Patent Publication Number: US-4544466-A

Title: Process of making U.V. cured polyurethanes using diazonium salt promoters

Description:
This invention relates to a process for the rapid curing of polyurethane compounds in the presence of ultraviolet light sensitive diazonium salt compounds. 
     The reaction of diisocyanates, diols, and polyols to form polyurethane compounds is well known. Furthermore, the addition of such promoters as tin salts and tertiary amines to the urethane reaction mixture is also known. The disadvantage of using these reaction promoters, though, is that they promote almost instantaneous curing of the urethane which is not always desirable. Instead, it may be more desirable to add the reaction promoter with urethane curing achieved later on. 
     Therefore, it is an object of this invention to provide a rapid, efficient process for the curing of polyurethane compounds yet which does not take place almost immediately when a promoter is added to the urethane reaction mixture. 
     Other aspects, objects, and advantages of the present invention are apparent from the specification and claims. 
     In accordance with the present invention, I have discovered that in a process wherein hydroxy-containing hydrocarbons and diisocyanates are reacted to form urethane polymers, an improvement is made in the curing process by the addition of ultraviolet light activated diazonium salts to the reaction mixture. In this manner, curing is not achieved until the reaction mixture is exposed to ultraviolet light sufficient to affect activation of the diazonium salt compound. This contrasts sharply with the situation wherein undesired instantaneous curing is achieved with the addition of certain tin salts and tertiary amines to the reaction mixture. 
     Briefly, the process of my invention comprises the steps of (a) mixing together a diisocyanate compound, a diol, a polyol, and a diazonium salt compound and then thereafter (b) exposing the resulting mixture to ultraviolet light. 
     The diisocyanate compounds useful in the present invention are those represented by the formula OCN--R--NCO wherein R is a C 4  to C 12  alkylene, arylene, alkarylene, or aralkylene radical. 
     Exemplary of such diisocyanate compounds include 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, polymethylene polyphenyl isocyanate, hexamethylene diisocyanate, 4,4&#39;-methylene bis(cyclohexyl isocyanate) and mixtures thereof. Presently preferred are 4,4&#39;-methylene bis(cyclohexyl isocyanate), and mixtures of 2,4- and 2,6-toluene diisocyanate. 
     Any suitable diol may be used in the present invention such as 1,4-butane diol, polypropylene glycol, and hydroxy-terminated polyesters and mixtures thereof. 
     Additionally, any suitable polyol may be used in the present invention as well. Exemplary of such polyols are trimethylolpropane, pentaerythritol, glycerol, 1,4,6-hexanetriol, polyether polyols such as those derived from 1,2,6-hexanetriol and propylene oxide and mixtures thereof. 
     The diazonium salts useful in the present invention are those represented by the formula: ##STR1## wherein R 1  represents an electron withdrawing group (preferably either F, Cl, Br, I, or NO 2 ), M is an element selected from the group consisting of B, P, As, Sb, Bi, and Sn, n is 4, 5, or 6, and x is 1, 2, or 3. 
     Examples of such diazonium salts are: 
     p-chlorobenzenediazonium tetrafluoroborate 
     p-chlorobenzenediazonium hexafluorophosphate 
     p-bromobenzenediazonium hexafluorophosphate 
     p-fluorobenzenediazonium hexafluorophosphate 
     p-iodoenzenediazonium hexafluoroarsenate 
     p-nitrobenzenediazonium hexafluoroarsenate 
     p-nitrobenzenediazonium tetrafluoroborate 
     p-nitrobenzenediazonium hexafluoroarsenate 
     2,4-dichlorobenzenediazonium tetrafluoroborate 
     2,4-dibromobenzenediazonium hexafluoroarsenate 
     2,4-dichlorobenzenediazonium hexafluorophosphate 
     2,4-dichlorobenzenediazonium pentafluorostannate 
     2,4-dichlorobenzenediazonium hexafluorobismate 
     2,4,6-trichlorobenzenediazonium tetrafluoroborate 
     2,4,6-trichlorobenzenediazonium hexafluorophosphate 
     2,4,6-trichlorobenzenediazonium hexafluoroarsenate 
     2,4,6-trichlorobenzenediazonium hexafluoroantimonate 
     2,4-dinitrobenzenediazonium pentafluorostannate 
     2,6-dichlorobenzenediazonium hexafluoroborate 
     and mixtures thereof. 
     The synthesis of diazonium salts is well known in the art. Generally, it involves the reaction of a primary aromatic amine, NaNO 2 , and a mineral acid at a temperature usually in the range of about 0° C. to about 25° C. 
     In the present invention, the amount of diazonium fluoro compound employed is generally about 0.5 to about 5 weight percent based on the total weight of the isocyanate/diol/polyol/diazonium salt mixture. 
     Generally, the same approximate number of equivalents of diisocyanate should be employed as the total hydroxy equivalent amount of the diol and polyol. 
     After thorough mixing of the above ingredients, the above mixture is exposed to ultraviolet light, generally in the wavelength of about 2000 to about 4000 Angstroms to effect curing of the polyurethanes. Such light is available from sunlight and from many different commercial lamps including mercury vapor lamps, UV fluorescent lamps, and the like. 
     Conditions of exposure to ultraviolet light under which the desired product is obtained are generally exposure of about 0.1 second to about 20 minutes at a temperature in the range of about 0° F. to about 180° F., preferably about 1 minute to 5 minutes at a temperature in the range of about 75° F. to about 140° F. 
     The cured compounds of this invention are useful as resins in both the paint and ink industries. 
     The following examples further illustrate the present invention. 
    
    
     EXAMPLE I 
     This example describes the general procedure used to synthesize the diazonium compounds disclosed herein. 
     p-Chlorobenzenediazonium tetrafluoroborate was prepared as follows: To an 800 milliliter beaker was added 60 milliliters of concentrated hydrochloric acid and 60 milliliters of water followed by 12.75 grams (0.1 mole) of p-chloroaniline. The mixture was then cooled in a wet-ice bath and diazotized with 14 grams (0.2 mole) sodium nitrite dissolved in 24 milliliters of water. This solution was then filtered and the filtrate added slowly with a high rate of stirring to 34 grams (0.3 mole) of sodium tetrafluoroborate dissolved in 60 milliliters of water. The resultant mixture was stirred for an additional 5 minutes and then filtered. The residue was washed with 100 milliliters of distilled water which dissolved away about 50 percent of the product. The remaining material was dried for 4 hours at ambient room temperature and stored in a vacuum desiccator until used. 
     Additional similar diazonium compounds were prepared in the same manner. These compounds are listed in Table I. 
     
                       TABLE I                                                     
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Preparation of Aromatic Diazonium Fluoro Compounds                        
Basic Ingredients                                                         
Com-              Fluoro-                                                 
pound Amine       Salt     Product                                        
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1     p-Chloroaniline                                                     
                  NaBF.sub.4                                              
                           p-Chlorobenzenediazonium                       
                           tetrafluoroborate                              
2     p-Chloroaniline                                                     
                  NaPF.sub.6                                              
                           p-Chlorobenzenediazonium                       
                           hexafluorophosphate                            
3     p-Nitroaniline                                                      
                  NaAsF.sub.6                                             
                           p-Nitrobenzenediazonium                        
                           hexafluoroarsenate                             
4     p-Nitroaniline                                                      
                  NaBF.sub.4                                              
                           p-Nitrobenzenediazonium                        
                           tetrafluoroborate                              
5     p-Nitroaniline                                                      
                  NaPF.sub.6                                              
                           p-Nitrobenzenediazonium                        
                           hexafluorophosphate                            
6     2,4-Dichloro-                                                       
                  NaBF.sub.4                                              
                           2,4-Dichlorobenzene-                           
      aniline              diazonium                                      
                           tetrafluoroborate                              
7     2,4-Dichloro-                                                       
                  NaPF.sub.6                                              
                           2,4-Dichlorobenzene-                           
      aniline              diazonium                                      
                           hexafluorophosphate                            
8     2,4,6-Trichloro-                                                    
                  NaBF.sub.4                                              
                           2,4,6-Trichlorobenzene-                        
      aniline              diazonium                                      
                           tetrafluoroborate                              
9     2,4,6-Trichloro-                                                    
                  NaPF.sub.6                                              
                           2,4,6-Trichlorobenzene-                        
      aniline              diazonium                                      
                           hexafluorophosphate                            
10    2,4,6-Trichloro-                                                    
                  NaAsF.sub.6                                             
                           2,4,6-Trichlorobenzene-                        
      aniline              diazonium                                      
                           hexafluoroarsenate                             
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     EXAMPLE II 
     This example describes a qualitative determination of the sensitivity of substituted benzenediazonium polyfluoro compounds in a typical isocyanate/polyol reaction and illustrates that unlike other catalysts the diazonium compounds do not catalyze the isocyanate/polyol reactions unless subjected to ultraviolet light. 
     A mixture of 13.1 grams (0.1 equivalent) of Hylene W 4,4&#39;-methylene bis(cyclohexyl isocyanate), 3.60 grams (0.08 equivalent) of 1,4-butenediol and 1.02 grams (0.02 equivalent) of trimethylolpropane were mixed and placed in a test tube to which was then added 0.35 gram of a catalyst assumed to be dibutyltindilaurate. This catalyst was prepared in-situ from 0.17 gram (0.0006 mole) dibutyltin dichloride, 0.13 grams (0.0006 mole) of p-chlorobenzenediazonium tetrafluoroborate, and 0.11 gram (0.0006 mole) of lauric acid. The isocyanate/polyol/catalyst mixture cured to a hard foamy material within 10 minutes of mixing. 
     The procedure was repeated except the catalyst in-situ mixture was replaced with only 0.17 gram (0.0006 mole) dibutyltin dichloride. Again the isocyanate/polyol/catalyst mixture cured to a hard foamy material in 10 minutes. 
     Again the procedure was repeated except the catalyst consisted of only 0.13 gram (0.0006 mole) p-chlorobenzenediazonium tetrafluoroborate. The isocyanate/polyol/catalyst mixture did not cure at ambient room temperature in over 3 hours. The mixture was then irradiated with a 4 inch 100 Watt/inch Hanovia ultraviolet light whereupon some curing took place. Heating to about 150° F. (66° C.) and irradiating for 6 minutes resulted in about one-half the solution being cured. The cured material had a dark cherry red color. 
     These results which are summarized in Table II show the p-chlorobenzenediazonium tetrafluoroborate useful as a catalyst that is activated upon exposure to ultraviolet light. 
     
                       TABLE II                                                    
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Effect of Catalyst on a Isocyanate/Polyol Reaction                        
13.1 g (0.1 eq.) 4,4&#39;-methylene bis(cyclohexyl isocyanate)                
 3.6 g (0.08 eq.) 1,4-butanediol                                          
 1.02 g (0.02 eq.) trimethylolpropane                                     
Run                                                                       
No.  Catalyst             Results                                         
______________________________________                                    
1    0.35 g In-Situ dibutyltin dilaurate                                  
                          1.    Cures to hard                             
     (0.17 g dibutyltin dichloride                                        
                                foamy material in                         
     0.11 g lauric acid         10 minutes.                               
     0.13 g p-chlorobenzenediazonium                                      
     tetrafluoroborate)                                                   
2    0.17 g dibutyltin dichloride                                         
                          2.    Cured to hard                             
                                foamy material in                         
                                10 minutes.                               
3    0.13 g p-chlorobenzenediazonium                                      
                          3.    Does not cure in                          
     tetrafluoroborate          3 hours. Partial                          
                                cure after U.V.                           
                                exposure.                                 
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     EXAMPLE III 
     This example describes the procedure used to evaluate the diazonium fluoro compounds as catalysts for the isocyanate/polyol curing reaction. 
     The isocyanate, polyols and catalyst were mixed and placed in a quartz test tube. The contents were then exposed to ultraviolet light (4 inch 100 watt/inch Hanovia lamp) for the various times. The temperature of the liquid rose to about 150° F. (66° C.) due to the heat from the lamp. After 1 minute exposure time, the solution was cooled, transferred into a Soxhlet extractor through which refluxing acetone passed for about 8 hours. The remaining solid material was filtered, dried and weighed to determine the amount of polymerization that had occurred. This value was reported as % Polymerization. The process was repeated at 3, 5 and 10 minute exposure times. 
     These results are listed in Table III and indicate the best catalysts are those based on hexafluoro phosphorous (Runs 2, 5, 7 and 9) followed by those based on hexafluoro arsenic (Runs 3 and 10) followed by those based on tetrafluoro boron (Runs 6, 1, 4 and 8). 
     
                       TABLE III                                                   
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Effect of Diazonium Fluoro                                                
Compounds on Isocyanate/Polyol Polymerization (Curing)                    
Formulation:                                                              
           13.1 grams (0.1 eq.) Isocyanate.sup.a                          
            3.6 grams (0.08 eq.) 1,4-Butanediol                           
            1.02 grams (0.02 eq.) Trimethylolpropane                      
            0.18 gram Diazonium Catalyst                                  
                   % Polymerization                                       
                   at Various                                             
                   U.V. Exposure Times.sup.b                              
                         1      3    5    10                              
No.   Diazonium Catalyst min.   min. min. min.                            
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1     p-Chlorobenzenediazonium                                            
                         0       1.7 36.1 36.8                            
      tetrafluoroborate                                                   
2     p-Chlorobenzenediazonium                                            
                         2.6    12.2 75.5 72.8                            
      hexafluorophosphate                                                 
3     p-Nitrobenzenediazonium                                             
                         --     57.7 66.0 65.6                            
      hexafluoroarsenate                                                  
4     p-Nitrobenzenediazonium                                             
                         1.0    36.3 44.1 31.2                            
      tetrafluoroborate                                                   
5     p-Nitrobenzenediazonium                                             
                         1.1    60.9 68.6 64.6                            
      hexafluorophosphate                                                 
6     2,4-Dichlorobenzenediazonium                                        
                         0.5    17.7 39.2 58.6                            
      tetrafluoroborate                                                   
7     2,4-Dichlorobenzenediazonium                                        
                         1.4    71.1 64.9 66.3                            
      hexafluorophosphate                                                 
8     2,4,6-Trichlorobenzenediazonium                                     
                         0.3     2.9 26.1 39.3                            
      tetrafluoroborate                                                   
9     2,4,6-Trichlorobenzenediazonium                                     
                         1.3    52.2 59.0 65.4                            
      hexafluorophosphate                                                 
10    2,4,6-Trichlorobenzenediazonium                                     
                         2.5    81.5 72.6 71.1                            
      hexafluoroarsenate                                                  
11    Control-No Catalyst                                                 
                         0.1     0.1 29.5 29.2                            
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 .sup.a Hylene W, 4,4methylene bis(cyclohexyl isocyanate).                
 .sup.b 4 in. 100 watt/inch Hanovia U.V. lamp, exposure temp. 150° 
 F. (66° C.).                                                      
 
    
     Reasonable variations and modifications which will be apparent to those skilled in the art can be made in this invention without departing from the spirit and scope thereof.