WATERBORNE HOMO OR COPOLYMER DISPERSION
The present invention refers to a waterbome homo or copolymer dispersion comprising at least one alkenyl functional dendritic polymer being physically admixed into a homo or copolymer obtained by homo or copolymerisation, such as emulsion homo or copolymerisation, in an aqueous medium. In further aspects the present invention refers to a process for production of said waterbome homo or copolymer dispersion and to the use of said homo or copolymer dispersion.
Emulsion polymerisation is the most important industrial method for manufacture of aqueous dispersion polymers. Emulsion polymerisation is typically performed in an aqueous medium in the presence of a surfactant and a water-soluble initiator and is usually rapidly giving high molecular weight homo or copolymers at high solids content and low dispersion viscosity. The final product is normally an opaque, grey or milky- white dispersion of high molecular weight polymer(s) at a solids content of typically 30-60% in water. Said dispersion typically comprises acrylic, methacrylic and crotonic acid homo and copolymers, methacrylate and acrylate ester homo or copolymers, vinyl acetate homo or copolymers, vinyl and vinylidene chloride homo or copolymers, ethylene homo or copolymers, styrene and butadiene homo or copolymers, acrylamide homo or copolymers, butadiene-acrylonitrile copolymers, styrene- acrolein copolymers and/or where applicable carboxylated versions. Traditional applications for such aqueous dispersions are adhesives, binders for fibres and particulate matter, protective and decorative coatings, dipped goods, foam, paper coatings, backings for carpet and upholstery, modifiers for bitumens and concrete and thread and textile modifiers. More recent applications include biomedical applications as protein immobilisers, visual detectors in immunoas- says, as release agents, in electronic applications as photoresists for circuit boards, in batteries, conductive paint, copy machines and as key components in molecular electronic devices.
Numerous recipes have been published, primarily in the patent literature, that describe the preparation and property improvements of homopolymer and copolymer dispersions. For instance WO 02/32982 discloses aqueous coating compositions exhibiting prolonged open time obtained by addition of crosslinkable water dispersible hyperbranched macromolecules. The hyperbranched macromolecules are either completely water soluble or have partial solubility in water. The water solubility is obtained by introducing into the hyperbranched macromolecule hydrophilic water dispersing groups, such as long chain polyethylene oxide groups and acid groups neutralised, with for instance ammojiA °r - hydroxide, to form a salt. Despite many property improvements related to various dispersions and paints etc. made
therefrom, there are still need for further improvements, such as improved blocking.
The present invention accordingly refers to a novel waterbome homo or copolymer dispersion exhibiting, among other properties, substantially improved blocking properties. Said homo or copolymer dispersion comprises 0.1-25%, such as 1-10% or 2-6%, by weight of at least one alkenyl functional dendritic polymer being built up from a dendritic core polymer and at least one alkenyl functional compound. It has, in view of what is disclosed in WO 02/32982, quite surprisingly through the present invention been possible to produce a waterbome polymer dispersion comprising a dendritic polymer lacking neutralised acid groups and/or other groups known per se to render water dispersibility. The alkenyl functional dendritic polymer is physically admixed into at least one homo or copolymer obtained by polymerisation in an aqueous medium of at least one polymerisable allyl, vinyl, maleic or diene monomer. The core polymer of said alkenyl functional dendritic polymer is optionally chain extended and said at least one alkenyl functional compound is added to said core polymer and/or said optional chain extension.
The homo or copolymer is in preferred embodiments obtained in a one stage emulsion homo or copolymerisation or is a polymer obtained in a multi stage emulsion homo or copolymerisation. Said emulsion homo or copolymerisation may for instance yield latex particles having a heterogeneous morphology, such as a core-shell morphology. When monomers of different solubility or hydrophobicity are used or when staged polymerisations are carried out, core-shell morphologies are possible. In staged polymerisations, spherical core-shell particles are made when a polymer made from a first monomer is more hydrophobic than a polymer made from a second monomer.
The alkenyl functional dendritic polymer is prior to admixing preferably dissolved or dispersed in at least one coalescent agent, such as a glycol or a glycol ester or ether for instance selected from the group consisting of propylene glycol, hexylene glycol, butyl glycol, butyl diglycol, l-methoxy-2-propanol, 2,2,4-trimethyl-l,3-pentadiol monoisobutyrate, 2,2,4-trimethyl-l,3-pentanediol diisobutyrate, dipropylene glycol methyl ether, dipropylene glycol propyl ether, dipropylene glycol rc-butyl ether, propylene glycol phenyl ether, tripropylene glycol monoisobutyrate, tripropylene glycol n-butyl ether, butyl glycol acetate and butyl diglycol acetate. Further suitable coalescent agents include for instance white spirit, pine oil, 2-ethylhexyl benzoate, dibutyl phthalate, dioctyl phthalate, N-methyl pyrrolidone, tributoxyethyl phosphate and diisobutyl esters of long chain jdicarboxylic acids.
Said dendritic core polymer is advantageously and preferably a hydroxyfunctional dendritic polyester, polyether, polyesteramide or polyetheramide built up from alcohols, epoxies, oxetanes, aminoalcohols, hydroxyfunctional carboxylic acids, carboxylic acids or anhydrides, glycidyl esters and/or glycidyl ethers as disclosed in for instance WO 93/17060, WO 93/18075, WO 96/07688, WO 96/12754, WO 00/56802 and WO 01/16213. It is of course understood that alcohols, epoxies, oxetanes, aminoalcohols, hydroxyfunctional carboxylic acids, carboxylic acids or anhydrides, glycidyl esters and/or glycidyl ethers include mono, di, tri and polyfunctional compounds possessing necessary amount of reactive groups, sites and/or functions to yield and/or participate in formation of dendritic structures, including dendrimers. It is also understood that the hydroxyfunctionality of said dendritic core polymer may be derived from one or more hydroxyl, hydroxyalkyl, hydroxyalkoxy, hydroxyalkoxyalkyl, hydroxyalkylamide groups and the like.
The alkenyl functionality of said alkenyl functional dendritic polymer is in preferred embodiments obtained by addition, to said core polymer and/or its optional chain extension, of at least one aliphatic unsaturated carboxylic acid or a corresponding anhydride or halide, at least one unsaturated carboxyfunctional ester, polyester, ether or polyether and/or obtained by reaction with at least one alkenyl halide. The alkenyl functionality can for instance be obtained by addition of acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid or a to a said acid corresponding anhydride or halide. Further suitable alkenyl functional compounds, added to said core polymer and or its optional chain extension, include unsaturated monoacids, such as benzoic acid, _p-tertbutylbenzoic acid, soybean fatty acid, linseed fatty acid, tall oil fatty acid, castor fatty acid, dehydrated castor fatty acid, sunflower fatty acid, oleic acid, linoleic acid and linolenic acid and diacids, such as maleic acid, or its anhydride, and fumaric acid. Alkenyl functionality can also be obtained by reaction with for instance at least one alkenyl halide, such as allyl chloride and/or allyl bromide.
Said alkenyl functionality can, furthermore, be obtained by addition of an unsaturated carboxyfunctional ester of at least one saturated or unsaturated di, tri or polyfunctional carboxylic acid and at least one hydroxyfunctional (having at least one hydroxyl group) allyl ether of at least one di, tri or polyhydric alcohol or at least one di, tri or polyhydric reaction product between at least one alkylene oxide and at least one di, tri or polyhydric alcohol or at least one hydroxyfunctional allyl ether of a di, tri or polyhydric alcohol. Said di, tri or polycarboxylic acid is, in these embodiments, suitably and preferably selected from the group consisting of maleic acid, fumaric acid, tetrahydrophthajic acid, hexahydrophthalic acid, azelaic acid, adipic acid, trimelletic acid and a to a said acid corresponding anhydride. Said di,
tri or polyhydric alcohol is likewise preferably a l,ω-diol, 5,5-di(hydroxyalkyl)-l,3-dioxane, 2-alkyl-l,3-propanediol, 2,2-dialkyl-l,3-propanediol, 2-hydroxy-l,3-propanediol, 2-hydroxy- -2-alkyl-l,3-propanediol, 2-hydroxyalkyl-2-alkyl-l,3-propanediol, 2,2-di(hydroxyalkyl)- -1,3-propanediol or a dimer, trimer or polymer of a said di, tri or polyhydric alcohol. Further embodiments include hydroxyfunctional allyl ethers and alkoxylates of a said .polyhydric compound. Alkyl is in above disclosure preferably C1-C24 alkyl or C2-C24 alkenyl, such as
Ci-Cj2 or C2-C8 alkyl or alkenyl. Suitable di, tri or polyhydric alcohols can be exemplified by and include compounds such as 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol,
1,6-cyclohexane dimethanol, 5,5-dihydroxymethyl-l,3-dioxane, 2-methyl-l,3-propanediol,
2-methyl-2-ethyl-l,3-propanediol, 2-ethyl-2-butyl-l,3-propanediol, neopentyl glycol, dimethylolpropane, 1,1-dimethylolcyclohexane, glycerol, trimethylolethane, trimethylolpropane, diglycerol, ditrimethylolethane, ditrimethylolpropane, pentaerythritol, dipentaerythritol, anhydroennea-heptitol, sorbitol, mannitol, hydroxyfunctional allyl ethers and alkoxylates of a said polyhydric compound.
Alkoxylates as disclosed above are to be understood as reaction products between at least one alkylene oxide, such as ethylene oxide, propylene oxide, 1,3-butylene oxide, 2,4-butylene oxide, cyclohexene oxide, butadiene monoxide and/or phenylethylene oxide, and at least one said di, tri or polyalcohol.
Said polymerisable, where applicable homo and/or copolymerisable, monomer is in preferred embodiments suitably selected from the group consisting of acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, itaconic acid, maleic anhydride, fumaric acid, glycidyl acrylates, glycidyl methacrylates, acrylamide, methacrylamide, ethyl imidazolidon methacrylate, ethylene, propylene, styrene, divinylstyrene, vinylacetate, vinyl propionate, vinyl versatate, dibutyl maleate, butadiene, isoprene and C1-C10 alkyl acrylates and methacrylates, such as methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, methyl methacrylate, ethyl methacrylate or butyl methacrylate.
Further embodiments of the dispersion according to the present invention include species comprising at least one polymerisable surfactant, such as a surfactant comprising at least one alkenyl group, and/or a conventional surfactant in combination with said at least one alkenyl functional dendritic polymer.
In a further aspect, the present invention refers to a process for production of a waterbome homo or copolymer as disclosed above. Said process comprises the steps of (a) dissolving at
least one alkenyl functional dendritic polymer in at least one coalescent agent and (b) subsequently physically admixing obtained solution into at least one homo or copolymer obtainable by polymerisation in an aqueous medium of at least one polymerisable allyl, vinyl, maleic or diene monomer. Preferred embodiments of the alkenyl functional dendritic polymer, the dendritic core polymer, the polymerisable allyl, vinyl, maleic or diene monomer,; the coale- sent agent and other included raw materials are as disclosed above.
In yet a further aspect, the present invention refers to the use of said novel waterbome copolymer dispersion, as disclosed above or produced by said process, in binders for coatings, such as decorative and/or protective paints and lacquers, adhesives and glues.
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilise the present invention to its fullest extent. The following preferred specific embodiments are, therefore, to be construed as merely illustrative and not limitative of the remainder of the disclosure in any way whatsoever. In the following Example 1 illustrate preparation of a dendritic acrylate of the polyester type and Examples 2-4 refer to dispersions, and paints made therefrom, comprising the dendritic product of Example 1.
Example 1
350.0 g of a commercial dendritic polyester (Boltom® H20, Perstorp Specialty Chemicals AB, Sweden), having a nominal molecular weight of 1750 g/mole and a hydroxyl value of 511 mg KOH/g, and 816.3 g of sun flower fatty acid were charged to a 2 litres glass reactor equipped with a stirrer, a Dean-Stark water trap, a cooler and nitrogen purge. The reaction mixture was during 20 minutes heated from 23 °C to 103°C and 11.7 g of benzoic acid was now added. The temperature had after a further 10 minutes reached 140°C and 1.09 g of Ca(OH)2, 1.2 g of an organic tin catalyst and 75 ml of xylene were now charged to the reactor. The temperature of the reaction mixture was during 50 minutes further increased from 140°C to 200°C, at which temperature reaction water started to form. The reaction was allowed to continue for 9 hours until an acid value of 8.3 mg KOH/g was reached. The reaction product was cooled and a filtering aid was added and the mixture was passed through a pressure filter. Obtained clear solution was re-charged to the reactor and was heated to 120°C. Full vacuum was now applied to remove residual xylene.
The final product was a low viscous clear, yellow liquid with the following properties:
Molecular weight, g/mole: 6 542
Molecular weight (nominal), g/mole: 5 600
Number of unsaturated fatty acid groups, eq: 14.4
Final acid value, mg KOH/g: 5.1
Final hydroxyl value, mg KOH/g: 15
Viscosity at 23°C (Brookfield), mPas: 1 200
Non- volatile content, % by weight: 100
Example 2
The dendritic product obtained in Example 1 was admixed at varying amounts into acrylate and styrene/acrylate dispersions. Said dendritic product was prior to said admixing dissolved in butyl diglycol acetate. The formulations and amounts are given in below table. Reference samples without said dendritic product were also prepared (Samples 1, 4 and 7). All amounts in below table are given in parts per weight.
FA 184 S = Mowilith® FA 184 S, acrylic dispersion, Clariant Emulsion Norden AB, Sweden. LDM 6048 = Mowilith® LDM 6048, styrene/acrylic dispersion, Clariant Emulsion Norden AB, Sweden.
LDM 7741 = Mowilith® LDM 7741, acrylic dispersion, Clariant Emulsion Norden AB,
Sweden.
BDGA = Butyldiglycol acetate.
The following dispersion characteristics were determined:
* Brookfield.
Example 3
The dendritic product obtained in Example 1 was admixed at varying amounts into white paints based on acrylate and styrene/acrylate dispersions. Said dendritic product was prior to said admixing dissolved in butyl diglycol acetate. Formulations and amounts are given in below table. Reference samples without'said dendritic product were also prepared (Samples 1, 4 and 7). All amounts in below table are given in parts per weight.
FA 184 S = Mowilith® FA184 S, acrylic dispersion, Clariant Emulsion Norden AB, Sweden. LDM 6048 = Mowilith® LDM 6048, styrene/acrylic dispersion, Clariant Emulsion Norden AB, Sweden.
LDM 7741 = Mowilith® LDM 7741, acrylic dispersion, Clariant Emulsion Norden AB,
Sweden.
BDGA = Butyldiglycol acetate.
The mill base used in the preparation of above paints had the following composition in parts per weight:
Titanium dioxide 69.5
Disp ersing agent 1.6
Antifoam agent 0.7
Preservative 0.7
Low molecular weight cellulose thickerner, 5% in water 19.9 ,
Water 7.6
The following paint characteristics were determined:
* Brookfield.
RH = Relative humidity.
Blocking was performed and evaluated according to following procedure: Paint is applied using a 200 μm on foils and is allowed to dry at 23°C and 50% or 70% relative humidity for 16 hours. Samples having the dimensions 4 x 4 cm are cut out from said foils and placed two and two, with the coated surfaces facing each other, between glass plates and loaded with a 2 kg weight. The loaded samples are now placed in a heating cabinet holding a temperature of 50°C for 5 hours and subsequently cooled to room temperature. Evaluation of blocking is performed and judged by the ease to separate said samples. Judgement is visually performed according to a scale of 0-5, wherein 0 means no adhesion between the coated surfaces and/or no damage to the paint films.
Example 4
The dendritic product obtained in Example 1 was admixed at 2, 5 and 10% by weight into a vinyl acetate/ethylene dispersion. White paints where prepared from obtained mixtures. Formulations and amounts are given in below table. A reference sample without said dendritic product were also prepared (Sample 1). All amounts in below table are given in parts per weight.
FE 174 = Mowilith® FE 174, Vinyl acetate/ethylene dispersion, Clariant Emulsion Norden AB, Sweden.
The mill base used in the prepared paints had the following composition in part per weight:
Titanium dioxide 69.5
Kaolin 3.0
Filler 3.0
Dispering agent 0.5
Antifoam agent 0.3
Preservative 0.2
High molecular weight cellulose thickener, 2% in water 10.0
Low molecular weight cellulose thickener, 5% in water 20.0
Water 2.7
The following paint characteristics were determined:
Blocking test was performed according to following procedure:
Paint is applied using a 200 μm on foils and is allowed to dry at 23 °C and 50% relative humidity for 16 hours. Samples having the dimensions 4 x 4 cm are cut out from said foils and placed two and two, with the coated surfaces facing each other, between glass plates and loaded with a 2 kg weight. The loaded samples are now placed in a heating cabinet holding a temperature of 50°C for 5 hours and subsequently cooled to room temperature. Evaluation of
blocking is performed and judged by the ease to separate said samples. Judgement is visually performed according to a scale of 0-5, wherein 0 means no adhesion between the coated surfaces and/or no damage to the paint films.