Photochemical modification of polymers
RELATED APPLICATION 
     This is a continuation-in-part of copending U.S. Pat. Application Ser. No. 183,276, filed Sept. 23, 1971, now abandoned. The benefit of 35 USC 120 is claimed. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to the preparation of novel polymeric materials by the chemical modification of polyolefins, olefin copolymers, and other polymeric materials with a structure containing saturated aliphatic carbon atoms. The resulting modified polymers are highly suitable for use in coating, adhesive, and packaging applications. 
     More particularly, this invention relates to the chemical combination of a polyolefin polymer or copolymer with one or more non-polymeric organic compounds having the generalized structure R-X, where R is a saturated linear, branched, or cyclic aliphatic hydrocarbon residue containing at least six carbon atoms, and X is a polar functional group which is a member of the series comprising the following groups: 
     Hydroxyl (--OH); 
     carboxyl (--COOH); 
     amide (--CONH 2 ); 
     mono- or disubstituted amide 
     (--CONHR 1  or --CONR 1  R 2 ), where the substituents R 1  and R 2  are the same or different lower alkyls containing one to four carbons; 
     Amino (-NH 2 ); 
     mono- or disubstituted amino 
     (--NHR 1  or --NR 1  R 2 ), where the substituents R 1  and R 2  are the same or different lower alkyls containing one to four carbons; ##STR1## where the substituents R 1 , R 2 , and R 3  are lower alkyls containing one to four carbon atoms; 
     Sulfonic acid (--SO 3  H); 
     hydrogen sulfate (--OSO 3  H); 
     and 
     Dihydrogen phosphate (--OPO 3  H 2 ). 
     The group X may also bear one or more units of positive or negative charge, as in the case of the following groups: 
     Carboxylate (--COO.sup.⊖); 
     sulfonate (--SO 3 .sup.⊖); 
     singly charged sulfate (--OSO 3 .sup.⊖); 
     singly or doubly charged phosphate (--OPO 3  H.sup.⊖ or --OPO 3 .sup.⊖); 
     ammonium (--N.sup.⊕ R 1  R 2  R 3 ); where the substituents R 1 , R 2  and R 3  are hydrogens or lower alkyls containing one to six carbons; 
     Sulfonium (--S.sup.⊕ R 1  R 2 ), where the substituents R 1  and R 2  are the same or different lower alkyls containing one to six carbons; 
     And 
     Phosphonium (--P.sup.⊕ R 1  R 2  R 3 ), where the substituents R 1 , R 2  and R 3  are the same or different lower alkyls containing one to six carbon atoms. 
     In the case of such charged groups, it should be understood that an ion of opposite charge is simultaneously present, such as a sodium ion in the case of a carboxylate or sulfonate group, and a halide ion in the case of an ammonium, sulfonium, or phosphonium group. 
     It is further contemplated that the co-reactant R-X may contain heterocyclic rings as a part of the structure of R, in addition to the essential aliphatic hydrocarbon group or groups. Furthermore, it should be understood that more than one group of type R, and/or more than one group of type X, may be present per molecule of co-reactant R--X. 
     Many compounds of the type R--X as described hereinbefore, particularly those having a single group of type R and a single group of type X, are referred to as `surfactants` owing to their surface-active properties. 
     This invention consists of effecting the chemical combination of the polymeric polyolefin reactant and the non-polymeric co-reactant (R--X), preferably in the presence of one or more sensitizing additives, to ultraviolet or visible radiation of appropriate wavelength. 
     The term `sensitizer` is applied to reagents which are capable of absorbing ultraviolet and/or visible radiation and, following such photochemical excitation, of initiating or accelerating chemical reactions which lead to chemical combination of the polymer and co-reactant. Preferred additives are those which are known to initiate free-radical reactions, such as photopolymerization and photooxidation. 
     While the mechanism of the photosensitized chemical modification process is not presently understood in detail, it is believed that the excited state of the photosensitizer undergoes subsequent processes (such as unimolecular decomposition, hydrogen abstraction, or energy transfer) which lead directly or indirectly to the formation of free-radical intermediates. Free radicals derived from the polymer combine with other free radicals derived from the co-reactant, so that polar groups (X) derived from the co-reactant became chemically bonded to the polymer molecules. 
     The formation of crosslinked polymers by processes involving the formation and interaction of free-radical intermediates is known in the prior art. In such processes, a crosslink between polymer chains is formed as a result of the combination of polymeric radicals. Typically, this is accomplished by heating a mixture of a polymer and an organic peroxide to a temperature at which the peroxide decomposes to free radicals. 
     The formation of graft copolymers by free-radical processes is also known in the prior art. In such processes, a polymeric radical is formed, and undergoes an addition reaction with the reactive carbon-carbon double bond of a vinyl monomer, such as styrene or methyl methacrylate; the resulting radical then adds further units of vinyl monomer by successive radical addition reactions. Typically, such a graft copolymerization is accomplished by heating a mixture of a polymer, a vinyl monomer, and an organic peroxide to a temperature at which the peroxide decomposes to yield free radicals. 
     Likewise, the preparation of physical blends of polymers with certain types of non-polymeric additives of the type R--X is known in the prior art. Typically, such additives are employed so as to confer antistatic properties or to aid in the dispersion of particulate materials in polymers or polymer solutions. 
     The use of sensitizing additives which facilitate the initiation of certain types of free-radical reactions is also known in the prior art. For example, irradiation of a mixture of a vinyl monomer and a sensitizing additive is known to lead to photopolymerization. 
    
    
     In one preferred embodiment of this invention, a mixture of a thermoplastic olefin polymer or copolymer, a saturated fatty acid co-reactant, and a sensitizing additive is exposed to an artificial source of ultraviolet and/or visible radiation. 
     In the case of such preferred embodiment, examples of the polymeric reactant, fatty acid, and sensitizer are given hereinafter. 
     Examples of polymeric reactants include: 
     polyethylene; 
     polypropylene; 
     poly(1-butene); 
     poly(4-methyl-1-pentene); 
     ethylene-propylene copolymers; 
     ethylene-1-butene copolymers; 
     ethylene-1-hexene copolymers; 
     ethylene-vinyl acetate copolymers; 
     ethylene-ethyl acrylate copolymers; 
     ethylene-acrylic acid copolymers. 
     and 
     Examples of fatty acids include: 
     capric acid; 
     lauric acid; 
     stearic acid; 
     palmitic acid; 
     myristic acid; 
     Examples of suitable sensitizing additives include the following: 
     Ketones 
     Acetophenone 
     Acetoin 
     1-Acetonaphthone 
     2-Acetonaphthone 
     Anisoin 
     Anthrone 
     Bianthrone 
     Benzil 
     Benzoin 
     Benzoin Methyl Ether 
     Benzoin Isopropyl Ether 
     1-Decalone 
     2-Decalone 
     Benzophenone 
     p-Chlorobenzophenone 
     Dibenzalacetone 
     Benzoylacetone 
     Benzylacetone 
     Deoxybenzoin 
     2,4-Dimethylbenzophenone 
     2,5-Dimethylbenzophenone 
     3,4-Dimethylbenzophenone 
     4-Benzoylbiphenyl 
     Butyrophenone 
     9Fluorenone 
     4,4-Bis-(dimethylamino)-benzophenone 
     4-Dimethylaminobenzophenone 
     Dibenzyl Ketone 
     4-Methylbenzophenone 
     Propiophenone 
     Benzanthrone 
     1-Tetralone 
     2-Tetralone 
     Valerophenone 
     4-Nitrobenzophenone 
     Di-n-hexyl Ketone 
     Isophorone 
     Xanthone 
     Azo Compounds 
     2-Azo-bis-isobutyronitrile 
     2-Azo-bis-propionitrile 
     Dimethyl-2-azo-bis-isobutyrate 
     1-Azo-bis-1-cyclohexanecarbonitrile 
     2-Azo-bis-2-methylheptanitrile 
     2-Azo-bis-2-methylbutyronitrile 
     4-Azo-bis-4-cyanopentanoic Acid 
     Azodicarbonamide 
     Azobenzene 
     `Azo Dyes` 
     Hydroperoxides 
     tert-Butyl Hydroperoxide 
     Cumene Hydroperoxide 
     Diisopropylbenzene Hydroperoxide 
     2,5Dimethylhexane-2,5-dihydroperoxide 
     p-Menthane Hydroperoxide 
     1,1,3,3-Tetramethylbutyl Hydroperoxide 
     Peroxides 
     Acetyl Peroxide 
     Benzoyl Peroxide 
     p-Chlorobenzoyl Peroxide 
     2,4Dichlorobenzoyl Peroxide 
     Ditoluoyl Peroxide 
     Decanoyl Peroxide 
     Lauroyl Peroxide 
     Isobutyryl Peroxide 
     Diisononanoyl Peroxide 
     Pelargonyl Peroxide 
     tert-Butyl Peroxyacetate 
     tert-Butyl Peroxymaleic Acid 
     tert-Butyl Peroxyisobutyrate 
     tert-Butyl Peroxypivalate 
     tert-Butyl Peroxybenzoate 
     tert-Butyl Peroxycrotonate 
     tert-Butyl Peroxy-(2ethylhexanoate) 
     2,5-Dimethyl-2,5-bis-(2-ethylhexanoylperoxy)hexane 
     2,5-Dimethyl-2,5-bis-(benzoylperoxy)hexane 
     2,5-Dimethyl-2,5-bis-(tert-butylperoxy)hexane 
     2,5-Dimethyl-2,5-bis-(tert-butylperoxy)-hexane-3 
     Di-tert-butyl Diperoxyphthalate 
     1,1,3,3Tetramethylbutylperoxy-2ethyl-hexanoate 
     Di-tert-butyl Peroxide 
     Di-tert-amyl Peroxide 
     tert-Amyl-tert-butyl Peroxide 
     1,1-tert-butylperoxy-3,3,5-trimethyl Cyclohexane 
     Bis-(tert-butylperoxy)-diisopropylbenzene 
     n-Butyl-4,4bis-(tert-butylperoxy)valerate 
     Dicumyl Peroxide 
     Acetyl Acetone Peroxide 
     Methyl Ethyl ketone Peroxide 
     Cyclohexanone Peroxide 
     tert-Butylperoxy Isopropyl Carbonate 
     2,2Bis-(tert-butylperoxy)butane 
     Di-(2-ethylhexyl)peroxydicarbonate 
     Bis-(4tert-butylcyclohexyl)peroxydicarbonate 
     Quinones 
     Anthraquinone 
     1-Aminoanthraquinone 
     2-Aminoanthraquinone 
     1-Chloroanthraquinone 
     2-Chloroanthraquinone 
     1Methylanthraquinone 
     2-Methylanthraquinone 
     1-Nitroanthraquinone 
     2-Phenylanthraquinone 
     1,2-Naphthoquinone 
     1,4-Naphthoquinone 
     2-Methyl-1,4-Naphthoquinone 
     1,2-Benzanthraquinone 
     2,3-Benzanthraquinone 
     Phenanthrenequinone 
     `Anthraquinone Dyes` 
     Organic Sulfur Compounds 
     Diphenyl Disulfide 
     Dibenzyl Disulfide 
     Dibenzoyl Disulfide 
     Dilauroyl Disulfide 
     1-Naphthalenethiol 
     Diisopropylbenzene Thiol 
     2-Mercaptobenzothiazole 
     2-Mercaptobenzimidazole 
     Tetramethylthiuram Monosulfide 
     Tetramethylthiuram Disulfide 
     Ethyl-2-benzothiazylsulfonate 
     p-Toluenesulfonyl Chloride 
     Organic Halogen Compounds 
     Chlorinated Paraffins 
     Chlorinated Biphenyls and Polyphenyls 
     Chlorinated Toluenes, Xylenes, etc. 
     Benzyl Chloride 
     3,4-Dimethylbenzyl Chloride 
     Benzyhydryl chloride 
     Benzal Chloride 
     Benzotrichloride 
     Chlorinated Naphthalenes 
     1-Chloromethylnaphthalene 
     Tetrachlorotetrahydronaphthalene 
     Phenacyl Chloride 
     Phenacyl Bromide 
     Styrene Dibromide 
     Metallo-organic Reagents 
     Cobalt 2ethylhexanoate 
     Cobalt naphthenate 
     Cobalt tallate 
     Copper naphthenate Copper phthalocyanine 
     Copper acetylacetonate 
     Ferric acetylacetonate 
     Ferrous acetylacetonate 
     Ferrous stearate 
     Iron neodecanoate 
     Iron tallate 
     Manganese naphthenate 
     Manganese tallate 
     In the aforementioned specific embodiment, the saturated fatty acid may be replaced by another suitable co-reactant of the general type R--X. Suitable co-reactants would include alcohols such as lauryl alcohol, stearyl alcohol, cetyl alcohol, and amines such as lauryl dimethyl amine, stearyl dimethyl amine, and stearyl amine; and amine oxides such as lauryl dimethyl amine oxide, stearyl dimethyl amine oxide, and cetyl dimethyl amine oxide; fatty acid amides such as lauric acid diethanolamide, stearic acid diethanolamide, lauric acid N, N-dimethyl amide, and stearic acid N, N-dimethyl amide; and dicarboxylic acids and salts such as sebacic acid, azelaic acid, and sodium sebacate. 
     In the aforementioned specific embodiment, the saturated fatty acid may be replaced by a nonionic, anionic, or cationic surfactant. 
     Examples of nonionic surfactants include: 
     mono and di glycerides, e.g. monostearin, distearin, 
     and 
     polyethylene glycol and derivatives, including saturated fatty acid esters (mono and di). 
     Examples of cationic surfactants include: 
     lauryl trimethyl ammonium chloride; 
     lauryl pyridinium chloride; 
     cetyl trimethyl ammonium bromide; 
     cetyl pyridinium bromide; 
     cetyl pyridinium chloride; 
     cetyl dimethyl benzyl ammonium chloride; 
     stearyl dimethyl benzyl ammonium chloride; 
     and 
     dilauryldimethyl ammonium bromide. 
     Examples of anionic surfactants include: 
     sodium laurate; 
     sodium stearate; 
     sodium lauryl sulfate; 
     sodium dioctyl sulfosuccinate; 
     sodium dinonyl sulfosuccinate; 
     and 
     lauryl acid phosphate. 
     An important feature of many photosensitized processes, including those described here, is that no chemical changes take place in the absence of light. Thus a mixture of a thermoplastic polymer, co-reactant, and sensitizer has substantially the same thermal stability as the polymer alone. Consequently, it is highly convenient to prepare such a mixture, to shape it by one or more methods known to the plastics and coating art, (such as extrusion, molding, calendaring, casting, etc.) and subsequently to conduct the reaction in situ by exposure of the resulting shaped article or coating to a source of ultraviolet or visible radiation. 
     In one highly preferred embodiment, a coating composition containing an olefin polymer or copolymer, a suitable co-reactant, and a sensitizer, optionally containing at least one volatile solvent, is applied to the surface of a glass container, allowed to dry, and subsequently `cured` in situ by ultraviolet or visible radiation to afford an adherent coating which protects the glass substrate from damage. 
     In either or both of the preceding embodiments, a mixture of two or more co-reactants of type R--X, or of two or more sensitizing additives, may be employed. 
     In the practice of this invention it is contemplated that the reactive composition will ordinarily contain about 70-98% by weight of the polymer or copolymer, 1-20% of the co-reactant, and 1-10% of the sensitizing additive(s). In certain cases, the presence of sensitizing groups in the polymer or co-reactant, or the use of radiation of specific wavelengths, will make it possible to omit the sensitizing additives entirely. 
     Additional materials, such as fillers, pigments, dyes, plasticizers, foaming agents, reinforcing agents, etc., may also be present during the reaction, or may be added subsequently. It should be understood that such additives are not to be considered in calculating the percentages of polymer, co-reactant, and sensitizer, as specified above. 
     In comparison to the starting polymers, the modified polymers prepared in accordance with this invention have a number of useful properties. Such properties include increased susceptibility to environmental deterioration; increased susceptibility to microbiological attack (`biodegradability`); improved adhesion to surfaces such as metal, glass and wood; improved receptivity to dyes, inks, and coatings; improved wetting of fillers, reinforcing agents, and pigments; anti-static properties; improved emulsifiability; and improved solubility in certain solvents. 
     Such properties suggest a wide variety of practical applications, in such areas as coatings, adhesives, packaging films, inks, plastic cups and bottles, etc.