Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D135/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical, and containing at least another carboxyl radical in the molecule, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Coating compositions based on derivatives of such polymers
  • C09D135/06—Copolymers with vinyl aromatic monomers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F8/00—Chemical modification by after-treatment
  • C08F8/30—Introducing nitrogen atoms or nitrogen-containing groups
  • C08F8/32—Introducing nitrogen atoms or nitrogen-containing groups by reaction with amines

Definitions

• the present invention relates to an aqueous polymer dispersion comprising a copolymer of anhydride monomer units and vinyl monomer units, which copolymer has been subjected to an imidization reaction.
• the present invention further relates to a method for the production and use of such dispersion.
• EP-A-1060197 a method is known for the production of an aqueous dispersion of a styrene maleic anhydride copolymer (abbreviated generally as SMA) which is partly imidized resulting in a poly(styrene-co-maleimide) [SMI] dispersion, to be used as a paper sizing composition.
• SMA styrene maleic anhydride copolymer
• SI poly(styrene-co-maleimide)
• the copolymer is synthesised using generally known processes.
• the copolymer is subjected to an imidization reaction, by contacting it with an aqueous solution of NH 3 or an amine (RNH 2 ), at a temperature of at least 95° C. and a pressure which is chosen such as to avoid boiling of the reaction mixture.
• the molar ratio of maleic anhydride monomer units and NH 3 or amine is selected between 1:0.8 and 1:5.
• the imidization reaction is continued until a degree of imidization of the maleic anhydride monomer units is obtained of at most 75%. Thereafter, the dispersion is applied in a top coat to the paper and the paper is dried and calendared.
• EP-A-1060197 also includes a comparative example of a polymer dispersion prepared according to DE-A-1720746.
• DE-A-1720746 describes an aqueous dispersion of a polymer obtained by subjecting an SMA containing about equal molar amounts of maleic anhydride and styrene to an imidization reaction in an aqueous solution of NH 3 at a temperature above 120° C. The degree of imidization in the examples is not revealed.
• the SMA is 89% imidized. It has been observed that this dispersion has a very wide particle size distribution and forms an unstable dispersion, forming a sediment already after standing for a short period.
• the present invention aims at providing an aqueous polymer dispersion composition for use in a top coat for paper, with which an improved printing of the paper may be achieved.
• the aqueous polymer dispersion of this invention comprises a copolymer of anhydride monomer units and vinyl monomer units, of which copolymer at least 90% of the moles of the anhydride monomer units are imidized.
• This polymer dispersion contains SMI in the form of discrete particles which can be called organic pigment.
• Suitable anhydride monomers for use in the copolymer are, for example, ⁇ - ⁇ -unsaturated dicarboxylic anhydrides such as maleic anhydride, fumaric anhydride, citraconic anhydride, itaconic anhydride and mixtures thereof.
• the copolymer contains maleic anhydride monomer units.
• Suitable vinyl monomers for use in the copolymer include vinyl aromatic monomers (such as styrene, ⁇ -methyl styrene, vinyl toluene and indene), mono-olefinic unsaturated hydrocarbons (such as ethylene, propylene and isobutylene), ⁇ - ⁇ -unsaturated carboxylic esters (such as acrylate esters (like ethylacrylate, butylacrylate and 2-ethylhexylacrylate), methacrylate esters (like methylmethacrylate, ethylmethacrylate and 2-hydroxyethylmethacrylate) and maleate diesters (like dioctylmaleate)), halogenated olefins (such as vinyl chloride and vinylidene chloride) and mixtures thereof.
• the copolymer contains readily commercially available styrene or ⁇ -methyl styrene, although the presence of styrene monomer units
• a coating which consists of a plurality of small, discrete pigment particles showing good adhesion to each other and to the surface to be coated. It has further been found that upon printing a paper surface that has been coated with the aqueous polymer dispersion of this invention, an improved printing quality may be achieved: the characters being well delimited from each other, superimposed successively applied printing layers being well delimited from each other, fading of adjacent characters and colours into each other being limited.
• the observation of the improved printing quality is attributed to the fact that the coating is built up of a plurality of discrete particles, drainage channels being formed between the particles, the presence of these drainage channels taking care of fast removal of ink solvent.
• application of the coating has the effect that in the course of the calendaring the partially imidized SMI copolymer particles disintegrate, flow together and form a film.
• Film formation has the effect that upon printing, the removal of solvent or dispersing agent for the ink is retarded and the printing quality is adversely affected.
• the organic pigment dispersion coating of the present invention shows no tendency to film formation when applied in a coating, or during calendaring.
• the anhydride monomer content of 15-29 mole % is particularly preferred, as in this range the copolymer shows suitable water solubility, giving optimum imidization yield and high solid content of the final dispersion. It has been surprisingly found that the anhydride monomer content further determines the particle size, the particle size increasing with increasing anhydride monomer content, as well as the hardness of the copolymer.
• the properties of the copolymer particles after imidization are determined not only by the composition of the starting material, but also by the physical conditions prevailing in the imidization reaction, e.g. concentration and agitation.
• the vinyl monomer content of the copolymer ranges between 95-50 mole %, preferably between 95-81 mole %.
• the aqueous polymer dispersion of this invention preferably has a solid content of more than 20 wt. %, more than 30 wt. % or even more than 40 wt. %.
• the dispersion comprises discrete particles having a particle diameter above 30 nm, sometimes above 40 or 50 nm, but smaller than 400 nm, often smaller than 250 or even 120 nm, the particle size distribution being narrow.
• the diameter of the particles is smaller than the wavelength of visible light, a smooth, high gloss and transparent coating may be obtained.
• preference may be given to a coating with a higher or lower gloss, being more transparent or showing some opaqueness.
• the formation of small particles further entails the advantage that stabilisation of the dispersion can be dispensed with. This is in contrast to a dispersion containing larger particles which needs the presence of an emulsifier to attain a stable dispersion.
• the present invention also relates to a process for the production of the above described aqueous polymer dispersion. According to this process an aqueous polymer dispersion is prepared by
• the imidization reaction is preferably continued until at least 95 mole %, or even virtually all anhydride monomer units have been imidized.
• a copolymer containing vinyl monomer units and anhydride monomer units may be synthesised according to processes well known to the man skilled in the art, such as for example the process described in Hanson and Zimmerman, Ind. Eng. Chem. Vol. 49, nr. 11 (1957), p. 1803-1807.
• the copolymer is reacted in water, an emulsifier optionally being present.
• an aqueous solution of NH 3 or an amine RNH 2 is added, in which R may be an alkyl group having between 1-18 carbon atoms or an aryl group. It is however preferred to use NH 3 , although butylamine and stearylamine also appear to be suitable imidization reactants.
• the molar ratio between the amine or NH 3 and the anhydride monomer in the copolymer to be imidized ranges between 0.8:1 and 1.2:1, but is preferably an equimolar ratio or slightly less. In the latter case, complete conversion of the reaction gives an odourless dispersion as all amine or NH 3 is consumed.
• the amount of NH 3 or RNH 2 such that the upper limit of the molar ratio of (NH 3 or RNH 2 ): (anhydride monomer present in the copolymer to be subjected to imidization) is 10:1.
• the lower limit may be 0.5:1.
• the imidization reaction may be carried out in the presence of an alkali salt of an acid functional polymer containing acid functional monomer units and vinyl aromatic monomer units.
• alkali salt of styrene maleic anhydride copolymer may be used, which preferably has molecular mass of from 500 to 10000 g/mol and with maleic anhydride content of at least 30 mole %.
• the alkali salt may function as an emulsifying agent.
• the anhydride monomer/vinyl monomer copolymer has a molecular weight which preferably is not too high and neither too low so as to allow obtaining a dispersion with a sufficiently high solid content.
• the anhydride monomer/vinyl monomer copolymer has a molecular weight which is at least 1000 g/mole, preferably at least 10000 g/mole, more preferably at least 60000 g/mole.
• the molecular weight of this copolymer is preferably less than 500000, more preferably less than 200000 g/mole or less than 150000 g/mole.
• the molecular weight of the starting copolymer is between approximately 50000 and 80000 g/mole as it allows obtaining so-called monodisperse dispersion with a narrow particle size distribution of between 50 and 100 nm, the mean particle diameter being approximately 70 nm. Ultimately such dispersion allows obtaining a coating with an optimum gloss.
• the anhydride monomer/vinyl aromatic monomer copolymer used may be a copolymer composition comprising a plurality of copolymers having varying molecular weights. This function may be fulfilled by the emulsifier. The molecular weight of the copolymer after imidization has been found to be a key parameter when processing it.
• a too high molecular weight of the copolymer involves the risk that the viscosity of the dispersion becomes too high and the solid content too low.
• a too low molecular weight of the copolymer involves the risk that the solid content of the dispersion gets too high, which has an adverse effect on the applicability of the dispersion.
• a too low molecular weight of the copolymer involves the additional risk to intra-particle adhesion and agglomeration, due to Van der Waals attraction between the particles, involving entanglement and the formation of particles with too large dimensions.
• the imidization reaction will mostly be carried out at a temperature above 100° C., preferably between 120-195° C., more preferably at a temperature between 130-180° C., or even 150-175° C. Below 100° C. insufficient imidization has been observed.
• a temperature above 170° C. and in particular above 195° C. there is an increasing risk to agglomeration of the polymer, as a consequence of which particle formation in the dispersion is counteracted, giving particles with a too large size which are visible when applied as a coating and easily involve film formation.
• the imidization reaction is favoured over the formation of an imine-amine compound.
• the temperature range of 130-180° C. is preferred as within this range a well-defined dispersion with respect to Tg and mechanical properties and composition is obtained and the process showing good reproducibility.
• the reaction mixture is stirred. It has namely been found that after the aqueous solution of the copolymer has been contacted with ammonia or the amine, in the course of the imidization reaction a gel phase is formed, which may be broken or cut through stirring, adhesion to the reactor wall thereby being minimised. This cutting action assists in shaping the particles of the dispersion formed following imidization.
• the rotation speed applied upon stirring of the reaction mixture and the time during which the reaction mixture Is stirred will be in general adapted by the man skilled in the art. Adapting this parameter allow controlling the physical properties and particle size of the dispersion obtained, i.e. allows controlling whether small particles with a smooth surface are formed which ultimately give a coating with a high gloss and good transparency, or larger particles if a more opaque coating is aimed at. Stirring assists in avoiding the formation of particles with a rough surface and non-uniform shape which, when applied as a coating would give undesired scattering. It has been observed that the more uniform the shape of the particles, the better the gloss of the coating and the better the drainage properties of the coating when imprinted. The shape of the particles is determined by forces prevailing in the course of the imidization reaction, and e.g. by the time the reaction mixture is stirred.
• the imidization reaction may be carried out in the presence of an anti-foaming agent and/or an emulsifier.
• Suitable emulsifiers may be anionic or nonionic surfactants.
• an aqueous dispersion of the imidized organic pigment may be obtained with the above-described solid content and particle size.
• the solid content of the dispersion may be increased by methods known by man skilled in the art, especially suitable are evaporation and ultra filtration.
• the particles of the dispersion of this invention are capable of filling gaps left in the already applied coating. In that way a surface may be obtained which is covered by an optimum coating, providing optimum drainage properties that are hardly disturbed by the underlying coatings.
• the size of the individual particles is relatively small, a dense packing of the particles is obtained when the dispersion Is applied to a surface to be coated, and dried.
• the small size of the particles facilitates solvent release and drying of the coating, thus minimising the risk to crack formation upon drying of the coating and improving drying time of the coating.
• the formation of small pigment particles further has the advantage that inter-particle attraction is governed by Van der Waals forces, giving strong inter-particle adhesion and good adhesion to the surface to be coated. Due to the dense packing, a closed top coating is achieved which when imprinted shows good drainage properties thus providing quick drying of the ink, even after for example a coated paper has been subjected to a calendaring process. This is attributed to the formation of drainage channels upon drying of the coating.
• the dense coating assists in minimising penetration of ink particles to underlying coatings, as a consequence of which the sharpness and fineness with which the coated material is imprinted, thus the over-all printing quality, is improved as compared to prior art coatings. Furthermore, tearing of paper coated with the coating composition of this invention and the occurrence of wet pick is decreased.
• the imidized pigment particles obtained are microporous. As the dimensions of the micropores are small, penetration of ink particles into the pigment particles is inhibited, as a consequence of which the printing quality of a surface coated with a coating containing the dispersion of this invention, is further improved.
• the present invention further relates to a coating composition for a surface to be coated, the coating composition comprising an amount of the aqueous dispersion of this invention.
• the amount of organic pigment incorporated may vary within wide ranges and will mostly be determined by the application. In case of cheap paper applications, low amounts of organic pigments will be used so as to obtain a low density coating. When using a dispersion with a high concentration of organic pigment, either a more dense coating may be obtained, or the amount of dispersion used may be decreased.
• the coating composition may further comprise the usual ingredients, such as binders (starch, latex, polyvinylalcohol, etc) and conventional pigments (kaolin, PCC, GCC, talc, silica, etc), which may be partly substituted by the polymer dispersion of this invention if so desired.
• the coating composition may further contain thickening agents. Hyperbranched polyesteramides such as those disclosed in U.S. Pat. No. 6,392,006 may be added to control the viscosity of the coating composition.
• the aqueous polymer dispersion of the present invention is a suitable coating material for a wide variety of surfaces that are to be imprinted.
• the aqueous dispersion of this invention appears suitable for coating paper, paperboard, cardboard, an organic film (for example a polyethylene film), a metal foil, a textile sheet, etc.
• an increased gloss of coated paper of 5-10 points after calendaring has been observed. This gloss improvement may be further increased by using a coating which exclusively consists of the dispersion of this invention.
• the extent to which the anhydride monomer/vinyl monomer copolymer has been imidized determines the acidity of the imidized copolymer. Controlling the pH allows controlling foam formation in the course of the coating process. This is an advantage as compared to known coating compositions as they often contain calcium carbonate showing superfluous foaming.
• the pH further determines the area in which the dispersion of this invention may be applied. The dispersion of this invention has been found to have a pH close to 7.
• the average hydrodynamic radius of the particles of the dispersion after imidization was determined using Photon Correlation Spectroscopy.
• the solid content was determined using an infrared instrument, type Mettler LP16/PM600.
• the pH value of each sample was measured with a Knick 752 Cl, nr. 051489 pH measurement instrument.
• the degree of imidization may for example be determined with Raman FTIR spectroscopy, by correlating the absorption intensity to the intensity of the absorption at the same wavelength of a completely imidized and a non-imidized reference sample.
• Raman-FTIR signals were normalised based on the absorption signals originating from the aromatic rings in the polymer chains. The calculations were based on the following absorptions:
• an aqueous ammonia solution of an imide free polymer prepared starting from 26 mole % of maleic anhydride (MA) and 74 mole % of styrene, a NH 3 :maleic anhydride ratio of 3:1, at 50° C.; (2) a SMA powder that had been subjected to an imidization reaction by mixing 2 g of SMA (28 wt. % of MA, 72 wt. % of styrene; molecular weight 110000 g/mole) with 0.50 g of ureum in a double vice mini extruder, at 240° C. for 5 minutes at a rotation speed of 100 rpm.
• MA maleic anhydride
• styrene a NH 3 :maleic anhydride ratio of 3:1
• the MA had been completely converted to imide.
• the Tg of the polymer after completion of the imidization was found to be between 190 and 200° C.
• the dispersion had a pH of 7.0.
• the contact angle of the dispersion when applied to paper was found to be smaller than 40°.
• Example 4 The procedure of Example 4 was repeated, this time dissolving 1400 kg of ground SMA type Stapron 26080 (DSM, The Netherlands) in 2352 kg of water in a pilot reactor at room temperature, to which 0.05 kg of Surfinol 420 of Air Products was added.
• the SMA had a MA content of 26 mole % and a molecular weight of 80000 g/mole.
• To this solution 249 kg of a 25% NH 3 solution in water was added, so that the MA:NH 3 ratio was 1:1.
• the temperature was increased to approximately 86° C.
• the reactor was further heated until the reaction mixture had a temperature of approximately 150° C.
• the electric power needed to drive the stirrer stirring the reaction mixture was recorded as a function of time.
• a dispersion of SMI in water was obtained having a solids content of 40 wt. %, a pH of 7, a mean particle diameter of 72 nm.
• TABLE 2 Reaction Reaction Electric Time temperature power Pressure (min) (° C.) (Ampère) Rpm (bar) Observations 0 23 2 50 0.50 Introduction of H 2 O 15 75 4 35 0.50 Introduction of Stapron 26080* 60 86 7 37 0.70 Introduction of 25% NH 3 75 101 10 46 1.00 Start of increase of viscosity 90 108 15 50 1.10 Strong viscosity increase 105 114 15 50 1.15 Idem 120 116 15 50 1.15 Idem 135 118 17 50 1.80 Idem 150 122 17 50 2.00 Idem 165 124 17 50 2.00 Increase of visco elasticity 180 127 22 50 2.70 Decrease of vortex 195 131 22 50 3.00 High gloss and jelly aspect 210 135 22 50 3.30 Slow movement of gel phase in the reactor 225 137 24 50 3.40 No vortex 240 138 24
• Example 1 The experiment of Example 1 was repeated using SMA type 2000 (from Atofina, France).
• the resulting dispersion had a solid content of approximately 20 wt % and a pH of 7.1.
• the particle size was 1500 nm.
• Example 5 Approximately 3 kg of the product obtained from Example 5 was subjected to ultrafiltration using a Valmet Flootek CR 200/1 with a 30000 Dalton cut-off. The final stable dispersion had a 58.6% solid content.
• Wood free paper with dry weight of 67 g/m 2 was coated with an on-line film press at a speed of 1300 m/min with base coating of 5 g/m 2 on both paper sides calculated as dry matter.
• the applied coating had a solid content of 60 wt. % and contained 100 parts calcium carbonate, 8 parts latex and 8 parts starch.
• an mid coating of 13 g/m 2 calculated as dry matter was applied off-line on both paper sides having the same composition as the base coating, however with a solids content of 64 wt. %.
• the thus pre-treated paper was coated on both sides with a top coating of 6 g/m 2 calculated as dry matter.
• the top coating had the following composition: 75 parts of CaCO 3 , 25 parts of kaolin, 14 parts of latex, the usual additives and 10 parts of the polymer dispersion of this invention, the properties of which are given in Table 3 below.
• the paper was passed through a calendar having 9 successive nip passages, at a nip pressure of 220 N/m.
• the thus obtained paper had a total dry weight of 115 g/m 2 .
• Example 8 The experiment of Example 8 was repeated, however this time using as a top coat a reference coating containing 75 parts of CaCO 3 , 25 parts of kaolin, 14 parts of latex and the usual additives.
• the reference coating did not contain the polymer dispersion of this invention.
• the paper was passed through a calendar having 11 successive nip passages, at a pressure of 280N/m at each nip.
• the thus obtained paper had also a total dry weight of 115 g/m 2 as the dry weight of the base paper and the amount of coatings was the same as in Example 8.
• the paper obtained according to this invention was thicker and had higher Scott Bond values as compared to the paper obtained with the Comparative example. This is attributed to the fact that with the invention the number of nips required in the calendaring process may be reduced as well as the nip pressure, as a consequence of which the paper strength is less affected during calendaring and a high initial gloss may be obtained.

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• 2003
  • 2003-10-06 US US10/528,760 patent/US20060009573A1/en not_active Abandoned
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