Core-shell particles and preparation and use thereof

• US 6,337,131 B1
• Filed: 04/26/1999
• Issued: 01/08/2002
• Est. Priority Date: 05/04/1998
• Status: Expired due to Term

• Current Assignee: BASF AG (BASF SE)
• Original Assignee: BASF AG (BASF SE)
• Inventors: Rupaner, Robert, Leyrer, Reinhold J, Schuhmacher, Peter
• Primary Examiner(s): Le, Hoa T.
• Application Number:
  US09/299,071
• Time in Patent Office: 988 Days
• Field of Search: 428/403, 428/407, 428/212, 523/201
• US Class Current: 428/403
• CPC Class Codes: B05D 5/061 Special surface effect
• CPC Class Codes: C08F 2/22 Emulsion polymerisation
• CPC Class Codes: C08F 257/02 on to polymers of styrene or alkyl-substituted styrenes
• CPC Class Codes: C08F 265/04 on to polymers of esters
• CPC Class Codes: C08F 285/00 Macromolecular compounds obtained by polymerising monomers on to preformed graft polymers
• CPC Class Codes: C08F 291/00 Macromolecular compounds obtained by polymerising monomers on to macromolecular compounds according to more than one of the groups C08F251/00 - C08F289/00
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C09D 151/003 grafted on to macromolecular compounds obtained by reactions only involving unsaturated carbon-to-carbon bonds C09D151/04, C09D151/06 take precedence
• CPC Class Codes: C09D 5/36 Pearl essence, e.g. coatings containing platelet-like pigments for pearl lustre
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/2991 Coated
• CPC Class Codes: Y10T 428/2998 including synthetic resin or polymer

Abstract

Disclosed are core-shell particles, whose core and shell materials are capable of forming a two-phase system, the shell material being filmable, the core being essentially form-stable under shell-filming conditions and being only very minimally swellable by the shell material, if at all, the cores having a monodisperse size distribution, and there being a difference between the refractive indices of the core material and of the shell material of at least 0.001. Also disclosed are the preparation of the core-shell particles and their use for preparing effect colorants.

Claims

1. Core-shell particles, whose core and shell materials are capable of forming a two-phase system, the shell material being filmable, the core being essentially form-stable under shell-filming conditions and being swellable by the shell material by not more than 10% of its original value when embedded in the shell material, if at all the cores having a monodisperse size distribution, and there being a difference between the refractive indices of the core material and of the shell material, and wherein the weight ratio of core:

shell in the particles is within the range from 1⅓

;

1 to 20;

1.

2. Core-shell particles as claimed in claim 1, wherein the difference Δ

n between the refractive indices of the shell and core materials is at least 0.001.

3. Core-shell particles as claimed in claim 2, wherein the difference Δ

n between the refractive indices of the shell and core materials is at least 0.01.

4. Core-shell particles as claimed in claim 3, wherein the difference Δ

n between the refractive indices of the shell and core materials is at least 0.1.

5. Core-shell particles as claimed in claim 1, wherein the core of the core-shell particles is from 100 to 700 nm in size.

6. Core-shell particles as claimed in claim 5, wherein the core of the core-shell particles is from 150 to 500 nm in size.

7. Core-shell particles as claimed in claim 6, wherein the core of the core shell particles is from 200 to 400 nm in size.

8. Core-shell particles as claimed in claim 1, wherein the cores of the core-shell particles have a polydispersity index PDI of below 0.4.

9. Core-shell particles as claimed in claim 8, wherein the cores of the core-shell particles have a polydispersity index PDI of below 0.3.

10. Core-shell particles as claimed in claim 9, wherein the cores of the core-shell particles have a polydispersity index PDI of below 0.2.

11. Core-shell particles as claimed in claim 1, wherein the weight ratio of core:

shell in the particles is within the range from 2;

1 to 10;

1.

12. Core-shell particles as claimed in claim 11, wherein the weight ratio of core:

shell in the particles is within the range from 2;

5;

1 to 5;

1.

13. Core-shell particles as claimed in claim 1, wherein the core comprises one or more polymers (core polymers), and the shell comprises one or more polymers (shell polymers) or polymer precursors and optionally up to 30% by weight, of auxiliary and additive substances and the shell, when in a nonswelling environment at room temperature, is essentially form-stable and nontacky.

14. Core-shell particles as claimed in claim 13, wherein the core polymers are crosslinked.

15. Core-shell particles as claimed in claim 13, wherein the shell polymers or polymer precursors are optionally present up to 20% by weight.

16. Core-shell particles as claimed in claim 1, obtained by emulsion polymerization in an aqueous medium.

17. Solid preparations comprising from 70 to 99% by weight, of core-shell particles as claimed in claim 1 and from 30 to 1% by weight, of a mixture of auxiliary and/or additive substances which is solid at standard temperature.

18. Solid preparations as claimed in claim 17, wherein the core-shell particles comprise from 80 to 95% by weight.

19. Solid preparations as claimed in claim 17, wherein the core-shell particles comprise from 20 to 5% by weight.

20. A process for producing decorative and/or protective coatings by applying a coating composition in a conventional manner to the pretreated or unpretreated material to be protected, which comprises applying the preparation of claim 17, removing any liquid dispersing and/or diluting medium present and subsequently filming and if desired crosslinking the shell material and so orienting the cores.

21. A process for preparing an effect colorant, comprising the following steps:

a) applying the preparation of claim 17, to a substrate of low adhesivity,

b) if necessary evaporating or expelling any solvent or diluent present in the applied layer,

c) converting the shell material of the core-shell particles into a liquid, soft or viscoelastic matrix phase,

d) orienting the cores of the core-shell particles at least into domains of regular structure,

e) curing the shell material to fix the regular core structure,

f) detaching the cured film from the substrate, and

g) comminuting the detached film to the desired particle size if a pigment or powder is to be prepared.

22. The process as claimed in claim 21, wherein an effect colorant is prepared in the form of a pigment by effecting the applying as per step a) in the form of a multiplicity of dots in the size of the desired pigment particles to facilitate or obviate step g).

23. The process as claimed in claim 21, wherein an effect colorant is prepared in the form of a film by selecting a shell polymer which is elastically deformable in the cured state and omitting step g).

24. Pasty or fluidic preparations comprising from 5 to 75% by weight, of core-shell particles as claimed in claim 1 and from 95 to 25% by weight, of a mixture of dissolving, dispersing, auxiliary and/or additive substances which is liquid at standard temperature or becomes liquid at elevated temperature.

25. Pasty or fluidic preparations as claimed in claim 24, wherein the preparations are spreadable, sprayable or pourable.

26. Pasty or fluidic preparations as claimed in claim 24, comprising 10 to 65% by weight of core-shell particles.

27. Pasty or fluidic preparations as claimed in claim 26, comprising 20 to 50% by weight of core-shell particles.

28. Pasty or fluidic preparations as claimed in claim 24, comprising 90 to 35% by weight of the mixture of dissolving, dispersing, auxiliary and/or additive substances.

29. Pasty or fluidic preparations as claimed in claim 28, comprising 80 to 50% by weight of the mixture of dissolving, dispersing, auxiliary and/or additive substances.

30. A process for producing decorative and/or protective coatings by applying a coating composition in a conventional manner to the pretreated or unpretreated material to be protected, which comprises applying the preparation of claim 24, removing any liquid dispersing and/or diluting medium present and subsequently filming and if desired crosslinking the shell material and so orienting the cores.

31. A process for preparing an effect colorant, comprising the following steps:

a) applying the preparation of claim 24 to a substrate of low adhesivity,

b) if necessary evaporating or expelling any solvent or diluent present in the applied layer,

c) converting the shell material of the core-shell particles into a liquid, soft or viscoelastic matrix phase,

d) orienting the cores of the core-shell particles at least into domains of regular structure,

e) curing the shell material to fix the regular core structure,

f) detaching the cured film from the substrate, and

g) comminuting the detached film to the desired particle size if a pigment or powder is to be prepared.

32. The process as claimed in claim 31, wherein an effect colorant is prepared in the form of a pigment by effecting the applying as per step a) in the form of a multiplicity of dots in the size of the desired pigment particles to facilitate or obviate step g).

33. The process as claimed in claim 31, wherein an effect colorant is prepared in the form of a film by selecting a shell polymer which is elastically deformable in the cured state and omitting step g).

34. A process for preparing the core-shell particles of claim 1 by homogenizing core polymer particles prefabricated in a separate step with monomers or prepolymers of the shell polymers and if desired auxiliary and/or additive substances in an inert liquid reaction medium and incipiently or completely polymerizing the polymer precursors under polymerization conditions such that the shell polymers or polymer precursors become deposited on the core particles, which comprises selecting the monomers and/or prepolymers according to amount and type in such a way that the shell material be filmable, the core be form-stable under shell-filming conditions and be swellable by the shell material by not more than 10% of its original value when embedded in the shell material, if at all, the cores having a monodisperse size distribution, and there be a difference between the refractive indices of the core material and of the shell material.

35. A process as claimed in claim 34, wherein the process is carried out as a two-step one-pot process, the core polymer particles being prepared from the selected polymer precursors (monomers and/or prepolymers) in the first reaction step and then being further processed as claimed in claim 34.

36. The process as claimed in claim 34, wherein the polymerization of the shell polymers is carried out in the presence of all or some of the auxiliary and/or additive substances present in the preparation and optionally dispersing or diluting media, or these are wholly or partly added during or on completion of the polymerization, in which case the adds are chosen so that their mixture is solid or fluidic as required, and the inert reaction medium is wholly or partly removed after completion of the polymerization.

37. The process as claimed in claim 34, wherein the inert reaction medium is removed by evaporation, optionally under reduced pressure, by freeze drying or by spray drying.

38. A process for producing decorative and/or protective coatings by applying a coating composition in a conventional manner to the pretreated or unpretreated material to be protected, which comprises applying core-shell particles of claim 1, removing any liquid dispersing and/or diluting medium present and subsequently filming and if desired crosslinking the shell material and so orienting the cores.

39. A process for preparing an effect colorant, comprising the following steps:

a) applying the core-shell particles of claim 1 to a substrate of low adhesivity,

b) if necessary evaporating or expelling any solvent or diluent present in the applied layer,

c) converting the shell material of the core-shell particles into a liquid, soft or viscoelastic matrix phase,

d) orienting the cores of the core-shell particles at least into domains of regular structure,

e) curing the shell material to fix the regular core structure,

f) detaching the cured film from the substrate, and

g) comminuting the detached film to the desired particle size if a pigment or powder is to be prepared.

40. The process as claimed in claim 39, wherein an effect colorant is prepared in the form of a pigment by effecting the applying as per step a) in the form of a multiplicity of dots in the size of the desired pigment particles to facilitate or obviate step g).

41. The process as claimed in claim 39, wherein an effect colorant is prepared in the form of a film by selecting a shell polymer which is elastically deformable in the cured state and omitting step g).