Novel Vinyl Chloride Resins and Compositions Incorporating Such Resins

Colon and Mallon Ser. No. 636,895, filed Aug. 2, 1984, now abandoned, for Novel Phosphorylated Reaction Products and Compositions Incorporating Such Products.

1. Field Of The Invention

This invention relates to novel vinyl chloride resins and, more particularly, to novel resins for use in compositions to be used in magnet recording media, enhancing the dispersion and magnetic property characteristics of such medium.

2. Description Of The Prior Art

Over the years, magnetic recording has come to occupy a vital place in a myriad of industries. Magnetic tape is accordingly utilized for audio, video, computer, instrumentation and other recordings. Magnetic recording media are utilized in a variety of forms, including, for example, magnetic cards and disks, reels, video tapes, high performance audio tapes, computer tapes, floppy disks and the like.

While there are several different types of magnetic recording media, all types consist of a layer of magnetic particles, sometimes referred to as "pigment", coated on a plastic, paper or metal base. Information to be recorded is stored in the magnetic pigment applied to the base as a series of small domains magnetized by a recording head. The coating layer of the magnetic pigment includes a binder system which provides a cohesive matrix between the magnetic pigment particles and adheres such particles to the base.

The magnetic coating is applied to the base by coating equipment such as, for example, a gravure roll coater, and the coated base then typically immediately proceeds to a magnetic orientation step wherein orientation of the pigment particles is effected on the undried layer. In this step, the long axis of the pigment particles, typically acicular crystals, is made to coincide with the magnetization direction.

In order to achieve good recording performance, the magnetic coating must possess a wide variety of characteristics. Pigment particles, desirably of relatively uniform particle size, should form as high a proportion of the coating layer as possible. Further, the degree of dispersion of the pigment particles in the coating, often evaluated as degree of gloss, should be as high as possible. Further, the highly dispersed pigment particles must be capable of being adequately oriented as previously described (the degree of orientation often measured as "squareness").

Still further, the adhesion and wear resistance of the magnetic coating or film should be high. Also, the coefficient of friction of the magnetic surface should be low against the head material, and yet have an adequate value against the driving media such as pitch rollers and capstan rollers.

Satisfying these and other diverse criteria have proven to require a delicate balance of basically reciprocal, or opposing, properties. A substantial amount of effort over the years has been directed to improving the various characteristics of magnetic recording media.

To satisfy the performance criteria, the binder system must possess adequate modulus, yet have satisfactory tensile strength and resilience. It has generally been found desirable to satisfy these criteria by utilizing more than one material in the binder system. Typically, a polymer of relatively high molecular weight which is capable of being cross-linked or cured is utilized to provide the desired modulus. Various elastomers are also incorporated to achieve the desired resilience, toughness and durability.

Conventional binder systems include a wide variety of high Tg (viz. - glass transition temperature) hardening polymers or resins, such as, for example, polyacrylates, polyesters, polyester amides, polyhydroxyethers and copolymers from monomers such as vinyl chloride, vinyl acetate, acrylonitrile, vinyl alcohol, vinyl butyral, and vinylidene chloride in combination with low Tg elastomeric polymers, including nitrile rubbers, polyesters, alkyd resins and polyester polyurethanes. The latter elastomers often represent the material of choice for high performance applications. Such resins have excellent toughness and abrasion resistance. Typically, the hardening polymers contain hydroxyl functionality since crosslinking to further increase the modulus, durability and abrasion resistance characteristics can then be achieved by using polyfunctional isocyanates.

The degree of dispersion and the capability of the pigment particles to be oriented in many binder systems are often considered inadequate in the absence of dispersion aids. A wide variety of techniques have been proposed to improve these characteristics. Thus, many surface active agents have been employed for this purpose. These include higher aliphatic amines, higher fatty acids, phosphoric acid esters of higher alcohols such as polyoxyethylene phosphate alkyl ethers, esters of higher fatty acids and sorbitol, sodium alkylbenzenesulfonate, betaine-type, nonionic surface active agents and the like.

Magnetic coatings obtained by employing such surface active agents generally exhibit uniform dispersion of magnetic powder as well as good orientation, when the powder or pigment is in the form of acicular particles. On the other hand, utilization of such agents often adversely affects wear resistance or causes difficulties in quality during use. These problems are often attributed to migration or blooming of such surface active agents to the magnetic coating surface or to unnecessary plasticization of the hardening resin or of other components in the magnetic coating.

One attempt to obviate the migration problem is suggested by Great Britain Patent No. 2,097,415A. This suggests using with a cross-linkable or polymerizable resin binder a phosphoric acid ester having at least one polymerizable unsaturated double bond. Preferably, the phosphoric acid ester is a product obtained by reacting a phosphoric acid ester of a compound having two or more hydroxyl groups with an acrylic or methacrylic compound having a functional group reactive with an isocyanate group and also with a polyisocyanate compound. The phosphoric esters disclosed include two major types: (1) the reaction products of a long chain alkylether or polyester, an acrylic or methacrylic compound having a functional group reactive with an isocyanate group, and a polyisocyanate compound with (2) phosphoric esters of hydroxyalkyl acrylates. Other binder systems disclosed utilize compounds containing various hydrophilic groups such as sulfates, sulphonates, hosphonates and the like.

Japanese application No. 116,474 discloses a magnetic layer binder composition of a polyurethane and optionally a polyester containing sulphonate groups, and a vinyl chloride polymer containing sulphonate, sulphate, carboxylate or phosphonate groups. The binder is stated to have good dispersing function to magnetic powder and the recording medium to have excellent service durability and good surface gloss.

Japanese Patent No. J57092421-A(8229) discloses a magnetic recording medium which includes a polyester urethane having (1) at least one hydrophilic group such as --SO.sub.3 M,--OSO.sub.3 H, --COOM, --P(O)(OM').sub.2, --NH.sub.2, --NHR, NR.sub.1 R.sub.2, a bond NR.sub.1 R.sub.2 R.sub.3, wherein M may be H, Li, Na or K; M' may be H, Li, Na, K or a hydrocarbon group; and the R groups may be hydrocarbon groups and (2) at least two acrylic type double bonds.

Japanese No. J57092422-A(8229) discloses a magnetic layer containing a polyurethane or polyester resin having (1) at least one hydrophilic group selected from --OSO.sub.3 H, --COOM, --P(O)(PM').sub.2 wherein M may be H, Li, Na, K and M' may be H, Li, Na, K or a hydrocarbon group and (2) a molecular weight of 200 to 5000 per hydrophilic group.

International Publication No. W08400240-A discloses a magnetic recording medium containing a polyvinyl chloride-vinyl acetate-vinyl alcohol and a polyurethane resin containing polar groups such as --SO.sub.3 M, --OSO.sub.3 M', --COOM or ##STR1## wherein M may be H, Li, Na or K and M.sub.1 and M.sub.2 may be Li, Na, K or an alkyl group, preferably an alkyl group with up to 23 carbon atoms.

Japanese J55117734-A(8043) discloses a binder for a magnetic recording medium which contains a copolymer of a phosphoric acid ester of an alkylene glycol acrylate or an alkylene glycol methacrylate and a copolymerizable monomer. The wetting properties to ferromagnetic material is stated to be very good, so that dispersibility in the binder is improved. Blooming is said not to occur as no high aliphatic acid, metallic soap, or the like is used.

Among the binder polymers in use in magnetic coating media are commercially available, partially hydrolyzed, (viz. - partly saponified) vinyl chloride - vinyl acetate coploymers and terpolymers. Unfortunately, the dispersion and orientation characteristics of coatings utilizing such binder polymers are typically less than is desired. Considerable efforts have been undertaken to improve these characteristics with the use of a wide variety of dispersion aids.

U.S. Pat. No. 4,420,537 to Hayama et al. thus discloses a magnetic recording medium including a commercially available vinyl chloride-vinyl acetate-vinyl alcohol copolymer and a phosphoric ester type anionic surfactant (e.g.--"GAFAC RE 610"). It is noted that when the content of the surfactant is more than 5 weight percent of the coating, the surfactant is bloomed out from the magnetic layer.

U.S. Pat. No. 4,153,754 to Huisman notes difficulties with prior dispersing agents. Low molecular weight agents, such as lecithin, have the disadvantage that an excess is necessary to fully cover the particles to be dispersed. The high molecular weight dispersing agents, as described, for example in Netherlands Patent Application No. 65.11015, have the disadvantage that, due to their poor wetting properties, agglomerates of the particles are also covered with a dispersing agent. It is not readily possible, or it is possible only by the use of much energy, to disintegrate such agglomerates to individual particles. Huisman suggests using an Nacylsarcosine derivative as a dispersing agent with the binders. The Examples show use of such a dispersing agent with a commercially available vinyl chloride-vinyl acetate-vinyl alcohol terpolymer.

U.S. Pat. No. 4,291,100 to Horigome et al. discloses a magnetic recording medium utilizing a polyoxyethylenesorbitane higher fatty acid ester surfactant. The Examples include use of such surfactants with vinyl chloride-vinyl acetate copolymers and vinyl chloride-vinyl acetate-vinyl alcohol terpolymers.

U S. Pat. No. 4,305,995 to Ota et al. shows a magnetic recording medium including a mixture of sorbitan mono-, di- and tri- higher fatty acid ester surfactants. The Examples show use of such surfactants with vinyl chloride-vinyl acetate copolymers.

U.S. Pat. No. 4,330,600 to Kawasumi et al. discloses a magnetic recording medium in which the dispersion characteristics of magnetizable particles are improved which results in improved saturation magnetic flux density and squareness ratio. These are achieved by treating the magnetizable particles with a titanium alcoholate compound having at least one group which is easily hydrolyzed and at least one oleophilic group which is hard to hydrolyze in an organic solvent. The examples show use of such titanium alcoholates with a commercially available vinyl chloride-vinyl acetate copolymer binder.

U.S. Pat. No. 4,400,435 to Yoda et al. notes that vinyl chloride-vinyl acetate copolymers have been used as binders, but that such copolymers do not have functional groups whereby it is easy to improve the dispersibility of magnetic powder in a magnetic layer. It is further said that it is not easy to carry out a thermosetting reaction. The use of vinyl chloride-vinyl acetate-vinyl alcohol copolymers instead had been proposed; and, because of the hydroxyl groups present, the dispersibility of magnetic powder is improved and the thermosettable reaction can be performed. However, because of the vinyl alcohol component, the glass transition temperature of the copolymer is disadvantageously high so as to provide difficulties in improving the surface properties by a calender process. A magnetic recording medium having improved orientation and maximum residual magnetic flux density is provided by using a vinyl chloride-vinyl acetate-maleic acid copolymer having a content of the maleic acid component of at least 1.5 percent.

In addition, there are available various vinyl chloride-vinyl acetate resins which are employed in magnetic recording media. For example, such resins include vinyl chloride-vinyl acetate-vinyl alcoholmaleic acid polymers in which the vinyl alcohol portion is obtained by hydrolysis.

J56077930-A(8133) discloses magnetic recording media in which a substrate is coated with a magnetic lacquer composed of ferromagnetic powder bonded with a binder containing a copolymer of 70-95 weight percent vinyl chloride and 1-25 weight percent hydroxyethylacrylate or hydroxyethylmethacrylate and 0-10 (meth)acrylic acid. It is stated that the squareness ratio and mass residual magnetic flux density are improved. When polyisocyanate (hardening agent) is added, the abrasion resistance is also improved.

U.S. Pat. No. 4,415,630 to Kubota et al. discloses a radiation-sensitive modified resin which is capable of being cross-linked by radiation. As one example, thermoplastic resins which can be effectively modified for radiation sensitivity include vinyl chloride-based copolymers such as vinyl chloride-vinyl acetate-vinyl alcohol copolymers, vinyl chloride-vinyl acetate-maleic acid copolymers, and vinyl chloride-vinyl acetate-end-OH-side-chain alkyl radical copolymers. Such thermoplastic resins which have one or more hydroxyl groups in the molecule can be reacted with a polyisocyanate compound, followed by reaction with a monomer having groups reactive to the isocyanate group and also having unsaturated double bonds that harden upon irradiation at a rate of one molecule of the former to one or more molecules of the latter. A further example involves a reaction product of the compound having at least one epoxy group in the molecule and a monomer having groups reactive with the epoxy group and also having radiation-setting, unsaturated double bonds. Specifically, an epoxy-containing thermoplastic resin, obtained by radical polymerization with glycidyl alcohol, is reacted with acrylic acid. By the ring-opening reaction of the carboxyl and epoxy groups, a resin is obtained which carries the acrylic double bonds as a pendant group.

Further, U.S. Pat. No. 3,755,271 to Montgomery discloses terpolymers of vinyl chloride, vinyl acetate and certain acrylic esters. These terpolymers can be employed alone or in admixture with other resins to make useful coatings. U.S. Pat. No. 3,884,887 to Montgomery provides a similar disclosure.

Also, East German DL140-463 discloses a crosslinkable binder for providing improved weather resistance, particularly to water, for various substrates. The composition comprises an acrylate ester, vinyl chloride, maleic acid or the half ester and one of the following: an epoxy containing monomer or (2) hydroxyethylacrylate or (3) a derivative of methylacrylamide.

Japanese Publication No. JA7203734-R discloses a composition which is said to provide good weathering properties and chemical resistance. The composition includes 2-6 weight percent of acrylic acid or maleic acid, 3-15 weight percent of glycidyl methacrylate and hydroxyethylacrylate, and 79-95 weight percent of an acrylate ester, alone or with other olefinically unsaturated monomers such as styrene or vinyl chloride.

Co-pending application Ser. No. 636,895 now abandoned, discloses novel phosphorylated compositions of a vinyl chloride copolymer or terpolymer having improved dispersion characteristics which are suitable for use in applications such as magnetic recording media. While such phosphorylated compositions provide improved dispersion characteristics, there still remains the need for improvement. More specifically, the phosphorylation reaction is not as facile as would be desired. Moreover, it is necessary to carefully carry out such reaction because of the inherent lack of thermal stability of such vinyl chloride compositions.

In addition, while vinyl chloride compositions are highly desirable for use as binder resins in magnetic recording media, it has long been recognized that compositions having improved thermal stability would be highly desirable. This is apparent because a wide variety of conditions must be met. Thus, binder resins must be storage stable under ambient conditions as well as being stable during a variety of processing operations in forming the various products, including grinding, drying and calendering operations. Likewise, the product must not unduly degrade in storage and must provide substantial durability in operation.

From the product performance standpoint, a high level of stability is desirable for such binder resins so that the magnetic recording medium performs adequately during its expected lifetime. The primary binder function of holding the particulate magnetic pigment on the base film through the rigors of production and use are critically dependent upon the molecular weight of such resins. Cumulative exposure to higher temperatures can reduce the molecular weight of vinyl resins, which results in premature mechanical failure. The obvious flaking of pigment and loss of information can be, of course, catastrophic. Degradation often manifests itself by low molecular weight products blooming to the surface with fouling of the heads or tape sticking to the guides.

Another failure mode results from the failure of the other components in the system due to the evolution of HCl from vinyl chloride resins. Thus, the polyester urethane elastomer binder ingredient often used in such media can itself degrade through acid-catalyzed hydrolysis. The loss of molecular weight and evolution of blooming species can cause the same problem as the primary degradation in the hardening polymer. In the extreme case, low levels of HCl could well be generated during long-term, still-frame playing which could corrode the head surfaces.

Accordingly, despite the considerable prior effort in this field, the need remains for binder systems utilizing vinyl chloride resins that can not only achieve the desired dispersion and magnetic characteristics over a widespread variety of usage requirements but can also provide relative freedom from thermal instability problems.

A principal object of the present invention is to provide novel vinyl chloride polymers for use in applications such as magnetic coatings to impart desirable dispersion and orientation characteristics while having superior thermal stability.

A further object of this invention provides a novel binder system for a magnetic recording medium which may be substituted for conventional binders in formulations as essentially a plug-in substitution.

Yet another object lies in the provision of novel compositions that may be obtained by utilizing a straightforward, facile synthesis. A related and more specific object provides binder compositions that may be formed in a one-step, or direct, polymerization.

Another object of the present invention is to provide a binder system for magnetic recording media which minimizes or eliminates the need to employ a dispersing agent which ca cause blooming in use.

A still further object lies in the provision of a magnetic coating which is capable of being processed in conventionally utilized magnetic coating equipment.

These and other objects of the present invention will be apparent from the description set forth hereinafter.

The present invention is based on the a binder system for particulate matter to be used in magnetic recording media, which is capable of imparting not only desirable dispersion and magnetic characteristics but also excellent thermal stability, and is provided by utilizing a copolymer of vinyl chloride, a hydroxyalkyl acrylate or methacrylate or allyl alcohol, an epoxy-containing vinyl monomer, and a monomer having an organic carboxylic acid moiety selected from the group consisting of acrylic acid, methacrylic acid, maleic acid or anhydride, itaconic acid and fumaric acid or a phosphorus ester moiety. Optionally, the binder system can include minor amounts of a vinyl ester such as vinyl acetate.

The relative amounts of the various constituents of the binder resins of this invention must be carefully tailored to provide the desired composite properties. Thus, the relative amount of vinyl chloride should be adequate to provide the desired mechanical characteristics, as determined by the Tg (viz.--glass transition temperature) for the resin. The hydroxyalkyl acrylate or methacrylate or allyl alcohol should be present in the media, in an amount to provide facile curing with polyisocyanates and miscibility with the elastomer component, when this component is used. The acid functionality (either a carboxylic or phosphoric acid) should be utilized in an amount that will provide the desired dispersibility characteristics but not in excess since undesirable rheological characteristics or the like can result. The epoxy-containing moiety is present in an amount necessary to provide the desired thermal stability as well as, when a phosphorylating agent is used, to provide reactive groups to incorporate adequate amounts of the phosphoric acid functionality. Vinyl esters such as vinyl acetate may be used in minor amounts, commonly being incorporated in the preparation of vinyl chloride polymers to impart processing latitude.

In accordance with one aspect of the present invention, when a monomer containing a carboxylic group is used to provide the acid functionality, it has been found that the binder resins can be prepared by a one-step, or direct, polymerization. This affords a facile preparation that can allow considerable economic savings. Thus, it is considered that any post modification following preparation of a polymer can add at least 50% to the manufacturing cost.

With respect to the vinyl chloride constituent, this will generally be the major component that determines the adequacy of the mechanical properties necessary to appropriately function as a binder resin in magnetic recording media and the like. Accordingly, it is necessary to utilize an amount of vinyl chloride sufficient to provide the requisite properties for the resin, which properties can be adequately determined by reference to the Tg of the resin.

It will be generally desired to utilize amounts of vinyl chloride adequate to provide the resins of this invention with a Tg of at least 40.degree. C., preferably at least about 50.degree. C., and more preferably at least about 70.degree. C. It will accordingly be necessary to utilize a resin having at least about 70% by weight of vinyl chloride. More preferably, it is desirable to utilize about 80 to about 90% by weight of vinyl chloride. Amounts in excess of about 90% by weight may have inadequate solubility in conventional solvents.

Concerning the hydroxyalkyl acrylate and methacrylate or allyl alcohol constituent, an amount should be present in the resin that is sufficient to provide the requisite cross-linking upon reaction with the polyisocyanate employed and, when used, miscibility with the elastomer. It is preferred to utilize an amount which will provide at least about 0.5% by weight of hydroxyl groups to achieve this result. As an upper limit, since these constituents will typically have a Tg substantially less than that of vinyl chloride, it is accordingly desirable to utilize an amount which provides no more than about 2.5% by weight of hydroxyl groups, although amounts providing up to about 3% hydroxyl groups may be employed in some applications. In this connection, relative to the hydroxyalkyl acrylates, somewhat higher amounts of the hydroxyalkyl methacrylates may be employed since the Tg of such monomers will generally be somewhat higher.

Among the hydroxyalkyl acrylates and methacrylates, it is preferred to utilize from the economic standpoint either hydroxypropyl acrylate or hydroxyethyl acrylate. While less advantageous from the economic standpoint, other species that may desirably be utilized include hydroxyethyl methacrylate and hydroxypropyl methacrylate and allyl alcohol. The methacrylates have the advantage from the performance standpoint of having a higher Tg than that of the acrylates.

As regards the component imparting the requisite dispersibility, whether phosphorylation is involved or whether dispersibility is provided with a monomer yielding or having a carboxyl group, an amount should be used as a minimum which will impart the requisite dispersibility. Where a monomer having a carboxyl functionality is used, this will generally require at least 0.2% by weight of the carboxyl groups, preferably at least about 0.5%. Where the acid functionality is obtained by phosphorylation, the resin should contain at least about 0.03% by weight phosphorus.

It has been found that an excess acid functionality can lead to undesirable rheological effects. Such effects are apparent due to undesirably high viscosities which result. Accordingly, it is generally preferred to avoid amounts in excess of about 1.5% by weight, more preferably about 1.0% by weight of carboxyl groups. When the acid functionality is provided by phosphorylation, it is preferred to avoid amounts that result in greater than about 1.0% by weight of phosphorus in the resin. More preferably, the phosphorus content is maintained in the range of 0.03 to about 0.5% by weight.

Among the organic carboxylic acids which are useful are acrylic, methacrylic, maleic , itaconic, fumaric, and the like. Of course, anhydrides such as maleic anhydride can likewise be employed in the synthesis of the resins.

With respect to the constituent imparting thermal stability, a compound providing a source of oxirane oxygen is utilized. Epoxy-containing vinyl monomers such as acrylic or methacrylic esters may thus be employed. More specifically, glycidyl acrylates and methacrylates are useful, as is 4-vinyl cyclohexene monoepoxide (sometimes referred to as "vinylcyclohexene monoxide"). Other species that should be capable of being employed include methyl glycidyl methacrylate, methyl glycidyl acrylate, allyl glycidyl ether, the allyl glycidyl ether of bisphenol-A, allyl phenol glycidyl ether, glycidyl butadiene, and the like.

The amount of the epoxy-containing vinyl monomer should be that which provides the resin with the desired heat stability. Relatively higher molecular weight resins tend to be relatively more stable than lower molecular weight vinyl chloride copolymers. Accordingly, the amount utilized will be determined, in part, by the molecular weight of the resin being prepared. Typically, an amount that provides from about 0.1 to 1.5 percent oxirane oxygen should be useful. This will correspond, for example, to about 1 to about 12 percent by weight of glycidyl methacrylate.

One major consideration in the amount utilized is the Tg of the resin itself since most useful constituents will reduce the Tg of the resin. Further, when phosphorylation is utilized to provide the acid functionality, it is necessary to incorporate an adequate amount of the oxirane oxygen source to not only provide the requisite thermal stability but also to afford adequate functionality to incorporate the desired amount of phosphate.

Optionally, and if desired, a vinyl ester such as vinyl acetate may be employed. Other useful vinyl esters include vinyl formate, vinyl propionate, vinyl butyrate and the like. Other higher vinyl esters up to about 6 carbon atoms also may be used, if desired. Typically, such vinyl esters are employed in preparing vinyl chloride copolymers and terpolymers so as to allow what is considered to be improved processing latitude. Suitable amounts can vary up to about 12% by weight of the resin.

Conventional solution polymerization techniques may be desirably utilized, as will be discussed hereinafter, to form the binder resins of this invention. Similarly, other polymerization techniques such as conventional suspension or emulsion polymerization may also be used. Thus, the process employed for making the resins of this invention is not critical, and such technology is well understood by those in the art. Suitable preparative techniques are, for example, set forth in U.S. Pat. No. 3,755,271.

In general, and as an illustrative example, the resins of this invention may be prepared by utilizing solution polymerization, employing a solvent for the resulting resin as well as for the various components employed. Suitable solvents include, for example, the conventional ester solvents such as butyl acetate, ethyl acetate, isopropyl acetate, and the like, as well as the ketone solvents such as methylethylketone, methyl-n-butylketone, methylisopropylketone, and the like.

The polymerization may be carried out either batch-wise or continuously. Typically, the ratio of solvent/monomer will vary from about 0.3/1 to about 4/1, depending upon the molecular weight desired. The temperature selected may vary from about 35.degree. C. to about 80.degree. C., depending upon the reaction rate and resin molecular weight desired. Any oil-soluble, free radical catalyst may be used in an amount varying from about 0.01 to about 3.0%, based on the weight of the monomer. Suitable catalysts include, as illustrative examples, dibenzoyl peroxide, dilauroyl peroxide, azobisbutyronitrile and isopropyl peroxide carbonate. Any pressure above the vapor pressure of the components of the system may be employed, pressures from about 30 to 100 psi being typical.

In accordance with one aspect of this invention, when the requisite acid functionality is provided by employing an organic carboxylic acid monomer, the resins of the present invention may be prepared in a direct, one-step polymerization. Surprisingly, it has been found that the resin preparation may be carried out without any significant by-product reactions taking place, such as might be expected to occur between the organic carboxylic acid and the epoxy monomer used. Indeed, these resins may be prepared using the equipment and reaction parameters employed in making commercially available vinyl chloride-vinyl acetate copolymers and the like.

When the acid functionality is provided through phosphorylation, the resins of the present invention will typically be prepared in a two-step polymerization. The first step involves forming an intermediate from all of the monomer components other than the phosphorylating agent. This can be prepared using the techniques and parameters described in the direct polymerization, one-step process.

Thereafter, the phosphorylation reaction may be carried out by dissolving the intermediate in an aprotic solvent such as, for example, methylethylketone, tetrahydrofuran or cyclohexanone, to which the desired phosphorylating agent is added with stirring. The reaction may proceed at room temperature or, if desired, elevated temperatures, again with stirring, until the reaction is complete.

The temperature at which the phosphorylating reaction is carried out is not critical but is dependent on the phosphorylating agent employed. In general, however, it is desirable that the phosphorylation reaction be carried out at elevated temperatures to provide adequate reaction of the oxirane groups with the phosphorylating agent and insure complete reaction, suitable temperatures being from about ambient to about 60.degree. C. While the resins of the present invention are characterized by superior thermal stability, it will be generally preferable to keep the temperature as low as possible, consistent with the conditions needed to insure adequate reaction. Since heat may be generated, such as when high speed agitation equipment is used, it may be desirable to utilize cooling means to minimize the temperature rise. Minimizing the thermal history during resin preparation should translate to enhanced thermal stability of the resin during use.

In carrying out the phosphorylation, the reaction should utilize a phosphorylating agent and conditions that will avoid forming significant amounts of higher molecular weight species, as would result when two intermediate molecules are linked together through the phosphate moiety. The presence of such high molecular weight species can result in systems having undesirably high viscosities. This is obviously of greater significance when the intermediate starting material is already of a relatively high molecular weight.

Suitable phosphorylation agents include phosphoryl chloride and its derivatives: PO(OR.sup.2).sub.n' Cl.sub.3-n', wherein n' is 0, 1, 2, or 3 and R.sup.2 is hydrogen, a saturated or unsaturated hydrocarbon radical having from 1 to about 20 carbon atoms, a cycloalkyl radical of from 1 to about 20 carbon atoms, an alkyl acrylate or methacrylate in which the alkyl radical is from 1 to about 10 carbon atoms, aryl and substituted aryl of from 6 to about 20 carbon atoms and adducts of hydroxyalkyl acrylates and methacrylates and a lactone, and mixtures thereof, or phosphorus pentoxide or the reaction production of phosphorus pentoxide with a hydroxylcontaining material, including water, saturated or unsaturated alcohols having from 1 to 20 carbon atoms, hydroxyalkyl acrylates or methacrylates having from 2 to 10 carbon atoms, substituted and unsubstituted phenols and adducts of hydroxyalkyl acrylates and methacrylates and a lactone, and mixtures thereof. Suitable adducts of hydroxyalkyl acrylates and methacrylates and a lactone are described in the copending Colon et al. application, Ser. No. 636,895, now abandoned the disclosure of which is herein incorporated by reference.

The phosphorylation reaction may be carried out in any of a variety of aprotic solvents. Suitable examples include methylethylketone, tetrahydrofuran and cyclohexanone. The amount of the intermediate starting material added to the aprotic solvent may be varied within a wide range, provided the material is soluble in the solvent and the viscosity of the solution is not so high as to prevent stirring. In general, a level of about 25 weight percent has been satisfactorily employed. The relative amounts of the phosphorylating agent and the intermediate may be selected to provide the desired level of phosphorylation.

Inclusion of small amounts of water in the reaction mixture should prevent the formation of the undesirable high molecular weight species. Often, the intermediate will contain a small amount of water that is sufficient to prevent the formation. However, if the water level is unduly high, this will result in an inefficient utilization of the phosphorylating agent. As an alternative, the intermediate may be dried; and the level of water optimized to maximize the utilization of the phosphorylating agent while still preventing the formation of significant amounts of the high molecular weight species.

The level or degree of phosphorylation suitable to provide the desired characteristics will be generally such that, based on the weight of the phosphorylated intermediate, the phosphorus content of the material may be as low as about 0.03% by weight, more desirably at least about 0.1%. However, levels above about 1.0% by weight should be avoided so as to prevent undesirable resin rheology and the like which will adversely affect the desired characteristics.

It has been found that the efficiency of the phosphorylating reaction is improved relative to that which can be obtained by reaction with the hydroxyl groups in a vinyl chloride-vinyl acetate-vinyl alcohol terpolymer or the like. More specifically, in contrast to the 10 to 20 percent efficiency obtained when utilizing hydroxy groups, the present invention is capable of achieving efficiency on the order of about 40 to about 50 percent. This is achieved due to the epoxy functionality involved in the phosphorylation. Indeed, this reaction is sufficiently more facile so that essentially no reaction occurs with the hydroxyl groups present in the resins of this invention.

Alternatively, if desired, certain other preparative techniques may be feasible. For example, to avoid a second step in the reaction, an adduct may be formed by reaction of the desired phosphorylating reagent with the oxirane oxygen source, e.g. glycidyl methacrylate. This adduct may then be utilized in forming the resins of this invention in a direct polymerization.

Also, the intermediate resin reaction product in the solvent used may be directly reacted with the desired phosphorylating agent without first recovering the intermediate. After completion of the phosphorylating reaction, the resulting resin can then be recovered by conventional techniques.

It can be seen from the description of the phosphorylating agents described above that phosphorus may be included in the phosphorylated vinyl resins of the present invention in the form of a wide variety of phosphorus ester moieties, characterized by the formula: ##STR2## wherein R.sup.6 comprises hydrogen, an alkyl or alkenyl radical having from 1 to 20 carbon atoms, an alkyl acrylate or methacrylate residue having from 2 to 10 carbon atoms in the alkyl segment, substituted and unsubstituted phenyl, the lactone-adducts referred to herein, or mixtures thereof.

The formula for the phosphorus moieties represents an idealized formula. Depending upon the reaction conditions and the particular phosphorylating agent employed, the resulting reaction product comprises a distribution of mono-, di- and tri-phosphate esters. Accordingly, in the idealized formula, R.sup.6 may be solely hydrogen (providing a phosphate monoester), a mixture of hydrogen and the hydrocarbon residue of the hydrocarbon from which the derivative was prepared (providing a diester), or solely the hydrocarbon residue (providing a triester). For the purpose of the present invention, the phosphorus moiety will be described in terms of the formula set forth, wherein the formula is used to represent the reaction product, including those situations wherein a complex mixture or distribution of compositions is obtained.

Base

Any base or substrate may be utilized, and the particular substrate of choice will be dictated for the most part by the particular application. Polyethylene terephthalate and polypropylene films are in wide use as base materials for magnetic recording media. Where heat resistance is an important consideration, a polyimide film, polyamide film, polyarylether film, or the like may be utilized. In the case of a polyester film as a thin base, it is often used after monoaxial or biaxial orientation. It is likewise well known that pretreatment of the film may be beneficial to promote wetting and adhesion.

The magnetic particles may be any of those known and useful in conventional magnetic recording media. Representative examples include acicular or granular .gamma.Fe.sub.2 O.sub.3, Fe.sub.3 O.sub.4, Co-doped .gamma.-Fe.sub.2 O.sub.3, Co-doped .gamma.Fe.sub.2 O.sub.3 -Fe.sub.3 O.sub.4 solid solution, Co-base-compoundadsorbed adsorbed .gamma.Fe.sub.2 O.sub.3, a Co-base-compound-adsorbed Fe.sub.3 O.sub.4 (including those oxidized to an intermediate state between itself and .gamma.-Fe.sub.2 O.sub.3), and acicular CrO.sub.2. (The term "Co-base compound" as used herein means cobalt oxide, cobalt hydroxide, cobalt ferrite, cobalt ionadsorbates and the like which enable the magnetic particles to take advantage of the magnetic anisotropy of cobalt in improving its coercive force). Also, the magnetic particles may be a ferromagnetic metal element or alloy, such as Co, Fe--Co, Fe--Co--Ni, or the like. Such a fine magnetic particle is prepared in a number of ways, including wet reduction of the starting material with a reducing agent such as NaBH.sub.4, a treatment of the iron oxide surface with a Si compound and subsequent dry reduction with H.sub.2 gas or the like, and vacuum evaporation in a low-pressure argon gas stream. Fine particles of monocrystalline barium ferrite may be employed as well. The fine magnetic powder is used in the form of acicular or granular particles, depending on the application of the resulting magnetic recording medium.

It will be generally desirable to utilize a relatively large amount of magnetic particles in the coating layer. Typical compositions of the coating layer will thus include about 65 or 70 to about 85 or 90 percent magnetic particles, based upon the total weight of the coating layer. As is known, it is desirable to utilize pigment particles of relatively uniform size, with typically used particles having a long axis of about 0.4 micron or even less being employed.

The remainder of the coating layer will comprise the binder system, including the hardening resin, and typically an elastomeric polymer, a dispersant, a crosslinker and any auxiliary agents. Depending upon the resin of the present invention which is utilized, the dispersant as such may be minimized or even eliminated.

Conceptually, however, in addition to the pigment particles, the only additional essential component in accordance with this invention is the hardening resin itself and the crosslinker. Typical coating layers will, however, often include the additional components identified depending upon the particular end use application. As is apparent from the amount utilized in typical formulations of the pigment particles, the remainder of the coating layer will generally represent about 10 or 15 to 30 or 35 percent by weight of the coating layer.

As has been previously discussed, the binder system will generally desirably include an elastomeric polymer in an amount sufficient to provide the coating layer with the desired resilience and the like. Many elastomeric polymers suitable for this purpose are known and may be utilized. Polyester urethanes are often preferred for high performance applications. Suitable materials are commercially available. These materials may be, in general, described as the reaction products of polyester polyols, short chain diols, and isocyanates. These resins have excellent toughness and abrasion resistance characteristics.

A wide variety of polyisocyanate crosslinkers are known and may be used. Typically, polymeric polyisocyanates are employed. As one example, it is suitable to use polymeric toluene diisocyanate (TDI) adducts. The amount of the crosslinking agent used is typically about 20 to 50 percent of the amount that would be required based upon the hydroxyl stoichiometry, although up to 100% of the stoichiometry may be employed, if desired.

As is known, a variety of auxiliary agents are sometimes employed in the magnetic coating layer. Such additives are known and may be employed, if desired for the particular application. Examples of such auxiliary agents include antistatic agents, lubricants, sensitizers, leveling agents, wearresisting agents, and film-reinforcing agents.

In accordance with the present invention, the magnetic coating layer utilizes the resins of the present invention to provide the necessary dispersing and orientation characteristics of the coating, and to function as the hardening resin as well. No other hardening resin need be employed; however, if desired, the resins of the present invention can be utilized with compatible hardening resins to provide the desired magnetic coating layer.

In accordance with this invention, the use of the resins of the present invention should provide improved dispersion and orientation characteristics. However, if desired, other conventional dispersing agents may be employed.

The recording medium may generally be prepared by dissolving the binder system in a sufficiently volatile vehicle to provide a coatable dispersion of fine magnetizable particles. The dispersion can then be coated onto the substrate to provide a coating thereon. The magnetic recording medium may be prepared by methods described in the art such as in, for example, S. Tochihara, "Magnetic Coatings and Their Applications in Japan", Progress in Organic Coatings, 10 (1982), pages 195 to 204.

Other Applications

While use of the resins of the present invention provides highly advantageous properties in magnetic recording media and the present invention has been described in conjunction with this application, it should be appreciated that such materials likewise can be utilized as dispersants and/or hardening resins in any other application where the characteristics of such resins could desirably be incorporated. For example, conventional zinc-rich coatings are useful in many applications which require corrosion resistance and the like. Such compositions typically comprise a high percentage of zinc particles (up to 85 to 90 percent by weight of the composition) and a resin together with such optional components as anti-settling agents, thickening agents and water scavengers, as is known For zinc-rich maintenance coatings, and other clear and pigmented coatings, any of the resins of the present invention should provide improved dispersibility and thus improved adhesion to substrates. The resins of this invention can accordingly be readily utilized in conjunction with such coatings.

The following Examples are representative of the present invention, and not in limitation thereof. The starting materials used, abbreviations employed, control resins evaluated, polymerization method used, the preparation of the magnetic media formulations, and the evaluation techniques utilized in the ensuing Examples were as follows:

Elastomer A

B.F. Goodrich "Estane.RTM. 5701 F-1" polyester polyurethane elastomer having a specific gravity of 1.21, a Tg of -25.degree. C. and a Brookfield viscosity of 300 cps. for a 15% total solids solution in tetrahydrofuran.

Resin A

A commercially available vinyl chloride-vinyl acetate-vinyl alcohol terpolymer having a composition of 90/4/6, respectively, and an intrinsic viscosity of 0.53.

Resin B

A commercially available vinyl chloride copolymer containing vinyl acetate, vinyl alcohol and maleic acid and having a composition of 90/4/5/1, respectively, and an intrinsic viscosity of 0.50.

The following abbreviations are used in the following Examples:

VCl--vinyl chloride

VAc--vinyl acetate

GMA--glycidyl methacrylate

HPA--hydroxypropyl acrylate

AA--acrylic acid

SR--squareness ratio

SFD--switching field distribution

Hc--coercivity

Vinyl Copolymer

The vinyl chloride copolymers were produced via continuous solution polymerization in a stainless steel stirred tank reactor. Vinyl chloride and the other monomers used, as well as the solvent, were pre-mixed and fed continuously to the reactor. The free radical initiator, diisopropyl/peroxydicarbonate, was also fed continuously as an acetone solution, at a rate necessary to maintain constant conversion. Product solution was continuously withdrawn from the reactor. The temperature in the reactor was maintained at 50.degree.-60.degree. C. while the pressure was kept between 90-110 psi.

The product solution was stripped of unreacted vinyl chloride monomer. The polymer was then recovered from solution by precipitation with an isopropanol/water mixture, filtered, and dried in a fluid bed drier.

A solution of the epoxy-containing vinyl chloride copolymer intermediate in an aprotic solvent was prepared. This solution was placed in a stirred reactor and, to this stirred solution, was added the appropriate amount of the phosphorylating agent (either P.sub.2 O.sub.5 or polyphosphoric acid). This reaction mixture was then reacted at an initial temperature between ambient and 60.degree. C. for a period of from several minutes to several hours, depending upon the stirring rate. Since, in most instances, high speed agitation equipment was used, the final reaction temperature was above the initial temperature. No cooling means were used.

Formulations were prepared by premixing 134 grams of a 15 percent cyclohexanone solution of the resin with 160 grams of cyclohexanone and adding 200 grams of cobalt-modified, iron oxide magnetic pigment with particles having a long axis of about 0.4 micron ("PFERRICO 2566" magnetic pigment, Pfizer, Inc.). After the mixture was well blended with an air stirrer for 15-30 minutes, the resulting slurry was added to a Premier Mill filled with l.3mm. glass beads and milled for about one hour.

Those formulations containing only the resins of the present invention were discharged at this point and evaluated. Where Elastomer A was added to the formulation, 134 grams of a 15% solution in cyclohexanone were used. The formulation was then milled for an additional hour and discharged.

Gloss

This was evaluated by preparing a 1 mil drawdown on glass, allowing the formulation to air dry and then measuring the gloss with a 60.degree. gloss meter.

Squareness

This was measured by preparing a 3 mil wet drawdown on a Mylar substrate and then pulling the Mylar across a bar magnet to orient the magnetic particles. Squareness was then measured on a 2X2 inch piece of this oriented coating using a LDJ Model 7000A B-H Meter. According to the pigment manufacturer, the maximum squareness achievable with the magnetic pigment utilized is 0.84.

Switching Field Distribution (SFD)

This was obtained using the sample employed in determining squareness and is a measure of the variation in particle coercivities. The lower the value, the more well defined is the recording zone. A value of less than 0.60 is considered desirable.

Coercivity (Hc)

Obtained using the squareness ratio sample, this measures the magnetizing field needed to reduce maximum magnetic induction to zero. A value of greater than 700 is considered desirable for the magnetic particle utilized.

Tensile Strength and Elongation

These values were obtained using ASTM-638 Type 5.

Viscosity

The values reported are Brookfield viscosities at 25.degree. C., using RF Spindle #4 at 20 r.p.m.

Intrinsic Viscosity

The values reported employed the procedure set forth in ASTM D-1243, using cyclohexanone as the solvent.

This Example illustrates the compatibility of a thermally stable vinyl resin containing hydroxyl functionality with Elastomer A.

A VCl/VAc/GMA resin having the composition 81/11/8 was prepared and was then hydrolyzed. The hydrolyzed resin was then phosphorylated using P.sub.2 O.sub.5 and a resin/P.sub.2 O.sub.5 ratio of 500/1. The resulting resin had a phosphorus content of 0.20%, an intrinsic viscosity of 0.32 and a Tg of 73.degree. C.

The Tg of resin/Elastomer blends of 60/40 and 75/25 were, respectively, 40.degree. C. and 53.degree. C. Since a single Tg was obtained for each blend and the value was between that of the resin and that of Elastomer A, the resin and Elastomer A were miscible and, accordingly, compatible. Accordingly, while not a resin of this invention, this Example illustrates that miscibility with elastomers can be obtained with vinyl chloride resins having hydroxyl functionality and that miscibility will vary with hydroxyl content.

These Examples show the phosphorylation of vinyl resins including a source of oxirane oxygen.

A VCl/VAc/GMA resin was prepared having the composition of 81/11/8. Resin samples were then phosphorylated in Examples 2-4 by mixing with the phosphorylating agent at ambient temperature and then left overnight. In Examples 5-7, the resins were phosphorylated by heating to reflux for 3 hours and were then cooled. Each sample was then coagulated using isopropanol/water (60/40), filtered, washed and dried (at about 43.degree. C. in vacuo) until a stable weight was obtained.

The relative amounts of the constituents and the percent phosphorus in the phosphorylated product are set forth in Table I:

These Examples show that both techniques produced essentially the same product, efficiently incorporating the phosphate moiety into the vinyl resin. While not resins of this invention since no hydroxyl functionality is present and the resins would not be miscible with standard elastomers used in magnetic recording media formulations, these Examples do illustrate the more facile nature of the phosphorylation reaction with the epoxy groups in comparison to that when hydroxyl functional resins are used. This can be seen from the level of phosphorus that is incorporated which is significantly greater than can be easily incorporated when employing hydroxyl functional resins.

These Examples show the magnetic properties of magnetic recording media made using the vinyl resins of this invention where the acid functionality is obtained using phosphorylation.

A resin was prepared using VCl/HPA/GMA/VAc to provide a composition, respectively, of 75/10/5.5/9.5. These samples had a Tg of 72.degree. C., a tensile strength of 5,400 and an elongation of 5.7% and an intrinsic viscosity of about 0.36.

The resin was phosphorylated in cyclohexanone, using a resin/P.sub.2 O.sub.5 ratio of 34/1 in Example 8 and 260/1 in Example 9 and an initial temperature of 25.degree. C. The reaction proceeded for 25 minutes in Example 8, reaching a final temperature of 50.degree. C. and proceeded for 20 minutes in Example 9, the ending temperature being 40.degree. C. The resulting resin was recovered, and a magnetic recording media composition prepared.

Table II sets forth the viscosity and magnetic properties:

Although the molecular weight of the resin is less than desirable, these Examples demonstrate that excellent magnetic properties can be obtained using the phosphorylated resins of the present invention. In addition, these vinyl chloride copolymers are miscible with elastomers commonly used in magnetic media formulations.

These Examples illustrate the magnetic properties of recording media made using the phosphorylated resins of this invention made with a resin having a higher intrinsic viscosity than that used in Examples 8 and 9.

Resins were prepared having the following compositions and physical properties:

These resins were phosphorylated by reaction with P.sub.2 O.sub.5 in cyclohexanone using resin/P.sub.2 O.sub.5 ratios of 260/1 (Example 10), 180/1 (Example 11) and 80/1 (Example 12). The initial temperature in Example 10 was 49.degree. C., the reaction proceeded for 23 minutes, and the final temperature was 85.degree. C. The respective reaction conditions for Example 11 were 50.degree. C., 25 minutes and 113.degree. C., while the respective conditions for Example 12 were 29.degree. C., 10 minutes and 70.degree. C.

Magnetic recording media were prepared using these resins, and the magnetic properties and viscosity are set forth below:

These Examples illustrate that excellent magnetic and physical properties can be obtained using the resins of this invention, which resins have molecular weights considered suitable for magnetic recording media formulations.

These Examples show the utilization of vinyl resins of the present invention, made using resins prepared in a direct polymerization, in magnetic recording media.

Resins were prepared having the following compositions and physical properties, Example 13 being a control:

No GMA was intentionally added in preparing the resin of Example 13. The minor amount noted by analysis is believed due to contamination.

Magnetic recording media were prepared using the resins, and the magnetic properties and viscosity are set forth below:

These Examples demonstrate that magnetic recording media having excellent magnetic and physical properties may be obtained using resins of the present invention made from a direct, one-step polymerization. While having acceptable magnetic and physical properties, the control resin (Example 13) has significantly less thermal stability as seen in Table VII.

These Examples illustrate the increased thermal stability of the resins of this invention.

Resin samples from prior Examples, together with comparative samples of commercially available vinyl chloride resins, were tested by placing a powder sample in a 5 cm. dish, 1 cm. deep, and then placing the samples in a circulating air oven for 60 minutes. A visual rating was obtained (1--white, 2--pink, 3--tan, 4--brown, 5--black). The higher the number, the more extensive was the degradation.

Table VII sets forth the results:

As can be seen, the resins of the present invention may be prepared with visually less thermal degradation than can prior vinyl chloride polymers. A comparison of Examples 18 and 19 with the control (from Ex. 13) illustrates that the thermal stability of the vinyl chloride copolymers of this invention is markedly superior to that obtained when direct polymerization is employed, but the resin does not include an adequate amount of an epoxy-containing vinyl monomer.