Polyfunctional amines with hydrophobic modification for controlled crosslinking of latex polymers

Abstract

Polyfunctional amine structures exhibiting at least one hydrophobic moiety selected from the group consisting of; hydrophobic epoxides, hydrophobic glycidyl ethers and hydrophobic (meth)acrylates are described which provide crosslinking capabilities for latex polymer compositions. These crosslinkers not only exhibit latent crosslinking properties but also improved hydrophobicity when compared with existing latex formulations. Latent crosslinking provides advantages associated with fast interactions between the anionic latex charge and the cationic charge associated with these hydrophobically modified polyfunctional amine crosslinkers. Once the latex is coated onto a substrate, the volatile base evaporates and the groups react to form a crosslinked coating with both improved hydrophobic and wash-off properties.

Claims

1. A polyfunctional amine comprising recurring units derived from the reaction of one bi- or tri-glycidyl moiety and a single, di-, or tri-functional amino monomer(s), or combination of, mono/tri, mono/tetra, bi/bi, bi/tri, bi/tetra, tri/tri, tri/tetra, and tetra/tetra functional amino monomers resulting in one or more polyfunctional amines ##STR00019## wherein I-x-2-b is a hydrophobic crosslinking agent and comprises at least three pH responsive amino group sites configured to accept or release proton(s) in response to a change in pH, and comprises at least one NH and/or one NH.sub.2 site providing reactive sites for hydrophobic compounds that introduce at least one hydrophobic moiety into hydrophobic modifications of I-x-b-2 structures represented by formulae I-x-b-2 a, I-x-b-2b, I-x-b-2c and I-x-b-2d: ##STR00020## ##STR00021## wherein said structures of formulae I-x-b-2a, I-x-b-2b, I-x-b-2c and I-x-b-2d have at least one hydrophobic moiety introduced into said structures from the group consisting of: hydrophobic epoxides, hydrophobic glycidyl ethers and hydrophobic (meth)acrylates.

2. The polyfunctional amine of claim 1, wherein said hydrophobic moiety is provided by post modification reactions with said epoxides, glycidyl ethers and (meth)acyrlates at ambient temperature and pressure.

3. A latex formulation comprising the polyfunctional amine of claim 1.

4. The latex formulation of claim 3, wherein said hydrophobic moiety is provided by carrying out post modification reactions with said epoxides, glycidyl ethers and (meth)acrylates at ambient temperature and pressure.

Description

DETAILED DESCRIPTION

(1) The present invention provides polyfunctional amine crosslinkers for use in latex polymer compositions and the latex polymer compositions containing them. The latex polymer compositions of the present invention typically include, but are not limited to, latexes, dispersions, microemulsions, or suspensions. The latex polymer compositions of the present invention may be stored at room temperature or moderately above room temperature (e.g., about 50 to 60 C.) and provide adhesion and crosslinking upon film formation when applied to a substrate. A film or coating formed with polymers of the present invention may be cured at room temperature (ambient cure) or at elevated temperatures (thermal cure).

(2) The latex polymer binders used to prepare the waterborne polymer composition of the present disclosure are generally prepared as particles. The particles may be structured or unstructured. Structured particles include, but are not limited to, core/shell particles and gradient particles. The average polymer particle size may range from about 100 to about 300 nm.

(3) The polymer particles have a spherical shape. In one embodiment, the spherical polymeric particle may have a core portion and a shell portion. The core/shell polymer particles may also be prepared in a multi-lobe form, a peanut shell, an acorn form, or a raspberry form. It is further preferred in such particles that the core portion comprises about 20 to about 80 of the total weight of said particle and the shell portion comprises about 80 to about 20 of the total weight volume of the particle.

(4) The present disclosure includes compositions and methods for the preparation of water soluble polyfunctional amines for use as crosslinking agents in solutions of fast drying latex emulsions and the further modification of these crosslinkers for use as hydrophobic crosslinking agents in solutions of fast drying latex emulsions. The oligomeric/polymeric polyfunctional amine synthesized in a Reaction Type I process by reacting bi- or tri-functional glycidyl and/or glycidyl isocyanurate groups with water soluble bi-, tri- and tetra-amines as the starting materials (reactants) serve as crosslinkers for latex paints. The resulting Reaction Type I process polyfunctional amines can be combined with epoxy, acrylic, and glycidyl ether compounds in a post-modification Reaction Type II process to form hydrophobic compounds. The Reaction Type II processes can be carried out without the selection of Reaction Type I compounds such as I-x-2. The use of polyethyleneimine, polyallylamine, polyvinylamine, and/or polychitosan as the starting material in a direct reaction with hydrophobic moieties (hydrophobic epoxy groups and hydrophobic glycidyl ethers and (meth)acrylate groups) without post modification is also possible. The determination of whether the resulting chemical compound structures are an oligomer or polymer depends on the final weight average molecular weight (as determined primarily by the number and molecular weight) of the repeating structural monomeric chains.

(5) The fast drying and proper curing due to crosslinking of the latex emulsion is triggered by rapid evaporation of NH.sub.3 in the paint formulation concurrent with a rise in the pH of the emulsion during and after being applied to the intended surface. The interaction of the latex binder together with the hydrophobically modified crosslinking polyfunctional amine (primarily) oligomers results in fast dry traffic latex polymers (as paints or coatings) which harden quickly. These polymeric/oligomeric amines provide for adequate water (especially rain water) resistant films due in part due to their rapid cure times. The waterborne fast dry paint serves as road and pavement marking paint which can be used to mark lines or symbols on roads, parking lots, and walkways etc.

(6) The synthesis of the crosslinkers of the present disclosure can be completed utilizing either a Reaction Type I or Reaction Type II process. The Reaction Type I process provides crosslinkers resulting from the reactions using glycidyl monomer(s) and/or amino monomer(s). The Reaction Type II process provides crosslinkers of the Reaction Type I process that have been further reacted with hydrophobic groups resulting in structures containing hydrophobic moieties. Examples of hydrophobically modified crosslinkers which do not employ the use of glycidyl/amino monomers of the Reaction Type I process can be used in the Reaction Type II process with the proviso that there are at least three or more amino nitrogen groups available for bonding with the chosen hydrophobic moiety that are pH responsive and will accept or release proton(s) in response to a change in pH. Examples of hydrophobically modified crosslinkers not employing the use of glycidyl/amino monomers of the Reaction Type I process include starting materials including polyethyleneimines, polyallylamines, polyvinylamines, and polychitosans.

(7) Selection of Monomers

(8) Triglycidyl isocyanurate is the trifunctional glycidyl monomer used in the present disclosure. Diglycidyl monomers include: poly(propylene glycol)diglycidyl ether, poly(ethylene glycol)diglycidyl ether, resorcinol glycidyl ether, neopentyl diglycidyl ether, and butanediol diglycidyl ether. The glycidyl monomer(s) employed in the disclosure can be used singularly or in combination.

(9) Amine monomers employed in this work can be bi-, tri- or tetra-monomers or combinations of, mono/tri, mono/tetra, bi/bi, bi/tri, bi/tetra, tri/tri, tri/tetra and tetra/tetra functional monomers. In amine monomers, the number of functionalities is defined by the number of NH bonds.

(10) A full list of mono-functional amine monomers include: dimethyl amine, diethyl amine, diethanol amine, dipropyl amine, pyrrolidine, piperidine, 1-methyl piperazine, N,N,N-trimethyl-1,2-ethane diamine, N,N,N, triethyl-1,2-ethane diamine, N-methyl-N,N-diethyl-1,2-ethane diamine, N-ethyl-N,N-dimethyl-1,2-ethane diamine, N-methyl-N,N-diethyl-1,3-propane diamine, and N-ethyl-N,N-dimethyl-1,3-propane diamine,

(11) A full list of bi-functional amine monomers includes: methyl amine, ethyl amine, 1-propyl amine, ethanol amine, 2-propyl amine, 1-butyl amine, 2-butyl amine, 2-methyl-2-propyl amine, piperazine, N,N-dimethyl-ethyl diamine, N,N-diethyl-ethyl diamine, N,N-dimethyl propyl diamine, N,N-diethyl-propyl diamine, N,N-dimethyl amino propylamine, N,N-dimethyl ethylene amine, N,N-diethyl amino propylene amine, and N,N-diethylamino ethylene amine.

(12) A full list of tri-functional amine monomers includes: amino ethyl-piperazine, N-methyl-1,2-ethane diamine, N-ethyl-1,2-ethane diamine, N-methyl-1,3-propane diamine, and N-ethyl-1,3-propane diamine.

(13) A full list of tetra-functional amine monomers includes: 1,2-diamine ethane, 1,3-diamino propane, 1,4-diamino butane, cadaverine, cystamine, 1,6-diamino hexane, 1,2-diamine benzene, 1,3-diamino benzene, 1,4-diamino benzene, 1,4-diamino butanol, 4,4-diamino-3-hydroxy butanoic acid, 5-amino-1,3,3-trimethylcyclohexanemethylamine, 2,2-oxybis ethanamine, alanine, and lysine.

(14) Type I Reactions: Glycidyl/Amino Polyfunctional Amines (I-x-Ib-12)

(15) A first aspect of the present disclosure involves starting with polyfunctional amine crosslinkers comprising recurring units derived from the reaction of one tri-glycidyl moiety and a single di-, or tri-functional amino monomer, or combination of mono/tri, mono/tetra, bi/bi, bi/tri, bi/tetra, tri/tri, tri/tetra and tetra/tetra functional amino monomers resulting in a polyfunctional amine of the general formula 0-4

(16) ##STR00007##

(17) Where the substituent J is the result of a ring-opening reaction during nucleophilic substitution of a bi- or tri-glycidyl moiety;

(18) and wherein R1 is selected from the group consisting of all possible mono-functional, bi-functional, tri-functional or tetra-functional amines, as provided above;

(19) and wherein R2 is selected from the group of all possible bi-functional, tri-functional or tetra-functional amines;

(20) and where R1 is equal to or different than R2;

(21) and where n is a number 1 to 100.

(22) Further possible structures for providing polyfunctional amines using a Reaction Type I process are provided in general formulae (I-x) and/or (I-x-a) to (I-x-f):

(23) ##STR00008##

(24) Where the substituents J, J1, and J2 are the result of a ring-opening reaction during nucleophilic substitution of a bi- or tri-glycidyl moiety,

(25) and wherein J is equal to or different than J1 and J2;

(26) and wherein J1 is equal to or different than J2;

(27) and wherein R1 is selected from the group consisting of all possible mono-functional, bi-functional, tri-functional or tetra-functional amines;

(28) and wherein R2 and R3 are selected from group consisting of all possible bi-functional, tri-functional or tetra-functional amines and wherein R1 is equal to or different than R2 and R3;

(29) and wherein R2 is equal to or different than R3;

(30) and where n is an number 1 to 100;

(31) and where m is an number equal to or different than n

(32) and wherein said I-x structure is represented as I-x-2;

(33) ##STR00009##

(34) and wherein the polyfunctional amine of any of formulae (I-x) and/or (I-x-a) to (I-x-f) must also include at least three pH responsive amino group sites and additionally, at least one NH and/or one NH2 site providing reactive sites for hydrophobic compounds thereby introducing at least one hydrophobic moiety as represented by structures of formulae I-x-2a, I-x-2b, I-x-2c and I-x-2d, all of which are hydrophobic modifications of I-x-2;

(35) ##STR00010##

(36) For the Reaction Type I synthesis of polyfunctional amines, it is possible to provide a combination of amines. The combination can be mono/tri, mono/tetra or bi/bi, bi/tri, bi/tetra, tri/tri, tri/tetra and tetra/tetra for tri-glycidyl monomer, and can be bi/bi, bi/tri, bi/tetra, tri/tri, tri/tetra and tetra/tetra for bi-glycidyl monomer. Combinations of mono/mono will not provide the required moieties for the present disclosure.

(37) To make the reactions in the current disclosure work, proper ratios of glycidyl monomers to amine monomers and ratios among all amines when combinations of amines are involved and ratios among all glycidyl monomers when combinations of glycidyl monomers are used, need to be controlled. The following relations have to be true for construction of desired polyamine in this disclosure: 1. Reaction between triglycidyl monomer and single bi, tri and tetra amines, or combinations of bi/bi, bi/tri, bi/tetra, tri/tri, tri/tetra and tetra/tetra amines:
M.sub.a/M.sub.g=2n+1 2. Reaction between triglycidyl monomer and combination of mono/tri amines
M.sub.a/M.sub.g=2n+1, and 2M.sub.tria/M.sub.g>=1-1/n 3. Reaction between triglycidyl monomer and combination of mono/tetra amines
M.sub.a/M.sub.g=2n+1, and 3M.sub.tetra/M.sub.g>=1-1/n 4. Reaction between biglycidyl monomer/combination of biglycidyl monomers and single bi, tri, tetra amines, or combinations of bi/bi, bi/tri, bi/tetra, tri/tri, tri/tetra and tetra/tetra amines:
M.sub.a/M.sub.g=n+1 5. Reaction between biglycidyl monomer/combination of biglycidyl monomers and combination of mono/tri amines:
M.sub.a/M.sub.g=n+1, and 2M.sub.tria/M.sub.g>=1-1/n 6. Reaction between biglycidyl monomer/combination of biglycidyl monomers and combination of mono/tetra amines:
Ma/Mg=n+1, and 3Mt.sub.etraa/M.sub.g>=1-1/n

(38) Where: M.sub.a: molar amount of total amine used in reaction. M.sub.g: molar amount of total glycidyl monomer used in reaction. M.sub.tria: molar amount of total triamine used in reaction. M.sub.tetraa: molar amount of total tetraamine used in reaction. n: designed polymerization degree of polyfunctional amine.

(39) Type II Reaction: Hydrophobic Modification of Polyfunctional Amines

(40) Oligomeric Reaction Type I polyfunctional amines can be prepared from the reaction between tri-glycidyl monomer and a bi, a tri-, and/or a tetra functional amine, or combinations of bi/bi, bi/tri, bi/tetra, tri/tri, tri/tetra and tetra/tetra amines, or between bi glycidyl monomers and a tri or tetra amine, or combinations of bi/tri, bi/tetra, tri/tri, tri/tetra or tetra/tetra amines carrying NH or NH.sub.2 groups. A further aspect of the present disclosure includes treatment of the obtained oligomeric polyfunctional amines with hydrophobic epoxide compounds, hydrophobic glycidyl ethers or hydrophobic acrylate and (meth)acrylate compounds for the preparation of one or more hydrophobically modified oligomeric polyamine(s). The mild reaction is conducted at ambient temperature. Modifications can be carried out with all of the polyfunctional amines described above.

(41) Another embodiment of the disclosure is the use of polyethyleneimines, polyallylamines, polyvinylamines, and polychitosans with hydrophobic epoxide compounds, hydrophobic glycidyl ethers or hydrophobic acrylate and (meth)acrylate compounds used to prepare one or more hydrophobically modified oligomeric polyfunctional amine(s).

(42) The molecular weights were determined using the following GPC Methodology for amine testing in aqueous solutions. An HPLC unit Waters 2695 with selective gel permeation columns designated as; Guard and one 30 cm PL Aquagel-OH Mixed-M 8 m columns. The detectors used included a Waters 410 Differential Refractometer (RI) with a Viscotek Dual Detector 270(RALS, DP, IP, LALS). The running solvent used was deionized water with 0.2% ethylenediamine (EDA).

(43) The polyfunctional amine crosslinker samples were diluted in DI water and filtered through 0.22 um PTFE filters into 1.5 mL vials and run through the GPC system at a flow rate of 1.0 mL/min. Each vial had a run time of 30 minutes to allow samples to be entirely flushed out before the next run. To find the Molecular weights, a set of Polyethylene Glycol (Oxide) samples were run as a calibration curve ranging from 232 to over one million Daltons. Omnisec software was used to create a method to fit the molecular weight distributions of the amine samples to the calibration curve of the standardized PEG samples.

(44) The present disclosure involves the use of crosslinkers for the preparation of final latex polymer compositions containing at least one polyfunctional amine primarily acting as a component for ionic bonding. An example of a starting constituent as well as one resulting polyfunctional amine of the present disclosure has been designated I-x-2 schematically represented below;

(45) ##STR00011##

(46) Processes for Preparing Hydrophobically Modified Polyfunctional Amine Crosslinkers:

(47) A general method for achieving the reaction leading to the oligomeric polyfunctional amine I-x-2 as represented above is as follows;

(48) A solution of the indicated amine is charged to a 2 liter reactor and an appropriate amount of rinsing water is used to ensure that no residual remains around the sides of the reactor. This solution is then heated to 20-30 C. and thoroughly agitated, with one or multiple portions of TGIC subsequently added to the amine solution. The reaction temperature should be maintained between 20-60 C., and more preferably 35-50 C. The TGIC, which is present as a white granular substance or powder, is dissolved gradually. The reaction should be maintained at ambient temperature between 40-45 C. for another two hours. The reaction solution is discharged from the reactor (kettle) and results in final concentrations of polyamine crosslinkers preferably in the 10-80 weight % range and most preferably 20-25 weight % range. In some cases previous reactions involving the direct addition of the entire amount of TGIC resulted in polyamine crosslinkers of 20% with no water removed.

(49) Here, equation (1) describes how the w/0 (weight percent) of the polyamine is determined:
weight % polyamine=weight of reactants/total weight (w/water)(1)

(50) In at least one embodiment, the crosslinkers made from the glycidyl/amine condensation chemistry of the present disclosure should include at least three amino group sites that are responsive to changes in pH and will accept or release proton(s) in response to such a change in pH and additionally, at least one NH/NH2 site.

(51) The synthesis of the structure of oligomer (I-x-2), as provided in Reaction 1, was performed using the following procedure; (A)+(B).fwdarw.(I-x-2), where (A) is triglycidyl isocyanurate (TGIC) (B) is a bi-functional amine (such as DMAPA), and (I-x-2) is a polyfunctional amine group with repeating units, n, of structure (I-x-2) which is derived from the I-x-b structure.

(52) More specifically, as summarized in Table 1, a solution of 174.1 g DMAPA in 1582 g water was added to a 10 liter reactor (kettle) and stirred with a 3.5 inch pitched blade driven by a mechanical stirring motor. 98.9 g of TGIC was poured into this reactor at room temperature comprising the first TGIC portion. 8.3 g of water for rinsing was used to ensure that no residual TGIC remains. The resulting exothermic conditions of this reaction elevated the reaction temperature to 41.3 C., after ten minutes. The reaction is next cooled with an ice bath to 25-35 C., and the second portion of TGIC is added in the amount of 674.1 g. The reaction is again agitated for approximately 10 minutes and the exothermic conditions of this reaction elevate the reaction temperature to 41.3 C. The reaction is again cooled with an ice bath to 25-35 C., and 74.1 g TGIC of the third portion is then added. 46.6 g of water for rinsing was used again to ensure that no residual remains. It takes approximately 6 minutes for the TGIC powder to dissolve and the heat released from the reaction elevates the reaction by 5-10 C. The reaction is then maintained at ambient temperature between 35-45 C. for another 140 minutes. The reaction solution is finally discharged from the reactor (kettle) resulting in polyamine linker concentrations of approximately 20%. Using this procedure, the number average molecular weight (Mn) of the polyamine linker was determined to be 14,065.

(53) TABLE-US-00001 TABLE 1 Summary of Method of Preparation of I-x-2 Polyamine Linker Chemical MW Weight (g) Kettle Triglycidyl 297.26 98.9 isocyanurate Triglycidyl 297.26 74.1 isocyanurate Triglycidyl 297.26 74.1 isocyanurate dimethyl 102.18 174.1 aminopropylamine Water 1582.00

(54) The actual reaction schema for the synthesis (preparation) of the (I-x-2) compound is provided below;

(55) REACTION 1: Preparation of (I-x-2), a representative TGIC/DMAPA Condensate Reaction

(56) ##STR00012##

(57) Epoxide and acrylate functional groups are introduced for post hydrophobic modification providing additional sites for anchoring to the latex particles of the final latex composition. Epoxides or acrylates employed for modification provides between 5 and 100% of all available NH or NH2 reactive sites.

(58) The synthesis of the structure of the oligomeric compound (I-x-2a), includes the addition of reactive groups as shown, for example in Reaction 2, and was performed according to the following procedure; (I-x-2)+(C).fwdarw.(I-x-2a), where (I-x-2) is a polyfunctional amine as provided in Reaction 1; (C) is a hydrophobic epoxide (such as 1-butene oxide) and (I-x-2a) is a hydrophobically modified polyfunctional amino group with repeating units, n, of structure (I-x-2a).

(59) To a 1 liter reactor, a solution of 300 g I-x-2 is charged together with 9.8 g 1-butene oxide. The solution was stirred with a mechanical stirring blade for 3 hours and ten minutes. The internal temperature was maintained between 35-40 C. The reaction was allowed to cool naturally resulting in a butane oxide modified polyfunctional amine crosslinker, (I-x-2a). The details of the reaction are provided below;

(60) REACTION 2:

(61) The reactants leading to the polyfunctional polymeric/oligomeric amine product shown above (I-x-2a), result in the introduction of a hydrophobic moiety. Introduction of the hydrophobic moiety serves as a method of adding anchor points facilitating increased later interactions with the latex component and thereby increasing dry time and water resistance.

(62) ##STR00013##

(63) The synthesis of the structure of oligomer (I-x-2b), which includes the addition of groups as shown in Reaction 3, was performed using the following procedure; (I-x-2)+(D) (I-x-2b), where (I-x-2) is a polyfunctional amine as provided in reaction 1 (D) is a hydrophobic glycidyl ether (such as butyl glycidyl ether) and (I-x-2b) is a hydrophobically modified polyfunctional amino group with repeating units, n, of structure (I-x-2b).

(64) To a 1 liter reactor, a solution of 300 g I-x-2 is charged together with 10 g butyl glycidyl ether. The solution was stirred with a mechanical stirring blade for 35 minutes. The internal temperature was maintained between 30-35 C. The reaction was allowed to cool naturally resulting in a clear butyl glycidyl ether modified polyfunctional amine crosslinker, (I-x-2b).

(65) REACTION 3:

(66) The reactants leading to the polyfunctional polymeric/oligomeric amine product shown above (I-x-2b), result in the introduction of a hydrophobic moiety. Introduction of the hydrophobic moiety serves as a method of adding anchor points facilitating increased interactions with the latex component and thereby increasing dry time and water resistance.

(67) ##STR00014##

(68) The synthesis of the structure of oligomer (1-x-2c), which includes the addition of groups as shown in Reaction 4, was performed using the following procedure; (I-x-2)+(E).fwdarw.(I-x-2c), where (I-x-2) is a polyfunctional amine as provided in Reaction 1 (E) is a hydrophobic epoxide (such as cyclohexene oxide) and (I-x-2c) is a hydrophobically modified polyfunctional amino group with repeating units, n, of structure (I-x-2c).

(69) To a 1 liter reactor, a solution of 300 g I-x-2 is charged together with 9 g cyclohexene oxide. The solution was stirred with a mechanical stirring blade for 3 hours. The internal temperature was maintained between 30-35 C. The reaction was allowed to cool naturally resulting in a clear cyclohexene oxide modified polyfunctional amine crosslinker, (I-x-2c).

(70) REACTION 4:

(71) The reactants leading to the polyfunctional polymeric/oligomeric amine product shown above (I-x-2c), results in the introduction of a hydrophobic moiety. Introduction of the hydrophobic moiety serves as a method of adding anchor points facilitating increased interactions with the latex component(s) and thereby increasing dry time and water resistance.

(72) ##STR00015##

(73) The synthesis of the structure of oligomer (I-x-2d), which includes the addition of groups as shown in Reaction 4, was performed using the following procedure; (I-x-2)+(F).fwdarw.(I-x-2d), where (I-x-2) is a polyfunctional amine as provided in Reaction 1 (F) is a hydrophobic acrylic monomer emulsion (such as Acrylic ME) and (I-x-2d) is a hydrophobically modified polyfunctional amino group with repeating units, n, of structure (I-x-2d).

(74) For this reaction, the molar ratio of (I-x-2): Acrylic-ME is 1:0.2. The rate limiting reactant is the Acrylic-ME and in this case limits the yield of I-x-2d.

(75) Preparation of Acrylic Monomer Emulsion (Acrylic ME):

(76) In a 2 L reactor, 108.0 g water, 4.6 g ADS 30%, 122.2 BA, 1453.8 MMA, and 2.8 g MAA were added and mixed with a 3 inch pitched blade at 300 rpm for 30 minutes allowing for the preparation of a homogeneous emulsion for further use in hydrophobic modification of polyfunctional amines for crosslinking of latex particles.

(77) To a 1 liter reactor, a solution of 150 g I-x-2 and 5 g of the acrylic monomer emulsion (Acrylic ME) were charged together. The solution was stirred with a mechanical stirring blade for 15 hours. The internal temperature was maintained between 40-50 C. The reaction was allowed to cool naturally resulting in a homogeneous acrylic monomer emulsion (Acrylic ME) modified polyfunctional amine crosslinker, (I-x-2d).

(78) REACTION 5:

(79) The reactants leading to the polyfunctional polymeric/oligomeric amine product shown above (I-x-2d), result in the introduction of a hydrophobic moiety. Introduction of the hydrophobic moiety serves as a method of adding anchor points facilitating increased interactions with the latex component.

(80) ##STR00016##

(81) These hydrophobically modified polyfunctional amine structures, shown above, are representative of one group of polyfunctional polymeric amines which possess the necessary cationic charge and molecular weight so that when placed in solution with the latex binder allows for providing a final aqueous based crosslinked polymer latex coating that forms proper films, is quick drying, and exhibits increased resistance to water wash-off.

(82) Examples of Reaction Type II hydrophobically modified polyfunctional amine crosslinkers that are not provided by Reaction Type I products can be prepared as follows:

(83) The synthesis of the structure (QDA-D), which includes the addition of groups as shown in Reaction 6, was performed using the following procedure; (PEI)+(D).fwdarw.(QDA-D), where (PEI) is polyethyleneimine, (D) is a hydrophobic glycidyl ether (such as butyl glycidyl ether) and (QDA-D) is a hydrophobically modified polyfunctional imine that is a quick drying agent.

(84) REACTION 6:

(85) ##STR00017##

(86) Preparation of Quick Drying Agent (QDA-D):

(87) In a 250 mL bottle, 20 g water, 430 g polyethyleneimine (PEI) (50%, Mn=1200), and 10 g butyl glycidyl ether were added and mixed with a magnetic stirrer for 36 minutes at a temperature of 35-45 C. A homogeneous solution was obtained for further use in modification of polyfunctional amines for crosslinking of latex particles.

(88) REACTION 7:

(89) The synthesis of the structure of oligomer (QDA-F), which includes the addition of groups as shown in Reaction 7, was performed using the following reaction schema; (PEI)+(F).fwdarw.(QDA-F), where (PEI) is polyethyleneimine (F) is a hydrophobic acrylic monomer emulsion (such as Acrylic ME) and (QDA-F) is a hydrophobically modified polyfunctional imine that is a quick drying agent.

(90) ##STR00018##

(91) Method of Making Crosslinkable Latex Polymers

(92) The latex polymer compositions of the present invention will have various properties, often depending on end-use applications. In general, the polymer component may have glass transition temperatures (Tg) of 15 to 40 C. and more preferably 20 to 30 C.

(93) The weight average molecular weight of the latex polymer compositions may vary from about 5,000 to 5,000,000 Daltons; more preferably from 20,000 to 2,000,000 and most preferably from 40,000 to 100,000.

(94) A waterborne polymer composition may be prepared using the latex polymer composition of the present invention along with other known additives and may also employ other emulsion polymerization methodologies.

(95) The examples below are illustrative of the preparation of latex polymers and waterborne polymer compositions, according to one aspect of the present invention.

(96) First a latex seed must be prepared.

(97) A 2 liter reactor was charged with 210.9 g SDS solution (14% of the total solution), 4.6 g NaHCO.sub.3, 503.3 g water, 158.0 g BA, 189.5 g MMA, 6.8 g MAA and 16.2 g APS. The solution was mechanically stirred and heated to 65 C. Radical polymerization occurred immediately to raise the temperature quickly. The exotherm was controlled using 410.1 g water which was added gradually over a period of four minutes. The seed solution was allowed to react for another 130 minutes to ensure the reaction proceeds to completion. The latex particle size obtained was determined to be 51 nm.

(98) Latexes or other waterborne compositions contain small particle size seed polymers, those ranging from about 25 to about 700 nm, preferably from about 50 to about 500 nm and more preferably from about 75 to about 300 nm, represent one embodiment of the invention.

(99) Next, it was necessary to prepare the latex. This procedure was performed as follows: a kettle was charged with 231.9 g water, 32.5 acrylic seed (23% solids) and 0.8 g sodium bicarbonate. Once charged, the kettle charge was heated to 80 C using a water bath. A solution of 2.1 g APS in 30 g water and the monomer emulsion, as indicated below in Table 2, was feed into the kettle over 195 minutes. To ensure no loss of reactants, 20 g of water was used to rinse the solution. While maintaining the temperature, the latex polymerization and resulting latex polymer binder was allowed to react for another 90 minutes to ensure reaction completion. Ammonium hydroxide, 16.1 g. (30%) was added to the polymerized latex emulsion after it was cooled to ambient conditions.

(100) TABLE-US-00002 TABLE 2 Constituents of Acrylic Monomer Emulsion (ME) BA 315.9 MMA 379 MAA 13.5 NaHCO3 0.8 SDS solution (14%) 81.92 IGEPAL CA 407 10.2 Water 270

(101) Once the latex polymerization yielding the latex binder was complete, it was possible to complete the process by producing latex paints.

(102) The following examples are intended to illustrate, not limit, the invention:

Comparative Example 1 (White Paint)

(103) To prepare a latex based white paint with the non-hydrophobically modified polyfunctional amine crosslinker I-x-2 (Comparative Example 1) of the present disclosure, the following procedure was employed; to a quart can containing 444.0 g of the acrylic latex polymerized based on the procedure described above for preparing the dry latex, 11.1 g of I-x-2 untreated crosslinker solution was added and the mixture was stirred for 5 minutes using a high sheer mixing blade at moderate speed. Next 8.0 g dispersant was added along with 5.0 g defoamer, 2.5 g surfactant, and 0.2 g biocide while stirring with a high sheer mixing blade at a moderate speed, normally not greater than 100 rpm, for another 5 minutes. Next a rheology agent and/or thickener was mixed with 19.6 g of water and added to the stirring mixture and stirred at high speed for another 5 minutes. To this, 0.8 g ammonia was added bringing the pH to 9.6. Then pigments, extenders, and calcium carbonate were added carefully while stirring at high speed for 15 minutes. After completion of the mixing and accompanying grinding, 30.0 g of solvent was added slowly and at a reduced stirring speed to which 5.6 g coalescent was added to the mixture with continued stirring. Next, 20 g of the co-solvent coalescent was added and stirred into the mixture. The total contents of the solution were then continuously stirred for another 5 minutes until complete.

Examples 1-5 (White Paint)

(104) The same procedure as provided for Comparative Example 1 is used for Examples 1-5 (as described in Table 3 below), with the exception being the type and amount of crosslinker selected. The dry weight ratio of crosslinker to dry latex polymer for each of Examples 1-5 is 1:100. Comparative Example 2 is provided as the yellow paint counterpart to that of Comparative Example 1.

(105) Table 3 below summarizes the polyfunctional amine crosslinker content using the described procedures and resulting latex paint solutions.

(106) TABLE-US-00003 TABLE 3 Polyfunctional Amine Crosslinker Content of Latex Paints with and without Hydrophobic Modification Latex Components Example Example Example Example Example Example Comp. Comp. (g) 1 2 3 4 5 6 Ex. 1 Ex. 2 Crosslinker 11.1 g 11.0 g I-x-2 Crosslinker 9.7 g 9.6 g I-x-2a Crosslinker 10.1 g I-x-2b Crosslinker 10.6 g I-x-2c Crosslinker 10.3 g I-x-2d QDA 7.1 g

Comparative Example 2 (Yellow Paint)

(107) To prepare a latex based yellow paint with the non-hydrophobically modified polyfunctional amine crosslinker I-x-2 (Comparative Example 2), the following procedure was employed; to a quart can containing 439.0 g of the acrylic latex polymerized based on the procedure above for preparing the dry latex, 11.0 g of I-x-2 untreated crosslinker solution was added to providing a mixture that was stirred for over 2 minutes using a high sheer mixing blade at moderate speed. Then 8.0 g dispersant, 3.0 g surfactant, 6.0 g defoamer, and 0.2 g biocide were added while stirring with a high sheer mixing blade at a moderate speed, normally not greater than 100 rpm, for another 5 minutes. 0.4 g rheology agent or thickener was then mixed with 28.3 g water and added to the stirring mixture and stirred at higher speeds (normally not greater than 1000 rpm) for another 5 minutes. The pH of the mixture was checked and adjusted to 9.8 with ammonium hydroxide as needed. 19.0 g organic pigment, 1.0 g inorganic pigment, 25.0 g titanium oxide, and 189.6 g of an inorganic extender was then added carefully while stirring at the same higher speed for 15 minutes. After grinding was completed, 33.0 g of solvent was added slowly at a reduced stirring speed (300-500 rpm). 3.0 g coalescent was added to the mixture while stirring continuously. Next, 20.0 g of co-solvent was added and stirred into the mixture. The total content of the solution was then continuously stirred for another 5 minutes until complete.

Example 6 (Yellow Paint)

(108) Example 6 was a yellow paint containing the hydrophobically modified crosslinker I-x-2a. This paint was achieved with the addition of 9.6 g of Example 1 (containing the polyfunctional amine crosslinker I-x-2a) into 439.0 g latex by stirring the mixture for two minutes. Next, 8.0 g dispersant, 3.0 g surfactant, 6.0 g defoamer, and 0.2 g biocide were added while the mixture was being stirred with a high sheer mixing blade at moderate speed (normally less than 100 rpm) for 5 minutes. In addition, 0.4 g thickener was mixed with 28.3 g water and added to the stirring mixture. Stirring at higher speeds (normally less than 1000 rpm) continued for another 5 minutes. The pH of the mixture was checked and adjusted to 9.8 with ammonium hydroxide as needed. Next 19.0 g organic pigment, 1.0 g inorganic pigment, 25.0 g titanium oxide, and 189.6 g inorganic extender were added while stirring at the same higher speed for 15 minutes. After grinding was completed, 33.0 g of solvent was added slowly at a reduced stirring speed (300-500 rpm). 3.0 g coalescent was added to the mixture while stirring continuously. Next 20.0 g of co-solvent was added and stirred into the mixture. The total content of the solution was then continuously stirred for another 5 minutes until complete.

(109) Test Methods

(110) To determine the effectiveness of the polyfunctional amine crosslinkers, a water wash-off test was performed to compare 30 minutes dry time for both Example 1 and Comparative Example 1 according to the procedures detailed in ASTM D711-10.

(111) This is the procedure for paint film preparation and dry time test:

(112) A sample of paint is drawn to 15 mil wet film thickness onto to a clean black scrub test panel and allowed to dry horizontally in a conditioned room at 23 C.2 C. and 75% relative humidity under a constant 2 mph air flow. Standard method ASTM D711-10 was used to judge the no tire pick up dry time.

(113) Water Immersion Testing

(114) A 15-mil wet draw down is performed on scrub panels. The panel is allowed to dry for 25 minutes under the following conditions of 1) 20.2 mph wind speed; 2) 50%5% relative humidity; 3) 75 F.2 F. When the paint film is ready, the panel carrying the paint film is immersed into water in such a way that half of the paint film is merged into water and the remaining half is exposed to the air. The water temperature in this case should be 72 F.2 F. Thirty (30) minutes later, the panel should be removed and the percentage of blistering area recorded. Results of the water immersion test are provided below in Tables 4 and Table 5 for white and yellow latexes respectively.

(115) TABLE-US-00004 TABLE 4 Results of Water Immersion Testing for White Latex Compositions Containing Different Amounts of Hydrophobically Modified Polyfunctional Amine Crosslinkers Sample Dry Time Water Blistering % Comparative 12.0 43 Example 1 Example 1 9.0 60 Example 2 12.75 0 Example 3 9.5 20 Example 4 9.1 40 Example 5 11.0 18

(116) TABLE-US-00005 TABLE 5 Results of Water Immersion Testing for Yellow Latex Compositions Containing Different Amounts of Hydrophobically Modified Polyfunctional Amine Crosslinkers Sample Dry Time Water Blistering % Comparative Example 2 11.5 65 Example 6 7.25 10

(117) Water-Wash Off

(118) The water wash-off procedure generally follows the ASTM D7377-08 procedure but is modified by using section 4.6.2 of ASTM D711-10 for controlled air flow. Paint viscosity is determined by measuring Krebs Units (KU) using a paddle type viscometer. Viscosities of 80 to 90 KU are considered suitable for testing.

(119) Drawdown Samples are Prepared Via the Procedure Provided Herein:

(120) A sample of paint is drawn to 15 mil wet film thickness onto to a clean black scrub test panel and allowed to dry horizontally for 15 to 60 minutes in a conditioned room at 23 C.2 C. and 50 to 55% relative humidity under a constant 2 mph air flow. When the drying time is complete, the samples are placed under a stream of 25 C. tap water flowing at a rate of 1.5 gal/min and allowed to remain there for 5 minutes, during which the time of film break through is recorded. After completion of the test, the samples are then removed from the flowing water and observed to note the percentage of wash off.

(121) Surfactants

(122) In the present disclosure, a combination of an anionic surfactant and a non-ionic surfactant is used. The type of anionic surfactants provided are not limited to: sodium dodecyl sulfate (SDS), ammonium dodecylsulfate (ADS), disodium salt of ethoxylated lauryl sulfosuccinate and sodium benzyl dodecyl sulfate. The nonionic surfactants of the present disclosure include but are not limited to IGEPAL CA-407 (available from Rhodia Inc.), Triton X-100 (available from Dow, Inc.), Triton X-405 (available from Dow, Inc.) and E-Sperse 703 (available from Ethox, Inc.).

(123) The polymers and waterborne polymer compositions of the present disclosure invention are useful in a variety of paint and coating formulations such as; architectural coatings, metal coatings, wood coatings, plastic coatings, textile coatings, cementitious coatings, paper coatings, inks, and adhesives. Examples of such coating formulations adapted for particular uses include, but are not limited to, corrosion inhibitors, concrete coatings, maintenance coatings, latex paints, industrial coatings, automotive coatings, textile backcoatings, surface printing inks and laminating inks. Accordingly, the present invention relates to such coating formulations containing a waterborne polymer composition of the invention, preferably a water-based latex. The polymers and waterborne polymer compositions of the invention may be incorporated in those coating formulations in the same manner as known polymer latexes and used with the conventional components and or additives of such compositions. The coating formulations may be clear or pigmented. With their crosslinking ability, adhesion properties, and resistance properties, the water-based latexes of the invention impart new and/or improved properties to the various coating formulations.

(124) Upon formulation, a coating/paint formulation containing a latex polymer or waterborne polymer composition of the invention may then be applied to a variety of surfaces, substrates, or articles, e.g., paper, plastic, steel, aluminum, wood, gypsum board, concrete, brick, masonry, or galvanized sheeting (either primed or unprimed). The type of surface, substrate, or article to be coated generally determines the type of coating formulation used. The coating formulation may be applied using means known in the art. For example, a coating formulation may be applied by spraying or by coating a substrate. In general, the coating may be dried by heating but preferably is allowed to air dry. Advantageously, a coating employing a polymer of the invention may be thermally or ambiently cured. As a further aspect, the present invention relates to a shaped or formed article which has been coated with coating formulations of the present invention.

(125) A waterborne polymer composition according to the invention may further comprise water, along with a solvent, a pigment (organic or inorganic) and/or other additives and fillers known in the art, and enumerated below. When a solvent is used, water-miscible solvents are preferred. A latex paint composition of the present disclosure may comprise a waterborne polymer composition of the present invention, a pigment, and one or more additives or fillers used in latex paints.

(126) Additives or fillers used in formulating coatings include, but are not limited to, leveling, rheology, and flow control agents such as silicones, fluorocarbons, urethanes, or cellulosics; extenders; curing agents such as multifunctional isocyanates, multifunctional carbonates, multifunctional epoxides, or multifunctional acrylates; reactive coalescing aids such as those described in U.S. Pat. No. 5,349,026; flatting agents; pigment wetting and dispersing agents and surfactants; ultraviolet (UV) absorbers; UV light stabilizers; tinting pigments; extenders; defoaming and antifoaming agents; anti-settling, anti-sag and bodying agents; anti-skinning agents; anti-flooding and anti-floating agents; fungicides and mildewcides; corrosion inhibitors; thickening agents; plasticizers; reactive plasticizers; drying agents; catalysts; crosslinking agents; or coalescing agents. Specific examples of such additives can be found in Raw Materials Index, published by the National Paint & Coatings Association, 1500 Rhode Island Avenue, NW, Washington, D.C. 20005.

(127) A polymer or waterborne polymer composition of the present invention can be utilized alone or in conjunction with other conventional waterborne polymers. Such polymers include, but are not limited to, water dispersible polymers such as consisting of polyesters, polyester-amides, cellulose esters, alkyds, polyurethanes, epoxy resins, polyamides, and acrylics.

(128) The present disclosure and associated invention has been described in detail with particular reference to embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.