Abstract:
The present invention provides an ambient temperature cured coated articles where the coating ts robbery, high elongation. weatherable coating composition as a mixture of two parts, one part containing a solution of a functional film forming polymer. and the other part providing the curing component. The stability as a premixed. one-part solution is limited to up to several months. The curable film former and curing component are mixed together at an overall 4% to 25% solids content The viscosity is less than 20,000 cps (Brookfield) such that the coating can be sprayed, brushed or dipped to form thin coatings of from 0. 001 - 0 020 mils. Coated rubber articles containing metal conductive particles exhibit heat emissive properties useful for extending the service life of the articles.
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Notices, Deadlines & Correspondence
Ambient Cured Coatings and Coated Rubber Products Trerefrom
Field of Invention
[0001] The present invention is directed to low viscosltyorganic solutions as
ambient temperature curable coatings which are brushed,dipped or spray-
applied to substrates such as rubbery elastomers, rigid metals or flexible-rigid
thermoplastic substrates to provide enhanced appearance, resistance to solvents
and fuels, and enhanced ozone resistance to the substrate. Such a coating is
flexible and can be factory-applied on original equipment or provided as a an
after-market coating or repair finish.
Background of the Invention
[0002] Fast reacting sealants which are moisture curable and contain plasticized
rubbery polymers and reactive silanes, along with catalysts are known. See for
example U.S. Pat. Nos 6,335,412, 5,051,463, 6,025,445, and 6,410,640. Such
rheology, and plasticizer renders these compositions unsuitable as brushable,
dippable and sprayable coatings, and plasticizer. As thin film coatings of 1-5
mils, plasticizer would be expected to interfere with adhesion and scuffing.
Furthermore catalysts used in such sealants provide problems regarding pot life.
[0003] Coatings In which the application is made by way of brushing, dipping
and spraying require low viscosity solutions with sufficient pot life so that gelation
does not occur once the coating composition is open to the atmosphere.
Coatings that provide a curing speed whereby they are dry-to-the-touch in a few
hours, but provide sufficient pot life would be useful
Summary of the Invention
[0004] The present invention provides an ambient temperature curable coating
and coated articles therefrom in a rubbery, high elongation, weatherable coating
composition which can be applied to flexible elastomeric substrates for a variety
of purposes. Preferred film forming polymers used in the composition provide
resistance to ozone, oils and solvents, and other embodiments may be applied
for the purposes of enhancing the cosmetic appearance of the substrate rubber.
The coating composition of the invention is resistant to long-term flex-fatigue and;
provides for excellent adhesion to flexible elastomeric substrates and exhibits in
the cured state at least 100% elongation as an unsupported film.
[0005] The curable coating mixture is a mixture of two parts, one part containing
a solution of a functionalized formingt polymer, and the other part providing
the curing component coreactive with the functionalized polymer. The stability as
a prernixed, one-part solution is limited to up to several months. The curable film
former and curing component are mixed together at an overall 4% to 25% solids
content. The viscosity can vary depending on the selected components and
must be less than 20,000 cps (Brookfield) such that the coating can be sprayed,
brushed or dipped to form thin coatings of from 0.001 - 0.020 mils.
[0006] More specifically, the coating composition of the invention comprises a
dilute, sprayable coating containing from 4 to 25% solids content in an organic
solution, in the substantial absence (< 1000 ppm) of water and less than 1000
ppm of free isocyanate groups, and devoid of condensation catalyst where part
(A) contains 100 parts of a functionalized hydrophobic, film former having a Tg of
less than 0°C, (b) 25 to 150 parts a co-reactive silane curing component per 100
wt. parts of film former, and the remainder of at least one organic solvent for said
film former. The silane chemically bonds to functional sites on the film forming
polymer and cures to form siloxane bonds upon condensing of hydrolyzable
groups upon exposure of the coated article to air.
[0007] In another specific embodiment, metal-filled emissive elastomeric
coatings, which are devoid of rubber accelerator, and curable without heat to
exhibit durable, weatherable adhesion and long term heat dissipation when
applied to flexible polymeric substrates, especially vulcanized rubber articles.
[0008] The preferred coatings disclosed herein cure at ambient conditions and
are resistance to solvents and fuels, and enhanced bzone resistance. The cured
film forming polymer utilized has at least about 90% light transmissivity or
transparency, contains no more than about 90% unsaturation in the cured state,
and provides a matrix through which radiant heat reflective (emissive) and
thermal transfer properties from the thermally conductive metal particulate filler
can deflect and dissipate a significant amount of heat, while the coating adheres
permanently and doe not undergo stress or environmental cracking or
embrittlement. Such coatings are useful to coat molded rubber goods, such as
pneumatic or non-neumatic wheels and tires, hoses, belts, mounts, and the like,
especially where used near hot bodies, like engine blocks or other industrial
components emitting radiant heat.
Detailed Description of the Preferred Embodiments
Functionalized Film Former and methods for Functionalizing
[0009] By hydrophobic is meant that at least 80% of the film forming polymer is
derived from water insoluble monomers. Film formers exclude the
polyoxyalkylene copolymers.
[0010] Functionalized elastomer film-formers used herein cure with the curing
component by one or more reaction routes. Blends of two different functionalized
film formers are suitable, each having the same of different type of functional
groups on the polymer. For example, a blend of carboxylated hydrogenated
nitrile butadiene and ethylene acrylic polymer will work. Salt forming reactions
and condensation reactions can occur between the film forming polymer and
curing component. The interaction between curing component and functional
groups on the film forming polymer include electrophile -nucleophile interactions.
Functional groups on the film former provide curing routes between the curing
component and film forming polymer in addition to the curing of the polymer and
curing component to itself and to the coating substrates. Functional groups on
the film forming polymer can be provided, such as by copolymerization of a
comonomer bearing a reactive group and in various methods to modify film
forming polymers by incorporation of functional groups onto the polymer after
polymerization.
[0011] The term "functionalized" means (1) that an electrophile, nucieophile,
especially an active hydrogen-bearing moiety is part of an ethylenic unsaturated
comonomer that is copolymerized, or (2) an electrophile, nucleophile and
especially an active hydrogen bearing compound is part of a graftlinking
compound or ethylenic unsaturated comonomer, which is graft-linked to the film
former base polymer, after- or post-polymerization, (3) a group which is reactive
to an active hydrogen group as part of a comonomeror graftlinking compound
and graft-linked to the film forming base polymer, post-polymerization. The
comonomer or grafted compound becomes ionically and/or covalently bonded to
the film forming polymer structure, and provides a pendant group capable of
reacting with the curing component which is coreactive therewith at ambient
temperatures.
[0012] Conventional approaches for incorporation of an active hydrogen-bearing
functional group or a co-reactive group therewith into a polymerized non-
functional elastomer such as by converting a functional group-bearing compound
into a suitable functional group precursor or the direct incorporation of a suitable
precursor radical may be accomplished when the elastomer-is in solution or in .
the molten state via the "Ene" reaction, whereby an allylic hydrogen transfer to an
enophile followed by coupling between two unsaturated termini occurs, or via
free-radical addition across a carbon-carbon double bond or in the molten state.
When the polymer is in the molten state, however, means capable of imparting
high mechanical shear, such as an extruder, will be used to effect the desired
reaction to incorporate the functional group to be converted or to directly
incorporate a suitable precursor radical. When the functional group to be
converted to a suitable precursor or the precursor radical incorporated directly is
incorporated via techniques such as metallation followed by reaction with a
suitable electrophile, on the other hand, incorporation1 will, preferably, be
accomplished with the polymer in solution.
[0013] Of the several methods available for incorporation of a functional group or
functional group precursor, those methods tending to incorporate a single
function group or functional group precursor unit at each site of incorporation with
minimal coupling of the elastomer polymer such as the ENE reaction and the
method involving metallation followed by reaction with an electrophile are
preferred. When a functional group to be converted to a suitable precursor is
incorporated into the elastomer, conversion of the functional group to the
precursor radical will also, generally, be accomplished with the polymer in
solution. In general, any of the solvents known to be useful for preparing such
elastomer polymers in solution may be used to effect these reactions or
conversions.
[0014] A variety of post-polymerization functionalization techniques are known
which provide heretofore non-functional addition polymers with nucleophilic, or
electrophilic crosslinking cure sites for use in the present invention. Hydroxyl
groups are useful functional groups for effecting the crosslinking reactions with
curing components used herein. U.S. Pat. No. 4,118,427 discloses hydroxyf-
containing curable liquid hydrocarbon prepolymers by ozonizing a high molecular
weight saturated hydrocarbon polymer such as polyisobutylene or ethylene-
propylene rubber, followed by reducing the ozonized material; e.g., by using
reducing agents such as diisobutyl aluminum hydride, to form the hydroxyl-
containing polymer.
[0015] A partial listing of nucleophilic and/or active hydrogen functional groups
that can be incorporated on the film forming polymer that are coreactive with
electrophilic group-substituted curing components or hydrolyzable groups are,
hydroxy-, mercapto-, isocyanato-, amino-, phenolic-, and carboxyl- groups.
Exemplary electrophilic groups incorporated on the film former and coreactive
with nucleophilic group-substituted curing components are alkyl halide-, benzyl
halide-, allyl halide-, ester-, ethers-, anhydride- groups, and the like. When the
film forming polymer contains a pendant nucleophilic group, the corresponding
group provided on at least one valency of the silicone atom of the silane curing
component can also include an alkoxy-, hydroxy-, mercapto-, isocyanato-,
amino-, phenolic-, glycido-, carboxyl-, oxirane-, benzyl halide-, allyl halide-, alkyl
halide-, ester-, ethers-, and/or anhydride- group.
(A) FUNCTIONALIZED COMONOMERS
[0016] The curable film forming polymer employed herein can be formed by
copolymerization of elastomer-forming monomers together with functionalized
comonomers or by reaction of a polymer with a functional group containing
monomer or reactive compound. The incorporated reactive group subsequently
cures the polymer by reaction of the curing component as described herein. The
curing method utilizes reactions of a crosslinking component with an active
hydrogen-bearing functional group or active hydrogen reactive group which
crosslinks with the corresponding reactive functional group on the copolymer or
pendant on the copolymer. It is convenient to introduce a functional group
bearing comonomer during polymerization of the film former polymer, as is
conventionally practiced. The various approaches of free radical addition
copolymerization, anionic addition polymerization, free-radical graftlinking,
metathesis grafting, and hydrolytic grafting are known in the art. The functional
group containing polymers, or copolymers include polymers characterized by
their major constituents, such as a-olefin elastomers, diene elastomers,
hydrogenated diene elastomers, fluoroelastomers, crosslinkable a-olefin
copolymer elastomers, acrylatic rubber, acrylate or methacrylate acrylate
copolymers, and ethylene-carboxylates, etc..
[0017] Preferred examples of rubbery copolymer elastomers include but are not
limited to anionic polymerized olefinic elastomers. Examples of anionic
polymerized olefinic rubbers include ethylene-propylene rubber, ethylene-
propylene-diene monomer rubber, polyisobutylene, or "butyl rubber", or any other
polymer of isoolefin optionally copolymerized with conjugated diene (such as
isoprene), optionally containing up to 30 wt. % or an a,b-ethylenic unsaturated
nitrile and/or styrenic comonomer (such as styrene and/or alkyl substituted
styrene), and the like. Particularly preferred elastomers include isobutylene-
isoprene copolymer, isobutylene-paramethylstyrene copolymer and the like.
[0018] A suitable pendant active hydrogen functional group is provided by
methods for forming amine-functionalized ethylene propylene diene monomer
rubber (EPDM) by the process described in U.S. Pat. No. 4,987,200. Likewise
higher molecular weight isobutylene copolymers functionalized with hydroxyl
groups can be produced using the process described in EPA 325 997.
Furthermore any commercially available halogenated isobutylene based polymer
containing a low level of halogen typically 0.5 to 2.0 mole % can be combined
with an alkylamine or an amino alcohol to produce the amine or the hydroxyl
functional group respectively.
[0019] Functionalized elastomers having an weight average molecular weight of
1000 up to 200,000 and containing hydroxyl and/or amine functional groups are
known. Hydroxy terminated polyisobutylene are conventionally prepared by
introducing hydroxy groups into the terminal positions of cationically polymerized
isobutylene by dehydrochlorinating, hydroborating and oxidizing chloro-terminal
polyisobutylene. Chloro terminated polyisobutylenes obtained by cationically
polymerizing an isobutylene monomer are known. See Faust and Kennedy in,
"Living Carbocationic Polymerization: III. Demonstration of the Living
Polymerization of Isobutylene," Polym. Bull. 15:317-23 (1986), disclose living
carbocationic polymerization of isobutylene and quenching the living recipe with
methanol and other reagents such as amines.
[0020] Living polymerization methods, some of which are described in U.S. Pat.
Nos. 5,350,819; 5,169,914; and 4,910,321 are preferred techniques to form the
film forming polymer. General conditions under which living polymerizations can
be achieved, for example using isobutylene include: (1) an initiator such as a
tertiary alkyl halide, tertiary alkyl ether, tertiary alkyl ester, or the like; (2) a Lewis
acid co-initiator which typically comprises a halide of titanium, boron or
aluminum; (3) a proton scavenger and/or electron donor; (4) a solvent whose
dielectric constant is selected considering the choice of the Lewis acid and the
monomer in accord with known cationic polymerization systems and monomer.
Terminal Functional Film Forming Polymers.
[0021] Electrophilc groups, nucleophilic groups, groups characterized by
bearing an active hydrogen group or groups reactive with active hydrogen groups
can be incorporated at the terminus of film former polymers which are useful
herein. Terminal groups coreactive with active hydrogen groups on a curing
component are useful. These film forming polymers are prepared by known
methods.
[0022] U.S. Pat. No. 5,448,100 discloses sulfonated telechelic polyisobtuylene
prepared by the "inifer" (initiator-transfer agents) initiated carbocationic
polymerization of isobutylene with Lewis acid to form polymer, followed by end-
quenching with acetyl sulfate and precipitation by steam stripping or with
methanol, ethanol, isopropyl alcohol, or acetone. The polymerization preferably
occurs in a chlorinated solvent, most preferably in a mixture of solvents, such as
methylene chloride, methyl chloride, or an aliphatic or alicyclic compound
containing five to ten carbon atoms. The Lewis acid can be, for example, boron
trichloride or titanium tetrachloride, or other metal halide (including tin
tetrachloride, aluminum chloride, or an alkyl aluminum). End-quenching
preferably occurs at a temperature between -90 ° to 0 °C, and most preferably at
the polymerization temperature or at the decomposition temperature of the
complex. The molar ratio of polyisobutylene to acetyl sulfate is preferably 1:1 or
greater.
[0023] Another example providing a film former polymer, such as
polyisobutylene with terminal active hydrogen groups reactive with a curing
component is a terminal silane group bearing a hydroxy or alkoxy group or other
hydrolyzable group. These can be obtained by a known route of
dehydrohalogenating a terminal tertiary carbon-chlorine g followed by an addition
reaction with an ethylenic unsaturated silane, the reaction of a polymer having a
terminal tertiary carbon-chlorine bond with allyltrimethylsilane to give a
polyisobutylene having an unsaturated group terminally and subsequent addition
reaction between the terminal unsaturated group and a hydrosilane compound by
using a platinum catalyst.
[0024] As the hydrosilane compound, there can be mentioned halogenated
siianes such as trichlorosilane, methyldichlorosilane, dimethylchlorosilane,
phenyldichlorosilane; alkoxysilanes such as trimethoxysilane, triethoxysilane,
methyldiethoxysilane, methyldimethoxysilane, phenyldimethoxysilane, etc.;
acyloxysilanes such as methyldiacetoxysilane, phenyldiacetoxysilane, etc.; and
ketoximate siianes such as bis(dimethylketoximate)methylsilane,
bis(cyclohexylketoximate) methylsilane, etc. Among these, halogenated siianes
and alkoxysilanes are preferred.
[0025] Such production processes are described, for example, in Japanese
Kokoku Publication Hei-4-69659, Japanese Kokoku Publication Hei-7-108928,
Japanese Kokai Publication Sho-63-254149, Japanese Kokai Publication Sho-
64-22904, and Japanese Patent Publication 2539445.
(i) Diene Elastomers
[0026] Functionalized hydrogenated diene copofymers suitable for use herein
as the film forming polymer are solid phase, high polymers having a molecular
weight of about 50,000 and higher, more typically 200,000 to 500,000, and
contain no more than 10% conjugated diene segments by weight. These
polymers are distinguished from liquid, functionalized oligomers, such as reactive
terminal-group functional liquid polymers, e.g., ATBN and CTBN that are not
suitable as the sole film former polymer herein but are blendable with a higher
molecular weight film forming polymer (50,000 and higher). The unsaturated
functionalized polymer for preparing the hydrogenated coating polymer
comprises broadly, from 50 to 85 percent by weight of conjugated diene
monomer units, 5 percent to 50 percent by weight one or more non-conjugated,
ethylenically unsaturated monomer units, and 1 to 20 percent by weight of a
functional comonomer or graft-linked compound bearing a reactive crosslinking
site. The preferred conjugated diene monomer units are derived from 1,3-
butadiene monomer, and the non-conjugated ethylenically unsaturated monomer
units are derived from one or more ethylenically unsaturated monomers selected
from unsaturated acrylic esters, methacrylic esters, nitrites such as acrylonitrile
and methacrylonitrile, and monovinyl aromatic hydrocarbons such as styrene and
alkylstyrenes, and vinylidene comonorners. Divinyl aromatic hydrocarbons such
as divinyl benzene, dialkenyl aromatics such as diisopropenyl benzene are
preferably absent. Other comonomers include alkyl (meth) acrylates such as
methyl acrylate, methyl methacrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl
acrylate or methacrylate, vinyipyridine, and vinyl esters such as vinyl acetate.
The preferred functional comonomers are selected from unsaturated carboxyiic
acids and esters thereof such as acrylic acid, methacryiic acid, crotonic acid,
itaconic acid, and maleic acid. The preferred glass transition temperature of
functionalized diene elastomer film formers must not exceed 0°C , and preferably
is less than -25°C in order to provide flex-cracking/ flex-fatigue resistance in the
coating. A preferred emulsion polymer latex comprises
[0027] Carboxyl end groups can be formed on diene elastomer high polymers
containing -C-CH=CH-C- type unsaturation by a chain scission methods in which
a rubber ozonide is formed, and aldehyde end groups are oxidized to carboxyl
groups using peroxide or peracid. Alternatively hydroxyl end groups on the
rubber ozonide can be formed by reductive techniques by catalytic hydrogenation
or by reducing agents like metal hydrides or borohydrides, and the like. See for
example British Patent No. 884,448. Likewise, U. S. Pat. No. 4,118,427
discloses liquid hydroxyl-containing curable liquid hydrocarbon prepolymers by
ozonizing a high molecular weight saturated hydrocarbon polymer such as
polyisobutylene or ethylene-propylene rubber, followed by reducing the ozonized
material; e.g., by using reducing agents, preferably diisobutyl aluminum hydride,
to form the above-noted hydroxyl-containing liquid prepolymers having a
substantially lower molecular weight than the parent polymer.
[0028] Incorporation of mercapto alcohol, or marcaptocarboxylates as
functionalized grafting compounds is readily adaptable for use in the present
invention. Suitable hydroxymercaptans and/or mercaptocarboxylic acid esters
containing hydroxyl. HS-R-OH compounds include those where R is a linear,
branched or cyclic C1-C36 alkyl group which can optionally be substituted by up
to 6 further hydroxyl groups or can be interrupted by nitrogen, oxygen or sulfur
atoms. Mercaptocaboxylates such as HS-{CHR2}n-(C(O)OR3OH)m wherein R2 is
hydrogen or a C1 -C6 alkyl group,
R3 is a linear, branched or cyclic C2 -C36 alkyl group which can optionally be
substituted by up to 6 further hydroxyl groups or can be interrupted by nitrogen,
oxygen or sulfur atoms, preferably -OH is primary, n is an integer from 1 to 5 and
m is an integer from 1 to 2 are suitable.
[0029] Preferred hydroxymercaptans are mercaptoethanol, 1-mercapto-3-
propanol, 1-mercapto-4-butanol, a-mercapto-a-hydroxyoligoethylene oxides,
e.g., a-mercapto-w-hydroxyoctaethylene glycol, or the corresponding ethyfene
oxide/propylene oxide copolyethers. Mercapto-ethanol and a-mercapto-w-
hydroxyoligoethylene oxides are preferred. Preferred mercaptocarboxylic acid
esters containing hydroxyl groups are esters of mercaptoacetic acid,
mercaptopropionic acid and mercaptobutyric acid with ethylene glycol, propylene
glycol, butylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol,
octaethylene glycol, dipropylene glycol, tripropylene glycol, tetrapropylene glycol
and N-methyldiethanolamine. The corresponding esters of mercaptoacetic acid
and 3-mercaptopropionic acid are particularly preferred.
Suitable types of elastomer film former base polymers reacted with the mercapto
compound include polymers of isobutylene, chloroprene, polybutadiene,
isobutylene/isoprene, butadiene/acrylonitrile, butadiene-acrylate copolymers, S-
B copolymers, butadiene-vinylidene chloride-acrylate type copolymers. Methods
for incorporation of mercapto compounds are described in U. S. Patent
6,252,008 to make a functional film former polymer. The rubber contains in the
region of 0.1 to 5 wt.% of bonded hydroxyl groups. The molecular weight of the
solution polymerized diene rubber containing hydroxyl groups incorporated
according to the method of U.S. 6,252,008 should lie in a range that dilute
solutions of 5 to15% solids can be obtained and be sprayable, brushable or
dippable, such as from 10,000 to 200,000 Mn (gel permeation chromatogragphy).
[0030] There are other known approaches for incorporating OH groups into the
suitable film forming polymers used herein, such as by addition reactions with
formaldehyde, reaction with carbon monoxide followed by hydrogenation, and
hydroboration followed by hydrolysis and copolymerization using silanes
containing an ethylehic unsaturated group. Representative silane comonomers
include vinylsilane or allyisilane having a reactive silicon group, of which there
may be mentioned vinyltrichlorosilane, vinylmethyldichlorosilane,
vinyldimethylchlorosiiane, vinyldimethylmethoxysilane, divinyldichlorosilane,
divinyldimethoxysilane, allyltrichlorosilane, allylmethyldichlorosilane,
allyldimethylchlorosilane, allyldimethylmethoxysilane, diallyldichlorosilane,
diallyldimethoxysilane, Y-methacryloyloxypropyltrimethoxysilane, and y-
methacryloyloxypropylmethyldimethoxysilane.
[0031 ] The functionalized diene elastomer will be described as follows with
respect to the most preferred embodiment for organic solvent-based coating
embodiments of the present invention as a functionalized butadiene acrylonitrile
copolymer but applies equally to preparation of the myriad other suitable
functionalized diene copolymers in light of the teachings herein. Nitrile
elastomers offer beneficial characteristics such as low temperature flexibility, oil,
fuel and solvent resistance as well as good abrasion and water-resistant
qualities, making them suitable for use in a wide variety of coating applications in
accordance with the invention.
[0032] The present invention is most preferredly carried out with a functionalized
hydrogenated nitrile rubber. The functionalization of HNBR with reactive
functionality provides critical enabling methods for crossiinking the coating
composition and obtaining the essential level of adhesion to the elastomer
substrates. Without adequate adhesion to the elastomer substrate, coatings
exhibit premature flex-cracking and/or delamination . The functional groups for
HNBR can be generally classified as containing active hydrogen groups,
ethylenic unsaturated groups or hydrolyzable groups. Crossiinking can be
effected through the addition of crossiinking components mentioned herein, by
exposure to moisture, heat (infra-red, thermal), by UV radiation, or by e-beam
radiation. Depending on the reactive functionality incorporated into the diene
copolymer. Some functionalized HNBR embodiments mentioned herein below
are self-curing without added crosslinker, and all can be are cured with suitable
crosslinking components added to the functionalized HNBR such as but not
limited to dinitrosobenzene, ZnO, gamma-POM, resoles, multifunctional amine,
isocyanates, acrylates, dicyandiamide , dicarboximides, and formaldehyde (or
UF, MF) resins.
[0033] As another example, a functionalized HNBR can be prepared by a
variety of ways known in the art. Functional groups can be incorporated by the
use of functional-group-containing comonomers, or by the use of graft-linkable,
functional-group-bearing compounds, and by functionalization of NBR using
metathesis, followed by hydrogenation of the modified NBR to give functionalized
HBNR or reaction of NBR with methylolated phenols followed by hydrogenation
of the modified NBR to give functionalized HBNR.
[0034] Functionalized HNBR containing active-hydrogen bearing functional
groups are preferred crosslinkable film formers in the curable emissive coating
composition. The presence of unsaturated groups (i.e., vinyl and disubstituted
olefins, nitriles) in the NBR provides reactive sites in which reactive functionality
may be attached and used for further crosslinking, post-polymer functionalization,
and grafting reactions. These reactive sites can be modified through either
catalytic or non-catalytic chemistries. Such modification can introduce any
number of active-hydrogen functional groups such as epoxides by epoxidation of
olefinic sites. Epoxides are readily converted to other functional groups through
ring-opening reactions. For example, glycols are produced by ring-opening with
base, glycol ethers with alkoxides or phenoxides, alcohols with carbanions or
hydrides. In addition, epoxides serve as crosslinkable sites using chemistry
available to one skilled in the art. Many other functional groups may be
introduced by reaction of the backbone olefins: hydrofomnylation (aldhehydes,
alcohols, carboxylic acids), hydrocarboxylation (carboxylic acids),
hydroesterification (esters), hydrosilylation (silanes), hydroamination (amines),
halogenation (halogens), chlorosulfonylation (chlorine, sulfonic acids),
hydroboration (boranes, alcohols, amines). Examples of such transformations
have been reviewed by Tremont (McGrath, M.P.; Sail, E.D.; Tremont, S.J.
"Functionalization of Polymers by Metal-Mediated Processes," Chem. Rev.
1995, 95, 381). The nitrile group of NBR elastomers also can be converted to an
amide by reaction with alcohols in an acid catalyzed process and to carboxylic
acids through hydrolysis.
[0035] Crosslinking can be effected through the addition of a crosslinking
component, moisture, thermal, UV radiation, or e-beam radiation. Depending on
the reactive functionality attached to HNBR and its intended use, suitable
crosslinking components can be added to the functionalized HNBR such as
dinitrosobenzene, ZnO, gamma-POM, resoles, multifunctional amine,
isocyanates, acrylates, and dicyandiamide. Particularly preferred crosslinking
components are those components known in the art for obtaining good bonds to
elastomeric articles. These components include DNB, ZnO, and QDO and can
be added to enhance the adhesion of the functionalized HNBR to a wide variety
of elastomeric materials.
[0036] The reactive functionality incorporated onto the diene elastomer,
includes, as non-limiting examples, phenolic OH, aliphatic OH, amine,
isocyanate, epoxy, acrylate, silyl ethers, siiyl chlorides, anhydrides, maleimides,
and Diels-Alder dieneophiles among the aforementioned functional groups.
[0037] The appropriate curing components and aids for the curing reactions are
well-known in the prior literature and patents in the adhesive and coating area for
curing the R.F. of this invention. For example, when the functional group on the
polymer is phenol, then isocyanate, dicarboximide, formaldehyde source, and
resoles are suitable curing components that are useful for crosslinking the
phenol-functionalized HNBR. Likewise, amine functionalized HNBR can be
crosslinked using isocyanate or dicarboximide, formaldehyde source, and
resoles, as examples. Epoxy functionalized HNBR can be crosslinked and cured
with appropriate amines and dicyandiamide components, as is known in the art
of Epoxy adhesive and coatings. Isocyanate functionalized HNBR is of particular
interest because it can be crosslinked or cured by moisture or by the addition of
other curative agents such as amine or polyols. Incorporation of the isocyanate
as part of the HNBR is particularly desirable because it reduces that amount of
free monomeric and therefore volatile isocyanate and its reported health and
safety issues. A latent isocyanate functionalized HNBR can be prepared by
reaction of an amine functionalized HNBR (or NBR) with a diary! carbonate to
give a urethane functionalized HNBR (or NBR). Thermal cracking of the
urethane forms the isocyanate functionalized HNBR (or NBR) (For example, see:
Kothandaraman, K.; Nasar, A.S. "The Thermal Dissociation of Phenol - Blocked
Toluene Diisocyanate Crosslinkers", J.M.S. - Pure Applied Chem. 1995, A32,
1009; Wicks, D.A.; Wicks, Z.W. "Blocked Isocyanates III: Part A. Mechanisms
and Chemistry", Progress in Organic Coatings 1999, 36, 148; Mohanty, S.;
Krishnamurti, N. "Synthesis and Thermal Deblocking of Blocked Diisocyanate
Adducts," Eur. Poiym. J. 1998, 34, 77). Anhydride functionality on the film
forming polymer can link to amine functional curing components. Silyl ether and
chlorosilanes can be utilized in other embodiments to crosslink the film forming
polymer.
[0038] Exemplary details of the aforementioned graft methods for incorporating
functional groups on a film forming elastomer is the melt processing of molten
film forming elastomer with a polyfunctional graftlinkable material such as
polyfunctional acrylate, maleated polybutadiene, and metal salts of difunctional
acrylates. For example an olefin elastomer such as EPDM can be masticated on
a two roll mill, with 5 parts of an acid scavenger such as zinc oxide, 1 part stearic
acid, an antioxidant and a peroxide followed by addition of 5 to 10 parts of a
multi-ethylenic unsaturated compound such as trimethylo propane triacrylate,
maleated liquid polybutadiene, or zinc diacrylate to the flux roll.
[0039] Functionalized HNBR can be prepared by the aforementioned
metathesis, followed by hydrogenation of the modified NBR to give functionalized
HNBR and (2) the reaction of NBR with methylolated phenols followed by
hydrogenation of the modified NBR to give functionalized HNBR.
[0040] A novel method for incorporating a reactive pendant functional group,
such as a carboxy, anhydride, hydroxy functionality is provided on a NBR
elastomer as follows:
[0041] Direct functionalization of any suitable unsaturated film former polymer
usable herein, and especially NBR, and is accomplished through the use of olefin
metathesis chemistry. Here, the olefin C=C double bonds are reacted with a
catalyst and a monomer. The olefin metathesis catalyst must be capable of
catalyzing metathesis reactions in the presence of nitrile functional groups. The
monomer can be any cycloolefin, olefin, or a,a)-diene that is capable of
undergoing an olefin metathesis reaction .(e.g., ring-opening metathesis
polymerization [ROMP], cross-metathesis, ring-opening-cross-metathesis, and
acyclic diene metathesis polymerization [ADMET]). These monomers are
derivatized with groups bearing functionality (e.g., carboxyiic acids, amides,
esters, anhydrides, epoxy, isocyanate, silyl, halogens, Diels-Alder diene and
dienophiles, etc.) to provide cure sites for secondary crosslinking reactions of the
cured film or to give new properties to the polymer. Kinetically, the metathesis
catalyst will likely attack the vinyl C=C bonds first, however, their low levels in the
HNBR copolymer may make attack at the backbone C=C double bond
competitive. Such attack on the backbone unsaturation will likely cause a drop in
molecular weight of the NBR, but the extent of such a process can be minimized
by using high NBR-to-catalyst levels. After reduction of the modified NBR using
for example the aforementioned catalytic hydrogenation methods, a reactive
modified HNBR polymer is obtained. The polymer can be crosslinked using
moisture, a selected curing agent, or an external energy source (UV or e-beam).
One particular preferred advantage of metathesis catalysis is that it provides a
unique means of introducing reactive functionality into NBR under mild conditions
in water or in solvent. So even NBR latex can be modified with reactive
functionality without de-stabilizing the latex thrbugh metathesis catalyst. This
feature allows the functionalization of a variety of commercially well known NBR
polymers, in solution or as aqueous dispersions, and latexes (water-based
polymerizate), followed by hydrogenation to yield functionalized HNBR.
Hydrogenated Protic Group terminated Diene polymers.
[0042] Hydrogenated hydroxy or carboxy terminated diene polymers, alone, or in
blends with high molecular weight (10,000 Mn and above) film forming polymers
are also suitable as a curable film former used in the emissive coating of the
present invention. Substantially saturated polyhydroxylated polydiene polymers
are known and commercially available. These represent anionic polymerized
conjugated diene hydrocarbons, such as butadiene or isoprene, with lithium
initiators, and terminated with OH groups. The process steps are known as
described in U.S. Pat. Nos. 4,039,593; Re. 27,145; and 5,376,745 for preparing
polyhydroxylated polydiene polymers. Such polymers have been made with di-
lithium initiator, such as the compound formed by reaction of two moles of sec-
butyllithium with one mole of diisopropylbenzene. Such a polymerization of
butadiene has been performed in a solvent composed of 90% by weight
cyclohexane and 10% by weight diethylether. The molar ratio of di-initiator to
monomer determines the molecular weight of the polymer. The polymer is
capped with two moles of ethylene oxide and terminated with two moles of
methanol to produce the dihydroxy polybutadiene. The hydroxylated polydiene
polymer is hydrogenated where substantially all of the carbon to carbon double
bonds become saturated. Hydrogenation has been performed by those skilled in
the art by established processes including hydrogenation in the presence of such
catalysts as Raney Nickel, noble metals such as platinum and the like, soluble
transition metal catalysts and titanium catalysts as in U.S. Pat. No. 5,039,755.
Suitable polyhydroxylated polydienes are those available from Shell Chemical
Company in the U.S.A. under the trade designation of KRATON LIQUID®
POLYMERS, HPVM 2200 series products, and from ATOCHEMIE under the
PolyBD® mark. The high molecular weight polymers suitable in blends with the
hydrogenated hydroxyl butadiene polymers are not limited, and include for
example the aforementioned carboxy modified chlorinated polyethylene,
chlorinated polyethylene, polymers of epichlorohydrin, ethylene-acrylic
copolymers, SBR, SBS, nitrile rubber (NBR), SIBS, EPDM, EPM, polyacrylates,
halogenated polyisobutylene, and polypropylene oxide, among others mentioned
herein, and known. The weight proportion of liquid hydrogenated polybutadiene
polyol to high molecular weight film former is limited such that the percent of
unsaturation in the combination is less than 20%, preferably less than 10%
overall. Therefore, where mixtures of the hydrogenated polydiene polyol are
made with unsaturated high polymers (Mn > 50,000) such as SBR, NBR, and the
like, the proportion of unsaturated polymer will be limited to maintain the overall
degree of saturation of at least 80%, preferably at least 90%. Modified
chlorinated polyolefins can include those modified with an acid or anhydride
group. Some examples of modified chlorinated polyolefins are described in U.S.
Pat. Nos. 4,997,882 (column 1, line 26 to column 4, line 63); 5,319,032 (column
1, line 53 to column 2, line 68); and 5,397,602 (column 1, line 53 to column 2,
line 68). The chlorinated polyolefins preferably have a chlorine content of from
about 10 to 40 weight percent, more preferably from about 10 to 30 weight
percent based on the weight of starting polyolefin. One suitable example of a
modified chlorinated polyolefin is the modified chlorinated polyolefin that has a
chlorine content of from about 10 to about 30 weight percent based on the weight
of polyolefin, which is not neutralized with an amine, and has an acid value in the
range of about 50 to about 100.
Hydrogenated Block Copolvmers
{0043] Suitable film formers adaptable according the invention are hydrogenated
styrene-butadiene-styrene block copolymers, hydrogenated styrene-isoprene-
styrene block copolymers, which are modified according to methods disclosed
herein above, adapted for chlorinated polyethylene, and elsewhere provide cure
functionality on the block copolymer for interaction with the curing agent. Some
elastomeric block copolymers containing carboxyl groups are available
commercially. Those block copolymers which contain more than 20%
unsaturation can be hydrogenated according to known hydrogenated methods,
including methods referenced herein.
Phenol Functional Elastomer
[0044] Functionalization of HNBR with phenol functionality can be carried out by
the combination of a methylolated phenol and the NBR, followed by
hydrogenation of the phenol-modified NBR intermediate. Methylolated phenols
can form covalent bonds with NBR and NBR copolymers by a variety of chemical
reactions as reported in the literature [A. Knop and L. Pilato, "Phenolic Resins
Chemistry and Applications and Performance1' Springer-Verlag, New York 1985,
Chapter 19 pg 288-297].
[0045] Various known isocyanate-reactive functional groups can be
incorporated in a functionalized elastomer film forming polymer. The
aforementioned carboxy-functional, hydroxy-functionai and amine functional
elastomers are most readily adaptable. Functional comonomers, like carboxy-
functional comonomers are readily adaptable to form a copolymer of
carboxylated hydrogenated nitrile rubber. For the purposes of the present
invention, the functionalized hydrogenated nitrile rubber can be defined as a
polymer comprising at least one diene monomer, nitrile monomer, and a
functional group-bearing compound such as a comonomer or a graftlinking
compound containing a functional group or a combination thereof. When the
abbreviation HNBR is utilized herein, it is to be understood that the term refers to
rubbers which can include diene monomer other than 1,3 butadiene, and
comonomers other than acrylonitrile, unless specifically stated. It is also
important to note that additional monomers can be polymerized along with or
grafted to the diene monomer to form the functionalized HNBR. The additional
monomers can, for example, provide at least one functional group to facilitate
crosslinking.
[0046] Functionalization of HNBR with phenolic functionality can be carried out
with the unsaturated un-hydrogenated polymer, or a partially hydrogenated
XHNBR polymer (80-97% hydrogenation level) by addition of methylol phenol or
ether derivative under heat and optionally catalyzed by suitable Lewis acid .
Preferably an ether blocking group is provided on the methylol phenol compound,
facilitating ease of post reaction hydrogenation. Addition can be through the
nitriie or carboxyl groups by ester formation, or by way of the aforementioned
addition at allylic sites. Preferably a metathesis reaction of an ethylenic
unsaturated compound bearing a phenol group can be done in solvent or water.
Alternatively, an olefinic bearing methylolated phenyl ether or phenol can be
metathesized with NBR, followed by hydrogenation. The phenol functionalized
NBR is subsequently hydrogenated. A methylolation reaction can be undertaken
using a phenol functional NBR or HNBR with formaldehyde to generate a
methylolated phenol functionality in the NBR, or with HNBR. Methylolated
phenols can form covalent bonds with NBR and NBR copolymers by a variety of
chemical reactions as reported in the literature. See, A. Knop and L. Pilato,
"Phenolic Resins Chemistry and Applications and Performance" Springer-Verlag,
New York 1985, Chapter 19 pg 288-297. The following structural diagrams
illustrate functionalizing with a representative phenolic bearing compound.
[0047] While it is possible to combine any methylolated phenol with NBR, mono-
methylolated phenols are especially preferred. The combination of Mono-
methylolated phenols with NBR polymers yields phenol functionalized-NBR
products which are stable. After hydrogenation of the phenol-modified NBR
according to known procedures in the art (e.g. cat. hydrogenation), a stable
phenol-modified HNBR copolymer is obtained. The pherrol-functionalized HNBR
copolymer can be crosslinked with a variety of well-known crosslinkers for
phenolic resins including those selected from the class of chemical compounds
dicarboximides, isocyanate, and formaldehyde source (paraformaldehyde,
gamma-POM, hexamethyiene amine, phenolic resoles or etherified phenols).
[0048] Phenol functionalized HNBR firstly to prepare a phenol functional
polymer via a phenol monomer with methylolated phenol functionalized
BNR/HBNR can be prepared by known procedures in the art. The phenol
functionalized NBR/HNBR can be prepared by either the mono-methylolated
phenol or by metathesis involving unsaturated monomer with the unsaturated
NBR. The methylolated phenol functionalized NBR/HBNR prepared by
metathesis utilizes a methylolated phenolic monomer with NBR. These
materials are useful not only as coatings in accordance with the present
invention, but also as components of elastomer-to-metal adhesives,
autodepositing materials, RFL dips, and reactive tougheners (e.g. epoxy
adhesives) taking advantage of their unique curing, film-forming, metal adhesion
and compatibility properties. Methylolated phenol functionalized NBR/HNBR are
capable of self-curing (i.e. without an external curing agent). Methylolated
phenol functionalized NBR/HNBRderivatives are capable of curing with other
coating components, such as phenolic novolaks, active hydrogen reactive or
active hydrogen containing crosslinkers and rubber/elastomer toughening
agents. Methylolated phenol functional HNBR can be used with known
vulcanizing agents for rubber. The vulcanization reaction is based on the
formation of either a quinone methide or a benzylic carbenium that is generated
by the thermal or catalytic activation of the methylolated phenols. The quinone
methide intermediate reacts by abstraction of allylic hydrogen. Alternatively,
methylolated phenols under acidic catalyzed conditions can generate reactive
benzyl carbenium ions which will react with unsaturated polymers in the
substrate.
[0049] Isocyanate functionalized HNBR can be crosslinked or cured by moisture
and on contact with carboxy, amine or polyol functional silanes. Incorporation of
the isocyanate as part of the HNBR is particularly desirable because it reduces
that amount of free monomeric isocyanate groups and therefore volatile
isocyanate and its reported health and safety issues. Maleimide functionalized
HNBR can be crosslinked either by the Michael addition reactions with suitable
curing nucleophiiic groups on the silane curing agent. Ethyienic unsaturated
acrylate-functionalized HNBR is capable of both free radical, UV and e-beam
curing. Anhydride functional HNBR can be cured using amines and components
described in the artsuch as epoxy functional silanes. Silyl ethers and chlorides
are moisture curing.
[0050] To provide the ethylenically unsaturated nitrile-conjugated diene rubber
with high saturation, the nitrile rubber is hydrogenated by conventional means.
Generally any of the numerous known processes for hydrogenation can be
utilized, including but not limited to, solution hydrogenation and
oxidation/reduction hydrogenation. The hydrogenation serves to saturate at least
80% of the unsaturated bonds of the rubber. When the degree of saturation is
less than 80%, the rubber's heat resistance is low, The more preferred degree of
saturation of the rubber is 95-99.99%.
[0051] The preferred conjugated diene monomers useful for preparing the
carboxylated acrylonitrile-butadiene copolymers which are further hydrogenated
can be any of the well-known conjugated dienes including dienes having from
about 4 to about 10 carbon atoms, such as, but not limited to, 1,3-butadiene; 2-
methyl-1,3-butadiene, 2,3-dimethyl- 1,3-butadiene; 1,3-pentadiene; 1,3-
hexadiene; 2,4-hexadiene; 1,3-heptadiene; piperylene; and isoprene, with 1,3-
butadiene presently being preferred.
[0052] The unsaturated nitrile monomers copolymerized to form a carboxylated
acrylonitrile-diene copolymer typically correspond to the following formula:
wherein each A is hydrogen or a hydrocarbyl group haying from 1 to about 10
carbon atoms. Examples of A groups include alky! and cycloalkyl, such as
methyl, ethyl, isopropyl, t-butyl, octyl, decyl, cyclopentyl, cyclohexyl, etc., and
aryls such as phenyl, tolyl, xylyl, ethylphenyl, t-butylphenyl, etc. Acrylonitrile and
methacrylonitrile are the presently preferred unsaturated nitriles.
[0053] The HNBR of the present invention also includes functional group
containing monomers which are polymerized into the backbone of the HNBR, or
functional group containing compounds which have been grafted to the HNBR, or
a combination thereof.
[0054] Carboxyl group containing monomers are optionally utilized in the
rubbers of the present invention. Carboxyl groups are derived from cc,|3-
unsaturated monocarboxylic acid monomers with 3 to about 5 C-.atoms such as
acrylic acid, methacrylic acid and crotonic acid and/or other known carboxyl
group-containing monomers such as, but not limited to a,p-unsaturated
dicarboxylic acids with 4 to about 5 or about 6 C-atoms, e.g., maleic acid, fumaric
acid, citraconrc acid and itaconic acid. The bound unsaturated carboxylic acid
may be present in an amount of from about 1 to about 10 weight percent of the
copolymer, with this amount displacing a corresponding amount of the
conjugated diolefin. Preferably, the monomer is an unsaturated mono- or di-
carboxylic acid derivative (e.g., esters, amides and the like). Functions of the
carboxyl group containing monomers include serving as a crosslinking site and
enhancing adhesion.
[0055] Additional, functionalized comonomers can be polymerized into the
backbone of the HNBR copolymer. Examples of the functional ethylenically
unsaturated monomers which are copolymerizable with the nitrile monomers and
the conjugated diene monomers are: hydrazidyl-group containing ethylenic
unsaturated monomers, amino-group-bearing ethylenic unsaturated monomers,
thiol-group bearing unsaturated ethylenic unsaturated monomers, unsaturated
carboxylic acids such as acrylic acid, methacrylic acid, itaconic acid and maleic
acid and salts thereof, alkyl esters of unsaturated carboxylic acids such as
various acrylates, for example methyl acrylate and butyl acrylate; alkoxyalkyl
esters of unsaturated carboxylic acids such as methoxy acrylate, ethoxyethyl
acrylate, methoxyethyl acrylate, acrylamide, and methacrylamide,
chlorodimethylvinylsilane, trimethylsilylacetylene, 5-trimethylsilyl-1,3-
cyclopentadiene, 3-trimethylsilylallyl alcohol, trimethylsilyl methacrylate, 1-
trimethylsilyloxy-1,3-butadiene, 1-trimethylsilyloxycyclopentene, 2-
trimethylsilyloxyethyl methacrylate, 2-trimethylsilyloxyfuran, 2-
trimethylsilyloxypropene, allyloxy-t-butyldimethylsilane and
allyloxytrimethylsilane..
[0056] Also suitable as functional comonomers are various classes of
monomers such as N,N-disubstituted-aminoaIkyl acrylates; N,N-disubstituted-
aminoalkyl methacrylates; N,N-disubstituted-arninoalkyl acrylamides; N,N-
disubstituted-aminoalkyl methacrylamides; hydroxyl-substituted-alkyl acrylates
and hydroxyl-substituted-alkyl methacrylates, N-alkylol substituted acryiamides
such as N-methylolacrylamide, N,N'-dimethylolacrylamide and N-
ethoxymethylolacrylamide; N-substituted methacrylamides such as N-
methylolmethacrylamide, N,N'-dimethylolmethacrylamide and N-
ethoxymethylmethacrylamide especially where free radical initiated
copolymerization occurs in the presence of an alkylthiol compound having 12 to
16 carbon atoms three tertiary carbon atoms.
[0057] Of these polar group-containing vinyl monomers, N,N-disubstituted-
aminoalkyl acrylates, N,N-disubstituted-aminoalkyl methacrylates, N,N-
disubstituted-aminoalkyl acrylamides and N,N-disubstituted-aminoalkyl
methacryiamides are preferable.
[0058] As specific examples of N,N-disubstituted-aminoalkyl acrylates, there can
be mentioned acrylic acid esters such as N,N-dimethylaminomethyl acrylate,
N,N-dimethylaminoethyl acrylate, N,N-dimethylaninopropyl acrylate, N,N-
dimethylaminobutyl acrylate, N,N-diethylaminoethy! acrylate, ISf.N-
diethylaminopropyl acrylate, N,N-diethylaminobutyl acrylate, N-methyl-N-
ethylaminoethyl acrylate, N,N-dipropylamlnoethyi acrylate, N,N-dibutylaminoethyl
acrylate, N,N-dibutylaminopropyl acrylate, N,N-dibutylaminobutyl acrylate, N,N-
dihexylaminoethyl acrylate, N,N-dioctylaminoethyl acrylate and acryloyl
morpholine. Of these, N,N-dimethylaminoethyl acrylate, N,N-diethyluninoethyI
acrylate, N,N-dipropylaminoethyl acrylate, N,N-dioctylaminoethyl acrylate and N-
methyl-N-ethylaminoethyl acrylate are preferable.
«
[0059] As specific examples of N,N-disubstftuted-aminoalkyl methacrylates,
there can be mentioned methacrylic acid esters such as N,N-
dimethylaminomethyl methacrylate N,N-dimethylaminoethyl methacrylate, N,N-
dimethylaminopropyl methacrylate, N,N-dimethylaminobutyl methacrylate, N,N-
diethylaminoethyl methacrylate, N,N-diethylaminopropyl methacrylate, N,N-
diethylaminobutyl methacrylate, N-methyl-N-ethylaminoethyl methacrylate, N,N-
dipropylaminoethyl methacrylate. N,N-dibutylaminoethyl methacrylate, N,N-
dibutylaminopropyl methacrylate, N,N-dibutylaminobutyl methacrylate, N,N-
dihexylaminoethyl methacrylate and N,N-dioctylaminoethyl methacrylate. Of
these, N,N-dimethylaminoethyl methacrylate, N,N-diethylaminoethyl
methacrylate, N,N-dipropylaminoethyl methacrylate, N,N-dioctylaminoethyl
methacrylate and N-methyl-N-ethylaminoethyl methacrylate are preferable.
[0060] As specific examples of N,N-disubstituted-aminoalkyl acrylamides, there
can be mentioned acrylamide compounds such as N,N-dimethylaminomethyl
acrylamide, N,N-dimethylaminoethyl acryiamide, N,N-dimethylaminopropyl
acrylamide, N,N-dImethyIaminobutyl acrylamide, N,N-diethyiaminoethyl
acrylamide, N,N-diethylaminopropyl acrylamide, N,N-diethylaminobutyl
acrylamide, N-methyl-N-ethylaminoethyl acrylamide, N,N-dipropylaminoethyi
acrylamide, N,N-dibutylaminoethyl acrylamide^N.N-dibutylaminopropyl
acryiamide, N,N-dibutylaminobutyl acjrylarnide, N.NTdihexylaminoethyl acrylamide
N.N-dihexylaminopropyl acrylamide and N,N-dioctylaminopropyl acrylamide. Of
these, N,N-dimethylaminopropyl acrylamide, N,N-dlethylaminopropyl acrylamide
and N,N-dioctylaminopropyl acrylamide are preferable.
[0061] As specific examples of N,N-disubstituted-aminoalkyi methacrylamides,
there can be mentioned methacrylamide compounds such as N,N-
dimethylaminomethyl methacrylamide, N,N-dimethylaminoethyl methacrylamide,
N,N-dimethylaminopropyl methacrylamide, N,N-dimethylaminobutyl
methacrylamide, N,N-diethylaminoethyl methacrylamide, N,N-diethylaminopropyl
methacrylamide, N,N-diethylaminobutyl methacrylamide, N-methyl-N-
ethylaminoethyl methacrylamide, N.N-dipropylaminoethyl methacrylamide, N,N-
dibutylaminoethyl methacrylamide, N,N-dibutylaminopropyl methacrylamide, N,N-
dibutylaminobutyl methacrylamide, N,N-dihexylaminoethyl methacrylamide, N,N-
dihexylaminopropyl methacrylamide and N,N-dioctylaminopropyl
methaorylamide. Of these, N,N-dimethylaminopropyl methacrylamide, N,N-
diethylaminopropyl methaorylamide and N,N-dioctylaminopropyl methacrylamide
are preferable.
[0062] As specific examples of the hydroxy-substituted-alkyl acrylates and
hydroxy-substituted-alkyl methacrylates, there can be mentioned hydroxymethyl
acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, 3-hydroxypropyl
acrylate, 3-chloro-2-hydroxypropyl acrylate, 3-phnoxy-2-hydroxypropyl acrylate,
hydroxymethyl methacryiate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl
methacrylate, 3-hydroxypropyl methacrylate, 3-chloro-2-hydroxypropyl
methacrylate and 3-phnoxy-2-hydroxypropyl methacrylate. Of these,
hydroxymethyl acrylate, 2-hydroxyethyl acrylate, hydroxymethyl methacrylate
and 2-hydroxyethyl methacrylate are preferable.
[0063] The NBR copolymers are polymerized by reaction of any of the
aforementioned exemplary conjugated dienes, unsaturated nitrile, and
unsaturated functional-group containing comonomers in the presence of a free
radical initiator by methods well known to those skilled in the art. Suitable free
radical initiators are beyond the scope of this disclosure, and are typically organic
oxides, peroxides, hydroperoxides, and azo compounds, etc., such as hydrogen
peroxide, benzoyl peroxide, cumene hydroperoxide, di-tert-butyl peroxide,
ascaridole, acetyl peroxide, tert-butyl hydroperoxide, trimethylamine oxide,
dimethylaniline oxide, isopropylperoxydicarbonate, diisobutylene ozonide,
peracetic acid, nitrates, chlorates, perchlorates, azobisisobutyronitrile, etc.
[0064] Hydrogenation of nitrile rubber is known to the art and to the literature.
For example, a preferred commercially available X-HNBR (carboxylated-HNBR)
is made from a carboxylated nitrile-diene copolymer that is hydrogenated in two
steps. It is known that the C-C double bonds of the 1,2-vinyl-configured
butadiene units in NBR are hydrogenated very rapidly, followed by the 1,4-cis
configured units. The 1,4-trans configured butadiene units are hydrogenated
comparatively slowly. The NBR products used for hydrogenation are
distinguished by a predominant proportion of the 1,4-trans configured double
bonds.
[0065] In the 2-stage hydrogenation carbon-to-carbon double bonds are first
reduced, followed by reduction of the carbon-to-nitrogen bond. As is known in
the art, this procedure avoids the gelation of the hydrogenated polymers which
may occur if the reduction is carried out in one step. In the first step, a different
catalyst may be used, for example, a palladium or ruthenium catalyst. If desired,
however, the nitriie groups alone may be reduced by proper choice of the
catalyst, leaving unsaturated carbon-to-carbon bonds in the linear polymeric
chain. It is possible also to use a combination of noble metal and nickel or
cobalt, operating first at a relatively low temperature, then at a higher
temperature. Other techniques for hydrogenating acrylonitrile-butadiene
copolymers are disclosed in, for example, U.S. Pat. Nos. 4,581,417; 4,631,315;
and 4,795,788.
[0066] A partly or completely hydrogenated nitrile rubber (HNBR) is also
described in several specifications (for example DE-OS No. (German Published
Specification) 2,539,132; DE-OS No. (German Published Specification)
3,329,974; DE-OS No. (German Published Specification) 3,046,008 and
3,046,251; and European Patent No. A-111,412). All of these specifications
describe a process for the preparation of a partly or completely hydrogenated
NBR which can be vulcanized (for example with the aid of sulphur vulcanization
systems or peroxide vulcanization systems).
[0067] Hydrogenation of X-HNBR latex can be carried out by known
conventional techniques. A carboxylated NBR polymer latex made conventionally
using anionic surfactants is combined with (1) an oxidant selected from the group
consisting of oxygen, air and hydroperoxides; (2) a reducing agent selected from
hydrazine and hydrates thereof; and (3) a metal ion activator; (b) and heating the
mixture to a temperature from 0 °C. to the reflux temperature of the reaction
mixture. This technique is taught in U.S. Patent No. 4,452,950, assigned to
Goodyear Tire and Rubber Co..
[0068] Furthermore, a hydrogenation process carried out in organic solution is
known from U.S. Patent No. 4,207,409 for NBR polymers manufactured by
anionic polymerization, taken up in solution in the presence of a catalyst mixture
comprising a soluble compound of iron, cobalt or nickel, an aluminum-organic
compound and water.
[0069] The most preferred acrylonitrile-butadiene copolymers are typically
hydrogenated to an extent such that the final product has an unsaturation level of
from about 1 to 20 mole percent, desirably from about 1 to about 10 or 15 mole
percent, and preferably from about 1 to about 5 mole percent.
[0070] A suitable carboxylated hydrogenated nitrile rubber X-HNBR is
manufactured by Bayer under a trade name of Therban®", for example Therban
KA 8889. X-HNBR may have an iodine value of preferably about 50% or less,
more preferably about 1 to 40%, most preferably from about 1 to 20%.
Resistance against heat and demanding solvents can be increased when X-
HNBR having a iodine value of 50% or less (high hydrogenation ratio) is used,
and rubber elasticity at a low temperature can be maintained by the use of the X-
HNBR rubber having a low hydrogenation ratio. The central value of the nitrile
content of HNBR is preferably from about 15 to 60%, more preferably from about
25 to 50%, most preferably from about 30 to 40%. Resistance against solvents
can be increased by the use of HNBR having a nitrile content of about 15% or
more, particularly about 30% or more, and low-temperature flexibility can be
retained by the use of the rubber having a nitrile content of about 60% or less,
particularly about 50% or less. In addition, its Mooney viscosity as the central
value of ML.1+4 (100° C.) (hereinafter referred to as "Mooney viscosity") is
preferably from about 40 to 100, and for a coating, lower Mooney viscosity of 40-
60 is preferred. When X-HNBR having a Mooney viscosity falling within this
range is used, the coating composition exhibits high resistance against organic
liquids and good flexibility and low-temperature resistance.
[0071] The HNBR of the present invention can also have crosslinker reactive
functional groups graft-linked thereto by aforementioned methods; either before
or after hydrogenation. As examples of the unsaturated compound having a
functional group, may be mentioned vinyl compounds having a functional group,
and cycloolefins having a functional group. The introduction of the functional
group by the graft-modifying method can be carried out by reacting the HNBR
with a functional group-containing unsaturated compound in the presence of an
organic peroxide. No particular limitation is imposed on the functional group-
containing unsaturated compound. However, epoxy group-containing
unsaturated compounds, carboxyl group-containing unsaturated compounds,
hydroxyl group-containing unsaturated compounds, silyl group-containing
unsaturated compounds, unsaturated organosilicon compounds, etc. are
mentioned for reasons of improvements of crosslinking density and adhesion to
substrates at a low modification rate.
[0072] Examples of the epoxy group-containing unsaturated compounds or
epoxy group-containing cycloolefins include glycidyl esters of unsaturated
carboxylic acids such as glycidyl acrylate, glycidyl methacrylate and glycidyi p-
styryl-carboxylate; mono- or polyglycidyl esters of unsaturated polycarboxylic
acids such as endo-cis-bicyclo[2,2,1]hept-5-ene-2,3-dicarboxylic acid and endo-
cis-bicyclo[2,2,1]hept-5-ene-2-methyl-2,3-dicarboxylic acid; unsaturated glycidyl
ethers such as ally! glycidyl ether, 2-methyl-allyl glycidyl ether, glycidyl ether of o-
allylphenol, glycidyl ether of m-allylphenol and glycidyl ether of p-allylphenol; and
2-
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