Colorless polymaleates and uses thereof

Details Colorless polymaleates and uses thereof Colorless polymaleates and uses thereof

2000-11-16

2002-05-07

Henderson, Christopher (Department: 1713)

Synthetic resins or natural rubbers -- part of the class 520 ser

Synthetic resins

Polymers from only ethylenic monomers or processes of...

C526S287000

Reexamination Certificate

active

06384166

ABSTRACT:

FIELD OF THE INVENTION
This invention relates to a low color or colorless polymaleate which is prepared by aqueous solution polymerization of maleic acid, an allylic sulfonate monomer, and a polyvalent transition metal ion. The polymaleates are useful as permanent press agents for textiles, and in laundry detergents to minimize calcium carbonate encrustation.
BACKGROUND OF THE INVENTION
Polymaleates are commonly used as water treatment agents, dispersing agents, and chelating agents in applications where color of the polymer is not critical. Since polymaleates generally appear dark brown in color, such polymers are inappropriate for many detergent and textile applications where low color is desirable. This is especially true where the polymer is to be applied to a textile, for example, as a durable press resin where a high color polymer may cause undesired color formation on the textile.
There are many processes for preparing polymaleates and copolymers thereof, for example, such processes are disclosed in U.S. Pat. Nos. 5,135,677; 5,064,563; 4,519,920; 4,555,557; 4,668,735; 4,589,995; and 4,659,793 wherein the polymaleates are prepared in an organic solvent or water. Unfortunately, these processes yield polymaleates which appear dark in color as evidenced by Gardner color number of greater than 8.
U.S. Pat. No. 4,709,091 describes a process for preparing polymaleic acid which involves neutralizing maleic acid in an aqueous medium with an alkali metal hydroxide or ammonia, polymerizing the maleic acid in the presence of an initiator, and adding a further amount of the alkali metal hydroxide or ammonia. U.S. Pat. No. 4,709,091 suggests that sulfonate comonomers may be used along with the maleic acid. The polymalic acid polymers, however, appear dark in color as evidenced by Gardner color number of greater than 8.
U.S. Pat. No. 6,020,297 describes the present invention. A terminal disclaimer has been included with the present application in regard to this prior art.
SUMMARY OF THE INVENTION
It has now been discovered that a low color or colorless polymaleate, as determined by a Gardner color number of 8 or less, may be prepared by aqueous solution polymerization comprising:
(a) 70 to 99.9 weight percent of maleic acid;
(b) 0.1 to 30 weight percent of an allylic sulfonate monomer having the formula
wherein R
1
is selected from the group consisting of H, C
1
-C
4
alkyl, C
1
-C
6
alkoxy, C
6
-C
10
aryl, ester, and COOH; R
2
is O—R
3
wherein R
3
is selected from the group consisting of C
1
-C
4
alkyl, C
1
-C
6
alkoxy, and C
6
-C
10
aryl; n is from 0 to 1; and M
+
is a cation selected from the group consisting of H
+
, NH
4
+
, alkali metals, alkaline earth metals, and quaternary organic amines; and
(c) 0.5 to 50 &mgr;m, based on the moles of monomer, of a polyvalent transition metal ion selected from group consisting of Group IVA, VA, VIA, VIIA, VIIIA, IB, IIB, and combinations thereof;
wherein the weight percents are based on the total weight of monomer, provided that 10 to 60 mole percent of the carboxylic acid groups on the maleic acid are neutralized prior to polymerization.
According to an additional aspect the invention provides a method for imparting permanent press properties to a textile containing cellulose fibers wherein said method comprises (I) adding an aqueous solution of the low color or colorless polymaleate to a laundering process comprising at least one textile; and (II) heating the textile at a sufficient temperature for a sufficient time to react the polymaleate with the textile wherein water is removed from the textile, to impart permanent press properties to the textile. Optionally, the polymaleate is combined with a catalyst prior to Step (II).
According to an additional aspect the invention provides a low color or colorless polymaleate as determined by a Gardner color number of 8 or less, said polymaleate is prepared by aqueous solution polymerization comprising 70 to 100 weight percent, based on the total weight of monomer, of maleic acid; and 0.5 to 50 &mgr;m, based on the moles of monomer, of a polyvalent transition metal ion selected from group consisting of Group IVA, VA, VIA, VIIA, VIIIA, IB, IIB, and combinations thereof; provided that 40 to 55 mole percent of the carboxylic acid groups on the maleic acid are neutralized prior to polymerization.
The low color or colorless polymaleate of the present invention provides permanent press properties to textiles treated therewith and increases the resistance of such textiles to laundering abrasion. Such treated textiles display a significant reduction in wrinkles compared with nontreated textiles. Moreover, the treated textiles have a tactile sensation of feeling soft and retain their smoothness after laundering.
According to a further aspect the invention provides a cleaning composition containing a surfactant and the polymaleate. The polymaleate enhances or “builds” the cleaning efficiency of a surfactant by inactivating hardness ions such as calcium and magnesium, and other metal ions such as iron. The polymaleates soften water by sequestration. In addition, the polymaleates assist in cleaning by dispersing and suspending soils to prevent the redeposition of soils onto cleaned substrates. Fabrics washed with detergent compositions containing the polymaleate of the invention have much less calcium carbonate deposited on the fabric as compared to fabrics washed without the polymaleate. Moreover, fabrics washed with detergent compositions containing the polymaleate of the invention display significantly less graying as compared to fabrics washed with detergent compositions without the polymaleates of the invention.
DESCRIPTION OF THE INVENTION
The low color or colorless polymaleate as determined by a Gardner color number of 8 or less is prepared by aqueous solution polymerization of (a) 70 to 99.9 weight percent of maleic acid, (b) 0.1 to 30 weight percent of an allylic sulfonate monomer, and (c) 0.5 to 50 &mgr;m, based on the moles of monomer, of a polyvalent transition metal ion selected from group consisting of Group IVA, VA, VIA, VIIA, VIIIA, IB, IIB, and combinations thereof. The weight percents of the maleic acid and allylic sulfonate monomer are based on the total weight of monomer used to prepare the polymaleate.
In another embodiment of the invention, a low color or colorless polymaleate as determined by a Gardner color number of 8 or less is prepared by aqueous solution polymerization of 70 to 100 weight percent, based on the total weight of monomer, of maleic acid; and 0.5 to 50 &mgr;m, based on the moles of monomer, of a polyvalent transition metal ion selected from group consisting of Group IVA, VA, VIA, VIIA, VIIIA, IB, IIB, and combinations thereof, provided that 40 to 55 mole percent of the carboxylic acid groups on the maleic acid are neutralized prior to polymerization.
As used herein, “polymaleate” includes copolymers and terpolymers, etc., of maleic acid. Preferably, the amount of maleic acid which is used to prepare the polymaleate is greater than 80 weight percent, more preferably greater than 90 weight percent, based on the total weight of monomers. Most preferably, the amount of maleic acid monomer which is used to prepare the polymaleate is greater than 98 weight percent. Preferably, the amount of allylic sulfonate monomer which is used to prepare the polymaleate is less than 20 weight percent, more preferably 8 or less weight percent, based on the total weight of monomers. Most preferably, the amount of allylic sulfonate monomer which is used to prepare the polymaleate is less than 2 weight percent.
The maleic acid may be present as maleic acid and/or maleic anhydride. In the embodiment of the invention wherein an allylic sulfonate comonomer is used with the maleic acid, 10 to 60 mole percent of the carboxylic acid groups on the maleic acid are neutralized prior to polymerization. Preferably 20 to 50 mole percent, more preferably 30 to 40 mole percent, of the carboxylic acid groups on the maleic acid are neutralized prior to polymerization.
The allylic su

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