THEREFROM

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to ion pairs of ethylenically unsaturated cationic monomers and anionic monomers suitable for polymerizing into a substantially chloride-free, even substantially halogen-free mixed-charge polymer. Introduction

Mixed-charge polymers are polymers that contain both positive (cationic) and negative (anionic) charged functionalities in a single polymer. Mixed-charge polymers are useful in detergent formulations including automatic dishwashing detergent formulations and laundry detergent formulations. In automatic dishwashing, mixed-charge polymers reduce spotting on dishes. In laundry applications, mixed-charge polymers inhibit soil redeposition.

Preparing mixed-charge polymers typically requires polymerization of a monomeric cationic chloride salt with an anionic monomer or monomers that are converted to anions after polymerization with the monomeric cationic chloride salt. The presence of chloride in such a process is problematic. Free chloride is corrosive to metal, including the metal typically used for polymerization reactors. Therefore, the reactors used for synthesis of mixed-charge polymers must be regularly monitored for wear and must be regularly repaired or they must be glass-lined or made of special chloride-resistant alloy. It is desirable to be able to prepare mixed-charge polymers without having the problems associated with chloride counterions so less expensive steel reactors can be used without degradation caused by the presence of chloride.

Similarly, use of mixed-charge polymers comprising chloride ions can be harmful to metal components exposed to the chloride ions. For example, use of a mixed-charge polymer in an automatic dishwasher detergent exposes the polymer to the metallic components inside the dishwasher. Chloride ions present with the mixed-charge polymer can corrode and degrade the metal components of the dishwasher, which is undesirable. Therefore, mixed-charge polymers that are substantially free of chloride ions, or any halide ions, are desirable, particularly mixed-charge polymers that are suitable for use in detergent formulations for laundry and/or automatic dishwashing applications.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a solution to the problem of preparing mixed-charge polymers without the challenges associated with chloride ions.

Surprisingly, the present invention is a result of discovering a way to prepare a composition containing ion pairs of monomeric cations and monomeric anions, thereby providing monomeric ion pairs. Even more surprisingly, the composition of cationic and anionic monomers can be polymerized to form mixed-charge polymers in the presence of less than one mole-percent (and even in an absence of) chloride ions or any halide ion, relative to total moles of cationic monomer. Compositions comprising the monomeric counterion pair as well as mixed-charged polymer prepared therefrom can be "substantially free" of chloride or any halide, which means the compositions contain one weight-percent or less chloride or any halide based on composition weight and can actually be free of chloride or any halide. In fact, compositions of the present invention can be substantially free of chloride or any halide without having to treat the composition to remove halide.

In a first aspect, the present invention is a composition comprising independent ethylenically unsaturated quaternary ammonium cations and ethylenically unsaturated carboxylate anions, the composition containing less than one mole-percent chloride relative to quaternary ammonium cations.

In a second aspect, the present invention is a method for producing a mixed-charge polymer from the composition of the first aspect, the method comprising copolymerizing the quaternary ammonium cation with the carboxylate anion.

In a third aspect, the present invention is a mixed-charge polymer obtainable by the method the second aspect, the mixed-charge polymer having independent pendant quaternary ammonium functionalities and pendant carboxylate functionalities.

The composition comprising monomeric cations and anions is useful for polymerizing to form mixed-charge polymers in a substantial absence of chloride or any halide. DETAILED DESCRIPTION OF THE INVENTION

"And/or" means "and, or alternatively". Ranges include endpoints unless otherwise stated.

In one aspect, the present invention provides a composition that comprises or consists of independent cationic and anionic monomers. A cationic monomer contains a cationic moiety and an ethylenic unsaturated moiety in a single covalently bonded molecule. Similarly, an anionic monomer contains an anionic moiety and an ethylenic unsaturated moiety in a single covalently bonded molecule.

Typically, and desirably, there is a single cationic functional group on each cationic monomer and a single anionic functional group on each anionic monomer. The monomers are ethylenically unsaturated, which means each monomer has a non-aromatic carbon-carbon double bond (an ethylenically unsaturated moiety). Desirably, each cationic monomer has only one non-aromatic carbon-carbon double bond, or each anionic monomer has only one non- aromatic carbon-carbon double bond, or each cationic and each anionic monomer has only one non-aromatic carbon-carbon double bond. Multiple carbon-carbon double bonds on a single monomer can be undesirable because they tend to result in crosslinking and possible loss of water solubility during polymerization. Upon initiating polymerization, the non-aromatic carbon-carbon double bonds of the cationic and anionic monomers copolymerize thereby incorporating cationic and anionic groups in a single polymer to form mixed-charge polymers.

The cationic monomers and anionic monomers are "independent", which means that they are not covalently bound to one another - the cationic monomers do not have a covalently bound anionic moiety and the anionic monomers do not have a covalently bound cationic moiety. However, it is desirable for the cationic monomers and anionic monomers to be ion pairs, thereby establishing monomeric ion pairs. As ion pairs, the cationic and anionic monomers are independent (not covalently bound) yet are ionically bound to one another. As ion pairs, the anionic monomer associates with the cationic monomer to establish electronic neutrality. It is desirable for each cationic functionality of the cationic monomers to have an anionic functionality of an anionic monomer as a counterion. In that regard, there are ideally equal molar amounts of cationic functional groups from the cationic monomers as there are anionic functional groups from the cationic monomers. It is desirable for there to be 1:0.9 to 1: 1.1 molar ratio, preferably a 1:0.95 to 1: 1.05 molar ratio, and even more preferably 1: 1 molar ratio of anionic functionalities of anionic monomers to cationic functionalities of cationic monomers in the composition of the present invention at a pH of 8.

If the identity and concentration of the cationic and anionic monomer is known in the composition, calculate the molar ratio of anionic functionalities to cationic functionalities from the known concentration and identities of the monomers. If the identity and concentration is unknown, experimentally determine the molar ratio of anionic functionalities to cationic functionalities by isolating two samples of the composition comprising the cationic and anionic monomers, adding a quantitative nonionic internal standard to each, running one through a cationic ion exchange column and the other through an anionic ion exchange column and then quantitatively determining the concentration of cationic and anionic monomer in each using nuclear magnetic resonance (NMR) spectroscopy.

The cationic and anionic monomers can be polymerized to form mixed-charge polymers in an environment that is free from chloride ions, halide ions and/or even any anionic counterions other than those of the anionic monomers of the composition from which the polymer is made. In particular, the mixed-charge polymers can be made in an environment that is free from chloride, or any halide.

Anionic species such as chloride, or any halide, are unnecessary in the composition of the present invention. Halides, particularly chloride, are often present as counterions to a cationic functional group. However, the present invention obviates a need for halide counterions by including anionic monomers. As a result, the compositions of the present invention can have less than one mole-percent (mol%), preferably 0.5 mol% or less, more preferably 0.1 mol% or less and most preferably is free of chloride. Moreover, the

compositions of the present invention can have less than one mole-percent (mol%) halide, preferably 0.5 mol% or less, more preferably 0.1 mol% or less and most preferably is free of any halide. Mol% chloride and halide is relative to total moles of cationic functional groups that are part of the cationic monomers. Determine mol% chloride and mol% halide by ion chromatography in which a test solution is passed through a column and the concentration of chloride (or other halide) ion is measured by the area under a peak whose elution time corresponds to that observed in a run of a calibration solution containing known levels of chloride (or other halide) ion. Detection is desirably done by suppressed conductivity.

The cationic monomer is desirably selected from a group consisting of unsaturated quaternary ammonium cations. Preferably, the cationic monomer is an unsaturated quaternary ammonium cation having the structure of Formula I:

where: Ri, R ₂ and R ₃ are independently selected from a group consisting of hydrogen, methyl and ethyl; A is selected from a group consisting of ^CH ₂ (or, "CH ₂ " for short) and ^C=0 (or "C=0" for short), B is selected from a group consisting of hydrogen, an acetoyl group, and a propionyl group; and C has a structure of one structure selected from a group consisting of Formula II and Formula ΠΙ, where Formula Π is

where R ₄ , R5 and R ₆ are independently selected from a group consisting of 0-0 ₂ alkyl or arylalkyl groups; and Formula ΠΙ

(ΙΠ) where R7-R11 are independently selected from a group consisting of hydrogen and C1-C12 alkyl groups. The groups of Formula II and Formula ΠΙ are quaternary ammonium cationic groups. Quaternary ammonium cations are understood herein to be groups with a cationic nitrogen having attached to the cationic nitrogen four carbon-nitrogen bonds. As in Formula ΙΠ, an aromatic double bond between the nitrogen cation and a carbon serves as two carbon-nitrogen bonds.

One desirable unsaturated quaternary ammonium cation of Formula I has Ri, R ₂ and R3 all hydrogens, A is CH ₂ , B is hydrogen and C is Formula Π where each of R ₄ , R5 and R ₆ are -CH3 groups.

Another desirable unsaturated quaternary ammonium cation of Formula I has Ri and R ₂ are hydrogens, R3 is -CH3, A is C=0, B is hydrogen and C is Formula II where each of R ₄ , R5 and R ₆ are -CH3 groups.

Yet another desirable unsaturated quaternary ammonium cation of Formula I has Ri, R ₂ and R3 all hydrogens, A is CH ₂ , B is hydrogen and C is Formula ΙΠ where each of R7, Rs, R9, Rio and Rn are hydrogen.

The anionic monomer is desirably an ethylenically unsaturated carboxylate anion. Preferably, the ethylenically unsaturated carboxylate anion is a deprotonated carboxylic acid selected from a group consisting of acrylic acid, methacrylic acid, and any combination of two or more than two thereof. Particularly desirably, the ethylenically unsaturated carboxylate anion is the deprotonated form (carboxylate form) of methacrylic acid or acrylic acid. The anionic monomer in the composition of the present invention can comprise a combination of more than one ethylenically unsaturated carboxylate anion as described above.

It is desirable to directly synthesize the cationic monomer and anionic monomers together simultaneously. In that manner, the process can avoid having to replace a counterion on the cationic monomer with the anionic monomer. As a result, there is a substantial absence of anions present in the composition of the present invention to compete with the anionic monomer as a counterion to the cationic monomer. In other words, there is desirably less than 10 mol%, preferably 8 mol% or less, more preferably 5 mol% or less, even more preferably 3 mol% or less, yet more preferably 2 mol% or less, yet even more preferably one mol% or less and most preferably zero mol% (an absence of) chloride ions and/or other halide ions and/or any anions present other than the anionic monomer counterion in the composition of the present invention wherein mol% is relative to total moles of cationic functionalities in the composition.

Generally, the composition comprises the cationic monomers and anionic monomers dispersed or dissolved in a solvent such a water. Solvent is generally 90 wt% or less, preferably 80 wt% or less, still more preferably 70 wt% or less, and can be 60 wt% or less, 50 wt% or less, 40 wt% or less, 30 wt% or less, 20 wt% or less, 10 wt% or less, 5 wt% or less and even zero wt% of the total composition weight. At the same time, solvent can be present at a concentration of greater than zero wt%, 5 wt% or more, 10 wt% or more, 20 wt% or more, 30 wt% or more, 40 wt% or more, 50 wt% or more, 60 wt% or more, 70 wt% or more, 80 wt% or more and even 90 wt% or more based on total weight of the composition.

The composition desirably comprises 70 wt% or more, preferably 75 wt% or more, and can be 80 wt% or more, 85 wt% or more, 90 wt% or more, 95 wt% or more and even 100 wt% of a combination of the cationic and anionic monomers relative total solids weight of the composition. At the same time, the combination of cationic and anionic monomers can be less than 100 wt%, 95 wt% or less, 90 wt% or less, 85 wt% or less, 80 wt% or less, even 75 wt% or less of the total solids weight of the composition. Solids weight refers to the weight of components other than a solvent (for example, water). Other solids that can be present in the composition include organic components other than the cationic and anionic monomers and inorganic materials such as impurities, salts and minerals.

The composition of the present invention is useful for preparing mixed-charge polymers that serve as their own counterions. In a second aspect, the present invention is a method for producing mixed-charge polymers from the composition of the present invention by

copolymerizing the ethylenically unsaturated cationic monomer with the ethylenically unsaturated anionic monomer. Copolymerize the cationic monomer and anionic monomers of the composition of the present invention by free radical polymerization of the non-aromatic ethylenically unsaturated moieties (the non-aromatic carbon-carbon double bonds) in the cationic and anionic monomers.

In general, the method for free radical polymerization of the monomer of the

composition of the present invention occurs through reaction of the monomers with free radicals, typically generated thermally or electrochemically from "initiators". For example, monomer and initiator can be simultaneously and continuously fed into a reactor containing solvent while maintaining the temperature of the reactor through heat removal. Initiator is generally fed in such a manner that the concentration of residual monomers present at the completion of the reaction process are minimized.

Preferably, after completing the polymerization to form the mixed-charge polymer, the composition comprises less than one mol% of non-polymerized anionic monomer, even more preferably 0.5 mol% or less, even more preferably 0.1 mol% or less and most zero mol% non- polymerized anionic monomer, with mol% of anionic monomer relative to total moles of cationic groups on the mixed-charge polymer. Measure the residual monomer concentrations by gas chromatography if the monomer is volatile and by liquid chromatography is the monomer is non-volatile.

The resulting mixed-charge polymer has a carbon chain backbone with pendant cationic functionalities and pendant anionic functionalities. The pendant anionic functionalities and pendant cationic functionalities can be pendant side chains or pendant side groups, meaning the cationic and anionic functionalities can be part of either a pendant side chain or a pendant side group of the mixed-charge polymer. A "pendant side chain" is an oligomeric or polymeric extension off from a backbone while a "pendant side group" is an extension off from a backbone that is neither oligomeric nor polymeric. For simplicity herein, the term "pendant functionality" will be used to generally refer to the pendant cationic functionality and/or pendant anionic functionality. For avoidance of doubt, pendant functionalities are covalently bound the polymer backbone.

A pendant functionality of the present mixed-charge polymer can contain either a cationic functionality or an anionic functionality but a single pendant functionality does not contain both a cationic functionality and an anionic functionality. In other words, the mixed- charge polymer comprises "independent" cationic and anionic pendant functionalities.

Desirably, the mixed-charge polymer comprises less than 10 mole-percent (mol%), preferably 8 mol% or less, more preferably 5 mol% or less, even more preferably 3 mol% or less, yet more preferably 2 mol% or less, yet even more preferably one mol% or less, 0.5 mol% or less, 0.1 mol% or less and most preferably zero mol% (an absence of) chloride ions and/or halide ions wherein mol% is relative to total moles of pendant cationic functionalities in the mixed-charge polymer. In this regard, the mixed-charge polymer avoids application challenges associated with chloride, or other halides. Determine mol% of halides by ion chromatography.

Desirably, compositions (for example, solutions) comprising the mixed-charge polymer comprise less than one wt% chloride, preferably less than one wt% of any halide relative to total composition weight. Determine wt% halide by ion chromatography.

Desirably, the pendant cationic functionality is a pendant quaternary ammonium functionality. Preferably, the pendant cationic functionality has the structure of Formula IV (the portion shown in brackets) with A attached to the backbone (represented by the curved line) of the polymer:

where A is selected from a group consisting of CH ₂ ( ^or _> "CH ₂ " for short) and _/ C=0 (or "C=0" for short), B is selected from a group consisting of hydrogen, an acetoyl group, and a propionyl group; and C is selected from a group consisting of Formula II and Formula ΠΙ, where Formula II is:

where R ₄ , R5 and R ₆ are independently selected from a group consisting of 0-0 ₂ alkyl or arylalkyl groups; and Formula ΠΙ is:

(ΙΠ) where R7-R11 are independently selected from a group consisting of hydrogen and C1-C12 alkyl groups.

One desirable unsaturated quaternary ammonium cation of Formula I has Ri, R ₂ and R3 all hydrogens, A is CH ₂ , B is hydrogen and C is Formula Π where each of R ₄ , R5 and R ₆ are - CH3 groups.

Another desirable unsaturated quaternary ammonium cation of Formula I has Ri and R ₂ are hydrogens, R3 is -CH3, A is C=0, B is hydrogen and C is Formula II where each of R ₄ , R5 and R ₆ are -CH3 groups.

Yet another desirable unsaturated quaternary ammonium cation of Formula I has Ri, R ₂ and R3 all hydrogens, A is CH ₂ , B is hydrogen and C is Formula ΙΠ where each of R7, Rs, R9, Rio and Rn are hydrogen.

The pendant anionic functionality is desirably a carboxylate anion. As such, the pendant anionic functionality desirably has the structure of Formula V, with the curved line representing the polymer backbone:

Desirably, the pendant anionic functionality is the remnant of copolymerizing into the polymer backbone a deprotonated carboxylic acid selected from a group consisting of acrylic acid, methacrylic acid, and any combination of two or more than two thereof. Preferably, the pendant anionic functionality originates from the copolymerization of a deprotonated methacrylic acid or acrylic acid.

Desirably, the mixed-charge polymer obtainable by polymerizing the monomers in the composition of the present invention has a weight- average molecular weight of 2000 daltons or more, and can be 3000 daltons or more, 5000 daltons or more 10,000 daltons or more 20,000 daltons or more 30,000 daltons or more, 40,000 daltons or more, 50,000 daltons or more, 60,000 daltons or more, 70,000 daltons or more and even 80,000 daltons or more while at the same time is generally 100,000 daltons or less and can be 90,000 daltons or less, 80,000 daltons or less, 70,000 daltons or less, 60,000 daltons or less, 50,000 daltons or less, 40,000 daltons or less and even 30,000 daltons or less. Determine weight- average molecular weight of the mixed-charge polymer by gel permeation chromatography.

EXAMPLES

Synthesis of Cationic/Anionic Monomer Pair

Example 1: 3-(allyloxy)-2-hydroxy-N,N,N-trimethylpropan-l-aminium methacrylate Fit a 3 -neck, two-liter fully jacketed round bottom flask with an overhead stirrer, dry ice condenser and a temperature probe. Into the flask add 225 grams (g) of a 30.04 weight-percent (wt%) aqueous solution (1.14 mole) of trimethylamine (TMA) and 0.20 g (675 ppm) of 4- hydroxy-2,2,6,6-tetramethyl-l-piperidinyloxy (also known as "4-hydroxyTEMPO" or "4-HT") inhibitor. Set the jacket temperature to one degree Celsius (°C) and turn on the overhead stirrer to 240 revolutions per minute. When the temperature of the TMA solution reaches 5 °C add 98.5 g (1.15 moles) glacial methacrylic acid dropwise over one hour. Maintain the reaction temperature between 4 and 8 °C using the reactor jacket temperature and by adjusting the glacial methacrylic acid addition rate. The resulting aminium salt solution is clear and slightly yellow-orange in color. Stir for an additional 30 minutes and then allow the solution to slowly reach room temperature over the course of one hour. Set the jacket coolant temperature to 40°C. When the solution temperature is 30°C add 131 g (1.15 mol) of allyl glycidyl ether

(AGE) to the solution dropwise over 90 minutes while controlling the temperature to stay in a range of 38-42°C by adjusting rate of addition. After completing addition of AGE the solution temperature increased to 43 °C over 10 minutes and then decreased to 38°C over 15 minutes. Stir the solution at 38°C for 2 hours during which time the solution changes from being cloudy to being a single clear phase indicating reaction completion.

The resulting product is a combination of anion/cation monomer pairs dissolved in water with a 65.3 wt% combined monomer concentration in the solution.

Quantitative nuclear magnetic resonance spectroscopy (NMR) of the solution in D ₂ 0 reveals that the solution contains 96.0 mol% of a primary product 3-(allyloxy)-2-hydroxy- N,N,N-trimethylpropan-l-aminium methacrylate with the balance being a mixture of 3- (allyloxy)-2-hydroxypropyl methacrylate and 3-(allyloxy)propane-l,2-diol.

The resulting primary product 3-(allyloxy)-2-hydroxy-N,N,N-trimethylpropan-l- aminium methacrylate is a composition comprising a 1: 1 mole ratio of cationic monomer with an anionic monomer counterion. The cationic monomer has the structure of Formula I where Ri, P 2 and R ₃ all hydrogens, A is CH ₂ , B is hydrogen and C is Formula Π where each of R ₄ , R5 and R ₆ are -CH ₃ groups. The anionic monomer counterion is methacrylate. The resulting product is free of halides, particularly chloride and free of free anions.

Polymerization of Cationic/Anionic Monomer Pair to form Mixed-charge Polymer

Example 2: Polymerization of Example 1 to form Mixed-charge Polymer (High concentration of monomers and Lower Mw resulting polymer)

Equip a 2-liter round-bottom flask with an overhead stirrer, thermocouple, nitrogen bubbler, reflux condenser, syringe pumps and reciprocating pumps. Charge the flask with 137.5 g of deionized water, 68.96 g of the 65.3 wt% solution of the product of Example 1 containing primarily 3-(allyloxy)-2-hydroxy-N,N,N-trimethylpropan-l-aminium methacrylate, and 1.66 g of a 0.15 wt% solution of iron(II) sulfate in deionized water. Raise the temperature of the resulting solution in the flask to 72°C using a heating mantle. Pour directly into the flask a solution of 4.76 g of a 26.5 wt% solution of sodium metabisulfite (SMBS) in deionized water. Simultaneously begin three feeds into the flask: (a) a solution of 1.42 g sodium persulfate in 15 g deionized water; (b) a solution of 28.24 g SMBS in 60 g deionized water; and (c) 160 g glacial acrylic acid. Feed (a) into the flask over 95 minutes, (b) over 80 minutes and (c) over 90 minutes. Maintain the solution temperature in the flask at 73 °C. After completing the additions, maintain the solution at 73 °C for an addition 10 minutes. Add a solution of 0.265 g sodium persulfate in 6 g deionized water over 10 minutes and then hold at 73 °C for another 20 minutes. Allow the solution to cool while adding 75 g of a 50 wt% aqueous solution of sodium hydroxide followed by addition of 1.36 g of a 35 wt% aqueous solution of hydrogen peroxide, followed by 48 g of a 50 wt% aqueous solution of sodium hydroxide. Add 10 g of deionized water to rinse.

The resulting aqueous solution is 44.84 wt% solids with a pH of 6.1, a residual acrylic acid level of 203 weight parts per million relative to total solution weight. The resulting solution (and, hence, polymer) are free of halides, particularly chloride.

The pendant cationic functionality has the structure of Formula I where Ri, R ₂ and R ₃ all hydrogens, A is CH ₂ , B is hydrogen and C is Formula Π where each of R ₄ , R5 and R ₆ are - CH ₃ groups.

The mixed-charge polymer has a weight- average molecular weight of 12,400 daltons and a number average molecular weight of 2,800 daltons as determined by gel permeation chromatography .

Example 3: Polymerization of Example 1 to form Mixed-charge Polymer (higher Mw) Equip a 2-liter round-bottom flask with an overhead stirrer, thermocouple, nitrogen bubbler, reflux condenser, syringe pumps and reciprocating pumps. Charge the flask with 137.5 g of deionized water, 32.08 g of the 65.2 wt% solution of the product of Example 1 containing primarily 3-(allyloxy)-2-hydroxy-N,N,N-trimethylpropan-l-aminium methacrylate, and 1.66 g of a 0.15 wt% solution of iron(II) sulfate in deionized water. Raise the temperature of the resulting solution in the flask to 72°C using a heating mantle. Pour directly into the flask a solution of 4.15 g of a 15.7 wt% solution of sodium metabisulfite (SMBS) in deionized water. Simultaneously begin three feeds into the flask: (a) a solution of 0.73 g sodium persulfate in 15 g deionized water; (b) a solution of 14.7 g SMBS in 60 g deionized water; and (c) 180 g glacial acrylic acid. Feed (a) into the flask over 95 minutes, (b) over 80 minutes and (c) over 90 minutes. Maintain the solution temperature in the flask at 73 °C. After completing the additions, maintain the solution at 73 °C for an addition 10 minutes. Add a solution of 0.265 g sodium persulfate in 3.5 g deionized water over 10 minutes and then hold at 73 °C for another 20 minutes. Allow the solution to cool while adding 75 g of a 50 wt% aqueous solution of sodium hydroxide followed by addition of 1.8 g of a 35 wt% aqueous solution of hydrogen peroxide, followed by 40 g of a 50 wt% aqueous solution of sodium hydroxide. Add 18 g of deionized water to rinse. The resulting aqueous solution is 45.08 wt% solids with a pH of 6.4, a residual acrylic acid level of less than 30 weight parts per million relative to total solution weight. The resulting solution and polymer are free of halides, particularly chloride.

The pendant cationic functionality has the structure of Formula I where Ri, R ₂ and R ₃ all hydrogens, A is CH ₂ , B is hydrogen and C is Formula Π where each of R ₄ , R5 and R ₆ are CH ₃ groups.

The mixed-charge polymer has a weight-average molecular weight of 20,400 daltons and a number average molecular weight of 5,600 daltons as determined by gel permeation chromatography .

Use of Mixed-charge Polymer in Automatic Dishwashing Detergent

To demonstrate the efficacy of the mixed-charge polymer of the present invention in an automatic dishwashing detergent, compare the dishwashing results of a detergent comprising Examples 2 and 3 with dishwashing results of a detergent comprising a chlorinated variation of Example 2 (Comparative Example A) and Example 3 (Comparative Example B).

Comparative Example A: Chloride-Containing Variation of Example 2.

Equip a round-bottom flask with an overhead stirrer, thermocouple, nitrogen bubbler, reflux condenser, syringe pumps and reciprocating pumps. Charge the flask with 137.5 g of deionized water, 1.66 g of a 0.15 wt% solution of iron (II) sulfate in deionized water. Raise the temperature of the resulting solution in the flask to 72°C using a heating mantle. Pour directly into the reactor a solution of 0.17 g SMBS in 3.5 g deionized water.

Simultaneously begin three feeds into the flask: (a) a solution of 0.57 g sodium persulfate in 15 g deionized water; (b) a solution of 6.23 g SMBS in 30 g deionized water; and (c) a mixture of 160 g glacial acrylic acid and 53.3 g of a 75 wt% aqueous solution of (3- acrylamidoropyl)trimethylammonium chloride (APT AC). Feed (a) into the flask over 95 minutes, (b) over 80 minutes and (c) over 90 minutes. Maintain the solution temperature in the flask at 73 °C. After completing the additions, maintain the solution at 73 °C for an addition 20 minutes. Add a solution of 0.26 g sodium persulfate in 3.5 g deionized water over 10 minutes and then hold at 73 °C for another 20 minutes. Add another solution of 0.26 g sodium persulfate in 3.5 g deionized water over 10 minutes and then hold at 73 °C for another 20 minutes. Allow the solution to cool while adding 75 g of a 50 wt% aqueous solution of sodium hydroxide followed by addition of 1.6 g of a 35 wt% aqueous solution of hydrogen peroxide, followed by 40 g of a 50 wt% aqueous solution of sodium hydroxide. Add 30 g of deionized water to rinse. The resulting solution is 42.81 wt% solids in water with a pH of 5.6, a residual acrylic acid level of less than 25 weight parts per million relative to total solution weight.

The resulting polymer has pendant carboxylic acid functionalities and separate pendant cationic groups with a chloride counterion having the following structure:

The resulting polymer has a weight- average molecular weight of 19,000 daltons and a number average molecular weight of 6,200 daltons as determined by gel permeation chromatography .

Comparative Example B: Chloride-Containing Variation of Example 3.

Equip a round-bottom flask with an overhead stirrer, thermocouple, nitrogen bubbler, reflux condenser, syringe pumps and reciprocating pumps. Charge the flask with 140 g of deionized water, 1.66 g of a 0.15 wt% solution of iron (II) sulfate in deionized water. Raise the temperature of the resulting solution in the flask to 72°C using a heating mantle. Pour directly into the reactor a solution of 0.19 g SMBS in 3.5 g deionized water.

Simultaneously begin three feeds into the flask: (a) a solution of 0.6 g sodium persulfate in 15 g deionized water; (b) a solution of 6.71 g SMBS in 30 g deionized water; and (c) a mixture of 180 g glacial acrylic acid and 26.65 g of a 75 wt% aqueous solution of (3- acrylamidoropyl)trimethylammonium chloride (APT AC). Feed (a) into the flask over 95 minutes, (b) over 80 minutes and (c) over 90 minutes. Maintain the solution temperature in the flask at 73 °C. After completing the additions, maintain the solution at 73 °C for an addition 20 minutes. Add a solution of 0.265 g sodium persulfate in 3.5 g deionized water over 10 minutes and then hold at 73 °C for another 20 minutes. Add another solution of 0.26 g sodium persulfate in 3.5 g deionized water over 10 minutes and then hold at 73 °C for another 20 minutes. Allow the solution to cool while adding 65 g of a 50 wt% aqueous solution of sodium hydroxide followed by addition of 2.85 g of a 35 wt% aqueous solution of hydrogen peroxide, followed by 65 g of a 50 wt% aqueous solution of sodium hydroxide. Add 40 g of deionized water to rinse. The resulting solution is 41.50 wt% solids in water with a pH of 5.8, a residual acrylic acid level of less than 23 weight parts per million relative to total solution weight.

Comparative Example B has the same pendant cation functionality as Comparative Example A, just a different concentration of them.

The resulting polymer has a weight- average molecular weight of 23,400 daltons and a number average molecular weight of 7,500 daltons as determined by gel permeation chromatography .

Automatic Dishwashing Detergent and Evaluation

Prepare a detergent composition according to Table 1, one composition using each of Example 2, Example 3, Comparative Example A and Comparative Example B as the "Polymer Component".

Table 1

Evaluate each detergent composition according to the following procedure. Each detergent formulation is used in a 30 cycles of washing test using "Cycle 1" in a Miele SS- ADW, Model G122SC European (230 Volt, 15 amp, 50 Hertz) dishwasher with fuzzy logic and water softener disengaged. Use water with a hardness of 375 weight parts per million (ppm) and a ratio of C ²⁺ : Mg ²⁺ of 3: 1 and a temperature of 18-30 °C. Feed water to the dishwasher by recycling from a 200 gallon tank using a 3 horsepower pump.

The dishwasher has three racks. On the top rack distribute stainless steel flatware (multiple butter knives, forks, teaspoons and tablespoons) as ballast. In the middle rack position 4 LIBBEY™ 10 ounce Collins glasses (LIBBEY is a trademark of LIBBEY Glass, Inc.) and one SCOTT ZWEISEL TITRAN 11.2 ounce Collins Longdrink glass centrally located along the left side of the rack to minimize contact with rack posts. In the bottom rack place the following articles as ballast: one dinner plate and one salad plate (CORELLE™ VITRELLE™ Tableware; CORELLE and VITRELLE are a trademarks of WKI Holding company)), one salad plate and one cereal bowl (ROOM ESSENTIALS™ Stoneware; ROOM ESSENTIALS is a trademark of Target Brands, Inc.), one dinner plate (ROOM ESSENTIALS melamine platicware, one dinner plate (THRESHOLD™ Stoneware; THRESHOLD is a trademark of Target Brands, Inc.) and one bowl (IKEA™ Fargrik Stoneware; IKEA is a trademark of Inter IKEA Systems B.V.).

Place a 50 gram sample of frozen food in a vial in the front, middle of the bottom rack so that the spray wand of the washer will send water into the vial prior to the first of the 30 cycles. Table 2 identifies the composition of the food soil. Prepare the food soil in lOOOg gram batches and divide into 50 g aliquots prior to freezing.

Table 2

Run the dishwasher through 30 cycles with the dishes and frozen food soil. After cycle 30 remove a centrally located LIBBEY Collins glass and a SCOTT ZWIESEL TITRAN Collins Longdrink glass and evaluate it for filming and spotting.

Two trained panelists rate the glasses for scale and spotting from 1 (no scale or spotting observed) to 5 (very heavy scale or spotting observed) using a light box. Average the value for the two glasses to provide a final performance value for the detergent composition. Results are shown in Table 3.

Table 3

The results show that the halide-free mixed-charge polymer of the present invention provides comparable, if not improved, results over the corresponding-chloride containing polymer. Hence, the halide-free mixed-charge polymers of the present invention are suitable for automatic dishwashing detergents and provide an option that does not contribute chloride ions.