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WO1997001587A1 - Procede de preparation de dispersions de pigments inorganiques - Google Patents

Procede de preparation de dispersions de pigments inorganiques Download PDF

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Publication number
WO1997001587A1
WO1997001587A1 PCT/US1996/010681 US9610681W WO9701587A1 WO 1997001587 A1 WO1997001587 A1 WO 1997001587A1 US 9610681 W US9610681 W US 9610681W WO 9701587 A1 WO9701587 A1 WO 9701587A1
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WO
WIPO (PCT)
Prior art keywords
polymer
inorganic pigment
weight
monomers
monomer
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PCT/US1996/010681
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English (en)
Inventor
Bruce Matta
Michael S. Wiggins
Stephen A. Fischer
Original Assignee
Henkel Corporation
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Publication date
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Publication of WO1997001587A1 publication Critical patent/WO1997001587A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/04—Acids; Metal salts or ammonium salts thereof
    • C08F220/06—Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D17/00—Pigment pastes, e.g. for mixing in paints
    • C09D17/004—Pigment pastes, e.g. for mixing in paints containing an inorganic pigment
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/02—Emulsion paints including aerosols
    • C09D5/024—Emulsion paints including aerosols characterised by the additives
    • C09D5/028—Pigments; Filters

Definitions

  • the present invention relates to polymers useful in preparing inorganic pigment dispersions and methods of preparing such polymers, methods of preparing inorganic pigment dispersions useful in the manufacture of latex paints, and latex paints prepared therewith.
  • Paint coatings are protective surface coatings applied to substrates and cured to form dry continuous films for decorative purposes as well as to protect the substrate.
  • Consumer latex paint coatings are air-drying aqueous coatings applied primarily to architectural interior or exterior surfaces, where the coatings are sufficiently fluid to flow out, form a continuous paint film, and then dry at ambient temperatures to form continuous films.
  • a paint coating is ordinarily comprised of an organic polymeric binder, pigments, and various paint additives.
  • the polymeric binder acts as a fluid vehicle for the pigments and imparts rheological properties to the fluid paint coating.
  • the polymeric binder functions as a binder for the pigments and provides adhesion of the dried paint film to the substrate.
  • the pigments may be organic or inorganic and functionally contribute to opacity and color in addition to durability and hardness.
  • the manufacture of paint coatings involves the preparation of a polymeric binder, mixing of component materials, grinding of pigment in the presence of a pigment dispersant, mixing the pigment grind with the polymeric binder, and thinning to commercial standards. High speed dispersers or dissolvers are used in the grinding step to disperse the pigments into the polymeric binder solution.
  • VOC volatile organic compounds
  • Polyacrylic acid in its neutralized form has been used to prepare aqueous pigment dispersions, particulariy dispersions of titanium dioxide.
  • Polyacrylic acid disperses the pigment well and contributes little, if at all, to the VOC of the latex paint into which the pigment dispersion is incorporated.
  • polyacrylic acid also tends to contribute to water sensitivity of the dried paint coating.
  • an exterior paint coating is more susceptible to water damage as a result of precipitation and an interior paint coating may be damaged when scrubbed with aqueous liquids, e.g. soap and water.
  • a pigment dispersant with a reduced contribution to the water sensitivity of the dried paint coating is therefore desirable.
  • This invention relates to a polymer useful as an inorganic pigment dispersant, said polymer being derived from monomers consisting essentially of an ethylenically unsaturated aromatic monomer and an ethylenically unsaturated acid monomer, wherein the amount of said ethylenically unsaturated acid monomer is sufficient to permit said polymer to associate with an inorganic pigment in an aqueous medium in a manner which disperses said inorganic pigment in said aqueous medium to form a stable aqueous dispersion of said inorganic pigment, and wherein the amount of said ethylenically unsaturated aromatic monomer is sufficient to reduce the water sensitivity of a dried coating of a latex paint comprised of said stable aqueous dispersion of said inorganic pigment.
  • This invention also relates to a process of preparing a polymer useful as an inorganic pigment dispersant, said process comprising dissolving monomers consisting essentially of an ethylenically unsaturated aromatic monomer and an ethylenically unsaturated acid monomer in a solvent consisting essentially of a major amount by weight of a water-miscible organic solvent having chain transfer activity and a minor amount by weight ofwater and polymerizing said monomers in said solution.
  • This invention also relates to a method of preparing an inorganic pigment dispersion useful in the preparation of latex paints, said method comprising dispersing an inorganic pigment in an aqueous medium further comprised of a dispersing polymer, said aqueous medium being essentially free of volatile organic solvents, and said dispersing polymer being derived from monomers consisting essentially of an ethylenically unsaturated aromatic monomer and an ethylenically unsaturated acid monomer, wherein the amount of said ethylenically unsaturated acid monomer is sufficient to permit said polymer to associate with an inorganic pigment in an aqueous medium in a manner which disperses said inorganic pigment in said aqueous medium to form a stable aqueous dispersion of said inorganic pigment, and wherein the amount of said ethylenically unsaturated aromatic monomer is sufficient to reduce the water sensitivity of a dried coating of a latex paint comprised of said stable aqueous
  • This invention also relates to latex paints comprising the inorganic pigment dispersion composition of this invention and to a method of coating a substrate comprising contacting a surface of a substrate with a composition comprising a latex paint binder and an inorganic pigment dispersion of this invention and drying said surface to form a film of said composition in contact with said surface.
  • this invention relates to a polymer produced by the process of polymerizing monomers consisting essentially of:
  • an acid monomer having the formula CH 2 C(R 3 )(C(O)OH) wherein R 3 is hydrogen or methyl, or mixtures thereof.
  • Said polymer is typically produced by polymerization of the monomers while in an aqueous alcohol solution.
  • the monomers consists essentially of one or more of said aromatic monomers in an amount from just greater than about 40% to about 50% by weight, and one or more of said acid monomers in an amount of from about 50% to just less than about 60% by weight.
  • the polymer typically has a molecular weight (e.g. weight average) of from about 1 ,000 to about 20,000. Certain of the polymers of this invention can also be represented by the formula:
  • R1 is an aromatic group having from 6 to 10 carbon atoms and R 2 and R 3 are each independently hydrogen or methyl
  • y is sufficient to permit said polymer to associate with an inorganic pigment in an aqueous medium in a manner which disperses said inorganic pigment in said aqueous medium to form a stable aqueous dispersion of said inorganic pigment
  • x is sufficient to reduce the water sensitivity of a dried coating of a latex paint comprised of said stable aqueous dispersion of said inorganic pigment.
  • the subscripts x and y represent the moie ratios of the monomeric units.
  • the subscripts will be integers for a mono-disperse polymer composition and will be average values when expressed in relation to a poly-disperse polymer composition.
  • the formula is not intended to convey that the polymer is a block copolymer. Thus, both random and block copolymers are within the scope of the formula.
  • a preferred class of polymers within the scope of this invention have the formula set forth above wherein R 1 is phenyl, R 2 and R 3 are hydrogen, and the ratio of x.y is chosen such that the polymer is comprised of monomeric units of formula A in an amount from just greater than about 40% to about 50% by weight and monomeric units of formula B in an amount from about 50% to just less than about 60% by weight, and the sum of x and y is chosen such that the polymer has a molecular weight (e.g. weight average) of from about 1 ,000 to about 20,000.
  • Another preferred class of polymers within the scope of this invention have the formula set forth above wherein R 1 is phenyl, R 2 is hydrogen and R 3 is methyl, and the ratio of x:y is chosen such that the polymer is comprised of monomeric units of formula A in an amount from greater than about 5% to about 50% by weight and monomeric units of formula B in an amount from about 50% to about 95% by weight, and the sum of x and y is chosen such that the polymer has a molecular weight (e.g. weight average) of from about 1,000 to about 20,000.
  • R 1 is phenyl
  • R 2 is hydrogen
  • R 3 is a mixture of hydrogen and methyl (typically in a weight ratio of about 1 :1 to about 4:1 hydrogen to methyl, more typically from about 1.5: to about 3:1 hydrogen to methyl, and preferably 2:1 hydrogen to methyl)
  • the ratio of x:y is chosen such that the polymer is comprised of monomeric units of formula A in an amount from at Ieast about 45% to about 50% by weight and monomeric units of formula
  • B in an amount from about 50% to about 55% by weight, and the sum of x and y is chosen such that the polymer has a molecular weight (e.g. weight average) of from about 1 ,000 to about 20,000.
  • this invention relates to novel polymers and to a method of making such polymers. In other aspects, this invention also relates to the use of the novel polymers to disperse an inorganic pigment in an aqueous medium and to the resulting dispersions. In still other aspects, this invention also relates to latex paint compositions comprised of a latex paint binder and an inorganic pigment dispersion of this invention and to a method of coating a substrate which employs such latex paint compositions.
  • the polymers of this invention can be generally characterized as copolymers, i.e. they have repeating units derived from at Ieast two different monomers: an aromatic monomer and an acid monomer.
  • the starting materials for preparing the novel polymers of this invention are ethylenically unsaturated aromatic compounds and ethylenically unsaturated acid compounds.
  • the monomeric unit A is derived from an ethylenically unsaturated aromatic compound.
  • the ethylenically unsaturated aromatic compounds include monovinyl aromatic hydrocarbons containing from 8 to 12 carbon atoms and halogenated derivatives thereof having halo-substituted aromatic moieties. Specific examples include styrene, alpha-methylstyrene, vinyl toluene (e.g.
  • meta-methylstyrene and para- methylstyrene meta-methylstyrene, para-methylstyrene, para-ethylstyrene, para-n-propylstyrene, para-isopropylstyrene, para-tert-butylstyrene, ortho- chlorostyrene, para-chlorostyrene, alpha-methyl-meta-methylstyrene, aipha- methyl-para-methylstyrene, tert-butyl styrene, alpha-methyl-ortho-chlorostyrene, and alpha-methyl-para-chlorostyrene.
  • the monomeric unit B is derived from an ethylenically unsaturated acid monomer.
  • alpha, beta-ethylen ically unsaturated carboxylic acids which may also be useful as comonomers to prepare the polymer ofthe invention include acrylic acid, beta-acryloxypropionic acid and higher oligomers of acrylic acid and mixtures thereof, methacrylic acid, itaconic acid, aconitic acid, crotonic acid, citraconic acid, maleic acid, fumaric acid, alpha-chloroacrylic acid, cinnamic acid, mesaconic acid and mixtures thereof.
  • Preferred examples are acrylic acid and methacrylic acid.
  • Such acids are described in "Acrylic and Methacrylic Acid Polymers", Encyclopedia of Polymer Science and Engineering, vol. 1 , pp. 211- 234 (John Wiley & Sons, Inc., N.Y., N.Y., 1985), the disclosure of which is incorporated herein by reference.
  • Further examples of acid monomers that may be useful include the partial esters of unsaturated aliphatic dicarboxylic acids and particularly the alkyl half esters of such acids. Examples of such partial esters are the alkyl half esters of itaconic acid, fumaric acid and maleic acid wherein the alkyl group contains 1 to 6 carbon atoms.
  • Representative members of this group of compounds include methyl acid itaconic, butyl acid itaconic, ethyl acid fumarate, butyl acid fumarate, and methyl acid maleate.
  • These acid monomers generally have greater molecular bulk than the preferred monomer, acrylic acid, and thus, may have less hydrophilic character than the preferred monomer, acrylic acid.
  • the use of such acid functional partial esters as the acid monomer may allow one to reduce the relative amount of aromatic monomer and yet obtain the same reduction in water sensitivity.
  • the acid groups of the B monomeric unit that are responsible for the ability of the polymer to associate with an inorganic pigment and, thus, stably disperse the inorganic pigment in an aqueous medium.
  • the polymer should form a stable pigment dispersion, but also have reduced water sensitivity. Therefore, the amount of the A monomeric units should be sufficient to obtain the desired reduction in water sensitivity of a latex paint prepared therewith. Likewise, the amount of the B monomeric units should be sufficient to obtain the desired degree of stability of the pigment dispersion.
  • the polymer should contain more than 10% by weight of A monomeric units, preferably more than 25%.
  • the amount of the A monomeric unit will, however, generally be a minor amount.
  • the B monomeric unit is derived from acrylic acid, the A monomeric unit will typically comprise from about
  • the A monomeric unit will typically comprise from about 5% to about 50% by weight of the polymer, e.g. from about 5% to about 15%, with the balance being the B monomeric unit.
  • the B monomeric unit is derived from a mixture of acrylic acid and methacrylic acid
  • the A monomeric unit will typically comprise from about 45% to about 50% by weight of the polymer, with the balance being the B monomeric unit.
  • the precise characteristics desired of the aqueous pigment dispersion and the latex paint prepared therefrom will influence the determination of what is an optimal amount of the A and B monomeric units, the precise identity of each monomer and the amount of each monomer affecting, as discussed herein, properties ofthe polymer which are important to its utility as an inorganic pigment dispersant.
  • dispersing polymers based on styrene and acrylic acid and/or methacrylic acid
  • styrene and acrylic acid and/or methacrylic acid are prepared without additional comonomers
  • other monoethylenically unsaturated polymerizable monomers useful in minor proportion (e.g. less than 10% by weight of the total monomer composition) as comonomers with the aromatic and acid monomers may be useful in preparing the polymers of this invention.
  • Examples of other monomers include the vinylidene halides, vinyl halides, acrylonitrile, methacrylonitrile, vinyl esters such as vinyl formate, vinyl acetate and vinyl propionate, and mixtures of ethylene and such vinyl esters, acrylic and methacrylic acid esters of alcohol ethers such as diethylene glycol monoethyl or monobutyl ether methacrylate, C 1 -C 10 alkyl esters of beta-acryloxypropionic acid and higher oligomers of acrylic acid, mixtures of ethylene and other alkylolefins such as propylene, butylene, pentene and the like, vinyl ethers such as methyl vinyl ether, ethyl vinyl ether, vinyl
  • the monomers from which the polymer is prepared may also be comprised of an ethylenically unsaturated monomer having at Ieast two sites of ethylenic unsaturation, i.e.
  • multiethylenic monomers include alkenyl acrylates or methacrylates (e.g. allyl methacrylate), di-alkenyl arenes, particularly di-alkenyl benzenes (e.g. divinyl benzene), di-alkenyl ethers (e.g. ethylene glycol di-allyl ether and pentaerythritol di-allyl ether), di-acrylamides (e.g.
  • methylene-bis-acrylamide trimethylene-bis- acrylamide, hexamethylene-bis-acrylamide, N.N'diacryloylpiperazine, m- phenylene-bis-acrylamide, and p-phenylene-bisacrylamide
  • di- or higher multi- acrylates e.g. diethylene glycol diacrylate, propylene glycol dimethacrylate, ethylene glycol dimethacrylate, polyethylene glycol diacrylate, bis(4-acryloxypolyethoxyphenyl)-propane, 1 ,3-butylene glycol dimethacrylate,
  • Such multifunctional monomers may be useful as crosslinking agents to modifying the molecular weight of the polymer and improve the paint film's water resistant properties.
  • the amount of the multiethylenic monomers will be a minor amount, typically from about 0.1% to about 3% by weight of total monomers, because the polymer should not be so highly crosslinked that it is rendered insoluble. While it is thus conceivable that the polymer will contain monomeric units derived from monomers other than the aromatic monomer and the acid monomer, in preferred embodiments, the polymer is prepared by solution polymerization of monomers consisting of:
  • a minor amount by weight e.g. from about 35% to about 50%, preferably from about 42% to about 47%, by weight based on the total weight of the polymer
  • an ethylenically unsaturated aromatic monomer having less than twelve carbon atoms, preferably styrene
  • a major amount by weight e.g. from about 50% to about 60%, preferably 53% to 58%, by weight, based on the total weight of the polymer
  • an ethylenically unsaturated carboxylic acid having less than six carbon atoms preferably acrylic acid and/or methacrylic acid.
  • the polymer will have a molecular weight (e.g. weight average) of from about 1 ,000 to about 20,000, typically from about 1 ,500 to about 10,000, and more typically from about 2,000 to about 6,000.
  • the acid value (expressed as mg of KOH per gram of polymer) of the polymer should be greater than about 240, typically greater than 250, more typically from about 300 to about 500, and even more typically from about 395 to about 425. These typical acid values are based on polymers in which acrylic acid is the acid monomer and the acid value of other polymers, given the same mole ratio of acid monomer to other monomers will depend, of course, on the molecular weight of the particular acid monomer used.
  • the monomers are dissolved in a solvent consisting essentially of a major amount by weight of a water-miscible organic solvent having chain transfer activity and a minor amount by weight of water.
  • the monomers are then polymerized in said solution.
  • the solvent of this invention has two components. It is an aqueous solvent in that one of the components is water.
  • the other component is an organic solvent that must meet two criteria. First, the organic solvent must be miscible with water in the proportion in which the water is present in the solvent system. It should be noted that the identity and amounts of the monomers in the solution may affect the miscibility of the organic solvent and the water. Thus, the organic solvent must not only be miscible with water, but miscible with the resulting solution as a whole.
  • water-miscible it is meant that the organic solvent will not form a discrete second liquid phase in the reaction medium.
  • the organic solvent must also have chain transfer activity. Chain transfer is discussed in “Chain Transfer”, Encyclopedia of Polvmer Science and Engineering, vol. 3, pp. 288-290 (John Wiley & Sons, Inc., N.Y., N.Y., 1985), the disclosure of which is incorporated herein by reference. Chain transfer refers to the termination of a growing polymer chain and the start of a new one by a chain transfer agent. The chain transfer coefficients of solvents are available in the literature, e.g. J. Brandrup and E. H. Immergut, Polymer Handbook. (2d ed.
  • the organic solvent will be an oxygenated hydrocarbon, for example an alcohol, ketone (e.g. acetone), or ester (e.g. ethyl acetate), typically having no more than about six (preferably no more than about three) carbon atoms per oxygen atom.
  • the organic solvent will be a lower alkanol, e.g. a more typically a C 2 -C 4 alkanol, e.g. isobutanol.
  • the preferred organic solvent is isopropanol.
  • the relative amounts of the organic solvent and water in the solvent system must be selected so that the monomers dissolved therein remain miscible with the solution during the course of the polymerization reaction.
  • the organic solvent will be present in a major amount (i.e. more than 50% by weight) and the water will be present in a minor amount by weight.
  • the weight ratio of organic solvent to water will typically be from about 1.5:1 to 8:1 , more typically from about 2:1 to about 6:1 , and even more typically from about 2.5:1 to about 3.5:1.
  • the polymerization process may be a thermal or redox type; that is, free radicals may be generated solely by the thermal dissociation of an initiator species or a redox system may be used.
  • a polymerization initiator of the free radical type such as ammonium or potassium persulfate
  • a redox system which also includes a reducing component such as potassium metabisulfite, sodium thiosulfate or sodium formaldehyde sulfoxylate.
  • the reducing component is frequently referred to as an accelerator.
  • the initiator and accelerator commonly referred to as catalyst, catalyst system or redox system, are typically used in proportion from about 0.01% to 10% or less each, based on the weight of monomers to be copolymerized.
  • redox catalyst systems include t-butyl hydroperoxide/sodium formaldehyde sulfoxylate/Fe(ll), and ammonium persulfate/sodium bisulfite/sodium hydrosulfite/Fe(ll).
  • the polymerization temperature may be from room temperature to 90 °C (with isobutanol) or 80 °C (with isopropanol), or more if the reaction zone is pressurized to maintain the solvent as a liquid, and may be optimized for the catalyst system employed, as is conventional.
  • the temperature of the reaction vessel during the polymerization may be controlled by cooling to remove heat generated by the polymerization reaction or by heating the reaction vessel.
  • Additional chain transfer agents including mercaptans, polymercaptans and polyhalogen compounds may also be desirable in the polymerization mixture to moderate polymer molecular weight.
  • chain transfer agents which may be used include long chain alkyl mercaptans such as t-dodecyl mercaptans, alcohols such as isopropanol, isobutanol, lauryl alcohol ort-octyl alcohol, carbon tetrachloride, tetrachloroethylene and trichlorobromoethane.
  • long chain alkyl mercaptans such as t-dodecyl mercaptans
  • alcohols such as isopropanol, isobutanol, lauryl alcohol ort-octyl alcohol
  • carbon tetrachloride tetrachloroethylene
  • trichlorobromoethane Generally from about 0.001 to 3% by weight of an additional chain transfer agent, based on the
  • the pH of the solvent system will typically be adjusted to retain at Ieast a portion, and preferably most, ofthe acid monomer in the free acid form.
  • the pH of the solvent system will be on the acid side of neutral, e.g. from about 2 to about 4.
  • this invention relates to a method of preparing a pigment dispersion useful in the preparation of latex paints.
  • the method in its broadest conception comprises dispersing a pigment in an aqueous medium further comprised of a dispersing polymer, said aqueous medium being essentially free of volatile organic solvents. While the acid monomer which forms part of the dispersing polymer will typically be in the free acid form during the solution polymerization, the aqueous medium in which the inorganic pigment is to be dispersed will typically have a neutral, or even alkaline, pH such that the monomeric unit derived from the acid monomer will typically be in the form of a charged anion, e.g. carboxylate.
  • the dispersing polymers of this invention form the pigment dispersions of this invention when dissolved in an aqueous solvent containing ammonia or an organic amine.
  • the polymer is added to the solvent typically in an amount of about 30-40% polymer solids based on the weight of the solvent.
  • the aqueous solvent will contain only ammonia to avoid any contribution to the volatile organic content of the pigment dispersion, but examples of suitable organic amines that can be used in place of or with ammonia include primary, secondary, and tertiary amines which can act as a base to salt polymer.
  • organic amines are the dialkyl aminoaikanols such as 2-(N,N-dimethylamino)ethanol and 2-(N,N-diethylamino)ethanol.
  • the ammonia or organic amine is present in the aqueous solution in an amount sufficient to solubilize the dispersing polymer.
  • the ammonia or organic amine will be present in the aqueous solution in an amount sufficient to theoretically neutralize the acid groups of the polymer, i.e., the amount of ammonia or organic amine is stoichiometrically equivalent to or greater than the acid value of the polymer.
  • a large excess of organic amine should be avoided because retention of the organic amine in the dried coating may adversely affect the water resistance of the coating.
  • the amount ofthe acid monomer used to prepare the dispersing polymer should be sufficient in relation to the amount of the aromatic monomer to yield a polymer that is sufficiently capable of associating with the inorganic pigment such that a stable pigment dispersion is formed. If the polymer is not sufficiently capable of associating with the inorganic pigment, observable precipitation ofthe pigment during the intended shelf life of the pigment dispersion or the latex paint prepared therewith may occur.
  • the pigment dispersion is typically made by first dissolving the dispersing polymer in water.
  • the dispersion will typically be essentially free of organic solvents, e.g. alcohol solvents such as the short chain aliphatic alcohols having from 2 to 4 carbon atoms, e.g.
  • pigment dispersions of this invention is an inorganic pigment or colorant.
  • the generic term pigment includes both colorant pigments and opacifying pigments.
  • colorant pigment is specifically used in this specification to refer to both pigments and dyes which impart a distinct color (i.e. a hue as opposed to white (the absence of color) or black and/or shades of gray) to the composition.
  • the pigment of the dispersion may be a colorant pigment, i.e. the pigment will impart a color to the pigment dispersion, to a printing ink prepared therefrom, and to the surface of a substrate printed with such an printing ink.
  • the colorant pigments useful in this invention will typically include black, inorganic red, inorganic yellow, as well as violet, orange, green, and brown.
  • Useful pigments include for instance ferrite yellow oxide, red iron oxides, ferric iron oxide brown (which is a blend of red, yellow, and black iron oxides), tan oxide (which is a similar blend), raw sienna and burnt sienna, raw and burnt umber, carbon black, lampblack.
  • the inorganic pigment will typically, however, be an opacifying pigment.
  • white opacifying pigments are not considered to be colorant pigments.
  • Opacifying pigments are generally pigments having a refractive index of at Ieast about 1.8.
  • Typical white opacifying pigments include rutile and anatase titanium dioxide.
  • the dispersions can further contain non-opacifying filler or extender pigments often referred to in the art as inerts and include clays, such as kaolinite clays, silica, talc, mica, barytes, calcium carbonate, and other conventional filler pigments. All filler or extender pigments have fairly low refractive indices and can be described generally as pigment other than opacifying pigment.
  • the pigment dispersions of this invention may be prepared as follows.
  • the pigment is mixed with an aqueous solution of the dispersing polymer and, at a properly adjusted viscosity, dispersed thereinto with ball mill, sand mill, high-shear fluid flow mill, Cowles Dissolver, Katy Mill or the like.
  • the process of dispersing causes agglomerates of the pigment particles to deagglomerate and the dispersing polymer causes the deagglomerated particles of pigment to be wetted with the aqueous solution. This wetting thus inhibits the reagglomeration of the pigment particles.
  • the pigment dispersion will typically be characterized as a slurry of the pigment in an aqueous medium which also contains a minor amount of the dispersing polymer.
  • the weight ratio of inorganic pigment to aqueous medium is from about 1:1 to about 10:1 , more typically from about 1.5:1 to about 5:1 , and even more typically from about 2:1 to about 4:1.
  • the weight ratio of inorganic pigment to dispersing polymer on a solid basis is typically from about 10:1 to about 1000: 1 , more typically from about 50:1 to about 500: 1 , and even more typically from about 75:1 to about 150:1.
  • the invention includes latex paint compositions containing an emulsion or dispersion of a water-insoluble polymer and a pigment dispersion of the invention.
  • the water-insoluble polymers may be any of the types conventionally utilized in latex paint compositions and include natural rubber latex ingredients and synthetic latices wherein the water-insoluble polymer is an emulsion polymer of mono- or poly-ethylenically unsaturated olefinic, vinyl or acrylic monomer types, including homopolymers and copolymers of such monomers.
  • Latices and latex paints are discussed extensively in "Latices", Encyclopedia of Polvmer Science and Engineering, vol. 8, pp.
  • the water-insol ⁇ ble emulsion polymer may include poly (vinyl acetate) and copolymers of vinyl acetate (preferably at Ieast 50% by weight) with one or more of vinyl chloride, vinylidene chloride, styrene, vinyltoluene, acrylonitrile, methacrylonitrile, acrylamide, methacrylamide, maleic acid and esters thereof, or one or more of the acrylic and methacrylic acid esters mentioned in U.S. Pat. Nos.
  • 2,795,564 and 3,356,627 which polymers are well-known as the film-forming component of aqueous base paints; homopolymers of C 2 -C 40 alpha olefins such as ethylene, isobutylene, octene, nonene, and styrene, and the like; copolymers of one or more of these hydrocarbons with one or more esters, nitriles or amides of acrylic acid or of methacrylic acid or with vinyl esters, such as vinyl acetate and vinyl chloride, or with vinylidene chloride; and diene polymers, such as copolymers of butadiene with one or more of styrene, vinyl toluene, acrylonitrile, methacrylonitrile, and esters of acrylic acid or methacrylic acid.
  • Acids used include acrylic, methacrylic, itaconic, aconitic, citraconic, crotonic, maleic, fumaric, the dimer of methacrylic acid, and so on.
  • the vinyl acetate copolymers are well-known and include copolymers such as vinyl acetate/butyl acrylate/2-ethylhexyl acrylate, vinyl acetate/butyl maleate, vinyl acetate/ethylene, vinyl acetate/vinyl chloride/butyl acrylate and vinyl acetate/vinyl chloride/ethylene.
  • acrylic polymer means any polymer wherein at Ieast 50% by weight is an acrylic or methacrylic acid or ester, including mixtures of such acids and esters individually and together.
  • the term "vinyl acetate polymer” means any polymer containing at Ieast 50% by weight of vinyl acetate.
  • the aqueous polymer dispersions may be prepared according to well- known procedures, using one or more emuisifiers of an anionic, cationic, or nonionic type. Mixtures of two or more emuisifiers regardless of type may be used, except that it is generally undesirable to mix a cationic with an anionic type in any appreciable amounts since they tend to neutralize each other.
  • the amount of emulsifier may range from about 0.1 to 6% by weight or sometimes even more, based on the weight ofthe total monomer charge. When using a persulfate type of initiator, the addition of emuisifiers is often unnecessary.
  • emulsifier may sometimes be desirable from a cost standpoint, and less sensitivity of the dried coating or impregnation to moisture, and hence less liability of the coated substrate to be affected by moisture.
  • the molecular weight of these emulsion polymers is high, e.g., from about 100,000 to 10,000,000 viscosity average, most commonly above 500,000.
  • the foregoing and other emulsion polymer systems which may be pigmented with the pigment dispersions of the invention are set forth in the extensive literature on the subject, such as U.S. Patent Nos. 3,035,004; 2,795,564; 2,875,166; and 3,037,952, for example.
  • the pigment dispersion may be added to polymer latex systems at any time during the preparation thereof, including during or after polymerization or copolymerization and by single or multiple additions. Normally, from about 0.1% to about 10%, preferably 1-3%, by weight of pigment dispersion on polymer latex solids is adequate to provide suitable levels of pigmenting. However, the amount may be higher or lower depending on the particular system, other additives present, and similar reasons understood by the formulator.
  • This invention also relates to a method of coating a substrate comprising contacting a surface of a substrate with a composition comprising a latex paint binder and an inorganic pigment dispersion of this invention and drying said surface to form a film of said polymer in contact with said surface.
  • Methods of coating substrates e.g. roll coating and spray coating, are described in "Coating Methods", Encyclopedia of Polymer Science and Engineering, vol. 3, pp. 553-575
  • U.S. patent application Serial No. (Case No. M5684 FPD/COAD), filed on even date herewith, relates to the use of terpolymers of an aromatic monomer, e.g. styrene, an acid monomer, e.g. acrylic acid, and an amide monomer, e.g. acrylamide or N-methylol acrylamide, to disperse an inorganic pigment.
  • U.S. patent application Serial No. (Case No. M5549 FPD/COAD) filed on even date herewith, relates to the use of terpolymers of two different aromatic monomers, e.g. styrene and alpha-methyl styrene, and an acid monomer, e.g. acrylic acid, to disperse an inorganic pigment.
  • the disclosures of these applications are incorporated herein by reference.
  • the initiator feed and monomer feed were started at a rate such that the feeds would be complete in about 2 hours.
  • the reaction temperature was maintained at about 80°C.
  • the reaction temperature was maintained for an additional hour after all feeds were finished.
  • Five ml of a 22% ammonium persulfate solution was added and allowed to react with residual monomer for one hour.
  • the contents of the reaction flask were cooled to 25 °C and then 102.5 grams of 29% ammonia solution was added.
  • the reaction mass was heated to reflux, to a maximum of 100°C, and 280.5 grams of an isopropanol-water azeotrope was removed while simultaneously adding 237.7 grams of diluting water. The diluting water was added at the same rate the azeotrope was removed.
  • the reactor contents were cooled to 25°C before discharging and the pH of the polymer solution was adjusted to 7.2 with 29% ammonia solution.
  • the resulting copolymer solution was a clear yellow liquid with a Brookfield viscosity of 359.5 cps (spindle #2 at 60 rpm at 25°C), solids of 29.4%, and a pH of 7.2.
  • SEC molecular weight distribution was Mw of 3,256 and Mn of 713.
  • EXAMPLE 2 (50% STYRENE / 50% ACRYLIC ACID COPOLYMER) Into a 0.5 liter round bottom reaction flask equipped with a thermometer, condenser, stirrer, nitrogen inlet, and several other addition inlets, were charged 168.2 grams of isopropanol and 56.1 grams of deionized water. A nitrogen sweep was started and the contents of the reaction flask were heated to 80°C. To a 60 ml syringe attached to a micro delivery pump, was charged 40.0 grams of a 10.0% ammonium persulfate solution (initiator feed).
  • the ammonia was added at the same rate the azeotrope was removed.
  • the reactor contents were cooled to 25°C before discharging and the pH of the polymer solution was adjusted to 7.5 with 29% ammonia solution.
  • the resulting copolymer solution was a clear yellow liquid with a Brookfield viscosity of 1220 cps (spindle #2 at 12 rpm at 25°C), solids of 33.3%, and a pH of 7.5.
  • SEC molecular weight distribution was Mw of 3,829 and Mn of 963.
  • the initiator feed and monomer feed were started at a rate such that the feeds would be complete in about 2 hours.
  • the reaction temperature was maintained at about 80°C.
  • the reaction temperature was maintained for an additional two hours after all feeds were finished.
  • Five mi of a 22% ammonium persulfate solution was added and allowed to react with residual monomer for one hour.
  • 195.5 grams of 29% ammonia solution was slowly added while simultaneously removing 240.0 grams of an isopropanol-water azeotrope at reflux to a maximum of 100° C. The ammonia was added at the same rate the azeotrope was removed.
  • the reactor contents were cooled to 25 °C before discharging and the pH of the polymer solution was adjusted to 10.0 with 29% ammonia solution.
  • the resulting copolymer solution was a clear yellow liquid with a Brookfield viscosity of 220 cps (spindle #2 at 60 rpm at 25 C C), solids of 24.2%, and a pH of 8.0 SEC molecular weight distribution was Mw of 5,805 and
  • the reaction temperature was maintained at about 80°C. The reaction temperature was maintained for an additional two hours after all feeds were finished. Five ml of a 22% ammonium persulfate solution was added and allowed to react with residual monomer for one hour. The contents ofthe reaction flask were cooled to 50°C and then 140.4 grams of 29% ammonia solution was added. The reaction mass was heated to reflux, to a maximum of 100°C, and 273.8 grams of an isopropanol-water azeotrope was removed while simultaneously adding 161.3 grams of diluting water. The diluting water was added at the same rate the azeotrope was removed. The reactor contents were cooled to 25°C before discharging.
  • the resulting copolymer solution was a clear yellow liquid with a Brookfield viscosity of 73 cps (spindle #2 at 60 rpm at 25°C), solids of 30.2%, and a pH of 6.9. SEC molecular weight distribution was Mw of 7,961 and Mn of 1 ,263.
  • EXAMPLE 5 (50% STYRENE / 33% ACRYLIC ACID / 17% METHACRYLIC ACID TERPOLYMER)
  • the initiator feed and monomer feed were started at a rate such that the feeds would be complete in about 2 hours.
  • the reaction temperature was maintained at about 80 °C.
  • the reaction temperature was maintained for an additional two hours after all feeds were finished.
  • Five ml of a 22% ammonium persulfate solution was added and allowed to react with residual monomer for one hour.
  • the contents of the reaction flask were cooled to 50°C and then 88.4 grams of 29% ammonia solution was added.
  • the reaction mass was heated to reflux, to a maximum of 100°C, and 280.0 grams of an isopropanol-water azeotrope was removed while simultaneously adding 265.8 grams of diluting water.
  • the diluting water was added at the same rate the azeotrope was removed.
  • the reactor contents were cooled to 25 °C before discharging.
  • the resulting copolymer solution was a clear yellow liquid with a Brookfield viscosity of 105 cps (spindle #2 at 60 rpm at 25°C), soiids of 26.2%, and a pH of 8.0.
  • SEC molecular weight distribution was Mw of 4,607 and Mn of
  • the initiator feed and monomer feed were started at a rate such that the feeds would be complete in about 2 hours.
  • the reaction temperature was maintained at about 80°C.
  • the reaction temperature was maintained for an additional two hours after all feeds were finished.
  • Five ml of a 22% ammonium persulfate solution was added and allowed to react with residual monomer for one hour.
  • 195.5 grams of 29% ammonia solution was slowly added while simultaneously removing 240.0 grams of an isopropanol-water azeotrope at reflux to a maximum of 100°C. The ammonia was added at the same rate the azeotrope was removed.
  • the reactor contents were cooled to 25 °C before discharging and the pH of the polymer solution was adjusted to 10.0 with 29% ammonia solution.
  • the resulting copolymer solution was a clear yellow liquid with a Brookfield viscosity of 170 cps (spindle #2 at 60 rpm at 25°C), solids of 30.5%, and a pH of 10.0.
  • SEC molecular weight distribution was 9,003 Mw and 1,468 Mn.
  • Example 1 was repeated, but sodium hydroxide was used to neutralize the polymer.
  • the resulting copolymer solution was a clear yellow liquid with a
  • Styrene acrylic latex binder (Rhoplex HG-74, Rohm & Haas) 543.0
  • Test paints are applied to aluminum Q-Panels having a mill finish 3003 (0.025"x3"x9" dimension). Paints are applied 6 mils wet using a wet film applicator. Coated panels are then allowed to air dry horizontally for 24 hours. After 24 hours of film dry time, the panels are placed (coated side facing inside the chamber) on the QCT Weatherometer. This test method is a modified version of ASTM D 4585 with an internal chamber temperature of 100°F. Panels are rated hourly for the first eight hours with the final rating taken at hour 24. ASTM D714 is used to rate both frequency and size of visible blisters. Prior to QCT testing, gloss values are taken using a BYK Gardner Micro TRI glossmeter.
  • Example 2 was evaluated to have very few blisters while the paint film of Example 1 , employing a dispersing polymer with less styrene, was observed to have no blisters is thought to be due to the subjective nature of the visual observation that is employed for evaluation of blistering and the fact that the paint films were prepared from different batches of paint ingredients and were prepared and evaluated separately and on different days.

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Abstract

L'invention porte sur un polymère dispersant pour pigments inorganiques, lequel est dérivé de monomères composés essentiellement d'un monomère aromatique à insaturation éthylénique, et d'un monomère acide à insaturation éthylénique. La quantité dudit monomère acide à insaturation éthylénique est suffisante pour permettre audit polymère de s'associer à un pigment inorganique dans un milieu aqueux de manière à disperser ledit pigment inorganique dans ledit milieu aqueux pour former une dispersion aqueuse stable dudit pigment inorganique. La quantité dudit monomère aromatique à insaturation éthylénique est suffisante pour abaisser la sensibilité à l'eau d'un revêtement séché de peinture au latex constituée de ladite dispersion aqueuse stable dudit pigment inorganique. L'invention porte également sur un procédé de préparation d'un polymère utile en tant que dispersant pour pigments inorganiques, et sur un procédé de préparation d'une dispersion de pigments inorganiques utiles à la préparation de peintures aux latex.
PCT/US1996/010681 1995-06-26 1996-06-25 Procede de preparation de dispersions de pigments inorganiques WO1997001587A1 (fr)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0858483A4 (fr) * 1995-10-31 1998-10-07 Henkel Corp Procede de preparation de dispersions de pigments inorganiques
EP0872494A3 (fr) * 1997-04-17 1999-05-12 Henkel Corporation Méthode de préparation de dispersions de polymères
JPWO2017038239A1 (ja) * 2015-08-31 2018-03-29 帝人フロンティア株式会社 布帛および繊維製品

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2772252A (en) * 1952-09-11 1956-11-27 Monsanto Chemicals Terpolymer systems
US4514540A (en) * 1983-09-26 1985-04-30 Union Camp Corporation Water reducible polyamides
JPS60248709A (ja) * 1984-05-22 1985-12-09 Kanegafuchi Chem Ind Co Ltd 耐熱性共重合体
US4628071A (en) * 1984-08-21 1986-12-09 S. C. Johnson & Son, Inc. Emulsion copolymerization process
US5138004A (en) * 1991-02-06 1992-08-11 Depierne Otto S Styrene/acrylic-type polymers for use as surface sizing agents
US5160370A (en) * 1988-12-27 1992-11-03 Canon Kabushiki Kaisha Recording liquid and ink-jet recording method making recording unit, ink cartridge, and ink-jet recording apparatus making use thereof
US5326843A (en) * 1993-10-04 1994-07-05 Rohm And Haas Company Method for making an alkali-soluble emulsion copolymer

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2772252A (en) * 1952-09-11 1956-11-27 Monsanto Chemicals Terpolymer systems
US4514540A (en) * 1983-09-26 1985-04-30 Union Camp Corporation Water reducible polyamides
JPS60248709A (ja) * 1984-05-22 1985-12-09 Kanegafuchi Chem Ind Co Ltd 耐熱性共重合体
US4628071A (en) * 1984-08-21 1986-12-09 S. C. Johnson & Son, Inc. Emulsion copolymerization process
US5160370A (en) * 1988-12-27 1992-11-03 Canon Kabushiki Kaisha Recording liquid and ink-jet recording method making recording unit, ink cartridge, and ink-jet recording apparatus making use thereof
US5138004A (en) * 1991-02-06 1992-08-11 Depierne Otto S Styrene/acrylic-type polymers for use as surface sizing agents
US5326843A (en) * 1993-10-04 1994-07-05 Rohm And Haas Company Method for making an alkali-soluble emulsion copolymer

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0858483A4 (fr) * 1995-10-31 1998-10-07 Henkel Corp Procede de preparation de dispersions de pigments inorganiques
US6197879B1 (en) 1995-10-31 2001-03-06 Henkel Corporation Methods of preparing inorganic pigment dispersions
EP0872494A3 (fr) * 1997-04-17 1999-05-12 Henkel Corporation Méthode de préparation de dispersions de polymères
JPWO2017038239A1 (ja) * 2015-08-31 2018-03-29 帝人フロンティア株式会社 布帛および繊維製品

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