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Title:
HIGH-GLOSS LATEX PAINTS AND POLYMERIC COMPOSITIONS FOR USE THEREIN
Document Type and Number:
WIPO Patent Application WO/1990/015102
Kind Code:
A2
Abstract:
A polymeric composition comprising a polymer and less than about 1 weight percent surfactant is useful for producing a high-gloss latex paint. The polymer comprises about 25 to about 60 weight percent of a soft monomer whose homopolymer has a Tg of less than about -20°C and about 40 to about 75 weight percent of a hard monomer whose homopolymer has a Tg of greater than about 30°C, and has a calculated Tg of about 15° to about 35°C, an actual Tg of about 10° to about 60°C, and a particle size of less than about 250nm.

Inventors:
BIALE JOHN (US)
Application Number:
PCT/US1990/003246
Publication Date:
December 13, 1990
Filing Date:
June 07, 1990
Export Citation:
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Assignee:
UNION OIL CO (US)
International Classes:
C09D5/02; C09D125/14; C08L57/00; C09D133/06; C09D157/00; C09D201/00; (IPC1-7): C08L57/00; C09D5/02
Foreign References:
EP0007042A11980-01-23
EP0075529A21983-03-30
EP0083781A11983-07-20
GB2091277A1982-07-28
DE2743764A11979-04-05
CS191563A
DE2137621A11973-02-01
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Claims:
What is claimed is:
1. A polymeric composition comprising a polymer and less than about 1 weight percent surfactant, the polymer comprising: (a) about 25 to about 60 weight percent of a soft monomer whose homopolymer has a T of less than about 20βC. ; a (b) about 40 to about 75 weight percent of a hard monomer whose homopolymer has a T ofgreater than about 30°C.
2. The composition of claim 1 wherein the compositi comprises less than about 0.5 weight percent surfactant.
3. The composition of claim 1 wherein the polymer comprises about 30 to about 50 weight percent of the soft mono and about 50 to about 70 weight percent of the hard monomer.
4. The composition of claim 1 wherein the soft monomer is selected from the group consisting of nonfunctional acrylic monomers, vinylidene halide monomers, alkylene monomers glycidyl acrylate monomer, and mixtures thereof.
5. The composition of claim 1 wherein the soft monomer is a nonfunctional acrylic monomer having the formula R, O ιl ii CH2 = C C OR2, wherein R. is selected from the group consisting of hydrogen a methyl, and R2 is an alkyl group.
6. The composition of claim 5 wherein R. contains to about 15 carbon atoms.
7. The composition of claim 1 wherein the soft monomer is selected from the group consisting of ethyl acrylat butyl acrylate, isobutyl acrylate, ethylhexyl acrylate, isodec methacrylate, lauryl methacrylate, tridecyl methacrylate, and mixtures thereof.
8. The composition of claim 1 wherein the soft monomer is butyl acrylate.
9. The composition of claim 1 wherein the hard monomer is selected from the group consisting of vinyl halide monomers, alkenyl aromatic monomers, nonfunctional methacryli monomers, acrylonitrile monomer, vinyl acetate monomer, and mixtures thereof.
10. The composition of claim 1 wherein the hard monomer is selected from the group consisting of alkenyl aroma monomers, nonfunctional methacrylic monomers, and mixtures thereof.
11. The composition of claim 1 wherein the hard monomer is an alkenyl aromatic monomer having the formula wherein X is an aliphatic radical containing at least one alke bond, Y is a substituent on the aromatic ring, and n is an integer from 0 to 5.
12. The composition of claim 11 wherein the alkenyl aromatic monomer is selected from the group consisting of styrene, pmethyl styrene, methyl styrene, o,pdimethyl styren o,pdiethyl styrene, pchlorostyrene, isopropyl styrene, tbut styrene, omethylpisopropyl styrene, o,ρdichlorostyrene, an mixtures thereof.
13. The composition of claim 1 wherein the hard monomer is styrene.
14. The composition of claim 1 wherein the hard monomer is a nonfunctional methacrylic monomer having the formula wherein R3 is an alkyl group.
15. The composition of claim 14 wherein R3 contains to about 6 carbon atoms.
16. The composition of claim 1 wherein the hard monomer is selected from the group consisting of methyl methacrylate, ethyl methacrylate, isobutyl methacrylate, and mixtures thereof.
17. The composition of claim 1 having a calculated of about 15° to about 35βC.
18. The composition of claim 1 having an actual T about.10° to about 60βC.
19. The composition of claim 1 further comprising a least one monomer selected from the group consisting of olefin carboxylic acid monomers, ureidocontaining amine monomers, functional acrylic monomers, acrylamide monomer, methacrylamid monomer, and mixtures thereof.
20. The composition of claim 1 further comprising least one monomer selected from the group consisting of olefi carboxylic acid monomers, functional acrylic monomers, and mixtures thereof.
21. The composition of claim 1 further comprising olefinic carboxylic acid monomer selected from the group consisting of mono and diolefinic carboxylic acids, and mixtures thereof.
22. The composition of claim 1 further comprising olefinic carboxylic acid monomer selected from the group consisting of acrylic acid, methacrylic acid, acryloxyacetic acid, methacryloxyacetic acid, acrylamidoglycolic acid, itaco acid, fumaric acid, and mixtures thereof.
23. The composition of claim 1 further comprising olefinic carboxylic acid monomer selected from the group consisting of acrylic acid, methacrylic acid, and mixtures thereof.
24. The composition of claim 1 further comprising functional acrylic monomer selected from the group consisting hydroxyalkyl acrylate monomers, aminoalkyl acrylate monomers, mixtures thereof.
25. The composition of claim 1 further comprising hydroxyalkyl acrylate monomer having the formula R, 0 •1 It CH2 = C C OR4 wherein R, is selected from the group consisting of hydrogen methyl, and R4 is a hydroxyalkyl group comprising up to about carbon atoms.
26. The composition of claim 1 further comprising a hydroxyalkyl acrylate monomer selected from the group consistin of hydroxyethyl methacrylate, hydroxypropyl methacrylate, hydroxyethyl acrylate, hydroxypropyl acrylate, and mixtures thereof.
27. The composition of claim 1 further comprising an aminoalkyl acrylate monomer having the formula wherein R, is selected from the group consisting of hydrogen a methyl, R5 is selected from the group consisting of hydrogen, halo, thio, and monovalent organic radicals; Rg is a divalent radical containing up to about 5 carbon atoms; and R7 and R„ ar each independently selected from the group consisting of hydro and alkyl radicals containing up to about 2 carbon atoms.
28. The composition of claim 1 further comprising a aminoalkyl acrylate monomer selected from the group consisting tbutylaminoethyl methacrylate, dimethylaminoethyl methacrylat tbutylaminoethyl acrylate, dimethylaminoethyl acrylate, and mixtures thereof.
29. The composition of claim 1 further comprising a ureidocontaining amine monomer.
30. The composition of claim 1 further comprising l[2(3allyloxy2hydroxypropylamino) ethyl]imidazolidin2o.
31. The composition of claim 1 wherein the polymer comprises about 40 to about 75 weight percent hard monomer selected from the group consisting of alkenyl aromatic monomer nonfunctional methacrylic monomers, and mixtures thereof; abo 0.1 to about 10 weight percent functional acrylic monomer; and about 0.1 to about 10 weight percent olefinic carboxylic acid monomer.
32. The composition of claim 1 wherein the polymer comprises about 30 to to about 50 weight percent soft monomer about 45 to about 65 weight percent hard monomer selected fr the group consisting of alkenyl aromatic monomers, nonfuncti methacrylic monomers, and mixtures thereof; about 0.1 to abou weight percent functional acrylic monomer; and about 0.1 to about 10 weight percent olefinic carbςxylic acid monomer.
33. The composition of claim 1 comprising less tha about 0.5 weight percent surfactant, and wherein the polymer comprises about 30 to to about 45 weight percent soft monomer about 50 to about 60 weight percent hard monomer selected fr the group consisting of alkenyl aromatic monomers, nonfuncti methacrylic monomers, and mixtures thereof; about 3 to about weight percent functional acrylic monomer; and about 1 to ab 5 weight percent olefinic carboxylic acid monomer.
34. The composition of claim 1 wherein the polymer a particle size of less than about 250 nm.
35. The composition of claim 1 wherein the polymer a particle size of about 90 to about 200 nm.
36. The composition of claim 1 further comprising seed.
37. The composition of claim 36 wherein the seed particle size of about 25 to about 80 nm.
38. The composition of claim 36 wherein the seed comprises an alkenyl aromatic monomer.
39. The composition of claim 1 having a calculated T of about 15° to about 35 C, an actual T of about 10β to about 60βC, and wherein the polymer comprises about 40 to about 75 weight percent hard monomer selected from the group consisting alkenyl aromatic monomers, nonfunctional methacrylic monomers, and mixtures thereof; about 0.1 to about 10 weight percent functional acrylic monomer; and about 0.1 to about 10 weight percent olefinic carboxylic acid monomer, the polymer having a •particle size of less than about 250 nm.
40. The composition of claim 39 wherein the polymer comprises about 30 to about 50 weight percent soft monomer; abo 45 to about 65 weight percent hard monomer selected from the group consisting of alkenyl aromatic monomers, nonfunctional methacrylic monomers, and mixtures thereof; about 0.1 to about weight percent functional acrylic monomer; and about 0.1 to about 10 weight percent olefinic carboxylic acid monomer, the polymer having a particle size of about 90 to about 200 nm.
41. The composition of claim 39 wherein the polymer comprises about 30 to about 45 weight percent butyl acrylate; about 50 to about 60 weight percent hard monomer selected from the group consisting of styrene and methyl methacrylate; about to about 7 weight percent functional methacrylic monomer select from the group consisting of hydroxyethyl methacrylate, hydroxypropyl methacrylate, and mixtures thereof; and about 1 t about 5 weight percent olefinic carboxylic acid monomer selecte from the group consisting of acrylic acid, methacrylic acid, an mixtures thereof.
42. An emulsion comprising: ( i) water; and (ii) the composition of claim 1.
43. An emulsion comprising: (a) water; and (b) a polymer, the polymer comprising about 25 to ab 60 weight percent of a soft monomer whose homopolymer has a T less than about 20βC, and about 40 to about 75 weight percen of a hard monomer whose homopolymer has a T of greater than about 30βC, wherein the emulsion has a surface tension greate than about 45 dynes/cm.
44. The emulsion of claim 43 wherein the emulsion h a surface tension of about 45 to about 55 dynes/cm.
45. A paint comprising: (a) a coalescing aid; (b) a thickening aid; (c) a dispersing aid; (d) a defoamer; (e) a biocide; (f) a filler; and (g) a binder, wherein the binder is the emulsion of claim 42.
46. The paint of claim 45 having a pigment volume concentration (pvc) of less than about 25 volume by volume percent (v/v%).
47. The paint of claim 45 having a pvc of about 15 about 25 v/v%.
48. A film formed by drying the paint of claim 45.
49. The film of claim 48 having a specular gloss of least about 75 percent reflectance at about a 60° angle of incidence.
50. The film of claim 48 having a specular gloss o least about 80 percent reflectance at about a 60° angle of incidence.
51. The film of claim 48 having a specular gloss of a least about 85 percent reflectance at about a 60° angle of incidence.
52. An article comprising a substrate having a surface, wherein at least a portion of the surface is coated wi the film of claim 48.
53. A latex paint comprising the composition of clai 1.
54. A polymeric composition comprising a polymer and less than about 1 weight percent surfactant, the polymer comprising: (a) about 25 to about 60 weight percent of a soft monomer whose homopolymer has a T of less than about 20βC, t soft monomer being selected from the group consisting of nonfunctional acrylic monomers, vinylidene halide monomers, alkylene monomers, glycidyl acrylate monomer, and mixtures thereof; and (b) about 40 to about 75 weight percent of a hard monomer whose homopolymer has a T of greater than about 30βC, the hard monomer being selected from the group consisting of vinyl halide monomers, alkenyl aromatic monomers, nonfunctiona methacrylic monomers, acrylonitrile monomer, vinyl acetate monomer, and mixtures thereof.
55. The composition of claim 54 wherein the composition comprises less than about 0.5 weight percent surfactant and has a calculated T of about 15β to about 35°C. and an actual and different T of about 10° to about 60βC, and the polymer comprises about 30 to about 50 weight percent of th soft monomer and about 50 to about 70 weight percent of the har monomer, the polymer having a particle size of less than about 250 nm.
56. The composition of claim 54 wherein the soft monomer is a nonfunctional acrylic monomer having the formula R, o CH„ = cC1 C_ OR. wherein R^ is selected from the group consisting of hydrogen a methyl, and R is an alkyl group; and the hard monomer is selected from the group consisting of: (i) alkenyl aromatic moπpmers having the formula wherein X is an aliphatic radical containing at least one alke bond, Y is a substituent on the aromatic ring, and n is an integer from 0 to 5; (ii) nonfunctional methacrylic monomers having t formula CH, 0 I || CH2 = C C OR3, wherein R3 is an alkyl group; and (iii) mixtures of (i) and (ii).
57. The composition of claim 54 wherein soft monome is selected from the group consisting of ethyl acrylate, butyl acrylate, isobutyl acrylate, ethylhexyl acrylate, isodecyl methacrylate, lauryl methacrylate, tridecyl methacrylate, and mixtures thereof; and the hard monomer is selected from the gr consisting of styrene, pmethyl styrene, methyl styrene, o,pdimethyl styrene, o,pdiethyl styrene, pchlorostyrene, isopropyl styrene, tbutyl styrene, omethylpisopropyl styr o,pdichlorostyrene, methyl methacrylate, ethyl methacrylate, isobutyl methacrylate, and mixtures thereof.
58. The composition of claim 57 wherein the composition comprises less than about 0.5 weight percent surfactant and has a calculated T„ of about 15° to about 35βC. and an actual and different T of about 10° to about 60βC, and the polymer comprises about 30 to about 50 weight percent of th soft monomer and about 50 to about 70 weight percent of the har monomer, the polymer having a particle size of less than about 250 nm.
59. The composition of claim 54 wherein soft monomer is butyl acrylate; and the hard monomer is selected from the group consisting of styrene, methyl methacrylate, and mixtures thereof.
60. The composition of claim 54 further comprising a least one monomer selected from the group consisting of olefini carboxylic acid monomers, ureidocontaining amine monomers, functional acrylic monomers, acrylamide monomer, methacrylamide monomer, and mixtures thereof.
61. The composition of claim 60 wherein the composition comprises less than. about 0.5 weight percent surfactant and has a calculated T of about 15° to about 35°C. and an actual and different T of about 10° to about 60βC, an the polymer comprises about 30 to about 50 weight percent of t soft monomer and about 50 to about 70 weight percent of the har monomer, the polymer having a particle size of less than about 250 nm.
62. The composition of claim 54 further comprising least one monomer selected from the group consisting of: (i) olefinic carboxylic acid monomers selected from the group consisting of acrylic acid, methacrylic acid, acryloxyacetic acid, methacryloxyacetic acid, acrylamidoglycol acid, itaconic acid, fumaric acid, and mixtures thereof; (ii) ureidocontaining amine monomers; (iii) functional acrylic monomers selected from t group consisting of hydroxyalkyl acrylate monomers, aminoalky acrylate monomers, and mixtures thereof; (iv) acrylamide monomer; (v) methacrylamide monomer; and (vi) mixtures of (i), (ii), (iii), (iv), and (v) .
63. The composition of claim 54 further comprising least one monomer selected from the group consisting of: ( i ) hydroxyalkyl acrylate monomer having the formula R, 0 I1 II CH2 = C C OR4 wherein R, is selected from the group consisting of hydrogen methyl, and R4 is a hydroxyalkyl group comprising up to about carbon atoms; (ii) aminoalkyl acrylate monomer having the for R. R— I1 I7 R5 CH = C Rg N Rg wherein R. is selected from the group consisting of hydrogen methyl, R_ is selected from the group consisting of hydrogen, halo, thio, and monovalent organic radicals; Rg is a divalent radical containing up to about 5 carbon atoms; and R and Rβ each independently selected from the group consisting of hydr and alkyl radicals containing up to about 2 carbon atoms; and (iii) mixtures of (i) and (ii).
64. The composition of claim 63 wherein the composition comprises less than about 0.5 weight percent surfactant and has a calculated T of about 15° to about 35*C. and an actual and different T of about 10° to about 60βC, an the polymer comprises about 30 to about 50 weight percent of t soft monomer and about 50 to about 70 weight percent of the ha monomer, the polymer having a particle size of less than about 250 nm.
65. The composition of claim 54 further comprising least one monomer selected from the group consisting of acryli acid, methacrylic acid, hydroxyethyl methacrylate, hydroxyprop methacrylate, hydroxyethyl acrylate, hydroxypropyl acrylate, tbutylaminoethyl methacrylate, dimethylaminoethyl methacrylat tbutylaminoethyl acrylate, dimethylaminoethyl acrylate, l[2(3allyloxy2hydroxypropylamino)ethyl]imidazolidin2on and mixtures thereof.
66. An emulsion comprising: (a) water; and (b) a polymer, the polymer comprising: (i) about 25 to about 60 weight percent of a sof monomer whose homopolymer has a T of less than about 20βC, soft monomer being selected from the group consisting of nonfunctional acrylic monomers, vinylidene halide monomers, alkylene monomers, glycidyl acrylate monomer, and mixtures thereof; and (ii) about 40 to about 75 weight percent of a har monomer whose homopolymer has a T of greater than about 30βC the hard monomer being selected from the group consisting of vinyl halide monomers, alkenyl aromatic monomers, nonfunction methacrylic monomers, acrylonitrile monomer, vinyl acetate monomer, and mixtures thereof, wherein the emulsion has a surface tension greater than about dynes/cm.
67. The composition of claim 66 wherein the emulsio has a surface tension of about 45 to about 55 dynes/cm and the polymer comprises about 30 to about 50 weight percent of the s monomer and about 50 to about 70 weight percent of the hard monomer, the polymer having a particle size of less than about 250 nm.
68. The emulsion of claim 66 wherein the polymer further comprises at least one monomer selected from the group consisting of: ( i ) hydroxyalkyl acrylate monomer having the formula R, O ♦1 II CH2 = C C OR4 wherein R. is selected from the group consisting of hydrogen a methyl, and 4 is a hydroxyalkyl group comprising up to about carbon atoms; (ii) aminoalkyl acrylate monomer having the for R« R— I1 I7 R5 CH C Rg N Rg wherein R, is selected from the group consisting of hydrogen methyl, R5 is selected from the group consisting of hydrogen, halo, thio, and monovalent organic radicals; Rg is a divalent radical containing up to about 5 carbon atoms; and R7 and R„ each independently selected from the group consisting of hydr and alkyl radicals containing up to about 2 carbon atoms; and (iii) mixtures of (i) and (ii).
Description:
HIGH-GLOSS LATEX PAINTS AND POLYMERIC COMPOSITIONS FOR USE

THEREIN

Background

The present invention relates to high-gloss latex paints, binders capable of producing high-gloss paints, and polymeric compositions for use in binders.

Paints can be divided into three basic categories, namely, (1) flat paints having a specular gloss of less than about 15 percent reflectance, (2) semi-gloss paints having a specular gloss of about 35 to about 50 percent reflectance, an (3) high-gloss paints having a specular gloss greater than abo 70 percent reflectance based upon light having about a 60° ang of incidence. Oil-base paints can easily be formulated into these three categories of paints. However, it is difficult to formulate latex paints having a high specular gloss. The inability to readily formulate high-gloss latex paints is a significant drawback since oil-base paints are being phased ou due to environmental restrictions limiting the volatile organi compounds (VOC) content of paints.

SUMMARY OF THE INVENTION

The present invention provides polymeric composition that are used in the production of high-gloss latex paints. T polymeric compositions comprise a polymer and less than about weight percent surfactant based on the total monomer weight in the polymer. The polymer comprises about 25 to about 60 weigh percent soft monomer, and about 40 to about 75 weight percent hard monomer. As used in the specification and claims, the t "soft monomer" means a monomer whose homopolymer has a T of l than about -20° C. , and the term "hard monomer" means a monome whose homopolymer has a T of greater than about 30° C. Generally, the polymers have a particle size of less than 250

Optionally, a seed is present in the compositions. Some of the polymeric compositions exhibit an interesting phenomenon in tha they have a theoretical or calculated glass transition temperature (T ) of about 15° to about 35° C. but exhibit an actual T of about 10° to about 60° C.

The invention also encompasses an emulsion comprising water and at least one of the above polymeric compositions. In addition, the invention encompasses a paint. The emulsion is used as a binder in a high-gloss paint. Typically, the paint i of the type comprising (a) a coalescing aid, (b) a thickening aid, (c) a dispersing aid, (d) a defoamer, (e) a biocide, (f) a filler, " and (g) the binder. When the paint is applied to a surface and dried, it forms a film capable of having a specular gloss of at least about 70 percent reflectance. Preferably, th paint has a pigment volume concentration (pvc) of less than abo 25 volume percent (v/v%).

DRAWING

The high-gloss promoting characteristics of the polymeric compositions, and other features, aspects, and advantages of the present invention will become better understo with reference to the following description, appended claims, a accompanying drawing where the sole figure is a perspective vie of a substrate having a surface coated with a film of the prese invention.

DETAILED DESCRIPTION OF THE INVENTION

In accordance with the present invention, each polymeric composition comprises a polymer and less than about 1 weight percent surfactant. As used in the specification and th claims, "weight percent surfactant" is defined as the total dry weight of the surfactant(s) employed in making the polymer divided by the total weight of the monomers employed in making

the polymer, this quotient being multiplied by 100%. Preferab the composition comprises less than about 0.5 weight percent surfactant. In general, when all other parameters are held constant, the lower the surfactant content of the polymer, the more insensitive the polymer is to water.

The surfactant is normally a copolymerizable surfactant, an anionic surfactant, a nonionic surfactant, or a mixture of two or more of these surfactants. Exemplary copolymerizable surfactants include, but are not limited to, sulfoethylmethacrylate, vinylsulfonate salts, sulfopropylmethacrylate, styrene sulfonate salts, 2-acrylamido-2-methylpropanesulfonic acid salts, and mixtures thereof. Anionic surfactants include, but are not limited to, alkylphenolethoxylate sulfates and sulfonates, alkylsulfates a sulfonates, and mixtures thereof. Nonionic surfactants includ but are not limited to, alkylarylpolyether alcohols, alkylphenolethoxylates, alkylethoxylates, ethyleneoxide/propy oxide block copolymers, and mixtures thereof.

The polymer generally comprises about 25 to about 6.. weight percent of a soft monomer, and about 40 to about 75 we percent of a hard monomer. Preferably, the polymer comprises about 30 to about 50 weight percent of the soft monomer and a 50 to about 70 weight percent of the hard monomer. More preferably, about 30 to about 45 weight percent of the soft monomer and about 55 to about 70 weight percent of the hard monomer are present in the polymer.

Typical soft monomers include, but are not limited t non-functional acrylic monomers, vinylidene halide monomers, a alkylene monomers. As used in the specification and claims, t term "non-functional monomer" means a monomer that is devoid any group, e.g., hydroxyl, carboxyl, amide, and a ine, that c undergo further reaction after polymerization of the monomer. mixture of soft monomers can also be employed in the polymer.

Non-functional acrylic and vinylidene halide monomers are the preferred soft monomers .

The non-funct ional acrylic monomers have the formula

R, O l I I

CH 2 - C - C - OR 2 ( I )

wherein R, is selected from the group consisting of hydrogen an methyl, and R, is an alkyl group, preferably having up to about 15 carbon atoms. As used in the specification and claims, the term "alkyl" means cyclic and acyclic saturated hydrocarbon groups that can be either branched or unbranched. Exemplary soft, non-functional acrylic monomers include, but are not limited to, ethyl acrylate, butyl acrylate, isobutyl acrylate, ethylhexyl acrylate, isodecyl methacrylate, lauryl methacrylate tridecylmethacrylate. Butyl acrylate is the preferred soft, non-functional monomer.

If the soft monomer is vinylidene halide, the halide moiety is preferably selected from the group consisting of chlorine, bromine, and mixtures thereof. The preferred vinylidene halide monomer is vinylidene chloride. Illustrative soft alkylene monomers include, but are not limited to, isobutylene, ethylene, and propylene.

With respect to the hard monomer, the hard monomer is preferably selected from the group consisting of vinyl halide monomers, alkylene aromatic monomers, non-functional methacryli monomers, acrylonitrile monomer, and vinyl acetate monomer. More preferably, the hard monomer is selected from the group consisting of alkylene aromatic monomers and non-functional methacrylic monomers.

When the hard monomer is vinyl halide, the halide moiety is preferably selected from the group consisting of

chlorine, bromine, and mixtures thereof. Vinyl chloride is th preferred hard vinyl halide monomer.

As used in the specification and claims, "alkenyl aromatic monomers" are defined as any organic compound contain at least one aromatic ring and at least one aliphatic-containi moiety having alkenyl unsaturation. Preferred alkenyl aromati monomers are represented by the formula II

wherein X is an aliphatic radical containing at least one alke bond, Y is a substituent on the aromatic ring, and n is the number of Y substituents on the ring, n being an integer from to 5. Generally, X comprises at least 2 carbon atoms, but usually no more than about 6, and preferably no more than abo carbon atoms. X is preferably a substituted or unsubstituted alkenyl group. Preferred alkenyl group substituents are halo radicals, e.g., chloride. However, the most preferred alkeny group is unsubstituted, i.e., a hydrocarbon, and contains onl one olefinic unsaturation. Ethylene is the most preferred X.

Y is an organic or inorganic radical. As used throughout the specification and claims, the term "organic radical" means any group containing at least one carbon atom, the term "inorganic radical" means any group devoid of carbon atoms. When n is 2 or more, Y can be the same or different. organic, Y generally contains from 1 to about 15 carbon atoms and, preferably, is an aliphatic radical. Even more preferab Y is a saturated aliphatic radical. If inorganic, Y is preferably a halogen. Exemplary Y substituents include halo cyano radicals and substituted and unsubstituted alkyl radica of 1 to about 10 carbon atoms. Preferred Y substituents are chloride and unsubstituted alkyl groups of 1 to about 6 carbo

atoms. Y is more preferably a chloride radical and C 1 to about C 4 unsubstituted alkyl radicals.

Illustrative alkenyl aromatic monomers include styren p-methyl styrene, methyl styrene, o,p-dimethyl styrene, o,p-diethyl styrene, p-chlorostyrene, isopropyl styrene, t-buty styrene, o-methyl-p-isopropyl styrene, o,p-dichlorostyrene, and mixture thereof. Due to its commercial availability and low cost, styrene is the preferred alkenyl aromatic monomers.

With respect to non-functional methacrylic monomers, exemplary non-functional methacrylic monomers have the formula III

wherein R 3 is an alkyl group that preferably contains up to abo 6 carbon atoms. Typical non-functional methacrylic monomers include methyl methacrylate, ethyl methacrylate, isobutyl methacrylate, and mixtures thereof.

Preferably, the polymeric composition also comprises least one monomer selected from the group consisting of olefini carboxylic acid monomers, functional acrylic monomers, ureido-containing monomers, acryla ide monomer, methacrylamide monomer, glycidyl acrylate monomer, and glycidyl methacrylate monomer. As used in the specification and claims, the term "functional monomers" means a monomer that contains at least on group, e.g., hydroxyl, carboxyl, amide, and amine, that can undergo further reaction after polymerization of the monomer.

Olefinic carboxylic acid monomers include both mono-olefinic carboxylic acid monomers and di-olefinic carboxy acid monomers. Exemplary mono-olefinic carboxylic acids inclu but are not limited to, acrylic acid, methacrylic acid,

acryloxyacetic acid, ethacryloxyacetic acid, acrylamidoglycol acid, and mixtures thereof. Exemplary di-olefinic carboxylic acids include, but are not limited to, itaconic acid, fumaric acid, and mixtures thereof. The preferred olefinic carboxylic acid monomers are selected from the group consisting of acryli acid, methacrylic acid, and mixtures thereof.

Functional acrylic monomers include hydroxyalkyl acrylate monomers having the formula IV

R, 0

I 1 II

CH 2 - C - C - OR 4 , (IV)

and aminoalkyl acrylate monomers having the formula V

VI R 7 R 5 - CH = C - R 6 - N - R 8 (V)

In formula IV, supra, R, is as defined above, and R. is a hydroxyalkyl group, preferably comprising up to about 6 carbo atoms. More preferably, the hydroxyalkyl group comprises up carbon atoms. Typical hydroxyalkyl acrylates include, but ar not limited to, hydroxyethyl methacrylate,. hydroxypropyl methacrylate, hydroxyethyl acrylate, hydroxypropyl acrylate,a mixtures thereof.

In formula V, supra, R, is as defined above, R 5 is selected from the group consisting of hydrogen and halogen, R a divalent alkyl radical containing 1 to about 5 carbon atoms and R 7 and R„ are each independently selected from the group consisting of hydrogen and alkyl radicals containing up to ab 2 carbon atoms. Exemplary aminoalkyl acrylates include dimethylaminoethyl methacrylate, t-butylaminoethyl methacryla dimethylaminoethyl acrylate, t-butylaminoethyl acrylate, and mixtures thereof.

The aminoalkyl acrylate monomers of formula V, supra, and the ureido-containing amines are capable of enhancing the w adhesion strength of a paint incorporating the polymer. An exemplary ureido-containing amine is l-[2-(3-allyloxy-2- hydroxypropyla ino)ethyl]imidazolidin-2-one, commercially known as Sipomer WAM brand monomer by Alcolac.

In one preferred version, the polymer comprises about 40 to about 75 weight percent alkenyl aromatic monomer (e.g., styrene) and/or non-functional methacrylic monomer (e.g., methy methacrylate), up to about 10 weight percent hydroxyalkyl acrylate monomer (e.g., hydroxypropyl methacrylate), and up to about 5 weight percent olefinic carboxylic acid monomer (e.g., acrylic acid and/or methacrylic acid). In this version of the invention, the polymer more preferably comprises about 45 to about 65 weight percent alkenyl aromatic and/or non-functional methacrylic monomer, about 0.1 to about 10 weight percent hydroxyalkyl acrylate monomer, and about 0.1 to about 10 weight percent olefinic carboxylic acid monomer. Even more preferably the polymer of this version of the invention comprises about 50 to about 60 weight percent alkenyl aromatic and/or non-function methacrylic monomer, about 3 to about 7 weight percent hydroxyalkyl acrylate monomer, and about 1 to about 5 weight percent olefinic carboxylic acid monomer.

The polymer can optionally comprise a seed, generally having a particle size of about 25 to about 80 nm. An exemplar seed is comprised of styrene.

The polymers of the present invention generally have particle size (i.e., a maximum cross-sectional diameter) of les than about 250 nm. Preferably, the particle size of the polyme is within the range of 90 to about 200 nm. When the polymer is comprised of a soft, non-functional acrylic monomer (e.g., buty acrylate), an alkylene aromatic monomer (e.g., styrene), an hydroxyalkyl acrylate monomer (e.g., hydroxypropyl methacrylate

and an olefinic carboxylic acid monomer (e.g., methacrylic aci the polymer preferably has a particle size of about 150 to abo 200 nm. However, when the polymer is comprised of the soft, non-functional acrylic monomer (e.g., butyl acrylate), a methacrylic monomer (e.g., methyl methacrylate), a hydroxyalky acrylate monomer, and a olefinic carboxylic acid monomer, the polymer preferably has a particle size of about 90 to about 12 nm. Because small particle-sized polymers when incorporated i an emulsion make the emulsion more viscous and, therefore, mor difficult to stabilize, it is preferred that the particle size as large as possible without unduly sacrificing the compositio gloss enhancing capability.

An interesting phenomenon exhibited by some of the compositions of the present invention is that they have a theoretical T of about 15° to about SS" C. , but demonstrate a actual (and different) T of about 10° to about 60° C. The theoretical T of each composition is calculated by multiplyin the weight percent of each constituent monomer by the T of a homopolymer made from that monomer and adding all the resultin numerical products.

There are several ways of determining the actual T the compositions. For purposes of the present specification a ccllaaiimmss,, tthhee aaccttuuaall T is determined by differential scanning calorimetry (DSC).

The compositions of the present invention can be mad for example, by a delayed addition polymerization process and pre-emulsion polymerization process. Typically, the delay-addition polymerization process comprises forming a mono mixture containing about 25 to about 60 weight percent of the soft monomer and about 40 to about 75 weight percent of the ha monomer. Water is added to a reactor and heated, generally to about 180° F., while preferably purging the reactor with an in gas, such as nitrogen, to remove substantially all oxygen fro

the reactor. A catalyst is then added to the reactor. Preferably, a seed and/or a surfactant is also then added to th reactor. After the addition of the catalyst, the delay-additio of the monomer mixture is then commenced. The addition of the monomer mixture typically takes up to about 3 hours. Optionall a portion, for example up to about 1/2 of the monomer mixture, can be added to the reactor at the beginning of the reaction along with the addition of the catalyst and/or seed and/or surfactant. Exemplary catalysts include, but are not limited t t-butyl hydroperoxide, sodium persulfate, hydrogen peroxide, an mixtures thereof.

The pre-emulsion polymerization process for making th compositions of the present invention is similar to the delayed addition process with a major exception that a surfactant is al incorporated into the monomer mixture to form a pre-emulsion.

In another version of the delayed-add polymerization process, in addition to the monomer mixture feedstream, at leas one additional monomer feedstream is also added to the reactor simultaneously during at least a portion of the time that the monomer mixture is added.

The polymerization processes yield an emulsion comprising the composition and water. However, as indicated in the above described processes, the emulsion can further compris a surfactant, and a catalyst. Typically, the emulsion has a surface tension greater than about 45 dynes/cm, and preferably between about 45 and about 55 dynes/cm. In addition, the emulsion commonly contains at least about 45 weight percent solids. The solids content of the emulsion is generally within the range of about 45 to about 55 weight percent.

The emulsion is used as a binder in a water-base pain A typical paint comprises a coalescing aid, a thickening aid, a dispersing aid, a defoamer, a biocide, a filler, and the binder

Coalescing aids, thickening aids, dispersing aids, defoamers, biocides, and fillers suitable for use in water-base paint are well known to those skilled in the art. Paints suitable for u in conjunction with the polymer generally have a pigment volum concentration (pvc) of less than about 25 volume by volume percent (v/v%). Preferably, the paint has a pvc of about 15 t about 25 v/vl.

As shown in the sole figure, the paint can be applie to at least a portion of a surface 12.of a substrate 10. When applied to a substrate 10 having a white glossy surface 12, th paint, upon drying forms a film 14 that typically has a specul gloss of at least about 70 percent reflectance when measured a an angle of incidence i of about 60°. A commercially availabl substrate having a white, glossy surface is Form WB grade plai white charts available from Leneta Company of Ho-Ho-Kus, New Jersey. Since specular gloss is directly proportioned to the percent reflectance at a given angle of incidence, it is preferred that the percent reflectance obtained by the film 14 at least about 75, more preferably at least about 80, * and even more preferably at least about 85. Accordingly, the compositi of the instant invention is capable of enhancing the specular gloss of a paint.

EXAMPLES

The following examples demonstrate the preparation o exemplary polymeric compositions within the scope of the prese invention as well as the specular gloss obtained by paints incorporating these compositions. However, the invention is n limited to the examples, but is defined by the claims.

EXAMPLES 1 -5

Preparation Of Polymeric Compositions

Monomer mixtures having the compositions set forth in the following Table I were prepared:

TABLE I

Monomer, oτn

Siamda SΔ a £I b - c HPMA d MAΔ e l-h

1 195 330 - 30 15 -

2 195 330 30 7.5

3 195 330 - 30 - 7.5

4 195 - 330 30 15

5 195 - 330 30 - 7.5

a. BA denotes butyl acrylate. b. ST denotes styrene. c. MMA denotes methyl methacrylate. d. HPMA denotes hydroxypropyl methacrylate. e. MAA denotes methacrylic acid. f. AA denotes acrylic acid.

In each of Examples 1-5, the ingredient(s) listed in Table II below were added to a reactor and heated while purging the reactor with nitrogen.

TABLE II

Ingredients. om

Example ]______ Surfactant 9 1 550 - 2 550 - 3 550 7.5 4 550 - 5 550 7.5

g. The surfactant was Alipal EP 110 brand anionic surfactant available from GAF.

When the contents of the reactor reached a temperatu of about 180° F., the ingredient(s) given in Table III, infra, were individually added to the reactor.

TABLE. IΣZ

Ingredients, g

Example Sodium Persulfate SBAS h SS 1

1 0.9 36 -

2 0.9 - 18

3 0.9 - -

4 0.9 36 -

5 0.9 - -

h. SBAS denotes a styrene/butyl acrylate seed having a parti size of about 50 nm. i. SS denotes a styrene seed having a particle size of about nm.

Next, the monomer mixture shown in the above Table and the catalyst solution described in the following Table IV were separately added to the contents of the reactor over a

period of about 3 hours while maintaining the temperature withi the reactor at about 185° F.

TABLE IV

Ingredients , ςrm

Example Sodium Persulfate Hatar Surfactant- 1 Sodium Bicarbona

1 0.9 27 3.3

2 0.9 27 3.3

3 0.9 27 ^ 3.3

4 0.9 27 3.3

5 0.9 27 3.3 0.5

j. The surfactant was Dowfax 2AI brand anionic surfactant (45% active) .

At the end of the 3 hour period, the contents of the reactor were neutralized with a solution of about 10% ammonium hydroxide to a pH of about 8.5.

EXAMPLE 6

A monomer mixture containing about 195 gm butyl acrylate, about 330 gm styrene, about 30 gm hydroxypropyl methacrylate, and about 15 gm methacrylic acid was prepared. Next, water was added to a reactor and the reactor was purged with nitrogen. A styrene/butyl acrylate seed (about 36 gm) and about 1/3 of the monomer mixture were then added to the reactor while continuing to purge the reactor with nitrogen. The contents of the reactor were then heated and when they reached temperature of about 100° F., about 0.5 gm of sodium sulfoxylat formaldehyde in about 10 ml of water and about 1 gm of t-butyl hydroperoxide were added to the reactor. When the reactor's contents reached about 185° F., the remaining portion of the monomer mixture and a catalyst solution containing about 1.8 g sodium persulfate, about 30 gm water, and about 1 gm Dowfax 2AI

brand anionic surfactant (45% active) were added to the react over a period of about 2 hours while maintaining the temperat of the rector's contents at about 185° F. At the end of the hour period, the contents of the reactor were neutralized to about 8.5 with a solution of about 10% ammonium hydroxide.

EXAMPLES 7-fl

The monomer mixtures set forth in Table V, infra, w prepared.

TABLE Y

Monomers. am

Example BΔ SI MR ___ k

7 195 360 15 -

8 126 330 15 126

k. EHA denotes ethylhexyl acrylate.

In each of Examples 7 and 8, water in the amount st in Table VI below was added to a reactor and heated while pur the reactor with nitrogen.

TABLE VI

Example Water. gm 7 550 8 475

When the water in the reactor reached a temperature about 180° F., the ingredients given in Table VII, infra, wer individually added to the reactor.

16

TABLE VT T

Ingredients , gm

Example Sodium Persulfate SBAS SS.

7 0. 9 36 -

8 0. 9 18

Next, the monomer mixture shown in the above Table V and a catalyst solution (containing about 0.9 gm sodium persulfate, about 27 gm water, and about 3.3 gm Dowfax 2AI bran anionic surfactant [45% active]) were added to the reactor over period of about 3 hours while maintaining the temperature withi the reactor at about 185° F. At the middle of the reaction, th basic solution set forth in Table VIII was the added to the reactor over about the next 20 minutes followed by the addition of the monomeric system set forth in Table IX over the remainin portion of the reaction.

TABLE VIII

Basic Solution Ingredients, ςrm

Example Water Ammonium Hydroxide

7 25 10 8 25 6

TABLE IX

Monomeric System Ingredients, gm

Example Water Si omer WAM Monomer 7 50 6 8 25 3

EXAMPLES 9-11

Monomer mixtures having the compositions set forth i the following Table X were prepared:

Monomer, gm

Example BΔ SI MMA HPMA MAA AA

9 195 330 - 30 7.5 -

10 195 - 330 30 7.5 -

11 195 360 - - - 7.5

In each of Examples 9-11, the ingredient(s) listed Table XI below were added to a reactor and heated while purgin the reactor with nitrogen.

TABLE XI

Ingredients, m

Example Water Surfactant 9 9 500 4 10 500 0.4

11 500 —

g. The surfactant was Alipal EP 110 brand anionic surfactant available from GAF.

In Example 9, when the contents of the reactor reach a temperature of about 160° F., 0.9 gm sodium persulfate was added to the reactor. Next, the monomer mixture shown in the above Table X for Example 9, an emulsion comprising about 50 water, about 9 gm acrylamide, and about 5.6 gm Alipal C0436 br anionic surfactant (available from GAF), and a catalyst soluti comprising about 0.9 gm sodium persulfate and 27 gm water wer

separately added to the contents of the reactor over a period o about 3 hours while maintaining the temperature within the reactor at about 165° F. At the end of the 3 hour period, an ammonium hydroxide solution containing about 6 gm ammonium hydroxide and about 20 gm water was slowly added to the content of the reactor and then the reactor's contents were neutralize to a pH of about 8.5 with a solution of about 10% ammonium hydroxide.

In the case of Example 10, when the contents of the reactor reached a temperature of about 180° F., 0.9 gm sodium persulfate was added to the reactor. Next, the monomer mixtur shown in the above Table X for Example 10, an emulsion comprisi about 50 gm water, about 9 gm acrylamide, and about 5.6 gm Ali C0436 brand anionic surfactant (available from GAF), and a catalyst solution comprising about 0.9 gm sodium persulfate an 27 gm water were separately added to the contents of the react over a period of about 3 hours while maintaining the temperatu within the reactor at about 185° F. At the end of the 3 hour period, an ammonium hydroxide solution containing about 5 gm ammonium and about 20 gm water was slowly added to the content of the reactor and then the reactor's contents were neutralize to a pH of about 8.5 with a solution of about 10% ammonium hydroxide.

With respect to Example 11, when the contents of the reactor reached a temperature of about 180° F., 0.9 gm sodium persulfate and about 36 gm of a styrene/butyl acrylate seed having a particle size of about 50nm were individually added t the reactor. Next, the monomer mixture shown in the above Tab X for Example 11, a solution comprising about 50 gm water and about 9 gm acrylamide, and a catalyst solution comprising abou 0.9 gm sodium persulfate and 27 gm water were separately added the contents of the reactor over a period of about 3 hours whi maintaining the temperature within the reactor at about 185° F At the end of the 3 hour period, the reactor's contents were

neutralized to a pH of about 8.5 with a solution of about 10% ammonium hydroxide.

EXAMPLE 12

Water (about 350 gm) and Alipal 110 brand anionic surfactant (about 5.6 gm) were charged to a reactor and heated When the contents of the reactor reached about 180° F., sodiu persulfate (about 0.9 gm) was added to the reactor. Next, a monomer mixture containing about 195 gm butyl acrylate, about gm styrene, about 30 gm hydroxypropyl methacrylate, and about gm acrylic acid and a pre-emulsion containing about 200 gm wa and about 1.9 gm Alipal C0436 brand anionic surfactant were combined with mixing. The resulting combination was added to reactor over a period of about 3 hours while maintaining the temperature of the reactor at about 185" F. At the end of th hour period, the contents of the reactor were neutralized to of about 8.5 with a solution of about 10% ammonium hydroxide.

The emulsions prepared in Examples 1-12 had the properties listed in the following Table XII:

TABLE XTT

Total Solids, Particle Size, Viscosity,

Example Percent nm cps

1 49.1 165 175

2 48.8 123 430

3 46 91 620

4 49.1 174 70

5 48.8 95 2200

6 48.2 172 125

7 48.4 192 30

8 49.2 198 130

9 48.5 107 2000

10 45.0 93 830

11 49.1 181 370

12 46.2 100 425

EXAMPLES 13- -24

The gloss of a paint formulation using as a binder ea of the emulsions prepared in Examples 1-12 was determined as follows.

Preparation Of Paste

A paste was prepared by combining methyl carbitol, Tamol 731 brand dispersing aid (25% active; available from Rohm and Haas Co.), Triton CF-10 brand surfactant (available from Ro and Haas Co.), Foamaster AP brand defoamer (available from Diamond Shamrock Corp.), titanium dioxide, and water in the proportions set forth in Table XIII below.

TABLE XIII

Materials Weigh r lbs Volume, gallons

Methyl Cabitol 45.0 5.29

Tamol 731 7.9 0.86

Triton CF-10 1.8 0.20

Foamaster AP 2.0 0.26

Titanium Dioxide 190.0 5.64

Water 11.3 1.35

The combination of materials listed in Table XIII w ground at a high speed to a National Standard Rating of about Next, water and a Dowicil brand biocide (available from Dow Chemical Co. ) in the proportions stated in Table XIV were add to the ground mixture.

TABLE XIV

Materials Weigh . lbs Volume, gallons

Water 97.3 11.67

Dowicil.-Water (1:5) 8.0 0.96

The pH of the resulting slurry was adjusted to bet about 8.3 and about 8.5 with ammonium hydroxide. Afterwards, premix of Acrysol RM-5 brand rheology modifier (available fr Rohm and Haas Co.), water, and a 28% ammonium hydroxide solut in the proportions shown in Table XV was added to the pH adj slurry to form the paste.

TABLE XV

Materials Weight, lbs Volume, gallons

Acrysol RM-5 20.0 2.27

Water 28.2 3.38

Ammonium Hydroxide,

28% Solution 2 0.24

The final pH of the paste was adjusted to be about 8.5

Preparation Of Paint

A paint was prepared by mixing about 168.6 gm of the above paste, about 14.0 gm of Texanol brand coalescing aid (available from Eastman Chemicals), one of the latex emulsions prepared in Examples 1-12, and water, the amount of latex emulsion and water being selected so as to provide about 85.34 dry latex in the final paint formulation.

A wet coating of each paint formulation was applied t a Form WB grade plain white chart (available from Leneta Compan and drawn down using a 6 mil Bird applicator. The coating was dried in a constant temperature and constant humidity room for least 3 days. The specular gloss of each coating was measured using a gloss meter set at 20° and 60°. The readings were recorded and are set forth in Table XVI, infra.

IΔBLi XVI

Paint Formulation 60° Gloss, 20° Gloss,

Using Emulsion Of Percent Percent

Example Reflectance Reflectance

1 86 54

2 85 49

3 86 48

4 77 45

5 80 47

6 84 46

7 84 48

8 84 43

9 88 50

10 83 52

11 86 50

12 84 47

All of the paint formulations of Examples 1 to 12 contain a binder that comprises a polymeric composition withi the scope of the present invention. Accordingly, as evidence the data shown in Table XVI, paint formulations which use bin that contain the polymeric.compositions of the present invent are high-gloss latex paints.

Although the present invention has been described i considerable detail with reference to certain preferred versi thereof, other versions are possible. For example, the paint include one or more ingredients that enhance other paint properties. Therefore, the spirit and scope of the appended claims should not necessarily be limited to the description o the preferred embodiments contained herein.