Self-crosslinking aqueous dispersions

• US 5,919,716 A
• Filed: 08/10/1998
• Issued: 07/06/1999
• Est. Priority Date: 09/18/1996
• Status: Expired due to Term

• Current Assignee: Eastman Chemical Company
• Original Assignee: Eastman Chemical Company
• Inventors: Raynolds, Peter Webb, Scott, Duane Allan
• Primary Examiner(s): RAIMUND, CHRISTOPHER W
• Application Number:
  US09/132,165
• Time in Patent Office: 330 Days
• Field of Search: 442/154, 442/155, 442/164, 442/170, 442/171, 442/173, 442/178, 442/179, 442/180, 427/389.9
• US Class Current: 442/154
• CPC Class Codes: C08F 212/08 Styrene
• CPC Class Codes: C08F 220/00 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
• CPC Class Codes: C08F 220/14 Methyl esters , e.g. methyl (meth)acrylate
• CPC Class Codes: C08F 220/1804 C4-(meth)acrylate, e.g. butyl (meth)acrylate, isobutyl (meth)acrylate or tert-butyl (meth)acrylate
• CPC Class Codes: C08F 220/20 of polyhydric alcohols or phenols , e.g. 2-hydroxyethyl (meth)acrylate or glycerol mono-(meth)acrylate
• CPC Class Codes: C08F 2800/20 as weight or mass percentages
• CPC Class Codes: C08F 2810/20 leading to a crosslinking, either explicitly or inherently
• CPC Class Codes: C08F 8/00 Chemical modification by after-treatment graft polymers, block polymers, crosslinking with unsaturated monomers or with polymers C08F251/00 - C08F299/00; of conjugated diene rubbers C08C
• CPC Class Codes: C08F 8/14 Esterification
• CPC Class Codes: C08F 8/28 Condensation with aldehydes or ketones
• CPC Class Codes: C08L 2666/34 Oxygen-containing compounds, including ammonium and metal salts
• CPC Class Codes: C09D 133/066 containing -OH groups
• CPC Class Codes: D04H 1/587 characterised by the bonding agents used
• CPC Class Codes: D04H 1/64 the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• CPC Class Codes: D04H 1/68 the bonding agent being applied in the form of foam
• CPC Class Codes: D06M 13/123 Polyaldehydes; Polyketones
• CPC Class Codes: D06M 15/233 aromatic, e.g. styrene
• CPC Class Codes: D06M 15/263 of unsaturated carboxylic acids; Salts or esters thereof
• CPC Class Codes: D06M 15/285 of unsaturated carboxylic acid amides or imides
• CPC Class Codes: D06M 15/31 of unsaturated nitriles
• CPC Class Codes: D06M 15/423 : Amino-aldehyde resins
• CPC Class Codes: D06M 23/10 : Processes in which the treating agent is dissolved or dispersed in organic solvents; Processes for the recovery of organic solvents thereof
• CPC Class Codes: D06N 3/04 : with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: Y10T 442/2779 : Coating or impregnation contains an acrylic polymer or copolymer [e.g., polyacrylonitrile, polyacrylic acid, etc.]
• CPC Class Codes: Y10T 442/2787 : Coating or impregnation contains a vinyl polymer or copolymer
• CPC Class Codes: Y10T 442/2861 : Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/291 : Coated or impregnated polyolefin fiber fabric
• CPC Class Codes: Y10T 442/2918 : Polypropylene fiber fabric
• CPC Class Codes: Y10T 442/2934 : Coating or impregnation contains vinyl polymer or copolymer
• CPC Class Codes: Y10T 442/2975 : Coated or impregnated ceramic fiber fabric
• CPC Class Codes: Y10T 442/2984 : Coated or impregnated carbon or carbonaceous fiber fabric
• CPC Class Codes: Y10T 442/2992 : Coated or impregnated glass fiber fabric

Abstract

The present invention is directed to polymer compositions containing a vinyl polymer component (A), formed by polymerization of α,β-ethylenically unsaturated monomers, one which contains at least one hydroxyl group and one which contains no hydroxyl groups; a crosslinker component (B); an additive component (C); and a solvent component (D). The composition is useful for backcoating woven substrates and as a binder composition for non-woven substrates.

Claims

1. A method for coating a woven substrate, comprising:

(1) applying to said substrate a polymer composition; and

(2) drying said substrate containing said polymer composition;

wherein said polymer composition comprises;

(A) a vinyl polymer component present in an amount from 20.0 to 65.0 weight percent, based on the total amount of said backcoating formulation, said vinyl polymer comprising the polymerization product of;

(a) at least one first, copolymerizable α

,β

-ethylenically unsaturated monomer containing at least one hydroxyl group, present in an amount from 2.0 to 25.0 weight percent based on the total amount of α

,β

-ethylenically unsaturated copolymerizable monomers;

(b) a second copolymerizable α

,β

-ethylenically unsaturated monomer containing no hydroxyl groups, present in an amount from 75.0 to 98.0 weight percent, based on the total amount of ethylenically unsaturated copolymerizable monomers;

said second monomer comprising;

(i) 40.0 to 98.0 weight percent, based on the total amount of monomers, of a C₁ -C₁₈ alkyl (meth)acrylate,

(ii) optionally, up to 40.0 weight percent, based on the total amount of monomers, of a styrenic monomer,

(iii) optionally, up to 10.0 weight percent, based on the total amount of monomers, of (meth)acrylamide,

(iv) optionally, up to 20.0 weight percent, based on the total amount of monomers, of (meth)acrylonitrile,

(v) optionally, up to 20.0 weight percent, based on the total amount of monomers, of an additional copolymerizable monomer, and

(vi) optionally, up to 2.0 weight percent, based on the total amount of monomers, of a copolymerizable crosslinkable monomer;

(B) a free glyoxal crosslinker component present in an amount from 0.1 to 15.0 weight percent, based on the total amount of component (A);

(C) an additive component present in an amount up to 2.0 weight percent, based on the total amount of component (A); and

(D) the remainder of the formulation being a solvent.

2. A method for impregnating a non-woven substrate, comprising:

(1) applying to said substrate a polymer composition; and

(2) drying said substrate containing said polymer composition;

wherein said polymer composition comprises;

(A) a vinyl polymer component present in an amount from 10.0 to 65.0 weight percent, based on the total amount of said backcoating formulation, said vinyl polymer comprising the polymerization product of;

(a) at least one first, copolymerizable α

,β

-ethylenically unsaturated monomer containing at least one hydroxyl group, present in an amount from 2.0 to 25.0 weight percent based on the total amount of α

,β

-ethylenically unsaturated copolymerizable monomers;

(b) a second copolymerizable α

,β

-ethylenically unsaturated monomer containing no hydroxyl groups, present in an amount from 75.0 to 98.0 weight percent, based on the total amount of α

,β

-ethylenically unsaturated copolymerizable monomers;

said second monomer comprising;

(i) 40.0 to 98.0 weight percent, based on the total amount of monomers, of a C₁ -C₁₈ alkyl (meth)acrylate,

(ii) optionally, up to 40.0 weight percent, based on the total amount of monomers, of a styrenic monomer,

(iii) optionally, up to 10.0 weight percent, based on the total amount of monomers, of (meth)acrylamide,

(iv) optionally, up to 20.0 weight percent, based on the total amount of monomers, of (meth)acrylonitrile,

(v) optionally, up to 20.0 weight percent, based on the total amount of monomers, of an additional copolymerizable monomer, and

(vi) optionally, up to 2.0 weight percent, based on the total amount of monomers, of a copolymerizable crosslinkable monomer;

(B) a free glyoxal crosslinker component present in an amount from 0.1 to 15.0 weight percent, based on the total amount of component (A);

(C) an additive component present in an amount up to 2.0 weight percent, based on the total amount of component (A);

(D) the remainder of the formulation being a solvent;

(E) an associative thickener component present in an amount from 0.5 to 10 weight percent, based on the total amount of the backcoating formulation;

(F) optionally a surfactant component present in an amount up to 10 weight percent, based on the total amount of the formulation of a surfactant;

(G) optionally, a plasticizer component present in an amount up to 10.0 weight percent based on the total amount of the backcoating formulation; and

(H) optionally, a filler component present in an amount up to 10.0 weight percent, based on the total amount of the backcoating formulation.

3. A woven substrate coated with a backcoating formulation, comprising:

(A) a vinyl polymer component present in an amount from 10.0 to 65.0 weight percent, based on the total amount of the polymer composition, said vinyl polymer comprising the polymerization product of

(a) first, at least one copolymerizable based on the total amount of α

,β

-ethylenically unsaturated copolymerizable monomers;

containing at least one hydroxyl group, present in an amount from 2.0 to 25.0 weight percent, based on the total amount of α

,β

-ethylenically unsaturated copolymerizable monomers;

(b) a second copolymerizable α

,β

-ethylenically unsaturated monomer containing no hydroxyl groups present in an amount from 75.0 to 98.0 weight percent, based on the total amount of α

,β

-ethylenically unsaturated copolymerizable monomers;

said second monomer comprising;

(i) 40.0 to 98.0 weight percent, based on the total amount of monomers, of a C₁ -C₁₈ alkyl (meth)acrylate,

(ii) optionally, up to 40.0 weight percent, based on the total amount of monomers, of a styrenic monomer,

(iii) optionally, up to 10.0 weight percent, based on the total amount of monomers, of (meth)acrylamide,

(iv) optionally, up to 20.0 weight percent, based on the total amount of monomers, of (meth)acrylonitrile,

(v) optionally, up to 20.0 weight percent, based on the total amount of monomers, of an additional copolymerizable monomer, and

(vi) optionally, up to 2.0 weight percent, based on the total amount of monomers, of a copolymerizable crosslinkable monomer;

(B) a crosslinker component present in an amount from 0.1 to 15.0 weight percent, based on the total amount of component (A)

(C) an additive component present in an amount up to 2.0 weight percent, based on the total amount of component (A);

(D) a solvent component being the remainder of said polymer composition;

(E) an associative thickener component present in an amount from 0.5 to 10 weight percent, based on the total amount of the backcoating formulation;

(F) optionally, a surfactant component present in an amount up to 10 weight percent, based on the total amount of the formulation of a surfactant;

(G) optionally, a plasticizer component present in an amount up to 10.0 weight percent based on the total amount of the backcoating formulation; and

(H) optionally, a filler component present in an amount up to 10.0 weight percent, based on the total amount of the backcoating formulation.

4. A non-woven substrate impregnated with a backcoating formulation, comprising:

(A) a vinyl polymer component present in an amount from 10.0 to 65.0 weight percent, based on the total amount of said backcoating formulation, said vinyl polymer comprising polymerization product of

(a) first, at least one copolymerizable based on the total amount of α

,β

-ethylenically unsaturated copolymerizable monomers;

containing at least one hydroxyl group, present in an amount from 2.0 to 25.0 weight percent, based on the total amount of α

,β

-ethylenically unsaturated copolymerizable monomers;

(b) a second copolymerizable α

,β

-ethylenically unsaturated monomer containing no hydroxyl groups, present in an amount from 75.0 to 98.0 weight percent, based on the total amount of α

,β

-ethylenically unsaturated copolymerizable monomers;

said second monomer comprising;

(i) 40.0 to 98.0 weight percent, based on the total amount of monomers, of a C₁ -C₁₈ alkyl (meth)acrylate,

(ii) optionally, up to 40.0 weight percent, based on the total amount of monomers, of a styrenic monomer,

(iii) optionally, up to 10.0 weight percent, based on the total amount of monomers, of (meth)acrylamide,

(iv) optionally, up to 20.0 weight percent, based on the total amount of monomers, of (meth)acrylonitrile,

(v) optionally, up to 20.0 weight percent, based on the total amount of monomers, of an additional copolymerizable monomer, and

(vi) optionally, up to 2.0 weight percent, based on the total amount of monomers, of a copolymerizable crosslinkable monomer; and

(B) crosslinker component present in an amount from 0.1 to 15.0 weight percent, based on the total amount of component (A);

(C) an additive component present in an amount up to 2.0 weight percent, based on the total amount of component (A);

(D) a solvent component being the remainder of the formulation;

(E) an associative thickener component present in an amount from 0.5 to 10 weight percent, based on the total amount of the backcoating formulation;

(F) optionally, a surfactant component present in an amount up to 10 weight percent, based on the total amount of the formulation of a surfactant;

(G) optionally, a plasticizer component present in an amount up to 10.0 weight percent based on the total amount of the backcoating formulation; and

(H) optionally, a filler component present in an amount up to 10.0 weight percent, based on the total amount of the backcoating formulation.