US 4,101,464 AGrant

Process for Preparing Foamed Solids Using Two or More Azo Compounds

Issue Date:1978-07-18

•23 Claims

Abstract

Cellular polymeric solids are made by mixing an acidulous or acidic polymerizable medium that is polymerizable and/or cross-linkable by a free radical mechanism (e.g. an unsaturated polyester) with an effective amount of two or more acid sensitive mono- or poly-azo compounds containing the group: ##STR1## wherein Y is an acid sensitive group (e.g. Cl, OH, --OCN, --NCO) which in the presence of an acidulous or acidic polymerizable medium causes sufficient decompsition of the azo compound that gas is released in the medium and during the decomposition the mono- or poly- azo compound promotes polymerization and/or cross-linking of the medium to provide a matrix that is sufficiently polymerized and/or cross-linked that the generated gases cause the matrix to expand, each of the remaining valences being satisfied by an organic radical; provided that any carbon atom that is directly linked to an azo nitrogen, except that of a carbonyl group, has at least two of its remaining three valences satisfied by a carbon to carbon bond or a carbon to hydrogen bond. Preferably, the mixture contains at least two such azo compounds having appreciably different sensitivity to decomposition by acid. The process is especially useful in making foamed flotation structures (e.g. boat hulls).

Metadata

Assignee

Pennwalt Corporation

Inventors

Ernest Rudolph Kamens
Donald Milton Kressin
Harold Carl Lange
Ronald Edward MacLeay

Application Information

Application Number:US 7236794

Filing Date:1976-09-16

Priority Date:1974-03-21

Art Unit:142

Classifications

IPC:

C08J 902

Field of Search:

2602.5 R;2.5 S;2.5 N;2.5 BD;2.5 D;2.5 F;2.5 EP;2.5 P;2.5 H

Patent Drawings

This patent does not have any drawings.

Description

Examples

The following examples are cited to illustrate the invention and advantages of the invention. They are not intended to limit it in any manner.

To permit comparative evaluations, unless otherwise stated in the Examples, a Standard Unsaturated Polyester Resin was employed. It was made by reacting maleic anhydride (1.0 mol), phthalic anhydride (1.0 mol), and propylene glycol (2.2 mols) until an acid number of 45-50 was obtained. To this was added hydroquinone at 0.013% concentration. Seven parts of this unsaturated polyester were diluted with three parts of monomeric styrene to obtain a homogenous blend having a viscosity of 21 to 25 poise and a specific gravity of 1.14 (The specific gravity of blend after curing in the absence of a foaming agent was 1.25 --obtained by mixing 100 g. of said resin with 1 g. methyl ethyl ketone peroxide, then mixing therewith 0.2 g. of a 6% solution of Co naphthenate--gel time of 5.5 minutes, a cure time of 12 minutes and a peak exotherm of 330.degree. F.)

Unless otherwise indicated in the Examples, the foam structure made from the Standard Resin was made by mixing 100 grams of the Standard Unsaturated Polyester Resin with 0.2 gram Lupersol DDM (Lucidol's methyl ethyl ketone peroxide formulation) or 0.05 to 1.0 gram t-butyl peroxy-benzoate and the desired number of grams of the azo compound (see column labeled Parts Azo) using an electric stirrer. Finally, the appropriate number of grams of an activator, (if required see columns labeled Activator and Parts Activator) was mixed into the formulation. The mixture was poured into a waxed cup at ambient temperature (75.degree. F) and allowed to foam and cure. The foaming and curing were complete in less than 30 minutes. After the foams had cooled to room temperature the foam density was determined in grams/cc. (see column labeled Foam Density).

The activator acetyl sec-hexylsulfonyl peroxide is designated as AH.sub.6 SP in the Examples. Where used, it was added as a 50% solution in dimethyl phthalate. The activator acetyl cyclohexylsulfonyl peroxide is designated as ACSP in the Examples, and where used, it was added as a 30% solution in dimethyl phthalate. The phosphoric acid when used as the activator was 86% by weight and the sulfuric acid when used was 60% by weight aqueous solutions.

Examples 1-11 inclusive, are intended to illustrate the wide variety of acid sensitive azo compounds useful in the present invention as employed with a variety of solvents, activators and the like. They are also intended to illustrate the experimental procedure which can be used to determine which azo compounds to use and in what relative proportions in order to produce a foam of a given density, hardness, etc. from a particular polymerizable or cross-linkable material.

Example 1 shows apparent synergistic effect of using two acid sensitive azos having very similar chemical structure.

Example 2 shows the use of two acid-sensitive azos where a strong acid is preferred in the process and where the same acid is used with the combination of the two azos as with each individual azo. Example 3 can be found in Ser. No. 548,946 (as Example 19) and illustrates the use of two azo compounds having appreciably different acid sensitivities. Examples 4 and 5 further illustrate the properties of the individual azo compound in Example 3, 2-t-butylazo-2-(t-butylperoxy) propane and show that it can produce curing and foaming in the presence of a strong acid.

Example 4 also illustrates an unsaturated polyester syrup made using methacrylonitrile as one source of the unsaturation.

Examples 6 and 7 show the group Y in Formula I herein can be hydroperoxy, that is, hydroperoxy azos such as 2-t-butylazo-2-hydroperoxy-4-methyl pentane can be used to produce foam and cure in the process of Ser. No. 548,946.

Examples 8 and 9 show the use of a combination of two azo peroxy compounds to foam and cure in the process of the present invention, these compounds being 2-t-butylazo-2-(t-butylperoxy) propane and 2-t-butylazo-2-hydroperoxy-4-methyl pentane.

Example 10 illustrates the use of mixtures of certain chloro azo thio compounds to cure and foam a polyester. Example 10 can also be found in Ser. No. 548,946 (as Examples 5-100, 5-101 and 5-102).

Example 11 illustrates the use of mixtures of certain chlorazo isothiocyanato and isocyanato derivatives to foam and cure the standard polyester. Example 11 can also be found (as Examples 6-20, 6-21, 6041, 6-42 and 6-43) in Ser. No. 548,946.

EXAMPLE 1

Using Multiple Azo Compounds to Foam and Cure Polyesters

In data given below, the extent of cure was determined by a Shore hardness tester. (1) The formulations were prepared by blending in 9 oz. waxed paper cups, 60 g. of polyester resin (2) and 40 g. of hydrated alumina (3), using an electric mixer. The indicated quantities of foaming agents were then added and mixed at high speed for 20 seconds. 45 g. of the mixtures were then immediately poured into 100 ml glass petri dishes and allowed to foam and cure. Temperatures were monitored using a strip-chart recorder with thermocouple probe centered in mixture.

Note that in the range of 25% to 50% "LUCEL 4" (or 75 to 50% "LUCEL 6") the decrease in density was greater than would be expected, showing an apparent synergism.

With regard to commercial utility, mistures containing about 50% weight of each azo appear very promising. That is, while the more acid sensitive compound (2-t-butylazo-2-hydroxy butane) provides the lowest foam density, it is more toxic, more volatile, less thermally stable (requiring storage at -18.degree. C or lower) and has a higher flash point than does the other less acid-sensitive component. However, the 50-50 mixture is significantly improved in all of these properties (especially in flash point and thermal stability) while having sufficient acid sensitivity to be useful in most, if not all, of the foaming which has been described herein for the 2-t-butylazo-2-hydroxy butane.

Example 2

Using Multiple Azo Compounds to Foam and Cure Polyesters

100 g. of Standard Polyester resin, 1.0 g. of Dow Corning 193 surfactant, 1.0 g. of 60% H.sub.2 SO.sub.4, and 0.02 g. of 5% copper naphthenate in styrene were placed in 9-oz. waxed paper cups and blended using an electric mixer. The indicated quantities of foaming agents were then added and mixed at high speed for 20 seconds.

In general, the two azo compounds in this example are more stable at room temperature and are less acid-sensitive than the "hydroxy" azos used in Example 1. Accordingly, addition of a strong mineral acid (here H.sub.2 SO.sub.4) is preferred in the process.

Dow Corning 193 surfactant is further defined in Example 22 of Ser. No. 548,946.

EXAMPLE 3

Using Mixtures of Azo Compounds with Appreciably Different Acid-Sensitivity

Crude 2-t-butylazo-2-butylperoxypropane was prepared by reacting 2-t-butylazo-2-chloropropane with an aqueous solution of the potassium salt of t-butyl hydroperoxide according to the method described in MacLeay, Lange and Sheppard application Ser. No. 426,411 filed Dec. 19, 1973, (which is incorporated herein by reference). The resultant product contained approximately 75% 2-t-butylazo -2-t-butylperoxypropane and 25% 2-t-butylazo-2-hydroxy-propane (which has been marketed as "LUCEL 3").

To 20 grams of the Standard Unsaturated Polyster Resin was added 0.2 grams of the above mixture, the resin was stirred well using a wood tongue depressor for about 15 seconds, and the resin poured into a 20 .times. 150 mm test tube to a depth of 3 inches. The internal temperature of the mixture was recorded as a function of time and a peak exotherm of 250.degree. F (121.degree. C) was reached in 5.5 minutes indicating an excellent cure of the resin had occurred. In addition, the resin had expanded to twice its original volume. The test tube was broken and the foam removed. The foam was very hard and did not crumble. Note that no "activator" (such as added acid) was used to produce foaming and curing using this mixture.

EXAMPLE 4

Foaming and Curing Polyesters using 2-t-butylazo-2-(t-butylperoxy)propane

95 g. of Standard Polyester resin, 5.0 g. of methacrylonitrile, 1.0 g. of Dow Corning 193 Surfactant, and 3.0 g. of acetyl sec-heptyl sulfonyl peroxide (50% in dimethylphthalate) were placed in a 9 oz. waxed paper cup and blended using an electric stirrer. 2.0 g. of 2-t-butylazo-2-(t-butyl)peroxy) propane (50% in hexane) was then added and mixed at high speed for 20 seconds. The mixture foamed and cured to a density of 20 lb/ft.sup.3 in about 12 minutes.

EXAMPLE 5

Foaming and Curing an acrylic syrup using 2-t-butylazo-2-(t-butylperoxy) propane

To 65 parts of methyl methacrylate (inhibited with 10 ppm of monomethylether of hydroquinone) stirring in a mixing bowl, 35 parts of Elvacite 2009 was added. The mixture was stirred until a clear syrup was obtained. 70 g. of the above syrup, 2.5 g. of trimethylolpropanetrimethacrylate, 1.0 g. of Dow Corning 193 Surfactant, 1.0 g. of dichloroacetic acid, 0.15 g. of 10% copper napthenate in dioctylphthalate and 30 g. of hydrated alumina were placed in a 9 oz. waxed paper cup and blended using an electric mixer. 2.0 g. of 2-t-butylazo-2-(t-butylperoxy) propane (50% in hexane) was then added and the mixing was continued at high speed for 20 seconds. The mixture foamed and cured to a density of 25.6 lb/ft.sup.3 in about 5 minutes. Elvacite 2009 is further defined in Ser. No. 548,946 (Example 50).

EXAMPLE 6

Foaming and Curing Plyester using 2-t-butylazo-2-hydroperoxy-4-methyl pentane

95 g. of Standard Polyester resin, 5.0 g. of methacrylonitrile, 1.0 g. of Dow Corning 193 Surfactant, and 3.0 g. of acetyl sec-heptyl sulfonyl peroxide (50% in dimethyl phthalate) were placed in a 9 oz. waxed paper cup and blended using an electric stirrer. 2.0 g. of 2-t-butylazo-2-hydroperoxy-4-methylpentane (50% in mineral spirits) was then added and mixed at high speed for 20 seconds. The mixture foamed and cured to a density of 29 lb/ft.sup.3 in about 25 minutes.

EXAMPLE 7

Foaming and Curing an acrylic syrup using 2-t-butylazo-2-hydroperoxy-4-methyl pentane

To 65 parts of methyl methacrylate (inhibited with 10 ppm of monomethyl ether of hydroquinone) stirring in a mixing bowl, 35 parts of Elvacite 2009 was added. The mixture was stirred until a clear syrup was obtained. 70 g. of the above syrup, 3.0 g. of acetyl sec-heptyl sulfonyl peroxide (50% in dimethyl phthalate) 1.0 g. of Dow Corning 193 Surfactant, 0.5 g. of trimethylolpropanetrimethacrylate, and 30 g. of hydrated alumina were placed in a 9-oz. waxed paper cup and blended using an electric mixer. 2.0 g. of 2-t-butylazo-2-hydroperoxy-4-methyl pentane (50% in mineral spirits) was then added and the mixing was continued at high speed for 20 seconds. The mixture foamed and cured to a density of 16.5 lb/ft.sup.3 in about 15 minutes.

When this example was tried using dichloroacetic acid instead of the acetyl sec-heptyl sulfonyl peroxide, no foaming occurred.

EXAMPLE 8

Foaming Polyester Resin using Combination of two acid-sensitive azo peroxy compounds

95 g. of Standard Polyester resin, 5.0 g. of methacrylonitrile, 1.0 g. of Dow Corning 193 Surfactant, and 3.0 g. of acetyl sec-heptyl sulfonyl peroxide (50% in dimethylphthalate) were placed in a 9-oz. waxed paper cup and blended using an electric stirrer. 1.0 g. of 2-t-butylazo-2-(t-butylperoxy) propane (50% in hexane), and 1.0 g. of 2-t-butylazo-2-hydroperoxy-4-methylpentane (50% in mineral spirits) were then added and mixed at high speed for 20 seconds. The mixture foamed and cured to a density of 24 lb/ft.sup.3 in about 17 minutes.

EXAMPLE 9

Foaming of an acrylic syrup using combination of two acid-sensitive azo/peroxy compounds

1.0 g. of 2-t-butylazo-2-(t-butylperoxy) propane (50% in hexane), and 1.0 g. of 2-t-butylazo-2-hydroperoxy-4-methyl pentane (50% in mineral spirits) were then added and the mixing was continued at high speed for 20 seconds. The mixture foamed and cured to a density of 16 lb/ft.sup.3 in about 16 minutes.

EXAMPLE 10

Mixtures of phenyl, mono, di and tri chlorophenyl, alpha-aryl and alkyl thio-substituted azoalkanes

Mixtures jof phenyl, mono, di and tri chlorophenyl, alpha-aryl and alkyl thio-substituted azoalkanes were prepared in accordance with the methods illustrated in Examples 4 and 5 of Ser. No. 548,946 and used as such to foam the Standard Unsaturated Polyester Resin. Table I reports the specific azo mixtures, the foaming conditions and the density of the resulting foam. Without a foaming agent, the unsaturated polyester cured to a density of 1.25 g/cc.

EXAMPLE 11

Mixtures of isocyanato or isothiocyanato azo Derivatives to Foam and Cure Polyester

Mixtures of phenyl, chlorophenyl, dichlorophenyl and trichlorophenyl alpha-substituted azo alkanes, wherein the alpha substituents are derivatives of isocyanato and isothiocyanato functions were prepared in accordance with the methods illustrated in Examples 4, 5 and 6 of Ser. No. 548,946. The results of foaming and curing the Standard Unsaturated Polyester Resin with these mixtures is reported in Table II herein, wherein the derivatives are ureido, thioureido, carbamyl, and thiocarbamyl.

Claims

We claim:

1. A process for preparing cellular polymeric structures which comprises mixing an acidulous or acidic polymerizable medium that is polymerizable and/or cross-linkable by a free radical mechanism with an effective amount of two or more acid sensitive mono- or poly-azo compounds containing the group: ##STR19## wherein in Y is an acid sensitive group which in the presence of an acidulous or acidic polymerizable medium causes sufficient decompositon of the azo compound that gas is released in said medium and during said decomposition said mono- or poly-azo compound promotes polymerization and/or corss-linking of said medium to provide a matrix that is sufficiently polymerized and/or cross-linked that the generated gases cause the matrix to expand, each of the remaining valences being satisfied by an organic radical; provided that any carbon atom that is directly linked to an azo nitrogen, except that of a carbonyl group, has at least two of its remaining three valences satisfied by a carbon to carbon bond or a carbon to hydrogen bond.

2. The process of claim 1 wherein said effective amount comprises a mixture of phenyl and chlorophenyl alpha-aryl and alkyl thio-substituted azo alkanes or a mixture of phenyl and chlorophenyl alpha isocyanato azo or alpha isothiocyanato azo derivatives selected from ureido, thioureido, carbamyl, and thiocarbamyl.

3. The process of claim 1 wherein said effective amount comprises a mixture of 2-t-butylazo-2-t-butylperoxypropane and 2-t-butylazo-2-hydroxypropane.

4. The process of claim 3 wherein said mixture contains about 75 weight% 2-t-butylazo-2-t-butylperoxypropane.

5. The process of claim 1 wherein the relative rate of decomposition in said medium between two said azo compounds is at least about as great as that between 2-t-butylazo-2-t-butylperoxypropane and 2-t-butylazo-2-hydroxypropane.

6. The process of claim 1 wherein Y in one said azo compound is a hydroxy group and in another said compound Y is a peroxy group.

7. The process of claim 6 wherein the remaining substituents in said Formual I of the said azo compounds containing hydroxy and peroxy groups are all hydrocarbyl.

8. The process of claim 7 wherein at least one said hydrocarbyl group is t-butyl.

9. The process of claim 8 wherein the relative weight proportion of said azo compound containing the peroxy group to said azo compound containing the hydroxy group is about 3/1.

10. The process of claim 1 wherein Y in one said azo compound is a hydroxy group.

11. The process of claim 1 wherein at least one said azo compound is a peroxy compound.

12. The process of claim 11 wherein said peroxy compound is of the form R"OO--, where R" is tertiary alkyl containing 4 to 18 carbon atoms, or tertiary aralkyl containing 9 to 18 carbon atoms.

13. The process of claim 1 wherein Y in at least two said azo compounds is different.

14. The process of claim 1 wherein Y in at least two said azo compounds is the same.

15. The process of claim 1 wherein Y is OH, ##STR20## each of R, R.sup.2 and R.sup.3 is the same or different substituent including H, a hydrocarbon radical containing 1 to 18 carbon atoms, such as: alkyl, cycloalkyl, aralkyl, arcycloalkyl, aryl, alkaryl, cycloalkaryl, alkenyl, cycloalkenyl, and 5 and 6 membered heterocyclic and benzheterocyclic radical wherein the hetero atoms are selected from oxygen, sulfur and nitrogen, and R and R.sup.2 together may form an alkylene diradical, said hydrocarbon radicals being optionally substituted by a group containing 1 to 18 carbon atoms selected from alkoxy, aryloxy, aroyloxy, alkanoyloxy, alkoxycarbonyl, alkanoyl, aroyl, and carbamoyl, hydroxy, halogen, and cyano; when Y is other than OH, R, R.sup.2 and/or R.sup.3 may also be substituted by carboxyl; R.sup.1 is a substituted or nonsubstituted hydrocarbon radical containing 1 to 18 carbon atoms such as alkyl, cycloalkyl, aralkyl, arcycloalkyl, aryl, alkaryl, or cycloalkaryl, said hydrocarbon radical being optionally substituted by a group containing 1 to 18 carbon atoms selected from t-alkylperoxy-, t-aralkylperoxy, t-cycloalkylperoxy, t-alkylperoxycarbonyl, t-alkylperoxycarbonyloxy, alkanoylperoxy, alkanoylperoxycarbonyl, .alpha.-hydroxyalkylperoxy-.alpha.-hydroxyalkyl, .alpha.-hydroperoxyalkylperoxy-.alpha.-hydroxyalkyl, alkanoylperoxycarbonyloxy, di-(t-alkylperoxy)-methylene, alkenyl, cycloalkenyl, alkynyl, cycloalkynyl, alkoxy, cycloalkoxy, aryloxy, alkaryloxy, cycloalkaryloxy, aroyloxy, alkaroyloxy, carbamoyloxy, alkanoyloxy, alkoxycarbonyloxy, cycloalkoxycarbonyloxy, alkaryloxycarbonyloxy, aryloxycarbonyloxy, alkoxycarbonyl, cycloalkoxycarbonyl, aryloxycarbonyl, alkaryloxycarbonyl, alkoxycarbonylamino, cycloalkoxycarbonylamino, aryloxycarbonylamino, alkaryloxycarbonylamino, alkanoyl, aroyl, alkaroyl, carbamoyl, acylamino, aroylamino, alkylamino, arylamino, thioalkanoyl, dithioalkanoyl, thioaroyl, dithioaroyl, alkylthio, arylthio and 5 and 6 membered heterocyclic and benzheterocyclic wherein the hetero atoms are selected from oxygen, sulfur and nitrogen; as well as amino, hydroxy, halogen and cyano; R.sup.4 is a substituted or non-substituted divalent hydrocarbon radical of 1 to 20 carbon atoms, such as alkylene, cycloalkylene arylene, aralkylene, or cycloalkylalkylene, such divalent radicals optionally containing one or two non-terminal and non-adjacent hetero atoms selected from oxygen, nitrogen, and sulfur in the chain, the substituents borne by R.sup.4 being any of those defined herein for R.sup.1.

16. The process of claim 15 wherein one azo compound has the formula: ##STR21## or one of the substituted or nonsubstituted hydrocarbon radicals defined herein for R.sup.1, provided that any substituent borne by R.sup.5 is not linked to the R.sup.5 carbon atom directly attached to an azo nitrogen of FORMULA II; R.sup.12, R.sup.13 and R.sup.14 are same or different radicals as defined for R.sup.1 : R.sup.6 is ##STR22## or one of the substituted or nonsubstituted hydrocarbon radicals defined for R.sup.1 ; R.sup.7 is a substituted or nonsubstituted hydrocarbon radicals containing 1 to 18 carbon atoms, such as alkyl, cycloalkyl, aralkyl, and arcycloalkyl wheein the substituent borne by R.sup.7 is selected from the substituents defined in claim 14 for R.sup.1 ; R.sup.7 can be hydrogen when Y is --OH or R--C(.dbd.O)O; R.sup.6 and R.sup.7 may together form a ring with the carbon linked to the azo nitrogen; R.sup.7a is the same as R.sup.7 except it is not H; R.sup.8 is ##STR23## R.sup.9 is the same as R.sup.6 except it is not any of the azo radicals defined therefor; R.sup.10 is lower alkyl (1 to 6 carbon atoms) or cycloalkyl (5 to 6 carbon atoms); Y is defined hereinbefore plus ##STR24## Y' is a monovalent group that is the same as Y except Y' is not ##STR25## Y" is the same as Y when Y is divalent; Y" and R.sup.7 taken together with the carbon to the azo nitrogen form a ring containing 4 to 12 atoms; R.sup.5a is the same as R.sup.5 except that where R.sup.5 is ##STR26## n is 1 or 2.

17. The process of claim 16 wherein Y is --OH in Formula II.

18. The process of claim 17 wherein said azo compound is 2-t-butylazo-2-hydroxypropane.

19. The process of claim 17 wherein said azo compound is 2-t-butylazo-2-hydroxybutane.

20. The process of claim 17 wherein said azo compound is 1-t-butylazo-1-hydroxycyclohexane.

21. Cellular structures prepared in accordance with the process of claim 1.

22. The cellular structures of claim 21 further characterized in that said structures are essentially in the form of open cells.

23. The cellular structures of claim 21 further characterized in that said structures are essentially in the form of closed cells.

Patent Citations (4)

Patent	Date	Inventor
US2576073	1951-11-01	Kropa et al.
US3260688	1966-07-01	Watanabe et al.
US3677981	1972-07-01	Wada et al.
US3993609	1976-11-01	Kamens et al.

Abstract

Description