NELSON JAMES M (US)
PINNOW MATTHEW J (US)
SCHMID MATTHEW J (US)
MARX RYAN E (US)
NELSON JAMES M (US)
PINNOW MATTHEW J (US)
SCHMID MATTHEW J (US)
| WO2005061638A1 | 2005-07-07 |
| US6716944B2 | 2004-04-06 | |||
| US3553179A | 1971-01-05 | |||
| US6395821B1 | 2002-05-28 | |||
| US5919527A | 1999-07-06 |
We claim:
1. A block copolymer comprising at least one block comprising a fluorinated monomer having the genera] formula Rfj O(Rf2θ) n (Rf3θ) m (Rf4)AQC(R)=CH2 wherein:
A is a carbonyloxy or carbonylimino group,
Rfj, Rf2, Rβ, and Rpψ are each independently a Cl to ClO perfluoroalkyl,
R is an H or a Cl to C4 alkyl,
Q is a divalent linking group, n is from 2 to 25, and m is from 0 to 25.
2. A block copolymer according to claim 1 wherein Q is selected from the group consisting of an alkylene, a hydroxy substituted alkylene, a heteroalkylene, a hydroxy substituted heteroalkylene, an arylene, a hydroxy substituted arylene, a carbonyl, a carbonyloxy, a carbonylimino, an oxy, an imino, and a combination thereof.
3. The composition of claim 1 wherein the block copolymer is a star-branched block copolymer.
4. The composition of claim 1 wherein the block copolymer is a di- or tri-block copolymer having AB, ABA, or ABC architecture.
5. The composition of claim 1 wherein at least one of the blocks is a random copolymer of at least two monomeric species.
6. The composition of claim 1 wherein at least one of the blocks comprises a monomer that is selected from the group consisting of vinyl aromatics, styrenics, dienes, vinyl pyridines, acrylates, methacrylates, epoxides, oxiranes, cyclic sulfides, lactones, lactides, cyclic carbonates, lactams, cyclosiloxanes, acrylonitrile, [n]metallocenophanes, fluorinated acrylates, fluorinated methacrylates, and anionically-polymerizable polar monomers.
7. The composition of claim 1 wherein at least one of the blocks comprises a hydrogenated polydiene block.
8. The composition of claim 1 wherein the block copolymer comprises at least three blocks i wherein each block is selected from the group consisting of a hydrophilic block, a lipophilic block, and a fluorophilic block.
9. The composition of claim 1 having acid or anhydride functionality in at least one block.
> 10. The composition of claim 1 wherein the block copolymer is end-functionalized with a single reactive group.
11. The composition of claim 1 wherein at least one block comprises a quaternary ammonium ion.
12. A method of reducing the surface tension of a liquid comprising adding to a liquid a surface active agent in an amount of from 0.0025 to 10 % by weight of the surface active agent, based on the total weight of the liquid and surface active agent, wherein the surface active agent comprises the block copolymer of claim 1.
13. The method of claim 12, wherein the liquid is in the form of a froth comprising a gas and a polymerizable monomer.
14. A method for modifying the surface chemistry of a polymeric substrate comprising adding to a polymer a surface active agent in an amount of from 0.1 to 10% by weight of the surface active agent, based on the total weight of the polymer and surface active agent, wherein the surface active agent comprises the block copolymer of claim 1.
15. A polymerized foam composition made from a mixture containing one or more of monomers, oligomers, and polymers, the mixture comprising from 0.1 to 10% by weight of a surface active agent, based on the total weight of the mixture, wherein the surface active agent comprises the block copolymer of claim 1.
16. An article comprising the polymerized foam composition of claim 15. 5
17. The article of claim 16 wherein the article is a pressure sensitive adhesive tape.
18. A composition comprising a block copolymer comprising at least one block comprising a fluorinated monomer having the general formula:
) CH 2 =CRICO 2 CH 2 CH 2 S-[X] S -R 1 wherein X is RfiO(Rf2θ) n (Rf3θ) m (Rf4)AQC(R)CH 2 , wherein A is a carbonyloxy or carbonylimino group, RfI is a Cl to ClO perfluoroalkyl,
Rf2, Rf3, and Rf4 are each independently a Cl to ClO perfluoroalkyl, > R is an H or a Cl to C4 alkyl, Q is a divalent linking group,
19. The composition of claim 18 wherein Q is selected from the group consisting of alkylene, hydroxy substituted alkylene, heteroalkylene, hydroxy substituted heteroalkylene, arylene, hydroxy substituted arylene, carbonyl, carbonyloxy, carbonylimino, oxy, and imino. |
CONTROLLED ARCHITECTURE MATERIALS
SUMMARY
In one aspect, the present invention relates to a block copolymer comprising at least one block comprising a fluorinated monomer having the general formula R flO(Rf2θ) n (Rf3θ) m (Rf4)AQC(R)=CH 2 ("HFPOMA") where: A is a carbonyloxy or carbonylimino group, Rfj is a Cl to ClO perfluoroalkyl,
Rf2, Rf3, and Rf4 are each independently a Cl to ClO perfluoroalkyl,
R is an H or a Cl to C4 alkyl,
Q is a divalent linking group. Examples of divalent linking groups include alkylene, hydroxy substituted alkylene, heteroalkylene, hydroxy substituted heteroalkylene, arylene, hydroxy substituted arylene, carbonyl, carbonyloxy, carbonylimino, oxy, and/or imino.
In another aspect, the present invention relates to a block copolymer comprising at least one block having a quaternary ammonium ion and at least one block comprising a fluorinated monomer having the general formula RfiO(Rf2θ) n (Rf3θ) m (Rf4)AQC(R)=CH2 where: A is a carbonyloxy or carbonylimino group, RfI is a Cl to ClO perfluoroalkyl,
Rf2, Rfj, and Rf4 are each independently a Cl to ClO perfluoroalkyl,
R is an H or a Cl to C4 alkyl,
Q is a divalent linking group. Examples of divalent linking groups include alkylene, hydroxy substituted alkylene, heteroalkylene, hydroxy substituted heteroalkylene, arylene, hydroxy substituted arylene, carbonyl, carbonyloxy, carbonylimino, oxy, and/or imino. n is from 2 to 25, and m is from 0 to 25.
Tn yet another aspect, the present invention relates to a method of reducing the surface tension of a liquid comprising adding to said liquid from 0.0025 to 10 wt% of a surface active agent
derived from a block copolymer comprising at least one block comprising a fluorinated monomer having the general formula RfiO(Rf2θ) n (Rf3θ) m (Rf4)AQC(R)=CH2 where: A is a carbonyloxy or carbonylimino group, RfI is a Cl to ClO perfluoroalkyl,
Rf2, Rf3, and Rf4 are each independently a Cl to ClO perfluoroalkyl,
R is an H or a Cl to C4 alkyl,
Q is a divalent linking group. Examples of divalent linking groups include alkylene, hydroxy substituted alkylene, heteroalkylene, hydroxy substituted heteroalkylene, arylene, hydroxy substituted arylene, carbonyl, carbonyloxy, carbonylimino, oxy, and/or imino. n is from 2 to 25, and m is from 0 to 25.
In a further aspect, the present invention relates to a method for modifying the surface chemistry of a polymeric substrate comprising adding from 0.1 to 10 wt% of a surface active agent derived from a block copolymer comprising at least one block comprising a fluorinated monomer having the general formula Rfi 0(RQO) n (Rf 3 O) 111 (Rf 4 )AQC(R)=CH 2 where:
A is a carbonyloxy or carbonylimino group, Rf] is a Cl to ClO perfluoroalkyl,
Rf2, Rf3, and Rf4 are each independently a Cl to ClO perfluoroalkyl,
R is an H or a Cl to C4 alkyl,
Q is a divalent linking group. Examples of divalent linking groups include alkylene, hydroxy substituted alkylene, heteroalkylene, hydroxy substituted heteroalkylene, arylene, hydroxy substituted arylene, carbonyl, carbonyloxy, carbonylimino, oxy, and/or imino. n is from 2 to 25, and m is from 0 to 25.
Another aspect of the present invention relates to a polymerized foam composition made from a mixture containing one or more of monomers, oligomers, and polymers, the mixture comprising from 0.1 to 10 wt% of a surface active agent derived from a block copolymer comprising at least one block comprising a fluorinated monomer having the general formula Rf 1 Q (Rf 2 O) n (Rf 3 O) 1n (Rf 4 )AQC(R)=CH 2 where:
A is a carbonyloxy or carbonylimino group, RfI is a Cl to ClO perfiuoroalkyl,
Rf2, Rf3, and Rf4 are each independently a Cl to ClO perfluoroalkyl,
R is an H or a Cl to C4 alkyl,
Q is a divalent linking group. Examples of divalent linking groups include alkylene, hydroxy substituted alkylene, heteroalkylene, hydroxy substituted heteroalkylene, arylene, hydroxy substituted arylene, carbonyl, carbonyloxy, carbonylimino, oxy, and/or imino. n is from 2 to 25, and m is from 0 to 25.
In another aspect, the present invention relates to an article comprising the polymerized foam composition. An example of an article is a pressure sensitive adhesive tape.
In yet another aspect, the present invention relates to a block copolymer comprising at least one block comprising a fluorinated monomer having the general formula:
CH 2 =CR 1 CO 2 CH 2 CH 2 S-[X] 3 -R l wherein X is Rfl O(Rf2θ) n (RβO) m (Rf4)AQC(R)CH 2 , wherein
A is a carbonyloxy or carbonylimino group, RfI is a Cl to ClO perfluoroalkyl,
Rf2, Rf3, and Rf4 are each independently a Cl to ClO perfluoroalkyl,
R is an H or a Cl to C4 alkyl,
Q is a divalent linking group. Examples of divalent linking groups include alkylene, hydroxy substituted alkylene, heteroalkylene, hydroxy substituted heteroalkylene, arylene, hydroxy substituted arylene, carbonyl, carbonyloxy, carbonylimino, oxy, and/or imino.
By "group derived from an initiator" it is meant a group, such as H, an alkyl, an alkyloxy, a halogen, a phenyl, a benzyl, a benzoyl, a hydroxyl, a carboxyl, an amine, an amide, a sulfide, a sulfoxide, a sulfate, a phosphate, a phosphate ester, a nitroxide, a thioester, and a carbonyl, or another organic or inorganic group, that is used to initiate the oligomerization of the RflO(Rf2θ) n (Rf3θ) m (Rf4)AQC(R)CH2 segment in the preparation of the macromonomer
CH 2 =CR 1 CO 2 CH 2 CH 2 S-[X] n -R 1 .
For purposes of the present invention, the following terms used in this description are defined as follows:
"block" refers to a portion of a block copolymer, comprising many monomeric units, that has at least one feature which is not present in the adjacent block or blocks;
"Block copolymer" means a polymer having at least two compositionally discrete segments, for example a di-block copolymer, a tri-block copolymer, a random block copolymer, a graft-block copolymer, a star-branched block copolymer or a hyper-branched block copolymer; "Random block copolymer" means a copolymer having at least two distinct blocks wherein at least one block comprises a random arrangement of at least two types of monomer units; "Di-block copolymers" and "Tri-block copolymers" means a polymer in which all the neighboring monomer units (except at the transition point) are of the same identity,jfor example, -AB is a di- block copolymer comprised of an A block and a B block that are compositionally different and ABC is a tri-block copolymer comprised of A, B, and C blocks, each compositionally different; "Graft-block copolymer" means a polymer consisting of a side-chain polymers grafted onto a main chain. The side chain polymer can be any polymer different in composition from the main chain copolymer;
"Star-branched block copolymer" or "Hyper-branched block copolymer" means a polymer consisting of several linear block chains linked together at one end of each chain by a single branch or junction point, also known as a radial block copolymer;
"End functionalized" means a polymer chain terminated with a functional group on at least one chain end.
DETAILED DESCRIPTION
This invention is a new class of block copolymers wherein at least one of the block copolymer contains a fluorinated monomer. Specifically, the fluorinated monomer in these block copolymer structures is the fluorinated monomer Rf]O(Rf2θ) n (Rf3θ) m (Rf4)AQC(R)=CH2
("HFPOMA") where:
A = carbonyloxy or carbonylimino,
RfI is a Cl to ClO perfluoroalkyl,
Rf2, Rf3, and Rf4 are each independently a Cl to ClO perfluoroalkyl,
R is an H or a Cl to C4 alkyl,
Q is a divalent linking group. Examples of divalent linking groups include alkylene, hydroxy substituted alkylene, heteroalkylene, hydroxy substituted heteroalkylene, arylene, hydroxy substituted arylene, carbonyl, carbonyloxy, carbonylimino, oxy, and/or imino. n if from 2 to 25, and m is from 0 to 25.
In some embodiments, specific structures illustrating the block copolymers described herein may be illustrated by the following fluorinated copolymer structures:
where Rl is H or a Cl to C4 alkyl group; R2 is A(Rf4)(Rf3θ) m (Rf2θ) n Rfi, where A, RfI , Rf2, RO, and Rf4 are as described above, and R3 is H, or any alkyl or aryl substituent.
Block copolymers according to the present invention can be synthesized using any suitable living polymerization technique, including living anionic or living radical methods.
The block copolymers described in this invention have many potential applications as a result of their unique chemical structure, morphology, and molecular topology. The block copolymers described herein are fluorinated materials, typically having very low surface energies. The block copolymers may function effectively as surface modifiers, surfactants, compatibilizers, rheology modifiers, or other polymer additives. Because these materials can contain a block of a non-fluorinated material, it is possible to tailor the solubility of the block copolymers described herein in a variety of polymers and solvents, thus improving the dispersibility either of the block copolymers themselves, or some other additive to the polymer or solvent (that is, wherein the block copolymer acts as a dispersing agent for the other additive in the polymer or solvent).
In other embodiments, block copolymers of the present invention may form ordered morphologies at the molecular level. Such ordered morphology block copolymers could be applied for a variety of applications related to nano-engineering, including the functions of dispersion, encapsulation, transport, delivery, and separation.
Furthermore, block copolymers produced from the monomer described herein may possess a higher concentration of fluorine atoms per side chain than, for instance, similar block copolymers produced from the monomer 2-(N-methylperfluorobutanesulfonamido) ethyl methacrylate (MeFBSEMA). The higher concentration of fluorine atoms may enhance the repellant (oil, water) properties of block copolymers and materials containing block copolymers described herein over block copolymers and materials containing block copolymers produced from the monomer MeFBSEMA.
Furthermore, in some embodiments, the fluorinated monomer described herein may be incorporated into a block copolymer composition containing other inexpensive, readily available hydrocarbon monomers, such as methacrylate monomers. Such block copolymers may display substantially improved oil and water repellency over the same compositions of free radically polymerized polymers (that is, copolymers of the fluorinated monomer and a hydrocarbon monomer, that is not a block copolymer). In some embodiments, block copolymer compositions according to the present invention can provide nearly the same level of surface energy reduction as fluoromethacrylate homopolymers, where the block copolymers described herein incorporate levels of fluorinated monomer as low as 10 to 20% by weight.
In yet further embodiments, the block copolymers of the present invention provide utility in surfactancy and surface modification applications, even where the overall block copolymer has very low fluorine content, for instance, less than 50% by weight, less than 30% by weight, less than 20% by weight, or even less than 10% by weight, based on the weight of the block copolymer.
The block copolymers according to the present invention include di-block copolymers, as well as those having more complex molecular architectures, such as, for instance, triblock, multiblock, star, graft, and comb-like architectures. Materials where at least one of the blocks constitutes a copolymer of multiple monomers, for instance the fluorinated monomer described herein, are also within the scope of this invention. Some embodiments of block copolymers include di-block copolymers, trt-block copolymers, random block copolymers, graft-block copolymers, star- branched copolymers or hyper-branched copolymers. Additionally, block copolymers may be end functionalized (that is, have end functional groups).
Some embodiments of the present invention comprise block copolymers comprising at least one block having a quaternary ammonium ion and at least one block comprising at least one block comprising a fluorinated monomer having the general formula Rf 1 0(Rf 2 O) n (Rf 3 O) 1n (Rf 4 )AQC(R)=CH 2 where: A is a carbonyloxy or carbonylimino group, l RfI is a Cl to ClO perfluoroalkyl,
Rf 2 , Rf3, and Rf 4 are each independently a Cl to ClO perfluoroalkyl,
R is an H or a Cl to C4 alkyl,
Q is a divalent linking group. Examples of divalent linking groups include alkylene, hydroxy substituted alkylene, heteroalkylene, hydroxy substituted heteroalkylene, arylene, hydroxy substituted arylene, carbonyl, carbonyloxy, carbonylimino, oxy, and/or imino. n is from 2 to 25, and m is from 0 to 25.
In some embodiments of the present invention, the block copolymers comprising HFPOMA can modify the surfaces of polymeric substrates and plastics when a small amount is blended into the substrate. When a block copolymer of the present invention is added into a polymeric material or plastic using standard compounding processes (for example melt extrusion), the resulting surface properties of the plastic can be modified. This can potentially provide unique surface attributes to
the substrate including: antifouling, scratch resistance, lubrication, printability, and others. The amount of fluorinated polymer added to a substrate is preferably less than 10 wt %, more preferably less than 5 wt%, and most preferably less than 1 wt %.
Useful thermoplastic elastomeric polymeric resins for substrates include, for example, polybutadiene, polyisobutylene, ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, sulfonated ethylene-propylene-diene terpolymers, polychloroprene, poly(2,3- dimethylbutadiene), poly(butadiene-co-pentadiene), chlorosulfonated polyethylenes, polysulfide elastomers, block copolymers, made up of segments of glassy or crystalline blocks such as polystyrene, poly(vinyltoluene), poly(t-butylstyrene), polyester and the like and the elastomeric blocks such as polybutadiene, polyisoprene, ethylene-propylene copolymers, ethyl ene-butylene copolymers, polyether ester and the like as for example the copolymers in poly(styrene-butadiene- styrene) block copolymer manufactured by Shell Chemical Company under the trade name of "KRATON". Copolymers and/or mixtures of these aforementioned polymers can also be used
Useful polymeric resins for substrates also include fluoropolymers, that is, at least partially fluorinated polymers. Useful fluoropolymers include, for example, those that are preparable (for example, by free-radical polymerization) from monomers comprising chlorotrifluoroethylene, 2- chloropentafluoropropene, 3-chloropentafluoropropene, vinylidene fluoride, trifluoroethylene, tetrafluoroethylene, 1-hydropentafluoropropene, 2-hydropentafluoropropene, 1,1- dichlorofluoroethylene, dichlorodifluoroethylene, hexafluoropropylene, vinyl fluoride, a perfluorinated vinyl ether (for example, a perfluoro(alkoxy vinyl ether) such as CF3θCF2CF2CF2θCF=CF2, or a perfluoro(alkyl vinyl ether) such as perfluoro(methyl vinyl ether) or perfluoro(propyl vinyl ether)), cure site monomers such as for example nitrile containing monomers (for example, CF 2 =CFO(CF 2 ) LCN, CF 2 =CFO[CF 2 CF(CF 3 )O] q (CF 2 O) y CF(CF 3 )CN, CF 2 =CF[OCF 2 CF(CF 3 )JrO(CF 2 ^CN, or CF 2 =CFO(CF 2 ) U OCF(CF3)CN where L = 2-12; q = 0-4; r = 1-2; y = 0-6; t = 1-4; and u = 2-6), bromine containing monomers (for example, Z-Rf-O x - CF=CF2, wherein Z is Br or I, Rf is a substituted or unsubstituted Cj-Ci 2 fluoroalkylene, which may be perfluorinated and may contain one or more ether oxygen atoms, and x is O or 1); or a combination thereof, optionally in combination with additional non-fluorinated monomers such as, for example, ethylene or propylene. Specific examples of such fluoropolymers include polyvinylidene fluoride; terpolymers of tetrafluoroethylene, hexafluoropropylene and vinylidene
fluoride; copolymers of tetrafluoroethylene, hexafluoropropylene, perfluoropropyl vinyl ether, and vinylidene fluoride; tetrafluoroethylene-hexafluoropropylene copolymers; tetrafluoroethylene- perfluoro(alkyl vinyl ether) copolymers (for example, tetrafluoroethylene-perfluoro(propyl vinyl ether)); and combinations thereof.
In some embodiments, the present invention may provide a method for stabilizing cellular polymeric membranes when a block copolymer comprising at least one block comprising HFPOMA is added into various monomeric and/or polymeric systems (for example, curable acrylic monomer/polymer mixtures including froths that comprise gas and polymerizable material). For instance, the block copolymer may be added in an amount less than 10 wt%, less than 5 wt %, or even less than 1 wt % of a surface-active agent derived from a block copolymer of the present invention. These materials provide for and control the formation of a large number of small cells or voids in the membrane, which leads simultaneously to the formation of a cellular membrane with low density and an opaque, uniform appearance. The properties and methods of making cellular pressure-sensitive adhesive (PSA) membranes of this type are described in U.S. Pat. No. 4,415,615 (Esmay). Cellular PSA membranes or foam tapes can be made not only by forming a cellular polymeric membrane that has PSA properties, but also by applying a layer of PSA to at least one major surface of a cellular polymeric membrane.
Block copolymers according to the present invention may be formed by sequentially polymerizing different monomers. Useful methods for forming block copolymers include, for example, anionic, cationic, coordination, and free radical polymerization methods.
In multi-component compositions the block copolymers of the present invention may interact with fillers through functional moieties. For instance, the block copolymers of the present invention may be useful as a dispersing agent in a composition comprising a host polymer, a filler, and a block copolymer according to the present invention. Suitable host polymers include, for instance, any of a number of thermoplastic polymers and thermoplastic elastomeric polymers, which may be fluorinated or non-fluorinated.
Useful thermoplastic polymer resins include polylactones such as, for example, poly(pivalolactone) and poly(caprolactone); polyurethanes such as, for example, those derived from reaction of diisocyanates such as 1,5-naphthalene diisocyanate, p-phenylene diisocyanate, m- phenylene diisocyanate, 2,4-toluene diisocyanate, 4,4'-diphenylmethane diisocyanate, 3,3 '-dimethyl-
4,4'-diphenylmethane diisocyanate, 3,3'-dimethyl-4,4'~biphenyl diisocyanate, 4,4'- diphenylisopropylidene diisocyanate, 3,3 l -dimethyl-4,4'-diphenyl diisocyanate, 3,3'-dimethyI-4 3 4'- diphenylmethane diisocyanate, 3,3'-dimethoxy-4,4'-biphenyl diisocyanate, dianisidine diisocyanate, toluidine diisocyanate, hexamethylene diisocyanate, or 4,4'-diisocyanatodiphenylmethane with linear long-chain diols such as poly(tetramethylene adipate), poly(ethylene adipate), poly(l,4- butylene adipate), poly(ethylene succinate), poly(2,3-butylenesuccinate), polyether diols and the like; polycarbonates such as poly(methane bis(4-phenyl) carbonate), poly(l,l -ether bis(4-phenyl) carbonate), poly(diphenylmethane bis(4~phenyl)carbonate), ρoly(l,l-cyclohexane bis(4- phenyl)carbonate), or poly(2,2-(bis{4-hydroxyphenyl) propane) carbonate; polysulfones; polyether ether ketones; polyamides such as, for example, poly(4-aminobutyric acid), poly(hexamethylene adipamide), poly(6-aminohexanoic acid), poly(m-xylylene adipamide), poly(p-xylylene sebacamide), poly(metaphenylene isophthalamide), and poly(p-phenylene terephthalamide); polyesters such as, for example, poly(ethylene azelate), poly(ethylene-l,5-naphthalate), poly(ethylene-2,6-naphthalate), poly(l,4-cyclohexane dimethylene terephthalate), poly(ethylene oxybenzoate), poly(para-hydroxy-benzoate), poly(l,4-cyclohexylidene-dimethylene terephthalate) (cis), poly(l,4-cyclohexylidene-dimethylene terephthalate) (trans), polyethylene terephthalate, and polybutylene terephthalate; poly(arylene oxides) such as, for example, poly(2,6-dimethyl-l,4- phenylene oxide) and poly(2,6-diphenyl-l,lphenylene oxide); poly(arylene sulfides) such as, for example, polyphenylene sulfide; polyetherimides; vinyl polymers and their copolymers such as, for example, polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride, polyvinyl butyral, polyvinylidene chloride, and ethylene-vinyl acetate copolymers; acrylic polymers such as , for example, poly(ethyl acrylate), poly(n-butyl acrylate), poly(methyl methacrylate), poly(ethyl methacrylate), poly(n-butyl methacrylate), poly(n-propyl methacrylate), polyacrylamide, polyacrylonitrile, polyacrylic acid, ethylene-ethyl acrylate copolymers, ethylene-acrylic acid copolymers; acrylonitrile copolymers (for example, poly(acrylonitrile-co-butadiene-co-styrene) and poly(styrene-co-acrylonitrile)); styrenic polymers such as, for example, polystyrene, poly(styrene-co maleic anhydride) polymers and their derivatives, methyl methacrylate-styrene copolymers, and methacrylated butadiene-styrene copolymers; polyolefins such as, for example, polyethylene, polybutylene, polypropylene, chlorinated low density polyethylene, poly(4-methyl-l-pentene); ionomers; poly(eρichlorohydrins); polysulfones such as, for example, the reaction product of the sodium salt of 2,2-bis(4-
hydroxyphenyl) propane and 4,4'-dichlorodiphenyl sulfone; furan resins such as, for example, poly(furan); cellulose ester plasties such as, for example, cellulose acetate, cellulose acetate butyrate, and cellulose propionate; protein plastics; polyarylene ethers such as, for example, polyphenylene oxide; polyimides; polyvinylidene halides; polycarbonates; aromatic polyketones; polyacetals; polysulfonates; polyester ionomers; and polyolefϊn ionomers. Copolymers and/or combinations or blends of these aforementioned polymers can also be used.
Useful thermoplastic elastomeric polymeric resins include, for example, polybutadiene, polyisobutylene, ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, sulfonated ethylene-propylene-diene terpolymers, polychloroprene, poly(2,3-dimethylbutadiene), poly(butadiene-co-pentadiene), chlorosulfonated polyethylenes, polysulfide elastomers, block copolymers, made up of segments of glassy or crystalline blocks such as polystyrene, poly(vinyltoluene), poly(t-butylstyrene), polyester and the like and the elastomeric blocks such as polybutadiene, polyisoprene, ethylene-propylene copolymers, ethylene-butylene copolymers, polyether ester and the like as for example the copolymers in poly(styrene-butadiene-styrene) block copolymer manufactured by Shell Chemical Company under the trade name of "KRATON". Copolymers and/or combinations or blends of these aforementioned polymers can also be used
Useful polymeric resins also include fluoropolymers, that is, at least partially fluorinated polymers. Useful fluoropolymers include, for example, those that are preparable (for example, by free-radical polymerization) from monomers comprising chlorotrifluoroethylene, 2- chloropentafluoropropene, 3-chIoropentafluoropropene, vinylidene fluoride, trifluoroethylene, tetrafluoroethylene, 1-hydropentafluoropropene, 2-hydropentafluoropropene, 1,1- dichlorofluoroethylene, dichlorodifluoroethylene, hexafluoropropylene, vinyl fluoride, a perfluorinated vinyl ether (for example, a perfluoro(alkoxy vinyl ether) such as CF3θCF2CF2CF2θCF=CF2, or a perfluoro(alkyl vinyl ether) such as perfiuoro(methyl vinyl ether) or perfluoro(propyl vinyl ether)), cure site monomers such as for example nitrile containing monomers (for example, CF2=CFO(CF2) L C H CF 2 =CFO[CF2CF(CF3)O] q (CF2O) y CF(CF 3 )CN, CF2=CF[OCF 2 CF(CF3)] r O(CF 2 )tCN, or CF2=CFO(CF 2 ) U OCF(CF 3 )CN where L = 2-12; q = 0-4; r = 1-2; y = 0-6; t = 1-4; and u = 2-6), bromine containing monomers (for example, Z-Rf-O x - CF=CF2, wherein Z is Br or I, Rf is a substituted or unsubstituted Ci-Ci 2 'fluoroalkylene, which may be perfluorinated and may contain one or more ether oxygen atoms, and x is 0 or 1); or a
combination thereof, optionally in combination with additional non-fluorinated monomers such as, for example, ethylene or propylene. Specific examples of such fluoropolymers include polyvinylidene fluoride; terpolymers of tetrafluoroethylene, hexafluoropropylene and vinylidene- fluoride; copolymers of tetrafluoroethylene, hexafluoropropylene, perfluoropropyl vinyl ether, and vinylidene fluoride; tetrafluoroethylene-hexafluoropropylene copolymers; tetrafluoroethylene- perfluoro(alkyl vinyl ether) copolymers (for example, tetrafluoroethylene-perfluoro(propyl vinyl ether)); and combinations thereof.
Useful commercially available thermoplastic fluoropolymers include, for example, those marketed by Dyneon LLC under the trade designations "THV" (for example, "THV 220", "THV 400G", "THV 500G", "THV 815", and "THV 610X"), "PVDF", "PFA","HTE", "ETFE", and "FEP"; those marketed by Atochem North America, Philadelphia, Pennsylvania under the trade designation "KYNAR" (for example, "KYNAR 740"); those marketed by Ausimont, USA, Morristown, New Jersey under the trade designations "HYLAR" (for example, "HYLAR 700") and "HALAR ECTFE".
Suitable fillers include, for instance, carbon black, carbon nanotubes, clay, and any conventional filler or additive utilized, for instance, in melt processing compositions. In particular, fillers may also include pigments, carbon fibers, hindered amine light stabilizers, anti-block agents, glass fibers, aluminum oxide, silica, mica, cellulosic materials, or one or more polymers with reactive or polar groups. Examples of polymers with reactive or polar groups include, but are not limited to, polyamides, polyimides, functional polyolefins, polyesters, polyacrylates and methacrylates.
In one aspect of the invention, the filler is a cellulosic material. Cellulosic materials are commonly utilized in melt processable compositions to impart specific physical characteristics to the finished composition. Cellulosic materials generally include natural or wood materials having various aspect ratios, chemical compositions, densities, and physical characteristics. Non-limiting examples of cellulosic materials include wood flour, wood fibers, sawdust, wood shavings, newsprint, paper, flax, hemp, rice hulls, kenaf, jute, sisal, peanut shells. Combinations of cellulosic materials, or cellulosic materials with other interfering components, may also be used in the melt processable composition.
The block copolymers of the present invention may also be used as part of a composition for melt processing. Non-limiting examples of melt processes amenable to this invention include methods such as extrusion, injection molding, batch mixing and rotomolding.
The block copolymers of the present invention may also be suitable for use as a polymer processing aid or as a coupling agent improve the melt processability of polymer composite systems containing conventionally known fluoropolymer, particularly fluoroplastic and fluoroelastomeric processing aids. In particular, the present invention may improve the melt processability of compositions containing fillers, particularly interfering components that may have a strong interfacial tension with host polymers. The block copolymers may enable a significant reduction in the interfacial tension between the host polymer and the fillers, thus resulting in an improved efficacy of the block copolymer either as a polymer processing aid or as an additive to improve the performance of a fluoropolymer processing aid. The resulting processed material may exhibit a significant reduction in melt fracture as well as improved physical characteristics such as water uptake, flexural modulus, or tensile strength.
The block copolymers of the present invention may comprise functional blocks, typically having one or more polar moieties such as, for example, acids (for example, -CO2H, -SO3H, -
PO3H); -OH; -SH; primary, secondary, or tertiary amines; ammonium; N-substituted or unsubstituted amides and lactams; N-substituted or unsubstituted thioamides and thiolactams; anhydrides; linear or cyclic ethers and polyethers; isocyanates; cyanates; nitriles; carbamates; ureas; thioureas; heterocyclic amines (for example, pyridine or imidazole)). Useful monomers that may be used to introduce such groups include, for example, acids (for example, acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, and including methacrylic acid functionality formed via the acid catalyzed deprotection of t-butyl methacrylate monomeric units as described in U.S. patent publication No. U.S. 2004/0024130 A 1 (Nelson et al.)); acrylates and methacrylates (for example, 2-hydroxyethyl acrylate), acrylamide and rnethacrylarnide, N-substituted and N 5 N- disubstituted acrylamides (for example, N-t-butylacrylamide, N,N-(dimethylamino)ethyl- acrylamide, N,N-dimethyl-acrylamide, N,Ndimethylmeth-acrylamide), N-ethyl-acrylamide, N- hydroxyethyl-acrylamide, N-octyl-acrylamide, N-t-butyl-acrylamϊde, N,N-dimethyl-acrylamide, N,N-diethyl-acrylamide, and N-ethyl-N-dihydroxyethyl-acrylamide), aliphatic amines (for example, 3-dimethylaminopropyl amine, N,N-dimethylethylenediamine); and heterocyclic monomers (for
example, 2-vinylpyridine, 4-vinylpyridine, 2-(2-aminoethyl)pyridine, l-(2-aminoethyl)pyrrolidine, 3-aminoquinuclidine, N-vinylpyrroIidone, and N-vinylcaprolactam).
Other suitable blocks may have one or more hydrophobic moieties such as, for example, aliphatic and aromatic hydrocarbon moieties such as those having at least 4, 8, 12, or even 18 carbon atoms; fluorinated aliphatic and/or fluorinated aromatic hydrocarbon moieties, such as for example, those having at least 4, 8, 12, or even 18 carbon atoms; and silicone moieties. Non- limiting example of useful monomers for introducing such blocks include: hydrocarbon olefins such as ethylene, propylene, isoprene, styrene, and butadiene; cyclic siloxanes such as decamethylcyclopentasiloxane and decamethyltetrasiloxane; fluorinated olefins such as tetrafluoroethylene, hexafluoropropylene, trifluoroethylene, difluoroethylene, and chlorofluoroethylene; nonfluorinated alkyl acrylates and methacrylates such as butyl acrylate, isooctyl methacrylate lauryl acrylate, stearyl acrylate; fluorinated acrylates such as perfluoroalkylsulfonamidoalkyl acrylates and methacrylates having the formula H^C=C(RzJ)C(O)O-
X-N(R)Sθ2Rf wherein: R f » s -Co 17 13» -C4F9, Or-^Fy; R is hydrogen, Cl to ClO alkyl, or C6- ClO aryl; and X is a divalent connecting group.
The block copolymers according to the present invention may also have blocks selected from the group consisting of vinyl aromatics, styrenics, dienes, vinyl pyridines, acrylates, methacrylates, epoxides, oxiranes, cyclic sulfides, lactones, lactides, cyclic carbonates, lactams, cyclosiloxanes, acrylonitrile, [n]metallocenophanes, fluorinated acrylates, fluorinated methacrylates and anionically-polymerizable polar monomers.
Other non-limiting examples of useful block copolymers having functional moieties include poly(HFPOMA-block-methacrylic acid)), poly(HFPOMA-block-t-butyl methacrylate), poly(styrene-block-t-butyl methacrylate-block-HFPOMA), poly(styrene-block-methacrylic anhydride-block-HFPOMA), poly(styrene-block- methacrylic acidblock-HFPOMA), poly(styrene- block-(methacrylic anhydride-co-methacrylic acid)-block-HFPOMA)), poly(styrene-block- (methacrylic anhydride-co-methacrylic acid-co-HFPOM A)), poly(styrene-block-(t-butyl methacrylate-co-HFPOMA)), poly(styrene-block-isoprene-block-t-butyl methacrylate-block- HFPOMA), poly(styrene-isoprene-block-methacrylic anhydride-block-HFPOMA), poly(styrene- isoprene-block-methacrylic acid-block-HFPOMA), poly(styrene-block-isoprene-block- (methacrylic anhydride-co-methacrylic acid)-block-HFPOMA), ρoly(styrene-block-isoprene-block-
(methacrylic anhydride-comethacrylic acid-co-HFPOMA)), poly(styrene-block-isoprene-block-(t- butyl methacrylateco-HFPOMA)), poly(HFPOMA-block-methacrylic anhydride), poly(HFPOMA- block-(methacrylic acid-co-methacrylic anhydride)), poly(styrene-block-(t-butyl methacrylateco-- HFPOMA)), and hydrogenated forms of poly(butadiene-block- HFPOMA), and poly(butadiene- 5 block-methacrylic acid-block-HFPOMA).
EXAMPLES Test Methods
) Molecular Weight and Polydispersity
The average molecular weight and polydispersity of a sample was determined by Gel Permeation Chromatography (GPC) analysis. Approximately 25 mg of a sample was dissolved in 10 milliliters (mL) of tetrahydrofuran (THF) to form a mixture. The mixture was filtered using a 0.2 micron polytetrafluoroethylene (PTFE) syringe filter. Then about 150 microliters (μL) of the i filtered solution was injected into a Plgel-Mixed B column (available from Polymer Laboratories,
Amherst, MA) that was part of a GPC system also having a Waters® 717 Autosampler and a Waters® 590 Pump (available from Waters Corporation, Milford, MA). The system operated at room temperature, with a THF eluent that moved at a flow rate of approximately 0.95mL/min. An Erma ERC-7525A Refractive Index Detector (available from JM Science Inc. Grand Island, NY)
1 was used to detect changes in concentration. Number average molecular weight (Mn) and polydispersity index (PDI) calculations were based on a calibration mode that used narrow polydispersity polystyrene controls ranging in molecular weight from 580 to 7.5 x 10^. The actual calculations were made with PL Caliber® software available from Polymer Laboratories, Amherst, MA.
Block Concentration
The concentration of different blocks in a block copolymer was determined by Nuclear Magnetic Resonance (NMR) spectroscopy analysis. A sample was dissolved in deuterated chloroform to a concentration of about 10 weight % and placed in a Unity® 500 MHz NMR
Spectrometer available from Varian Inc., Palo Alto, California. Block concentrations were calculated from relative areas of characteristic block component spectra.
Material Description
Example 1
Synthesis of P(I-ό-HFPOMA) block copolymer via continuous polymerization:
The P(I-O-HFPOMA) block copolymer was synthesized by sequential anionic polymerization according to the methods outlined in U.S. Patent 6,969,491. A solution containing a .living sample of DPE-modified PI in toluene (200 g) was collected from the end of the STR and stored in an inert atmosphere. To this solution, 50 g of HFPOMA was added and the resultant 2 phase system was agitated for 20 minutes, resulting in a homogeneous dispersion. The polymerization was quenched by adding 10 ml of isopropanol. Tables 2-3 detail the experimental conditions, temperature profile and polymer analytical data for the P(I-ό-HFPOMA) block copolymer respectively.
TABLE 1
The temperature profile in each zone was, by zone, Tl (40 0 C); T2 (50 0 C); T3 (50°C); T4 (10°C); T5 (10 0 C).
The Polymer analytical data for the P(I-ό-HFPOMA) block copolymer showed a composition in mole % (wt %) of: 1,2 PI 1.2% (0.7); 1,4 PI 68.6% (40.1); and PHFPOMA 5.2%
(44.5). The number average molecular weight was 9.6 x 10^ g/mol and the polydispersity index was 3.3.
Example 2
Synthesis of P(S-b-HFPOMA) block copolymer via continuous polymerization.
The P(S-^-HFPOMA) block copolymer was synthesized by sequential anionic polymerization. A "living" polystyrene polymer was synthesized in a 0.94 L stirred tubular reactor (STR) according to the methods outlined in US 6,969,491. The "living" polystyrene-DPE polymer was synthesized continuously in the STR and collected under nitrogen in a separate vessel. 30.5 g of HFPOMA was added to 1000 g of the "living" polymer solution and the solution was shaken vigorously to form the P(S-ό-HFPOMA) block copolymer. Tables 3-5 detail the experimental conditions, temperature profile and polymer analytical data for the P(S-έ-HFPOMA) block copolymer, respectively.
TABLE 2
The temperature profile in each zone was, by zone, Tl (70°C); T2 (50°C); T3 (50°C); T4 (2O 0 C); T5 (20°C).
The Polymer analytical data for the P(S-ό-HFPOMA) block copolymer showed a composition in mole % of: Styrene (96.1); and PHFPOMA (3.9). The number average molecular weight was 2.8 x 10^ g/mol and the polydispersity index was 1.7.