CN104650684A - 冻融稳定的漆制剂 - Google Patents

冻融稳定的漆制剂 Download PDF

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CN104650684A
CN104650684A CN201410604436.1A CN201410604436A CN104650684A CN 104650684 A CN104650684 A CN 104650684A CN 201410604436 A CN201410604436 A CN 201410604436A CN 104650684 A CN104650684 A CN 104650684A
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D·G·凯利
M·罗兹
P·罗
Y·蒂瓦里
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Abstract

本发明涉及一种漆前复合物,该漆前复合物包含TiO2颗粒和粘附及未粘附的聚合物粘结剂的水性浆液,和足量的通式为C10-15H22-32O(CH2CH2O)xH的仲醇乙氧基化物,以使基于漆前复合物中全部聚合物粘结剂的重量为基准计35-90重量%的聚合物粘结剂粘附在TiO2颗粒上,其中x为15-50,O(CH2CH2O)xH基团与C10-15H22-32链上的CH基团相连。本发明还涉及含有该复合物的涂料组合物,以及制备漆前复合物和涂料组合物的方法。

Description

冻融稳定的漆制剂
背景技术
本发明涉及具有改进的冻融稳定性的漆制剂。例如US 8,283,404和WO2012/116025中所述的,包含被聚合物包封的TiO2颗粒的粘结剂复合物已经在漆制剂中表现出改进的遮盖性,有时候这种改进是非常显著的。不幸的是,用这些复合物配制的漆往往表现出较差的冻融稳定性。因此,在漆制剂领域中,如果能提供同时具有极佳的遮盖性和冻融稳定性的制剂将是一大进步。
发明内容
一方面,本发明通过提供一种制备漆前复合物的方法而解决了该需求,所述方法包括以下步骤:a)使以下组分i),ii),iii)和iv)的混合物接触:i)TiO2颗粒和吸附性含硫酸官能化聚合物的水性分散体,ii)阴离子表面活性剂,iii)苯乙烯磺酸钠,和iv)氧化还原引发剂体系,由此形成第一复合物中间体;
然后,b)在乳液聚合条件下使第一复合物中间体与包含以下组分i),ii)和iii)的第一单体乳液接触:i)甲基丙烯酸甲酯或苯乙烯或它们的组合,ii)丙烯酸C1-C10烷基酯,和iii)含羧酸的单体,由此形成第二复合物中间体;
然后,c)使第二复合物中间体与包含以下组分i),ii),iii)和iv)的第二单体乳液接触:i)苯乙烯或甲基丙烯酸甲酯或它们的组合,ii)丙烯酸C1-C10烷基酯,iii)含羧酸的单体,和iv)结构式为C10-15H22-32O(CH2CH2O)xH的仲醇乙氧基化物,由此形成TiO2颗粒与不完全粘附的聚合物粘结剂的水性分散体;其中x为15-50,O(CH2CH2O)xH基团与C10-15H22-32链上的CH基团相连。
在第二方面,本发明是一种漆前复合物,该漆前复合物包含TiO2颗粒和粘附及未粘附的聚合物粘结剂的水性浆液,和足量的通式为C10-15H22-32O(CH2CH2O)xH的仲醇乙氧基化物,以使基于漆前复合物中全部聚合物粘结剂的重量为基准计35-90重量%的聚合物粘结剂粘附在TiO2颗粒上,其中x为15-50,O(CH2CH2O)xH基团与C10-15H22-32链上的CH基团相连。
本发明通过提供一种可用于要求冻融稳定性的漆组合物的漆前复合物而解决了本领域中的需求。
发明详述
一方面,本发明是一种制备漆前复合物的方法,该方法包括以下步骤:a)使以下组分i),ii),iii)和iv)的混合物接触:i)TiO2颗粒和吸附性含硫酸官能化聚合物的水性分散体,ii)阴离子表面活性剂,iii)苯乙烯磺酸钠,和iv)氧化还原引发剂体系,由此形成第一复合物中间体;然后,b)在乳液聚合条件下使第一复合物中间体与包含以下组分i),ii)和iii)的第一单体乳液接触:i)甲基丙烯酸甲酯或苯乙烯或它们的组合,ii)丙烯酸C1-C10烷基酯,和iii)含羧酸的单体,由此形成第二复合物中间体;然后c)使第二复合物中间体与包含以下组分i),ii),iii)和iv)的第二单体乳液接触:i)苯乙烯或甲基丙烯酸甲酯或它们的组合,ii)丙烯酸C1-C10烷基酯,iii)含羧酸的单体,和iv)通式为C10-15H22-32O(CH2CH2O)xH的仲醇乙氧基化物,由此形成TiO2颗粒与不完全粘附的聚合物粘结剂的水性分散体;其中x为15-50,O(CH2CH2O)xH基团与C10-15H22-32链上的CH基团相连。
文中所用的术语“吸附性含硫酸官能化聚合物”指含有含硫酸官能度的吸附TiO2的聚合物分散剂,所述含硫酸官能度优选来自含硫的酸官能单体,例如甲基丙烯酸磺乙酯,甲基丙烯酸磺丙酯,苯乙烯磺酸,乙烯基磺酸,丙磺酸2-丙烯酰氨基-2-甲基酯,以及它们的盐,优选的是丙磺酸2-丙烯酰氨基-2-甲基酯和甲基丙烯酸磺乙酯。
含硫酸官能化聚合物优选是吸附性两性聚合物,更优选是通过烯键式不饱和含硫酸官能单体与烯键式不饱和胺官能单体共聚制备的聚合物。合适的烯键式不饱和胺官能单体的例子包括甲基丙烯酸二甲基氨基乙基酯,二甲基氨基丙基甲基丙烯酰胺和甲基丙烯酸叔丁基氨基乙基酯,优选的是甲基丙烯酸二甲基氨基乙基酯(DMAEMA)。
除了包含胺官能度和含硫酸官能度之外,所述两性聚合物还可包含由水溶性单体的共聚产生的官能团,所述水溶性单体是例如甲基丙烯酸羟乙酯、甲基丙烯酰胺、丙烯酰胺、或甲基丙烯酸、或丙烯酸、或其组合。
优选地,通过将TiO2缓慢加入到两性聚合物的水性溶液中,并同时进行研磨来制备TiO2与优选的吸附性两性聚合物的分散体。以TiO2、两性聚合物以及水的重量为基准计,TiO2/两性聚合物分散体优选的固体含量为70-80重量%。
在优选的第一步骤中,将TiO2/两性聚合物分散体加入容器中,然后添加a)阴离子表面活性剂,例如本领域熟知的阴离子表面活性剂,优选作为水溶液加入;和b)优选的苯乙烯磺酸钠的水溶液,更优选作为基于水和苯乙烯磺酸钠的重量5-20重量%的溶液加入。
然后,优选使氧化还原引发剂体系与所述混合物接触,引发聚合,形成第一复合物中间体。如本文所用,术语“氧化还原引发剂体系”指的是还原剂、氧化剂以及金属离子催化剂的组合。合适的氧化剂的例子包括:过硫酸盐,例如过硫酸铵和过硫酸碱金属盐;氢过氧化物,例如叔丁基过氧化氢和氢过氧化枯烯;过氧化物,例如过氧化苯甲酰、过氧化辛酰以及二叔丁基过氧化物;过酸酯,例如过乙酸叔丁酯、过邻苯二甲酸叔丁酯以及过苯甲酸叔丁酯;过碳酸盐/酯;以及过磷酸盐/酯;优选的是叔丁基过氧化氢。
合适的还原剂的例子包括;抗坏血酸、异抗坏血酸、苹果酸、乙醇酸、草酸、乳酸和巯基乙酸;碱金属亚硫酸氢盐,例如亚硫酸氢钠;连二亚硫酸盐,例如连二亚硫酸钾;或者偏亚硫酸氢盐,例如偏亚硫酸氢钾;以及甲醛合次硫酸氢钠。
合适的促进剂包括少量使用的钴、铁、镍和铜的卤化物和硫酸盐。优选的氧化还原引发剂体系的一个例子是叔丁基过氧化氢/异抗坏血酸/Fe+2。优选地,在加入氧化剂和还原剂之前加入促进剂。更优选地,随时间推移加入氧化剂和还原剂,以在添加单体的过程中维持较均匀水平的基团通量。
第一单体乳液优选在等待30秒到约10分钟、更优选1分钟到5分钟之后添加到第一复合物中间体中。应理解,所用的术语“第一单体乳液”指一种或多种单体的水性乳液,优选的是不止一种单体的水性乳液。第一单体乳液中优选的单体组合包括甲基丙烯酸甲酯;羧酸单体,例如丙烯酸、甲基丙烯酸或衣康酸,优选基于全部单体的重量在0.3-3重量%的范围内;和C2-C10丙烯酸酯单体,例如丙烯酸丁酯、丙烯酸乙酯或丙烯酸乙基己酯,或它们的组合。
所述第一单体乳液还可包含交联单体,我们发现低含量的所述交联单体能够改善经包封颗粒的遮盖效果。所述交联单体优选为多烯键式不饱和交联单体,更优选二烯键式不饱和单体,其用量足以形成抗变形的聚合物,以第一单体的重量为基准计,优选0.05-3重量%。合适的交联单体的例子包括以全部第一单体的重量为基准计0.1-2重量%的甲基丙烯酸烯丙酯、二甲基丙烯酸乙二醇酯、二甲基丙烯酸丁二醇酯和二乙烯基苯。
第一单体在聚合条件下聚合,优选在20℃-75℃的起始温度下,形成具有所需Tg的第一阶段聚合物。
然后,通过向含有第二复合物中间体的容器中添加第二单体乳液来进行第二阶段聚合。第二单体乳液包含i)苯乙烯或甲基丙烯酸甲酯或它们的组合;ii)丙烯酸C1-C10烷基酯,优选丙烯酸乙酯、丙烯酸丁酯、丙烯酸2-乙基己酯或它们的组合;iii)含羧酸的单体,优选甲基丙烯酸、丙烯酸或衣康酸,更优选甲基丙烯酸;和iv)通式为C10-15H22-32O(CH2CH2O)xH的仲醇乙氧基化物表面活性剂,优选C12-14H26-30O(CH2CH2O)xH,其中x优选为15-50,更优选20-40。可商购的合适的表面活性剂的例子包括TERGITOLTM15-S-40仲醇乙氧基化物表面活性剂(Secondary Alcohol EthoxylateSurfactant)和TERGITOLTM15-S-20仲醇乙氧基化物表面活性剂(陶氏化学公司或其附属公司的商标(The Dow Chemical Company or its Affliliates)。以漆前复合物的总重量为基准计,第二单体乳液中仲醇乙氧基化物表面活性剂的浓度优选为从0.1重量%、更优选0.2重量%、最优选0.3重量%至优选3.0重量%、更优选2.5重量%、更优选1.5重量%、最优选1重量%。第二单体乳液优选还包含含硫酸单体的盐,更优选还包含苯乙烯磺酸钠。
然后进行第二阶段聚合,形成TiO2颗粒与不完全粘附的聚合物粘结剂的水性分散体(漆前复合物)。优选地,由Fox等式计算的第二阶段聚合物的Tg为-40℃到40℃。
全部单体与TiO2固体的重量/重量之比优选为0.8-1.6,更优选为1.0-1.4。
在第二方面,本发明是一种漆前复合物,该漆前复合物包含TiO2颗粒和粘附及未粘附的聚合物粘结剂的水性浆液,和足量的通式为C10-15H22-32O(CH2CH2O)xH的仲醇乙氧基化物,以使基于漆前复合物中全部聚合物粘结剂的重量为基准计35-90重量%的聚合物粘结剂粘附在TiO2颗粒上,其中x为15-50,O(CH2CH2O)xH基团与C10-15H22-32链上的CH基团相连。优选地,漆前复合物包含0.2-2.5重量%的通式C12-14H26-30O(CH2CH2O)xH表示的仲醇乙氧基化物,其中x是20-40。更优选地,聚合物粘合剂对TiO2颗粒的粘附度为从50重量%、最优选60重量%到90重量%、更优选85重量%的粘附粘结剂。
本发明的漆前复合物可用于制备涂料制剂,该涂料制剂包含漆前复合物和一种或多种选自下组的组分:分散剂、消泡剂、表面活性剂、溶剂、其它粘结剂、增稠剂、增量剂、聚结剂、杀生物剂和着色剂。已经惊奇地发现,向第二单体乳液中添加仲醇乙氧基化物表面活性剂可以明显改善最终漆制剂的冻融性质。还发现,在最终漆制剂中而不是第二单体乳液中添加仲醇乙氧基化物表面活性剂不能改善漆制剂的冻融性质。似乎聚合物粘结剂对TiO2颗粒的不完全粘附(水相中存在大于10重量%的聚合物粘结剂证明了这一点)与良好的冻融稳定性有关。
在以下实施例中,基本按照US2010/0298483实施例2和5中所述制备TiO2两性聚合物浆液。
实施例1A–用仲醇乙氧基化物制备漆前复合物
通过混合水(45g)、Polystep A-16-22表面活性剂(9g)、丙烯酸丁酯(123.3)、甲基丙烯酸(2.16g)和甲基丙烯酸甲酯(78.8g)来制备单体乳液1(ME1)。
通过混合水(225g)、Polystep A-16-22表面活性剂(60.3g)、苯乙烯(398.7g)、甲基丙烯酸(9.9g)、丙烯酸丁酯(612.9g)、苯乙烯磺酸钠(5.2g)和TERGITOLTM15-S-40仲醇乙氧基化物表面活性剂(70%水溶液,36g)来制备单体乳液2(ME2)。
向配备有搅拌器、热电偶、氮气进口和回流冷凝器的5升四颈圆底烧瓶中加入TiO2两性聚合物浆料(1420.7g)和水(265.5g)。将该混合物在N2下加热到30℃,然后向烧瓶中依次加入Polystep A-16-22表面活性剂(10.8g),苯乙烯磺酸钠的水溶液(8.6g,在50g水中),叔丁基过氧化氢的水溶液(1.71g,在22g水中),异抗坏血酸的溶液(0.95g,在22g水中),和0.15%七水合硫酸铁水溶液(42.8g)和1%乙二胺四乙酸水溶液(EDTA,1.1g)的混合物。以1.6克/分钟的速率向烧瓶中加入共进料催化剂(17.1g叔丁基过氧化氢,在212g水中)和共进料活化剂(9.5g异抗坏血酸,在212g水中)。三分钟后,以12.9克/分钟的速率向反应器中添加ME1,烧瓶温度升高到50℃。ME1加料完成后,用去离子水(27g)清洗单体乳液容器,洗涤液进入烧瓶中。共进料催化剂和活化剂加料继续3分钟,然后停止,烧瓶保持在50℃。18分钟后,共进料催化剂和活化剂加料以1.6克/分钟的速率重新开始进料。2分钟后,以13.5克/分钟的速率向反应器中添加ME2,反应器温度控制在68℃。在ME2加料完成后,用去离子水(27g)清洗单体乳液容器,洗涤液进入烧瓶中,共进料溶液继续加料20分钟,直到加料完成。使烧瓶冷却到室温;当烧瓶的温度达到45℃时,在30分钟内添加ACRYSOLTM ASE-60阴离子增稠剂溶液(陶氏化学公司或其附属公司的商标(The Dow Chemical Company or Its Affiliates),19.4g,在40g水中),然后添加29%氢氧化铵(14.4g)和水(36g)的溶液。当烧瓶内物质到达室温时,对它们进行过滤,除去任何凝胶。经发现,过滤的分散体的固体含量为57.42%,pH8.6,38ppm干凝胶。
比较例1A–无仲醇乙氧基化物的情况下制备漆前复合物
基本按照实施例1A的步骤,不同之处在于ME2不含TERGITOLTM15-S-40仲醇乙氧基化物表面活性剂。
实施例2A–用仲醇乙氧基化物制备漆前复合物
基本按照实施例1A的步骤,不同之处在于一半的TERGITOLTM15-S-40仲醇乙氧基化物表面活性剂(70%水溶液,18g)用于ME2制剂中。
实施例3A–用仲醇乙氧基化物制备漆前复合物
基本按照实施例1A的步骤,不同之处在于两倍的TERGITOLTM15-S-40仲醇乙氧基化物表面活性剂(70%水溶液,72g)用于ME2制剂中。
实施例4A–用仲醇乙氧基化物制备漆前复合物
基本按照实施例1A的步骤,不同之处在于TERGITOLTM15-S-20仲醇乙氧基化物表面活性剂(70%水溶液,36g)用于ME2制剂中。
用各种漆前复合物制备漆,测量KU冻融稳定性和遮盖性。对于各实施例,各漆制剂的总颜料体积浓度(PVC)为40,体积固体含量为42%。
实施例1B–漆制剂
实施例1B的制剂示于表1。TAMOL、TRITON、PRIMAL、ROPAQUE、CARBITOL和ACRYSOL都是陶氏化学公司或其附属公司(The Dow ChemicalCompany or its Affiliates)的商标。
表1–使用实施例1A漆前复合物的漆制剂
实施例2B-4B–漆制剂
基本按照表1所示的配方,使用实施例2A-4A的漆前复合物制备漆。
比较例1B–无仲醇乙氧基化物的漆制剂
按照表1配制漆,不同之处在于漆前复合物不含仲醇乙氧基化物(按照比较例1A)。
比较例2B–单独添加仲醇乙氧基化物的漆制剂
按照表1配制漆,不同之处在于漆前复合物不含仲醇乙氧基化物(按照比较例1A);在该实施例中单独向漆中添加TERGITOLTM15-S-40仲醇乙氧基化物表面活性剂(70%水溶液,0.54g)。
冻融稳定性的测试方法
将漆样品(约130g)放在塑料容器中,测量KU粘度;然后将容器盖上盖子,用带子封好,放入保持在-10℃的冷冻机中16小时。将样品从冷冻机中移出后,使它们在环境温度下融化4小时或更长时间,以使全部冰晶融化。然后,手动混合漆,再次测量KU粘度(构成一个冻融循环)。再重复该过程两次,以测量在三次冻融循环后漆粘度的变化。
测量粘附在TiO 2 上的聚合物粘结剂的测试方法
向在50mL离心瓶中的去离子水(约12g)中添加复合物(约20g),然后将瓶子盖上,剧烈手动混合约1分钟。将稀释的样品放入Fischer Scientific LegendX1R离心机中,在7000rpm(按照设定9加速和减速)和20℃运行30分钟。移出约5mL上层清液,在液体移出后在150℃ 20分钟后,利用重量差重复两次测量固体含量。还测量在底部的离心的固体栓料的重量。上层清液中的固体的量被认为是未粘附于TiO2的聚合物。粘附的聚合物粘结剂的百分含量按照下式计算:
(全部聚合物–未粘附的聚合物)/全部聚合物*100。
库贝尔卡-蒙克(Kubelka-Munk)S/密耳测试方法
对于每一种漆,使用1.5密耳博德下拉棒(Bird draw down bar)在黑色脱模卡片(Leneta Form RC-BC)上制备四个下拉样,卡片干燥过夜。用X-ACTO刀使用模板在每一个卡片上切割出3.25”x4”的矩形。使用X-Rite Color i7分光光度计在每一刻划区域对Y-反射率测量五次,在起始于矩形顶部的对角线上进行测量,并记录平均Y-反射率。对于每一种漆,使用3”25密耳块下拉棒(block draw down bar)在黑色脱模卡片上制备厚膜下拉样,卡片干燥过夜。在下拉样的五个不同区域测量Y-反射率,并记录平均Y-反射率。库贝尔卡-蒙克遮盖值S由以下等式1得出:
等式1
S = R X × ( 1 - R 2 ) × ln 1 - ( R B × R ) 1 - R B R
其中X是平均膜厚度,R是厚膜的平均反射率,RB是薄膜在黑色上的平均反射率。可以通过漆膜的重量(Wpf)、干膜的密度(D)以及膜面积(A)计算得到X。3.25”×4”模板的膜面积是13英寸2
实施例1B-4B和比较例1B-2B的漆制剂的冻融和遮盖(S/密耳)数据总结在表2中。
在该表中,SAE指仲醇乙氧基化物;重量%活性SAE是基于漆前复合物的重量;15-S-40和15-S-20分别指TERGITOLTM15-S-40仲醇乙氧基化物表面活性剂和TERGITOLTM15-S-20仲醇乙氧基化物表面活性剂;ME2实际上是指15-S-40或15-S-20添加到第二单体乳液中;PAINT实际上是指SAE是15-S-40,添加到漆中;%粘附指粘附到TiO2上的聚合物粘结剂的百分数;F/T指冻/融。
表2–漆制剂的冻融和遮盖数据
这些数据表明当第二单体乳液中包含具有20-40个乙氧基化物单元的仲醇乙氧基化物时,显示可接受的冻融和遮盖性质。不含该表面活性剂的ME2显示较差的冻融性质。数据显示可接受的冻融和遮盖性质与聚合物粘结剂对TiO2颗粒不完全粘附之间的关联。

Claims (9)

1.一种制备漆前复合物的方法,该方法包括以下步骤:
a)使以下组分i),ii),iii)和iv)的混合物接触:
i)TiO2颗粒和吸附性含硫酸官能化聚合物的水性分散体;
ii)阴离子表面活性剂;
iii)苯乙烯磺酸钠;和
iv)氧化还原引发剂体系;
由此形成第一复合物中间体;然后,
b)在乳液聚合条件下使第一复合物中间体与包含以下组分i),ii)和iii)的第一单体乳液接触:
i)甲基丙烯酸甲酯或苯乙烯或它们的组合;
ii)丙烯酸C1-C10烷基酯;
iii)在乳液聚合条件下的含羧酸的单体;
由此形成第二复合物中间体;然后,
c)使第二复合物中间体与包含以下组分i),ii),iii)和iv)的第二单体乳液接触:
i)苯乙烯或甲基丙烯酸甲酯或它们的组合;
ii)丙烯酸C1-C10烷基酯;
iii)含羧酸的单体;
iv)通式C10-15H22-32O(CH2CH2O)xH的仲醇乙氧基化物;
由此形成TiO2颗粒与不完全粘附的聚合物粘结剂的水性分散体;其中x是15-50,O(CH2CH2O)xH基团与C10-15H22-32链上的CH基团相连。
2.如权利要求1所述的方法,其特征在于,在步骤a)中,吸附性含硫酸官能化的聚合物是吸附性两性聚合物;在步骤b)中,在乳液聚合条件下,第一复合物中间体与甲基丙烯酸甲酯、丙烯酸丁酯和甲基丙烯酸接触,形成第二复合物中间体;在步骤c)中,第二单体乳液还包含硫酸单体的盐。
3.如权利要求2所述的方法,其特征在于,在步骤c)中,第二单体乳液包含苯乙烯、丙烯酸丁酯、苯乙烯磺酸钠、甲基丙烯酸和仲醇乙氧基化物。
4.如权利要求1-3中任一项所述的方法,其特征在于,所述仲醇乙氧基化物用通式C12-14H26-30O(CH2CH2O)xH表示,其中x是20-40;以漆前复合物的重量为基准计,所述仲醇乙氧基化物的浓度为0.2-1.5重量%。
5.如权利要求1-3中任一项所述的方法,其特征在于,所述仲醇乙氧基化物用通式C12-14H26-30O(CH2CH2O)xH表示,其中x是20-40;以漆前复合物中全部聚合物粘结剂的重量为基准计,所述聚合物粘结剂粘附到TiO2颗粒上的程度为35-90重量%。
6.如权利要求5所述的方法,其特征在于,以漆前复合物中全部聚合物粘结剂的重量为基准计,所述聚合物粘结剂粘附到TiO2颗粒上的程度为50-90重量%。
7.如权利要求1-5中任一项所述的方法,其特征在于,以漆前复合物中全部聚合物粘结剂的重量为基准计,所述聚合物粘结剂粘附到TiO2颗粒上的程度为60-85重量%。
8.如权利要求1-7中任一项所述的方法,其特征在于,所述方法还包括通过使漆前复合物与一种或多种选自下组的组分接触来制备涂料的步骤:分散剂、表面活性剂、溶剂、消泡剂、其它粘结剂、增稠剂、增量剂、聚结剂、杀生物剂和着色剂。
9.一种漆前复合物,其包含TiO2颗粒和粘附及未粘附的聚合物粘结剂的水性浆液,和足量的通式为C10-15H22-32O(CH2CH2O)xH的仲醇乙氧基化物,以使基于漆前复合物中全部聚合物粘结剂的重量为基准计35-90重量%的聚合物粘结剂粘附在TiO2颗粒上,其中x为15-50,O(CH2CH2O)xH基团与C10-15H22-32链上的CH基团相连。
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