(en)A composition and method whereby the same group that is attached to or within the backbone of an associative thickener is reversibly switched between being hydrophilic and hydrophobic in nature. When the group that is attached to or within the backbone is rendered hydrophilic, the aqueous thickener is pourable and readily incorporated into aqueous polymer compositions. When this group is rendered hydrophobic, the thickener performs its thickening function efficiently. Switching is readily accomplished by adjusting the pH of the associative thickener composition and the aqueous polymer composition being thickened. The thickeners may be prepared from monomers by an all-aqueous solution polymerization.

1.ApplicationNumber: US-80027310-A
1.PublishNumber: US-2011281980-A1
2.Date Publish: 20111117
3.Inventor: BOBSEIN BARRETT RICHARD
JOHNSON MELISSA MERLAU
MADLE THOMAS GLENN
RABASCO JOHN JOSEPH

4.Inventor Harmonized: BOBSEIN BARRETT RICHARD(US)
JOHNSON MELISSA MERLAU(US)
MADLE THOMAS GLENN(US)
RABASCO JOHN JOSEPH(US)

5.Country: US
6.Claims:
(en)A composition and method whereby the same group that is attached to or within the backbone of an associative thickener is reversibly switched between being hydrophilic and hydrophobic in nature. When the group that is attached to or within the backbone is rendered hydrophilic, the aqueous thickener is pourable and readily incorporated into aqueous polymer compositions. When this group is rendered hydrophobic, the thickener performs its thickening function efficiently. Switching is readily accomplished by adjusting the pH of the associative thickener composition and the aqueous polymer composition being thickened. The thickeners may be prepared from monomers by an all-aqueous solution polymerization.

7.Description:
(en)This invention claims priority to the earlier filed and co-pending U.S. patent application Ser. No. 12/661,856 filed Mar. 25, 2010 and its earlier provisional filing, U.S. Provisional Application No. 61/284,739 filed Dec. 23, 2009. Additionally, this application is a continuation-in-part of, and claims the benefit of the earlier filing dates of, the earlier filed and co-pending U.S. patent application Ser. No. 11/974,071 filed Oct. 11, 2007 and its earlier provisional filing, U.S. Provisional Application No. 60/919,209 filed Mar. 21, 2007, all of which are herein incorporated in their entirety by reference.


BACKGROUND
This invention generally relates to aqueous thickener polymer compositions, their method of manufacture and method of use. In particular, this invention relates to acid suppressible aqueous thickener polymer compositions made by an aqueous free radical solution polymerization process.
Aqueous polymer systems, for example coatings containing emulsion polymer binders, typically use thickeners to obtain the desired degree of viscosity needed for the proper formulation and application of the aqueous system. One general type of thickener used in aqueous polymer systems is referred to in the art by the term “associative.” Associative thickeners are so called because the mechanism by which they thicken is believed to involve hydrophobic associations between the hydrophobic moieties in the thickener molecules and/or between the hydrophobic moieties in the thickener molecules and other hydrophobic surfaces. One type of commonly used associative thickener has a polymeric backbone constructed from one or more blocks of polymerized oxyalkylene units, typically polyethylene oxide or polypropylene oxide, with hydrophobic groups attached to or within the backbone. Another type of commonly used associative thickener utilizes a cellulosic backbone with hydrophobic groups attached to the backbone. Both of these types of associative thickeners can be characterized as polyether thickeners as they both have backbones comprising ether linkages. Known polyether associative thickeners are non-ionic thickeners, and their thickening efficiencies in aqueous systems are substantially independent of pH.
In addition to polyether segments, other types of segments can be incorporated into the backbone of a polyether associative thickener. Associative thickeners with polyurethane polyether backbone segments and containing hydrophobic groups comprising tertiary and secondary amine functionalities have been disclosed. U.S. Pat. No. 6,939,938 discloses associative polyurethane polyether thickeners with amine functional hydrophobic groups in which at least 85% of the amine functionality is converted to permanently cationic quaternary amine functionality. Because the quaternary amines are permanently cationic, the associative nature of the groups cannot be turned on and off readily by, for example, pH changes.
Most of the associative thickeners presently on the market are sold as pourable aqueous liquids. For ease of use, it is desirable for the viscosity (Brookfield at 6 rpm) of such thickener products to be less than 15,000 mPa·s. (centipoise, cps), or even less than 5,000 mPa·s. (cps), so that the product will readily drain from its storage container, and be readily incorporated into the aqueous system to which it is added. The viscosity of the aqueous thickener product can be decreased by reducing the active solids concentration, but this has the drawback of limiting formulation latitude in terms of weight solids of the aqueous system to be thickened by the product.
Other techniques for lowering associative thickener viscosity are also unsatisfactory. Mixtures of associative thickener and water with water miscible, organic co-solvents such as diethylene glycol monobutyl ether, triethylene glycol monobutyl ether, ethylene glycol, polyethylene glycol, propylene glycol or polypropylene glycol, have been used. However, use of these volatile organic solvents is contrary to the need to meet ever more stringent environmental regulations, including the reduction of Volatile Organic Content (VOC). Thus, although the organic co-solvents perform their intended role, they possess potential environmental, safety and health disadvantages. Another method to suppress the product viscosity of associative thickeners is the admixture of surfactants with the aqueous associative thickener. However, the relatively high level of surfactant required can negatively impact the thickening efficiency of the thickener product in the aqueous system to be thickened, and it can degrade final dried coating properties. In addition, the surfactant adds cost to the product.
The admixture of cyclodextrin compounds with the aqueous thickener product to suppress viscosity has also been disclosed. The cyclodextrin suppresses the viscosity of the thickener product until the product is added to an aqueous system containing levels of surfactant high enough to displace the thickener hydrophobe from the cyclodextrin cavity. The primary disadvantage of this method has been the high cost of cyclodextrin compounds.
High product viscosity KU building polyether thickeners can be blended with low product viscosity, ICI building polyether thickeners to provide a blend at an intermediate viscosity. However, when using this method, the flexibility to thicken to different KU and ICI viscosity targets in different coating formulations is compromised.
A need in the art remains, therefore, for pourable associative thickeners with both low viscosity and the highest active thickener solids possible. A particular need exists for a cost-effective, environmentally friendly method to suppress the aqueous product viscosity of associative thickeners with practical active solids concentration. Acid suppressible HEUR thickeners have been disclosed (for example, copending United States Patent Application Publication Number 2010/0076145 A1), but special expensive processing equipment and reactors are required to manufacture HEURs and convert them to aqueous solutions, at least in part because the reactants must be employed under anhydrous conditions. Moreover, the HEUR processes typically require relatively high reaction temperatures to achieve acceptable reaction rates.
Some water soluble monomers are normally suitable for all-aqueous free radical solution polymerization processes. However, when modified with hydrophobic groups suitable for associative thickening mechanisms, these hydrophobically modified monomers are found to be difficult to incorporate homogeneously with other water soluble monomers, which results from the fact that these hydrophobic monomers have limited water solubility at conventional polymerization temperatures (55-90° C.). The resulting polymers have poor solubility in water and poor thickening efficiency.
Incorporation of this type of hydrophobic monomer is readily achieved, however, in an emulsion polymerization process due to their solubility in the monomer phase and particle phase. The emulsion polymer products are delivered in a low viscosity, low pH emulsion form where the polymer particle phase is dispersed in water. The industry has used this approach to develop commercial thickeners by incorporating large amounts of acid monomer into the polymer backbone: once the pH of the emulsion is raised to deprotonate the polymerized units of acid monomer, the polymer becomes water soluble and then thickens by an associative mechanism. These hydrophobically modified alkali swellable or soluble emulsion (HASE) thickeners rely upon the insolubility of the polymer backbone itself at low pH to allow the thickener to be provided at low viscosity and at relatively high solids in the emulsion form. However, the substantially ionic backbone ultimately generates other problems related to water sensitivity in the applied coating.
A further solution to the problem is outlined herein, which avoids the necessity of specialized equipment currently employed in HEUR technology and additionally avoids the inherent water sensitivity issues that accompany HASE thickeners. The novel thickeners are prepared from hydrophobic (di)alkylamino alkoxylate monomers (or (di)alkylphosphino alkoxylate monomers) in an aqueous free radical solution polymerization process, optionally with one or more water soluble monomer. The polymer thickeners produced are acid suppressible, and so can be provided at low aqueous viscosity at low pH, and then provide high aqueous viscosity at high pH by an associative mechanism and thereby function as thickeners.
STATEMENT OF THE INVENTION
In a first aspect, there is provided an aqueous associative thickener polymer composition comprising: (a) 1% to 60% by weight of an associative thickener made by an aqueous free radical solution polymerization process comprising a water soluble backbone and a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises one or more polymerized units of a monomer, formula (I), comprising a secondary amine, or a tertiary amine, or a tertiary phosphine:









for which:

Z=nitrogen, N, or phosphorus, P;

—(OA)- represents oxyalkylene units which are units of the monomeric residue of the homo- or co-polymerization reaction product of C 2-8 alkylene oxides;

x is an integer greater or equal to 5;

R 1 and R 2 are chosen from radicals and polymeric groups comprising one or more carbon atoms, where R 1 and R 2 may be the same or different; or one of R 1 and R 2 , but not both, may be H; and the group Y comprises at least one ethylenically unsaturated carbon-carbon double bond rendering the monomer radical-polymerizable; (b) sufficient acid to substantially protonate the secondary amine, or the tertiary amine, or the tertiary phosphine; (c) 40% to 99% by weight of water; and (d) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof, as a viscosity-suppressing additive.

For each aqueous associative thickener polymer composition of the inventions described herein, there exists a preferred embodiment for which the associative thickener has a substantially non-ionic water soluble backbone.
Herein, a water soluble backbone is soluble in water under acidic, neutral and basic conditions, preferably pH=3 to pH=10. Backbones which are insoluble in water under either acidic or basic conditions are not water soluble backbones. The backbone has a solubility in water at 25° C. of at least 10% by weight.
In an embodiment, the backbone of the associative thickener comprises from 1 to 30 wt. % of the one or more polymerized units of the monomer of formula (I).
In another embodiment, the water soluble backbone of the aqueous associative thickener polymer composition further comprises polymerized units of (meth)acrylamide or substituted (meth)acrylamide, or a copolymer comprising esters of (meth)acrylic acid. In one such embodiment, the backbone of the associative thickener comprises from 45-95 wt. % of polymerized units of one or more monomers selected from one or more of the group consisting of acrylamide, methacrylamide, hydroxyethylacrylate, and combinations thereof.
In yet another embodiment, the group Y (of formula (I)) of the aqueous associative thickener polymer composition comprises at least one ethylenically unsaturated carbon-carbon double bond unit selected from the group consisting of: acrylate, methacrylate, urethane acrylate, urethane methacrylate, urethane vinyl, vinyl, vinyl ether, allyl, allyl ether, vinyl benzyl, vinyl benzyl ether, maleic esters, fumaric esters, acrylamides, and methacrylamides.
In one such embodiment, the group Y (of formula (I)) of the aqueous associative thickener polymer composition is selected from the group consisting of:









In another embodiment, the group Y (of formula (I)) comprises only one ethylenically unsaturated carbon-carbon double bond unit.
In still another embodiment, the aqueous associative thickener polymer has a hydrolyzed weight average molecular weight of from 50,000 to 500,000.
In a preferred embodiment, the aqueous associative thickener polymer is made by an all-aqueous solution polymerization.
For each embodiment of the invention there is a preferred embodiment wherein the amount of acid (b) is sufficient to reduce the pH of the aqueous thickener composition below the value of the pKa of the secondary amine, or the tertiary amine, or the tertiary phosphine, thereby substantially protonating said secondary amine, or tertiary amine, or tertiary phosphine. In one such embodiment, the amount of acid is sufficient to adjust the pH of the composition to a pH of 2.5 to 6.0.
In a another aspect, there is provided a method to increase the viscosity of an aqueous polymer system, comprising (a) combining the aqueous polymer system with an aqueous thickener composition, wherein the aqueous thickener composition comprises: (i) 1% to 60% by weight of an associative thickener made by an aqueous free radical solution polymerization process comprising a water soluble backbone and a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises one or more polymerized units of a monomer, formula (I), comprising a secondary amine, or a tertiary amine, or a tertiary phosphine:









for which:

Z=nitrogen, N, or phosphorus, P;

—(OA)- represents oxyalkylene units which are units of the monomeric residue of the homo- or co-polymerization reaction product of C 2-8 alkylene oxides;

x is an integer greater or equal to 5;

R 1 and R 2 are chosen from radicals and polymeric groups comprising one or more carbon atoms, where R 1 and R 2 may be the same or different; or one of R 1 and R 2 , but not both, may be H; and the group Y comprises at least one ethylenically unsaturated carbon-carbon double bond rendering the monomer radical-polymerizable;

(ii) sufficient acid to substantially protonate the secondary amine, or the tertiary amine, or the tertiary phosphine; (iii) 40% to 99% by weight of water; and (iv) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof, as a viscosity-suppressing additive; and (b) adding an amount of a base sufficient to substantially deprotonate the protonated secondary amine, or protonated tertiary amine, or protonated tertiary phosphine.

For each inventive method to increase the viscosity of an aqueous polymer system described herein, there exists a preferred embodiment of the method for which the associative thickener has a substantially non-ionic water soluble backbone.
In another aspect, there is provided a polymer composition, comprising in admixture, (a) an aqueous polymer system; and (b) an aqueous thickener composition comprising, based on the weight of the aqueous thickener composition: (i) 1% to 60% by weight of an associative thickener made by an aqueous free radical solution polymerization process comprising a water soluble backbone and a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises one or more polymerized units of a monomer, formula (I), comprising a secondary amine, or a tertiary amine, or a tertiary phosphine:









for which:

Z=nitrogen, N, or phosphorus, P;

—(OA)- represents oxyalkylene units which are units of the monomeric residue of the homo- or co-polymerization reaction product of C 2-8 alkylene oxides;

x is an integer greater or equal to 5;

R 1 and R 2 are chosen from radicals and polymeric groups comprising one or more carbon atoms, where R 1 and R 2 may be the same or different; or one of R 1 and R 2 , but not both, may be H; and the group Y comprises at least one ethylenically unsaturated carbon-carbon double bond rendering the monomer radical-polymerizable;

(ii) 40% to 99% by weight of water; and (iii) 0% to 15% by weight of an organic co-solvent, surfactant, cyclodextrin compound, or any combination thereof; wherein the secondary amine, or the tertiary amine, or the tertiary phosphine, are substantially unprotonated.



DETAILED DESCRIPTION
This invention describes a composition and method whereby the same group that is attached to or within the backbone of an associative thickener is reversibly switched between being hydrophilic and hydrophobic in nature. When the group that is attached to or within the backbone is rendered hydrophilic, the aqueous thickener is pourable and readily incorporated into aqueous polymer compositions. When this group is rendered hydrophobic, the thickener performs its thickening function efficiently. Switching is readily accomplished by adjusting the pH of the associative thickener composition and the aqueous polymer composition being thickened. The compositions and methods solve a long-standing need in the art for aqueous polymer thickener compositions that are readily pourable, capable of having a high solids content, and do not adversely affect the properties of the aqueous polymer compositions being thickened or the products formed thereby. Further, since there is no requirement for the addition of volatile organic solvents or costly additives such as cyclodextrin compounds, the compositions and methods are environmentally friendly and cost-effective.
The term “associative thickeners” is known in the art, and refers to thickeners that act via an associative mechanism. The associative mechanism enables the unique set of properties exhibited by the associative thickeners in particular. For example, in latex based coatings, polyether associative thickeners are known to provide improved flow and leveling and better film build compared to high molecular weight, non-associative thickeners.
It is believed in the art that the associative mechanism arises from the structure of associative thickener polymers, which contain distinct hydrophilic and hydrophobic groups. The hydrophilic groups impart overall water solubility to the polymer molecule. The hydrophobic groups associate with other hydrophobic groups on other thickener molecules or on latex particle surfaces to form a dynamic three-dimensional network structure of micelles containing thickener hydrophobic groups. Although the associations in this network are dynamic, interaction lifetimes can be long enough to provide viscosity to the system depending upon the applied shear rate.
As disclosed in U.S. Pat. No. 4,496,708, the “micellar bridging” theory is based upon the existence within the aqueous phase of intermolecular, micelle-like associations between the hydrophobic groups bonded to the water soluble polymer. In the broadest characterization, the term “micelle-like association” is intended to mean the approximate aggregation of at least two hydrophobic groups serving to exclude water. The greater effective lifetime of the micelle-like association yields a stronger network and a higher observed viscosity, that is, greater thickening efficiency. The duration of time that an individual micelle-like association exists is related to the chemical potential of the hydrophobic group as compared to its aqueous environment and steric factors, such as the proximity of one hydrophobic group to another, which aid the approach of two or more hydrophobic groups to each other. The chemical potential of the hydrophobic group as compared to its aqueous environment is directly related to the solubility parameter of the hydrophobic group in water. When the hydrophobic group is less soluble in water, there is a greater driving force for micelle-like association, and thus the network lifetime is greater and the observed viscosity is greater. When the hydrophobic group is more soluble in water, there is a reduced driving force for micelle-like association, and thus the network lifetime is shorter and the observed viscosity is less.
In the polymer compositions described herein, the water solubility parameters of select hydrophobic groups are modulated by controlling the pH of the thickener's aqueous environment. Many aqueous systems of commercial importance are supplied at pH values above about 8. The thickeners described herein deliver better thickening efficiency at pH values above about 8, i.e., the select hydrophobic groups exist in their least water soluble form at pH values above about 8. In the aqueous product as supplied at pH values less than about 6 and more than about 2.5, the thickener's efficiency is suppressed because the select hydrophobic groups exist in a more water soluble form. Thus, the novel associative thickener compositions are supplied at desirably low viscosities and at practical active solids concentrations. However, the compositions thicken aqueous systems very effectively if the pH of the aqueous system is adjusted to above about 8.
Most secondary and tertiary amines, as well as some tertiary phosphines, can be protonated at aqueous pH values below about 6. Primary amines, as components of hydrophobic groups, tend to require pH values well above about 8 to deprotonate from their acid form. Thus, primary amines can generally be characterized as too basic to be useful as a component of hydrophobic groups. Nitrogen atoms that are characterized as urea or urethanes tend to not be basic enough. That is, urea and urethane functionalities tend to require a pH value below about 2.5 to exist in the protonated form. At these low pH values, the associative thickener's polyether backbone is more prone to acid catalyzed degradation. Additionally, the thickener product would be too corrosive for commercial use. Accordingly, associative thickeners with pH values below about 2.5 are not desirable. Within the range of 2.5 to 6.0, a pH of 2.5 to 5.0 or 3.0 to 4.5 can be used.
The following discussion concerning pH and pK a is applicable to secondary amines, or tertiary amines, or tertiary phosphines. The concentration of the protonated secondary or tertiary amine, that is, the conjugate acid form of the amine, is defined as [HA+]. The concentration of the unprotonated secondary or tertiary amine, that is, the base form of the amine, is defined as [A]. The concentration of protons in solution is defined as [H+]. The acidity constant of the acid form of the amine, K a , can be defined as follows (see, for example, Hendrickson, Cram and Hammond, Organic Chemistry, Third Edition, McGraw-Hill, pp 301-302, (1970)).



K
a
=[H+][A]/[HA+]


Furthermore, the pK a of the secondary or tertiary amine and the pH of the aqueous associative thickener composition can be defined as follows:
pK a =−log K a

pH =−log [ H+]

A useful relationship is that when [HA+] equals [A], the pH of the solution will have a value equal to the pK a . Therefore, at pH values less than the amine's pK a , the concentration of the protonated form of the amine will exceed the concentration of the unprotonated form of the amine. The aqueous associative thickener composition must contain sufficient organic or inorganic acid to reduce the pH of the aqueous associative thickener composition below the value of the pK a of the secondary or tertiary amine functionalities which comprise the thickener's hydrophobic groups thereby substantially protonating said secondary or tertiary amines. When the aqueous associative thickener composition is added to the aqueous system to be thickened, the final pH value of the thickened system should be higher than the pK a of the secondary or tertiary amine group to substantially deprotonate the protonated hydrophobic amine groups. A method to increase the viscosity of an aqueous polymer composition comprises combining an aqueous polymer system with an aqueous associative thickener composition, said associative thickener further comprising a plurality of hydrophobic groups wherein one or more of said hydrophobic groups comprises a secondary amine, or a tertiary amine, or a tertiary phosphine, or combination thereof, and optionally a quaternary amine, with the proviso that less than 80% of the total amine functionality is a quaternary amine, and where the aqueous associative thickener composition is provided at a pH below that of the pK a of the secondary amine, or tertiary amine, or tertiary phosphine, or combination thereof; followed by the addition of an amount of base sufficient to raise the pH of the aqueous polymer composition above the pK a of the secondary amine, or tertiary amine, or tertiary phosphine, or combination thereof, to substantially deprotonate the protonated secondary amine, or protonated tertiary amine, or protonated tertiary phosphine, or combination thereof. The hydrophobic amine or phosphine groups of the associative thickener comprising the thickened aqueous polymer composition are substantially deprotonated when the pH of the thickened aqueous polymer composition exceeds the pK a of the secondary amine, or tertiary amine, or tertiary phosphine, or combination thereof, of the associative thickener. The alternative “or” expression also encompasses the “and” combination and is used interchangeably.
The pK a value of the amine or phosphine functionalities in the hydrophobic groups can be experimentally determined by the following method. Disperse 25 gms of thickener solids homogeneously in approximately 975 gms of water and sufficient phosphoric acid to provide 1000 gms of aqueous thickener composition of 2.5% weight thickener solids at pH=4. A mechanical stirrer, a pH meter probe, and a Brookfield viscometer can be simultaneously mounted over the vessel to provide agitation, pH measurement and viscosity measurement of the aqueous composition. Temperature should be 25° C. The stirrer should be turned off while pH measurements and viscosity measurements are recorded. The pH of the aqueous composition is adjusted stepwise upwards with 10% aqueous ammonia until a maximum pH of about 10.5 is obtained. After each aliquot of ammonia is added, the composition is stirred for 5 minutes, and then pH and viscosity are measured. Viscosity in centipoise is measured at 60 rpm and spindle #3, although more viscous titrations may require 60 rpm or lesser speeds with spindle #4 to keep the viscometer readout on scale. The viscosity is plotted on a linear scale versus the pH on a linear scale. At low and high pH values, the viscosity of the aqueous composition is relatively independent of pH. At the intermediate pH values, the viscosity is more dependent upon pH. The viscosity value at the high pH end of titration curve where the viscosity starts to become relatively independent of pH is assigned as the maximum viscosity value. The point on the titration curve corresponding to half of the maximum viscosity value is defined as the midpoint of the titration. The pK a for the amine or phosphine functionalities comprising the hydrophobic groups of the associative thickener is defined as the pH value associated with the midpoint of the titration.
Aqueous associative thickeners for use in the compositions and methods described herein accordingly comprise a hydrophilic backbone comprising a plurality of hydrophobic groups attached to or within the backbone, wherein at least one of the hydrophobic groups comprises a secondary amine, or a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine.
The hydrophilic backbone of the associative thickener can take a variety of forms, for example, the backbone can be linear, branched, or crosslinked. A variety of different types of backbones can be used, for example a polyether such as a polyoxyalkylene, a polyacrylamide, a polymethacrylamide, a polysaccharide, a polyvinyl alcohol, a polyvinyl alkyl ether, or a polyvinyl pyrrolidone. The polyacrylamide and polymethacrylamide may collectively be referred to as poly(meth)acrylamide. In one embodiment, the hydrophilic backbone comprises a (co)polymer comprising esters of acrylic acid or esters of methacrylic acid. Again, acrylic acid and methacrylic acid may collectively be referred to as (meth)acrylic acid and the related esters may collectively be referred to as esters of (meth)acrylic acid, or as (meth)acrylates. Preferably, the backbone is substantially non-ionic. Examples of suitable esters of (meth)acrylic acid include hydroxyethyl(meth)acrylate, that is, HEA or HEMA.
In one embodiment the backbone is a polysaccharide based on a cellulosic backbone, for example a hydroxy ethyl cellulose backbone. Thus, the associative thickener may have a backbone comprising one or more saccharide segments greater than 10 saccharide units in length.
In another embodiment, a polyether associative thickener is based on building blocks of polyoxyalkylene segments, for example polyethylene glycol building blocks. For example, the associative thickener may have a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length. As used herein, the term “oxyalkylene” refers to units having the structure —(O-A)-, wherein O-A represents the monomeric residue of the polymerization reaction product of a C 2-8 alkylene oxides. Examples of oxyalkylenes include, but are not limited to: oxyethylene with the structure —(OCH 2 CH 2 )—; oxypropylene with the structure —(OCH(CH 3 )CH 2 )—; oxytrimethylene with the structure —(OCH 2 CH 2 CH 2 )—; and oxybutylene with the general structure —(OC 4 H 8 )—. POlymers containing these units are referred to as “polyoxyalkylenes.” The polyoxyalkylene units can be homopolymeric or copolymeric. Examples of homopolymers of polyoxyalkylenes include, but are not limited to polyoxyethylene, which contains units of oxyethylene; polyoxypropylene, which contains units of oxypropylene; polyoxytrimethylene, which contains units of oxytrimethylene; and polyoxybutylene, which contains units of oxybutylene. Examples of polyoxybutylene include a homopolymer containing units of 1,2-oxybutylene, —(OCH(C 2 H 5 )CH 2 )—; and polytetrahydrofuran, a homopolymer containing units of 1,4-oxybutylene, —(OCH 2 CH 2 CH 2 CH 2 )—.
Alternatively, the polyoxyalkylene segments can be copolymeric, containing two or more different oxyalkylene units. The different oxyalkylene units can be arranged randomly to form a random polyoxyalkylene; or can be arranged in blocks to form a block polyoxyalkylene. Block polyoxyalkylene polymers have two or more neighboring polymer blocks, wherein each of the neighboring polymer blocks contain different oxyalkylene units, and each polymer block contains at least two of the same oxyalkylene units. Oxyethylene is the preferred oxyalkylene segment.
In still another embodiment, polyoxyalkylene segments are linked with non-polyoxyalkylene segments or linkages. When the polyoxyalkylene units are linked with a multi-functional isocyanate, a hydrophobically modified polyurethane polyether associative thickener is generated as is known in the art. These thickeners can also contain urea linkages, ester linkages or ether linkages other than those linking the polyoxyalkylene units. The multi-functional isocyanates can be aliphatic, cycloaliphatic, or aromatic; and can be used singly or in admixture of two or more, including mixtures of isomers. Examples of suitable organic polyisocyanates include 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 2,2,4-trimethyl-1,6-diisocyanatohexane, 1,10-decamethylene diisocyanate, 4,4′-methylenebis(isocyanatocyclohexane), 1,4-cyclohexylene diisocyanate, 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane, m- and p-phenylene diisocyanate, 2,6- and 2,4-toluene diisocyanate, xylene diisocyanate, 4-chloro-1,3-phenylene diisocyanate, 4,4′-biphenylene diisocyanate, 4,4′-methylene diphenylisocyanate, 1,5-naphthylene diisocyanate, 1,5-tetrahydronaphthylene diisocyanate, hexamethylene diisocyanate trimer, hexamethylene diisocyanate biuret, and triphenylmethane-4,4′,4″-triisocyanate.
When the polyoxyalkylene segments are linked with a gem-dihalide reagent, hydrophobically modified polyacetal polyether and polyketal polyether associative thickeners are generated. Suitable gem-dihalide reagents include dihalogenomethanes, such as dibromomethane and dichloromethane; 1,1-dichlorotoluene, 1,1-dichloroethane, and 1,1-dibromomethane. When the polyoxyalkylene units are linked with an aminoplast reagent, a hydrophobically modified polyaminoplast polyether associative thickener is generated. When polyoxyalkylene units are linked with an epihalohydrin or trihaloalkane reagent, a hydrophobically modified polyEPI polyether associative thickener is generated, where EPI represents the residue of an epihalohydrin reagent's or a trihaloalkane reagent's reaction with amines, alcohols, or mercaptans. Thus, the associative thickener may have a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length and one or more segments selected from (i) a urethane segment, (ii) a urea segment, (iii) an ester segment, (iv) an ether segment, (v) an acetal segment, (vi) a ketal segment, (vii) an aminoplast segment, (viii) a segment comprising the residue of the reaction of an epihalohydrin with an alcohol, an amine, or a mercaptan, and (ix) a segment comprising the residue of the reaction of a trihaloalkane with an alcohol, an amine, or a mercaptan, and (x) combinations of the foregoing.
As stated above, at least one of the hydrophobic groups attached to or within the thickener backbone contains a secondary amine, or a tertiary amine, or a tertiary phosphine, or a combination thereof, and optionally a quaternary amine, that modulates the water solubility of the hydrophobic group, depending on the pH of the aqueous composition containing the thickener.
Herein, a secondary amine is defined as a nitrogen with bonds to only one hydrogen and two carbons, wherein neither of the two adjoining carbons are classified as carbonyls or thionyls. Carbonyls are carbons with a double bond to oxygen. Thus, nitrogen that can be classified as part of amide, urethane or urea groups are not secondary amines. Thionyls are carbons with a double bond to sulfur. The two carbons adjoining the nitrogen radical may have other atoms or groups of atoms, including hydrogen and carbon, bonded to them, with the proviso that at least one of the groups of atoms includes a covalent bond to the thickener backbone. The groups of atoms bonded to the two carbons adjoining the nitrogen radical may connect forming a heterocyclic nitrogen moiety. Optionally, the amine group may be oxidized to the corresponding amine oxide.
Herein, a tertiary amine is defined as a nitrogen with bonds to only two or three carbons wherein the adjoining carbon atoms are not classified as carbonyls or thionyls. Thus, nitrogen that can be classified as part of an amide, urethane or urea group is not a tertiary amine. The two or three carbons adjoining the nitrogen may have other atoms or groups of atoms, including hydrogen and carbon, bonded to them, with the proviso that at least one of the groups of atoms includes a covalent bond to the thickener backbone. The groups of atoms bonded to the two or three carbons adjoining the nitrogen may connect forming a heterocyclic nitrogen moiety. Optionally, the amine group may be oxidized to the corresponding amine oxide.
A quaternary amine is defined as a nitrogen with bonds to four carbons.
Herein a tertiary phosphine is defined as any of several organic compounds having the structure of a tertiary amine as described above, but with phosphorus in place of nitrogen.
The associative mechanism requires a plurality of (i.e., two or more) hydrophobic groups on each hydrophilic backbone to participate in the network structure responsible for viscosity generation. It has been found that the presence of only a single secondary amine, or tertiary amine, or tertiary phosphine, in the associative thickener is sufficient to decrease the thickening efficiency of the thickener at low pH. However, in one embodiment, at least 2, in another embodiment at least 3, and yet another embodiment at least 5 of the hydrophobic groups which comprise secondary amines, or tertiary amines, or tertiary phosphines are present per thickener molecule. By “attached to or within the backbone” of the thickener, we mean these hydrophobic groups may be located within the backbone, pendant to the backbone and/or on chain termini. The term “hydrophobic group” means a group chosen from radicals and polymeric groups comprising at least one hydrocarbon-based chain chosen from linear and branched, saturated and unsaturated hydrocarbon-based chains, which optionally comprise one or more hetero atom, such as P, O, N and S, and radicals comprising at least one chain chosen from perfluoro and silicone chains In the aqueous thickener composition, at least 10%, specifically at least 25%, more specifically at least 50%, and even more specifically at least 80% of the hydrophobic groups have one or more of a secondary amine or a tertiary amine, or a tertiary phosphine functionality.
Examples of reagents that can be used to generate hydrophobic groups comprising at least one secondary amine functionality include N-octylethylenediamine, N-dodecylethylene-diamine, N-octylaminoethanol, N-dodecylaminoethanol, and 2-(2,2,6,6-tetramethyl-4-piperidinyl)ethanol. Alternative routes to generate hydrophobic groups comprising at least one secondary amine functionality include the reaction of primary amines, such as octylamine, decylamine, and iso-tridecylamine, with an alkylhalide, epoxide, or aminoplast reagent.
Examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include 2-(dibutylamino) ethanol, 2-(dioctylamino) ethanol, 2-(diheptylamino) ethanol, 2-(dihexylamino) ethanol, 2-(diethylhexylamino) ethanol, 2-(dicocoamino) ethanol, 3-dibutylamino propylamine, N-benzyl, N-methyl ethanolamine, 1-(dibutylamino)-2-butanol, 2-amino-5-diethylaminopentane, 1-(bisβ-(dimethylamino)propyl)amino)-2-propanol, N-benzyl 3-hydroxypiperidine, diphenylmethyl piperazine, 1-(1-alkylpiperazine), 1-(1-arylpiperazine), 1-(2-Aminoethyl)-4-benzyl-piperazine, 4-amino-1-benzyl-piperidine, 6-dipropylamino-1-hexanol, 1-dodecylisonipecotamide. Alkoxylated analogs of the di-alkylamino ethanol compounds are also suitable reagents. For example, 2-(dihexylamino) ethanol ethoxylated with 1 to 100 units of ethylene oxide are suitable reagents.
In an embodiment, the associative thickener has a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length and is a hydrophobically modified polyurethane polyether comprising the reaction product of a dialkylamino alkanol with a multi-functional isocyanate, a polyether diol, and optionally a polyether triol. Preferably, the polyether diol has a weight average molecular weight between 2,000 and 12,000, preferably between 6,000 and 10,000.
Alternative routes to generate hydrophobic groups comprising at least one tertiary amine functionality include the reaction of secondary amines, such as di-octylamine, di-hexylamine, and di-ethylhexylamine, with an alkylhalide, epoxide, or aminoplast reagent. These reagents would be used to provide hydrophobic groups on the ends of polymer chains. Further examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include the corresponding amine oxides of the above, for example, 2-(dibutylamino)ethanol N-oxide, 2-(dioctylamino)ethanol N-oxide, and N-benzyl 3-hydroxypiperidine N-oxide.
Examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality where the nitrogen has bonds to two carbons only include pyridine derivatives, such as alkyl- or aryl-substituted hydroxypyridine derivatives, alkyl- or aryl-substituted aminopyridine derivatives, quinoline derivatives, such as hydroxyquinoline, aminoquinoline, 8-ethyl-4-quinolinol, and 6-amino-1,10-phenanthroline, pyrazole and pyrazoline derivatives, such as, 3-amino-5-phenylpyrazole and 5-aminoindazole, imidazole derivatives, such as 2-benzimidazole methanol, 2-butyl-4-hydroxymethylimidazole, and 2-mercapto-1-hexylimidazole, oxazole derivatives, such as, oxazol-2-yl-phenylmethanol, 2-amino-5-ethyl-4-phenyloxazole, 4-(5-methyl-1,3-benzoxazol-2-yl)phenylamine, and imine derivatives, such as alpha-(2-butylimino)-p-cresol, N-(benzylidene)ethanolamine, and 1-((2-hydroxyethyl)iminomethyl)naphthalene. Additional examples of suitable reagents are the corresponding amine oxides of any of the above compounds.
Further examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include the class of diols with the general formula









wherein —(OA)- represents the oxyalkylene units described earlier; R 3 is a hydrophobic group containing at least 10 carbon atoms; and integers s and t are each at least 1, and the sum (s+t) is from 2 to about 100. The R 3 group can be either linear or branched, saturated or unsaturated and aliphatic or aromatic in nature. Representative diols are available under the name Ethomeen™ from Akzo Nobel Chemicals B.V. (Amersfoort, Netherlands). Illustrative examples include bis(2-hydroxethyl)cocoamine, bis(2-hydroxethyl)cetylamine, bis(2-hydroxethyl)stearylamine, bis(2-hydroxethyl)tallowamine, bis(2-hydroxyethyl)soyaamine, bis(2-hydroxyethyl) isodecyloxypropylamine, bis(2-hydroxyethyl) isotridecyloxypropylamine, bis(2-hydroxyethyl) linear alkyloxypropylamine, and their ethoxylates. Additionally any of the corresponding amine oxides of the above materials can be used. These reagents would be used to provide hydrophobic groups located within and pendant to the polymer chain.
Further examples of reagents that can be used to generate hydrophobic groups comprising at least one secondary and/or tertiary amine functionality include the class of diols prepared via the reaction of primary amines and/or secondary amines with mono- or di-glycidyl ether derivatives or other mono- or di-epoxy derivatives. Examples of suitable epoxy compounds include the mono- or di-glycidyl ethers of various diols, such as ethylene glycol, propylene glycol, polyethylene glycol, polypropylene glycol, 1,4-butanediol, 1,6-hexanediol, bisphenol A, bisphenol F, and cyclohexanedimethanol. Examples of suitable amines include 1-hexylamine, 3-octylamine, 1-isotridecylamine, dibutylamine, dihexylamine, dioctylamine, di-2-ethylhexylamine, benzylamine, diphenylamine, and alkylaniline. For example, the reaction of 2 moles of dioctylamine with 1 mole of poly(ethylene glycol) diglycidyl ether affords the corresponding epoxy-amine adduct, bis[3-(dioctylamino)-2-hydroxypropyl]ether of poly(ethylene glycol). Thus, the associative thickener may have a backbone comprising one or more polyoxyalkylene segments greater than 10 oxyalkylene units in length and is a hydrophobically modified polyurethane polyether comprising the reaction product of an epoxy-amine adduct with a multi-functional isocyanate, and a polyether diol, said epoxy-amine adduct derived from the reaction of primary or secondary amines with mono- or di-glycidyl ether derivatives or other mono- or di-epoxy derivatives. Preferably, the polyether diol has a weight average molecular weight between 2,000 and 12,000, preferably between 6,000 and 10,000.
Further examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary amine functionality include the reaction products of an N-alkyl trimethylene diamine and an oxyalkylene, such as ethylene oxide, which are available under the name Ethoduomeen™ from Akzo Nobel Chemicals B.V.
Examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary phosphine functionality include 2-(dialkylphosphino)ethylamines, 3-(dialkylphosphino)propylamines, dialkylhydroxymethylphosphines, dialkylhydroxyethyl-phosphines, bis-(hydroxymethyl)alkylphosphines, bis-(hydroxyethyl)alkylphosphines, and the like. Specific examples include, 2-(diphenylphosphino)ethylamine, 3-(diphenylphosphino)propylamine, 2-(dihexylphosphino)ethylamine, 2-(dioctylphosphino)-ethylamine, bis-(hydroxymethyl)hexylphosphine, bis-(hydroxymethyl)octylphospine. For example, these reagents can be incorporated into polyurethane based associative thickeners.
Other examples of reagents that can be used to generate hydrophobic groups comprising at least one tertiary phosphine functionality include dialkylphosphines, such as dihexylphosphine, dioctylphosphine, dibenzylphosphine, diphenylphosphine, bis-(dodecyl)phosphine, and the like. For example, these reagents can be incorporated into associative thickener compositions via reaction with epoxy or alkyl halide functionality or via addition to double bonds.
Advantageously, in an embodiment, the associative thickener comprises a water soluble backbone which is preferably substantially non-ionic. The associative thickener polymers of this embodiment may be prepared via an all-aqueous free radical solution polymerization process, and may comprise one or more of a water soluble monomer or a hydrophobically modified monomer, and optionally an acid monomer. Herein, an “all-aqueous” free radical solution polymerization process is a free radical solution polymerization process performed in an aqueous solution that is 96-100% water; and an “aqueous” free radical solution polymerization process is a free radical solution polymerization process performed in an aqueous solution that is 50-100% water. Monomers herein are compounds comprising radical-polymerizable carbon-carbon double bonds, and include polymerizable ethylenically unsaturated hydrocarbons, polymerizable ethylenically unsaturated acids or anyhdrides, polymerizable ethylenically unsaturated esters, polymerizable ethylenically unsaturated amides, polymerizable ethylenically unsaturated ethers, and polymerizable ethylenically unsaturated urethanes. Preferred classes of monomers include acrylic esters, methacrylic esters, acrylic acid, methacrylic acid, acrylamides, methacrylamides, and substituted compounds thereof. Preferred monomers exhibit water solubility.
Examples of water soluble monomers include, hydroxyalkylacrylates, such as hydroxyethylacrylate (HEA), hydroxyalkylmethacrylates, such as hydroxyethylmethacrylate (HEMA), hydroxylalkylamides, hydroxyalkyl(meth)acrylamides, dimethylacrylamide, and acrylamide.
Examples of hydrophobically modified monomers suitable for aqueous free radical solution polymerization include preferred monomers with the general formula, formula (I):









for which: Z=nitrogen, N, or phosphorus, P;

x is an integer greater or equal to 5;

R 1 and R 2 are chosen from radicals and polymeric groups comprising one or more carbon atoms, where R 1 and R 2 may be the same or different; or one of R 1 and R 2 , but not both, may be H; and the group Y comprises at least one ethylenically unsaturated carbon-carbon double bond rendering the monomer radical-polymerizable; and

wherein —(OA)- represents oxyalkylene units, described above, which are units of the monomeric residue of the homo- or co-polymerization reaction product of C 2-8 alkylene oxides, and x is an integer greater or equal to 5. Oxyethylene is the preferred predominant oxyalkylene unit.

R 1 or R 2 may be linear or branched, alkyl or alkenyl hydrocarbon-based chains, and may be aliphatic, cycloaliphatic, aromatic, and may optionally comprise one or more hetero atom, such as P, O, N and S, or radicals comprising at least one chain chosen from perfluoro and silicone chains. Representative alkyl groups for R 1 and R 2 include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, amyl, hexyl, heptyl, octyl, 2-ethylhexyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, eicosyl, docosyl, trityl, tristyryl, benzyl, phenyl, aryl, alkylaryl, alkenylaryl, alkylphenyl, alkenylphenyl, and cycloaliphatics such as cyclohexyl.

The ethylenically unsaturated bond (carbon-carbon double bond) which renders the monomer radical-polymerizable is contained within the group Y. Examples of group Y include, acrylate, methacrylate, vinyl ether, maleic esters, fumaric esters, acrylamides, methacrylamides, and urethanes, such as those derived from 3-isopropenyl-α,α-dimethylbenzyl isocyanate.
Further examples of hydrophobically modified monomers include the corresponding amine oxides of the above hydrophobically modified, polymerizable ethylenically unsaturated monomers.
Examples of acid monomers include acrylic acid, methacrylic acid, vinyl sulfonic acid, sodium vinyl sulfonate, styrene sulfonic acid, sodium styrene sulfonate, 2-acrylamido-2-methylpropane sulfonic acid, vinyl esters of phosphoric acid, vinyl esters of phosphonic acid, maleic acid; and salts thereof.
Preferably, the associative thickener comprising a water soluble backbone is an acrylic polymer, i.e., one having at least 50 wt % polymerized residues of (meth)acrylic or (meth)acrylamide monomers, preferably at least 70 wt %, preferably at least 80 wt %, preferably at least 90 wt %, preferably at least 95 wt %, preferably at least 98 wt %. (Meth)acrylic monomers include (meth)acrylic acids and their C 1 -C 22 alkyl or hydroxyalkyl esters, including (meth)acrylate monomers of structure H 2 C═C(R)CO 2 (CH 2 CH 2 O) r (CH(R)CH 2 O) q (CH 2 CH 2 O) p NR 1 R 2 , and their maleate, amide, urethane and ether derivatives where the maleate, amide, urethane and ether linkage connects the polymerizable ethylenically unsaturated H 2 C═C(R) group to the polyoxyalkyleneamino-dialkyl, -diaryl or -diarylalkyl hydrophobic group. In the above monomer structure, p, q, and r are integers; R is an alkyl radical or H; and R 1 and R 2 have the same meaning as described earlier. Preferably, R 1 and R 2 are C 4 -C 22 alkyl or C 6 aryl or C 6 aryl substituted with C 4 -C 22 alkyl (arylalkyl); more preferably C 6 -C 22 alkyl; and still more preferably C 8 -C 20 alkyl. Preferably, p is 1-4, q is 0-10, r is 5-50, and the sum of p+q+r is equal to or greater than 5; and more preferably p is 1, q is 0-5, and r is 10-25; preferably R is methyl or hydrogen; more preferably, R is methyl.
Additionally, crotonic acid, itaconic acid, fumaric acid, maleic acid, maleic anhydride; and alkyl- or hydroxyalkyl-esters thereof; and (meth)acrylonitrile may also be employed. The acrylic and/or acrylamide polymer may also comprise one or more other polymerized monomer residues such as, for example, non-ionic (meth)acrylate esters, cationic monomers, monounsaturated dicarboxylates, vinyl esters, vinyl amides (including, for example, N-vinylpyrrolidone and derivatives), sulfonated acrylic monomers, vinyl sulfonic acid, vinyl halides, phosphorus-containing monomers, heterocyclic monomers, styrene and substituted styrenes. Preferably, the associative thickener comprises from 0 to 60 wt % polymerized residues of one or more carboxylic acid monomers, more preferably from 2 to 50 wt %, or from 2 to 20 wt %, most preferably from 2 to 15 wt %. Preferably, the carboxylic acid monomer comprises one or more C 3 -C 4 carboxylic acid monomer, such as (meth)acrylic acid and/or maleic acid, preferably (meth)acrylic acid, and most preferably acrylic acid. Preferably, the associative thickener comprises from 1 to 30 wt % polymerized residues of monomers of structure H 2 C═C(R)CO 2 (CH 2 CH 2 O) r (CH(R)CH 2 O) q (CH 2 CH 2 O) p NR 1 R 2 or their maleate, amide, urethane and ether linked derivatives, as described above, preferably from 2 to 20 wt %, more preferably from 5 to 18 wt %, and most preferably from 6 to 15 wt %. In an embodiment, the associative thickener composition comprises from 45 to 95 wt % polymerized residues of (meth)acrylamides or C 2 hydroxyesters of (meth)acrylic acid. Accordingly, preferred monomers include one or more of acrylamide, dimethylacrylamide and hydroxyethylacrylate. In some preferred embodiments of the present invention, the associative thickener is a chain transferred polymer, having a reduced molecular weight. Known chain transfer agents (CTA's) may be used. Preferred chain transfer agents are C 8 -C 18 alkyl mercaptans; mercaptoacetic acid, mercaptopropionic acid and their C1-C18 esters; and hydroxyalkylmercaptans such as 2-mercaptoethanol, 3-mercaptopropanol and 6-mercaptohexanol. Mercaptopropionic acid is a preferred chain transfer agent.
In an embodiment, when the associative thickener comprising a water soluble backbone is used as a thickener or rheology modifier, the weight average molecular weight of the hydrolyzed associative thickener polymer is in the range of from 50,000 to 1,000,000, preferably from 100,000 to 500,000. The weight average molecular weight (M w ) and the number average molecular weight (M n ) for the water soluble associative thickeners are measured using aqueous gel permeation chromatography. Preferably, the associative thickener is provided as an aqueous composition comprising polymerized units of acid monomers in the partially or fully un-neutralized form (i.e. in the acid form). Preferably, the pKa for the dialkylamino polyalkyleneoxide monomer is pKa 3.5-7, more preferably having a pKa of 4-6, and most preferably having a pKa of 4.5-5.5. Suitable pH ranges for the aqueous solution of this embodiment are related to the pKa of the dialkylamino polyalkyleneoxide monomer. Preferably, the dialkylamino polyalkyleneoxide monomer is kept fully protonated by maintaining the solution pH at or below pH 6, more preferably at or below pH 4. Preferably, the associative thickener is provided as a low viscosity, stable, clear, water soluble polymer at pH 2-6, preferably pH 2-4.
In a particularly preferred embodiment, the aqueous thickener composition comprises: (a) 1% to 60% by weight of an associative thickener comprising a substantially non-ionic water soluble backbone and a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises one or more polymerized units of a monomer of formula (I) comprising a secondary amine, or a tertiary amine, or a tertiary phosphine:









for which:

Z=nitrogen, N, or phosphorus, P;

—(OA)- represents oxyalkylene units which are units of the monomeric residue of the homo- or co-polymerization reaction product of C 2-8 alkylene oxides;

x is an integer greater or equal to 5;

R 1 and R 2 are chosen from radicals and polymeric groups comprising one or more carbon atoms, where R 1 and R 2 may be the same or different; or one of R 1 and R 2 , but not both, may be H; and the group Y comprises at least one ethylenically unsaturated carbon-carbon double bond rendering the monomer radical-polymerizable;

and wherein the substantially non-ionic backbone, prepared via an aqueous free radical polymerization process, comprises 60-90 weight percent HEA or (meth)acrylamide, 5-15 weight percent acrylic acid, and 5-15 weight percent of the monomer of formula (I), with a hydrolyzed polymer weight average molecular weight ranging from 100,000-600,000, more preferably ranging from 150,000-500,000; and (b) sufficient acid to substantially protonate the secondary amine, or the tertiary amine, or the tertiary phosphine; and (c) 40% to 99% by weight of water.

In one such preferred embodiment, the monomer of formula (I) is bis(2-ethylhexyl)amino-(EO) 20 -methacrylate or bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -methacrylate.

Thus, a preferred method to increase the viscosity of an aqueous polymer system comprises: (a) combining the aqueous polymer system with an aqueous thickener composition, wherein the aqueous thickener composition comprises: (i) 1% to 60% by weight of an associative thickener comprising a substantially non-ionic water soluble backbone and a plurality of hydrophobic groups attached to or within the backbone wherein one or more of said hydrophobic groups comprises one or more polymerized units of a monomer of formula (I) comprising a secondary amine, or a tertiary amine, or a tertiary phosphine:









for which:

Z=nitrogen, N, or phosphorus, P;

—(OA)- represents oxyalkylene units which are units of the monomeric residue of the homo- or co-polymerization reaction product of C 2-8 alkylene oxides;

x is an integer greater or equal to 5;

R 1 and R 2 are chosen from radicals and polymeric groups comprising one or more carbon atoms, where R 1 and R 2 may be the same or different; or one of R 1 and R 2 , but not both, may be H; and the group Y comprises at least one ethylenically unsaturated carbon-carbon double bond rendering the monomer radical-polymerizable;

and wherein the substantially non-ionic backbone, prepared via an aqueous free radical polymerization process, comprises 60-90 weight percent HEA or (meth)acrylamide, 5-15 weight percent acrylic acid, and 5-15 weight percent of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -methacrylate, with a hydrolyzed polymer weight average molecular weight ranging from 100,000-600,000, more preferably ranging from 150,000-500,000;

(ii) sufficient acid to substantially protonate the secondary amine, or the tertiary amine, or the tertiary phosphine; (iii) 40% to 99% by weight of water; and (b) adding an amount of a base sufficient to substantially deprotonate the protonated secondary amine, or protonated tertiary amine, or protonated tertiary phosphine.

Not all of the hydrophobic groups in the associative thickener are required to comprise secondary amines or tertiary amines or tertiary phosphines. Examples of reagents that can be used to form the hydrophobic groups not comprising secondary amines or tertiary amines or tertiary phosphines include branched or linear aliphatic alcohols, alkylaryl alcohols, aliphatic amines and p-alkylene glycol mono-alkyl ethers. Reagents may be mono-functional or multi-functional. Examples of suitable branched aliphatic alcohols include 2-butyl 1-octanol, 2-butyl 1-decanol, 2-hexyl 1-octanol, 2-hexyl 1-decanol, isononyl alcohol, isodecyl alcohol, and isoundecyl alcohol. Examples of suitable linear aliphatic alcohols include 1-hexadecanol, 1-tetradecanol, 1-dodecanol, 1-undecanol, 1-decanol, 1-nonanol, 1-octanol, 1-hexanol, 1,2-hexadecanediol, and 1,16-hexadecanediol. Examples of suitable alkyl aryl alcohols include nonyl phenol and tri-styryl phenol. Examples of suitable aliphatic amines include 1-decyl amine, 1-octyl amine, 1-hexyl amine, di-octyl amine, di-hexyl amine. Examples of suitable p-alkylene glycol mono-alkyl ethers include alkyl ethoxylates where the alkyl group ranges from 1 carbon to 24 carbons.
Organic or inorganic acids can be used for protonating the amine functionality in the associative thickener. Suitable acids include, for example, phosphoric acid, acetic acid, hydrochloric acid, sulfuric acid, citric acid, carbonic acid, ascorbic acid, glycolic acid, isoscorbic acid, adipic acid, succinic acid, oxalic acid, homopolymers and copolymers of acrylic acid, homopolymers and copolymers of methacrylic acid, homopolymers and copolymers of maleic anhydride, homopolymers and copolymers of styrenesulfonate, homopolymers and copolymers of 2-acrylamido-2-methylpropane sulfonic acid, polyphosphoric acid, homopolymers and copolymers of phosphoethylmethacrylate, alpha hydroxy acids and trans-cinnamic acid. Phosphoric acid, or polyacrylic acid with a molecular weight between 1000 and 5000, or copolymers comprising (meth)acrylic acid are preferred.
The thickener and acid are combined to provide an aqueous thickener composition. As used herein, the term “aqueous thickener composition” (or “aqueous thickener polymer composition” or “aqueous associative thickener composition”) refers to a composition that is provided predominantly in water rather than organic solvent, although a minor amount of a water-miscible organic solvent can be present. Preferably the aqueous thickener composition comprises less than 5 weight % water miscible solvent, more preferably less than 2 weight % water miscible solvent, and most preferably, less than 1 weight % water miscible solvent, based on the weight of the aqueous thickener composition. In one embodiment, no organic solvent is present in the aqueous thickener composition.
The aqueous thickener composition can further comprise other optional additives useful to decrease the viscosity of the composition. The embodiment is especially useful where the amine or phosphine functionalities are not completely protonated, that is, where it is desired to adjust the pH of the composition to be in the higher end of the pH range of 2.5 to 6. Suitable viscosity suppressing additives include, for example, surfactants such as dialkylsulfosuccinates, sodium lauryl sulfate, alkyl ethoxylates and alkylarylethoxylates; cyclodextrin compounds such as cyclodextrin (which includes α-cyclodextrin, β-cyclodextrin, and γ-cyclodextrin), cyclodextrin derivatives, cycloinulohexose, cycloinuloheptose, cycloinulo-octose, calyxarene, and cavitand. “Cyclodextrin derivatives” refer to α-cyclodextrins, β-cyclodextrins, and γ-cyclodextrins in which at least one hydroxyl group located on the rim of the cyclodextrin ring has been functionalized with a substituent group such as methyl, acetyl, hydroxypropyl, hydroxyethyl group. Cyclodextrin derivatives also include cyclodextrin molecules with multiple substituent groups including cyclodextrin molecules with more than one type of substituent group. Cyclodextrin derivatives do not include polymers with more than one attached cyclodextrin ring. Preferred cyclodextrin derivatives are methyl-β-cyclodextrin and hydroxypropyl-β-cyclodextrin, in particular methyl-β-cyclodextrin. Since surfactants degrade the effectiveness of the cyclodextrin compound in reducing viscosity, it is preferred that surfactants not be employed when a cyclodextrin compound is added to the aqueous thickener polymer composition.
In an embodiment for the preparation of the aqueous thickener composition, the associative thickener of the types described above is first dissolved or dispersed in water with no added acid; sufficient acid is then added such that the amount of acid is sufficient to adjust the pH of the aqueous thickener composition to a pH of 2.5 to 6. In another embodiment, the acid or some portion of the total acid is first pre-mixed with water, then the associative thickener polymer is subsequently dissolved or dispersed with stirring or agitation into the acid and water mixture, and if necessary, additional acid is added. Other additives, e.g., water miscible organic solvents or cyclodextrin compounds can be incorporated into the compositions at any point.
In an advantageous feature, the aqueous associative thickener compositions may be pourable at 25° C. The composition can have a viscosity of 500 mPa·s. (cps) to 15,000 mPa·s. (cps), specifically less than 10,000 mPa·s. (cps), even more specifically less than 5,000 mPa·s. (cps). In a specific embodiment, the compositions are pourable without addition of any organic solvent and/or other viscosity-reducing additive, e.g., a cyclodextrin compound.
In still another advantageous feature, the aqueous associative thickener compositions can be formulated to contain a wide range of solids content. For example, the aqueous associative thickener composition can comprise 1 weight % to 60 weight % thickener solids, specifically 5 weight % to 40 weight % thickener solids, even more specifically 15 weight % to 25 weight % thickener solids, based on the total weight of the aqueous associative thickener compositions. The compositions further comprise 40 weight % to 99 weight % aqueous solution, specifically 60 weight % to 95 weight % aqueous solution, even more specifically 75 weight % to 85 weight % aqueous solution, based on the total weight of the aqueous associative thickener compositions. As stated above, the “aqueous solution” can comprise up to 5 weight percent of a water-miscible organic solvent. The optional additives used to further decrease the viscosity of the composition can be present in an amount of 0 weight % to 15 weight %, specifically 1 weight % to 10 weight %, even more specifically 1 weight % to 3 weight %, based on the total weight of the aqueous associative thickener compositions.
Mixing techniques to incorporate the aqueous associative thickener in the aqueous composition to be thickened include conventional mixing equipment such as mechanical lab stirrers, high speed dispersers, ball mills, sand mills, pebble mills, and paddle mixers. The aqueous associative thickener composition can be incorporated into aqueous polymer compositions in amounts from 0.005 weight % to 20 weight %, preferably from 0.01 weight % to 10 weight %, and most preferably from 0.05 weight % to 5 weight %, based on the weight of the aqueous composition.
Typical aqueous polymer systems in which the aqueous associative thickener compositions are added include paints, such as latex paints; dispersed pigment grinds; coatings, including decorative and protective coatings; wood stains; cosmetics, personal care items such as, for example, shampoos, hair conditioners, hand lotions, hand creams, astringents, depilatories, and antiperspirants; adhesives; sealants; inks; cementitious coatings; joint compounds and other construction materials; drilling fluids; topical pharmaceuticals; cleaners; fabric softeners; pesticidal and agricultural compositions; paper or paperboard coating formulations; textile formulations; and non-woven formulations.
In one embodiment, the aqueous polymer system to be thickened is a latex composition. A latex composition contains discrete polymer particles dispersed in an aqueous medium. Examples of such latex compositions include latex emulsion polymers, including but not limited to polymers that comprise (meth)acrylates, styrene, vinyl actetate or other ethylenically unsaturated monomers; latex paints; pre-blend formulations for paints or coatings; textile formulations; non-woven formulations; leather coatings; paper or paperboard coating formulations; and adhesives.
In another embodiment, the aqueous associative thickener polymer composition may be supplied at the lower pH, such that the amine or phosphine groups are protonated as described above, together with a latex emulsion polymer or other aqueous polymer system. The pH may be raised in a further formulating step, which may include, for example, the addition of an amount of base sufficient to substantially deprotonate the protonated amine or phosphine groups of the aqueous associative thickener polymer, and thereby effect an increase in viscosity. Thus, advantageously, a latex emulsion polymer is supplied together with the latent thickener, which is later formulated into an aqueous paint composition providing the desired increase in viscosity during formulation of the paint.
Optionally, the aqueous polymer compositions may comprise other components, such as pigments, fillers, and extenders such as, for example, titanium dioxide, barium sulfate, calcium carbonate, clays, mica, talc, and silica; surfactants; salts; buffers; pH adjustment agents such as bases and acids; biocides; mildewcides; wetting agents; defoamers; dispersants; pigments; dyes; water miscible organic solvents; anti-freeze agents; corrosion inhibitors; adhesion promoters; waxes; crosslinking agents; and other formulation additives known in the art.
EXAMPLES
The following examples are presented to illustrate the process and the composition of the invention. These examples are intended to aid those skilled in the art in understanding the present invention. The present invention is, however, in no way limited thereby.
The following abbreviations are used in the examples:
HMDI 4,4′-Methylene bis(cyclohexyl isocyanate)

IPDI Isophorone diisocyanate

HDI Hexamethylene diisocyanate

PEG polyethylene glycol

HEUR Hydrophobically modified ethylene oxide urethane polymer

SEC size exclusion chromatography

HPLC high pressure liquid chromatography

Mw weight average molecular weight

Mn number average molecular weight

The weight average molecular weights (Mw) of the associative thickeners were determined using size exclusion chromatography (SEC). The separations were carried out at room temperature on a liquid chromatograph consisting of an Agilent 1100 Model isocratic pump and autoinjector (Waldbronn, Germany), and a POlymer Laboratories ELS-1000 Model evaporative light scattering detector (POlymer Laboratories, International, Ltd., Church Stretton, UK). The detector was operated with a 140° C. nebulizer, a 180° C. evaporator, and a 1.5 liter 2 /minute gas flow rate. System control, data acquisition, and data processing were performed using version 3.0 of Cirrus® software (POlymer Laboratories, Church Stretton, UK). Samples were prepared in N,N-dimethylacetamide (DMAc, HPLC grade) at concentrations of 2 milligram/milliliter (mg/ml), shaken for 6 hours at 80° C., and filtered using 0.45 micron polytetrafluoroethylene (PTFE) filter. The SEC separations were performed in DMAc (HPLC grade) at 0.5 milliliter/minute (ml/min) using a SEC column set comprised of three PLgel™ columns (300×7.5 mm ID) packed with polystyrene-divinylbenzene gel (pore size marked as 100 Å, 10 3 Å and 10 4 Å, particle size 5 microns) purchased from POlymer Laboratories (Church Stretton, UK). The injection volume was 100 microliters (ul) of sample solution at a concentration of 2 mg/ml. The molar mass characteristics of the analyzed samples were calculated based on polyethylene glycol/oxide (PEG/PEO) standards also purchased from POlymer Laboratories (Church Stretton, UK).
Comparative Example A
A mixture of 200.0 g PEG (molecular weight 8000) and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 8.8 g HMDI and 0.2 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 3.4 g n-decanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after toluene evaporation. Mw was measured as 40,000.
Comparative Example B
A mixture of 200.0 g PEG (molecular weight 8000) and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 8.8 g HMDI and 0.2 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 3.1 g 1-decylamine was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 41,000.
Comparative Example C
A mixture of 200.0 g PEG (molecular weight 8000) and 325.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 8.8 g HMDI and 0.2 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 4.7 g dioctylamine was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 41,000.
Thickener Example 1
A mixture of 35.0 g PEG (molecular weight 8000) and 60.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 1.5 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 1.0 g di-n-octylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 41,000.
Thickener Example 2
A mixture of 216 g PEG (molecular weight 8000) and 22.4 g Ethomeen™ 18/25 was heated to 115° C. under vacuum in a batch melt reactor for 2 hours. Ethomeen™ 18/25 is a bis(2-hydroxethyl)stearylamine with 25 total units of ethylene oxide. The mixture was cooled to 105° C., and 9.1 g IPDI and 0.5 g bismuth octoate solution (28%) were added. The mixture was then held at 105° C. with stirring for 20 min. The resulting molten polymer was removed from the reactor and cooled. Mw was measured as 21,000.
Thickener Example 3
A mixture of 50.0 g PEG (molecular weight 8000) and 80.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 2.2 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 1.4 g di-2-ethylhexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 47,000.
Thickener Example 4
A mixture of 50.0 g PEG (molecular weight 8000) and 100.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 5.0 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 7.7 g di-2-ethylhexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 14,000.
Thickener Example 5
A mixture of 50.0 g PEG (molecular weight 8000) and 100.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 5.0 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 3.85 g di-2-ethylhexylaminoethanol and 3.1 g of di-hexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 43,000.
Thickener Example 6
A mixture of 50.0 g PEG (molecular weight 8000) and 100.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 5.0 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 6.7 g di-2-ethylhexylaminoethanol and 0.4 g of hexanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 13,000.
Thickener Example 7
A mixture of 50.0 g PEG (molecular weight 8000) and 100.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 5.0 g HMDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 6.2 g of di-hexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 36,000.
Thickener Example 8
A mixture of 50.0 g PEG (molecular weight 8000) and 80.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 1.4 g HDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 1.4 g di-2-ethylhexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 35,000.
Thickener Example 9
A mixture of 50.0 g PEG (molecular weight 8000) and 80.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 1.9 g IPDI and 0.1 g dibutyltin dilaurate were added. After 1 hour at 90° C. with stirring, 1.4 g di-2-ethylhexylaminoethanol was added. The mixture was then held at 90° C. with stirring for another hour. The resulting solid polymer was isolated after precipitation with hexanes. Mw was measured as 48,000.
Thickener Example 10
A mixture of 52.8 g di-hexylamine and 74.9 g PEG-diglycidyl ether (Mn=526) was stirred under a nitrogen atmosphere for 4 hours at 80° C. followed by another 2 hours of stirring at 100° C. Nuclear magnetic resonance analysis of the resulting reactor contents showed approximately 94 weight % purity of the desired epoxy-amine adduct product, bis[3-(dihexylamino)-2-hydroxypropyl]ether of poly(ethylene glycol), resulting from the ring opening reaction of the oxiranes by the amine. A mixture of 150.1 g PEG (molecular weight 8000), 16.1 g epoxy-amine adduct described above, and 340.0 g toluene was dried by azeotropic distillation. The mixture was cooled to 90° C., and 7.4 g HMDI and 0.2 g dibutyltin dilaurate were added. The mixture was then held at 90° C. with stirring for another 3 hours. The resulting solid polymer was isolated after precipitation with hexanes.
Thickener Example 11
A mixture of 50.0 g PEG (molecular weight 8000) and 100.0 g toluene is dried by azeotropic distillation. The mixture is cooled to 90° C., and 5.0 g HMDI and 0.1 g dibutyltin dilaurate added. After 1 hour at 90° C. with stirring, 6.2 g 2-(diphenylphosphino)ethylamine is added. The mixture is then held at 90° C. with stirring for another hour. The resulting solid polymer is isolated after precipitation with hexanes.
Dispersions of thickener in water were produced by weighing solid dry polymer and water into 50 milliliter (mL) plastic centrifuge tubes. In some cases, glacial acetic acid was also added. The tubes were capped and mounted on a rotator for continuous tumbling over 48 hours. For each example, the highest pH sample was obtained by adding only water and solid dry polymer to the centrifuge tube. The pH value in the samples with added acetic acid varies depending upon how much acetic acid was added. Once homogeneous, the samples were equilibrated in a 25° C. water bath just prior to measuring pH and viscosity on a Brookfield DV-II+LV viscometer. Aqueous sample pH values were measured on a Corning pH Meter Model 430 (Corning Incorporated, Corning, N.Y., USA). The pH meter was calibrated with pH=7.0 and pH=4.0 buffer solutions from Fisher Scientific (Fair Lawn, N.J., USA).
In the following examples and comparative examples, the objective is to provide the thickener solution at low viscosity so that formulators can add it easily while maintaining a practical active solids concentration. That is, without excessive dilution.
Aqueous Composition of Comparative Example A
Decanol Capped HEUR
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener do not comprise a secondary or tertiary amine functionality. The diisocyanate linker's reaction with the hydroxyl functionality on the decanol results in a urethane residue. At 20% thickener solids, the viscosity is too high to measure (at any pH). As shown in Table 1, the aqueous thickener solution viscosity does not decrease as solution pH is reduced with acid.








TABLE 1



Aqueous
% Thickener

Viscosity (#4, 60 rpm),

Thickener
Solids
pH
mPa · s · (cps)










Comparative A
11.5
6.14
8,570

Comparative A
11.5
4.25
9,200

Comparative A
11.5
4.04
9,278
























Aqueous Composition of Comparative Example B
Decylamine Capped HEUR
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener do not comprise a secondary or tertiary amine functionality. The diisocyanate linker's reaction with the amine functionality on the decylamine results in a urea residue. At 20% thickener solids, the viscosity is too high to measure (at any pH). As shown in Table 2, the aqueous thickener solution viscosity does not decrease as solution pH is reduced with acid. Thus, in this case, lowering the pH does result in a large viscosity change, but it is in the wrong direction.








TABLE 2



Aqueous
% Thickener

Viscosity (#4),

Thickener
Solids
pH
mPa · s · (cps)











Comparative B
10
7.4
9430
(60 rpm)

Comparative B
10
4.0
19,000
(30 rpm)

Comparative B
10
3.8
19,000
(30 rpm)
























Aqueous Composition of Comparative Example C
Dioctylamine Capped HEUR
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener do not comprise an amine functionality. The diisocyanate linker's reaction with the amine functionality on the dioctylamine results in a urea residue. At 20% thickener solids, the viscosity is too high to measure (at any pH). As shown in Table 3, the aqueous thickener solution viscosity does not decrease as solution pH is reduced with acid. Lowering the pH does result in a large viscosity change, but, again, it is in the wrong direction.










TABLE 3





Aqueous
% Thickener

Viscosity (#4),


Thickener
Solids
pH
mPa · s. (cps)





Comparative C
5
7.5
30,800 (12 rpm)


Comparative C
5
4.0
106,000 (3 rpm)


Comparative C
5
3.8
115,000 (3 rpm)





















Aqueous Composition Example 1
2-(Dioctylamino)-Ethanol Capped HEUR
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener comprise a tertiary amine functionality. The diisocyanate linker's reaction with the hydroxyl functionality on the 2-(dioctylamino)-ethanol results in a urethane residue. This thickener is an example of the hydrophobic groups comprising tertiary or secondary amine functionality being located at the ends of backbone chains. The tertiary amine functionality is protonated as solution pH is reduced with added acid, in this case acetic acid. As shown in Table 4, aqueous thickener solution viscosity is suppressed at lower pH values.










TABLE 4





Aqueous
% Thickener

Viscosity (#4, 60 rpm),


Thickener
Solids
pH
mPa · s. (cps)













Example 1
5.0
6.22
10,400


Example 1
5.0
5.26
300


Example 1
5.0
4.28
13 (#4, 100 rpm)

























Aqueous Composition Example 2
Internal C18 Ethomeen™ HEUR
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener comprise a tertiary amine functionality. The diisocyanate linker's reaction with the two hydroxyl functionalities on the Ethomeen™ 18/25 results in urethane residues. This thickener is an example of the hydrophobic groups comprising the tertiary or secondary amine functionality being located pendant to the backbone chain. The tertiary amine functionality is protonated as solution pH is reduced with added acid. As shown in Table 5, aqueous thickener solution viscosity is suppressed at lower pH values.










TABLE 5





Aqueous
% Thickener

Viscosity (#4, 60 rpm),


Thickener
Solids
pH
mPa · s. (cps)













Example 2
11.5
7.32
9560


Example 2
11.5
5.91
1910


Example 2
11.5
4.9
980

























Aqueous Composition Examples 3 and 4
2-(Diethylhexylamino)-Ethanol Capped HEUR
The hydrophobic groups in these hydrophobically modified polyurethane polyether associative thickeners comprise a tertiary amine functionality. The diisocyanate linker's reaction with the hydroxyl functionality on the 2-(diethylhexylamino)-ethanol results in a urethane residue. These thickeners are examples of the hydrophobic groups comprising the tertiary or secondary amine functionality being located at the ends of backbone chains. Samples were made at 20% thickener concentration, with and without added acetic acid. The samples containing either 20% Thickener Example 3 and no added acid or 20% Thickener Example 4 and no added acid were gel-like solids. Thus, the no added acid sample viscosities were too high to reliably measure pH or viscosity. The samples containing acetic acid were low enough in viscosity to measure viscosity and pH reliably. An active thickener concentration of 20% is a typical solids level in commercial pourable aqueous thickener compositions. Data are shown in Table 6.










TABLE 6





Aqueous
% Thickener

Viscosity (#4, 60 rpm),


Thickener
Solids
pH
mPa · s. (cps)





Example 3
20.0
3.5
1,950


Example 4
20.0
3.5
1,100




















Aqueous Composition Example 5
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener comprise two different tertiary amine functionalities. The diisocyanate linker's reaction with the hydroxyl functionality on the 2-(diethylhexylamino)-ethanol and the 2-(dihexylamino)-ethanol results in urethane residues. Samples were made at 20% thickener concentration, with and without added acetic acid. The sample containing 20% Thickener Example 5 and no added acid was a gel-like solid. Thus, the no added acid sample viscosity was too high to reliably measure pH or viscosity. The sample containing acetic acid was low enough in viscosity to measure viscosity and pH reliably. Data are shown in Table 7.










TABLE 7





Aqueous
% Thickener

Viscosity (#4, 60 rpm),


Thickener
Solids
pH
mPa · s. (cps)





Example 5
20.0
3.9
1,240



















Aqueous Composition Example 6
The hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener comprise a tertiary amine functionality and a linear alkyl chain. Samples were made at 18% thickener concentration, with and without added Acumer™ 9932. Acumer™ 9932 is a polyacrylic acid with a molecular weight of approximately 3000, supplied by Rohm and Haas Company (Philadelphia, Pa., USA) at a solids content of 46%. An aqueous thickener composition was made by combining 9.00 g of the solid
Thickener Example 6, 38.83 g of water and 2.17 g of Acumer™ 9932. The sample containing 18% Thickener Example 6 and no added acid was a gel-like solid. Thus, the no added acid sample viscosity was too high to reliably measure pH or viscosity. The sample containing Acumer™ 9932 was low enough in viscosity to measure viscosity and pH reliably. Data are shown in Table 8.









TABLE 8



Aqueous
% Thickener
% Acumer

Viscosity (#4, 60 rpm),

Thickener
Solids
9932
pH
mPa · s. (cps)



Example 6
18.0
2.0
3.6
2,800


















Aqueous Composition Example 7
The pendant hydrophobic groups in this hydrophobically modified polyurethane polyether associative thickener comprise a tertiary amine functionality. Samples were made at 18% thickener concentration, with and without added Acumer™ 9932. An aqueous thickener composition was made by combining 9.00 g of the solid Thickener Example 10, 38.83 g of water and 2.17 g of Acumer™ 9932. The sample containing 18% Thickener Example 10 and no added acid was a gel-like solid. Thus, the no added acid sample viscosity was too high to reliably measure pH or viscosity. The sample containing Acumer™ 9932 was low enough in viscosity to measure viscosity and pH reliably. Data are shown in Table 9.









TABLE 9



Aqueous
% Thickener
% Acumer

Viscosity (#4, 60 rpm),

Thickener
Solids
9932
pH
mPa · s. (cps)



Example 10
18.0
2.0
4.0
7,000


















Examples of Viscosity Versus pH Titration to Determine pK a
25 gms of Thickener Example 7 was dissolved in water, with sufficient phosphoric acid addition, to generate a 2.5% weight thickener solids solution at pH=4. Brookfield viscosity (#3 spindle, 60 rpm) was less than 8 mPa·s. (cps). Concentrated ammonia was added in stepwise additions and pH and viscosity were measured following 5 minutes stirring. The viscosity versus pH titration curve was generated from the data shown in Table10. The maximum viscosity value is 172 mPa·s. (cps). Therefore, the pKa determined for Thickener Example 7 is 8.7.





TABLE 10



Viscosity of Thickener Example 7 (2.5 weight %)






pH
Viscosity (mPa · s. (cps)









4.0
7


5.0
6


6.0
7


7.0
7


7.43
8


7.65
12


7.85
12


8.07
20


8.21
28


8.38
44


8.53
58


8.69
78


8.81
96


8.90
110


9.00
132


9.18
150


9.28
166


9.38
170


9.48
172











































The pK a was evaluated similarly for the Thickener Examples shown in Table 11.








TABLE 11





Thickener Example
Measured pK a





3
7.4


5
8.0


7
8.7


8
7.4


9
7.4






















Thickener Performance:
The performance obtained by the use of associative thickeners comprising hydrophobic groups that comprise partially or wholly protonated secondary or tertiary amine functionality is demonstrated in a latex paint composition. A latex paint composition, Pre-paint #1, was prepared by combining the following components:












Kronos 4311 titanium dioxide slurry
262.8
g


Water
150.1
g


Ethylene glycol
24.3
g


Ropaque Ultra plastic pigment
49.7
g


Rhoplex SG-30 binder
420.9
g


Drewplus L-475 defoamer
4.0
g


Texanol coalescent
19.2
g


Triton X-405 surfactant
2.5
g


Acrysol RM-2020NPR cothickener
30.0
g


Total
963.5
g





Kronos 4311 is a product of Kronos Incorporated (Chelmsford, MA, USA).


Acrysol ™ RM-2020NPR, Ropaque ™ Ultra and Rhoplex ™ SG-30 are products of Rohm and Haas Company (Philadelphia, PA, USA).


Drewplus ™ L-475 is a product of Ashland Specialty Chemical Company (Dublin, OH, USA).


Triton ™ X-405 is a product of Dow Chemical Company (Midland, MI, USA).

























The formulated paint was obtained by adding thickener and water to 963.5 g of Pre-paint #1. To maintain constant solids of the fully formulated paint, the combined weight of added thickeners and water equals 49.5 g. The density of the fully formulated paint was 1013 pounds per 100 gallons (1.2 kilogram per liter). The pH of the fully formulated paints were in the range of 8.5 to 9.0.
Formulated paints were made by the following method. To 963.5 g Pre-paint #1, an amount of aqueous thickener dispersion and an amount of water were slowly added and stirred on a lab mixer for ten minutes. The total combined amount of aqueous thickener dispersions and water is 49.5 grams. In the following data presentation, thickener concentrations in the paint are described in terms of dry grams of thickener added even though the aqueous thickener composition was admixed into the paint. For example, a concentration of 3 dry grams of a thickener can be obtained in the paint by adding 15 grams of 20% solids thickener dispersion. Following a 24 hour equilibration at room temperature, the thickened paint was stirred for one minute on a lab mixer before measuring viscosity values.
“KU viscosity” is a measure of the mid-shear viscosity as measured by a Krebs viscometer. The Krebs viscometer is a rotating paddle viscometer that is compliant with ASTM-D562. KU viscosity was measured on a Brookfield Krebs Unit Viscometer KU-1+ available from Brookfield Engineering Labs (Middleboro, Mass., USA). “KU” shall mean Krebs unit.
“ICI viscosity” is the viscosity, expressed in units of poise, measured on a high shear rate, cone and plate viscometer known as an ICI viscometer. An ICI viscometer is described in ASTM D4287. It measures the viscosity of a paint at approximately 10,000 sec −1 . ICI viscosities of paints were measured on a viscometer manufactured by Research Equipment London, Ltd (London, UK). An equivalent ICI viscometer is the Elcometer 2205 manufactured by Elcometer, Incorporated (Rochester Hills, Mich., USA). The ICI viscosity of a paint typically correlates with the amount of drag force experienced during brush application of the paint.
Thickener performance in the formulated latex paints was comparable to that of commercially available thickeners (Table 12).









TABLE 12




Concentration

ICI
Brookfield

Thickener
(g)
KU
(poise)
(#3, 6 rpm)











Acrysol SCT-275
1.93
101
1.0
8,200

Comparative
3.86
88
0.8
1,420

Example A

Example 1
1.72
93
0.7
12,600

Example 2
8.97
89
0.8
4,920

Example 3
0.98
95
0.7
15,600

Example 4
1.90
91
0.7
8,360



Acrysol ™ SCT-275 is a product of Rohm and Haas Company (Philadelphia, PA, USA).



























The white paint formulated with Example 4 above was tinted by adding 35 g of red iron oxide colorant to 200 g of base paint followed by mixing on a paint shaker for 10 minutes. The red iron oxide colorant was obtained from the Sherwin Williams Company (Cleveland, Ohio, USA). KU, ICI, and Brookfield viscosities were measured one hour after tinting. The viscosity measurement was preceded by one minute of stirring on a mechanical mixer. The red iron oxide tinted paint exhibited KU, ICI, and Brookfield viscosities of 82, 0.6 and 3,800 mPa·s. (cps), respectively, showing acceptable performance in formulations with added colorant.
Part B. Acid Suppressible Thickeners Made by an All-Aqueous Free Radical Solution POlymerization
Suitable polymerization techniques for use in the method of this invention include mixed solvent-water (50% or more water) and all-water (all-aqueous, 96-100% water) solution polymerization, as known in the art. Aqueous based solution polymerization processes typically are conducted in an aqueous reaction mixture, which may contain one or more water soluble monomer and various synthesis adjuvants such as the free radical initiators, chain transfer agents, reductants, metal catalysts and, optionally, surfactants to help maintain water solubility of the polymer. The aqueous reaction medium is the continuous fluid phase of the aqueous reaction mixture, and solvates and hydrates the aqueous polymer. The aqueous reaction medium preferably contains greater than 50 weight % water and optionally one or more water soluble surfactants or co-solvents. Preferably, upon forming the polymer, the polymer phase is 15-50 weight % of the total reaction medium, which includes polymer, water, water miscible co-solvents and water miscible surfactants. Suitable water miscible co-solvents include methanol, ethanol, propanol, isopropanol, t-butanol, acetone, ethylene glycol, propylene glycol. Suitable water miscible surfactants include non-ionic surfactants with the general formula: OH—(CH 2 CH 2 O) w R 4 where R 4 is a C 8 to C 30 hydrocarbon and w is between 20 and 50. R 4 may also be tristyrylphenol. Preferably, for environmental reasons, the solvent-water reaction medium, excluding the polymer phase, contains 50-85 weight % water, and most preferably, 98-100 weight % water based on the total weight of the aqueous reaction medium excluding the polymer phase. The residual amount may be solvent or surfactant. Most preferred is an “all-aqueous” reaction medium containing 96-100 weight % water and 0-4 weight % non-ionic surfactant. The preferred non-ionic surfactant is Tergitol 15-S-40 (The Dow Chemical Company, Midland, Mich., USA).
The weight average molecular weights of the water soluble associative thickeners was determined by gel permeation chromatography as described above but followed a modified procedure as follows (the weight average molecular weight was determined for the hydrolyzed polymer thickeners):
Solid thickener (0.5 g), potassium hydroxide pellets (1.0 g) and ethanol (8.0 milliliters) were added to a 22 ml non-stirred Parr pressure vessel. The pressure vessel was sealed and heated at 150° C. in a forced air oven for 5 days. The pressure vessel was then removed from the oven and allowed to cool for 4 hrs. at room temperature. The ethanolic supernatant was carefully poured off and the solid hydrolyzed polyacid pellet was then rinsed with three 10 milliliter portions of ethanol, and the pellet was dried overnight at 60° C. in a vacuum oven. Ten milligrams of the resulting dried poly-acid pellet was weighed into a 1 ounce glass jar and dissolved in 5 milliters of 20 millimolar disodium phosphate buffer solution. The resulting solution was filtered thru a 0.5 micron Millex-LCR syringe driven filter unit and the molecular weight of the filtrate was evaluated on an Agilent 1100 Series Aqueous GPC Liquid Chromatography unit in the manner described earlier. Molecular weights obtained in this manner are referred to herein as the molecular weight of the hydrolyzed polymer, or as hydrolyzed molecular weight.
The hydrophobically modified associative thickener of the present invention is useful as a thickener for paints and other coating compositions.
Example B1
Synthesis of Water Soluble Hydrophobic Amine-Functional Monomers
Abbreviations:
TEMPO-2,2,6,6-tetramethylpiperidine-1-oxy (Sigma-Aldrich Company, Milwaukee, Wis., USA)

MEHQ-4-methoxyhydroquinone (Sigma-Aldrich Company, Milwaukee, Wis., USA)

BEHA-bis(2-ethylhexyl)amine (Sigma-Aldrich Company, Milwaukee, Wis., USA)

CS-(EO) 20 -cetyl-stearyl (EO) 20 polyether alcohol (Macol CSA 20) (BASF Corp, Ludwigshafen, Germany)

BEHA-(EO) 20 -bis(2-ethylhexyl)amino-(EO) 20 polyether alcohol (Ethox Chemicals, Greenville, S.C., USA)

BEHA-(EO) 1 (PO) 5 (EO) 20 -bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 polyether alcohol (Ethox Chemicals, Greenville, S.C., USA)

The following hydrophobic amine-functional monomers were synthesized:
Monomer Example B-1.1
Preparation of BEHA-(EO) 70 -Methacrylate Monomer
A 500 ml reactor fitted with a thermometer, a heating mantle, a temperature regulator, an over-head stirring motor, a dry air sweep and a condenser was charged with 100.0 g of bis(2-ethylhexyl)amino-(EO) 20 polyether alcohol (molecular weight, Mw, 1121). The reactor contents were heated under air to 85° C., and 0.056 g of 4-hydroxy-TEMPO and 0.056 g of MEHQ inhibitors were added, followed by 13.95 g of methacrylic anhydride. The contents of the reactor were maintained at 85° C. for 5 hrs., and then cooled to room temperature to provide the methacrylate monomer (monomer B-1.1) shown below.









Monomer Example B-1.2
Preparation of BEHA-(EO) 1 (PO) 5 (EO) 20 -Methacrylate Monomer
The same procedure as for Example B-1.1 was followed, except the 100.0 g of bis(2-ethylhexyl)amino-(EO) 20 polyether alcohol was replaced with 100.0 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 polyether alcohol (molecular weight 1455), and the addition of methacrylic anhydride utilized 10.7 g instead of 13.95 g. The contents of the reactor were maintained at 85° C. for 5 hrs. and then cooled to room temperature to provide the methacrylate monomer (monomer B-1.2) shown below.









Monomer Example B-1.3
Preparation of BEHA-(EO) 20 -Vinyl Urethane Monomer
A 500 ml reactor fitted with a thermometer, a heating mantle, a temperature regulator, an over-head stirring motor, a nitrogen sweep and a condenser with a Dean-Stark trap was charged with 100 g of bis(2-ethylhexyl)amino-(EO) 20 -polyether alcohol (molecular weight 1121) and 100 ml of toluene. The reactor contents were heated under nitrogen to reflux, and residual water was removed by the water/toluene azeotrope into the Dean-Stark trap. The contents of the reactor were cooled to 90° C., and then 0.1 g of 4-methoxy phenol, 0.1 g of 4-hydroxy-TEMPO, 0.1 g dibutyl tin dilaurate, and 18.0 g of α,α-dimethyl-m-isopropenyl benzyl isocyanate were added, in order, to the reactor. The contents of the reactor were maintained at 90° C. for 60 minutes and then cooled to room temperature. The toluene was removed by roto-evaporation to provide the vinyl monomer with urethane linkage shown below (monomer B-1.3).









Monomer Example B-1.4
Preparation of BEHA-(EO) 1 (PO) 5 (EO) 20 -Vinyl Urethane Monomer
The same procedure as for Example B-1.3 was followed, except the 100.0 g of bis(2-ethylhexyl)amino-(EO) 20 polyether alcohol was replaced with 100.0 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 polyether alcohol (molecular weight 1455), and the addition of α,α-dimethyl-m-isopropenyl benzyl isocyanate utilized 13.8 g instead of 18.0 g. The vinyl monomer with urethane linkage (monomer B-1.4) is shown below.









Monomer Example B-1.5
Preparation of BEHA-(EO) 1 (PO) 5 (EO) 20 -Vinyl Ether Monomer
A 500 ml reactor fitted with a thermometer, a heating mantle, a temperature regulator, an over-head stirring motor, a dry air sweep and a condenser with a Dean-Stark trap is charged with 100 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -polyether alcohol (molecular weight 1455) and 100 ml of toluene. The reactor contents are heated to reflux and residual water is removed by the water/toluene azeotrope into the Dean-Stark trap. The contents of the reactor are cooled to 60° C., and then 0.1 g of 4-methoxy phenol, 0.1 g of 4-hydroxy-TEMPO, 10.5 g 4-vinylbenzyl chloride and 1.58 g of sodium “lumps” (solid sodium, available from Aldrich; 99% with 1% kerosene) are added, in order, to the reactor. The contents of the reactor are maintained at 60° C. for 60 minutes and then cooled to room temperature. The toluene is removed by roto-evaporation to provide the vinyl benzyl ether monomer shown below (monomer B-1.5).









Monomer Example B-1.6
Preparation of BEHA-(EO) 1 (PO) 5 (EO) 20 -Maleate Monomer
A 250 ml reactor fitted with a thermometer, a heating mantle, a temperature regulator, an over-head stirring motor, a dry air sweep and a condenser was charged with 72.1 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -polyether alcohol (molecular weight 1455). The reactor contents were heated under dry air to 85° C., and then 0.072 g of 4-hydroxy-TEMPO were added followed by 4.9 g of maleic anhydride. The contents of the reactor were maintained at 85° C. for 5 hrs. and then cooled to room temperature to provide the maleate monomer shown below (monomer B-1.6).









Monomer Comparative Example B-1A
Preparation of Nonionic CS-(EO) 20 -Methacrylate Monomer (No Amine Functionality)
To a 500 ml reactor fitted with a thermometer, a heating mantle, a temperature regulator, an over-head stirring motor, a dry air sweep and a condenser was charged with 100.0 g of cetyl-stearyl-(EO) 20 -polyether alcohol (Macol CSA 20; molecular weight 1150). The reactor contents were heated under dry air to 85° C., and then 0.056 g of 4-hydroxy TEMPO and 0.056 g of MEHQ inhibitors were added, followed by 14.3 g of methacrylic anhydride. The contents of the reactor were maintained at 85° C. for 8 hrs. and then cooled to room temperature to provide the non-ionic CS-(EO) 20 -methacrylate monomer shown below (monomer B-1A).









Synthesis and Evaluation of Associative Thickeners as Acid Suppressible Thickeners
Example B2
Hydroxyethyl Acrylate (HEA) Associative Thickeners
Synthesis of HEA Thickener Comparative Example B-2A(i)
(Non-Acid Suppressible Thickener Comprising HEA Backbone and Conventional Non-Ionic C 16-18- (EO) 20 -Methacrylate Hydrophobic Monomer B-1A; Solvent=100% Water)
A 500 ml round bottom four-neck reactor flask, equipped with a mechanical stirrer, heating mantle, thermocouple, condenser and inlets for the addition of monomer, initiator and nitrogen, was charged with 112.5 g of de-ionized water (DI water). The reactor flask water was then heated to 45° C. with an external heating source. A monomer mixture was prepared in a 50 milliliter glass beaker by adding 20.0 g of hydroxyethylacrylate, 2.5 g of acrylic acid, 0.625 g of 10% aqueous 3-mercaptopropionic acid chain transfer agent (“CTA”) and 2.5 g of the non-ionic C 16-18- (EO) 20 -methacrylate monomer described in monomer synthesis example B-1A. Then, 0.8 grams of a 0.15% aqueous solution of ferrous sulfate heptahydrate, 10.0 g of a 0.25% aqueous solution of isoascorbic acid and the monomer mixture described above were charged to the reactor flask. With the reactor temperature at 40 degrees centigrade, 10.2 g of a 1.6% aqueous sodium persulfate catalyst co-feed solution was co-fed to the reactor kettle at 0.33 g/minute. Simultaneously, 10.2 g of a 0.25% aqueous isoascorbic acid solution was co-fed to the reactor kettle at 0.33 g/minute. The polymerization was allowed to proceed without external heating or cooling. The reactor temperature was allowed to gradually increase, over a period of 10 to 15 minutes, from 40° C. to 55-60° C., from the inherent heat of polymerization. When the reaction temperature peaked (55-60° C.), an external heating source was applied to maintain the reaction temperature at 60° C. Once the sodium persulfate and isoascorbic acid co-feeds were finished, the reactor temperature was held at 60° C. for an additional 30 minutes. After the additional 30 minute hold, the contents of the reactor were cooled to room temperature. The final aqueous solution polymer had a solids content of 15.0%, a pH=1.8, and an “as is” aqueous solution viscosity of 40 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #1 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-2A(i) appeared opaque like a milk solution. Some water-insoluble grit-like particles were also present in the aqueous solution. The HEA polymer had a hydrolyzed molecular weight of 194,000.
Synthesis of HEA Thickener Comparative Example B-2A(ii)
(Non-Acid Suppressible Thickener Comprising a HEA Backbone and Conventional Non-Ionic C 16-18 -(EO) 20 -Methacrylate Hydrophobic Monomer; Solvent=75% Water/25% T-Butanol)
A similar thickener composition was prepared according to synthesis example B-2A(i) above, except that 33.7 g of the initial 112.5 g DI water reactor charge was replaced with 33.7 g of t-butanol and the t-butanol was stripped out of the reaction at the end of the 30 minute hold. The final aqueous solution polymer, after stripping out the t-butanol and replacing with equal amount of DI water, had a solids content of 15.0%, a pH=2.0, and an “as is” aqueous solution viscosity of 90,000 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #4 at 6 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-2A(ii) was clear and transparent and free of water-insoluble grit particles. The HEA polymer had a hydrolyzed molecular weight of 137,000.
Synthesis of HEA Thickener Example B-2.1
(Acid Suppressible Aqueous Thickener Comprising Bis(2-Ethylhexyl)Amino-(EO) 20 -Methacrylate Hydrophobic Monomer B-1.1; Solvent=100% Water)
A thickener composition was prepared according to the same synthesis procedure of example B-2A(i) above, except that the 2.5 g of the non-ionic C 16-18- (EO) 20 -methacrylate monomer described in synthesis example B-2A(i) was replaced with 2.44 g (equal moles) of the bis(2-ethylhexyl)-amino-(EO) 20 -methacrylate monomer described in monomer synthesis example B-1.1. The final aqueous solution polymer had a solids content of 15.0%, a pH=2.6, and an “as is” aqueous solution viscosity of 60 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #1 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-2.1 was clear and transparent and free of water-insoluble grit particles. The HEA polymer had a hydrolyzed molecular weight of 155,000.
Synthesis of HEA Thickener Example B-2.2
(Acid Suppressible Aqueous Thickener Comprising a HEA Backbone and Bis(2-Ethylhexyl)Amine-(EO) 1 (PO) 5 (EO) 20 -Methacrylate Hydrophobic Monomer; Solvent=100% Water)
A thickener composition was prepared according to the same synthesis procedure of example B-2A(i) above, except that the 2.5 g of the non-ionic C 16-18- (EO) 20- methacrylate monomer described in synthesis example B-2A(i) was replaced with 3.12 g (equal moles) of the bis(2-ethylhexyl)-amino-(EO) 1 (PO) 5 (EO) 20 -methacrylate monomer described in monomer synthesis example B-1.2. The final aqueous solution polymer had a solids content of 15.0%, a pH=2.4, and an “as is” aqueous solution viscosity of 120 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #2 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-2.2 was clear and transparent and free of water-insoluble grit particles. The HEA polymer had a hydrolyzed molecular weight of 153,000.





TABLE B1



Evaluation of HEA Polymers as Acid Suppressible Associative Thickeners












“As Supplied”






Thickener





Viscosity
SG-30 Binder



Type
Phobic
(mPa · s.)
Viscosity 1

Thickener

“phobic”
Monomer
15% Solids
(mPa · s.)

Example #
Solvent
Monomer
Structure
pH = 3.0
2% Thickener










B-2A(i)
100% water
Non-ionic
C 18 -alkyl-(EO) 20 -MA 2
1,500
1,000

Comparative

(B-1A)

B-2A(ii)
75% water
Non-ionic
C 18 -alkyl-(EO) 20 -MA 2
90,000
1,500,000

Comparative
25% t-BuOH
(B-1A)

B-2.1
100% water
(B1.1)
C 8 -dialkylamine-
60
3,200

Suppressible


(EO) 20 -MA 2

B-2.2
100% water
(B-1.2)
C 8 -dialkylamine-
120
940,000

Suppressible


(EO) 1 (PO) 5 (EO) 20 -MA 2



1 Viscosity was measured at 25° C. and pH 9 after 1 day. The viscosity of SG-30 binder (25% solids) without thickener = 5 mPa · s. (cps) at 25° C. and pH 9.

2 MA = methacrylate.




































Synthesis and Evaluation of Associative Thickeners as Acid Suppressible Thickeners
Example B3
Acrylamide (Am) Associative Thickeners
Synthesis of Acrylamide Thickener Example B-3.2
(Acid Suppressible Thickener Comprising Low Molecular Weight Acrylamide Backbone and Bis(2-Ethylhexyl)Amino-(EO) 1 (PO) 5 (EO) 20 -Methacrylate Hydrophobic Monomer B-1.2; Solvent=100% Water)
A 500 ml round bottom four neck reactor flask, equipped with a mechanical stirrer, heating mantle, thermocouple, condenser and inlets for the addition of monomer, initiator and nitrogen, was charged with 90.0 g of DI water. The reactor flask water was then heated to 85° C. with an external heating source. A monomer mixture was prepared in a 200 milliliter glass beaker by adding 70 g of 50% aqueous acrylamide, 10.0 g of acrylic acid, 1.88 g of 10% aqueous 3-mercaptopropionic acid chain transfer agent (“CTA”) and 6.2 g of bis(2-ethylhexyl)amino(EO) 1 (PO) 5 (EO) 20 -methacrylate monomer described in monomer synthesis example B-1.2. Then, 0.8 g of a 0.15% aqueous solution of ferrous sulfate heptahydrate, and 10.0 g of a 0.25% aqueous solution of isoascorbic acid were charged to the 85° C. reactor water. With the reactor temperature at 83-85° C., 10.2 g of a 1.6% aqueous sodium persulfate catalyst co-feed solution was co-fed to the reactor kettle at 0.33 g/minute. Simultaneously, 10.2 g of a 0.25% aqueous isoascorbic acid solution was co-fed to the reactor kettle at 0.33 g/minute. Simultaneously, the monomer mixture in the 200 ml glass beaker was co-fed to the reactor kettle at 3.16 g/minute. The polymerization was allowed to proceed at 85° C. with external heating and cooling applied to the reactor to maintain the reactor temperature at 85° C. throughout the polymerization. When all the co-feeds were completed, the reaction temperature was held an additional 30 minutes at 85° C. with an external heating source. After the additional 30 minute hold, the contents of the reactor were cooled to room temperature. The final aqueous solution polymer had a solids content of 22.0%, a pH=3.3, and an “as is” aqueous solution viscosity of 620 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #3 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-3.2 was slightly cloudy but still transparent and free of water-insoluble grit particles. The Acrylamide polymer had a hydrolyzed molecular weight of 83,000.
Synthesis of Acrylamide Thickener Example B-3.3
(Acid Suppressible Thickener Comprising Low Molecular Weight Acrylamide Backbone and Bis(2-Ethylhexyl)Amine-(EO) 20 -Vinyl Urethane Hydrophobic Monomer B-1.3; Solvent=100% Water)
The same process and composition as described in comparative thickener synthesis Example B-3.2 was repeated except that the 6.2 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -methacrylate monomer described in monomer synthesis Example B-1.2 was replaced with 5.6 g of bis(2-ethylhexyl)amino-(EO) 20 -vinyl urethane monomer described in monomer synthesis Example B-1.3. The final aqueous solution polymer had a solids content of 22.0%, a pH=3.3, and an “as is” aqueous solution viscosity of 700 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #3 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-3.3 was a clear transparent solution and free of water-insoluble grit particles. The Acrylamide polymer had a hydrolyzed molecular weight of 83,000.
Synthesis of Acrylamide Thickener Example B-3.4
(Acid Suppressible Thickener Comprising Low Molecular Weight Acrylamide Backbone and Bis(2-Ethylhexyl)Amino-(EO) 1 (PO) 5 (EO) 20 -Vinyl Urethane Hydrophobic Monomer B-1.4; Solvent=100% Water)
The same process and composition as described in comparative thickener synthesis Example B-3.2 was repeated except that the 6.2 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -methacrylate monomer described in monomer synthesis Example B-1.2 was replaced with 6.8 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -vinyl urethane monomer described in monomer synthesis Example B-1.4. The final aqueous solution polymer had a solids content of 22.0%, a pH=3.3, and an “as is” aqueous solution viscosity of 640 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #3 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-3.4 was slightly cloudy but still transparent and free of water-insoluble grit particles. The Acrylamide polymer had a hydrolyzed molecular weight of 85,000.





TABLE B2



Evaluation of Acrylamide Polymers as Acid Suppressible Associative Thickeners












“As Supplied”






Thickener





Viscosity
SG-30 Binder





(mPa · s.)
Viscosity 1

Thickener
Type
Type
Monomer
22% Solids
(mPa · s.)

Example #
Process
Monomer
Structure
pH = 3.3
2% Thickener



B-3.2
100% water
Methacrylate
C 8 -dialkylamine-
620
8,500




(EO) 1 (PO) 5 (EO) 20




(Monomer B-1.2)

B-3.3
100% water
Vinyl
C 8 -dialkylamine-
700
2,250



Urethane
(EO) 20




(Monomer B-1.3)

B-3.4
100% water
Vinyl
C 8 -dialkylamine-
640
4,300



Urethane
(EO) 1 (PO) 5 (EO) 20




(Monomer B-1.4)



1 Viscosity was measured at 25° C. and pH 9 after 1 day. The viscosity of SG-30 binder (25% solids) without thickener = 5 mPa · s. (cps) at 25° C. and pH 9.

































Synthesis of Acrylamide Thickener Example B-3.1(a)
(Acid Suppressible Thickener Comprising High Molecular Weight Acrylamide Backbone and Bis(2-Ethylhexyl)Amino-(EO) 20 -Methacrylate Hydrophobic Monomer B-1.1; Solvent=100% Water)
A 500 ml round bottom four-neck reactor flask, equipped with a mechanical stirrer, heating mantle, thermocouple, condenser and inlets for the addition of monomer, initiator and nitrogen, was charged with 95.0 g of DI water. The reactor flask water was then heated to 50° C. with an external heating source. A monomer mixture was prepared in a 100 milliliter glass beaker by adding 35 g of 50% aqueous acrylamide, 5.0 g of acrylic acid, 0.12 g of 10% aqueous 3-mercaptopropionic acid chain transfer agent (“CTA”) and 2.5 g of bis(2-ethylhexyl)amino-(EO) 20 -methacrylate monomer described in monomer synthesis example B-1.1. Then, 0.8 grams of a 0.15% aqueous solution of ferrous sulfate heptahydrate, and 10.0 g of a 0.25% aqueous solution of isoascorbic acid was charged to the 50° C. reactor water. With the reactor temperature at 50° C., the monomers in the 100 milliliter beaker were added to the reactor kettle all at once and 10.2 g of a 1.6% aqueous sodium persulfate catalyst co-feed solution was immediately co-fed to the reactor kettle at 0.33 g/minute. Simultaneously, 10.2 g of a 0.25% aqueous isoascorbic acid solution was co-fed to the reactor kettle at 0.33 g/minute. The polymerization was allowed to proceed with external cooling applied to the reactor to maintain the reactor temperature at 45-50° C. throughout the polymerization. When all the co-feeds were completed, the reaction temperature was held an additional 30 minutes at 48° C. with an external heating source. After the additional 30 minute hold, the contents of the reactor were cooled to room temperature. The final aqueous solution polymer had a solids content of 16.0%, a pH=2.2, and an “as is” aqueous solution viscosity of 5,000 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #4 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-3.1(a) was clear and transparent and free of water-insoluble grit particles. The Acrylamide polymer had a hydrolyzed molecular weight of 430,000.
Synthesis of Acrylamide Thickener Example B-3.4(a)
(Acid Suppressible Thickener Comprising High Molecular Weight Acrylamide Backbone and Bis(2-Ethylhexyl)Amino-(EO) 1 (PO) 5 (EO) 20 -Vinyl Urethane Hydrophobic Monomer B-1.4; Solvent=100% Water)
A 500 ml round bottom four-neck reactor flask, equipped with a mechanical stirrer, heating mantle, thermocouple, condenser and inlets for the addition of monomer, initiator and nitrogen, was charged with 176.4 g of DI water. The reactor flask water was then heated to 85° C. with an external heating source. A monomer mixture was prepared in a 200 milliliter glass beaker by adding 70 grams of 50% aqueous acrylamide, 10.0 g of acrylic acid, 0.12 g of 10% aqueous 3-mercaptopropionic acid chain transfer agent (“CTA”) and 6.8 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -vinyl urethane monomer described in monomer synthesis example B-1.4. Then, 0.8 grams of a 0.15% aqueous solution of ferrous sulfate heptahydrate, and 10.0 g of a 0.25% aqueous solution of isoascorbic acid was charged to the 85° C. reactor water. With the reactor temperature at 83-85° C., 10.2 g of a 1.6% aqueous sodium persulfate catalyst co-feed solution was co-fed to the reactor kettle at 0.33 g/minute. Simultaneously, 10.2 g of a 0.25% aqueous isoascorbic acid solution was co-fed to the reactor kettle at 0.33 g/minute. Simultaneously, the monomer mixture in the 200 milliliter glass beaker was co-fed to the reactor kettle at 2.9 g/minute. The polymerization was allowed to proceed at 85° C. with external heating and cooling applied to the reactor to maintain the reactor temperature at 85° C. throughout the polymerization. When all the cofeeds are completed the reaction temperature was held an additional 30 minutes at 85° C. with an external heating source. After the additional 30 minute hold, the contents of the reactor were cooled to room temperature. The final aqueous solution polymer had a solids content of 16.0%, a pH=3.2, and an “as is” aqueous solution viscosity of 1,800 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #4 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-3.4(a) was cloudy and opaque but free of water-insoluble grit particles. The Acrylamide polymer had a hydrolyzed molecular weight of 180,000.





TABLE B3



Evaluation of Acrylamide Polymers as Acid Suppressible Associative Thickeners












“As Supplied”






Thickener
SG-30 Binder





Viscosity
Viscosity 1

Thickener
Type
Type
Monomer
(mPa · s.)
(mPa · s.)

Example #
Process
Monomer
Structure
16% Solids
1% Thickener



B-3.1(a)
100% water
Methacrylate
C 8 -dialkylamine-
5,000
2,500


45° C. Batch 2

(EO) 20
(pH = 2.2)




(B-1.1)

B-3.4(a)
100% water
Vinyl
C 8 -dialkylamine-
1,800
7,200


85° C. Grad
Urethane
(EO) 1 (PO) 5 (EO) 20
(pH = 3.2)


Add 2

(B-1.4)



1 Viscosity was measured at 25° C. and pH 9 after 1 day. The viscosity of SG-30 binder (25% solids) without thickener = 5 mPa · s. (cps) at 25° C. and pH 9.

2 Batch process: all monomers are added simultaneously to the reaction flask before the free radical initiator is added; Grad Add is a gradual addition process, in which the monomers are co-fed over a period of time in the presence of the initiator.






























Synthesis and Evaluation of Associative Thickeners as Acid Suppressible Thickeners
Example B4
Dimethylacrylamide (DmAm) Associative Thickeners
Synthesis of Dimethylacrylamide Thickener Example B-4.6
(Acid Suppressible Thickener Comprising High Molecular Weight Dimethylacrylamide Backbone and Bis(2-Ethylhexyl)Amino-(EO) 1 (PO) 5 (EO) 20 -Maleate Hydrophobic Monomer B-1.6; Solvent=100% Water)
A 500 ml round bottom four-neck reactor flask, equipped with a mechanical stirrer, heating mantle, thermocouple, condenser and inlets for the addition of monomer, initiator and nitrogen was charged with 112.5 g of DI water. The reactor flask water was then heated to 42° C. with an external heating source. A monomer mixture was prepared in a 50 milliliter glass beaker by adding the following ingredients to the beaker: 24.4 g of dimethylacrylamide, 5.0 g of acrylic acid, 0.12 g of 10% aqueous 3-mercaptopropionic acid chain transfer agent (“CTA”) and 3.1 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -maleate monomer described in monomer synthesis example B-1.6. Then, 0.8 grams of a 0.15% aqueous solution of ferrous sulfate heptahydrate, and 10.0 g of a 0.25% aqueous solution of isoascorbic acid, and the monomer mixture described above were charged to the reactor. With the reactor temperature at 42° C. the contents of the 50 milliliter beaker were added to the reactor. Immediately, 10.2 g of a 1.6% aqueous sodium persulfate catalyst co-feed solution was co-fed to the reactor kettle at 0.33 g/minute. Simultaneously, 10.2 g of a 0.25% aqueous isoascorbic acid solution was co-fed to the reactor kettle at 0.33 g/minute. The polymerization was allowed to proceed without external heating or cooling. The reactor temperature was allowed to gradually increase from 42° C. to 55-60° C. without external heating or cooling over a 10 to 15 minute period from the inherent heat of polymerization. When the reaction temperature peaked (55-60° C.), an external heating source was applied to maintain the reaction temperature at 60° C. Once the sodium persulfate and isoascorbic acid co-feeds were finished, the reactor temperature was held at 60° C. for an additional 30 minutes. After the additional 30 minute hold, the contents of the reactor were cooled to room temperature. The final aqueous solution polymer had a solids content of 18.0%, a pH=2.7, and an “as is” aqueous solution viscosity of 4,200 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #4 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-4.6 was clear and transparent and free of any water-insoluble grit-like particles. The Dimethylacrylamide polymer had a hydrolyzed molecular weight of 336,000.
Synthesis of Dimethylacrylamide Thickener Example B-4.1
(Acid Suppressible Thickener Comprising High Molecular Weight Dimethylacrylamide Backbone and Bis(2-Ethylhexyl)Amine-(EO) 20 -Methacrylate Hydrophobic Monomer B-1.1; Solvent=100% Water)
The same process and composition as described in thickener synthesis Example B-4.6 was repeated, except that the 3.1 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -maleate monomer described in monomer synthesis example B-1.6 was replaced with 2.56 g (equal moles) of bis(2-ethylhexyl)amino-(EO) 20 -methacrylate monomer described in monomer synthesis example B-1.1. The final aqueous solution polymer had a solids content of 18.0%, a pH=2.9, and an “as is” aqueous solution viscosity of 1,700 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #4 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-4.1 was clear and transparent and free of any insoluble grit-like particles. The Dimethylacrylamide polymer had a hydrolyzed molecular weight of 330,000.
Synthesis of Dimethylacrylamide Thickener Example B-4.3
(Acid Suppressible Thickener Comprising High Molecular Weight Dimethylacrylamide Backbone and Bis(2-Ethylhexyl)Amine-(EO) 20 -Vinyl Urethane Hydrophobic Monomer B-1.3; Solvent=100% Water)
The same process and composition as described in thickener synthesis Example B-4.6 was repeated except that the 3.1 g of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -maleate monomer described in monomer synthesis example B-1.6 was replaced with 2.85 g (equal moles) of bis(2-ethylhexyl)amino-(EO) 20 -vinyl urethane monomer described in monomer synthesis example B-1.3. The final aqueous solution polymer had a solids content of 18.0%, a pH=2.9, and an “as is” aqueous solution viscosity of 1,800 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #4 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-4.3 was clear and transparent and free of any insoluble grit-like particles. The Dimethylacrylamide polymer had a hydrolyzed molecular weight of 340,000.
Synthesis of Dimethylacrylamide Thickener Example B-4.2
(Acid Suppressible Thickener Comprising High Molecular Weight Dimethylacrylamide Backbone and Bis(2-Ethylhexyl)Amine-(EO) 1 (PO) 5 (EO) 20 -Methacrylate Hydrophobic Monomer B-1.2; Solvent=100% Water)
The same process and composition as described in thickener synthesis Example B-4.6 was repeated except that the 3.1 g of (2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -maleate monomer described in monomer synthesis example B-1.6 was replaced with 3.10 g (equal moles) of bis(2-ethylhexyl)amino-(EO) 1 (PO) 5 (EO) 20 -methacrylate monomer described in monomer synthesis example B-1.2. The final aqueous solution polymer had a solids content of 18.0%, a pH=3.1, and an “as is” aqueous solution viscosity of 5,800 mPa·s. (cps) as measured by a Brookfield Viscometer using LV spindle #4 at 60 RPMs. By HPLC and GC, the total monomer conversion to polymer was determined to be >98.0%. Visually, the aqueous solution polymer B-4.2 was clear and transparent and free of any insoluble grit-like particles. The Dimethylacrylamide polymer had a hydrolyzed molecular weight of 336,000.





TABLE B4



Evaluation of Dimethylacrylamide Polymers as Acid Suppressible Associative Thickeners












“As Supplied”
SG-30 Binder





Thickener
Viscosity 1





Viscosity
(mPa · s.)

Thickener
Type
Type
Monomer
(mPa · s.)
1% or 2%

Example #
Process
Monomer
Structure
18% Solids
Thickener



B-4.1
100% water
Methacrylate
C 8 -dialkylamine-
1,700
2% Thickener


45° C. Batch 2

(EO) 20
(pH 2.9)
22,500


Polymerization

(B-1.1)

B-4.2
100% water
Methacrylate
C 8 -dialkylamine-
5,800
1% Thickener


45° C. Batch 2

(EO) 1 (PO) 5 (EO) 20
(pH 3.2)
150,000


Polymerization

(B-1.2)

B-4.3
100% water
Vinyl
C 8 -dialkylamine-
1,400
2% Thickener


45° C. Batch 2
Urethane
(EO) 20
(pH 3.0)
23,000


Polymerization

(B-1.3)

B-4.6
100% water
Maleate
C 8 -dialkylamine-
4,200
2% Thickener


45° C. Batch 2

(EO) 1 (PO) 5 (EO) 20
(pH 2.7)
5,500


Polymerization

(B-1.6)



1 Viscosity was measured at 25° C. and pH 9 after 1 day. The viscosity of SG-30 binder (25% solids) without thickener = 5 mPa · s. (cps) at 25° C. and pH 9.

2 Batch process: all monomers are added simultaneously to the reaction flask before the free radical initiator is added;




































The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one skilled in the art. The endpoints of all ranges directed to the same component or property are inclusive of the endpoint and independently combinable. As used herein, the term “(meth)acrylic” encompasses both acrylic and methacrylic. Similarly, the term “poly(meth)acrylamide” encompasses both polyacrylamide and polymethacrylamide. Herein, the term “(meth)acrylamide” includes substituted acrylamide and substituted methacrylamide.
As described earlier herein, the associative thickener of this invention preferably has a substantially non-ionic water soluble backbone. The addition of minor amounts of ionic groups in the backbone of the inventive associative thickener is also contemplated. Minor amounts of ionic groups are less than 20 weight percent, and more preferably less than 5 weight percent, of ionic monomer units existing at a pH greater than the pKa of the secondary amine or tertiary amine or tertiary phosphine based on the total weight of backbone monomer units.
All cited documents are incorporated herein by reference.