Anti-bacterial metallo ionomer polymer nanocomposite powders and methods of making the same

Patent metadata

Field	Value
Publication number	US-10113059-B2
Application number	US-201615203675-A
Country	US
Kind code	B2
Filing date	Jul 6, 2016
Priority date	Jul 6, 2016
Publication date	Oct 30, 2018
Grant date	Oct 30, 2018

Abstract

A composite powder includes a core particle comprising a styrene/acrylate polymer resin, and a shell comprising a styrene/acrylate ionomer resin, wherein the styrene/acrylate ionomer resin comprises a metal ion acrylate monomer, and methods of making thereof. Various articles can be manufactured from such composite powders.

First claim

What is claimed is:

1. A composite powder comprising:
a core particle comprising a styrene/acrylate polymer resin and optionally a first metal ion acrylate monomer; and
a shell comprising a styrene/acrylate ionomer resin, wherein the styrene/acrylate ionomer resin comprises a second metal ion acrylate monomer;
wherein the total amount of metal presented in the composite powder ranges in a concentration of from about 0.5 ppm to about 50,000 ppm; and further wherein the composite powder has a particle size of from about 10 microns to about 300 microns.

2. The composite powder of claim 1 , wherein the first metal of the shell comprises a silver.

3. The composite powder of claim 1 , wherein the styrene/acrylate ionomer resin of the shell comprises a silver monomer selected from a silver acrylate monomer, a silver methacrylate monomer or combinations thereof.

4. The composite powder of claim 3 , wherein the silver monomer is present in the shell resin from about 0.01% to about 10% by weight of the total monomers.

5. The composite powder of claim 1 , wherein the styrene/acrylate ionomer resin of the shell comprises a co-monomer selected from methyl methacrylate, butyl acrylate, diacrylate, cyclohexyl methacrylate, styrene, methacrylic acid, dimethylaminoethyl methacrylate or combinations thereof.

6. The composite powder of claim 1 , wherein the styrene/acrylate polymer resin of the core is selected from the group consisting of styrene acrylates, styrene butadienes, styrene methacrylates, and combinations thereof.

7. The composite powder of claim 6 , wherein the styrene/acrylate polymer resin of the core is selected from the group consisting of poly(styrene-alkyl acrylate), poly(styrene-1,3-diene), poly(styrene-alkyl methacrylate), poly(styrene-alkyl acrylate-acrylic acid), poly(styrene-1,3-diene-acrylic acid), poly(styrene-alkyl methacrylate-acrylic acid), poly(alkyl methacrylate-alkyl acrylate), poly(alkyl methacrylate-aryl acrylate), poly(aryl methacrylate-alkyl acrylate), poly(alkyl methacrylate-acrylic acid), poly(styrene-alkyl acrylate-acrylonitrile-acrylic acid), poly(styrene-1,3-diene-acrylonitrile-acrylic acid), poly(alkyl acrylate-acrylonitrile-acrylic acid), poly(styrene-butadiene), poly(methylstyrene-butadiene), poly(methyl methacrylate-butadiene), poly(ethyl methacrylate-butadiene), poly(propyl methacrylate-butadiene), poly(butyl methacrylate-butadiene), poly(methyl acrylate-butadiene), poly(ethyl acrylate-butadiene), poly(propyl acrylate-butadiene), poly(butyl acrylate-butadiene), poly(styrene-isoprene), poly(methylstyrene-isoprene), poly(methyl methacrylate-isoprene), poly(ethyl methacrylate-isoprene), poly(propyl methacrylate-isoprene), poly(butyl methacrylate-isoprene), poly(methyl acrylate-isoprene), poly(ethyl acrylate-isoprene), poly(propyl acrylate-isoprene), poly(butyl acrylate-isoprene), poly(styrene-propyl acrylate), poly(styrene-butyl acrylate), poly(styrene-butadiene-acrylic acid), polystyrene-butadiene-methacrylic acid), poly(styrene-butadiene-acrylonitrile-acrylic acid), poly(styrene-butyl acrylate-acrylic acid), poly(styrene-butyl acrylate-methacrylic acid), poly(styrene-butyl acrylate-acrylonitrile), poly(styrene-butyl acrylate-acrylonitrile-acrylic acid), poly(styrene-butadiene), poly(styrene-isoprene), poly(styrene-butyl methacrylate), poly(styrene-butyl acrylate-acrylic acid), poly(styrene-butyl methacrylate-acrylic acid), poly(butyl methacrylate-butyl acrylate), poly(butyl methacrylate-acrylic acid), poly(acrylonitrile-butyl acrylate-acrylic acid) and combinations thereof.

8. The composite powder of claim 1 having a glass transition temperature (Tg) of from about −50° C. to about 400° C.

9. The composite powder of claim 1 having a thermal conductivity of from about 0.04 W/(mK) to about 50 W/(mK).

10. The composite powder of claim 1 having a weight average molecular weight of from about 10,000 to about 600,000.

11. The composite powder of claim 1 further comprises an additive selected from the group consisting of a wax, a pigment, a ceramic, a carbon fiber, a nanotube, or a combination thereof.

12. A method of producing a composite powder, comprising:
polymerizing a first mixture comprising a first styrene/acrylate copolymer to form a core styrene/acrylate polymer resin in an organic-free solvent;
heating the core styrene/acrylate polymer resin;
adding a shell styrene/acrylate ionomer resin by polymerizing a second mixture comprising a second styrene/acrylate copolymer and initiator to the formed polymer core styrene/acrylate polymer resin to form a shell disposed about the core styrene/acrylate polymer resin, thereby forming an emulsion of composite particles, wherein the shell styrene/acrylate ionomer resin comprises a metal;
aggregating the emulsion of composite particles to form aggregated particles; coalescing the aggregated particles to form coalesced particles;
washing the coalesced particles, thereby forming the composite powder.

13. The method of claim 12 , wherein the metal is silver, copper, gold, palladium, or mixtures thereof.

14. The method of claim 12 , wherein the styrene/acrylate ionomer resin of the shell comprises a silver monomer selected from a silver acrylate monomer, a silver methacrylate monomer or combinations thereof.

15. The method of claim 12 , wherein the core comprising a styrene/acrylate polymer resin selected from the group consisting of poly(styrene-alkyl acrylate), poly(styrene-1,3-diene), poly(styrene-alkyl methacrylate), poly(styrene-alkyl acrylate-acrylic acid), poly(styrene-1,3-diene-acrylic acid), poly(styrene-alkyl methacrylate-acrylic acid), poly(alkyl methacrylate-alkyl acrylate), poly(alkyl methacrylate-aryl acrylate), poly(aryl methacrylate-alkyl acrylate), poly(alkyl methacrylate-acrylic acid), poly(styrene-alkyl acrylate-acrylonitrile-acrylic acid), poly(styrene-1,3-diene-acrylonitrile-acrylic acid), poly(alkyl acrylate-acrylonitrile-acrylic acid), poly(styrene-butadiene), poly(methylstyrene-butadiene), poly(methyl methacrylate-butadiene), poly(ethyl methacrylate-butadiene), poly(propyl methacrylate-butadiene), poly(butyl methacrylate-butadiene), poly(methyl acrylate-butadiene), poly(ethyl acrylate-butadiene), poly(propyl acrylate-butadiene), poly(butyl acrylate-butadiene), poly(styrene-isoprene), poly(methylstyrene-isoprene), poly(methyl methacrylate-isoprene), poly(ethyl methacrylate-isoprene), poly(propyl methacrylate-isoprene), poly(butyl methacrylate-isoprene), poly(methyl acrylate-isoprene), poly(ethyl acrylate-isoprene), poly(propyl acrylate-isoprene), poly(butyl acrylate-isoprene), poly(styrene-propyl acrylate), poly(styrene-butyl acrylate), poly(styrene-butadiene-acrylic acid), poly(styrene-butadiene-methacrylic acid), poly(styrene-butadiene-acrylonitrile-acrylic acid), poly(styrene-butyl acrylate-acrylic acid), poly(styrene-butyl acrylate-methacrylic acid), poly(styrene-butyl acrylate-acrylonitrile), poly(styrene-butyl acrylate-acrylonitrile-acrylic acid), poly(styrene-butadiene), poly(styrene-isoprene), poly(styrene-butyl methacrylate), poly(styrene-butyl acrylate-acrylic acid), poly(styrene-butyl methacrylate-acrylic acid), poly(butyl methacrylate-butyl acrylate), poly(butyl methacrylate-acrylic acid), poly(acrylonitrile-butyl acrylate-acrylic acid) and combinations thereof.

16. The method of claim 12 , wherein the aggregating is conducted at a temperature of from about 30° C. to about 80° C.

17. The method of claim 12 , wherein the coalescing is conducted at a temperature of from about 30° C. to about 95° C.

18. An article comprising:
a composite powder comprising:
a core partic

Assignees

• Xerox Corp

Inventors

• Farrugia Valerie M
• Keoshkerian Barkev
• Chretien Michelle N

Classifications

• C08J2425/08

  Copolymers of styrene (C08J2429/08, C08J2435/06, C08J2455/02 take precedence) · CPC title

• C08J3/16

  by coagulating dispersions {(C08J3/122 takes precedence)} · CPC title

• C08J2325/08

  Copolymers of styrene (C08J2329/08, C08J2335/06, C08J2355/02 take precedence) · CPC title

• C08J3/126

  Polymer particles coated by polymer, e.g. core shell structures · CPC title

• C08F265/06

  Polymerisation of acrylate or methacrylate esters on to polymers thereof · CPC title