Phosphate polymerizable adhesion promoters.We describe novel applications of phosphate functional monomers in polymers obtained by radical polymerization Radical polymerization is a type of polymerization in which the reactive center of a polymer chain consists of a radical. The polymerization reaction is initiated by three classes of free-radical initiators: ********** INTRODUCTION The ability of a coating to adhere onto different substrates under both dry and wet conditions is critical for many applications. One method of improving adhesion is to incorporate functional groups that promote adhesion into the resins. These functional groups engage in specific interactions with the substrates, and, thus, improve the adhesion. [ILLUSTRATION OMITTED] There have been many publications reporting adhesion promotion to metal substrates by phosphorus-containing functional groups. (1-6) The phosphorus-containing functional groups can be incorporated into the polymers during the polymerization polymerization Any process in which monomers combine chemically to produce a polymer. The monomer molecules—which in the polymer usually number from at least 100 to many thousands—may or may not all be the same. or through post-modification of the resins. When these resins are used in coatings or adhesives, the adhesion and anticorrosion performance of the final products are significantly improved. DelDonno (7) discussed the adhesion promotion to metal using polymers with pendant pendant or pendent In architecture, a sculpted ornament suspended from a vault or ceiling, especially an elongated boss (carved keystone) at the junction of the intersecting ribs of the fan vaulting associated with the English Perpendicular style. phosphorus phosphorus (fŏs`fərəs) [Gr.,=light-bearing], nonmetallic chemical element; symbol P; at. no. 15; at. wt. 30.97376; m.p. 44.1°C;; b.p. about 280°C;; sp. gr. 1.82 at 20°C;; valence −3, +3, or +5. groups. Obviously, incorporating a phosphorus-containing monomer monomer (mŏn`əmər): see polymer. monomer Molecule of any of a class of mostly organic compounds that can react with other molecules of the same or other compounds to form very large molecules (polymers). during the radical polymerization is a more direct approach than the post-modification of the resins. However, commercially available phosphonate monomers are generally very expensive and have poor reactivity (for example, vinyl phosphonic acid In inorganic chemistry, phosphonic acid is a phosphorus oxoacid with a formula of H3PO3, more commonly known as phosphorous acid. It exists in solution as two tautomers, the major one being HP(O)(OH)2 and the minor one P(OH)3 ). On the other hand, there are very few phosphated monomers available on the market. Of these existing monomers, some are not compatible with other common monomer compositions, the polymer formed, and solvents. Moreover, they generally contain a substantial amount of residual phosphoric acid phosphoric acid, any one of three chemical compounds made up of phosphorus, oxygen, and hydrogen (see acids and bases). The most common, orthophosphoric acid, H3PO4, is usually simply called phosphoric acid. that can be detrimental to the end use properties. This, combined with the usual high dialkyl phosphate content [low ratio of monoalkyl phosphate (MAP) to dialkyl phosphate (DAP)] of these monomers, makes them difficult to use, especially in a solution polymerization Solution polymerization is a method of industrial polymerization. In this procedure, a monomer is dissolved in a non-reactive solvent that contains a catalyst. The heat released by the reaction is absorbed by the solvent, and so the reaction rate is reduced. process, because dialkyl phosphate has two double bonds and is a crosslinker for polymerization. Rhodia has developed a proprietary technology that makes it possible to produce phosphate monomers with high MAP/DAP ratio, low acid content, and good compatibility with commonly used monomer compositions or solvents. Three monomers (two methacrylates--Sipomer[R] PAM-100 and Sipomer[R] PAM-200; and one acrylate--Sipomer PAM-300), all made by this technology, are commercially available. All the monomers have the following general structure: [GRAPHIC OMITTED] where R = C[H.sub.3] or H, and [R.sub.1] = alkyl alkyl /al·kyl/ (al´k'l) the monovalent radical formed when an aliphatic hydrocarbon loses one hydrogen atom. al·kyl n. . The monomers were incorporated into resins by radical polymerization and subsequently formulated into paints. These paint formulations have shown a significant improvement in both wet and dry adhesion as well as other coating properties. MATERIALS The phosphate monomers were prepared using Rhodia's proprietary technology. No further purification was performed. They are yellow to brown viscous viscous /vis·cous/ (vis´kus) sticky or gummy; having a high degree of viscosity. vis·cous adj. 1. Having relatively high resistance to flow. 2. Viscid. liquids. Typically the monomers have a MAP/DAP ratio higher than 80:20, and the weight percentage of the residual nonionic compound and phosphoric acid are typically less than 6%. All other materials were purchased from Aldrich or obtained from other suppliers directly. They were used without further treatment. RESIN SYNTHESIS Acrylic latexes were polymerized thermally at 80[degrees]C in a 1.2 liter resin kettle with mechanical agitation using a seeded procedure (Table 1). The phosphate monomers were incorporated at a level of 0-4% based on total monomer (BOTM BOTM Bud of the Month BOTM Bank of Tokyo-Mitsubishi, Ltd. BOTM Brotherhood of The Mercenary (gaming clan) ). While PAM-200 had no impact on the monomer pre-emulsion stability or polymerization, PAM-100 did de-stabilize the monomer emulsion emulsion: see colloid. emulsion Mixture of two or more liquids in which one is dispersed in the other as microscopic or ultramicroscopic droplets (see colloid). Emulsions are stabilized by agents (emulsifiers) that (e.g. at >2% BOTM level. A separate monomer feed is needed in this case. A similar latex latex, emulsion of a polymer (e.g., rubber) in water (see colloid). Natural latexes are produced by a number of plants, are usually white in color, and often contain, in addition to rubber, various gums, oils, and waxes. polymerization procedure was used to make the thermosetting thermosetting, adj having the property of becoming irreversibly rigid or hardened with the application of heat. In dentistry the term is used in connection with resins. coil coating latex with a different monomer composition (Table 2). To provide the hydroxyl hydroxyl /hy·drox·yl/ (hi-drok´sil) the univalent radical OH. hy·drox·yl n. The univalent radical or group OH, a characteristic component of bases, certain acids, phenols, alcohols, carboxylic functionality which would later allow crosslinking by melamine melamine (mĕl`əmēn'), common name for 2,4,6-triamino-1,3,5-triazine. Melamine is a trimer (see polymer) of cyanamide, H2NC≡N, and is synthesized from calcium carbide. , 2-hydroxyethyl methacrylate methacrylate /meth·ac·ry·late/ (meth-ak´ri-lat) an ester of methacrylic acid, or the resin derived from polymerization of the ester. See also acrylic resins, under resin. (HEMA HEMA Hydroxyethyl Methacrylate HEMA Hollandsche Eenheidsprijzen Maatschappij Amsterdam (Dutch international retail organization) HEMA Hydroxy Ethyl Methacrylate HEMA Health and Environment Ministers of the Americas HEMA Hemophilia, Classic ) was used. In addition, isobonyl methacrylate (IBOMA IBOMA Inter-Bank Organisation and Methods Association ) was used to adjust the mechanical properties of the film. Phosphate monomers were used at a level of 1, 2, and 4% BOTM, respectively, to compare with the control that did not contain any phosphate monomer. The solventborne acrylic polyol was made by solution polymerization with a monomer composition of MMA/2-hydroxyethyl methacrylate (HEM)/BA/Styrene/Sipomer[R] IBOMA with PAM-200 (Table 3). At 0-10%, PAM-200 was used in the same formulation without change of the procedure. IBOMA was used to reduce the viscosity of the resins while improving the mechanical properties of the film. The polymerization was carried out at 122[degrees]C in butyl acetate The chemical compound n-butyl acetate, also known as butyl ethanoate, is commonly used as a solvent in the production of lacquers and other products. It is also used as a synthetic fruit flavoring in foods such as candy, ice cream, cheeses, and baked goods. , and n-dodecyl mercaptan mercaptan (mərkăp`tăn) or thiol (thī`ōl), any of a class of organic compounds containing the group -SH bonded to a carbon atom. was used to control the molecular weight. PAINT FORMULATION The latexes were formulated into an industrial white paint (Table 4) or clearcoat in order to evaluate the performance. Rhodoline[R] 1560 (from Rhodia) at a level of 0.7-0.8% of the total formula weight was used to adjust the rheology of the formulation. Irgacor[R] 252FC (from Ciba) was necessary to keep the flash rusting from occurring in some situations such as cold rolled steel substrate. The solution polyols were formulated with Tolonate[R] HDT-LV, which is an isocyanate i·so·cy·a·nate n. Any of a family of nitrogenous chemicals that are used in industry and can cause respiratory disorders, especially asthma, if inhaled. crosslinker, and other additives/solvents into a polyurethane polyurethane Any of a class of very versatile polymers that are made into flexible and rigid foams, fibres, elastomers (elastic polymers), surface coatings, and adhesives. clearcoat (Table 5). For further salt spray tests Salt spray test is a standardized test method used to check corrosion resistance of coated samples. Coatings provide corrosion resistance to metallic parts made of steel, zamak or brass. , anticorrosion pigments, titanium titanium (tītā`nēəm, tĭ–) [from Titan], metallic chemical element; symbol Ti; at. no. 22; at. wt. 47.88; m.p. 1,675°C;; b.p. 3,260°C;; sp. gr. 4.54 at 20°C;; valence +2, +3, or +4. dioxide, and fillers were used to formulate into a polyurethane primer. The polyurethane primers were applied to proper substrates with dry film thickness of 25 [micro]m and cured at room conditions for five days before the tests. TEST METHODS The following test methods and instruments were used to characterize the latexes: viscosity measurement by Brookfield Model DV-111 Programmable Rheometer rhe·om·e·ter n. An instrument for measuring the flow of viscous liquids, such as blood. ; mechanical stability by Waring Blender 22,000 RPM; freeze/thaw cycles, accelerated aging Accelerated aging is a testing method used to estimate the useful lifespan of a product when actual lifespan data is unavailable. This occurs with products that have not existed long enough to have gone through their useful lifespan: for example, a new type of car engine or a new tests at 60[degrees] C for 30 days; and particle size Particle size, also called grain size, refers to the diameter of individual grains of sediment, or the lithified particles in clastic rocks. The term may also be applied to other granular materials. analysis by Nicomp Submicron Particle Sizer Auto Dilute model A370. Wet gum was determined by weighing the amount, in grams, of the coagulum coagulum /co·ag·u·lum/ (ko-ag´u-lum) pl. coa´gula [L.] clot (1). co·ag·u·lum n. pl. co·ag·u·la 1. A clot; a curd. 2. on the blade and thermocouple. The collected grit was filtered, rinsed, and dried by paper towel. The total dry gum is the sum of the grit and coagulum after drying overnight. Grit is used to describe the amount of filtered particles only. Aluminum, cold rolled steel, galvanized gal·va·nize tr.v. gal·va·nized, gal·va·niz·ing, gal·va·niz·es 1. To stimulate or shock with an electric current. 2. steel, iron phosphate treated steel (Bonderite[R] 1000), and zinc phosphate Zinc phosphate (Zn3(PO4)2) is an inorganic chemical compound used as a corrosion resistant coating on metal surfaces either as part of an electroplating process or applied as a primer pigment (see also red lead). treated steel (Bonderite[R] 952) were used to conduct the paint property studies. In the case of coil coatings, chromated aluminum and steel were used for comparison. All panels were cleaned with acetone acetone (ăs`ĭtōn), dimethyl ketone (dīmĕth`əl kē`tōn), or 2-propanone (prō`pənōn), CH3COCH3 before the application. The test paints were applied with either S28 or S36 wet film applicator ap·pli·ca·tor n. An instrument for applying something, such as a medication. applicator, n a device for applying medication; usually a slender rod of glass or wood, used with a pledget of cotton on the end. rods, depending on the individual tests. The targeted wet film thickness was 2.8 mils X S28 or 3.6 mils X S36. The coatings were allowed to dry for seven days at ambient conditions prior to testing. Wet and dry adhesion over the metal substrates was determined by X-hatch tape test, ASTM ASTM abbr. American Society for Testing and Materials D 3359. Gloss measurements were performed at 20[degrees] and 60[degrees] using a BYK BYK Bouake Cote d'Ivoire (Ivory Coast airport code) Gardner Micro Tri Gloss meter. The wet scrub resistance was measured according to according to prep. 1. As stated or indicated by; on the authority of: according to historians. 2. In keeping with: according to instructions. 3. ASTM D 2486 with slight modifications. The control paint and the experimental paint were applied on the same test panel side by side, and allowed to dry at ambient conditions. Scrub test, using a Gardco scrub testing apparatus with Leneta Standard Scrub Media Abrasive abrasive, material used to grind, smooth, cut, or polish another substance. Natural abrasives include sand, pumice, corundum, and ground quartz. Carborundum (silicon carbide) and alumina (aluminum oxide) are important synthetically produced abrasives. Type SC-2, was performed. Scrubbing was stopped as soon as one of the paints failed, and the numbers of cycles were recorded. RESULTS AND DISCUSSION Phosphate Monomers in Thermoplastic A polymer material that turns to liquid when heated and becomes solid when cooled. There are more than 40 types of thermoplastics, including acrylic, polypropylene, polycarbonate and polyethylene. Latex and Latex Coatings Phosphate monomers were incorporated into thermoplastic latex at a level of 0-4% based on total monomers, even though they can be incorporated into the latexes up to 10% without problems. Table 6 shows the latex performance data when PAM-100 was used in the latex synthesis. There is a clear trend of improved latex stability and increased viscosity when the PAM-100 usage level increases. It has been found that PAM-100 could destabilize de·sta·bi·lize tr.v. de·sta·bi·lized, de·sta·bi·liz·ing, de·sta·bi·liz·es 1. To upset the stability or smooth functioning of: emulsions in some monomer compositions at >2% level and a separate monomer feed is needed in this case. It was observed that PAM-200 gave similar performance improvement without increasing the viscosity significantly. After formulating the latexes into white pigmented pigmented /pig·ment·ed/ (pig-ment´id) colored by deposit of pigment. pig·ment·ed adj. Colored as the result of a deposit of pigment. light industrial paints or clearcoats, the film properties were examined with the methods described previously. The data in Table 7 indicates that the phosphate monomer improves the wet adhesion on both aluminum and zinc phosphate-treated steel substrates. A wet adhesion improvement from 0B to 5B was obtained in the paint with 3% BOTM phosphate monomer on the aluminum substrate and with only 1% BOTM of the same monomer on the zinc phosphate-treated steel substrate. The dry adhesion also showed significant improvement using latex with only 1% BOTM of the phosphate monomer. [FIGURE 1 OMITTED] Phosphate monomers can also improve the appearance of the film surface. With 3-4% dosage of PAM-100, the film gloss was superior to the control. On zinc phosphated panels, the resin made with different dosages of PAM-100 gave equivalent or higher gloss compared to the control. In addition, the hiding power of the paints was investigated by measuring the contrast ratio and comparing to the control. The results are shown in Figure 1. The hiding power of the paint improved and the improvement was proportional to the amount of PAM-100 in the latex. [FIGURE 2 OMITTED] [FIGURE 3 OMITTED] Wet scrub resistance of the latex paints was significantly improved by PAM-100. Figure 2 shows the scrub resistance of two phosphate-monomer modified paints on aluminum substrate. Two percent of PAM-100 was used in the latex synthesis. Scrub resistance was increased from ~300 cycles to over 4000 cycles in one system and from ~600 cycles to over 2700 cycles in another system. It is also noted that the failure mode in the test had changed. The control failed by adhesion loss, while the experimental paint films containing phosphate monomers failed by wearing (Figure 3). This test further confirms that the adhesion under wet conditions was improved significantly by the use of phosphate monomers in the latex. Phosphate Monomer in Thermosetting Acrylic Coil Latex Coatings The thermosetting latexes were synthesized syn·the·sized adj. 1. Relating to or being an instrument whose sound is modified or augmented by a synthesizer. 2. Relating to or being compositions or a composition performed on synthesizers or synthesized instruments. by incorporating both PAM-100 and PAM-200, respectively, and formulated into clearcoats crosslinked by Cymel[R] 303 (Cytec). The paints were applied onto either steel or aluminum substrates and cured in an oven at 180-190[degrees]C for two minutes. A comparison of the impacts of phosphate monomers on coatings with phosphate or chromate chromate /chro·mate/ (kro´mat) any salt of chromic acid. chro·mate n. A salt of chromic acid. chromate any salt of chromic acid. pretreated panels was also conducted (Table 8). The dry/wet adhesion properties were examined upon cooling. The results are summarized in Figure 4 and Table 9. It is clear that 2% PAM-100 or PAM-200 not only improves the adhesion on these substrates significantly, but also performed better than the control latexes without phosphate monomers coated on phosphate (CRS CRS Course CRS Certified Residential Specialist (real estate certification) CRS Central Reservation System CRS Can't Remember Stuff (polite form) CRS Cost Reduction Strategy CRS Consumer Relations Specialist vs B1000P95) or chromate (Al vs Al-36; CRS vs B1000 P60) treated substrates. Phosphate Monomers in Polyol Resin and Polyurethane Coatings Polyols were synthesized using the standard recipe and procedures indicated in the previous section. Up to 4% BOTM of PAM-100 and 10% of PAM-200 were successfully incorporated into the polyol systems without difficulty. PAM-100 generated turbidity turbidity /tur·bid·i·ty/ (ter-bid´i-te) cloudiness; disturbance of solids (sediment) in a solution, so that it is not clear.tur´bid Turbidity The cloudiness or lack of transparency of a solution. even at low usage level (1% BOTM), while PAM-200 gave a clear solution even up to 4% BTOM. Nevertheless, the final polyols were clear with almost no turbidity or precipitation precipitation, in chemistry precipitation, in chemistry, a process in which a solid is separated from a suspension, sol, or solution. In a suspension such as sand in water the solid spontaneously precipitates (settles out) on standing. and were light yellow to light brown in color. Although both monomers were successfully used in polyol synthesis, most application test data reported here is for PAM-200 due to its better compatibility with the organic system. No significant differences in the process or final products were observed during the polymerization with phosphate monomers compared to the control polymerization without the phosphate monomers. Table 10 summarizes the GPC (1) A PC that uses the Linux-based gOS operating system. See gOS. (2) (GPC Group) Originally the Graphics Performance Characterization committee of the NCGA, the GPC Group is now part of Standard Performance Evaluation Corporation (SPEC) and oversees the following analysis data for polyols with both phosphate monomers. The molecular weight did increase slightly when the phosphate monomers were used but it was not significant, even at 4% BOTM level. The relatively high MAP/DAP ratio dramatically minimized the degree of crosslinking and allowed the system to maintain a proper molecular weight/viscosity. [FIGURE 4 OMITTED] To understand the benefits of high MAP/DAP ratio, four phosphate monomers with different MAP/DAP ratios were synthesized. The monomer types and their MAP/DAP mole ratios are shown in Table 11, and the MAP/DAP ratio difference in each monomer set was designed to be about 10%. These monomers were incorporated into polymer backbones by using a model polymer system with ~2% of phosphate monomer and ~98% of MMA (Microcomputer Managers Association, Inc.) A membership organization with chapters throughout the U.S. that was devoted to educating personnel responsible for personal computers. It disbanded in 1996. Mma - A fast Mathematica-like system, in Allegro CL by R. Fateman, 1991. . In the experiments, 1.0 g of phosphate monomer, 50.0 g of methyl methacrylate methyl methacrylate (meth´il methak´rilāt), n an acrylic resin, CH2 = C(CH3)COOCH3, derived from methyl acrylic acid. Monomer is the single molecule and polymer is the polymerization product. monomer, 0.2 g of azobisisobutyronitrile (AIBN AIBN Australian Institute for Bioengineering and Nanotechnology (Brisbane, Australia) AIBN Azobis-Isobutyronitrile ) as the initiator, and 119.1 g of THF THF tetrahydrofolic acid. THF tetrahydrofolic acid. solvent were placed in a closed pressure reaction vessel equipped with a magnetic stir bar A stir bar (or flea) is a magnetic bar, used to stir a liquids in a laboratory. The stir bar rotates (and thus stirs) in synch with a separate rotating magnet located beneath the vessel containing the reaction. . After bubbling nitrogen through the reaction bottle, it was placed in a water bath for about 24 hr with magnetic stirring. At the end of the reaction, it was observed that the products with lower MAP/DAP ratio phosphate monomers had obviously higher viscosity and the solution was more elastic (the liquid drop can be elongated e·lon·gate tr. & intr.v. e·lon·gat·ed, e·lon·gat·ing, e·lon·gates To make or grow longer. adj. or elongated 1. Made longer; extended. 2. Having more length than width; slender. which indicates that the solution is closer to a gel state). [FIGURE 5 OMITTED] [FIGURE 6 OMITTED] [FIGURE 7 OMITTED] The polymer solution viscosities were measured using a Brookfield Rheometer and the G'/G" with an ARES strain-controlled Rheometer. The data are summarized in Figures 5-7. All the data clearly showed that the polymers with high MAP/DAP ratio phosphate monomer had lower molecular weight and had less gel-like properties, and the differences were significant enough to be observed even when the MAP/DAP ratio decreased from 93/7 to 85/15 or from 86/14 to 72/28. A high MAP/DAP ratio phosphate monomer is critical in the synthesis of polyols to prevent gelation gelation /ge·la·tion/ (je-la´shun) conversion of a sol into a gel. ge·la·tion n. 1. Solidification by cooling or freezing. 2. The process of forming a gel. 3. and allow a useful phosphate level to be introduced in the polyols. In a polyurethane clearcoat formulation, the polyols were tested for their dry/wet adhesion. The results again showed significant improvement in adhesion when phosphate monomers were used (Table 12). In addition, a white pigmented polyurethane primer with anticorrosion pigment pigment, substance that imparts color to other materials. In paint, the pigment is a powdered substance which, when mixed in the liquid vehicle, imparts color to a painted surface. was also examined. Slight viscosity reduction was observed with the phosphated polyols. Salt spray performance was tested by an independent lab. Significantly better corrosion resistance was observed (Figures 8 and 9). For the coatings on cold rolled steel substrate in Figure 8, the control panels without the phosphate monomer failed after only 100 hr and were full of blisters and rust, while the testing panels with PAM-200 remained clean until 500 hr. Similar results were also found on phosphate-treated steel substrates (Figure 9). The polyurethane film polyurethane film Wound care A transparent polymer-based wound dressing with variable vapor permeability with 2% of PAM-200 passed 1000-hr salt spray tests, and out performed the controls with 0% PAM, which rusted by 750 hr. It is to be noted that both the polyol synthesis and polyurethane formulation were not optimized for the test. The tests were also in very tough conditions, i.e., dry film thickness of 25 [micro]m and five days' curing before the tests. Better results could be obtained with careful optimization and formulation when phosphate monomers are used. The results indicate that it may be possible to formulate the real direct-to-metal polyurethane coatings, or to reduce or eliminate the coating steps in high performance situations such as automotive applications. [FIGURE 8 OMITTED] [FIGURE 9 OMITTED] Phosphate Monomers in UV-Curable Coatings Limited work was done on UV-curable coatings. However, significant adhesion improvement was observed as well. As a monomer in UV-curable formulations, PAM-100 was examined as an adhesion promoter. IBOA IBOA Irish Bank Officials Association was used in the formulation to adjust the hardness of the film. The adhesion was tested immediately after curing by UV light at 50 ft/min for two passes. With 2% of PAM-100, the adhesion improved from 0B to 5B on aluminum and from 0B to 3-4B on cold rolled steel substrates (Table 13). This again proves the effectiveness of phosphate monomers for adhesion promotion on metal surfaces. CONCLUSIONS PAM-100, PAM-200, and PAM-300--a novel class of phosphate monomers--have been shown to have some unique characteristics compared to other similar products in the market. These characteristics include better compatibility with common organic systems, higher MAP/DAP ratio, and lower phosphoric acid content. Coatings with resins made with these monomers, including thermoplastic latex, thermosetting latex coil, solventborne polyurethane, and UV-curable coatings, have shown significant adhesion improvement on various metal substrates. Other adhesion-related properties, such as scrub resistance and corrosion resistance, are also improved.
Table 1 -- Latex Formulation for Coatings
Ingredients Weight (g) % BOTM
Kettle Charge
Deionized water 200.6 --
Anionic surfactant 5.0 0.3
Monomer Emulsion
Deionized water 181.3 --
Anionic surfactant 20.0 1.2
Methyl methacrylate 260.0 52.0
Butyl acrylate (a) 235.0 47.0
Methacrylic acid 5.0 1.0
Initiator Solution
Deionized water 98.0 --
Ammonium persulfate 2.0 0.4
Total 1006.9 --
(a) PAM-100 or 200 at 1-6% were used to replace BA in evaluating
phosphate monomers.
Table 2 -- Coil Coating Latex Synthesis
Ingredients Weight (g) BOTM (%)
Kettle Charge
Deionized water 140.00 --
Abex 2005 @ 30% 1.33 0.1
Na Bicarbonate @ 100% 0.40 0.1
Monomer Emulsion
Deionized water 159.33 --
ABEX 2005 @ 30% 17.33 1.3
Hydroxyethyl methacrylate 20.00 5
Styrene 80.00 20
Butyl acrylate (a) 160.00 40
MMA 84.00 21
IBOMA 48.00 12
Initiator Solution
Deionized water 96.00 --
Ammonia persulfate 2.40 0.6
PAM-100 8.00 2
Total 816.80 --
(a) PAM-100 or 200 at 1-6% were used to replace BA in evaluating
phosphate monomers.
Table 3 -- Polyol Synthesis
Ingredient Weight (g) % BOTM
Kettle Charge
n-Butyl acetate 79.6 --
Monomer Mixture
IBOMA 63.0 20.7
Methyl methacrylate 45.0 14.7
2-Hydroxyethyl methacrylate 75.8 24.8
Butyl acrylate 58.4-x 19.1-Y
Styrene 63.0 20.7
PAM-200 or 100 x Y=x/305.2
n-Dodecyl mercaptane 24.7 8.1
Initiator Solution
Vazo 67 2.4 0.8
n-Butyl acetate 30.0 --
Chaser Solution
Vazo 67 1.2 0.4
n-Butyl acetate 5.0 --
Theoretical values: % solids: 75%; MW 2500; Equivalent weight: 524;
Glass transition temperature: 56[degrees]C.
Table 4 -- White Pigmented Gloss Paint Formulation
Materials Lb Gal
Grind to Hegman 6.5-7.0
Water 38.5 4.6
Rhodaline 111 (Rhodia) 7.6 0.8
Triton CF-10 (Rohm and Haas) 2.3 0.3
TiPure R900 (DuPont) 151.2 4.5
N[H.sub.4]OH 28% 1.0 0.1
Letdown
Water 49.7 6.0
Acrylic Latex (41.5%) 625.2 71.8
Dowanol EB 41.6 5.6
Dowanol DB 22.8 2.9
BYK 080 2.0 0.2
Irgacor 252FC (30% in water) 14.0 1.7
N[H.sub.4]OH (28%) 1.0 0.1
Total 956.9 98.6
Table 5 -- Polyurethane Formulation and Evaluation
Weight (g) % Solids Notes
Part I
Polyol 51.4 70.0 eq. wt. 524.0
BYK-361 (1%) 3.0 1.0
T-12 (0.5% in butyl acetate) 5.0 0.5
Butyl acetate 9.0
Xylene 17.9
Part II
Tolonate HDT 13.8 eq. wt. 191.0
(a) Weight % solids 50.0%, NCO/OH ratio 1.05, xylene/butyl acetate ratio
2.0
Table 6 -- Latex Properties of Phosphate Monomer Modified Latexes
Reference #
M1 M3 M4 M5
PAM-100 % BOTM 0 0.25 0.5 1.0
PAM-200 % BOTM -- -- -- --
% Wet gum (BOTL) .02 .06 .04 .02
% Solids/% conversion 50.4/99.8 50.4/99.8 50.5/99.9 50.6/100
Mean diameter (nm)/ 119/8 117/18 120/15 115/17
std dev
Viscosity (cP) 263 371 392 382
F/T stability 0 0 0 >5
(# cycles)
60[degrees]C oven >30 >30 >30 >30
stability (days)
Reference #
M6 M7
PAM-100 % BOTM 2.0 --
PAM-200 % BOTM -- 2.0
% Wet gum (BOTL) 0.08 0.02
% Solids/% conversion 50.4/100 50.4/100
Mean diameter (nm)/ 111/17 124/19
std dev
Viscosity (cP) 720 237
F/T stability >5 >5
(# cycles)
60[degrees]C oven >30 >30
stability (days)
(a) Monomer composition: 52 MMA/47BA/1 MAA/0-2% BOTM phosphate monomer.
Table 7 -- Coating Properties of Acrylic Latex Paint Made with PAM-100
over Untreated Aluminum and Zinc Phosphate Steel Panels.
Monomer: 51 MMA/47 BA/1 MAA/X PAM-100
PAM-100 Dry Wet
Paint ID (% BOTM) Adhesion Adhesion
Coatings over Al:
153A 0 4B 0B
153B 1 4B 3B
153C 2 5B 3B
153D 3 5B 5B
153E 4 5B 4B
Coatings over Zinc Phosphate Steel:
153A 0 5B 1B
153B 1 5B 5B
153C 2 5B 5B
153D 3 5B 5B
153E 4 5B 5B
Table 8 -- Substrates for Coil Coating Evaluation
Reference Description of the Substrates
CRS Cold roll steel
B1000P95 Phosphated non-chromated steel, DI water rinsed
B1000P60 Phosphated chromate sealed steel, DI water rinsed
Al Aluminum 3105 mill finished
Al-36 Aluminum 3105 mill finished with chromate treatement
HDG Hot dipped galvanized steel
Table 9 -- Phosphate Monomers to Improve Dry/Wet Adhesion of Coil
Coatings
0% PAM 1% PAM-100 2% PAM-100 2% PAM-200
CRS
Dry 5B (100%) 5B (100%) 5B (100%) 5B (100%)
24 hr wet 0B (0%) 0B (0%) 5B (100%) 5B (100%)
B1000P60
Dry 5B (100%) 5B (100%) 5B (100%) 5B (100%)
24 hr wet 0B (0%) 5B (100%) 5B (100%) 5B (100%)
B1000P95
Dry 5B (100%) 5B (100%) 5B (100%) 5B (100%)
24 hr wet 1B (65%) 5B (100%) 5B (100%) 5B (100%)
Al
Dry 3B (94%) 5B (100%) 5B (100%) 4B (99%)
24 hr wet 0B (0%) 4B (98%) 5B (100%) 5B (100%)
Al-36
Dry 5B (100%) 5B (100%) 5B (100%) 5B (100%)
24 hr wet 0B (0%) 5B (100%) 5B (100%) 5B (100%)
HDG
Dry 0B (0%) 5B (100%) 5B (100%) 5B (100%)
24 hr wet 0B (0%) 2B (70%) 5B (100%) 4B (97%)
Table 10 -- Effect of Phosphate Monomer on Molecular Weight of Polyol in
Solution Polymerization
Peak MW Wt Avg. No. Avg. Polydispersity
Sample [M.sub.p] [M.sub.w] [M.sub.n] [M.sub.w]/[M.sub.n]
Polyol control--no
phosphate 4,660 3,730 2,070 1.80
monomer
1% PAM-200 5,040 4,290 2,140 2.01
1% PAM-100 4,760 4,170 2,100 1.98
2% PAM-200 5,170 4,800 2,180 2.20
4% PAM-200 5,730 5,480 2,280 2.41
Table 11 -- Phosphate Monomers at Different MAP/DAP Mole Ratio
Sample Code MAP/DAP Ratio (Molar)
LowP_059 85/15
HighP_3452 93/7
LowE_057 72/28
HighE_3381 86/14
Table 12 -- Dry/Wet Adhesion Improvement of PAM-200 in Polyurethane
Clear Coatings
Aluminum
Immersion hours Dry 2 4
Control 1B 0B 0B
1% PAM 3-4B 0B 0B
4% PAM 5B 2-3B 0B
Cold Rolled Steel
Immersion hours Dry 2 4 8 24 48
Control 5B 4-5B 2B 0B 0B 0B
1% PAM 5B 3B 2B 1B 0B 0B
4% PAM 5B 5B 5B 5B 4-5B 4-5B
Table 13 -- Adhesion Improvement in UV-Curable Coatings
Control--no PAMs 2% PAM-100
Untreated Al 0B (0%) 5B (100%)
CRS 0B (0%) 3-4B (95-92%)
ACKNOWLEDGMENTS The authors thank Eugene Anderson and Robert Reierson for the syntheses of the phosphate monomer samples used in these experiments. We are also indebted to the NMR NMR: see magnetic resonance. analytical support by Heiko Mauermann, and the polyurethane application test support by Richard Rosen and Satyen Trivedi. References (1) Bressy-Brondino, C., Boutevin, B., Hervaud, Y., and Gaboyard, M., J. Appl. Polym. Sci., 83 (11), 2277-2287 (2002). (2) Wang, C.-S. and Shieh, J.-Y., Eur. Polym. J., 36 (3), 443-452 (2000). (3) Abd El Salam Shakal, M. and Pfeiffer, P., J. Adh. Sci. Technol., 12 (3), 349-361 (1998). (4) Matsumura, H., Tanaka, T., and Atsuta, M., J. Dentistry dentistry, treatment and care of the teeth and associated oral structures. Dentistry is mainly concerned with tooth decay, disease of the supporting structures, such as the gums, and faulty positioning of the teeth. , 25 (3-4), 285-290 (1997). (5) Liu, Y.-L., Hsiue, G.-H., and Chiu, Y.-S., J. Polym. Sci., Part A: Polym. Chem., 35 (3), 565-574 (1997). (6) Clark, P.J., Loctite Corp. Newington, CT, U.S. Patent 4,990 (1991). (7) DelDonno, T.A. U.S. Patent 5,191,029 (1993). by Hui Shirley Yang, Herve Adam, and Jon Kiplinger Rhodia, Inc.* * 259 Prospect Plains Rd., Cranbury, NJ 08512. |
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