Method for preparing an aqueous polymer dispersion

Patent metadata

Field	Value
Publication number	US-10544249-B2
Application number	US-201515303313-A
Country	US
Kind code	B2
Filing date	Apr 1, 2015
Priority date	Apr 11, 2014
Publication date	Jan 28, 2020
Grant date	Jan 28, 2020

Abstract

Aqueous polymer dispersions and their use for producing shaped articles having improved heat resistance are described.

First claim

We claim:

1. A process for producing an aqueous dispersion comprising a polymer P, the process comprising:
conducting a free-radically initiated aqueous emulsion polymerization of a mixture comprising ethylenically unsaturated compounds,
wherein the mixture comprises
≥0.5 and ≤4.0 wt % of at least one α,β-monoethylenically unsaturated C 3 to C 6 monocarboxylic acid or dicarboxylic acid, as a monomer A,
≥2.0 and ≤8.0 wt % of at least one monoethylenically unsaturated compound having at least one epoxy group, as a monomer B,
≥0.1 and ≤1.5 wt % of at least one monoethylenically unsaturated compound having at least one sulfonic acid group, as a monomer C,
≥75 and ≤85 wt % of at least one ester obtained from vinyl alcohol and a C 1 to C 5 monocarboxylic acid, as a monomer D, and
≥0.1 and ≤20 wt % of at least one ethylenically unsaturated compound other than the monomers A to D, as a monomer E, and
wherein the amounts of the monomers A to E sum to 100 wt %, for the polymerization.

2. The process according to claim 1 , wherein the at least one monomer A is at least one selected from the group consisting of acrylic acid, methacrylic acid, crotonic acid, fumaric acid, maleic acid, maleic anhydride, 2-methylmaleic acid and itaconic acid.

3. The process according to claim 1 , wherein the at least one monomer B is at least one selected from the group consisting of vinyloxirane, allyloxirane, glycidyl acrylate and glycidyl methacrylate.

4. The process according to claim 1 , wherein the at least one monomer C is at least one selected from the group consisting of vinylsulfonic acid and 2-acrylamido-2-methylpropanesulfonic acid.

5. The process according to claim 1 , wherein the at least one monomer D is at least one selected from the group consisting of vinyl acetate and vinyl propionate.

6. The process according to claim 1 , wherein the at least one monomer E is at least one selected from the group consisting of an olefin,
a conjugated aliphatic C 4 to C 9 diene,
an ester obtained from vinyl alcohol and a C 6 to C 18 monocarboxylic acid,
a C 1 to C 10 alkyl acrylate,
a C 1 to C 10 alkyl methacrylate,
a C 5 to C 10 cycloalkyl acrylate,
a C 5 to C 10 cycloalkyl methacrylate,
a C 1 to C 10 dialkyl maleate,
a C 1 to C 10 dialkyl fumarate,
a vinylaromatic monomer,
a mono- or dinitrile of an ethylenically unsaturated C 3 to C 6 mono- or dicarboxylic acid, and
a mono- or dicarboxamide of an ethylenically unsaturated C 3 to C 6 mono- or dicarboxylic acid.

7. The process according to claim 1 , wherein the mixture comprises
≥0.5 and ≤3.0 wt % of the at least one monomer A,
≥3.0 and ≤7.0 wt % of the at least one monomer B,
≥0.1 and ≤1.0 wt % of the at least one monomer C,
≥78 and ≤83 wt % of the at least one monomer D, and
≥5.0 and ≤15 wt % of the at least one monomer E.

8. The process according to claim 1 , wherein
the monomer A is acrylic acid, methacrylic acid, or both,
the monomer B is glycidyl acrylate, glycidyl methacrylate, or both,
the monomer C is vinylsulfonic acid,
the monomer D is vinyl acetate, and
the monomer E is n-butyl acrylate, 2-ethylhexyl acrylate, or both.

9. The process according to claim 1 , wherein the polymer P has a glass transition temperature of ≥20° C. and ≤40° C., as determined by ISO 11357-2:2013.

10. A method of producing a composition, the method comprising:
obtaining an aqueous polymer dispersion by the process according to claim 1 ,
optionally drying the aqueous polymer dispersion, thereby obtaining a polymer powder, and
producing the composition with the aqueous polymer dispersion, the polymer powder, or both,
wherein the composition is at least one selected from the group consisting of a binder in the manufacture of adhesives, sealants, renders and paints, a binder in sand consolidation, a component in the manufacture of textile or leather auxiliaries and impact modifiers for modifying mineral binders and plastics.

11. A process for producing a shaped article from a substrate, the process comprising:
obtaining an aqueous polymer dispersion by the process according to claim 1 ,
applying the aqueous polymer dispersion to the substrate to form a treated substrate, and
drying the treated substrate at a temperature above the glass transition temperature of the polymer P to form a shaped article,
wherein the substrate is a granular substrate, a fibrous substrate, or both.

12. The process according to claim 11 , wherein an amount of aqueous binder composition is present during the applying such that ≥1 and ≤100 g of the polymer P is present per 100 g of the substrate after the applying.

13. The process according to claim 11 , further comprising:
shaping the treated substrate after the applying of the aqueous polymer dispersion.

14. The process according to claim 1 , wherein the monomer E is not ethene.

Assignees

• Basf Se

Inventors

• Jimenez Garcia Lucia
• Blaul Juergen

Classifications

• D06N5/003

  coated with bitumen · CPC title

• D06M15/273

  of unsaturated carboxylic esters having epoxy groups · CPC title

• D06M15/333

  of vinyl acetate; Polyvinylalcohol · CPC title

• D06M15/263

  of unsaturated carboxylic acids; Salts or esters thereof · CPC title

• C09J131/04

  Homopolymers or copolymers of vinyl acetate · CPC title