The invention relates to an aqueous dispersion of vinyl polymers, to a process for preparing such dispersions and to coating compositions based on such polymer dispersions. Dispersions of vinyl polymers are frequently used in coating compositions for wall paints. A problem of said paints is that they detract from the performance as far as the water-resistance is concerned.

The present invention now provides an aqueous coating composition which may be used as wall paint, where a good water-resistance as well as a high gloss may be obtained.

The aqueous dispersion of vinyl polymers is characterized in that the particles comprise

(a) a core obtained by emulsion polymerization of ethylene and a vinyl monomer selected from the group consisting of

(1) vinyl chloride, and

(2) a vinyl ester of a Cj_i3 alkanoic acid, a free- radically polymerizable monomer containing at least two double bonds, and optionally vinyl chloride, and

(b) a shell obtained by copolymerization in a subsequent step of

(1) 30 to 90 wt.% of a (cyclo)alkyl ester of (meth)acrylic acid containing 4 to 12 carbon atoms in the alkyl group,

(2) 10 to 70 wt.% of a onoethylenically unsaturated monomer selected from the group consisting of an alkyl ester of (meth)acrylic acid containing 1 to 3 carbon atoms in the alkyl group, styrene, (α)methylstyrene and mixtures thereof, and

(3) 0 to 20 wt.% of a different copolymerizable, monoethylenically unsaturated monomer.

Best results are obtained with an aqueous dispersion wherein the weight ratio of the corershell copolymers is between 20:80 and 90:10, preferably between 40:60 and 80:20.

As examples of vinylesters of a Cj_-3 alkanoic acid suitable for preparing the core polymer may be mentioned: vinyl formiate, vinyl acetate, vinyl laurate, vinyl propionate, and vinyl octoate.

As nonlimiting examples of "free-radically polymerizable monomer containing at least two bonds" which are useful in the practice of the current invention may be mentioned glycerol diallylether, triallyl cyanurate, triallyl isocyanurate, allyl methacrylate, butanediol diacrylate, trimethylolpropane triacrylate, and preferably, trimethylolpropane diallylether. This is a nonlimiting list because the range of free-radically polymerizable monomers is too broad to include a complete listing, and further, such reactions and potential reactants are well-known in the art and need not be repeated here.

As examples of (cyclo)alkyl (meth)acrylates suitable for preparing the shell monomer and having a (cyclo)alkyl group with 4-12 carbon atoms may be mentioned: butyl acrylate, butyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, octyl acrylate, octyl methacrylate, isobornyl acrylate, isobornyl methacrylate, dodecyl acrylate, dodecyl methacrylate, cyclohexyl acrylate, and cyclohexyl methacrylate.

As examples of alkyl esters of (meth)acrylic acid containing 1 to 3 carbon atoms in the alkyl group may be mentioned: methyl acrylate, ethyl methacrylate, propyl acrylate and isopropyl methacrylate.

As suitable monomeric, monoethylenically unsaturated compounds of which maximally 20 wt.% may be used in the monomer mixture for the shell polymer may be mentioned: alkyl maleates and fumarates having 1 to 12 carbon atoms in the (cyclo)alkyl groups, such as dimethyl maleate, diethyl maleate, diethyl fumarate, and dipropyl maleate; (meth)acrylates having ether groups such as 2-methoxyethyl methacrylate, 2-ethoxyethyl methacrylate, 3-methoxypropyl acrylate; hydroxyalkyl ( eth)acrylates, e.g., 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, 4-hydroxybutyl acrylate, 6-hydroxyhexyl acrylate, p- hydroxycyclohexyl acrylate, p-hydroxycyclohexyl methacrylate, hydroxypolyethylene glycol (meth)acrylates, hydroxypolypropylene glycol (meth)acrylates and the corresponding alkoxy derivatives thereof; epoxy(meth)acrylates, such as glycidyl acrylate, glycidyl methacrylate; monovinyl aromatic hydrocarbons, such as vinyl toluene, vinyl naphthalene; also acrylamide and methacrylamide, acrylonitrile, methacrylonitrile, N-methylol acrylamide, N-methylol methacrylamide; N-alkyl (meth)acrylamides, such as N-isopropyl acrylacide, N-isopropyl methacrylamide, N-t-butyl acrylamide, N-t-octyl acrylamide, N,N-dimethyl a inoethyl methacrylate, N,N-diethyl aminoethyl methacrylate; (meth)acrylic acid, maleic acid, itaconic acid; monomers, such as vinyl chloride, vinyl acetate, vinyl propionate, and monomers containing one or more urea or urethane groups, such as for instance the reaction product of 1 mole of isocyanatoethyl methacrylate and 1 mole of butylamine, 1 mole of benzylamine, 1 mole of butanol , 1 mole of 2-ethylhexanol , and 1 mole of methanol , respectively. Mixtures of these compounds may also be used.

A particularly suitable aqueous dispersion according to the invention may be obtained when, based on core weight, said core is obtained by emulsion polymerization of

(1) 2 to 30 wt.% of ethylene,

(2) 0 to 10 wt.% of free-radically polymerizable monomer containing at least two double bonds,

(3) 0 to 80 wt.% of monomer(s) of vinyl ester of a Cj to (43 alkanoic acid, and

(4) 0 to 95 wt.% of vinyl chloride monomer.

The aqueous dispersions of a multi-layer polymer having core/shell form according to the current invention may be prepared by a process comprised of

(a) emulsion polymerizing, to form a core, a core monomer mixture comprising ethylene and a vinyl monomer selected from the group consisting of

(1) vinyl chloride, and

(2) a vinyl ester of a Cχ_i3 alkanoic acid, a free-radically polymerizable monomer containing at least two double bonds, and optionally vinyl chloride,

(b) followed by copolymerization in a subsequent step, to form a shell, a shell monomer mixture comprising

(1) 30 to 90 wt.% of a (cyclo)alkyl ester of (meth)acrylic acid containing 4 to 12 carbon atoms in the alkyl group,

(2) 10 to 70 wt.% of a monoethylenically unsaturated monomer selected from the group consisting of an alkyl ester of (meth)acrylic acid containing 1 to 3 carbon atoms in the alkyl group, styrene, (α)methylstyrene and mixtures thereof, and

(3) 0 to 20 wt.% of a different copolymerizable, monoethylenically unsaturated monomer.

The emulsion polymerization described in step (a) above may also be carried out in the presence of vinyl and/or acrylic seed latex. Preferably, such seed latices are typically composed of (meth)acrylic esters of C ^* _4 alkyl groups. The use of seed latex in emulsion polymerisation is known from, for example, EP-A-0287 144. The amount of seed latex typically used is in the range of 0,01 to 10 wt.% of the final multi-layer polymer. The typical particle size of the seed latex is in the range of 10 to 100 nm.

The emulsifiers of which use is preferably made in the emulsion polymerization are of an anionic or nonionic nature. Examples of anionic emulsifiers include: potassium laurate, potassium stearate, potassium oleate, sodium decyl sulphate, sodium dodecyl sulphate, and sodium rosinate. Examples of non-ionic emulsifiers include: linear and branched alkyl and alkyl aryl polyethylene glycol, and polypropylene glycol ethers and thioethers, alkyl phenoxypoly(ethyleneoxy)ethanols such as the adduct of 1 mole of nonyl phenol to 5-12 moles of ethylene oxide, or the ammonium salt of the sulphate of this adduct. Also, in emulsion polymerization, the conventional radical initiators may be used in the usual amounts. Examples of suitable radical initiators include: ammonium persulphate, sodium persulphate, potassium persulphate, bis(2-ethylhexyl) peroxydi carbonate, di-n-butyl peroxydi carbonate, t-butyl perpivalate, t-butyl hydroperoxide, cumene hydroperoxide, dibenzoyl peroxide, dilauroyl peroxide,

2,2'-azobisisobutyronitrile, and 2,2'-azobis-2-methylbutyronitrile. As suitable reducing agents which may be used in combination with e.g. a hydroperoxide may be mentioned: ascorbic acid, sodium sulphoxylate formaldehyde, thiosulphates, bisulphates, hydrosulphates, water-soluble amines such as diethylene tria ine, triethylene tetraamine, tetraethylene penta ine, N,N' -dimethyl ethanola ine,

N,N-diethyl ethanolamine, and reducing salts such as cobalt, iron, nickel, and copper sulphate. Optionally, a chain length regulator, for instance n-octyl mercaptan, dodecyl mercaptan, and 3-mercaptopropionic acid, may also be used.

Copolymerization of the monomer mixtures generally is carried out at elevated pressure and at a temperature of 40°-100°C or higher.

The aqueous dispersions of the instant invention are particularly useful in coating compositions which produce coatings having a surprisingly good water-resistance as well as a high gloss.

The water-dispersible dispersions according to the invention may be used as such or in combination with such water-dispersible materials as alkyd resins, polyesters, polyvinyl resins or polyurethanes. They are extremely suitable for use in wall paints and paints for wood. To this end the aqueous dispersions according to the invention are used in combination with the conventional additives and adjuvants, such as, for nonlimiting example, pigments, dispersing agents, dyes, and organic solvents. The applicable pigments may have an acid, a neutral or a basic character. Optionally, the pigments may be pre-treated to modify the properties. Nonlimiting examples of suitable pigments are the inorganic pigments, such as titanium dioxide, iron oxide, carbon black, silica, kaolin, talc, barium sulphate, lead silicate, strontium chromate, and chromium oxide; and organic pigments, such as phthalocyanine pigments.

The invention will be further described in the following examples and comparative examples, which must not be construed as limiting the scope of the present invention.

Examples

In the following examples, the mean particle size of the dispersions was determined by dynamic light scattering, the dispersion being diluted with water to a solids content of about 0.1 wt.%.

The solids content was determined in accordance with ASTM method 0 1644-59 with heating at 140°C over a period of 30 minutes.

As a representative example of the conventional and suitable emulsifiers there was used in all examples a 30 wt.% aqueous solution of the ammonium sulphate of the adduct of 1 molecule of nonyl phenol to 9 molecules of ethylene oxide.

The gloss was determined in accordance with ASTM D-523 at 20°. A gloss value on a sheet of glass of above 60 at 20° is considered high, while a gloss value of above 65 at 20° is considered very high.

The water resistance was determined by first applying a 150 μm coating layer onto a glass plate, followed by drying for 24 hrs at 23°C. After spotting with a drop of water, the coating layers were inspected visually after 1 week for the presence of bubbles and blisters. The test is rated on a 1-10 scale, where "1" is very poor and "10" is excellent.

In the Examples, use is made of the following abbreviations and product names:

Fenopon EP-110: ammonium salt of sulphated nonylphenoxypolyethylene oxide

Trigonox AW-70: tert.butyl hydroperoxide

SFS: sodium formaldehyde sulphoxylate

DAAA: diacetone acrylamide

2-EHA: 2-ethylhexyl acrylate

STY: styrene

MMA: methyl methacrylate

MAA: methacrylic acid

WAM: Nourycryl MA-125 is a wet adhesion monomer or promotor (WAM or

WAP)

BMA: butyl methacrylate

VAc: vinyl acetate

TMPDAE: trimethylol propane diallyl ether

TAC: triallyl cyanurate

Veova 9/10: hydrophobic vinyl esters (ex Shell)

VB: solids content

VC : vi nyl chl oride

Example 1

A. The preparation of a seed emulsion

Into a 3 1 three-necked flask fitted with a stirrer, a cooling apparatus, a dosing funnel with a pressure equalisation tube, a temperature control, and an N2/vacuum flushing mechanism were charged successively:

Fenopon EP-110 33.33 g demineralised water 1984.0 g

MMA 55.0 g

BA 45.0 g ascorbic acid 0.4 g

FeS0 .7H ₂ 0 1.0 mg

The dosing funnel was filled with a solution of 0.5 g of ammonium persulphate in 100 g of water.

The whole of the reactor was evacuated three times and then filled with N again.

The temperature of the contents of the reactor was raised to 60°C, after which 75 ml of ammonium persulphate solution were added in one go.

The reactor temperature increased to 65°C within about 5 minutes, whereupon the remaining ammonium persulphate solution was post-fed in 30 minutes.

Next, the flask was cooled down to room temperature.

The seed dispersion was a stable emulsion with a solids content of 5.0 wt.% and a particle size of 32 nm.

B. The preparation of the core dispersion

The preparation of the core dispersion was carried out in a 600 ml pressure reactor fitted with a stirrer, an electric heating jacket with temperature control, a stirrer with variable speed, a pressure gauge, and a bursting disc. The reactor could be connected to three metering streams and flushed with an inert gas.

Introduced into the reactor vessel were: seed emulsion (1A) 136.1 g demineralised water 30.0 g

FeS0 ₄ .7H2θ 1.0 mg

The reactor was flushed with nitrogen and its temperature brought to

60°C. Next, using ethylene, the pressure in the reactor was raised to

35 bar. There was no further ethylene feeding during the reaction.

The following were added simultaneously:

39.4 g of VC, feeding time 3 hours and 15 minutes a pre-emulsion, feeding time 3 hours and 30 minutes, the pre-emulsion being composed of:

Fenopon EP-110 1.68 g

VAc 78.7 g

Trigonox AW-70 0.21 g demineralised water 29.0 g

a reduci ng sol uti on , feedi ng time 5 hours : SFS 0.275 g

NH 0H (2N) 2.75 g demi neral i sed water 27.25 g

After the feedi ng of the pre-emul si on over 3 hours and 30 mi nutes an oxidati on sol uti on was added simul taneously with the reduci ng sol uti on over a peri od of 90 mi nutes .

The oxidation solution was composed of: Trigonox AW-70 0.125 g demineralised water 9.0 g

The feeding processes were interrupted after 4 hours and 15 minutes. At this time the ethylene pressure was eased down. When the reactor had become pressureless, the feeding of the oxidation and reducing solutions was started up again.

After 5 hours total the reactor was cooled down.

The core dispersion prepared in this manner was a stable emulsion with a solids content of 37.1 wt.% and a particle size of 93 nm. The conversion of the various monomers could be calculated from an analysis of the polymer elements:

%C = 52.14; %H = 6.91; %0 = 23.76; %C1 = 16.58. The VC conversion was 99%, the VAc conversion was 99.6%, and the ethylene uptake was 6.6 g.

C. The preparation of the core-shell dispersion

325.3 g of core dispersion having a VB=37.1% were added beforehand to a 1 1 reactor and rendered thoroughly oxygen-free by forming a vacuum, flushing with nitrogen, and then repeating this procedure twice more. The dispersion was next heated to 60°C, whereupon 180.0 g of pre- emulsion (see pre-emulsion preparation below) were added simultaneously with 22.5 g of reducing solution. On conclusion of the pre-emulsion feeding after 1.5 hours, the reducing solution was added for 15 more minutes. The obtained dispersion was _^ en kept at 60°C for a further 0.5 hours and subsequently cooled to 40°C. At this temperature 3.6 g of 25% ammonia were added, whereupon the dispersion was cooled to room temperature and diluted with 19.6 g of water to VB=45%. The dispersion had a pH=8,5 and a particle size of 118 nm. The

core/shell ratio was 50/50. The shell was composed of 36.7% of 2-EHA, 25.0% of STY, 28.8% of MMA, 3.5% of MAA, 3.0% of DAAA, and 3.0% of WAM. Tg(shell, calculated)=30°C.

_c A pre-emulsion was prepared which was composed of:

demineralised water 129.0 g

Fenopon EP-110 6.48 g

Trigonox AW-70 0.78 g _ιrι monomer mixture 277.4 g

10 ³

The monomer mixture was composed of:

DAAA 9.0 g

2-EHA 110.2 g

STY 75.0 g

15

MMA 86.4 g

MAA 10.5 g

WAM 9.0 g

20 To prepare the pre-emulsion Fenopon was added to the demineralised water, as was Trigonox AW-70. To this whole the monomer mixture was added in about 30 minutes, with vigorous stirring and under nitrogen.

The reducing solution was prepared by dissolving 1.03 g of SFS in 25 demineralised water to a concentration of weight of 1.03%.

Alternative synthesis options:

* use may be made of other surfactants: sodium lauryl sulphate, sodium dodecyl benzene sulphate, etc. , _n * also, it is possible to alter the initiation system: persulphate (ammonium, sodium, potassium) instead of Trigonox AW-70, ascorbic acid, metahydrogen sulphite, etc. instead of SFS. Also, a thermal initiation system may be used: persulphate, azo-initiators, etc.,

though often elevated temperatures (70°-80°C) are required. This temperature range may be employed for the present system. * alternatively, the pre-emulsion may be omitted. In that case, the soap is dissolved in, say, the reducing solution, and the Trigonox is added separately.

Example 2

Example 1 was repeated, except that the following changes were made in Example IB: 77.4 g of VAc and 1.31 g of TMPDAE were added via the pre-

10 emulsion (1 wt.% of crosslinker calculated on the monomers). The core dispersion prepared in this way was a stable emulsion having a solids content of 37.0 wt.% and a particle size of 88 nm. The conversion of the monomers could be calculated from an analysis of the polymer elements:

15

%C = 52.385; %H = 6.94; %0 = 24.01; %C1 = 16.7. The VAc conversion was 99.2%, the VC conversion was 99.3%, and the ethylene uptake was 6.44 g.

20 Example 3

Example 1 was repeated, except that the following changes were made in Example IB: 78.05 g of VAc and 0.65 g of TMPDAE were added via the pre-emulsion (0.5 wt.% of crosslinker calculated on the monomers). „r The core dispersion prepared in this way was a stable emulsion having a solids content of 37.05 wt.% and a particle size of 97 nm. The conversion of the monomers could be calculated from an analysis of the polymer elements:

%C = 52.27; %H = 6.83; %0 = 24.18; %C1 = 16.7. The VAc and VC conversions both were 99.0%. The ethylene uptake was 6.3 g.

Exampl e 4

Example 1 was repeated, except that the following changes were made in Example IB: 76.8 g of VAc and 1.96 g of TMPDAE were added via the pre- emulsion (1.5 wt.% of crosslinker calculated on the monomers). The core dispersion prepared in this way was a stable emulsion having a solids content of 36.3 wt.% and a particle size of 97 nm. The conversion of the monomers could be calculated from an analysis of the polymer elements:

%C = 52.2; %H = 7.035; %0 = 23.8; %C1 = 17.1. The VC conversion was 99.6%, the VAc conversion was 97.2%, and the ethylene uptake was 6.5 g.

Example 5

Example 1 was repeated, except that the following changes were made in

Example IB: 77.6 g of VAc and 0.85 g of TAC were added via the preemulsion (the crosslinking corresponding to 1.31 g of TMPDAE).

The core dispersion prepared in this way was a stable emulsion having a solids content of 37.1 wt.% and a particle size of 90 nm.

The conversion of the monomers could be calculated from an analysis of the polymer elements:

%C = 52.04; %H = 6.84; %0 = 23.82; %C1 = 16.58. The VC conversion was 99.0%, the VAc conversion was 99.6%, and the ethylene uptake was 6.6 g.

Example 6

Example 1 was repeated, except that the following changes were made in Example IB:

58.4 g of VAc and 1.31 g of TMPDAE were added via the pre-emulsion

58.4 g of VC were added the ethylene pressure was 55 bar.

The core dispersion prepared in this way was a stable emulsion having a solids content of 37.45 wt.% and a particle size of 91 nm. The conversion of the monomers could be calculated from an analysis of the polymer elements:

%C = 51.27; %H = 6.73; %0 = 17.0; %C1 = 24.14. The VC conversion was 99.2%, the VAc conversion was 92.1%, and the ethylene uptake was 13.6 g.

Example 7 0

Example 1 was repeated, except that the following changes were made in Example IB:

39.4 g of VAc and 1.31 g of TMPDAE were added via the pre-emulsion

77.4 g of VC were added the ethylene pressure was 55 bar. 5

The core dispersion prepared in this way was a stable emulsion having a solids content of 37.25 wt.% and a particle size of 88 nm. The conversion of the monomers could be calculated from an analysis of n the polymer elements:

%C = 48.90; %H = 6.67; %0 = 12.33; %C1 = 31.50. The VC conversion was 96.4%, the VAc conversion was 91.6%, and the ethylene uptake was 12.8 g.

Example 8

Example 1 was repeated, except that the following changes were made in Example IB:

118.1 g of VC were added there was no VAc addition via the pre-emulsion the ethylene pressure was 55 bar.

The core dispersion prepared in this way was a stable emulsion having a solids content of 38.1 wt.% and a particle size of 91 nm.

The VC conversion could be calculated from an analysis of the polymer elements:

%C = 44.71; %H = 6.30; %0 = 2.57; %C1 ^* - ^** 46.14. The VC conversion was 93.5%. The ethylene uptake was 12.8 g.

Example 9

0 Example 1 was repeated, except that the following changes were made in Example IB: the pre-emulsion contained the following monomers:

VAc 38.7 g

TMPDAE 1.31 g

Veova 9 22.15 g 5

Veova 10 13.55 g.

The core dispersion prepared in this way was a stable emulsion having a solids content of 36.4 wt.% and a particle size of 93 nm. 0 Only the chlorine content of the polymer was determined. It was

16.61%.

Example 10

Example 4 was repeated, except that the following change was made in Example 1C: the calculated Tg of the shell was set at =39°C by replacing part of the 2-EHA with BMA. The shell composition was as follows: 28.1% of 2-EHA, 8.6% of BMA, 25.0% of STY, 28.8% of MMA, 3.5% of MAA, _Q 3.0% of DAAA, and 3.0% of WAM.

Example 11

Example 4 was repeated, except that the following change was made in

Example 1C: the calculated Tg of the shell was set at =46°C by replacing part of the 2-EHA with BMA. The shell composition was as follows: 21.4% of 2-EHA, 15.3% of BMA, 25.0% of STY, 28.8% of MMA, 3.5% of MAA, 3.0% of DAAA, and 3.0% of WAM.

Paint Formulation

demineralised water 34.3 g propylene glycol 29.4 g Orotan SGI 2.1 g (dispersant) ammonia (25%) 2.0 g Proxel XL 2 0.5 g Tiθ2 RHD2 196.3 g Nopco 8034 E 1.0 g (antifoaming agent)

core-shell dispersion (VB45%) 544.0 g Berol 09 (25%) 21.6 g (non-ionic surfactant) demineralised water 70.8 g Nopco 8034 E 2.0 g

Texanol 32.0 g (coalescent)

Primal RM05 (up to ICI = 2) (thickener) ammonia (25%) 4.0 g demineralised water balance in all 1000.0 g

Example Core Compo¬ Cross-linker MFT Gloss Water sition ^* (°C) 20° Resistance

VAc/VC/ET

1 59/30/5 25 68 4

2 58/29/5 1% TMPDAE 27 63 6

3 58/29/5 0.5% TMPDAE 22 57 7

4 75/29/5 1.5% TMPDAE 27 63 7

5 58/29/5 0.65% TAC 24 58 6

6 39/42/10 1% TMPDAE 25 - -

7 27/55/10 1% TMPDAE 25 - -

8 0/81/11 - 29 70 6

9 29% VC 1% TMPDAE 25 66 6

10* 75/29/5 1.5% TMPDAE 31 62 7

113 75/29/5 1.5% TMPDAE >35 57 7

shell composition: 36.7% of 2-EHA, 25.0% of STY, 28.8% of MMA,

3.5% of MAA, 3.0% of DAAA, and 3.0% of WAM.

Tg(shell, calculated)=30°C. shell composition: 28.1% of 2-EHA, 8.6% of BMA, 25.0% of STY,

28.8% of MMA, 3.5% of MAA, 3.0% of DAAA, and 3.0% of WAM.

Tg(shell, calculated)=39°C. shell composition: 21.4% of 2-EHA, 15.3% of BMA, 25.0% of STY,

28.8% of MMA, 3.5% of MAA, 3.0% of DAAA, and 3.0% of WAM.

Tg(shell, calculated)=-39°C.