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
2001-12-13
2003-08-05
Moore, Margaret G. (Department: 1712)
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...
C525S100000, C427S387000, C526S279000
Reexamination Certificate
active
06602949
ABSTRACT:
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
Not applicable.
FIELD OF THE INVENTION
This invention relates to vinyl copolymer emulsions and to their use as additives for paints and coatings. More particularly, it relates to a highly storage stable vinyl copolymer emulsion that is capable of forming strongly water repellent and highly water resistant films and coatings. The invention also relates to a paint or coating additive that is highly compatible with paints and coating compositions and that includes the emulsion.
BACKGROUND OF THE INVENTION
Japanese Patent Application Publication 5-9248 (9,248/1993) and Japanese Patent Application Publication 1-284513 (284,513/1989) disclose silicone grafted vinyl copolymer emulsions with improved water repellency, water resistance, and lubricity of vinyl polymer emulsions. These silicone grafted vinyl copolymer emulsions are produced by emulsion polymerization of vinyl monomers with straight chain or partially branched silicone macromonomers bearing radically polymerizable functional groups. One problem, however, is the presence of residual unpolymerized silicone macromonomer after completion of the reaction. This is due to the inadequate reactivity of the silicone macromonomer with the vinyl monomer during emulsion polymerization. When the resulting vinyl copolymer emulsion is coated on a substrate, the unpolymerized silicone macromonomer bleeds out onto the surface of the coating. This impairs its compatibility with other materials, diminishes its adherence with various substrates, and reduces printability. In addition, the silicone grafted vinyl copolymer emulsions have an inadequate storage stability, while coatings produced from these compositions exhibit an inadequate water repellency and an inadequate water resistance. Finally, these silicone grafted vinyl copolymer emulsions suffer from the problem that they exhibit an unsatisfactory compatibility with waterborne coating compositions when employed as modifiers of waterborne coatings.
BRIEF SUMMARY OF THE INVENTION
Therefore, it is an object of this invention is to provide a highly storage stable vinyl copolymer emulsion that can form strongly water repellent and highly water resistant films and coatings. Another object is to provide paint or coating additives that are highly compatible with paints and coatings. These and other features of the invention will become apparent from a consideration of the detailed description.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
Not applicable.
DETAILED DESCRIPTION OF THE INVENTION
The vinyl copolymer emulsion according to this invention is obtained by the emulsion polymerization of:
(A) 50-99.9 weight percent a vinyl monomer;
(B) 0.1-50 weight percent of an organosilicon compound bearing a radically polymerizable organic group, the compound having the formula
in which X is a radically polymerizable organic group, R
1
is a C
1
to C
10
alkyl group or a C
6
to C
12
aryl group, R
2
is a C
1
to C
10
alkyl group, a is a number with an average value of 2-3; the sum of the amounts of components (A) and (B) being 100 weight percent; and
(C) a radically polymerizable surfactant used at 0.1-20 weight parts for each 100 weight parts of the total amount of components (A) and (B). The emulsion is useful as a paint and coating additive.
The vinyl monomer (A) should bear a radically polymerizable vinyl group, but the type and the properties of vinyl monomer (A) are not otherwise critical. When it is desired to obtain an improved water resistance for a film or coating, the main constituents of component (A) are preferably hydrophobic vinyl monomers and radically crosslinking vinyl monomer.
Hydrophobic vinyl monomers are exemplified by (i) alkyl (meth)acrylates such as methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, tert-butyl acrylate, n-hexyl acrylate, cyclohexyl acrylate, 2-ethylhexyl acrylate, octyl acrylate, lauryl acrylate, stearyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, n-hexyl methacrylate, cyclohexyl methacrylate, 2-ethylhexyl methacrylate, octyl methacrylate, lauryl methacrylate, and stearyl methacrylate; (ii) aromatic group containing (meth)acrylates such as benzyl acrylate, phenoxyethyl acrylate, benzyl methacrylate, and phenoxyethyl methacrylate; (iii) vinyl esters of aliphatic acids such as vinyl acetate, vinyl propionate, vinyl butyrate, vinyl caproate, vinyl 2-ethylhexanoate, vinyl laurate, and vinyl stearate; (iv) aromatic vinyl monomers such as styrene and vinyltoluene; (v) diene monomers such as butadiene and isoprene; (vi) halogenated vinyl monomers such as vinyl chloride and vinylidene chloride; (vii) nitrile monomers such as acrylonitrile and methacrylonitrile; and (viii) diorganopolysiloxanes bearing a radically polymerizable functional group such as an acrylic, methacrylic, or styryl group, at one molecular chain terminal. Most preferred are alkyl (meth)acrylates and aromatic vinyl monomers such as styrene.
The radically crosslinking vinyl monomers are compounds containing at least two radically polymerizable organic groups in their molecule. These compounds are exemplified by (i) alkenyl (meth)acrylates such as allyl methacrylate and allyl acrylate; (ii) multifunctional (meth)acryloyl functional compounds such as trimethylolpropane triacrylate, pentaerythritol triacrylate, ethylene glycol diacrylate, tetraethylene glycol diacrylate, polyethylene glycol diacrylate, 1,4-butanediol diacrylate, 1,6-hexanediol diacrylate, neopentyl glycol diacrylate, trimethylolpropane trioxyethylacrylate, tris(2-hydroxyethyl)isocyanurate diacrylate, tris(2-hydroxyethyl)isocyanurate triacrylate, trimethylolpropane trimethacrylate, pentaerythritol trimethacrylate, ethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, polyethylene glycol dimethacrylate, 1,4-butanediol dimethacrylate, 1,6-hexanediol dimethacrylate, neopentyl glycol dimethacrylate, trimethylolpropane trioxyethylmethacrylate, tris(2-hydroxyethyl)isocyanurate dimethacrylate, and tris(2-hydroxyethyl)isocyanurate trimethacrylate; (iii) diacrylates and dimethacrylates of diols that are adducts of ethylene oxide or propylene oxide on bisphenol A, and diacrylates and dimethacrylates of diols that are adducts of ethylene oxide or propylene oxide on hydrogenated bisphenol A; (iv) methacryloxypropyl functional polydimethylsiloxanes; and (v) multifunctional vinyl monomers such as divinylbenzene, triethylene glycol divinyl ether, and styryl functional polydimethylsiloxanes. The radically crosslinking vinyl monomer is employed in the range of 0.1-10 weight percent of the overall vinyl monomer content, preferably in the range of 1-5 weight percent.
In addition to vinyl monomers such as described above, component (A) may contain other vinyl monomers that bear a reactive functional group and/or vinyl monomers bearing a property conferring functional group. Monomers of this type are exemplified by (i) hydroxyl functional vinyl monomers such as 2-hydroxyethyl acrylate, 2-hydroxybutyl acrylate, 2-hydroxypropyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxybutyl methacrylate, and 2-hydroxypropyl methacrylate; (ii) epoxy functional vinyl monomers such as glycidyl acrylate, 3,4-epoxycyclohexylmethyl acrylate, glycidyl methacrylate, and 3,4-epoxycyclohexylmethyl methacrylate; (iii) amino functional vinyl monomers such as dimethylaminoethyl acrylate, dimethylaminoethyl methacrylate, diethylaminoethyl acrylate, and diethylaminoethyl methacrylate; (iv) amide functional vinyl monomers such as acrylamide, N-methylolacrylamide, N-methoxymethylacrylamide, isobutoxymethoxyacrylamide, N,N-dimethylacrylamide, methacrylamide, N-methylolmethacrylamide, N-methoxymethylmethacrylamide, isobutoxymethoxymethacrylamide, and N,N-dimethylmethacrylamide; (v) fluorinated vinyl monomers such a
Aso Takayuki
Furukawa Haruhiko
Morita Yoshitsugu
DeCesare Jim L.
Dow Corning Toray Silicone Co. Ltd.
Moore Margaret G.
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