Modified polyoxyethylene epoxy resin amphiphiles and stable aqueous epoxy dispersions thereof

Claim 2

A composition of the formula A--X--O--(CH.sub.2 CH.sub.2 O).sub.n --R wherein: A is the residue of a polyglycidyl ether of a polyhydroxy hydrocarbon, and is the reaction product of an epihalohydrin with one or more polyhydroxy hydrocarbons or halogenated polyhydroxy hydrocarbons; or the reaction product of a polyglycidylether of a polyhydroxy hydrocarbon with one or more polyhydroxy hydrocarbons, halogenated polyhydroxy hydrocarbons or carboxyl acid hydrocarbon or a mixture thereof; X is the residue of a difunctional compound which is capable of reacting with the primary hydroxy moiety of a monoalkylether of a polyethylene glycol and a 1,2-glycidyl ether moiety; R is C 1-10 alkyl moiety; and, n is a positive real number such that the composition is emulsifiable in water.

Claim 3

The composition of claim 1 wherein: A is the residue of a polyglycidyl ether of a polyhydroxy hydrocarbon which is the reaction product of an epihalohydrin with one or more of the polyhydroxy hydrocarbons selected from the group of compounds corresponding to the formulas ##STR20## or the reaction product such a polyglycidyl ether of a polyhydroxy hydrocarbon with one or more polyhydroxy hydrocarbons, halogenated polyhydroxy hydrocarbons or carboxyl substituted hydrocarbons; wherein: R 1 is C 1-10 alkylene, C 1-10 haloalkylene, C 4-10 cycloalkylene, carbonyl, sulfonyl, sulfinyl, oxygen, sulfur or a direct bond; R 2 is C 1-3 alkyl or a halogen; R 3 is C 1-10 alkylene; R 4 is H or methyl, with the proviso that only one R 4 on a ethylene unit can be methyl; m is independently in each occurrence an integer of 0 to 4; p is a positive real number from 0 to 10; and q is a positive real number of from 1 to 80.

Claim 4

The composition of claim 2 wherein X corresponds to the formula ##STR21## wherein Z is a C 1-20 hydrocarbylene moiety wherein the carbonyl moiety is bound to the residue of the poly(oxyethylene) monoalkyl ether.

Claim 5

The composition of claim 3 wherein Z is C 1-20 alkylene, C 3-20 arylene, or C 6-20 alkyl polyoxyethylene substituted arylene.

Claim 6

The composition of claim 4 which comprises a compound of one of the formulas: ##STR22## wherein: R 1 is C 1-10 alkylene, C 1-10 haloalkylene, C 4-10 cycloalkylene, carbonyl, sulfonyl, sulfinyl, oxygen, sulfur or a direct bond; R 2 is C 1-3 alkyl or a halogen; R 3 is C 1-10 alkylene; R 4 is H or methyl, with the proviso that only one R 4 on a ethylene unit can be methyl; m is independently in each occurrence an integer of 0 to 4; q is a positive real number of from 10 to 80; r is a positive real number of from 0 to 40; s is a positive real number of from 0 to 10.

Claim 7

The composition of claim 5 wherein Z is ##STR23## wherein: R 6 is C 1-10 alkyl; and, t is 0 or 1.

Claim 8

A water emulsifiable composition which comprises I. a polyglycidyl ether of a polyhydroxy hydrocarbon, halogenated polyhydroxy hydrocarbon, or the reaction product of a polyglycidyl ether of a polyhydroxy hydrocarbon, or halogenated polyhydroxy hydrocarbon with one or more polyhydroxy hydrocarbons, halogenated polyhydroxy hydrocarbons, or a carboxyl substituted hydrocarbon; and II. a sufficient amount of the composition of claim 1 to render the composition water emulsifiable.

Claim 9

The composition of claim 7 wherein polyhydroxy hydrocarbon is selected from the group of compounds corresponding to the formulas ##STR24## wherein: R 1 is C 1-10 alkylene, C 1-10 haloalkylene, C 4-10 cycloalkylene, carbonyl, sulfonyl, sulfinyl, oxygen, sulfur or a direct bond; R 2 is C 1-3 alkyl or a halogen; R 3 is C 1-10 alkylene; R 4 is H or methyl, with the proviso that only one R 4 on a ethylene unit can be methyl; m is independently in each occurrence an integer of 0 to 4; p is a positive real number from 0 to 10; g is a positive real number of 1 to 80.

Claim 10

The composition of claim 7 wherein component I is present in between about 70 and 96 percent by weight; and component II is present in between about 4 and 30 percent by weight.

Claim 11

The composition of claim 9 which comprises between about 4 and 30 percent by weight of a compound corresponding to one of the formulas ##STR25## : and between 70 and 96 percent by weight of a compound selected from one of the formulas ##STR26## wherein: R 1 is C 1-10 alkylene, C 1-10 haloalkylene, C 4-10 cycloalkylene, carbonyl, sulfonyl, sulfinyl, oxygen sulfur or a direct bond; R 2 is C 1-3 alkyl or a halogen; R 3 is H or methyl, with the proviso that only one R 4 on a ethylene unit can be methyl; m is independently in each occurrence an integer of 0 to 3; q is a positive real number of from 10 to 80; r is a positive real number of from 0 to 40; s is a positive real number of 0 to 10.

Claim 12

A water emulsifiable composition which comprises the reaction product of A. one or more of the compounds corresponding to the formulas ##STR27## B. one or more of the compounds of corresponding to the formula ##STR28## C. one or more of the compounds corresponding to the one of the formula ##STR29## wherein: R is R 1 is C 1-10 alkylene, C 1-10 haloalkylene, C 4-10 cycloalkylene, carbonyl, sulfonyl, sulfinyl, oxygen, sulfur or a direct bond; R 2 is C 1-3 alkyl or a halogen; R 3 is C 1-10 alkylene; R 4 is H or methyl, with the proviso that only one R 4 on a ethylene unit can be methyl; m is independently in each occurrence an integer of 0 to 4; p is a positive real number of from 0 to 10; q is a positive real number of from 1 to 80; r is a positive real number of from 0 to 40; s is a positive real number of from 0 to 10.

Claim 13

A water emulsifiable composition which comprises the reaction product of A. one or more of the compounds corresponding to the formulas ##STR27## B. one or more of the compounds of corresponding to the formula ##STR28## C. one or more of the compounds corresponding to the one of the formula ##STR29## wherein: R is R 1 is C 1-10 alkylene, C 1-10 haloalkylene, C 4-10 cycloalkylene, carbonyl, sulfonyl, sulfinyl, oxygen, sulfur or a direct bond; R 2 is C 1-3 alkyl or a halogen; R 3 is C 1-10 alkylene; R 4 is H or methyl, with the proviso that only one R 4 on a ethylene unit can be methyl; m is independently in each occurrence an integer of 0 to 4; p is a positive real number of from 0 to 10; q is a positive real number of from 1 to 80; r is a positive real number of from 0 to 40; s is a positive real number of from 0 to 10.

Claim 14

A water emulsifiable composition of claim 11 which comprises the reaction product of Component A; Component B, Component C; and D a carboxyl substituted hydrocarbon.

Claim 15

An aqueous emulsion which comprises I. water; and II. the composition of claim 7; wherein the solid content of the emulsion is between about 20 and 80 percent by weight.

Claim 16

A coating composition which comprises I. water; II. a composition of claim 7; and III. an epoxy resin curing agent.

Claim 17

A coating composition of claim 14 wherein the curing agents is a water soluble polyamine, polyamide or polyamidoamine capable of curing an epoxy resin.

Claim 18

A process for preparing a compound of the formula A--X--O--(CH.sub.2 CHO.sub.2).sub.n --R wherein A is the residue of a polyglycidyl ether of a polyhydroxy hydrocarbon and is the reaction product of an epihalohydrin with one or more polyhydroxy hydrocarbons, or halogenated polyhydroxy hydrocarbons, or the reaction product of a polyglycidyl ether of a polyhydroxy hydrocarbon, or halogenated polyhydroxy hydrocarbon with one or more polyhydroxy hydrocarbons, halogenated polyhydroxy hydrocarbons or a carboxyl substituted hydrocarbon; X corresponds to the formula ##STR30## Z is a C 1-20 hydrocarbon moiety; R is a C 1-10 alkyl moiety; and n is a positive real number such that the compound is capable of dispersing an epoxy resin composition in water, which process comprises

Claim 19

A process for preparing a compound of the formula A--X--O--(CH.sub.2 CHO.sub.2).sub.n --R wherein A is the residue of a polyglycidyl ether of a polyhydroxy hydrocarbon and is the reaction product of an epihalohydrin with one or more polyhydroxy hydrocarbons, or halogenated polyhydroxy hydrocarbons, or the reaction product of a polyglycidyl ether of a polyhydroxy hydrocarbon, or halogenated polyhydroxy hydrocarbon with one or more polyhydroxy hydrocarbons, halogenated polyhydroxy hydrocarbons or a carboxyl substituted hydrocarbon; X corresponds to the formula ##STR30## Z is a C 1-20 hydrocarbon moiety; R is a C 1-10 alkyl moiety; and n is a positive real number such that the compound is capable of dispersing an epoxy resin composition in water, which process comprises

Claim 20

Contacting a monomethyl ether of a polyethylene glycol of the formula ##STR31## with a dicarboxylic acid or acid anhydride which corresponds to one of the formulas ##STR32## at elevated temperatures under conditions such that a compound of the formula ##STR33##

Claim 21

Contacting a monomethyl ether of a polyethylene glycol of the formula ##STR31## with a dicarboxylic acid or acid anhydride which corresponds to one of the formulas ##STR32## at elevated temperatures under conditions such that a compound of the formula ##STR33##

Claim 22

is prepared 2. Contacting such compound with a polyglycidyl ether of a polyhydroxy hydrocarbon or the reaction product of a polyglycidyl ether of a polyhydroxy hydrocarbon with one or more polyhydroxy hydrocarbons, halogenated polyhydroxy hydrocarbon or a carboxyl substituted hydrocarbon in the presence of a catalyst for the reaction of a 1,2 epoxy moiety with a hydroxy or carboxyl moiety at elevated temperatures under conditions such that a compound of the formula A--X--O--(CH.sub.2 CHO.sub.2).sub.n --R is prepared.

Claim 23

is prepared 2. Contacting such compound with a polyglycidyl ether of a polyhydroxy hydrocarbon or the reaction product of a polyglycidyl ether of a polyhydroxy hydrocarbon with one or more polyhydroxy hydrocarbons, halogenated polyhydroxy hydrocarbon or a carboxyl substituted hydrocarbon in the presence of a catalyst for the reaction of a 1,2 epoxy moiety with a hydroxy or carboxyl moiety at elevated temperatures under conditions such that a compound of the formula A--X--O--(CH.sub.2 CHO.sub.2).sub.n --R is prepared.

Claim 24

A process for the preparation of a water dispersible resin composition which comprises 1. Contacting a monoalkyl ether of a polyethylene glycol with a dicarboxylic acid or acid anhydride at elevated temperatures under conditions such that an adduct of the monoalkylether of the polyethylene glycol and the dicarboxylic acid or acid anhydride is formed; 2. Contacting the a) adduct of the monoalkyl ether of the polyethylene glycol with the dicarboxylic acid or acid anhydride, b) one or more polyglycidyl ethers of a polyhydroxy hydrocarbon or halogenated polyhydroxy hydrocarbon; and c) optionally a polyhydroxy hydrocarbon containing at least one hydroxy moiety bound to an aromatic ring; in the presence of a catalyst capable of catalyzing the reaction between the 1,2 glycidyl ethers and hydroxy moieties at elevated temperatures under conditions such that a water dispersible epoxy resin composition is formed; wherein the residue of the monomethyl ether of the polyethylene glycol has sufficient ethyleneoxide units to render the epoxy resin composition emulsifiable.

Claim 25

A process for the preparation of a water dispersible resin composition which comprises 1. Contacting a monoalkyl ether of a polyethylene glycol with a dicarboxylic acid or acid anhydride at elevated temperatures under conditions such that an adduct of the monoalkylether of the polyethylene glycol and the dicarboxylic acid or acid anhydride is formed; 2. Contacting the a) adduct of the monoalkyl ether of the polyethylene glycol with the dicarboxylic acid or acid anhydride, b) one or more polyglycidyl ethers of a polyhydroxy hydrocarbon or halogenated polyhydroxy hydrocarbon; and c) optionally a polyhydroxy hydrocarbon containing at least one hydroxy moiety bound to an aromatic ring; in the presence of a catalyst capable of catalyzing the reaction between the 1,2 glycidyl ethers and hydroxy moieties at elevated temperatures under conditions such that a water dispersible epoxy resin composition is formed; wherein the residue of the monomethyl ether of the polyethylene glycol has sufficient ethyleneoxide units to render the epoxy resin composition emulsifiable.

Claim 26

The process of claim 17 wherein between about 4 and about 30% of the resin composition prepared comprises a reaction product of the adduct of the monoalkyl ether of polyethylene glycol and the dicarboxylic acid or acid anhydride with a polyglycidyl ether of polyhydroxy hydrocarbon or halogenated polyhydroxy hydrocarbon.

Claim 27

The process of claim 18 which comprises A. contacting a monoalkyl ether of a polyethylene glycol of the formula R--O--(CH.sub.2 CH.sub.2 O).sub.n --H with a dicarboxylic acid or acid anhydride of the formula ##STR34## at elevated temperatures under conditions such that a compound is prepared which corresponds to the formula ##STR35## and B. contacting 1. the reaction product of step A, 2. one or more polyglycidyl ethers of polyhydroxy compounds which correspond to one of the formulas and; ##STR36##

Claim 28

optionally, one or more poly hydroxy hydrocarbons or halogenated polyhydroxy hydrocarbons which correspond to one of the formulas; ##STR37## in the presence of a catalyst capable of catalyzing the reaction of a 1,2-glycidyl ether with a primary hydroxy moiety and a carboxylic acid moiety; under such conditions such that a water dispersible epoxy resin is prepared wherein R is C 1-10 alkyl moiety R 1 is R 1 is C 1-10 alkylene, C 1-10 haloalkylene, C 4-10 alkylene, carbonyl, sulfonyl, sulfinyl, oxygensulfur or a direct bond; R 2 is C 1-3 alkyl or a halogen; R 3 is C 1-10 alkylene; R 4 is H or methyl, with the proviso that only one R 4 on an ethylene unit can be methyl. Z is a C 1-20 hydrocarbylene moiety; m is independently in each occurrence an integer of 0 to 3; n is a positive real number of from 10 to 80; p is a positive real number of from 0 to 10; q is a positive real number of from 1 to 80; r is a positive real number of from 0 to 10; s is a positive real number of from 0 to 10.

Claim 29

optionally, one or more poly hydroxy hydrocarbons or halogenated polyhydroxy hydrocarbons which correspond to one of the formulas; ##STR37## in the presence of a catalyst capable of catalyzing the reaction of a 1,2-glycidyl ether with a primary hydroxy moiety and a carboxylic acid moiety; under such conditions such that a water dispersible epoxy resin is prepared wherein R is C 1-10 alkyl moiety R 1 is R 1 is C 1-10 alkylene, C 1-10 haloalkylene, C 4-10 alkylene, carbonyl, sulfonyl, sulfinyl, oxygensulfur or a direct bond; R 2 is C 1-3 alkyl or a halogen; R 3 is C 1-10 alkylene; R 4 is H or methyl, with the proviso that only one R 4 on an ethylene unit can be methyl. Z is a C 1-20 hydrocarbylene moiety; m is independently in each occurrence an integer of 0 to 3; n is a positive real number of from 10 to 80; p is a positive real number of from 0 to 10; q is a positive real number of from 1 to 80; r is a positive real number of from 0 to 10; s is a positive real number of from 0 to 10.

Claim 30

The process of claim 19 wherein the catalyst is an ammonium compound, phosphonium compound, tertiary amine, or phosphine.

Claim 31

The process of claim 20 wherein the first step is performed at a temperature of between about 50° C. and about 250° C. and the second step is performed at a temperature of between about 80° C. and 180° C.

Claim 32

The process of claim 21 wherein the compounds contacted in the second step further comprise a carboxyl substituted hydrocarbon.