Water-borne hybrid binder composition and use thereof

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

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C524S502000, C524S522000, C524S526000, C524S514000, C523S402000

Reexamination Certificate

active

06277910

ABSTRACT:

The present invention relates to a water-borne hybrid binder composition, as well as use thereof as a component in a paint or lacquer mixture.
Binders for paints and lacquers comprise, inter alia, the following two groups, a first group containing an organic solvent and a second group having water as solvent or dispersing agent.
The organic solvents in paints and lacquers cause a great deal of inconvenience. In recent years, above all health hazards for professional painters and decorators have been noticed when daily using such paints.
It would, of course, be natural to change to water-based systems in order to avoid the above-mentioned inconvenience of the organic solvents. However, the water-based paints and lacquers that have been available on the market up to now have not been sufficiently good to replace the paints and lacquers containing an organic solvent. Thus, the water-based products have generally resulted in surfaces that are more sensitive to scratching and water. Besides, it has not been possible in these products to reach a dry-solids content above about 60% by weight while maintaining a suitable application viscosity. This means that a relatively great amount of energy is required for drying and transporting the products. Moreover, considerable amounts of water in the products cause other types of inconvenience, such as rising fibres when painting on wood.
The present invention has quite unexpectedly made it possible to eliminate the above-mentioned inconvenience and to provide a water-borne hybrid binder composition.
The composition has a high dry-solids content and at the same time a low viscosity which make many paint formulation alternatives possible. Traditionally paints with a high dry-solids content have been formulated for example by using a high proportion of filler. At the present type of hybrid binder it is not necessary to take such measures to obtain a high dry-solids content. However, if a high proportion of filler is used this results in a further increase of the dry-solids content, Accordingly, the possibilities to vary the paint formulation ary very substantial.
If a hybrid binder with a high dry-solids content is produced with conventional binders such as an acrylate dispersion and an emulsified alkyd the viscosity will become too high to allow the binder to be used for a paint formulation.
The reason for the high dry-solids content and the low viscosity of the present hybrid binder is probably that the emulsifiable resin and the dispersion are formulated in such a way that the emulsifiable resin partially diffuse into the particles of the dispersion.
The selection of the components of the emulsifiable resin and the dispersion respectively is also of great importance for the compatibility of the hybrid system in the paint formulation as well as in the cured film. At the production of the hybrid binder the selection of surfactant is of crucial importance for the stability.
The composition is obtained by mixing 20-80, preferably 20-60% by weight of A), an aqueous dispersion of a polymer prepared from one or more monomers from at least one of the groups
i) a carboxyl functional monomer such as acrylic acid, methacrylic acid, crotonic acid, itaconic acid, maleic acid, fumaric acid and the like
ii) a hydroxyl functional monomer such as 2-hydroxyethyl acrylate, hydroxypropyl acrylate, hydroxybutyl acrylate, 2-hydroxyethyl methacrylate, hydroxypropyl methacrylate, hydroxybutyl methacrylate, allyl alcohol, methallyl alcohol and the like
iii) an epoxy functional monomer such as glycidyl methacrylate and the like
iv) an amino functional monomer such as acrylamide, methacrylamide, ethyl imidazolidon methacrylate and the like
v) an alkyl acrylate or an alkyl methacrylate such as methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, stearyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, stearyl methacrylate, isobornyl acrylate, isobornyl methacrylate and the like
vi) a polymerisable aromatic monomer, such as styrene, &agr;-methyl styrene, vinyl toluene, t-butyl styrene, diallyl phthalate and the like
vii) an &agr;-olefin such as ethylene, propylene and the like
viii) a vinyl monomer such as vinyl acetate, vinyl propionate, vinyl versatate, dibutyl maleate and the like, or
ix) a diene monomer such as butadiene, isoprene and the like,
said dispersion having a dry-solids content of at least 45% by weight, preferably 50-65% by weight and containing at least 0.1% by weight, preferably 0.5-5% by weight of B) a single surfactant or a mixture of two or more different surfactants and protective colloids from at least one of the groups
i) an ethoxylated nonionic surfactant such as alkylphenol ethoxylate, alcohol ethoxylate having different degrees of ethoxylation and similar compounds
ii) a nonionic sugar-based surfactant such as a nonethoxylated surfactant prepared with glycose or the like as polar part
iii) an anionic surfactant such as alkyl sulphate, alkyl ether sulphate, alkyl phenol ether sulphate, dialkyl sulfosuccinate, hemisulfosuccinate, alkyl phosphate, alkyl ether phosphate, alkyl phenol phosphate, alkyl phenol ether phosphate and the like, and
iv) a protective colloid such as a cellulose derivative, polyvinyl alcohol and the like,
and about 80-20, preferably 80-40% by weight of C) a resin being emulsifiable in water and having a dry-solids content above 90% by weight, preferably between 92 and 99.5% by weight and consisting of one or more resins from at least one of the groups
i) a polyester
ii) an alkyd resin
iii) an epoxy resin or an epoxy ester
iv) a polyurethane
v) a polyether
vi) a fatty acid, an epoxidised fatty acid or an ester of one of these
vii) a blocked di- or polyisocyanate
viii) an amino resin such as a melamine-formaldehyde resin or urea-formaldehyde resin, or
ix) an acryl or vinyl resin,
by adding the resin C to the dispersion A under agitation, the resulting hybrid binder composition obtaining a dry-solids content of 60-95% by weight, preferably 65-85% by weight and a viscosity of max. 100 Pa.s, preferably 0.2-70 Pa.s at room temperature.
The resin C normally contains at least 0.1% by weight, preferably 0.5-5% by weight of B before adding it to the dispersion A. Optionally, B and C can be added separately to the dispersion A. If the dispersion A contains a sufficiently high content of B, it might be possible to eliminate the addition of B in the resin C, or together with this.
According to the invention, it is important that the resin C which is emulsifiable in water is added to the aqueous polymer dispersion A and mixed therewith. The inversed mixing procedure does not result in a hybrid binder composition having the good properties according to the invention.
For a successful result, it is further suitable to effect the mixing procedure in a gentle manner by successive adding. Use can be made of, for instance, an agitator of the dissolver type. The process equipment including the agitator can be of a fairly simple type having a relatively low power consumption.
The dispersion A normally has a viscosity of 0.5-30 Pa.s, preferably 0.5-10 Pa.s, most preferred 0.5-4 Pa.s.
According to the invention, it has been found that the emulsified droplets of the resin C and the particles of the dispersion A interact so as to stabilise each other and make it possible to produce a stable, fluid hybrid binder composition having a dry-solids content of up to 95% by weight. The composition normally has a stability of at least 12 months, but it is not unusual to have a stability of 18 months.
Furthermore, it has been noticed according to the invention that the average size of the droplets of the emulsified resin C in such a hybrid system generally is smaller than that of the droplets in an emulsion prepared from the same resin while using the same equipment and using water as continuous medium.
The binder composition optionally contains a diluent and/or catalyst. The diluent normally is water. As a rule, the composition contains no organic solvent. If desired, a small amount thereof may, however, be included, f

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