Continuous bulk polymerization process

Details Continuous bulk polymerization process Continuous bulk polymerization process

1998-10-30

2002-03-26

Wu, David W. (Department: 1713)

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

Synthetic resins

Polymers from only ethylenic monomers or processes of...

C526S068000, C526S317100, C526S320000, C526S318000

Reexamination Certificate

active

06362296

ABSTRACT:

FIELD OF THE INVENTION
The invention relates to a continuous bulk polymerization process for making acrylate polymers suitable for use as flow control additives in systems which are used in the making of thermoset coated substrates, particularly for coating and casting resins, more particularly for powder coating systems, as well as casting resins for potting and flooring applications curing at ambient temperature. Such acrylate polymers can be solvent-free or substantially solvent-free and substantially free of unreacted monomer. In a particular embodiment, the invention relates to a process for making poly(butylacrylate-co-2-ethylhexylacrylate) resins with a low weight average molecular weight, which are suitable for use as flow control additives.
BACKGROUND OF THE INVENTION
Flow modifiers (i.e. flow control additives) perform many functions in a coating. Flow additives are essential ingredients of many organic resin systems for coating and casting applications. They are described in, for example, L. J. Calbo, Ed., Handbook of Coating additives, Vol. 1, p. 119 et seq., Marcel Decker, New York (1987) and in U. Zorll, Ed., ROEMPP-Lexikon—Lacke und Druckfarben, p. 602 et seq., Georg Thieme Verll, Stuttgart (1998). They are primarily used to reduce or eliminate surface defects, such as craters, fisheyes, orange peel and pinholes. This is achieved by enhancing the wet-out, flow and leveling of the uncured film. Most of the surface defects develop during the application of the coating material on the substrate.
Surface cratering results from insufficient wetting of the substrate by the wet or molten coating material. In order to achieve good wetting, a liquid coating must have a surface tension equal to or lower than that of the substrate. High solids coating systems, such as oil-free polyester/melamines, wet poorly due to the high surface tension of the resins and the use of polar solvents. Cratering also results from contamination of the substrate or the wet film with low surface tension material, such as silicones, greasy dust, or solvent droplets.
The driving force behind the formation of a crater is the flow of material from areas of low surface tension to areas of higher surface tension. Flow modifiers exhibit a surface tension much lower than the resin vehicles, promoting substrate wetting. The polymer structure of the flow modifier defines its surface activity and controls or limits the compatibility of the product in a coating.
Historically speaking, during the latter portion of the 1950s thermoset-type powder coating materials were introduced and used to coat metallic substrates. They generally consisted of a simple epoxy material. The end product was considered a functional, not a decorative, coating. Thermoset-type materials are materials that, when applied to a substrate and heated to a curing temperature, melt, flow and then cross-link chemically. Once cured, this material, if reheated, will not remelt or reflow. As time went by, thermoset-type coatings were applied to substrates to provide both protection and decorative appeal. Surface defects in thermoset coatings were to be avoided not only because they detracted from the appearance of the coatings but also because they could compromise the integrity of the substrate. Early on the presence of solvents in epoxy powder coating systems helped avoid surface defects.
Epoxy coating systems can be liquid systems or in other cases can be powder systems. Epoxy powder coating systems are generally made in a three-stage continuous process as follows. In the first stage, epoxy resins, argumented with other resin, preservatives, dyes, pigments, curing agent and so forth are dry-mixed in a blender. The blended material is then fed into a kneader. Because of the tremendous mechanical energy released inside the kneader, any solid resins quickly melt. Molten material which is extruded from the kneader is then cooled and subsequently pulverized.
Recent advances in coating technology have included the development of high solids, low volatile organic compound (VOC) coating systems and of powder coating systems. The low VOC content (i.e. solvent content) reduces the ability of the coating system to overcome poor wetting and flow at the time when the coating system is heated and cured. Further, vehicles (i.e. thinners) which have been developed for these coatings systems often exhibit poor wetting and flow characteristics, increasing the frequency of surface defects. These trends have resulted in a greater reliance on flow modifiers such as polyacrylates to provide better flow and leveling qualities.
Copolymerized acrylate resins such as poly(butylacrylate-co-2-ethylhexylacrylate) resins have been used as flow control agents for epoxy coating systems. These prior art polyacrylate resins are available in the marketplace. For example, these polyacrylate resins are available from Monsanto, The Chemical Group, 800 N. Lindbergh Boulevard, St. Louis, Mo. 63167 and are sold under trademarks such as Modaflow®, and Modaflow® 2100. Other such resins are available from Henkel KgaA, Duesseldorf, Germany, or from Henkel Corporation, Ambler, Pa., under the marks Perenol® F40, Perenol® F45, and Perenol®F30P. However, prior art polyacrylate resins have weight average molecular weights in range of 10,000-30,000, which means they are quite viscous and therefore tend to inhibit the flow of coatings systems containing them, sometimes requiring the use of high boiling, diluting carrier oils. This is particularly true if the epoxy coating systems themselves are liquid and are innately thick and/or lack clarity. Also, some of these prior art polyacrylate flow control resins often contain solvents such as xylene which are classified as volatile organic compounds (VOC's). Such resins when thermoset in ovens generate fumes of VOC's that are hazardous to work with.
SUMMARY OF THE INVENTION
All quantities stated below, except in the Examples, are to be considered modified by “about”. Unless otherwise stated all parts are by weight.
The invention relates to a bulk polymerization process as described in U.S. patent application Ser. No. 08/948,714 filed Oct. 10, 1997, which is a continuation-in-part of U.S. patent application Ser. No. 08/686,860 filed Jul. 26, 1996, both of which applications are incorporated herein by reference. The process comprises the steps of: charging into a continuous tube reactor (CTR) a feedstock of at least one vinylic monomer and a polymerization initiator; maintaining a flow rate through the reactor sufficient to provide a residence time of the feedstock in the reactor of from about one minute to about one hour; while maintaining a pressure in the tube reactor of about 80 psig to about 500 psig and while maintaining the temperature of the resin mixture that forms in the tube reactor, preferably with a heat transfer medium within the range from about 150° C. to about 260° C.; and then devolatilizing the resin product which exits the reactor to thereby remove unreacted monomers and any other volatiles. An additional embodiment comprises the additional step of recycling the unreacted monomers recovered during the devolatilization step and charging them into the continuous tube reactor as a fraction of the feedstock.
Generally, the invention relates to a process for producing a polymer or copolymer from monomer material comprising an acrylate, methacrylate, or mixture of such monomers, which comprises the steps of:
(a) charging into a continuous tube reactor a feedstock comprising said monomer material and a polymerization initiator;
(b) maintaining a flow rate of said material through the reactor at a reaction temperature in the reactor and under pressure sufficient to provide a residence time of the feedstock in the reactor during which polymerization will occur, to form a resin product in the reactor, and said resulting resin product comprising unreacted monomer, and
(c) devolatilizing said resin product exiting the reactor to remove unreacted monomers, to provide a substantially monomer-free resin product. Further, the inventi

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