Abstract:
A composition suitable for forming a paint marking on a roadway comprises a polyfunctional acrylate having at least four acrylate groups, an epoxy component and a polyfunctional amine. The polyfunctional acrylate reacts with the polyfunctional amine to form an adduct with secondary amine groups. The secondary amine reacts with the epoxy component to yield a chemically high crosslinked material having a no track time of less than about five minutes.

Description:
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     FIELD OF THE INVENTION 
     The invention relates to polymeric compositions that may be used in paint and adhesive applications. 
     BACKGROUND OF THE INVENTION 
     There has been recent activity surrounding the development of polymeric compositions that may be used, for example, in road- or pavement-marking applications. Due to the surface and ambient conditions under which the paint is subjected, it is desirable that the paint composition meet a number of requirements. These requirements include, for example, adhesion to road surfaces, resistance to chemical attack by water and/or salt, abrasion resistance, minimal hazard involving any processing solvents, ability to adhere to or hold or retain a glass bead filler or overcoating, long-term weather resistance, ability to be applied under a wide variety of ambient temperature and road surface conditions, flowability or sprayability, good wetting action with respect to roadway surfaces, and flexibility (i.e., the ability to move as road surfaces expand or contract). 
     A number of materials have been proposed for road surface paint compositions. For example, U.S. Pat. No. 4,185,132 to Gurney proposes the use of co-curative materials, namely a cycloaliphatic amine and an aliphatic amine, in combination with a liquid epoxide. The above mixture is applied to the paved surface, and the mixture cures in-situ. U.S. Pat. No. 4,105,808 to McKenzie proposes a paint composition for application at elevated temperatures on traffic roadways. The composition includes a paint vehicle having a nonvolatile organic film-forming binder and a volatile solvent in which the binder is dissolved. McKenzie alleges that the above mixture forms a non-tacky paint film when applied as a thin coating and exposed to ambient temperatures. U.S. Pat. No. 4,460,625 to Emmons et al. proposes coating and impregnating compositions for applications to concrete which include several monomers, a polyvalent metal salt or complex, and an organic peroxide. U.S. Pat. No. 4,051,195 to McWhorter proposes curable compostions formed from epoxide resin/polyacrylate ester or polymethacrylate ester compositions. 
     Notwithstanding the above developments, these compositions often cure in a relatively slow time period. As an example, the tack free time is typically more than 60 minutes during which time the road must be blocked to apply the paint. The lengthy delay is particularly troublesome in view of the increasing traffic volume in high growth regions. Moreover, the durability of this paint is believed to be limited. 
     U.S. Pat. Nos. 6,437,059 and 6,485,787 to Reichhold proposes for a composition suitable for forming a paint marking on a roadway comprises a polyfunctional urethane acrylate having at least two acrylate groups, an epoxy component and a polyfunctional amine. The polyfunctional urethane acrylate reacts with the polyfunctional amine to form an adduct with secondary amine groups. The secondary amine reacts with the epoxy component to yield a chemically crosslinked material having a no track time of less than about ten minutes. 
     Notwithstanding the above developments, these compositions often cure in a relatively fast time period, but the no track time of about ten minutes is not curing fast enough for road blocking free application. 
     Thus, there is a need in the art for a paint compositions which are faster curing, exhibit greater durability and friendly application. 
     SUMMARY OF THE INVENTION 
     The present invention addresses the shortcomings alluded to above, and provides a polymeric composition for use in traffic paint exhibiting a fast cure rate as defined in greater detail hereinbelow. The composition comprises a polyfunctional acrylate component, an epoxy component, and a polyfunctional amine component. Advantageously, the polyfunctional acrylate component reacts with the polyfunctional amine component to form a secondary amine component. The formation of the secondary amine proceeds relatively quickly. The secondary amine then reacts with the epoxy component such that a chemically high crosslinked or thermoset polymeric material is formed. The composition exhibits improved properties over conventional compositions, particularly two component epoxy system, in that the composition of the invention displays improved cure speed, improved durability and application friendly. 
     The polymeric composition may be employed in a traffic paint composition. The traffic paint composition comprises the polymeric composition and a pigment. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a reaction scheme in accordance with the method of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The invention will now be described in greater detail with reference to the preferred embodiments which follow. It should be appreciated, however, that these embodiments are for illustrative purposes only, and are not meant to limit the invention as defined by the claims. 
     As alluded to hereinabove, the invention refers to a polymeric composition that exhibits a fast cure rate. For the purposes of the invention, the term “fast cure rate” may be defined according to various measuring methods. In one instance, a fast cure rate may be defined by the term “no track time” which refers to the time necessary for the composition to cure on a road or other surface to the extent that no wheel tracks are left after the composition has been contacted by a vehicle. A preferred “no track time” is less than about 5 minutes, more preferably less than about 2 minutes, and most preferably less than or equal to about 1.5 minutes. In another instance, the term “through cure” refers to the time necessary for the composition (e.g., film) to develop hardness or integrity from a surface to a substrate. A preferred “through cure” time is less than about 8 minutes, and more preferably about 5 minutes. In yet another instance, the term “tack free time” refers to the time necessary for a composition in the form of a film to develop a hard surface. Preferably, the “tack free time” is less than about 15 minutes and is more preferably about 8 minutes. 
     The multi functional urethane acrylate component which is used as the polyfunctional acrylate component in the polymeric composition of the invention may be selected from those materials which are known in the art. Typically, the multi functional urethane acrylate component is a reaction product of a hydroxyl functional acrylate and an aliphatic isocyanate. Examples of hydroxyl functional acrylates include, but are not limited to, dipentaerythritolpentacrylate, ethoxylated dipentaerythritolpentacrylate, and propoxylated dipentaerythritolpentacrylate. A particularly preferred hydroxy functional acrylate is dipentaerythritolpentacrylate. Mixtures of the above may be employed. 
     Examples of aliphatic isocyanates that may be employed include, but are not limited to, isophoronediisocyanate, 1,1′-methylenebis(4-isocyantocyclohexane), hexamethyenediisocyanate, trimethyl-hexamethylenediisocyanate, biuret of isophoronediisocyanate, isocyanuratetrimer of isophoronediisocyanate, biuret of hexamethylenediisocyanate, isocyanuratetrimer of hexamethylenediisocycanate, prepolymers based on isophoronediisocyante and trimethylol propane, prepolymers of isophoronediisocyanate and pentaerythritol, and prepolymers of isophoronediisocyanate and hexane diol. Mixtures of the above may be employed. In general, the aliphatic isocyanate can either be a monomeric component or may be a material that is chain extended by a polyhydric alcohol that may include, but is not limited to, diols, triols, and tetraols that are known to one skilled in the art. Examples of alcohols include, but are not limited to, ethylene glycol, diethylene glycol, trimethylol propane, trimethylol ethane, pentaerythritol, ethoxylatedpentaerythritol, and propoxylatedpentaerythritol. The polyol may be in the form of a polyester polyol or a polyether polyol such as, but not limited to, polypropylene glycol or polyethylene glycol or a combination of both. 
     Particularly preferred aliphatic isocyanates are isophoronediisocyanate and prepolymers of isophoronediisocyanate and trimethylol propane and pentaerythritol. Mixtures of any of the above may be employed. 
     The multi functional urethane acrylate used in the invention preferably contains four or more acrylate functionalities, and more preferably six or more acrylate functionalities. 
     The multi functional acrylate component which is used as the polyfunctional acrylate component in the polymeric composition of the invention may be selected from those materials which are known in the art. Typically, the multi functional acrylate component is a reaction product of two hydroxyl functional acrylate. Examples of hydroxyl functional acrylates include, but are not limited to, dipentaerythritolpentacrylate, ethoxylated dipentaerythritolpentacrylate, and propoxylated dipentaerythritolpentacrylate. A particularly preferred hydroxy functional acrylate is dipentaerythritolpentacrylate. Mixtures of the above may be employed. 
     The multi functional acrylate used in the invention preferably contains four or more acrylate functionalities, and more preferably six or more acrylate functionalities. 
     The polymeric composition preferably comprises from about 5 to about 50 parts per weight of the polyfunctional acrylate component, and more preferably more from about 10 to about 40 parts by weight of this component. These percentages are based on the weight of the reactive components. 
     The epoxy component that is employed in the invention may be selected from a number of epoxy compounds that are known in the art. 
     For the purposes of the invention, the epoxy component may be selected from an epoxide resin, an epoxy diluent, and mixtures thereof. Preferably, the epoxy component has from about 1 to about 3 1,2-epoxy groups per molecule, and more preferably, from about 2 to about 2.5 1,2-epoxy groups per molecule. 
     For the purposes of the invention, an “epoxide resin” may be defined as an oligomer or polymer which contains epoxide functionality. The epoxide resin is preferably a glycidyl ether of a polyhydric phenol and polyhydric alcohol having an epoxide equivalent weight of from about 100 to about 500. Exemplary epoxide resins are the ones based on bisphenol-A and bisphenol-F, such as, but not limited to, the diglycidyl ether of bisphenol-A and the diglycidyl ether of bisphenol-F. Other epoxide resins include, but are not limited to, the diglycidyl ether of tetrabromobisphenol A, epoxy novolacs based on phenol-formaldehyde condensates, epoxy novolacs based on phenol-cresol condensates, epoxy novolacs based on phenol-dicyclopentadiene condensates, diglycidyl ether of hydrogenated bisphenol A, digylcidyl ether of resorcinol, tetraglycidyl ether of sorbitol, and tetra glycidyl ether of methylene dianiline. Mixtures of any of the above may be employed. 
     An “epoxy diluent” may be defined as an epoxy-containing monomeric component which is capable of reducing the viscosity of a composition. Examples of epoxy diluents include, but are not limited to, glycidyl ethers of the following alcohols: 2-ethylhexanol, C.sub.8-C.sub.10 alcohol, C.sub.12-C.sub.14 alcohol, cresol, p-tertiary butyl phenol, nonyl phenol, phenol, neopentyl glycol, 1,4-butanediol, cyclohexane dimethanol. propylene glycol, dibromoneopentyl glycol, trimethylol propane, trimethylol ethane, and n-butanol. Other diluents which do not contain epoxy functionality may be employed and include, for example, benzyl alcohol, and nonyl phenol. Diluents with acrylate functionality can be employed and include tripropylene glycol diacrylate, hexane dioldiacrylate, and trimethylol propane triacrylate. 
     Diluents with carbonate functionality may also be used and include ethylene and propylene carbonate. Preferably, the epoxy diluent has 1 1,2-epoxy group per molecule. Mixtures of any of the above can be used. 
     The polymeric composition may comprise various amounts of the epoxy component. Preferably, the composition comprises from about 10 to about 60 weight percent of the epoxy component, and more preferably from about 20 to about 50 weight percent. These amounts are based on the total weight of reactive components. 
     As set forth herein, the polymeric composition of the invention comprises a polyfunctional amine component. The polyfunctional amine preferably is an aliphatic amine. The polyfunctional amine preferably has at least two amine groups per molecule. Exemplary polyfunctional amines include, but are not limited to, diethylenetriamine, ethylene diamine, triethylenetetramine, tetraethylenepentamine, hexamethylenediamine, 1,2-diaminocyclohexane, amino ethyl piperazine, and the like. Mixtures of any of the above may be employed. Preferably, the polyfunctional amine is used in the polymeric composition an amount from about 10 to about 50 weight percent, and more preferably from about 20 to about 35 weight percent. These weight percentages are based on the total weight of reactive components. 
     In accordance with the invention, the polyfunctional amine may be used in the form of an adducted amine. The adducted amine may be prepared in accordance with procedures that are known in the art. Typically, the amine adduct is formed by reacting an excess of polyfunctional amine with an epoxy resin. An example of an amine adduct is set forth in U.S. Pat. Nos. 4,185,132 and 4,088,633 to Gurney; and U.S. Pat. No. 5,385,684 to Gutierrez et al, the disclosures of which are incorporated herein by reference in their entirety. In numerous instances, it may be preferable to employ the amine adducts. For example, the amine adducts may display a lower volatility relative to the unmodified polyfunctional amines thereby making them potentially safer to handle. Adduction may also be used to increase the amine hydrogen equivalent weight of the polyfunctional amine so that a practical mixing ratio of the components is possible, for example 2 parts of a component A (i.e., a polyfunctional urethane acrylate and an epoxy component) to 1 part of a component B (i.e., a polyfunctional amine) by volume. Moreover, adduction may improve the compatibility of the polyfunctional amine with the polyfunctional acrylate and epoxy component that potentially results in films with improved appearance. 
     The composition of the invention may also encompass other components that are conventionally employed in polymerizable systems. These components include, but are not limited to, accelerators, promoters, and the like. Examples of accelerators that may be used in the composition include, for example, nonyl phenol, t-butyl phenol, bisphenol A, benzyl alcohol, salicyclic acid, lactic acid, p-toluene sulfonic acid, and the like, along with mixtures of the above. 
     The polymeric composition of the invention is typically utilized in conjunction with a paint composition, although other uses are contemplated within the scope of the invention. The paint composition may employ those components, additives, and the like which are known to the skilled artisan. Examples of materials that are typically employed in traffic paint compositions are set forth in U.S. Pat. No. 4,105,808 to McKenzie, the disclosure of which is incorporated herein by reference in its entirety. In particular, the paint composition comprises pigments such that the paint is visible after being applied to the pavement. Typically, while or yellow pigment is employed in the composition, preferably in an amount ranging from about 15 to about 25 parts based on the weight of the composition. 
     In another aspect, the invention relates to a method of forming a paint marking on a roadway. The method comprises applying a traffic paint composition comprising the polymeric composition as defined herein to the surface of a roadway. The method is advantageous in that it may be used utilizing existing equipment under ambient conditions. 
     A preferred method for carrying out the invention is as follows. Preferably, the composition of the invention is present as a two-component composition in which polyfunctionalacrylate and epoxy component is part of Component A and the polyfunctional amine is part of Component B. Components A and B are applied, typically sprayed, to a substrate by employing conventional application equipment such as, for example, a plural component sprayer. Typically, Components A and B are mixed immediately prior to being applied. Subsequent to application to the substrate, the mixed composition of Components A and B rapidly cures generally according to the reaction scheme set forth in  FIG. 1 . 
     The foregoing examples are presented to illustrate the invention and are not intended to limit the scope of the invention as defined by the claims. All amounts listed in the examples are by weight, unless otherwise specified. The following list of resin components will be referred to in the examples: Resin A is diglycidyl ether of bisphenol A which is commercially available from Dow Chemical of Midland, Mich. as DER331. Resin A has an average molecular weight of 370 and an average epoxy equivalent weight of 187. Resin B is a decafunctional acrylate resin. Resin B is commercially available from Ruike Chemical of Zhejiang, China. as 3DA-80. Resin C a decafunctional urethane acrylate resin. Resin Cis commercially available from Ruike Chemical of Zhejiang, China. as UADEC-90. Resin D is a low molecular weight xylene formaldehyde resin, which is commercially available as Epodil LV5 from Air Products&amp; Chemicals Inc of Allentown, Pa. Resin E is an epoxy diluent, which is the glycidyl ether of C12-C14 alcohol. Resin E is commercially available from Reichhold Inc. of Research Triangle Park, N.C. as EPOTUF® 37-058. Resin F is a acrylate oligomer which is trimethol propane triacrylate and is commercially available from UCB Radcure of Smyrna, Ga. as TMPTA-N. Pigment A is titanium dioxide pigment, which is commercially available from Dupont of Wilmington, Del. as Ti-Pure® 902. 
     EXAMPLE 1 
     A pigment base was prepared by high-speed dispersing 50 parts of Pigment A in 50 parts of Resin A for 30 minutes until a Hegman Grind of 7 was obtained. 
     EXAMPLE 2 
     Component A of a fast curing traffic paint was prepared by blending 52 parts of pigment base from Example 1, 26 parts of Resin B, 22 parts of Resin A. The cure speed and durability properties of the cured films based on Example 6 are set forth in Table 1. 
     EXAMPLE 3 
     Component A of a fast curing traffic paint was prepared by blending 52 parts of pigment base from Example 1, 26 parts of Resin C, 17 parts of Resin A, 5 parts of Resin E. The cure speed and durability properties of the cured films based on Example 6 are set forth in Table 1. 
     EXAMPLE 4 
     Component A of a fast curing traffic paint was prepared by blending 52 parts of pigment base from Example 1, 30 parts of Resin C, 18 parts of Resin A. The cure speed and durability properties of the cured films based on Example 6 are set forth in Table 1. 
     EXAMPLE 5 
     Component A of standard epoxy traffic paint was prepared by blending 40 parts of pigment base from Example 1, 44 parts of Resin A, and 16 parts of Resin F. The comparative cure speed and durability properties of the cured films based on Example 6 are set forth in Table 1. 
     EXAMPLE 6 
     A polyfunctional amine adduct was prepared according to the following procedure. Into a 1 liter reaction flask equipped with stirring, temperature control, and nitrogen inert gas was charged 179.9 grams of diethylenetriamine was charged to reactor, no heat, start agitator, charge 30.8 grams of Resin D, and 384.3 grams of nonylphenol. 105 grams of resin A was charged while holding temperature at 70-90 degree. C. After addition is complete, hold for 30 minute sat 70 degree. C., and sample for final constants. The final composition had a calculated amine hydrogen equivalent weight of 86 and a viscosity of 55 stokes at 25.degree. C. 
     EXAMPLE 7 
     A plural component road-striping machine applied the paint compositions described in examples 4 and 6. The two components were heated to 120-130.degree. F. and spray applied to a road surface using a 2:1 mix ratio and a top dressing of retroreflective glass beads. A no track time test was run by driving an automobile over the stripe after the stripe was applied. The stripe passed the no track test after 2 minutes curing time. A standard epoxy stripe required approximately 6 minutes of curing time to pass the no track test. 
     
       
         
               
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                 Epoxy 
                   
                   
                   
               
               
                 Samples 
                 control 
                 Polyacrylate 
                 Polyacrylate 
                 Polyacrylate 
               
               
                   
               
             
             
               
                 Part A 
                 Example 5 
                 Example 2 
                 Example 3 
                 Example 4 
               
               
                 Part B 
                 Example 6 
                 Example 6 
                 Example 6 
                 Example 6 
               
               
                 Mix Ratio, 
                 2A to 1B 
                 2A to 1B 
                 2A to 1B 
                 2A to 1B 
               
               
                 by Volume 
               
               
                 Curing speed 
               
               
                 minutes 
               
               
                 Gel time 
                 6 
                 2 
                 2 
                 1:30 
               
               
                 No track Time 
                 30 
                 4 
                 4 
                 3 
               
               
                 without glass 
               
               
                 beads 
               
               
                 Through dry time 
                 59 
                 7 
                 6 
                 5 
               
               
                 Tack Free time 
                 63 
                 10 
                 9 
                 8 
               
               
                 Taber abrasion, 
                 85 
                 71 
                 69 
                 67 
               
               
                 mg lost after 
               
               
                 1000 cycles 
               
               
                 Flexibility ¾″ 
                 Fail 
                 pass 
                 pass 
                 pass 
               
               
                 Shore D hardness 
                 80 
                 82 
                 80 
                 82 
               
               
                 Accelerated 
                 5 
                 4 
                 3 
                 3 
               
               
                 werthering QUV 
               
               
                 initial Yellowness 
               
               
                 Index 
               
               
                 500 hour 
                 35 
                 18 
                 15 
                 9 
               
               
                 Yellowness Index 
               
               
                   
               
             
          
         
       
     
     Disclosed herein are typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation of the scope of the invention as defined by the claims.