Linking Reactions

Fig. 25. Cross-linking reactions in a three-component resist system. Both O-alkylation and C-alkylation are shown.

Two other important commercial uses of initiators are in polymer cross-linking and polymer degradation. In a cross-linking reaction, atom abstraction, usually a hydrogen abstraction, occurs, followed by termination by coupling of two polymer radicals to form a covalent cross-link ... 

Polymerization. Thermal polymerization or curing of an ink film at elevated temperatures can foUow many different chemical paths. Condensation and cross-linking reactions may be accompHshed with or without the use of catalysts. However, this method of drying generally has not been widely used for printing inks, except those used for metal and glass decoration, and some clear coatings. 

The thermal stability of polymers of types (1) and (2) is also dependent on the nature of the substituents on phosphoms. Polymers with methoxy and ethoxy substituents undergo skeletal changes and degradation above about 100°C, but aryloxy and fluoroalkoxy substituents provide higher thermal stability (4). Most of the P—N- and P—O-substituted polymers either depolymerize via ring-chain equilibration or undergo cross-linking reactions at temperatures much above 150—175°C. 

Substituted nonheat-reactive resins do not form a film and are not reactive by themselves, but are exceUent modifier resins for oleoresinous varnishes and alkyds. Thein high glass-transition temperature and molecular weight provide initial hardness and reduce tack oxygen-initiated cross-linking reactions take place with the unsaturated oils. 

The temperature of esterification has a significant influence on isomerization rate, which does not proceed above 50% at reaction temperatures below 150°C. In resins produced rapidly by using propylene oxide and mixed phthaUc and maleic anhydrides at 150°C, the polyester polymers, which can be formed almost exclusively in the maleate conformation, show low cross-linking reaction rates with styrene. 

Isomerization is faciUtated by esterification at temperatures above 200°C or by using catalysts, such as piperidine and morpholine (6), that are effective in raising isomerization of fumarate to 95% completion. Resins made by using fumaric acid are exclusively fumarate polymers, demonstrate higher reactivity rates with styrene, and lead to a complete cross-linking reaction. 

The free radicals initially formed are neutralized by the quinone stabilizers, temporarily delaying the cross-linking reaction between the styrene and the fumarate sites in the polyester polymer. This temporary induction period between catalysis and the change to a semisoHd gelatinous mass is referred to as gelation time and can be controUed precisely between 1—60 min by varying stabilizer and catalyst levels. 

The cross-linking reaction mechanism is also influenced by the presence of other monomers. Methyl methacrylate is often used to improve the uv resistance of styrene-based resins. However, the disparate reaction rates of styrene and methacrylate monomer with the fumarate unsaturation not only preclude the use of more than 8% of the methacrylate monomer due to the significant slowing of the cross-linking reaction but also result in undercured products. 

Methacrylate monomers are most effective with derivatives of bisphenol A epoxy dimethacrylates, in which the methacrylate—methacrylate cross-linking reaction proceeds at a much faster pace than with styrene monomer. This proves beneficial in some fabrication processes requiring faster cure, such as pultmsion and resin-transfer mol ding (RTM). 

Catalyst Selection. The low resin viscosity and ambient temperature cure systems developed from peroxides have faciUtated the expansion of polyester resins on a commercial scale, using relatively simple fabrication techniques in open molds at ambient temperatures. The dominant catalyst systems used for ambient fabrication processes are based on metal (redox) promoters used in combination with hydroperoxides and peroxides commonly found in commercial MEKP and related perketones (13). Promoters such as styrene-soluble cobalt octoate undergo controlled reduction—oxidation (redox) reactions with MEKP that generate peroxy free radicals to initiate a controlled cross-linking reaction. 

Some fabrication processes, such as continuous panel processes, are mn at elevated temperatures to improve productivity. Dual-catalyst systems are commonly used to initiate a controlled rapid gel and then a fast cure to complete the cross-linking reaction. Cumene hydroperoxide initiated at 50°C with benzyl trimethyl ammonium hydroxide and copper naphthenate in combination with tert-huty octoate are preferred for panel products. Other heat-initiated catalysts, such as lauroyl peroxide and tert-huty perbenzoate, are optional systems. Eor higher temperature mol ding processes such as pultmsion or matched metal die mol ding at temperatures of 150°C, dual-catalyst systems are usually employed based on /-butyl perbenzoate and 2,5-dimethyl-2,5-di-2-ethyIhexanoylperoxy-hexane (Table 6). 

The action of redox metal promoters with MEKP appears to be highly specific. Cobalt salts appear to be a unique component of commercial redox systems, although vanadium appears to provide similar activity with MEKP. Cobalt activity can be supplemented by potassium and 2inc naphthenates in systems requiring low cured resin color lithium and lead naphthenates also act in a similar role. Quaternary ammonium salts (14) and tertiary amines accelerate the reaction rate of redox catalyst systems. The tertiary amines form beneficial complexes with the cobalt promoters, faciUtating the transition to the lower oxidation state. Copper naphthenate exerts a unique influence over cure rate in redox systems and is used widely to delay cure and reduce exotherm development during the cross-linking reaction. 

Similar types of cross-linking reactions are observed for polymers to which photosensitive molecules ate chemically attached to the backbone of the polymer stmcture (Fig. 7). Radiation curing of polymers using uv and visible light energies is used widely in photoimaging and photoresist technology (Table 8) (58,59). 

Retarders were originally arenecarboxylic acids. These acidic materials not only delay the onset of cross-linking but also slow the cross-linking reaction itself. The acidic retarders do not function weU in black-fiUed compounds because of the high pH of furnace blacks. Another type of retarder, A/-nitroso diphenylamine [86-30-6] was used for many years in black-fiUed compounds. This product disappeared when it was recognized that it trans-nitrosated volatile amines to give a several-fold increase in airborne nitrosamines. U.S. production peaked in 1974 at about 1.6 million kg. 

The decomposition generates amine and MBTS. SmaH quantities of MBT and benzothiazyl (Bt) polysulftdes form just before the onset of cross-linking. Sulfur disappears and large quantities of MBT are formed during the main cross-linking reaction. The development of cross-links is shown as the rheometer line (curve C) in Figure 3. 

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