Polymeric dispersions and applications thereof

• US 20080234415A1
• Filed: 03/23/2007
• Published: 09/25/2008
• Est. Priority Date: 03/23/2007
• Status: Active Grant

• Current Assignee: Polyventive LLC
• Original Assignee: Peach State Labs Incorporated
• Inventors: Williams, Michael S., Grigat, Michael, Jackson, Robert S.
• Granted Patent: US 7,964,657 B2
• Time in Patent Office: Days
• US Class Current: 523/334
• CPC Class Codes: C08F 2/22 Emulsion polymerisation

Abstract

The present invention provides methods of conducting emulsion polymerizations and dispersion resulting therefrom. The present invention additionally provides substrates coated or treated with polymeric dispersions.

Claims

1. A dispersion comprising:

at least one emulsifier;

a monomeric component; and

a continuous phase comprising an aqueous solution of a compound of Formula (I)

2. The dispersion of claim 1, wherein R¹, R², R³, and R⁴ are hydrogen.

3. The dispersion of claim 1, wherein the monomeric component comprises a plurality of monomers having at least one polymerizable functionality.

4. The dispersion of claim 3, wherein the at least one polymerizable functionality comprises a site of unsaturation.

5. The dispersion of claim 3, wherein the monomeric component comprises a plurality of vinylic monomers.

6. The dispersion of claim 1, wherein the at least one emulsifier comprises a surfactant.

7. The dispersion of claim 6, wherein the surfactant comprises anionic surfactants, cationic surfactants, nonionic surfactants, amphoteric surfactants, or mixtures thereof.

8. The dispersion of claim 1, wherein the dispersion is colloidal.

9. The dispersion of claim 1, further comprising an organic solvent.

10. The dispersion of claim 1, wherein the dispersion does not comprise an organic cosolvent.

11. A polymeric dispersion comprising:

at least one emulsifier;

a dispersed phase comprising a polymeric component; and

a continuous phase comprising an aqueous solution of a compound of Formula (I)

12. The dispersion of claim 11, wherein polymeric component comprises a plurality of polymeric particles.

13. The dispersion of claim 12, wherein the polymeric particles have an average size ranging from about 1 nm to about 1 μ

m.

14. The dispersion of claim 12, wherein the polymeric particles comprise fluoroalkyl methacrylates, fluoroalkyl acrylates, fluoroalkyl aryl urethanes, fluoroalkyl urethanes, fluoroalkyl allyl urethanes, fluoroalkyl urethane acrylates, fluoroalkyl acrylamides, fluoroalkyl sulfonamide acrylates, or mixtures thereof.

15. The dispersion of claim 12, wherein the polymeric particles comprise polytetrafluoroethylene, fluorinated ethylene-propylene (FEP), perfluoroalkoxy resin, polytrichlorotrifluoroethylene, ethylene-tetrafluoroethylene, polyvinylidene fluoride, polyvinyl fluoride, or mixtures thereof.

16. The dispersion of claim 11, wherein the dispersion is colloidal.

17. A substrate comprising:

at least one surface at least partially coated with a polymeric dispersion comprising a dispersed phase comprising a polymeric component and a continuous phase comprising an aqueous solution of a compound of Formula (I)

18. The substrate of claim 17, wherein the substrate comprises paper, leather, woven articles, non-woven articles, carpet, metals, masonry, wood products, stone, ceramics, plastics, natural fibers, synthetic fibers, or combinations thereof.

19. The substrate of claim 18, wherein the synthetic fibers comprise polyamide fibers, polyester fibers, polyolefin fibers, polyurethane fibers, polyacrylonitrile fibers, or combinations thereof.

20. The substrate of claim 18, wherein the natural fibers comprise cotton fibers, cellulose acetate fibers, cellulose-based fibers, wool fibers, silk fibers, or combinations thereof.

21. The substrate of claim 17, wherein the substrate has an oil repellency of at least 5 according to AATCC 118.

22. The substrate of claim 17, wherein the substrate has an oil repellency of at least 6 according to AATCC 118.

23. The substrate of claim 17, wherein the substrate has an oil repellency of at least 7 according to AATCC 118.

24. The substrate of claim 17, wherein the substrate has a water/alcohol repellency of at least 6 according to AATCC 193.

25. The substrate of claim 17, wherein the substrate has a water/alcohol repellency of at least 8 according to AATCC 193.

26. The substrate of claim 17, wherein the substrate has a spray rating of at least 80 according to AATCC 22.

27. The substrate of claim 17, wherein the substrate has a spray rating of at least 90 according to AATCC 22.

28. The substrate of claim 17, wherein the substrate has a spray rating of 100 according to AATCC 22.

29. The substrate of claim 17, wherein the substrate has a dry crocking fastness of at least 3.5 according to AATCC 8.

30. The substrate of claim 17, wherein the substrate has a dry crocking fastness of at least 4.5 according to AATCC 8.

31. The substrate of claim 17, wherein the substrate has a wet crocking fastness of at least 3.5.

32. The substrate of claim 17, wherein the substrate has a dry crocking fastness of at least 4.5.

33. A method of conducting emulsion polymerization comprising:

providing a dispersion comprising at least one emulsifier, at least one initiator, a monomeric component, and a continuous phase comprising an aqueous solution of a compound of Formula (I)

34. The method of claim 33, further comprising forming a polymeric material.

35. The method of claim 34, wherein forming a polymeric material comprises initiating polymerization of the monomeric component, propagating polymerization of the monomeric component, and terminating polymerization of the polymeric component.

36. A method of conducting an emulsion polymerization comprising:

providing a dispersion comprising at least one emulsifier, at least one initiator, a monomeric component, and an aqueous continuous phase;

initiating polymerization of the monomeric component with the at least one initiator; and

adding to the dispersion during polymerization of the monomeric component a compound of Formula (I)

37. A method of conducting an emulsion polymerization comprising:

providing a dispersion comprising at least one emulsifier, at least one initiator, a monomeric component, and an aqueous continuous phase;

forming a polymeric material; and

adding to the dispersion, after forming the polymeric material, a compound of Formula (I)

38. The method of claim 37, wherein forming a polymeric material comprises initiating polymerization of the monomeric component, propagating polymerization of the monomeric component, and terminating polymerization of the monomeric component.

39. A method of producing a coated substrate comprising:

providing a substrate having at least one surface;

providing a polymeric dispersion comprising a dispersed phase comprising a polymeric component and a continuous phase comprising an aqueous solution of a compound of Formula (I);

40. The method of claim 39, wherein the substrate comprises paper, leather, woven articles, non-woven articles, carpet, metals, masonry, wood products, stone, ceramics, plastics, natural fibers, synthetic fibers, or combinations thereof.

41. The substrate of claim 40, wherein the synthetic fibers comprise polyamide fibers, polyester fibers, polyolefin fibers, polyurethane fibers, polyacrylonitrile fibers, or combinations thereof.

42. The substrate of claim 40, wherein the natural fibers comprise cotton fibers, cellulose acetate fibers, wool fibers, silk fibers, or combinations thereof.

43. A method for increasing the resistance to flammability of a dispersion comprising an organic solvent comprising:

substituting at least a portion of the organic solvent with a compound of Formula (I)

44. The method of claim 43, wherein substantially all of the organic solvent is substituted with a compound of Formula (I).