resins should also have ring and ball softening points between about 80°C and 115°C although mixtures of resms having high and low softening points may also be used. Useful resms include coumarone-mdene resms, polystyrene resms, vinyl toluene-alpha methylstyrene copolymers and polymdene resms. Examples of such reinforcing resms useful in the present invention are the hydrogenated Regalrez and Regalite resms from Hercules. Preferably, they are used m amounts from 1 to 50 percent by weight of the total composition. Other resins which are also useful in the compositions of this invention include hydrogenated rosms, esters of rosins, polyterpenes, terpenephenol resms and polymerized mixed olefins, lower softening point resins and liquid resms. An example of a liquid resin is Adtac LV resin from Hercules. Reactive co-curing components such as epoxy resins and epoxidized natural products are also useful as reinforcing agents. Examples of useful epoxy resins are aromatic resins such as EPON 828 resin from Shell and aliphatic resins such as EPONEX 1510 resin from Shell and UVR 6110 resin from Union Carbide. Examples of useful epoxidized or epoxy-containing natural products are the DRAPEX series of epoxidized oils from Witco and naturally occurring vernonia oil. A composition of the instant invention may contain plasticizers, such as rubber extending plasticizers, or compounding oils or organic or inorganic pigments and dyes. Rubber compounding oils are well-known in the art and include both high saturates content oils and high aromatics content oils. Preferred plasticizers are highly saturated oils, e.g. Tufflo 6056 and 6204 oil made by Arco and process oils, e.g. Shellflex 371 oil made by Shell. Reactive compounds can be used as plasticizers. The amounts of rubber compounding oil employed in the invention composition can vary from 0 to 500 phr, preferably from 0 to 100 phr, and most preferably between 0 and 60 phr. Optional components of the present invention are stabilizers which inhibit or retard heat degradation, oxidation, skin formation and color formation. Stabilizers are typically added to the commercially available compounds m order to protect the polymers against heat degradation and oxidation during the preparation, use and high temperature storage of the composition. Additional stabilizers known in the art may also be incorporated into the composition. These may be for protection during the life of the article against, for example, oxygen, ozone and ultra-violet radiation. However, these additional stabilizers should be compatible with the essential stabilizers mentioned hereinabove and their intended function as taught herein. Various types of fillers and pigments can be included in the formulation. This is especially true for exterior coatings or sealants in which fillers are added not only to create the desired appeal but also to improve the performance of the coatings or sealants such as its weatherability. A wide variety of fillers can be used. Suitable fillers include calcium carbonate, clays, talcs, silica, zinc oxide, titanium dioxide and the like. The amount of filler usually is in the range of 0 to about 65%w based on the solvent free portion of the formulation depending on the type of filler used and the application for which the coating or sealant is intended. An especially preferred filler is titanium dioxide. All adhesive, coating and sealant compositions based on the epoxidized polymers of this invention will contain some combination of the various formulating ingredients disclosed herein. No definite rules can be offered about which ingredients will be used. The skilled formulator will choose particular types of ingredients and adjust their concentrations to give exactly the combination of properties needed in the composition for any specific adhesive, coating or sealant application. The only two ingredients that will always be used in any adhesive, coating or sealant are the epoxidized polymer and the curing agent. Beyond these two ingredients, the formulator will choose to use or not to use among the various resins, fillers and pigments, plasticizers, reactive oligomers, reactive and non-reactive diluents, stabilizers, and solvents. Adhesives are frequently thin layers of sticky compositions which are used in protected environments (adhering two substrates together) . Therefore, unhydrogenated epoxidized polymers will usually have adequate stability so resin type and concentration will be selected for maximum stickiness without great concern for stability, and pigments will usually not be used. Coatings are frequently thin, non-sticky, pigmented compositions applied on a substrate to protect or decorate it. Therefore, hydrogenated epoxidized polymers may be needed to give adequate durability. Resins will be selected to assure maximum durability and minimum dirt pick-up. Fillers and pigment will be selected carefully to give appropriate durability and color. Coatings will frequently contain relatively high solvent concentration to allow easy application and give a smooth dry coating. Sealants are gap fillers. Therefore, they are used fairly thick layers to fill the space between two substrates. Since the two substrates frequently move relative to each other, sealants are usually low modulus compositions capable of withstanding this movement. Further, they generally have good adhesion to the substrates. Since sealants are frequently exposed to the weather, the hydrogenated epoxidized polymers are usually used. Resins and plasticizers will be selected to maintain low modulus and minimize dirt pick-up. Fillers and pigment will be selected to give appropriate durability and color. Since sealants are applied in fairly thick layers, solvent content is as low as possible to minimize shrinkage. A formulator skilled in the art will see tremendous versatility in the epoxidized polymers of this invention to prepare adhesives, coatings and sealants having properties suitable for many different applications. The adhesive, coating and sealant compositions of the present invention can be prepared by mixing the components together until a homogeneous blend is obtained. Various methods of blending are known to the art and any method that produces a homogenous blend is satisfactory. Frequently, the components can be blended together using solvent to control viscosity. Suitable solvents include common hydrocarbons, esters, ethers, ketones and alcohols as well as mixtures thereof. If solvent content is restricted or in solvent-free compositions, it may be possible to heat the components to help reduce viscosity during mixing and application. A preferred use of the present formulation is in weatherable bake-cured sealants. The sealant comprises a monohydroxylated epoxidized diene polymer, an aromatic anhydride curing agent, an optional curing accelerator, an optional reinforcing resm or co-curing agent, and an optional tackifying resin. Alternatively, when the amount of tackifying resm is zero, the compositions of the present invention may be used for adhesives that do not tear paper and molded goods and the like. Coating compositions of this invention can be used many applications, depending on the hardness, adhesion, durability and cure conditions chosen by the formulator. A fairly soft coating formulated for low adhesion could be used as a protective strippable coating. A fairly soft coating formulated for high adhesion could be useful as a shatter retentive coating for glass bottles for carbonated beverages. A fairly hard coating formulated for high adhesion and long durability could be used as a corrosion protective coating for metals such as lawn equipment, automobiles, etc. Sealant compositions of this invention can be used for many applications. Particularly preferred is their use as gap fillers for constructions which will be baked (for example, in a paint baking oven) after the sealant is applied. This would include their use in automobile manufacture and in appliance manufacture. Another preferred application is their use in gasketing materials, for example, in lids for food and beverage containers . EXAMPLE 1 A series of experiments were carried out using a variety of anhydrides to cure a monohydroxylated epoxidized polydiene block copolymer having the structure I-B-OH where I is a block of polymerized isoprene of weight average molecular weight 1000, B is a block of polymerized butadiene of weight average molecular weight 5000 and -OH is a terminal hydroxyl group. The polymer was partially hydrogenated and then fully epoxidized to yield an epoxy content of 1.5 Meq/g. Nonaro atic anhydridesmethyl tetrahydrophthalic anhydride (MTHPA) , hexahydrophthalic anhydride (HHPA) , methyl-5 norbornene-2, 3-dιcarboxylιc anhydride (Nadic methyl anhydride, NMA) , and dodecenyl anhydride (DSA)were compared with aromatic anhydridesphthalic anhydride (PA) , 4-methyl-phthalιc anhydride (MPA) , and 4-t-butylphthalιc anhydride (tBPA) . The amount ol curing agent used in each experiment was chosen to give a 1:1 molar ratio of epoxidized diene polymer to aromatic anhydride functionality. The accelerator, 2-ethyl-4-methyl imidazole (EMI) was used in an amount of one part per hundred parts of polymer. The formulation components were mixed and then placed in 0.16 cm (1/16 inch) glass molds. The composition was cured at 150C for two hours. Table I shows some of the physical properties of the cured compositions and also the reaction exotherm for each of the reactions. The reaction exotherm is a measure of the amount of reaction, i.e. crosslinking, which took place during the curing process and is measured calorimetrically. The maximum stress and elongation at maximum stress are derived from tensile deformation experiments. Table I anhydride melting point max. stress elongation rxn <°C) MPa (psi) at stress exotherm (%) (kJ/mole epoxy) MTHPA liquid at room 1.29 (187) 283 -20.6 temperature HHPA 37 1.19 (173) 402 -18.9 DSA 43 0.34 (50) 154 -19.9 NMA liquid at room 0.04 (6) 1600 -9.1 temperature PA 135 6.51 (944) 146 -47.0 MPA 94 3.50 (508) 165 -57.6 tBPA 78 - - -8.8 As can be seen from the reaction exotherms, the use of PA and MPA aromatic anhydrides led to a higher degree of conversion than the others. This increased level of crosslinking is also reflected in the mechanical properties of the cured polymer. The tensile strengths are significantly higher for the PA and MPA systems. Thus, the aromatic anhydrides lead not only to a bubble-free sample but also to a higher level of crosslinking in the polymer. This may be somewhat attributed to the lack of decarboxylation as that side reaction would yield unreactive anhydride and a necessarily lower conversion. However, another feature observed is the steric character of the anhydrides. The tri-substituted epoxy of this polymer is a relatively crowded reaction site. Therefore, bulky anhydrides like NMA and DSA may be unable to easily accommodate the steric requirements for reaction. PA and MPA are both flat molecules and as such may more easily approach the reaction site. The relative acid strengths may also play a role in extent of reaction. TBPA did not lead to carbon dioxide bubble formation. However, the extent of reaction was low. This is attributable to the relatively bulky nature of this curing agent. Both PA and MPA lead to superior physical properties. The lower melting point of MPA may present a processing advantage, though. In our laboratory experience we have found that the PA system must be heated to 150°C to thoroughly melt and mix the anhydride. At this elevated temperature, gel formation proceeds rapidly upon addition of the catalyst. With the MPA system, the anhydride is easily melted and mixed at 120°C. Addition of catalyst at this temperature does not lead to rapid gelation. Rheological experiments show that the gel time for the polymer/MPA/EMI system is near 1800 seconds at 120°C. Because of the avoidance of the adverse decarboxy- lation reaction, superior mechanical properties, ease of processing, and commercial availability, MPA is the most preferred aromatic anhydride curing agent for this polymer. EXAMPLE 2 This example demonstrates the use of the epoxidized monohydroxylated polymer of Example 1 with a variety of accelerating agents. The sealants of this example were formulated with a stoichiometric ratio of epoxy to anhydride where the anhydride was MPA. An accelerator was used at the 1 phr level . The formulations were mixed and then cured in 0.16 cm (1/16 inch) glass molds at 160°C for 2 hours. Table II lists the tensile property results. All formulations cured without the formation of carbon dioxide bubbles. These results show that BDMA is an effective accelerant for MPA cures of epoxidized polydiene polymers. Table II Accelerator Strength MPa (psi) Elongation (%) BDMA 1.59 (231) 320 TPP 0.35 (51) 630 None 1.10 (159) 430 EXAMPLE 3 This example demonstrates the use of the epoxidized monohydroxylated polymer of Example 1 with reinforcing additives m MPA cures. The molar ratio of epoxy to anhydride functionality was maintained at 1:1 all cases. This required consideration of the epoxy level of the additives. EMI was used at 1 part per 100 parts polymer to accelerate the cure. The cures were conducted m glass molds as in Example 1. The physical properties of the resulting bake-cured sealants are shown m Table III. No carbon dioxide was evolved during the cure of these sealants with the aromatic anhydride. Bubble-free test specimens with high strength were obtained. The data demonstrate that both hydrogenated hydrocarbon resins of elevated Tg and epoxidized oils are effective at providing aromatic anhydride cured sealants of elevated Tg. Table I I I reinforcing description EEW amount mixing compat. Tg strength MPa elong- cure additive (g/mole) basis temp (Y/N) CC) (psi) ation(%) condition polymer (°C) ("C/hours) mass (%) Drapex 6.8 epoxidized 229 10 130 Y 44 17.66 (2560) 185 170/2 soybean oil 25 130 Y 57 18.48 (2680) 74 170/2 50 130 Y 30-95 16.48 (2390) 13 170/2 Regalite hydrogenated 0 25 160 Y 56 10.48 (1520) 120 160/2 R125 hydrocarbon polymer Regalite hydrogenated 50 160 Y 53 7.10 (1030) 100 160/2 R125 hydrocarbon polymer None control — 0 130 — 36 9.38 (1360) 290 170/2

Claims: C A I M S 1. A process for curing an epoxidized diene polymer for use in adhesives, sealants, or coatings which comprises contacting the polymer with an aromatic anhydride curing agent at a polymer/aromatic anhydride molar ratio from 0.5/1 to 2.0/1.0 at a temperature of from 100 to 200°C for a period of 10 minutes to six hours . 2. The process of claim 1 which comprises contacting the polymer with the aromatic anhydride curing agent in the presence of from 0.1 to 10 phr of an accelerator. 3. The process of claim 1 or 2 where the aromatic anhydride is an aromatic carboxylic acid anhydride, preferably phthalic anhydride or an alkyl substituted phthalic anhydride. 4. The process of claim 1 where the structure of the epoxidized polydiene is (HO) X -A-S z -B- (OH) y wherein A and B are polymer blocks which may be homopolymer blocks of conjugated diolefin monomers, copolymer blocks of conjugated diolefin monomers, or copolymer blocks of diolefin monomers and monoalkenyl aromatic hydrocarbon monomers, S is a vinyl aromatic hydrocarbon block, Z is 0 or 1 and x or y is 1, the other being 0. 5. The process of claim 4 where x = 0, y = 1, z = 0, and block B is comprised of styrene and butadiene and block A is comprised of isoprene. 6. The process of claim 1 wherein the epoxidized diene polymer contains from 0.1 to 7.0 meq epoxy per gram of polymer. 7. The process of claim 1 wherein from 1 to 50 percent of reinforcing agent is added. 8. The process of claim 7 where the reinforcing agent is an aromatic or aliphatic epoxy resin, an epoxidized- naturally occurring oil or vernonia oil. 9. A crosslinked epoxidized polydiene polymer wherein the crosslinking in the polymer is through aromatic ester linkages. 10. A pressure sensitive adhesive composition comprising the crosslinked polymer of claim 9 and a tackifying resin. 11. A structural adhesive, sealant or coating composition comprising the crosslinked polymer of claim 9.

Inventors: MASSE MICHAEL ALAN, MASSE, MICHAEL, ALAN
Applicants: SHELL INT RESEARCH, SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1997
Main classification: C08G59
IPC codes: C08C19, C08G59, C09D163, C09J163, C09K3