CA2061386A1 - Novel non-aqueous dispersions - Google Patents

Abstract

ABSTRACT
This invention relates to high solids, low VOC, low viscosity, filterable, non-gritty non-aqueous dispersions, and coating compositions containing said non-aqueous dispersions.

Description

2~38~

R~ Tomko M. Rao M. Shalati J. Kraan BACKGROUND OF THE INVl :NTION
Non-aqueous dispersions (NAD's) are well known in the art and typically consist of disperaions of addition polymers in a relatively non-polar non-aqueous liquid containing a steric stabilizing agent having dual affinity to ~oth the dispersing and the dispersed media. For example, U.S. Patent 3,198,759 teaches dispersions of addition polymers in a hydrocarbon medium. The hydrocarbon medium contains one or more;aliphatic hydrocarbons containing dissolved therein an alkyd formed by either the direct esterification of a drying oil fatty acid with a dicarboxylic acid and a polyhydric alcohol or the indirect esteri~ication o~ a drying oil by first alcoholization with a polyhydric alcohol and second esterification with a polybasic acid. European Patent Application a 310 331 A2 teaches a non-aqueous dispersion of a soluble low molecular weiy~t non-alkyd polymer which is attached or adsorbed onto a second non-soluble alkyd-free polymer. U.S. Patent 4,530,957 teaches non-aqueous dispersions based on crosslinked acrylic poly~er partlcles dispersed in a non-aqueous medium having a polymeric dispersion stabilizer. The polymeric dispersion stabilizer can be an alkyd which is ~ormed by the sel~ condensation o~ 12-hydroxystearic acid ~ollowed by a capping reaction with glycidyl methacrylate. U.S. Patent 4,206,099 teaches non-aqueous dispersions o~ crosslinked polymer particLes in a non-aqueous ' :

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.ledium having an amphipathic steric stahilizing agent. Th ~
stabilizing agent can be a graft copolymer obtained by reacting a low molecular weight carboxyl group terminated condensate of linseed oil fatty acids and 12-hydroxystearic acid with acrylic copolymers. U.S. Patent 3,779,977 teaches non-aqueous dispersions of an acrylonitrile copolymer in a liquid butacliene homopolymer or copolymer in a non-polar organic hydrocarbon liquid.
A review of those patents clearly shows that most NAD's have solids contents in a range generally less than 60% ~y weight and have relatively high volatile organic contents. Attempts to raise the solids content and lower the volatile organic content of these NAD's has led to compositions which either gell unacceptably, exhibit extremaly high viscosities, are not stable fox any appreciable length of time or exhibit extremely long and unacceptable dxy times as air dry coatings.
In our attempts to decrease the VOC contents o~ NADIs, we have ~ound that many alkyds produced via the traditional "alcoholysis"
process (alcoholysis of a drying oil followed by reaction with a polybasic acid) have extremely high viscosities. The use of such alkyds in a non-aqueous dispersion can force the formulator to use a large amount of solvent to lower viscosity. This in turn causes the VOC of the NAD to increase unacceptably. Additionally, we have found that whila many alkyds produced via the traditional "fatty acid esterification" process can be used to produce stable NA~'s, they typically are limited in their ability to produce NAD's or coatings having NVM's greater than about 70% and VOC's less than .
, ~ ` ' 3 ~ ~
about 350 g/l.
The present invention produces very high solids NAD's, greater than about 75% NVM, with very low VOC's of less than 305 g/l, which exhibit excellent stability, filterability, low grit, viscosity and tack-free and dry times when formulated as air dry coating compositions. Thase NAD's are the result of a selection process wherein certain critical parameters, described fully below, must be observed.

SUMMARY OF THE INVENTION
This invention relates to novel, high solids, low VoC non-aqueous dispersions ~NADIs) and a process for producing these non-aqueous dispersions. The N~D'~ of this invention comprise an alkyd as the dispersing medium and steric stabilizer for the polymeri7.ation product of one or more monomers whlch are predominantly non-soluble in the alkyd medium. The N~DIs of this invention are the product of a process which requires, in addition to other factors, at least one alkyd stabilizer, which stabilizer has a z-average molecular weight between about 10,000 and 250,000, pre~erably between about 15,000 and 150,000; and which stabilizer has a polydispersity between about 2.0 and 20, preferably between about 2.0 and 6Ø The use of this alkyd as the dispersing medium for the polymerization of free radical addition monomers, one of which is hydroxy-functional, further in the presence of a chain transfer agent~ yields N~D's having non-volatile materials (NVM) contents greater than about 75% by weiyht, typically approaching ' . . . ..

, . , . ~

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100% NVM, having volatile organic contents (VOC) typically less than about 305 g/l, preferably less than about 250 g/l, which NAD's exhibit excellent dry times not heretofore associated with very high solids alkyds or NAD's. The NAD's of this invention are particularly suited for interior and exterior applications in the architectural, industrial maintenance, and traffic paint and coatings industries.
The process for producing the NAD's of this invention comprises using an alkyd meeting the criteria established herein as the dispersing medium, either alone or in combination with some minor amount of hydrocarbon, aromatic, polar, ketone, ester, or alcohol solvent, or in combination wlth other minor amounts of other alkyd, modified-alkyd, or hydrocarbon dispersing media, for the polymerization of monomers which are predominantly insoluble in the alkyd medium. The particular means for the production of the alkyd are not of import to this invention. Thus, the alkyd can be produced accordin~ to any of the traditional processes ~or the production of alkyds which are readily available from the art or the alkyd can be produced according to the teachings ~f pending patent application number 464,841 filed January 16, 1990, incorporated by refPrence herein. Critical to the success of this inven~ion i~ that the alkyds used must have z-average molecular weights between about 10,000 and about 250lO00, preferably between about 15,000 and 150,000; with a polydispersity between about 2.0 and 20, preferably between about 2.0 and about 6~0. Preferably, the alkyd stabilizer has an NVM solids content of at least about .
, .

.

r 3 ~3 5%, more preferably at least about 90%.
The alkyd serves as the dispersing medium and steric stabilizer for the reaction of free radical addition monomers which produce a polymer which is predominantly insoluble in the alkyd medium. The monomers are polymerized in the presence of the alkyd to produce the novel NAD's of this invention. Another critical parameter which must be followed is that at least one monomer must have hydroxy-functionality. A third critical parameter which must be followed is that the polymerization must take place in the presence of a chain transfer agent.
We have found that by following these key critical parameters, one can formulate an NAD having an NVM greater than about 70%, which is stable, non-gritty, filterable, and low in viscosity. ~e have found that failure to follow these key critical parameters results in NAD's which are not stable, have very poor yields, do not filter properly and/or are unacceptably high in viscosity.
~ ccordingly, it is an object of this invention to teach novel non~aqueous dispersions.
It is another object of this invention tv teach a high solids low VOC, non-aqueous dispersion having acceptable air dry times.
It is a further object of this invention to teach a process for producing high solids, low VOC non-agueous dispersions having acceptable air dry times.

DETAILED DESCRIPTION OF THE INVENTION
As stated above, t~e process for producing the NAD's of this 2 i~
invention comprisas selecting an alkyd having a z-average molecular weight between about lO,OOo and about 250,000, preferably between about 15,000 and 150,000, with a polydispersity hetween about 2-.0 and about 20, preferably between about 2.0 and about 6.0; and using this alXyd as the dispersing medium, either alone or in combination with some minor amount of solvent or other dispersing med.ia, for the polymeri ation of monomers which are predomînantly insoluble in the alkyd medium. The alkyd used in these NADIs is formed by any of the traditional processes such as fatty acid esteriEication or alcoholysis of a drying oil with later reaction with a di- or ~ri- basic acid, or the alkyd can be formed according to the teaching of U.S. patent application number 464,841 filed January 16, lg90.
The alkyds o~ this invention must have ~ z-average molecular weight between about 10,000 and 250,000, preEerably between about 15,000 and 150,000; with a polydispersity between about 2.0 and about 20, preferably between about 2.0 and about 6Ø Alkyds in this range provide the basis for a high solids, low VOC
composition.
Typical raw materials for the formation of alkyds include triglyceride oils or the fatty acids thereof. These can be selected from the group consisting of linseed oil, soya oil, coconut oil, cottonseed oil, peanut oil, canola oil, corn oil~
safflower oil, sunflower oil, dehydrated castor oil, fish oil, perilla, lard, walnut oil, tung oil, tall oil, the fatty acids thereof and mixtures thereof. Particularly preferred are those oils and acids containing unsaturation in the glyceride chains.
Particularly preferred are soya oil, dehydrated castor oil and lin~eed oil and the fatty acids thereof.
Multi-functional alcohols, and mixtures thereof, are also common raw materials for the production of alkyds. One suitable hexafunctional alcohol includes dipentaerythritol. One suitable tetrafunctional alcohol includes pentaerythritol. Suitable trifunctional alcohols include the group consisting of trimethylol propane, trimethylol ethane, glycerine, tris hydroxyethyl isocyanurate, and mixtures thereof, either alone or in com~ination with a difunctional alcohol selected from the group consisting of ethylene glycol, propylene glycol, cyclohexane dimethanoL, and mixtures thereof. Additionally, dimethylol propionic acid can be used in combination with the trifunctional alcohol. Multi-functional alcohols, trifunctional alcohols, and mixtures thereof are particularly preferred due ~o the degree of branching they allow. Difunctional alcohols, if used, are preferably used as a minor component in combination with trifunctional alcohols. A
portion of monofunctional alcohol, or monobasic acid ~uch as soya ~atty acid, linseed oil fatty acid or crotonic acid, up to about 20% by wei~ht of the total alkyd can be added with the multifunctional alcohol to control molecular weight and act as a chain stopper.
Another typical raw material used in the formation of alkyds is multi-~unctional carboxylic acids or anhydrides. Suitable trifunctional carboxylic acids include trimelletic acid, trimesic ~, .
" :

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Icid, 1,3,5-pentane tricarboxylic acid, citric acid and others whereas suitable trifunctional anhydrides include trimelletic .anhydride, pyromellet.ic anhydride and others. Difunctional carboxylic acids include phthalic acid, isophthalic acid, terephthalic acid~ maleic acid and fumaric acid and mixtures thereof. Mixtures of such acids and anhydrides are also acceptable.
The amounts of oil, acid and alcohol used should be such that the resulting alkyd has a high degree of branching~j a.z~.average molecular weight, M~, between about lU,000 and 250,000, preferably between about 15,000 and 150,000, a polydispersity between ahout 2.0 and about 20, preferably between about 2.0 and about ~.0, an oil length of between about 65% and 85%, an acid value less than about 20, and a hydroxyl number less than 100, preferably less than 60. The NVM should be above about 70%, preferably up ko about 100~6 .
If desired, a reaction catalyst such as lithium hydroxide monohydrate, barium hydroxide, or di-butyl tin oxide can be added in an amount of approximately 0.02% by weight of oil.
Alkyds having Mz between about 10,000 and about 250,000 are especially suitable ~or use in the non-aqueous dispersions of this invention as the dispersing medium and to disperse and stabilize insoluble monomers and polymers. The NAD's made according to this invention typically have NVM's of about 75% or more, preferably up to about 100~ NVM, have Brookfield LVT #3 (6/12 rpm) viscosities less than about 60,000 cps at 25 degrees C, preferably less than :.,' ~ , !i .
2~ 3~
about 30,000 cps, more preferably less than about lo,ooo cps, have volatile organic contents less than 305 g/l, preferably less than 250 g/l, and exhibi,t excellent air dry times usin~ conventional drier compounds.
Two particularly suitable commercially available alkyds which exhibit the requisite Mz values and thus are suitable for use in this invention include the 98% solids, long oil alkyd marketed by Cargill, Inc. under the designation 57-5843 (Mz of approximately 45,000 and polydi~persity of about S.63; and the 100% solids i~ophthalic alkyd oil marketed by McCloskey under the designation Varkydol~ 210-100 (Mz of approximately 18,000 and polydisparsity of about 2.7~.
When preparing non-aqueous dispersions according to this invention, the`monomers should be selected from monomers which would produce a polymer via the free radical addition reaction mechanism which is predominantly insoluble in the alkyd medium.
It is essential that at least one of the monomers contain hydroxy functionality. More preferably, between about 5~ and 35% by weight of the total reactor charge comprises hydroxy functional monomers.
Most preferably, between about 10% and about 30% by weight of the total reactor charge comprises a hydroxy functional monomer such as hydroxy ethyl acrylate. Suitable monomers can be selected from the group consisting of acrylonitril~, methacrylonitrile, hydroxy ethyl acrylate and methacrylate, hydroxy propyl acrylate and ~ethacrylate, methyl acrylate and methacrylate, ethyl acrylate and methacrylate, butyl acrylate and methacrylate, lauryl acrylate and ' 2~3~
..~ethacrylate, and the like, trimethylol propane triacrylate and trimethacrylate, hexanediol diacrylate, Tone M-100 (caprolactone modified hydroxy ethyl acrylate), polyethylene oxide acrylate,and methacrylate, polypropylene oxide acrylate and methacrylate, allyl alcohol, acrylamide, methacrylamide, vinyl chloride, vinylidene chloride, and mixtures thereof. In addition to pure monomers, preformed polymers, polymeric intermediates, multifunctional epoxides, melamines and isocyanates, can be included in the reactor charge. Most preferred is a combination of methyl methacrylate and hydroxy ethyl acrylate wherein the methyl methacrylate is present in an amount of between about 20 and ~0~, and the hydroxy ethyl acrylate is present in an amount of between about 10 and 30%, by weight of total reactor charge.
Certain monomers should be included in the reactor charge in relatively minor amounts, if at all, due to their affect on the viscosity of the NAD or the grittiness of the NAD. These include acrylic a~id, methacrylic acid, and itaconic acid as the inclusion of such acids tends to create a gritty NAD. Also included is styrene because of an unacceptable resultant increase in NAD
viscosity. Also included are divinyl benzene, vinyl napthalene, and vinyl toluene because these are generally soluble in a].kyds.
These monomers have been found to contribute to a decrease in yield, addltional grit, and/or a lessening of stability over time.
To prepare the NAD's o~ this invention, the alkyd dispersing medium is used as the polymeriæation medium for the monomer charge.
The alkyd medium can be diluted with mineral spirits or other .

;, ' 3 ~ ~
solvent if dasired, with the primary limitation being concern for the VOC of the composition.
The total amount of alkyd contained in the reaction vessel, including any alkyd which may be added with the monomer charge, should comprise between about 25% to about 75%, preferably from about 40% to about 60%, by weight of the total reactor charge. The fxae radical addition monomer charge should, after completely added to the reaction vessel, account for approximately 75% to about 25%, preferably between about 60% to about 40%, by weight of-the total reactor charge. A mercaptan-containing chain transfer agent such as methyl mercaptopropionate, dodecyl mercaptan, thioglycolic acid, or 2-mercapto ethanol must also be added to the vessel in an amount from about 0.1% to about 6.0% by weight of total reactor charge.
Most preferred is 2 mercapto ethanol. An initiator selected from the group consisting of organic peroxides such as benzoyl peroxide, lauroyl peroxide, di-t-butyl peroxide, acetyl peroxide, t--butyl peroctoate, t-amyl peroctoate, and t-butyl perbenzoate, and selected from the group consisting of nitrile initiators such as a,a'-azobisisobutyronitrile, and mixtures thersof are also added in an amount up to about 3% by weight of the total monomer charge.
All frea radical addition reactants are preferably added via dxopwise addition over a period of time to the alkyd dispersing medium. The monomer charge can be added pure, or, in a preferred embodiment, the monomers can be dispersed in an amount of the alkyd of this invention prior to addition to the dispersing medium. The amount of alkyd used for such a dispersion should be included in .
~ ' .. -, ' ':

~ ~ 2 ~ 8 ~
~he calculation of the overall amount of alkyd present in the reaction vessel. Any additional ingredients such as acrylic polymers and copolymers, macromonomers, silicones, XI-100~ from Monsanto (poly allyl glycidyl ether), alkyds, uralkyds, urethane-modified oils, polyesters, and epoxy esters can be included in the reactor charge provided thay are solubilized in either the monomer charge or the alkyd dispersing media.
The temperature of the contents o~ the reaction vessel should be maintained between about 200~F and 250F for the-entire period that monomer charge is being added. A nitrogen blanket is also highly preferred. Upon completion of the monomer addition, an activator selected from the group consisting of the iron, copper, vanadium, cobalt and manganese naphthenates, octoates, hexanates and isodecanoates is added to the reactor vesssl and a hydroperoxide chaser composition selected from the group consisting oP cumane hydroperoxide, t-butyl hydroperoxide, t-amyl hydroperoxide, and the like is added dropwise over a period o~
about 90 minutes. Upon completion o~ the chase, the temperature should be maintained between 200F and 250F for approximately one hour. At the end of that hour, the heat is removed and the contents of the vessel are filtered.
The non-aqueous dispersions of this invention can be used alone as coating compositions. Or, they can be used in combination with other high or low VOC alkyds to reduce the overall VOC of a coating. They can be combined with other film-forming compositions such as acrylic polymers and copolymers, polybutadiene, and , - , . - -, .' . . : . . .

~ :

polyallyl glycidyl ether. They can be formula~ed with other readily available, standard paint ingredients and components such as crosslinking agents, catalysts, rheology modifiers~ ~hixotropes, extenders, colors and pigments, solvents, anti-skinning agents, drying agents, dispersants and surfactants, fungicides, mildewcides, preservatives, UV absorbers, anti-marring agents, anti-cratering agents, flow and leveling agents, fragrances, defoaming agen~s, chelating agents, flattening agents, and anti-rusting agents.
Suitable rheology modifiers are well known in the art and can comprise organoclays, fumed silicat dehydrated castor oil organic derivatives (exemplary tradenames Thixatrol (R), NL Industries;
Flowtone ~R), English China Clay), polyamides, polyamide modified alkyds, MPSA-60, Rheox, alkylbenzene sulphonate derivatives, aluminum, calcium and zinc stearates, calcium soyate, and the like.
Suitable extenders are also well known in the art and can comprise amorphous, diatomaceous, fumed, quartz and crystalline ~ilica, clays, aluminum silicates, magnesium aluminum silicates, talc, mica, delaminated clays, calcium carbonates and silicates, gypsum, barium sulfate, zinc, calcium zinc molybdates, zinc oxide, phosphosiliaates and borosilicates of calcium, barium and strontium, barium metaborate monohydrate, and the like.
Suitable colors and pigments are well known in the art and can comprise for example, titanium dioxide, carbon black, graphite, ceramic black, antimony sulfide, black iron oxide, aluminum pastes, yellow iron oxide, red iron oxide, iron blue, phthalo blue, nickel .. ~ , :

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~itaslate, dianisidine orange, dinitroaniline orange, imidazole orange, quinacridone red, violet and magenta, toluidine red, molybdate orange, and the like.
Suitable solvents can comprise propylene and ethylene glycol ethers and acetates, alcohols, ketones, aliphatic and aromatic hydrocarbons and naphthas, petroleum and wood distillates, turpentine, pine oil, and the like. Solvent selection is limited primarily by the desire to maintain the overall VOC level of the coating composition below 305 g/l, preferably below~250 g~l.
Anti-skinning agents such as methyl ethyl ketoxime, o-cresol, and hydroquinone can be included.
Drying agents can comprise standard metallic and rare earth driers such as cobalt, calcium, potassium, barium, zinc, manganese, tin, aluminuml zirconium and vanadium napthenates, octoatest hexanates, and isodecanoates. A particularly preferred drier composition is a combination of cobalt, calc.ium and ~irconium driers present in an amount from about 0.1% to about 2.5% by weight of the coating composition.
Suitable dispersants and surfactants can comprise any of the rea~ily available dispersants and surfactants to the coatings industry, including the anionic and nonionic surfactants, soya lecithin, alkyl ammonium salts of fatty acids, amine salts of alkyl aryl sulfonates, unsaturated organic acids, sulfonated castor oil, mixtures of high boiling point aromatic and ester solvents, sodium salts of aryl sulfonic acid, Solsperse~ from ICI, and the like.
The following examples will demonstrate various embodiments , - ~ ~

3 8 ~
of this invention.
EXAMPLE ONE--PREPA~TION OF ALKYD WITII Mz OF ABCUT 13, 973 Charge 1819g of soya fatty acid, 496g of pentaerythritol, 0.36g of dibutyltin catalyst and 32g of xylene to a reactor equipped with inert gas, mechanical stirrer, barrett tube and Friedrich's condenser. Heat to 370 degrees F and hold for one hour. Cool to 360 degrees F and add 283g of crotonic acid, 400g isophthalic acid, 186g RJ-101 (a styrene-allyl alcohol copolymer available from Monsanto) and 32g xylene. ~eat to 485..degre~s F and hold for a viscosity of Z4 (maximum) and an acid value <20 at 97.5%
NVM. Cool. The resultant alkyd has an NVM of 98.2, a viscosity of Z3, an acid value of about 16, Mz of about 13,g73, Mw of about 5582, Mn of about 2113 and a polydispersity of about 2.64.
EXAMPLE TWO--PREPARATION OF ALKYD WITH Mz OF ABOVT 47,400 Charge 1808g of soya ~atty acid, 493g of pentaerythritol and 0.36g of a dibutyltin catalyst to a 51, 4-necked round bottom Plask equipped with inert gas, mechanical stirrer, barrett tube and Friedricks condenser. Heat to 370 degrees F and hold for one hour.
Add 280.96g of crotonic acid, 433.92g of isophthalic acid and 115.2g of RJ-101. Heat to about 478 degrees F and hold for a viscosity of Z-Z2 at 90% NVM in mineral spirits and an aci~ value ~14. Cool to room temperature~ and reduce to 90% NVM in ~I:ineral spirits. The resultant alkyd has ~0% NVM, viscosity of about Zl, acid value of about 13.5, color of 6-7, Mz of about 47,404, Mw of about 13,869, Mn of about 3r044 and a polydispersity of about 4.56.

.

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~AMPLE THREE--PREPARATION OF ALKYD WITH Mz OF ABOUT 2 8, 2?0 Charge 1354.7 grams of soya oil and 243.3 grams of trimelletic anhydride to a 3 liter, 4-necked, round bottom flask equippPd with inert gas blanket and mechanical stirrer. Heat the contents to about 480F and hold for about one-half hour. Cool to about 400F
and add 255.3 grams of trimethylol propane, 25.6 grams of trimethylol ethane and 408.2 grams of linseed fatty acid. Heat to 480F and hold for an Acid Value less than or equal to 13 and a viscosity of W.
The resulting alkyd has an NVM of about 100%, a Gardner-Holdt viscosity of about W, an Acid Value of about 9.7, an M2 of about 28,200, an oil length of about 80 and a Hydroxyl No. of about 37.
EXAMPLE FOUR--PREPARATION OF ALKYD WITH Mz OF ABOUT 23,639 Charge 1996.3g of soya fatty acid, 760.5g of dipentaerythritol and 0.41g of dibutyltin catalyst to a 51, 4-necked reactor equipped ~ith inert gas, mechanical stirrer, barrett tube and Friedrich's condenser. Heat to 370 degrees F and hold for one hour. Add 335.6g of crotonic acid, 321.6g of isophthalic acid and 85.76g of xylene. Heat to 480 degrees F and hold for a viscosity of Z4 (maximum) and an acid value <13 at 100% NVM. The resultant alkyd has an NVM of about 99.0%, a viscosity of about Z4, an acid value of about 11, Mz of about 23,639, Mw of about 8,432, Mn of about 2829 and a polydispersity of about 2.98.
COMPARATIVE EXAMPLE ONE--ALKYD WITH Mz OF ABOUT 9,700 Charge 1861.3g soya fatty a¢id, 507.lg pentaerythritol and 0.37g of dibutyltin catalyst to a 51, 4-necked reactor equipped .~lth inert gas, mechanica} stirrer, barrett tube and Friedric~'3(~
condenser. Heat to 370 degrees F and hold for one hour~ Add 189.8g RJ-101, 289.1g crotonic acid, 294.7g isophthalic acid and 58g of xylene. Heat to 485 degrees F and hold for a viscosity of Y-Zl and an acid value <14 at 97.5% NVM. The resultant alkyd has an NVM of about 98.25%, a viscosity of Y-z, an acid ~alue of about 10.8, color of about 4, Mz of about 9,716, Mw of about 3,927, Mn of about 1894, and a polydispersity of about 2.07.
PREPARATION OF NADS
Four cate~ories of NAD's were prepared from each of the above alkyds as well as from the Cargill 57-5843 alkyd and the McCloskey Varkydol~210-lO0 alkyd. The NAD categories had the following approximate compositions by weight:

NAD "Ai' 50 parts alkyd 35 parts methyl methacrylate 15 parts hydroxy ethyl acrylate 0.2 parts chain trans~er agent NAD "B" 50 parts alXyd 50 parts methyl methacrylate 0 parts OH-functional monomer 0.2 parts chain transfer agent NAD ~'C~' 50 parts alkyd 35 parts methyl methacrylate 15 parts hydroxy ethyl acrylate 0 parts chain transfer agent NAD "D" 50 parts alkyd 50 parts methyl methacrylate 0 parts OH-functional monomer 0 parts chain transfer agent The following procedure was used to make each NAD:
Charge about 1/2 of the alkyd to a reactor equipped with a mechanical stirrer. Heat to 100C. Disperse the monomer/chain :' .

2~3~
cransfer agent solution in the remainder of the alkyd and begin a three hour dropwise addition of the solution along with a initiator solution comprising t-butyl peroctoate in mineral spirits to the reactor. Upon completion of the addition of the solutions, hold for approximately one hour and then add vanadium naphthenat~ to the reactor. Begin a 90 minute addition of a "chase" comprisin~
mineral spirits and cumene hydroperoxide. Hold the temperature at 100C for approximately ~ to 1 hour after the chase has been completely added. Shut off heat and filter the contents o~ the reactar through a 15 micron polyester filter bag.
Table I demonstrates the properties of each NAD:
Alkyd~CTA NAD l'AI' NAD "Bl' NAD "CI' ND'~' Ex. I NVM 83% NVM 82.2% SCRAP SCRAP
2-Me* 6/12 rpm FILTER CLOG
3750/3875cps Hegman:0 **Hegman:8 Ex. II NVM 85.4% SCRAP SCRAP SCRAP
DM* 6 rpm 57000 cps Hegman:l Ex. III NVM 86.8% SCRAP SCRAP SCRAP
2-Me 6/12 rpm 2100/2150cps ~egman:8 Ex. IV NVM 82.1% SCRAP SCRAP SCRAP
2-Me 6/12 rpm 8800/9000cps Hegman:8 Ca~gill 5843 NVM 83% NVM 78.1% NVM 82.2% SCRAP
DM 6/12 rpm ~ILTER CLOG FILTER CLOG
5900/5200cps Hegman:1 Hegman:l Hegman:5 .

..
:
, tf~ 3 ~ ~

Cargill 5843 NVM 82.4% NVM 81.4% SCRAP SCRAP
2-Me 6/12 rpm FILTER CLOG
1850/1~50cps Hegman:5 McCloskey NVM 82.2~ NVM 86~3~ SCRAP SCRAP
2-Me 6/12 rpm FILTER CLOG
860/860cps Hegman:8 McCloskey NVM 97.8% NVM 95.9% SCRAP SCRAP
2-~e 6/12 rpm FILTER CLOG
24,600cps Hegman:8 Comp. ~x. I SCRAP SCRAP SCRAP SCRAP
2-Ma * 2-Me refers to 2-mercapto ethanol and DM refers to dodecyl mercaptan.
** The Hegman values were taken prior to filtration and measure grittiness with a value of "O" representiny all grit and a value of ~'8" representing no grit.

305 g/l VOC PAINT PREPARATION EXAMPLES
The following procedure was generally followed for each paint composition below. Charge a vessel with the initial NAD and the mineral spirits charges shown below. Start dispersing and add soya lecithin and titanium dioxide under low speed. Increase to high spee~ mixing. Run approximately 10 to 15 minutes. Decrea~e to low speed mixing and add the remaining materials in the order shown ~elow.
EXAMPLE FIVE

~ he following formula was used to prepare a 3U5 g/l VOC gloss paint:
:NAD l'A'I from Alkyd of Ex. I 302.33 lbs Mineral Spirits 24.96 Soya Lecithin 3.00 Rutile Titanium Dioxide190.00 NAD "All from Alkyd of Ex. I 305.63 Mineral Spirits 21.59 ~: :
: . -12% Cobalt Catalyst 1.24 10~ Ca Synthetic Acid Drier 7.96 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 98.36 The paint had KU and ICI viscosities at 25 degrees C of 67 and 3.1, respectively.
EXAMPLE SIX
The following formula was used to prepare a 305 g/l VOC gloss paint:
NAD "~" from Alkyd of Ex. II 302.33 lbs Mineral Spirits 24.96 Soya Lecithin 3.00 Rutile Titanium Dioxide 190.00 NAD "A" from Alkyd of Ex. II 282.86 Mineral Spirits 21.59 12~ Cobalt Catalyst 1.24 10~ Ca Synthetic Acid Driar 7.96 Methyl Ethyl Ketoxime 2.Q0 Mineral Spirits 119.38 The paint had XU and ICI viscosities at 25 degrees C of 106 and 5+, respectively.
EXAMP~E SEVEN
The following formula was used to prepare a 305 g/l VOC gloss paint:
NAD "A" from Alkyd of Ex~ III 305~66 lbs Mineral Spirits 24.96 Soya Lecithin 3.00 Rutile Titanium Dioxide 190.00 NAD "A" from AlXyd of Ex. III 319.76 Mineral Spirits 21.59 12% Cobalt Catalyst 1.24 10% Ca Synthetic Acid Drier 7.96 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 93.85 The paint had KU and ICI viscosities at 25 degrees C of 62 and 1.3, respectively~
EXAMPLE EIGHT
The following formula was used to prepare a 305 g/l VOC gloss paint:
NAD "A" from Alkyd of Ex. IV 302.33 lbs ~0 , : :
' ' ~ ' ' ' ~ " '' ' . ' ' 3 .
2 ~
Mineral Spirits 24.96 Soya Lecithin 3.00 Rutile Titanium Dioxidel90.Q0 NAD l'A" from Alkyd of Ex. IV 310.71 Mineral Spirits 21.59 12% Cobalt Catalyst 1.24 10% Ca Synthetic Acid Drier 7.96 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 92.08 The paint had KU and ICI viscosities at 25 degrees C of 72 and 4.8, respectively.
EXAMPLE NINE
The following formula was used to prepare a 305 ~ OC ~loss paint:
NAD "A" from Cargill 57-5843/DM 305.66 lbs Mineral Spirits 24.96 Soya Lecithin 3.00 Rutile Titanium Dioxide190.00 NAD "A" 303.20 Minexal Spirits 21.59 12% Cobalt Catalyst 1.24 10% Ca Synthetic Acid Drier 7.96 ~ethyl Ethyl Ketoxime 2.00 Mineral Spirits 98.23 The paint had KU and ICI visco5ities at 25 degrees C o~ 73 and 3.6, respectively.
EXAMPLE TEN
The following ~ormula was used to prepare a 305 g/l VOC gloss paint:
NAD "A" ~rom Cargill 57-5843/2-Me 304.47 lbs Mineral Spirits 24.96 Soya Lecithin 3.00 Rutile Titanium Dioxide190.00 NAD "A" 303.20 Mineral Spirits Z1.59 12% Cobalt Catalyst 1.24 10~ Ca Synthetic Acid Drier 7.96 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 95.00 The paint had KU and ICI viscosities at 25 degrees C of 61 and 1.6, respectively.

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EXAMPLE ELEVEN
The following formula was used to prepare a 305 ~/1 VOC gloss paint:
NAD "A" (NVM 82.2) McCloskey Alkyd 305.66 lbs Mineral Spirits 25~08 Soya Lecithin 3.00 Rutile Titanium Dioxide 190.00 NAD "Al' 300.00 Mineral Spirits 21.5 12~ Cobalt Catalyst 1.24 10% Ca Synthetic Acid Drier 7.96 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 93.73 The paint had KU and ICI viscosities at 25 degrees C of 65 and 1.5, respectively. ~
EXAMPLE TWELVE
The following formula was used to prepare a 305 g/l VOC gloss paint:
NAD "A" (NVM 97.~) McCloskey Alkyd 308.80 lbs Mineral Spirlts 25.08 Soya Lecithin 3.00 Rutile Titanium Dioxide 190.00 NAD "A" 190 32 Mineral Spirits 21 59 12% Cobalt Catalyst 1.24 10% Ca Synthetic Acid Drier 7.96 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 190.56 The~ paint had KU and ICI viscosities at 25 degrees C of 61 and 1.2, respectively.
243 g/l VOC PAINT PREPARATION EXAMPLES
EXAMPLE THIRTEEN
The following formula was used to prepare a 243 g/l VOC gloss paint ~ormula:
NAD l'A'' from Alkyd of Ex. I 302.33 lbs Mineral Spirits 24~96 Soya Lecithin 3.00 Rutile Titaniu~ Dioxide 190.00 MAD "A" from Alkyd of Ex. I 397.24 Mineral Spirits 21.59 12% Cobalt Catalyst 1.44 ' .

.
- ~ :

2~.3~
10~ Ca Synthetic Acid Drier 9.18 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 30.42 The paint had KU and ICI viscosities at 25 degrees C of 95 and 5+, respectively.
EXAMPLE FOURTEEN
The following formula was used to prepare a 243 g/l VoC gloss paint formula:
N~D "A" from Alkyd of Ex. III 305.66 lbs Mineral Spirits 24.g6 Soya Lecithin 3.00 Rutile Titanium Dioxide 190.00 NAD "A" Erom Alkyd of Ex. III 414.03 Mineral Spirits 21.59 12% Cobalt Catalyst 1.44 10% Ca Synthetic Acid Drier 9.18 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 25.21 The paint had KU and ICI viscosities at 25 degrees C of 83 and 3.7, respectively.
EXAMPLE FIFTEEN
The following formula was used to prepare a 243 g/l VOC gloss paint formula:
NAD 'IAl' from Cargill 57-5843/DM 305.66 lbs Mineral Spirits 24.96 Soya Lecithin 3.00 ~util~ Titanium Dioxide 190.00 NAD "A" 394.91 Mineral Spirits 21.59 12% Cobalt Catalyst 1.44 10% Ca Synthetic Acid Drier 9.18 Methyl Ethyl Ketoxime 2.00 ~ineral Spirits 30.29 The paint had KU and ICI viscosities at 25 degrees C of 124 and 5+, respectively.
EXAMPLE SIXTEEN
The following formula was used to prepare a 243 g/l VOC gloss paint formula:
NAD "A" from Cargill 57-5843/2-Me 304.47 lbs Mineral Spirits 24.96 ~, ' ' -. ~ - -:; :

2 ~
Soya Lecithin 3.00 Rutile Titanium Dioxide 190.00 NAD "A" 394-74 Mineral Spirits 21.59 12% Cobalt Catalyst 1.44 10% Ca Synthetic Acid Drier 9.18 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 26.54 The paint had KU and ICI viscosities at 25 degrees C of 86 and 5+, respectively.
EXAMPLE SEVENTEEN
The following formula was used to prepare a 243 ~/1 VOC gloss paint formula:
NAD "A" (NVM 82.2~ McCloskey Alkyd 305.66 lbs Mineral Spirits 24.13 Soya Lecithin 3.00 Rutile Titanium Dioxide 190.00 NAD "A" 391.33 Mineral Spirits 21.59 12% Cobalt Catalyst 1.44 10% Ca Synthetic Acid Drier 9.18 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 26.04 The paint had KU and ICI viscosities at 25 degrees C o ~6 and 4.8, respectively.
EXAMPLE EIGHTEEN
The following formula was used to prepare a 243 g/l VOC gloss paint ~ormula:
NAD "A" (NVM 97.8) McCloskey Alkyd 308.80 lbs Mineral Spirits Z5.08 Soya Lecithin 3.00 Rutile Titanium Dioxide ~90.00 NAD "A" 265.46 Mineral Spirits 21.59 12% Cobalt Catalyst 1.44 10% Ca Synthetic Acid Drier 9.18 Methyl Ethyl Ketoxime 2.00 Mineral Spirits 136.59 The paint had KU and ICI viscosities at 25 degrees C of 82 and 3.5, respectively.

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Claims (10)

1. A process for producing a non-aqueous dispersion of addition polymers in an alkyd medium comprising:
a) selecting an alkyd having a molecular weight, Mz, between about 10,000 and about 250,000, and having a polydispersity between about 2.0 and about 20, and b) polymerizing one or more monomers in the presence of the alkyd via the free radical addition mechanism;
wherein at least one of said monomers has. hydroxy-functionality; and wherein said polymerization is conducted in the presence of a chain transfer agent.

2. The process of Claim 1 wherein the monomers are selected from the group consisting of acrylonitrile, methacrylonitrile, hydroxy ethyl acrylate and methacrylate, hydroxy propyl acrylate and methacrylate, methyl acrylate and methacrylate, ethyl acrylate and methacrylate, butyl acrylate and methacrylate, lauryl acrylate and methacrylate, and the like, trimethylol propane triacrylate and trimethacrylate, hexanediol diacrylate, Tone M-100 (caprolactone modified acrylate), polyethylene oxide acrylate and methacrylate, polypropylene oxide acrylate and methacrylate, allyl alcohol, acrylamide, methacrylamide, vinyl chloride, vinylidene chloride, multifunctional epoxides, melamines and isocyanates, and mixtures thereof and preformed polymers and polymeric intermediates thereof.

3. The process of Claim 2 wherein the alkyd has a Mz of between about 15,000 and about 150,000 and a polydispersity of between about 2.0 and about 6Ø

4. The process of Claim 1 wherein between about 5% and 35% by weight of the reactor charge comprises at least one monomer having hydroxy functionality.

5. The process of Claim 4 wherein the alkyd has a Mz of between about 15,000 and about 150,000 and a polydispersity of between about 2.0 and about 6Ø

6. The process of Claim 5 wherein said hydroxy functional monomer is selected from the group consisting of hydroxy ethyl acrylate and hydroxy ethyl methacrylate, and mixtures thereof.

7. The process of Claim 6 wherein said monomer charge comprises methyl methacrylate and hydroxy ethyl acrylate.

8. The process of Claim 7 wherein said chain transfer agent is selected from the group consisting of methyl mercaptopropionate, dodecyl mercaptan and 2-mercapto ethanol.

9. The product produced according to Claim 1.

10. The product produced according to Claim 8.