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
  • C09D133/00—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 only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
  • C09D133/04—Homopolymers or copolymers of esters
  • C09D133/14—Homopolymers or copolymers of esters of esters containing halogen, nitrogen, sulfur or oxygen atoms in addition to the carboxy oxygen
• • 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
  • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
  • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
  • C08F220/10—Esters
  • C08F220/12—Esters of monohydric alcohols or phenols
  • C08F220/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
  • C08F220/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
  • C08F220/1808—C8-(meth)acrylate, e.g. isooctyl (meth)acrylate or 2-ethylhexyl (meth)acrylate
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J7/00—Adhesives in the form of films or foils
  • C09J7/10—Adhesives in the form of films or foils without carriers
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J7/00—Adhesives in the form of films or foils
  • C09J7/30—Adhesives in the form of films or foils characterised by the adhesive composition
  • C09J7/38—Pressure-sensitive adhesives [PSA]
  • C09J7/381—Pressure-sensitive adhesives [PSA] based on macromolecular compounds obtained by reactions involving only carbon-to-carbon unsaturated bonds
  • C09J7/385—Acrylic polymers
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J2203/00—Applications of adhesives in processes or use of adhesives in the form of films or foils
  • C09J2203/334—Applications of adhesives in processes or use of adhesives in the form of films or foils as a label
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J2301/00—Additional features of adhesives in the form of films or foils
  • C09J2301/30—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier
  • C09J2301/302—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier the adhesive being pressure-sensitive, i.e. tacky at temperatures inferior to 30°C
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J2433/00—Presence of (meth)acrylic polymer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/14—Layer or component removable to expose adhesive
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/14—Layer or component removable to expose adhesive
  • Y10T428/1405—Capsule or particulate matter containing [e.g., sphere, flake, microballoon, etc.]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/14—Layer or component removable to expose adhesive
  • Y10T428/1452—Polymer derived only from ethylenically unsaturated monomer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/14—Layer or component removable to expose adhesive
  • Y10T428/1462—Polymer derived from material having at least one acrylic or alkacrylic group or the nitrile or amide derivative thereof [e.g., acrylamide, acrylate ester, etc.]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/249921—Web or sheet containing structurally defined element or component
  • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
  • Y10T428/249926—Including paper layer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/27—Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
  • Y10T428/273—Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.] of coating

Definitions

• the present invention is directed to emulsion polymers, especially acrylic polymers useful as coatings and adhesives.
• Acrylic polymers are well known and are commonly used to produce adhesives, including PSA tapes, labels, and other constructions. They are also used as, or in, a variety of coatings, including paints, primers, barrier layers, scratch-resistant hard coatings, ink-receptive coatings, and chemical-resistant coatings. They can be prepared by a variety of polymerization processes, including bulk, solvent, and emulsion polymerization. In emulsion polymerization, a number of monomers are dispersed in a continuous aqueous phase with the aid of one or more emulsifiers (surfactants) and polymerization is catalyzed by, e.g., a free-radical initiator.
• surfactants e.g., a free-radical initiator.
• a colloidal dispersion of polymer particles is called a latex, an emulsion polymer, or simply, an emulsion.
• Particle size and molecular weight are typically distributed across a range of values, which can be expressed using statistical means.
• emulsion polymers used in the PSA industry is rarely higher than about 67% by weight.
• PSAs are used in a wide variety of applications, at different temperatures and environmental conditions.
• a given PSA may perform (adhere) well when applied to a given substrate, or at a particular temperature, yet be wholly unsuitable for other substrates and use temperatures. Particularly problematic are low temperature ( ⁇ 0°C) applications.
• acrylic emulsion polymers characterized by both high solids content and low viscosity can be prepared using a blend of surfactants and a split monomer feed.
• the resulting polymers have a multimodal (or at least bimodal) particle-size distribution.
• a high solids content, low-viscosity emulsion comprises an emulsified product of copolymerizing a plurality of monomers in the presence of a plurality of surfactants, wherein the plurality of monomers comprises, on a percent-by-weight basis, based on the total weight of monomers, about 90-98% alkyl acrylate(s) having an alkyl group containing from 4 to 12 carbon atoms; about 0.1 to 0.5% N-vinyl pyrrolidone; about 0.5 to 4.5% ethylenically unsaturated carboxylic acid(s); and 0 to about 0.5% (more preferably, about 0.1 to 0.5%) multifunctional crosslinking monomer(s); wherein the sum of all monomer weight percentages is 100%).
• the emulsified product has at least a bimodal particle-size distribution and a solids content of at least 68% by weight, yet, nevertheless, is pourable, with a viscosity of from about 300 to 15,000 centipoise (cps).
• the plurality of monomers may also contain a minor amount of methyl or ethyl acrylate, e.g., up to about 6% by weight, based on the total weight of all monomers. Minor amounts of other monomers commonly used to prepare PSA polymers may also be employed.
• Emulsion polymers according to the present invention are prepared in a straightforward manner.
• the emulsified product is formed sequentially by polymerizing (a) a pre-emulsified first portion of the plurality of monomers, which is fed into a reactor in two distinct feeds, wherein a first feed is relatively slow and contains about 0.4% to 1% by weight of the pre-emulsified first portion of the plurality of monomers, and a second feed is relatively fast and contains about 99 to 99.6% by weight of the pre-emulsified first portion of the plurality of monomers; and (b) a second portion of the plurality of monomers.
• the second portion of the plurality monomers can be, but does not need to be, pre-emulsified before it is fed into the reactor and polymerized.
• the emulsified product is formed by polymerizing a single pre-emulsion of the plurality of monomers, which is introduced into the reactor in two distinct feeds, wherein a first feed is relatively slow and a second feed is relatively fast, and the first and second feeds contain, preferably, the relative weight percentages stated above.
• the surfactant system consists of three anionic surfactants, each having a particular primary function, i.e., particle generation, emulsion stabilization, and wet-out/coating enhancement.
• a high solids content, low- viscosity emulsion comprises an emulsified product of copolymerizing a plurality of monomers in the presence of a plurality of surfactants, wherein the plurality of monomers comprises, on a percent by weight basis, based on the total weight of monomers, about 90 to 98% alkyl acrylate(s) having an alkyl group containing from 4 to 12 carbon atoms; about 0.1 to 0.5% N-vinyl pyrrolidone; about 0.5 to 4.5% ethylenically unsaturated carboxylic acid(s); and 0 to about 0.5%) (more preferably, 0.01 to 0.5%) multifunctional crosslinking monomer(s).
• the plurality of monomers contains a positive amount up to about 6% by weight of methyl acrylate or ethyl acrylate.
• the emulsified product of polymerization has at least a bimodal, more preferably a multimodal, particle-size distribution.
• alkyl acrylates having 4 to 12 carbon atoms in the alkyl group thereof include butyl, pentyl, hexyl, heptyl, octyl, iso-octyl, ethylhexyl, nonyl, decyl, and dodecyl acrylate.
• 2-ethylhexyl acrylate As between 2-ethylhexyl acrylate, butyl acrylate, and iso-octyl acrylate (three commodity acrylates commonly used to make PSA acrylic polymers), 2-ethylhexyl acrylate is preferred, because copolymers based on 2-ethylhexyl acrylate have a lower T g than copolymers whose main component is butyl acrylate. Iso-octyl acrylate is less preferred, because emulsion polymers based on iso-octyl acrylate appear to be less stable than polymers based on 2-ethylhexyl acrylate.
• Nonlimiting examples of ethylenically unsaturated carboxylic acids include acrylic acid, methacrylic acid, beta-carboxyethyl acrylate, and itaconic acid. A mixture of acrylic acid and methacrylic acid is preferred.
• multifunctional crosslinking monomer means a monomer which is copolymerizable with acrylic monomers and which as at least one carbon-carbon double bond and at least one other functional group capable of entering into a polymerization or crosslinking reaction.
• monomers include multifunctional (meth)acrylates, e.g., diacrylates, triacrylates, dimethyacrylates, and trirnethylacrylates; multifunctional allylic compounds, e.g., diallyl maleate and allyl methacrylate; multifunctional crosslinking monomers having a vinyl group; and multifunctional crosslinking monomers having a reactive hereroatom-containing functional group such as the imidazolidone group.
• a nonlimiting list includes the following.
• Imidazolidone Methacrylate MEIO A preferred multifunctional crosslinking monomer is Norsocryl7 104 (from Elf Atochem), a 35-37%) by weight solution of ethyl imidazolidone methacrylate (MEIO) in methyl methacrylate. Both MEIO and the methyl methacrylate copolymerize with the other monomers present in the monomer mix; thus, methyl methacrylate is considered one of the "plurality of monomers" in embodiments containing Norsocryl7 104.
• MEIO ethyl imidazolidone methacrylate
• the MEIO is dissolved in a different solvent, preferably a reactive (copolymerizable) diluent, for example, short chain alkyl (meth)acrylates like methyl, ethyl, or propyl (meth)acrylate.
• a reactive (copolymerizable) diluent for example, short chain alkyl (meth)acrylates like methyl, ethyl, or propyl (meth)acrylate.
• the multifunctional crosslinking monomer improves shear performance (enhanced cohesive strength) of the resulting emulsion polymer. If too much crosslinking monomer is used, however, the adhesive performance (e.g., looptack) is substantially diminished. It is particularly advantageous to include the multifunctional crosslinking monomer in low-temperature PSA formulations. By doing so, one can obtain good shear strength at low temperature, without loss of tack.
• the plurality of monomers includes a minor amount of methyl and/or ethyl acrylate, e.g., a positive amount up to about 6%, more preferably about 0.2 to 0.5%> by weight, based on the weight of all monomers. Including methyl or ethyl acrylate appears to speed-up the overall polymerization rate and decrease the amount of residual monomers (unreacted monomers present after polymerization has ended).
• the plurality of monomers also includes a minor amount of one or more other copolymerizable monomers commonly employed in the preparation of PSA polymers.
• Nonlimiting examples include vinyl acetate, styrene, and diesters of ethylenically unsaturated carboxylic acids, e.g., dioctyl maleate and dioctyl fumarate.
• the other monomer(s) are each present in no more than about 15% by weight, based on the total weight of monomers, with a corresponding reduction in the amount of alkyl acrylate(s) employed.
• the weight percent of any additional monomer(s) is further constrained by the desired T g of the resulting polymer, which, in general, should be at least 25°C below the lowest expected use temperature of the adhesive.
• NVP N- vinyl pyrrolidone
• a first surfactant has a primary function of emulsion polymer particle generation, and is present in an amount of about 10 to 20% by weight, based on the total weight of surfactants.
• a second surfactant has the primary function of emulsion stabilization, and is present in an amount of from about 20 to 30% by weight.
• a third surfactant has a primary function of enhancing substrate wet-out and/or emulsion coatability, and is present in an amount of about 55 to 65%. The sum of all surfactants, of course, is 100%.
• the first type of surfactant is preferably a sulfate of an ethoxylated alcohol, e.g., a sodium lauryl ether sulfate.
• a nonlimiting example is Disponil FES 77, from Henkel Corp.
• the second type of surfactant is preferably a sulfosuccinate or derivative, e.g., a disodium ethoxylated alcohol half ester of sulfosuccinic acid.
• a nonlimiting example is Aerosol A- 102, from Cytec Industries, Inc.
• the third type of surfactant is preferably a sulfosuccinate or derivative, e.g., a dioctyl ester of sodium sulfosuccinic acid.
• a nonlimiting example is Aerosol OT-75, also from Cytec Industries, hie.
• a nonlimiting list includes polymerization catalysts (initiators), for example, potassium persulfate (K 2 S 2 O 8 ); electrolytes, e.g., tetrasodium pyrophosphate (TSPP — an electrolyte used to control emulsion stability and particle-size), and other sodium or potassium salts; chain transfer agents, for example, n-dodecyl mercaptan (n-DDM); base solutions; (e.g., aqueous ammonia sodium hydroxide, etc.); accelerators, e.g., sodium formaldehyde sulfoxylate (AWC — used to decompose excess initiator); defoaming agents, for example, Drewplus L-191; biocides, for example, Kathon LX; and water or other emulsion media (the continuous phase
• Emulsion polymers according to the present invention are prepared in a straightforward manner.
• a pre-emulsified first portion of the monomers is fed into a reactor and polymerized in two distinct feeds, followed by a second portion of monomers, which may or may not be pre-emulsified.
• a portion of the monomers is dispersed in aqueous media with one or more surfactants, and the resulting pre-emulsion is fed into the reactor beginning with a slow feed of a very small initial quantity of the pre-emulsion, e.g., up, to about 2% by weight, more preferably from about 0.4 to 1% by weight of the pre-emulsified first portion of the plurality of monomers, followed by a fast second feed containing from about 99 to 99.6% by weight of the pre-emulsified first portion of the plurality of monomers. Thereafter, a second portion of the monomers is fed into the reactor.
• a slow feed of a very small initial quantity of the pre-emulsion e.g., up, to about 2% by weight, more preferably from about 0.4 to 1% by weight of the pre-emulsified first portion of the plurality of monomers, followed by a fast second feed containing from about 99 to 99.6% by weight of the pre-emulsified first portion of the pluralit
• the second feed rate is at least about five times faster than the first feed rate. In some embodiments, the second feed rate is as much as 10 or even 20 times that of the first feed rate.
• the entire plurality of monomers is pre-emulsified and then fed into the reactor as a split feed, with a first feed containing a very small amount, e.g., up to about 2%, more preferably from about 0.4 to 1% by weight, of the pre-emulsion of monomers, and the second feed containing the remainder of the monomers, e.g., from about 99 to 99.6% by weight of the pre-emulsion.
• the relative rates of feed are also quite disparate, with the second feed rate being at least about 5 times as great as the first feed rate.
• Emulsion polymers prepared according to the present invention are, in general, characterized by high molecular weights (>1, 000,000), high gel content (>60 or 70% by weight), high solids content and low viscosity, and, in the case of PSA polymers, a glass transition temperature (Tg) at least about 25°C below the expected use temperature of the PSA.
• Tg glass transition temperature
• emulsion polymers for PSAs used in room temperature applications should have a T g ⁇ about 0°C.
• the polymers have a T g ⁇ about -50°C.
• a solids content of about 82% by weight is achieved.
• the emulsified product After being neutralized and diluted with deionized water, the emulsified product has a solids content of about 70% (at a minimum, 68-69%) by weight, or higher.
• the emulsified product of polymerization is a pourable material, not a paste, with a viscosity of from about 300 to 15,000 cps.
• the viscosity of a given polymer according to the present invention can be controlled by adjusting the choice and amount of monomers and surfactants, and by adjusting the monomer feed rate.
• high solids content, high viscosity emulsions can be diluted to lower the viscosity, if necessary.
• the particular solids content and viscosity desired for a given emulsion polymer depends in part on the manner in which the emulsion polymer is to be coated on, or otherwise applied to, a backing or other substrate. It is known, for example, that reverse gravure, nip-fed coaters used in the preparation of PSA constructions do not work well with high viscosity materials, with 1,000 centipoise being the approximate limit of acceptable viscosity. To date, however, such low-viscosity materials have not been achievable at high solids content. As another example, die-coating techniques can handle much higher viscosity materials — as high as 10,000cps or higher — particularly if the material being coated is thixotropic. At the high shear forces encountered at the lips of an extrusion die-coater, the viscosity of a shear-thinning emulsion polymer will be much lower than 10,000cps.
• a coated construction is prepared by coating the polymer emulsion on a release liner, drying the emulsion, and laminating the resulting subassembly to a facestock or other substrate, e.g., a paper or film backing.
• the emulsion is coated directly on a facestock, dried, and then protected until use by a release liner or a low release energy backsize of the construction.
• a coated construction is prepared by simply coating the emulsion polymer on a substrate and allowing it to dry.
• Example 1 is a nonlimiting illustration of various embodiments of the invention.
• a polymerization reactor was charged with an initial Areactor charge,® except for the kick-off catalyst, and heated to 76 C. Agitation was set at 120rpm (laboratory) or 50rpm (pilot reactor).
• Monomer mixes (1) and (2) and a pre-emulsion soap (surfactant) solution were prepared separately.
• Monomer mix (1) was added to the soap solution under agitation to form a stable monomer pre-emulsion (1) and held for delay addition.
• a catalyst solution was prepared and held for a delay addition. When the reactor reached 76 C, the kick-off catalyst was added and the reactor was purged with nitrogen (N 2 ) for five minutes. The nitrogen was then turned off.
• Pre-emulsion (1) feed was started at 1.00 g/min. for 3.8 min., followed by a second faster feed at 4.85 g/min.
• the catalyst feed was started at 0.20 parts by weight per min. for 207 min. Batch temperature was maintained between 78 and 86 C. Agitation was increased as necessary to ensure effective mixing.
• Residual monomer concentration was checked. When the residual monomer concentration was below 0.10%, cooling of the batch was commenced to 35 C. After the temperature had been reduced to 60 C, the first 1.9% ammonia solution and 50% AWC solution were added. When the temperature reached 35 C, the defoamer and biocide were added. The second 19% ammonia solution and deionized water were added to adjust the pH and solid/viscosity of the emulsified product, which was then filtered through a 25 or 50 micron filter. The resulting product was checked for residual monomers, pH, total solids content, and viscosity. Table IB presents parts by weight and time (minutes) for the reaction delays. Theoretical solids were 67.62%>. Table 1 A - Example 1
• the emulsion polymer of Example 1 had a pH of 6.8 to 7.5; measured grit of less than 80 ppm on a 55 micron filter; residual monomers of less than 0.10%; and a viscosity of 1,000 to 5,000 cps, using a Brookfield LVT viscometer (#3 spindle), at 30 rpm and 25°C.
• the extremely low grit level is an extra advantage of the present invention.
• many commercial polymerizations yield grit levels exceeding 1,000 ppm. When coated, such high grit compositions tend to have striations and a streaked appearance.
• Example 2
• a high solids content, low- viscosity emulsion polymer is prepared according to Example 1, except a single monomer mixture is used ((1) + (2)) to prepare a pre-emulsion, which is then fed into a reactor as a split feed, with the first feed containing about 0.60% by weight of the monomer pre-emulsion, at a rate of about 1.00 g/min., and the second feed containing about 99.4% by weight of the monomer pre-emulsion, at a rate of about 4.85 g/min.
• PSA constructions were prepared and tested for adhesive performance on low density polyethylene (LDPE) and corrugated cardboard.
• An emulsion polymer prepared according to the present invention was coated on a siliconized release liner, dried in an oven for ten minutes at 75°C, and laminated to a 60 lb/ream high gloss paper facestock. Adhesive coat weight was 20 + lg/m 2 measured after drying.
• the PSA constructions were tested and compared to a commercial product, Flexcryl ATA, an acrylic emulsion polymer from Air Products and Chemical, Inc., Polymer Chemicals Division. The constructions were tested for 90° peel, looptack, T-peel, and shear strength.
• the "cold box” test a looptack test conducted in an environmental chamber at three temperatures (-5, -20, and -35°C) was carried out on an HDPE substrate.
• the T-peel test is a self-adhesion test designed to indicate performance in an airline luggage tag application.
• tackifiers and/or plasticizers can be added to adjust PSA performance and utility.
• a tackifier tends to increase the glass transition temperature and lower the modulus of the polymer to which it is added. Adding a tackifier can broaden the range of temperatures over which the emulsion polymers can be used, hi addition, many tackifying resins are 50-60% by weight solids.
• Adding such a tackifier to a high solids content polymer will reduce the overall solids content of the composition. For example, adding 40 parts by weight of a 55% solids content tackifier to 60 parts by weight of a 65% solids content emulsion will yield a final product with an overall solids content of 61%o by weight. If one starts with a 75% solids content emulsion polymer, the resulting composition will have a solids content of 67% by weight.
• the method of emulsion polymerization according to the present invention has a general utility extending beyond the particular monomer systems described herein.
• the slow initial monomer feed (0.4 to about 1% by weight of the monomers) followed by a fast second monomer feed (99 to about 99.6% by weight of the monomers) yields particle-size distributions that are multimodal, or at least bimodal.

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• Chemical & Material Sciences (AREA)
• Organic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Life Sciences & Earth Sciences (AREA)
• Polymers & Plastics (AREA)
• Medicinal Chemistry (AREA)
• Health & Medical Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Wood Science & Technology (AREA)
• Adhesives Or Adhesive Processes (AREA)
• Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
• Adhesive Tapes (AREA)
• Polymerisation Methods In General (AREA)
• Paints Or Removers (AREA)

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• 2002
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