Emulsion, composition comprising same, film formed therewith, and related methods

Patent metadata

Field	Value
Publication number	US-11248119-B2
Application number	US-201816483588-A
Country	US
Kind code	B2
Filing date	Feb 6, 2018
Priority date	Feb 6, 2017
Publication date	Feb 15, 2022
Grant date	Feb 15, 2022

Abstract

An emulsion is disclosed which comprises a non-aqueous phase comprising a solid silicone resin and a siloxane carrier vehicle having an average of at least one silicon-bonded functional group per molecule and capable of carrying the solid silicone resin, an aqueous phase comprising water, and a surfactant, wherein the emulsion is substantially free from organic solvents. Various methods relating to the emulsion and end uses thereof are also disclosed. A composition comprising the emulsion and an organic binder, as well as related methods, are further disclosed.

First claim

What is claimed is:

1. An emulsion, comprising:
a non-aqueous phase, which comprises:
a solid silicone resin; and
a siloxane carrier vehicle capable of carrying said solid silicone resin, said siloxane carrier vehicle comprising a resinous silicone and having an average of at least one silicon-bonded functional group per molecule;

an aqueous phase comprising water; and
a surfactant;
wherein said emulsion is substantially free from organic solvents.

2. The emulsion of claim 1 , wherein: (i) said solid silicone resin has the general formula (R 1 R 2 R 3 SiO 1/2 ) w R 4 R 5 SiO 2/2 ) x (R 6 SiO 3/2 ) y (SiO 4/2 ) z , where R 1 -R 6 are independently selected from H, OH, substituted or unsubstituted hydrocarbyl groups, alkoxy groups, amino groups, acetoxy groups, and aminoxy groups, and w, x, y and z are independently from ≥0 to ≤1, with the provisos that y and z are not simultaneously 0 and w+x+y+z=1; (ii) said non-aqueous phase comprises said solid silicone resin in an amount of from greater than 0 to 50 weight % based on the total weight of said non-aqueous phase; or (iii) both (i) and (ii).

3. The emulsion of claim 1 or 2 , wherein: (i) said non-aqueous phase comprises said siloxane carrier vehicle in an amount of from greater than 50 to less than 100 weight % based on the total weight of said non-aqueous phase; (ii) said at least one silicon-bonded functional group is selected from H, OH, alkoxy groups, alkenyl groups, aminoxy groups and acetoxy groups, alternatively is a silicon-bonded alkoxy group; or (iii) both (i) and (ii).

4. The emulsion of any one preceding claim, wherein said solid silicone resin: (i) comprises an MQ resin; (ii) comprises a T resin; or (iii) a combination of (i) and (ii).

5. The emulsion of claim 1 , wherein said siloxane carrier vehicle comprises an alkoxy-functional silicone resin, alternatively a methoxy-functional DT silicone resin.

6. The emulsion of claim 1 , wherein said surfactant comprises an anionic surfactant, alternatively sodium lauryl sulfate.

7. The emulsion of claim 1 , wherein: (i) said solid silicone resin comprises at least one of an MQ resin and a T resin and is present in said emulsion in an amount of from >5 to <25 wt. % based on the total weight of said non-aqueous phase; and (ii) said siloxane carrier vehicle comprises an alkoxy-functional silicone resin and is present in said emulsion in an amount of from >75 to <95 wt. % based on the total weight of said non-aqueous phase.

8. The emulsion of claim 1 , wherein: (i) said non-aqueous phase consists essentially of, alternatively consists of, said solid silicone resin, said siloxane carrier vehicle, and optionally said surfactant; (ii) said aqueous phase consists essentially of, alternatively consists of, water and optionally said surfactant; (iii) said surfactant comprises an anionic surfactant; or (iv) any combination of (i) to (iii).

9. The emulsion of claim 1 , further defined as a coating composition and further comprising a filler, a pigment, a binder, or combinations thereof.

10. A method of preparing the emulsion of claim 1 , said method comprising:
combining said solid silicone resin and said siloxane carrier vehicle to give a non-aqueous composition;
combining the non-aqueous composition, water, and the surfactant to give a mixture; and
shearing the mixture, thereby preparing the emulsion.

11. The method of claim 10 , wherein the non-aqueous composition and the surfactant are first combined to give an initial mixture, and wherein water is combined with the initial mixture to prepare the emulsion.

12. A method of preparing a film, said method comprising:
applying an emulsion on a substrate; and
forming the film on the substrate from the emulsion;
wherein the emulsion is the emulsion of claim 1 .

13. The method of claim 12 , wherein forming the film on the substrate comprises forming a wet film on the substrate, and drying the wet film on the substrate to form the film, wherein drying the wet film comprises (i) evaporating water from the wet film; (ii) exposing the wet film to an elevated temperature to drive water therefrom; (iii) curing the wet film; or (iv) any combination of (i) to (iii).

14. A film formed in accordance with the method of claim 12 .

15. The film of claim 14 having a thickness of from 1 to 50 μm.

16. A composition, comprising:
an emulsion; and
an organic binder;
wherein the emulsion is the emulsion of claim 1 .

17. A method of preparing a film, said method comprising:
applying a composition on a substrate; and
forming the film on the substrate from the composition;
wherein the composition is the composition of claim 16 .

18. A film formed in accordance with the method of claim 17 .

Assignees

• Dow Silicones Corp

Inventors

• Di Giovanni Gina
• Galeone Fabrizio
• Hrebi{Hacek Over (C)}Ík Michal
• Léger Pierre
• Pierre David
• Ugazio Stephane

Classifications

• C08J5/18

  Manufacture of films or sheets · CPC title

• C08J2423/12

  Polypropene · CPC title

• C08G77/04

  Polysiloxanes · CPC title

• C08K5/41

  Compounds containing sulfur bound to oxygen · CPC title

• C08L83/04 Primary

  Polysiloxanes · CPC title