Condensation Polymers Containing Methine Ultraviolet Radiation-Absorbing Residues and Shaped Articles Produced Therefrom

This invention pertains to novel condensation polymers such as polyesters and polycarbonates wherein an ultraviolet light screening amount of one or more methine moieties has been incorporated in the chain or backbone of the polymer. This invention also pertains to containers, such as those suitable for packaging beverages and foods, manufactured from our novel condensation polymers.

Many products such as certain fruit juices, soft drinks, wines, food products, cosmetics and shampoos are deleteriously affected, i.e., degraded, by ultraviolet (UV) light when packaged in plastic containers which pass significant portions of the available light at wavelengths in the range of approximately 250 to 390 nm. It is well known that polymers can be rendered resistant to degradation by UV light by physically blending in such polymers various UV light stabilizers such as benzophenones, benzotriazoles and resorcinol monobenzoates. See, for example, Plastics Additives Handbook, Hanser Publishers, Library of Congress, Catalog No. 83-062289, pp 128-134. Normally, such stabilizers are used in a weight concentration of at least 0.5 percent. Although these stabilizers function well to absorb radiation in the range of about 300 to 350 nm, absorbence in the range of 300 to 350 nm is not adequate to protect comestibles subject to UV light degradation packaged in clear plastic, i.e., essentially colorless, transparent plastic. The stabilizers in the known stabilized polymer compositions can be extracted from the polymer by solvents such as acids, alcohols and the like present in foods or beverages packaged within the stabilized polymers. Furthermore, many compounds used to stabilize polymers are not stable at high temperatures and would decompose under the conditions at which polyesters are manufactured or processed. Decomposition of such stabilizers frequently causes yellow discoloration of the polyester and results in the polyester containing little, if any, of the stabilizer.

U.S. Pat. No. 4,340,718 discloses the copolymerization of certain methine stabilizers with polyesters. The patent further discloses that the concentration of the methine stabilizers in the polyesters should be in the range of 0.3 to 5.0 percent, preferably 0.6 to 2.0 percent, i.e., 6000 to 20,000 ppm, to impart to the basic polyester improved weatherability in outdoor applications. This patent does not mention the use of methine compounds in low concentrations for the purpose of screening UV light.

U.S. Pat. No. 4,617,374 discloses polyesters having certain methine compounds reacted therein to absorb light in the range of 320 to 380 nm. That patent, however, does not disclose the methine compounds used in the polyester compositions and articles molded therefrom provided by our invention.

Our invention concerns a composition comprising molding grade condensation polymer having copolymerized therein the residue of a methine compound or mixture of methine compounds having the formula ##STR3## wherein R.sup.1 is an unsubstituted or substituted alkyl, cycloalkyl or aryl radical;

A is an unsubstituted or substituted 1,4-phenylene radical; phenylene radical;

R.sup.2 is hydrogen or an unsubstituted or substituted alkyl, alkenyl, cycloalkyl or aryl radical; and

R.sup.3 is ##STR4## cyano or an unsubstituted or substituted carbamoyl, alkanoyl, aroyl, alkylsulfonyl, arysulfonyl, aryl or aromatic heterocyclic radicals. R.sup.3 preferably is ##STR5## or cyano.

Examples of the unsubstituted alkyl groups include methyl, ethyl, propyl, 2-propyl, butyl, 2-butyl, hexyl, octyl, 2-ethylhexyl, decyl, dodecyl, etc. The cycloalkyl groups may be cyclopentyl, cyclohexyl, cycloheptyl anda the like. The aryl groups may be, for example, carbocyclic aryl such as phenyl and naphthyl. Examples of the unsubstituted alkanoyl, alkylsulfonyl and arylsulfonyl include acetyl, propionyl, butyryl, pivaloyl, hexanoyl, 2-ethylhexanoyl, methylsulfonyl, ethylsulfonyl, propylsulfonyl, octylsulfonyl, phenylsulfonyl, etc. Pyrrolyl, pyridyl, pyrimidyl, 2-benzothiazolyl, 2-benzoxazolyl, 2-benzimidazolyl, 2-thienyl, 2-furanyl, 1,3,4-thiadiazol-2-y1, 1,2,4thiadiazol-5-y1 and groups having the structure ##STR6## are examples of the unsubstituted aromatic heterocyclic residues which may constitute a part of the methine compounds. The alkyl radicals represented by R.sup.1 and R.sup.2 can be substituted with a wide variety of substituents such as alkoxy, alkylthio, halogen, hydroxy, cycloalkyl, cycloalkoxy, alkanoyloxy, cyano, aryl, aryloxy, arylthio, etc. The cycloalkyl, aryl and aromatic heterocyclic groups can be substituted with unsubstituted or substituted alkyl as well as with any of the substituents set forth hereinabove. Normally, those substituents containing alkyl moieties, such as alkyl, hydroxyalkyl, alkoxyalkyl, etc., will not contain more than a total of 12 carbon atoms. The unsubstituted and substituted cycloalkyl groups typically will contain from 5 to 12 carbon atoms whereas the unsubstituted and substituted aryl groups will contain from 6 to 12 carbon atoms. Illustrative of the 1,4-phenylene radical represented by A is the group having the structure ##STR7## wherein R.sup.4 is hydrogen, alkyl, alkoxy or halogen.

The methine compounds which are particularly preferred have the formula ##STR8## wherein R.sup.1 and R.sup.2 are lower alkyl, in which lower designates a carbon content of up to about 4 carbon atoms.

The methine compounds may be prepared using known procedures by reacting an intermediate aldehyde compound II with an active methylene compound III under Knovenagel reaction conditions, e.g., ##STR9##

Lower alcohols such as methanol, ethanol and 2-propanol are usually suitable solvents. With certain reactants, for example when R.sup.3 is ##STR10## it is sometimes advantageous to conduct the reaction in a hydrocarbon solvent such as benzene or toluene to permit the water or reaction to be azeotropically removed as it is formed. Bases such as piperidine, piperidine acetate, pyrrolidine, sodium acetate and pyridine are effective in promoting the reaction.

The polyesters which may be used in the preparation of the compositions of our invention include linear, thermoplastic, crystalline or amorphous polyesters produced by conventional polymerization techniques from one or more diols and one or more dicarboxylic acids. The polyesters normally are molding or fiber grade and have an inherent viscosity (IV) of about 0.4 to about 1.2. The preferred polyesters comprise at least about 50 mole percent terephthalic acid residues and at least about 50 mole percent ethylene glycol and/or 1,4-cyclohexanedimethanol residues. Particularly preferred polyesters are those containing from about 75 to 100 mole percent terephthalic acid residues and from about 75 to 100 mole percent ethylene glycol residues.

The unsaturated, curable polyesters which may be used in our novel compositions are the polyesterification products of one or more glycols and one or more unsaturated dicarboxylic acids or their anhydrides. Typical of the unsaturated polyesters is the polyesterification product of (a) 1,4-cyclohexanedimethanol and/or 2,2-dimethyl-1,3-propanediol and optionally an additional dihydric alcohol, such as ethylene glycol, and (b) maleic acid or fumaric acid and an aromatic dicarboxylic acid, which when crosslinked with an ethylenically-unsaturated monomer, e.g., styrene, produces a cured polyester resin which has, for example, high thermal resistance, high heat distortion values, excellent electrical and mechanical properties, and excellent resistance to chemicals.

Solutions of such unsaturated polyester resins in an ethylenically-unsaturated monomer such as styrene commonly are referred to as polyester resins.

The unsaturated polyester resins may be prepared in the presence of gelation inhibitors such as hydroquinone or the like, which are well known in the art of polyesterification. The esterification may be carried out for example under an inert blanket of gas such as nitrogen in a temperature range of 118.degree.-220.degree. C. for a period of about 6-20 hours until an acid number below 100 and preferably below 50 is obtained, based on milliequivalents of KOH necessary to neutralize 1 gram of the unsaturated polyester. The resulting polyester may be subsequently copolymerized, crosslinked, or cured with "curing amounts" of any of the well-known ethylenically unsaturated monomers used as solvents for the polyester. Examples of such monomers include styrene, alpha-methyl styrene, vinyl toluene, divinyl benzene, chlorostyrene, and the like as well as mixtures thereof. Typically, the mole ratio of such unsaturated monomer to the unsaturated moiety (e.g., maleic acid residue) in the polyester is from about 0.5 to about 3.0, although the "curing amounts" of such monomer can be varied from these ratios.

It is preferred that the unsaturated polyester be prepared from one or more dihydric alcohols, fumaric or maleic acid or mixtures thereof, and up to about 60 mole percent of total acid component of o-phthalic, isophthalic or terephthalic acids or mixtures thereof. Preferred for the dihydric alcohol component is one or a mixture of propylene glycol, neopentyl glycol, 2,2,4-trimethyl-1,3-pentanediol, ethlene glycol, or diethylene glycol. A specific preferred unsaturated polyester is prepared from about 75 to 100 mole percent propylene glycol, and as the acid component, from, about 75 to 100 mole percent o-phthalic and maleic acids in a mole ratio of from about 1/2 to about 2/1. Typical of these unsaturated polyesters are those disclosed, for example, in U.S. Pat. No. 4,359,570 incorporated herein by reference.

The diol components of the described linear polyesters may be selected from ethylene glycol, 1,4-cyclohexanedimethanol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 2,2-dimethyl-1,3-propanediol, 1,6-hexanediol, 1,2-cyclohexanediol, 1,4-cyclohexanediol, 1,2-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, X,8-bis(hydroxymethyl)tricyclo-[5.2.1.0]-decane wherein X represents 3, 4, or 5; and diols containing one or more oxygen atoms in the chain, e.g., diethylene glycol, triethylene glycol, dipropylene glycol, tripropylene glycol and the like. In general, these diols contain 2 to 18, preferably 2 to 8 carbon atoms. Cycloaliphatic diols can be employed in their cis or trans configuration or as mixtures of both forms.

The acid components (aliphatic, alicyclic, or aromatic dicarboxylic acids) of the linear polyester are selected, for example, from terephthalic acid, isophthalic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, succinic acid, glutaric acid, adipic acid, sebacic acid, 1,12-dodecanedioic acid, 2,6-naphthalene-dicarboxylic acid and the like. In the polymer preparation, it is often preferable to use a functional acid derivative thereof such as the dimethyl, diethyl, or dipropyl ester of the dicarboxylic acid. The anhydrides or acid halides of these acids also may be employed where practical.

Typical polycarbonates useful herein are disclosed in Kirk-Othmer Encyclopedia of Chemical Technology, third edition, Volume 18, pages 479-494, incorporated herein by reference.

The novel polymer compositions provided by this invention are useful in the manufacture of containers or packages for comestibles such as beverages and food. By the use of known heat-setting techniques, certain of the polyesters are, in terms of color, I.V. and heat distortion, stable at temperatures up to about 100.degree. C. Such stability characteristics are referred to herein as "hot-fill" stability. Articles molded from these polyesters exhibit good thin-wall rigidity, excellent clarity and good barrier properties with respect to moisture and atmospheric gases, particularly carbon dioxide and oxygen.

The linear polyesters most preferred for use in articles having "hot-fill" stability comprise poly(ethylene terephthalate) and poly(ethylene terephthalate) wherein up to 5 mole percent of the ethyene glycol residues have been replaced with residues derived from 1,4-cyclohexanedimethanol, wherein the polyesters have been sufficiently heat set and oriented by methods well known in the art to give a desired degree of crystallinity. By definition, a polymer is "hot-fill" stable at a prescribed temperature when less than 2% change in volume of a container manufactured therefrom occurs upon filling the same with a liquid at the temperature. For the manufacture of blow-molded beverage bottles, the most preferred polyesters have an I.V. of 0.65 to 0.85, and a Tg of >70.degree. C., and film sections cut from the bottle have a Water Vapor Transmission Rate of 1.5 to 2.5 g. mils/100 in..sup.2 --24 hrs., a Carbon Dioxide Permeability of 20-30 cc. mils/100 in..sup.2 --24 hrs.-atm., and an Oxygen Permeability of 4-8 cc. mils/100 in..sup.2 --24 hrs.-atm. The Tg is determined by Differential Scanning Calorimetry at a scan rate of 20 Centigrade Degrees/min., the Oxygen Permeability by the standard operating procedure of a MOCON OXTRAN 100 instrument of Modern Controls, Inc., of Elk River, Minnesota, and the Carbon Dioxide Permeability by the standard operating procedure of a MOCON PERMATRAN C II, also of Modern Controls.

The concentration of the residue of the methine compound in the condensation polymer can be varied substantially depending, for example, on the intended function of the UV-absorbing residue and/or the end use for which the polymer composition is intended. When the polymer composition is to be used in the fabrication of relatively thin-walled containers to screen UV light in the range of about 250 to 390 nm, the concentration of the residue of the methine compound normally will be in the range of about 50 to 1,500 ppm (parts by weight per million parts by weight polymer) with the range of about 200 to 800 ppm being especially preferred.

When the levels of the present ultraviolet light absorbers are increased to higher levels such as 5,000 ppm (0.5 weight percent) or higher, polymers containing these ultraviolet light absorbers show improved resistance to weathering and when these polymers per se or fibers thereof are dyed with disperse dyes, at a concentration, for example, of from about 0.01% to about 5.0% based on weight of polymer or fiber, many dyes exhibit increased lightfastness. Such disperse dyes are shown, for example, U.S. Pat. Nos. 4,305,719; 2,746,952; 2,746,953; 2,757,173; 2,763,668; 2,771,466; 2,773,054; 2,777,863; 2,785,157; 2,790,791; 2,798,081; 2,805,218; 2,822,359; 2,827,450; 2,832,761; 2,852,504; 2,857,371; 2,865,909; 2,871,231; 3,072,683; 3,079,373; 3,079,375; 3,087,773; 3,096,318; 3,096,332; 3,236,843; 3,254,073; 3,349,075; 3,380,990; 3,386,990; 3,394,144; 3,804,823, 3,816,388; 3,816,392; 3,829,410, 3,917,604; 3,928,311; 3,980,626; 3,998,801; 4,039,522; 4,052;379; and 4,140,683, the disclosures of which are incorporated herein by reference.

Polymer compositions containing substantially higher amounts, e.g., from about 2.0 to 10.0 weight percent, of the residue on one or more of the methine compounds described herein may be used as polymer concentrates. Such concentrates may be blended with the same or different polymer according to conventional procedures to obtain polymer compositions which will contain a predetermined amount of the residue or residues in a nonextractable form. In the preparation of these highly loaded, polymer composition concentrates the residue preferably is divalent and thus is derived from a difunctional methine compound such as the compounds wherein R.sup.1 is hydroxyalkyl and/or R.sup.3 is

The preparation of the methine compounds and their use in preparing the compositions of our invention are further illustrated by the following examples.

4-(Methylthio)benzaldehyde (1.52 g., .01 mol), methyl cyanoacetate (1.0 g, .01 mol), methanol (15 mL), and piperidine (5 drops) are mixed and heated at reflux for 1 hour. Upon cooling, the pale yellow solid crystallizes and is collected by filtration, washed with methanol and dried in air. The yield is 2.3 g, 98.7% of the theoretical yeild, of methyl 2-cyano-3-[4-(methylthio)phenyl]-2-propenoate. When dissolved in methylene chloride, the compound has an absorption maximum (.lambda.max), at 365 nm in the ultraviolet absorption. The structure of the product is confirmed by mass spectroscopy analysis.

4-(Methylthio)Benzaldehyde (3.04 g, .02 mol), diethyl malonate (3.20 g. .02 mol), toluene (25 mL), piperidine (4 drops) and acetic acid (2 drops) are mixed and heated at reflux for 2 hours with the water formed being removed azeotropically. The solution is cooled and 25 mL of water added stirring. After separation of the layers, the toluene is evaporated from the organic layer to yield the product, diethyl 2-[[4-(methylthio)phenyl]methylene]propanedioate, in essentially quantitative yield. When dissolved in methylene chloride, the product has an absorption maximum (.lambda.max) at 330 nm in the ultraviolet absorption spectrum. The identity of the product is confirmed by mass spectroscopy analysis.

Additional examples of methine compounds which may be used in the preparation of our novel polymer compositions are set forth in the following table. These compounds may be prepared according to the procedures described above and conform to the formula ##STR12##

The following materials are placed in a 500-mL, three-necked, round-bottom flask:

97 g (0.5 mol) dimethyl terephthalate

62 g (1.0 mol) ethylene glycol

0.00192 g Ti from a n-butanol solution of acetyl-triisopropyl titanate

0.0053 g Mn from an ethylene glycol solution of manganese acetate

0.0345 g antimony trioxide

0.0072 g Co from an ethylene glycol solution of cobaltous acetate

The flask is equipped with a nitrogen inlet, stirrer, vacuum outlet, and condensing flask. The flask and contents are heated at 200.degree. C. in a Belmont metal bath for 60 minutes and at 210.degree. C. for 75 minutes with a nitrogen sweep over the reaction mixture. Then 1.57 mL of an ethylene glycol slurry of a mixed phosphorus ester composition (Zonyl A) which contains 0.012 g phosphorus is added. The temperature of the bath is increased to 230.degree. C. At 230.degree. C., methyl 2-cyano-3-[4-(methylthio)phenyl]-2-propenoate (0.0384 g) is added to the flask. Five minutes after this addition, a vacuum with a slow stream of nitrogen bleeding in the system is applied over a five-minute period until the pressure is reduced to 200 mm Hg. The flask and contents are heated at 230.degree. C. under a pressure of 200 mm Hg for 25 minutes. The metal bath temperature is increased to 270.degree. C. At 270.degree. C. the pressure is reduced slowly to 100 mm Hg. The flask and contents are heated at 270.degree. C. under a pressure of 100 mm Hg for 30 minutes. The metal bath temperature is increased to 285.degree. C. and the pressure is reduced slowly to 4.5 mm Hg. The flask and contents are heated at 285.degree. C. under pressure of 4.5 mm Hg for 25 minutes. Then the pressure is reduced to 0.25 mm Hg and polycondensation is continued for 40 minutes. The flask is removed from the metal bath and is allowed to cool in a nitrogen atmosphere while the polymer crystallizes. The resulting polymer has an inherent viscosity of 0.58 measured in a 60/40 ratio by weight of phenol/tetrachloroethane at a concentration of 0.5 g per 100 mL. An amorphous film molded from this polymer to simulate the sidewall of a container showed a strong absorption at 380 nm.

The procedure described in Example 51 is repeated using 0.0384 g diethyl 2-[[4-methylthio)phenyl]methylene]propanedioate obtained in Example 2 instead of the methine compound used in Example 51. The resulting polymer has an inlet inherent viscosity of 0.56 measured in a 60/40 ratio by weight of phenol/tetrachloroethane at a concentration of 0.5 g per 100 mL. An amorphous film molded from this polymer shows a strong absorption peak with a maximum at 342 nm.

The inherent viscosities (I.V. of the copolyesters described herein are determined according to ASTM D2857-70 procedure in a Wagner Viscometer of Lab Glass Inc. of Vineland, N.J. having a 1/2 ml capillary bulb, using polymer concentration of 0.5%, by weight, in 60/40, by weight, phenol/tetrachoroethane solvent. The procedure comprises heating the polymer/solvent system at 120.degree. C. for 15 minutes to enhance dissolution of the polymer, cooling the solution to 25.degree. C. and measuring the time of flow at 25.degree. C. The I.V. is calculated from the equation ##EQU1## where: {.eta.}=Inherent viscosity at 25.degree. C. at a polymer concentration of 0.5 g/100 ml. of solvent;

ln=Natural logarithm;

t.sub.2 =Sample flow time;

t.sub.o =Solvent-blank flow time; and

C=Concentration of polymer in grams per

100 ml. of solvent =0.50.

The nonextractabilities of the methine residues described herein are determined as follows:

All extractions are done in glass containers with distilled solvents under the time and temperature conditions described below. The sample form is 1/2 inch.times.21/2 inch segments cut from the cylindrical side wall portion of 2-liter bottles. All samples are washed with cold solvent to remove surface contaminants and are exposed using 200 ml solvent/100 in..sup.2 surface area (2ml/in..sup.2).

Solvent blanks are run under the same extraction conditions without polymer. In most cases samples were extracted, spiked, with a known amount of additive as a control, and analyzed in duplicates. The solvents employed and the extraction conditions for each solvent are:

1. Water. The samples at room temperature are added to solvent and heated at 250.degree. F. for two hours. Half of the samples are then analyzed and the remainder are placed in a 120.degree. F. oven for 30 days and then analyzed.

2. 50% Ethanol/Water. The samples at room temperature are added to the solvent at room temperature, placed in an oven at 120.degree. F. and analyzed after 24 hours and again after 30 days.

3. Heptane. The samples at room temperature are added to solvent at room temperature and heated at 150.degree. F. for two hours. Part of the samples are cooled to room temperature and analyzed spectrophotometrically and the remainder are allowed to age at 120.degree. F. for 30 days before analysis.

Any suitable analytical technique and apparatus may be employed to determine the amount of methine residue extracted from the polymer.

The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.