Abstract:
This invention relates to the use of an N-alkylethanolamine or N,N-dialkylethanolamine wherein each N-alkyl group is independently a C 3  through C 12  straight chain or branched alkyl group, the substituted ethanolamine is used in combination with a biocide for the anaerobic shelf stabilization of a latex paint, uncured coating, uncured sealant, uncured adhesive or related product.

Description:
REFERENCE TO RELATED APPLICATION  
       [0001]    This application claims the benefit of U.S. Provisional Application Serial No. 60/378,830, filed May 8, 2002. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    This invention relates to compositions having physical biocide synergist activity and additionally to the use of these compositions for increasing the shelf life of stored formulated products.  
           [0004]    2. Description of the Prior Art  
           [0005]    Paints, coatings, sealants, adhesives and related products are typically produced as uncured and/or fluid mixtures which are sealed and stored for a period of time prior to use. The storage period can be as long as several years.  
           [0006]    During storage, microbial contaminants that were introduced during the production of the product can proliferate. Such microbial proliferation can result in a number of undesirable consequences. The microbes can discolor the product, produce stringy filamentous growths, produce foul odors, selectively consume components of the formulation and generally degrade the product to a point where it is no longer acceptable to the customer.  
           [0007]    In order to prevent such microbial proliferation during product storage, many formulators add “in-can” biocides to paints, coatings, sealants, adhesives and related products prior to final packaging for shelf storage. The use of such biocides controls the problems associated with microbial proliferation during storage, but these biocides introduce problems of their own. Biocides tend to be toxic, and government regulatory agencies are pressuring formulators to use less and less biocide in their products. The need to formulate bio-resistant products with less biocide has driven paint, coating, sealant and adhesive manufacturers to seek novel strategies for microbial control.  
           [0008]    The use of various compounds as biocides and biocide synergists in open circulating metalworking systems is known.  
           [0009]    Golec et al. (Tribology International, December 1989, 22(6), 375-382) have described the antimicrobial efficacy of alkanolamines in open circulating metalworking coolants.  
           [0010]    Aumann et al. (Lubes&#39;N&#39;Greases, June 2000, 6(6), 22-26) have described the efficacy of AMP (2-amino-2-methyl-1-propanol), MEA (monoethanolamine), TEA (triethanolamine) and DGA (diglycolamine) as antimicrobial synergists in open circulating metalworking coolants.  
           [0011]    Sandin et al. (International Biodeterioration, 1991, 27, 61-74) describe the use of diethanolamine, butylethanolamine and dimethylaminomethylpropanol as antimicrobial agents with an emphasis on controlling fungus in open circulating metalworking fluids.  
           [0012]    Edebo et al. (U.S. Pat. No. 5,132,046) describe the of long chain alkylaminoethanols as antimicrobial agents in open circulating metalworking fluids.  
           [0013]    Sandin et al. (Antimicrobial Agents And Chemotherapy, March 1990, 491-493 describe the use of diethanolamine, dimethylaminomethylpropanol and butylaminoethanol as antimicrobial agents for control of Pseudomonas pseudocaligenes with an emphasis on metalworking fluid applications.  
           [0014]    E. O. Bennett (Lubrication Engineering, March 1979, 35(3), 137-144) describes the effect of numerous alkylalkanolamines on the bio-resistance of open circulating metalworking fluids.  
           [0015]    E. O. Bennett (U.S. Pat. No. 4,925,582) claims the use of N-hexylethanolamine and N-amylethanolamine as biocide synergists in open circulating metalworking fluids.  
           [0016]    Additionally, a number of references have described the utility of alkanolamines and quaternary ammonium compounds derived from them as antimicrobial agents for use in cleaning solutions.  
           [0017]    Inoue et al. (U.S. Pat. No. 4,134,971 &amp; family) claim RNHCH 2 CH 2 OH, where R is a C10 to C20 straight chain alkyl, combined with metal chelating agents (e.g., sodium EDTA) as biocides for use in non-medical applications.  
           [0018]    Shimotomai et al. (JP 08193015) claim the use a number of alkanolamine type compounds in combination with BIT (benzoisothiazoline-3-one) as enhanced biocides in open systems.  
           [0019]    Lichtenberg et al. (WO 2002023990A1) describe the use of a limited set of alkanolamine synergists in combination with certain types of quaternary ammonium. biocides. The quaternary ammonium biocides discussed by Lichtenberg are not used for “in-can” preservation of paints, coatings, sealants and adhesives.  
           [0020]    All of the known work published to date is focused on the use of alkylalkanolamine (AAA) synergists in open circulating systems throughout the usable life of the system. The present invention differs in that it describes the use of physical biocide synergists in formulated products during their storage in sealed containers, and this invention is intended to be effective only for the period of storage.  
         SUMMARY OF THE INVENTION  
         [0021]    This invention can be described as the use of certain N-alkylalkanolamines and/or N,N-dialkylalkanolamines as biocide synergists for stabilization of stored paints, uncured coatings, uncured sealants, uncured adhesives and related products under mostly anaerobic conditions.  
           [0022]    The useful biocide synergists can be represented by the formulas:  
           RR′NCH 2 CH 2 OH and/or RN(CH 2 CH 2 OH) 2    
           [0023]    wherein R is a straight chain or branched alkyl group with 3 to 12 carbon atoms; and hydrogen or a straight chain or branched alkyl group with 3 to 12 carbon atoms, the alkyl group is the same or different from that of R.  
         DETAILED DESCRIPTION OF THE INVENTION  
         [0024]    This invention provides a novel means of using biocides more effectively. By combining typical biocides with the alkanolamines described herein, one can obtain much better microbial control per unit of biocide than is obtainable without the alkanolamine.  
           [0025]    Compounds that can enhance the effectiveness of biocides are generally known as synergists. The synergist alkanolamines described in this invention have the added advantage that they are intended for use in formulations that typically already employ added amines. Thus, the amine synergists can serve as pH adjustors, resin-solubilizing agents, corrosion inhibitors etc. while also enhancing biocide activity through physical synergist mechanisms. By substituting all or a portion of the amine content which is already contained in a paint, coating, sealant or adhesive formulation with one of the synergist alkanolamines described herein, one obtains a product with the same overall amine level and reduced levels of biocide.  
           [0026]    The synergist alkanolamines can be represented by the formulas:  
           RR′NCH 2 CH 2 OH and/or RN(CH 2 CH 2 OH) 2    
           [0027]    wherein R is a straight chain or branched alkyl group with 3 to 12 carbon atoms; and R′ is hydrogen or a straight chain or branched alkyl group with 3 to 12 carbon atoms, wherein the alkyl group is the same or different from that of R. Preferred are alkanalamines such as butylaminoethanol (BAE), isopropylaminoethanol (IPAE) and amylaminoethanol (AAE).  
           [0028]    A heteroatom substitution in the alkyl chain is not necessary, but such substitution should not preclude a compound from being covered by this disclosure.  
           [0029]    The disclosed alkanolamines are effective with a number of different biocides as is typical of physical biocide synergists. The alkanolamines are added to the uncured product as part of the formulation, and oftentimes these synergist amines can serve additional purposes for which amines are typically used. Such typical purposes include pH adjustment, resin solubilization, corrosion inhibition and metal ion complexation.  
           [0030]    The amines should be used at levels between 200 ppm and 15,000 ppm with 1,000 ppm to 10,000 ppm being preferred, and 1,500 ppm to 8,500 ppm being most preferred. Below about 200 ppm, the amines tend to lose effectiveness. Above 15000 ppm, the addition of further amine does little to improve the physical biocide synergy.  
           [0031]    The biocide may be any compound effective in stabilizing shelf stored paints, coatings, sealants and adhesives. Typical biocides include isothiazolinones, benzoisothiazolinones, formaldehyde, triazines, gluteraldehyde, bronopol and phenolics. Preferably the biocide is something other than a quaternary ammonium biocide.  
           [0032]    The amine is added to the formulation along with the other components and the biocide prior to sealing for shelf storage. The synergist alkanolamines should be used at a level between 200 ppm and 1,500 ppm in the shelf stored formulation with a preferred range of 1,000 ppm to 10,000 ppm. The synergist alkanolamine may be volatile (e.g., N-isopropylethanolamine) so that it will evaporate from the product after the package is opened, or the synergist alkanolamine may be non-volatile (e.g., didodecylaminoethanol) so that it will remain in the product after the package is opened. If the synergist alkanolamine and biocide remain in the product after the package is opened, then the benefit of enhanced biocide activity may continue in the cured material (e.g., in the cured paint film).  
           [0033]    For latex paints based on resins comprising copolymers of acrylate esters, vinyl acetate and/or styrene, a particularly preferred embodiment involves addition of between two pounds and ten pounds of butylaminoethanol (BAE) per 100 gallons of finished latex paint.  
           [0034]    The following examples are illustrative of the invention but are not intended to be exhaustive or to limit the invention to the precise form disclosed. Many other variations and modifications are possible in light of the specifications and examples. 
       
    
    
     EXAMPLE 1  
     Demonstrate the Effectiveness of Certain Alkylalkanolamines as Physical Biocide Synergists  
       [0035]    A 384 well microtiter plate set up for measuring optical density at 660 nm was employed. Each well was filled with 25 microliters of alkylalkanolamine (AAA) solution buffered with Tris to pH=7.5, 25 microliters of nutrient/innoculum solution at pH=7.5 (nutrient=TSB) and 25 microliters of biocide solution adjusted to pH=7.5 for a total volume of 75 microliters. In any given experiment, both the structure and concentration of the AAA were varied along with the concentration of the biocide. The temperature was maintained at 25° C. throughout the experiment. Optical density measurements were made at 15 min intervals. We established that the microbial concentration was linearly related to optical absorbance in all cases, and optical density (OD) values were used as a direct measurement of microbial density. Based on OD measurements, the maximum rate of microbial growth and the 18 hour and 48 hour end point microbial densities could be calculated.  
         [0036]    Below is a Table showing the end point concentration (based on optical density) at 18 hours for Pseudomonas aeruginosa (ATCC 10145) after treatment with various levels of Troysan 785 (78.5% aqueous solution of hexahydro-1,3,5-tris-2-hydroxyethyl-s-triazine as supplied by Troy Chemicals of Florham Park, N.J.) in the presence of different alkanolamines. The following acronyms have been used; AMP=2-amino-2-methyl-1-propanol, BAE=N-butylaminoethanol, DBAE=N,N-dibutylaminoethanol, OAE=N-octylaminoethanol.  
                                                                                                   Troysan Concentration            [AAA]   500 ppm   300 ppm   200 ppm   100 ppm   50 ppm                    AMP   0.33   0.36   0.38   0.4   0.4       (1000 ppm)       DBAE   0.19   0.23   0.24   0.24   0.24       (1000 ppm)       AMP   0.15   0.21   0.23   0.23   0.23       (2000 ppm)       BAE   0.12   0.18   0.22   0.23   0.23       (1000 ppm)       DBAE   0.12   0.14   0.15   0.15   0.15       (2000 ppm)       BAE   0.06   0.08   0.08   0.09   0.09       (2000 ppm)       OAE   0.05   0.04   0.04   0.03   0.03       (1000 ppm)       OAE   0.05   0.04   0.03   0.03   0.03       (2000 ppm)                  
 
         [0037]    One can see from the data that the amines described herein (BAE, DBAE and OAE) are more effective than an arbitrary AAA (e.g., AMP) in controlling microbial growth.  
         [0038]    A plot of the maximum growth slope (values given in milli-OD units per second) for this system is presented below (5 point best fit of the linear portion of the growth curve):  
                                                                                                   Troysan Concentration            [AAA]   500 ppm   300 ppm   200 ppm   100 ppm   50 ppm                    AMP   0.414   0.443   0.415   0.328   0.309       (1000 ppm)       DBAE   0.168   0.206   0.214   0.268   0.246       (1000 ppm)       AMP   0.131   0.343   0.368   0.318   0.251       (2000 ppm)       BAE   0   0.039   0.06   0.126   0.108       (1000 ppm)       DBAE   0.198   0.194   0.199   0.205   0.177       (2000 ppm)       BAE   0.093   0.113   0.105   0.098   0.115       (2000 ppm)       OAE   0   0   0   0   0       (1000 ppm)       OAE   0   0   0   0   0       (2000 ppm)                  
 
         [0039]    Again, the utility of the amines described herein is seen.  
       EXAMPLE 2  
     Demonstrate That BAE Can Be Used as a Neutralizing Amine in Latex Paint  
       [0040]    FORMULATIONS: Two amines (BAE and AMP) were incorporated separately into two architectural interior latex coatings (a flat and a semi-gloss coating). The paint formulations were:  
                                                                                                                           HIGH QUALITY FLAT INTERIOR PAINT                    AMP-95   BAE                            DI Water   150.0   150.0           Propylene Glycol   25.9   25.9           Proxel GXL   0.5   0.5           Colloid 226/35   8.0   8.0           Tergitol NP-9   2.2   2.2           Colloid 640   3.5   3.5           Polyphobe 102   15.0   15.0           AMP-95   5.0   —           BAE   —   5.0           Ti-Pure R-902   250.0   250.0           Snowflake PE   125.0   125.0           Minex 4   125.0   125.0            Disperse at high speed then letdown with:                    % NVM                   UCAR Latex 379G   (55)   419.8   419.8           UCAR Filmer IBT       16.8   16.8           Colloid 640       3.5   3.5            Adjust pH to 9.0 ± 0.2 and viscosity to 90 ± 2 KU with:                Polyphobe 102       14.5   14.5           AMP-95       2.0   —           BAE       —   2.0           DI Water       51.3   51.3           Total Weight   Pounds   1218.0   1218.0           Total Yield   Gallons   101.0   101.0                      
 
         [0041]    [0041]                                                                                                                       SEMIGLOSS INTERIOR ENAMEL                AMP-95   BAE                            DI Water   100.0   100.0           Cellosize ER-15000   2.0   2.0           Nuosept 145   2.4   2.4           Tamol 731   9.2   9.2           Triton N-57   2.1   2.1           AMP-95   1.0   —           BAE   —   1.0           Propylene Glycol   43.2   43.2           Byk 035   1.0   1.0           Tronox CR-800   250.0   250.0            Disperse at high speed then letdown with:                    % NVM                   UCAR Latex 379G   (55)   428.4   428.4           UCAR Filmer IBT       20.0   20.0           Byk 035       1.9   1.9           Triton GR-7M       0.5   0.5            Adjust pH to 8.5 ± 0.2 and viscosity to 88 ± 2 KU with:                AMP-95       0.5               BAE       —   0.5           DI Water       168.2   168.2           Acrysol SCT-275       10.0   10.0           DI Water       10.0   10.0           Propylene Glycol       10.0   10.0           Total Weight   Pounds   1060.4   1060.4           Total Yield   Gallons   100.1   100.1                        
         [0042]    PROCEDURES: The coatings were evaluated using the following procedures.  
                                                   Procedure   ASTM Test Method                           Fineness of Dispersion   D 1210           Viscosity-Stormer viscometer   D 562           pH   E 70           Dry Time   D 1640           Odor   D 1296           Gloss/Sheen   D 523           Opacity, 3-mil drawdown   D 2805           Package Stability-2 wks at 125° F.   D 1849           Syneresis           Settling           Ease of redispersion           Viscosity           Scrubbability   D 2486           Film Porosity   D 3258           Color acceptance   (a)           Color development   (b)           Application properties   (c)                      
 
         [0043]    Color Acceptance—The test paint was tinted with each tinting colorant at 1% by weight of paint and applied to a sealed chart using a 3-mil Bird applicator. After drying, the relative depth of color was rated in accordance with the ASTM Standardized Scoring Scheme below. The colorants used are Colortrend Universal Colorants, Series 888-1045F Red Iron Oxide, 7214E Thalo Blue, and 2009L Raw Umber.  
         [0044]    Color Development—Using the same drawdown application as above, as the paint begins to dry; a 1-inch area was gently rubbed to redisperse any flocculated colorant. The change in color of the rubbed area verses the unrubbed area was rated in accordance with the ASTM Standardized Scoring Scheme below.  
         [0045]    Application Properties—Two-thirds of a 24×32-Inch Upson Board was primed with one coat of a latex primer and allowed to dry 24 hours. A portion of the primer was tinted a gray color (nominal reflectance of 25) and applied as a 3-inch stripe horizontally across the center of the primed area. After 48 hours drying the test panel was ready for the application of the test paint.  
         [0046]    The test paints were applied freely over the entire panel using a 3-inch roller (EZ Painter No. 3 FPS) until the gray stripe was obliterated (wet). The spreading rate was calculated from the amount of paint used and the weight per gallon of the paint. After drying overnight, a second coat was applied to one-third of the panel. After fifteen minutes, a 6-inch lap coat was applied covering 3-inches each of the first coat and second coat areas. The painted panel was allowed to dry overnight before applying a 4×4-inch touch-up on the two-coat area.  
         [0047]    The paints were also evaluated for the following properties:  
         [0048]    Ease of Application  
         [0049]    Spreading Rate  
         [0050]    Practical Opacity  
         [0051]    Foaming  
         [0052]    Spatter  
         [0053]    Leveling  
         [0054]    Cratering  
         [0055]    Sheen Uniformity  
         [0056]    One coat versus two coat area  
         [0057]    Primed versus unprimed areas  
         [0058]    Lap area  
         [0059]    Touch-up area  
         [0060]    Some observations were subjective and have been rated using the following ASTM Standardized Scoring System in order to avoid lengthy descriptions:  
                                                     Score   Performance or   Effect                                10   Perfect   None       9   Excellent   Trace       8   Very good   Very slight       6   Good   Slight       4   Fair   Moderate       2   Poor   Considerable       1   Very poor   Severe       0   No value   Complete failure                  
 
         [0061]    Test Results  
                                                               HIGH QUALITY FLAT INTERIOR PAINT                AMP-95   BAE                        Fineness of Dispersion                   Mill base   Hegman   4   4       Grinding time   Minutes   15   15       Final   Hegman   4   4       Viscosity   KU       Initial       93   89       After 2 weeks at 125° F.       87   83       Difference       −6   −6       pH       Initial       9.2   9.1       After 2 weeks at 125° F.       8.5   8.1       Difference       −0.7   −1.0       Package Stability   Score       Syneresis       9   8       Settling       10   10       Ease of redispersion       10   10       Seeding       10   10       Dry Time   Minutes       Set to touch       10   10       Tack free       15   17       Dry hard       25   40       Dry through       30   45       Gloss - 60°   Units   8   8       Sheen - 85°   Units   9   9       Opacity - 3 mil drawdown       0.967   0.964       Contrast ratio       Odor       Not obnoxious   Not obnoxious       Scrubbability   Cycles   4100   4100       Film Porosity       Reflectance   Percent       Before staining       91.4   94.0       After staining       89.9   92.5       Difference       1.5   1.5       Color Acceptance   Score       Red Iron Oxide       10   10       Thalo Blue       10   10       Raw Umber       10   10       Color Acceptance   Score       Red Iron Oxide       8   8       Thalo Blue       8   8       Raw Umber       10   10       Application Properties       Ease of application   Score   9   9       Spreading rate   Ft 2 /gal   415   400       Practical opacity   Score   8   6       Foaming   ″   10   10       Spattering   ″   8   8       Leveling   ″   8   8       Cratering   ″   10   10       Sheen Uniformity       One coat versus two coat area   Score   9   9       Primed versus unprimed area   ″   10   10       Lap area   ″   8   8       Touch-up area   ″   8   8                  
 
         [0062]    [0062]                                                               SEMIGLOSS INTERIOR ENAMEL                AMP-95   BAE                        Fineness of Dispersion                   Mill base   Hegman   7   7       Grinding time   Minutes   15   15       Final   Hegman   7   7       Viscosity   KU       Initial       86   89       After 2 weeks at 125° F.       90   92       Difference       4   3       pH       Initial       8.4   8.3       After 2 weeks at 125° F.       7.6   7.4       Difference       −0.8   −0.9       Package Stability   Score       Syneresis       6   6       Settling       10   10       Ease of redispersion       8   8       Seeding       10   10       Dry Time   Minutes       Set to touch       15   20       Tack free       115   115       Dry hard       135   150       Dry through       150   165       Gloss - 60°   Units   70   70       Sheen - 85°   Units   91   91       Opacity - 3 mil drawdown       0.966   0.968       Contrast ratio       Odor   Score   Not obnoxious   Not obnoxious       Scrubbability   Cycles   &gt;2500   &gt;2500       Film Porosity Reflectance   Percent       Before staining       94.8   94.7       After staining       93.7   93.6       Difference       1.1   1.1       Color Acceptance   Score       Red Iron Oxide       10   10       Thalo Blue       10   10       Raw Umber       10   10       Color Acceptance   Score       Red Iron Oxide       10   10       Thalo Blue       10   10       Raw Umber       10   10       Application Properties       Ease of application   Score   9   9       Spreading rate   Ft 2 /gal   340   320       Practical opacity   Score   8   6       Foaming   ″   4   4       Spattering   ″   2   2       Leveling   ″   8   8       Cratering   ″   10   10       Sheen Uniformity       One coat versus two coat area   Score   6   6       Primed versus unprimed area   ″   10   10       Lap area   ″   6   6       Touch-up area   ″   4   4                    
         [0063]    The use of BAE as a replacement for AMP in either the flat or semi-gloss paints evaluated in this study provided for comparable results both when incorporated into the mill base and/or into the letdown phase of the paint manufacturing. The BAE material exhibited equal effectiveness with regard to pigment dispersion and pH adjusment. Some additional observations based on the data collected are:  
         [0064]    High Quality Flat Interior Paint  
         [0065]    1. The BAE flat coating was comparable to AMP-95 coating for Fineness of Dispersion, Viscosity, pH, Package Stability, Gloss, Sheen, Opacity, Odor, Scrubbability, Film Porosity, Color Acceptance, and Color Development.  
         [0066]    2. The BAE coating exhibited a noticeable increase in the Tack Free, Dry Hard and Dry Through Dry Time properties.  
         [0067]    Semi-gloss Interior Enamel  
         [0068]    1. The BAE semi-gloss coating was comparable to AMP-95 coating for Fineness of Dispersion, Viscosity, pH, Package Stability, Gloss, Sheen, Opacity, Odor, Scrubbability, Film Porosity, Color Acceptance, and Color Development.  
         [0069]    2. The BAE coating exhibited a very slight increase in the Tack Free, Dry Hard and Dry Through Dry Time properties.