Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
1998-06-26
2002-10-15
Thibodeau, Paul (Department: 1773)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C524S722000, C524S773000, C524S827000, C524S831000, C524S833000
Reexamination Certificate
active
06465556
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a coating/impregnating composition. More specifically, the composition is a latex which is formed by polymerizing monomers in the presence of crosslinkable surface active agents to form a dispersion, and then sequentially admixing said polymer dispersion with a crosslinking agent. The mixture of the latex synthesized in this manner and the crosslinking agent produces a material which can be coated onto a substrate to provide a water resistant coating.
2. Technology Description
U.S. Pat. No. 5,409,527 is directed to an aqueous water repellent composition comprising the reaction product of one or more of a carboxylic acid or anhydride containing from 3 to 22 carbon atoms and a polyfunctional aromatic or aliphatic amine or substituted amine containing from 2 to 25 carbon atoms with a water soluble metal complex crosslinking agent containing one or more metals selected from Groups Ia, IIa, IIIa, IVa and the first and second rows of transition metals from the Periodic Table of Elements. The composition may contain wax and is dispersed in water to form a water repellent system. This patent further discusses the possibility of adding an aqueous acrylic polymer to the resulting composition. The reference fails to suggest that the polymer can be synthesized by polymerizing the monomer in the presence of a crosslinkable surface active agent. The only mention of polymer dispersions are commercial polymers made with conventional polymerization surfactants. It would be desirable to undertake a synthesis where the monomers are polymerized in the presence of a crosslinkable surface active agent thereby reducing or eliminating altogether the conventional polymerization surface active agents which would tend to attract moisture to substrates which are coated or impregnated with such polymers that were made with the conventional surface active agents. On the other hand, if the monomers were polymerized in the presence of crosslinkable surface active agents, the resulting material would possess outstanding water repellent properties when subsequently reacted with a crosslinking agent. In addition, by making the polymerization with crosslinkable surfactants, the resulting polymer dispersion could be produced having a desired particle size profile. This reference fails to disclose or suggest such an embodiment.
Despite the above teachings, there still exists a need in the art for a method for producing a dispersion wherein monomers are added to an aqueous environment containing a crosslinkable surface active agent and thereafter polymerizing the monomers to form a polymer dispersion having the desired particle size properties, and after adding a crosslinking agent, has the ability to impart outstanding water repellent properties to substrates.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention a novel dispersion is provided. More, specifically, the dispersion comprises a polymer dispersion wherein said polymer is formed by reacting in the presence of water and in the presence of the reaction product of (i) one or more carboxylic fatty acids; and (ii) ammonia or one or more polyfunctional aromatic or aliphatic amines:
(1) one or more ethylenically unsaturated monomers which is capable of polymerizing in an aqueous environment.
In preferred embodiments, the one or more ethylenically unsaturated monomers of component (1) are acrylic compositions, and more preferably acrylic esters; and the reaction product is the product of (i) one or more carboxylic fatty acids of 3 to 30 carbon atoms; and (ii) one or more hydroxy-substituted amines containing from 2 to 25 carbon atoms.
In particularly preferred embodiments, a water soluble metal complex crosslinking agent containing one or more metals selected from Groups Ia, IIa, IIIa, IVa and the first and second rows of transition metals from the Periodic Table of Elements is added to the polymer/surface active agent dispersion. For a particularly preferred embodiment, component (1) comprises a mixture of butyl acrylate and methyl methacrylate; the surface active agent is the reaction product of 2-amino-2-ethyl-1,3-propanediol with a single or combination of fatty acids having a carbon number of 8-18; and the crosslinking agent comprises ammonium zirconium carbonate.
The resulting composition comprises a dispersion having a polymer particle size ranging from about 1 nanometer to about 2000 nanometers, and for specific applications, the reaction synthesis can be controlled so that the resulting particle size of the polymer is between about 1 to about 60 nanometers. Such a polymer particle size would enable the dispersion to be coated onto and fill surfaces having microscopic voids. This is particularly important to provide water resistance to the coated surface. The resulting dispersion also has a solids content in the amount of about 0.1 to about 50 percent by weight of the resulting dispersion.
Another embodiment of the present invention comprises a method for synthesizing a polymer dispersion comprising reacting in the presence of water and in the presence of the reaction product of (i) one or more carboxylic fatty acids; and (ii) ammonia or one or more polyfunctional aromatic or aliphatic amines: (1) one or more ethylenically unsaturated monomers which is capable of polymerizing in an aqueous environment.
Still another embodiment of the present invention comprises a method for rendering a substrate water resistant comprising the step of coating and drying onto one or more surfaces of said substrate an aqueous dispersion of
(A) a polymer produced by reacting in an aqueous environment and in the presence of the reaction product of (i) one or more carboxylic fatty acids; and (ii) one or more polyfunctional aromatic or aliphatic amines:
(1) one or more ethylenically unsaturated monomers which is capable of polymerizing in an aqueous environment; and
(B) a water soluble or water dispersible metal complex cross-linking agent stet.
In preferred embodiments, the surface to be coated is made of either wood, brick, stone, cement, concrete, roofing materials and the like. In specific embodiments the coating composition can either be in a “one package” or “two package” form. When using a “one package” form, all of the components are present in a single package and are thereafter coated and dried onto a substrate. In the “two package” embodiment, component (B) is maintained in a separate package from a package containing the remaining components, and the two packages are mixed together just prior to coating. The primary purpose for using a two package system is to enable the production of dispersions having higher levels of solids.
An object of the present invention is to provide a dispersion which has excellent water resistant properties.
Still another object of the present invention is to provide a method for making a dispersion which has excellent water resistant properties.
A further object of the present invention is to provide a method for rendering a surface water resistant by using a dispersion which has excellent water resistant properties.
These, and other objects, will readily be apparent to those skilled in the art as reference is made to the detailed description of the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In describing the preferred embodiment, certain terminology will be utilized for the sake of clarity. Such terminology is intended to encompass the recited embodiment, as well as all technical equivalents which operate in a similar manner for a similar purpose to achieve a similar result.
The present invention relates to the formation of an aqueous polymer dispersion. The dispersion is formed by the in situ polymerization of one or more monomers in an aqueous environment which contains the reaction product of one or more carboxylic fatty acids and ammonia or one or more polyfunctional aromatic or aliphatic amines as a surface active agent; and wherein the dispersion may also contain a water soluble or water dispersibl
Jakob Paul
Kiplinger Jon D.
Pratt Charles E.
Rhodia Inc.
Rickman Holly C.
Thibodeau Paul
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