Salt sensitive aqueous emulsions
First Claim
1. An aqueous emulsion comprising a water-dispersible copolymer characterized in that films formed from said water-dispersible copolymer are dispersible in water, yet non-dispersible in aqueous solutions containing 0.5% by weight or more of an inorganic salt, and wherein the water-dispersible copolymer comprises in percentages by weight:
- (A) from about 25% to about 80% of acidic ethylenically unsaturated monomer units, with the proviso that the acidic ethylenically unsaturated monomer units are not acrylic acid;
(B) from about 10% to about 80% of ethylenically unsaturated monomer units selected from the group of monomer formulas consisting of;
(i) CH2═
C(R1)COR2;
(i) R3OOC—
CH═
CH—
COOR4;
(iii) CH2═
C(R5)OCOR6;
(iv) CH2═
C(COOR7)CH2COOR8;
(v) CH3CH═
CHCOOR9;
(vi) R10C6H4CR11═
CHR11; and
(vii) R12CH═
CHR13;
wherein R1 is hydrogen or methyl and R2 is —
OZ′
or —
N(Z″
)(Z″
), wherein Z′
is an alkyl group having from 1 to 7 carbon atoms, and Z″
is independently selected from the group consisting of hydrogen and alkyl groups having from 1 to 6 carbon atoms;
R3 and R4 are independently hydrogen or an alkyl group having from 1 to 7 carbon atoms, with the proviso that R3 and R4 are not both hydrogen;
R5 is hydrogen or methyl and R6 is an alkyl group having from 1 to 7 carbon atoms;
R7 and R8 are independently hydrogen or an alkyl group having from 1 to 7 carbon atoms, with the proviso that R7 and R8 are not both hydrogen;
R9 is an alkyl group having from 1 to 7 carbon atoms;
R10 and R11 are hydrogen; and
R12 and R13 are independently selected from the group consisting of hydrogen, —
CN, —
NHCHO, and an all group having from 1 to 7 carbon atoms; and
(C) from about 10% to about 80% of ethylenically unsaturated monomer units selected from the group of monomer formulas consisting of;
(i) CH2═
C(R′
1)COR′
2;
(ii) R′
3OOC—
CH═
CH—
COOR′
4;
(iii) CH2═
C(R′
5)OCOR′
6;
(iv) CH2═
C(COOR′
7)CH2COOR′
8;
(v) CH3CH═
CHCOOR′
9;
(vi) R′
10C6H4CR′
11═
CHR′
11; and
(vii) R′
12CH═
CHR′
13;
wherein R′
1 is hydrogen or methyl, and R′
2 is selected from the group consisting of —
OZ′
, —
N(Z″
)(Z″
), and —
OZ′
″
OH, wherein Z′
is an alkyl group having from 8 to 18 carbon atoms;
Z″
is independently selected from the group consisting of alkyl groups having from 7 to 10 carbon atoms, dimethylamino alkyl groups having from 1 to 5 carbon atoms, and hydroxyalkyl groups having from 1 to 5 carbon atoms; and
Z′
″
is an alkyl group having from 1 to 4 carbon atoms;
R′
3 and R′
4 are independently an alkyl group having from 8 to 18 carbon atoms;
R′
5 is hydrogen or methyl and R′
6 is an alkyl group having from 8 to 18 carbon atoms;
R′
7 and R′
8 are independently an alkyl group having from 8 to 18 carbon atoms;
R′
9 is an alkyl group having from 8 to 18 carbon atoms;
R′
10 and R′
11 are independently an alkyl group having from 1 to 2 carbon atoms;
R′
12 and R′
13 are independently selected from the group consisting of 2-pyrrolidinone, N-caprolactam, and an alkyl group having from 7 to 18 carbon atoms, with the proviso that R12 and R13 are not both 2-pyrrolidinone, are not both N-caprolactam, or are not a mixture thereof; and
the copolymer has a weight average molecular weight greater than about 25,000 and is present in an amount from about 20% to about 70% by weight, based on the aqueous emulsion.
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Abstract
This invention relates to aqueous emulsions comprising a water-dispersible copolymer which is non-dispersible in aqueous solutions containing 0.5% or more of an inorganic salt, comprising acidic ethylenically unsaturated monomers and ethylenically unsaturated monomers. The acidic ethylenically unsaturated monomers and the ethylenically unsaturated monomers are defined herein. The present invention also pertains to emulsion polymerization methods for making the aqueous emulsions with or without a surfactant.
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Citations
26 Claims
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1. An aqueous emulsion comprising a water-dispersible copolymer characterized in that films formed from said water-dispersible copolymer are dispersible in water, yet non-dispersible in aqueous solutions containing 0.5% by weight or more of an inorganic salt, and wherein the water-dispersible copolymer comprises in percentages by weight:
-
(A) from about 25% to about 80% of acidic ethylenically unsaturated monomer units, with the proviso that the acidic ethylenically unsaturated monomer units are not acrylic acid;
(B) from about 10% to about 80% of ethylenically unsaturated monomer units selected from the group of monomer formulas consisting of;
(i) CH2═
C(R1)COR2;
(i) R3OOC—
CH═
CH—
COOR4;
(iii) CH2═
C(R5)OCOR6;
(iv) CH2═
C(COOR7)CH2COOR8;
(v) CH3CH═
CHCOOR9;
(vi) R10C6H4CR11═
CHR11; and
(vii) R12CH═
CHR13;
wherein R1 is hydrogen or methyl and R2 is —
OZ′
or —
N(Z″
)(Z″
), wherein Z′
is an alkyl group having from 1 to 7 carbon atoms, and Z″
is independently selected from the group consisting of hydrogen and alkyl groups having from 1 to 6 carbon atoms;
R3 and R4 are independently hydrogen or an alkyl group having from 1 to 7 carbon atoms, with the proviso that R3 and R4 are not both hydrogen;
R5 is hydrogen or methyl and R6 is an alkyl group having from 1 to 7 carbon atoms;
R7 and R8 are independently hydrogen or an alkyl group having from 1 to 7 carbon atoms, with the proviso that R7 and R8 are not both hydrogen;
R9 is an alkyl group having from 1 to 7 carbon atoms;
R10 and R11 are hydrogen; and
R12 and R13 are independently selected from the group consisting of hydrogen, —
CN, —
NHCHO, and an all group having from 1 to 7 carbon atoms; and
(C) from about 10% to about 80% of ethylenically unsaturated monomer units selected from the group of monomer formulas consisting of;
(i) CH2═
C(R′
1)COR′
2;
(ii) R′
3OOC—
CH═
CH—
COOR′
4;
(iii) CH2═
C(R′
5)OCOR′
6;
(iv) CH2═
C(COOR′
7)CH2COOR′
8;
(v) CH3CH═
CHCOOR′
9;
(vi) R′
10C6H4CR′
11═
CHR′
11; and
(vii) R′
12CH═
CHR′
13;
wherein R′
1 is hydrogen or methyl, and R′
2 is selected from the group consisting of —
OZ′
, —
N(Z″
)(Z″
), and —
OZ′
″
OH, wherein Z′
is an alkyl group having from 8 to 18 carbon atoms;
Z″
is independently selected from the group consisting of alkyl groups having from 7 to 10 carbon atoms, dimethylamino alkyl groups having from 1 to 5 carbon atoms, and hydroxyalkyl groups having from 1 to 5 carbon atoms; and
Z′
″
is an alkyl group having from 1 to 4 carbon atoms;
R′
3 and R′
4 are independently an alkyl group having from 8 to 18 carbon atoms;
R′
5 is hydrogen or methyl and R′
6 is an alkyl group having from 8 to 18 carbon atoms;
R′
7 and R′
8 are independently an alkyl group having from 8 to 18 carbon atoms;
R′
9 is an alkyl group having from 8 to 18 carbon atoms;
R′
10 and R′
11 are independently an alkyl group having from 1 to 2 carbon atoms;
R′
12 and R′
13 are independently selected from the group consisting of 2-pyrrolidinone, N-caprolactam, and an alkyl group having from 7 to 18 carbon atoms, with the proviso that R12 and R13 are not both 2-pyrrolidinone, are not both N-caprolactam, or are not a mixture thereof; and
the copolymer has a weight average molecular weight greater than about 25,000 and is present in an amount from about 20% to about 70% by weight, based on the aqueous emulsion.- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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9. The aqueous emulsion according to claim wherein the ethylenically unsaturated monomer from (B) is (v) CH3CH═
- CHCOOR9, wherein R9 is an alkyl group having from 2 to 4 carbon atoms.
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19. A method for preparing an aqueous emulsion comprising a water-dispersible copolymer characterized in that films formed from said water-dispersible copolymer are dispersible in water, yet non-dispersible in aqueous solutions containing 0.5% by weight or more of an inorganic salt, comprising the steps of:
-
(a) providing the following monomers in percentages by weight;
(A) from about 40% 25% to about 80% of acidic ethylenically unsaturated monomers;
(B) from about 10% to about 80% of ethylenically unsaturated monomer u selected from the group of monomer formulas consisting of;
(i) CH2═
C(R1)COR2;
(ii) R3OOC—
CH═
CH—
COOR4,(iii) CH2═
C(R5)OCOR6;
(iv) CH2═
C(COOR7)CH2COOR8;
(v) CH3CH═
CHCOOR9;
(vi) R10C6H4CR11═
CHR11; and
(vii) R12CH═
CHR13;
wherein R1 is hydrogen or methyl and R2 is —
OZ′
or —
N(Z″
)(Z″
), wherein Z′
is an alkyl group having from 1 to 7 carbon atoms, and Z″
is independently selected from the group consisting of hydrogen and alkyl groups having from 1 to 6 carbon atoms;
R3 and R4 are independently hydrogen or an alkyl group having from 1 to 7 carbon atoms, with the proviso that R3 and R4 are not both hydrogen;
R5 is hydrogen or methyl and R6 is an alkyl group having from 1 to 7 carbon atoms;
R7 and R8 are independently hydrogen or an alkyl group having from 1 to 7 carbon atoms, with the proviso that R7 and R8 are not both hydrogen;
R9 is an alkyl group having from 1 to 7 carbon atoms;
R10 and R11 are hydrogen; and
R12 and R13 are independently selected from the group consisting of hydrogen, —
CN, —
NHCHO, and an alkyl group having from 1 to 7 carbon atoms; and
(C) from about 10% to about 80% of ethylenically unsaturated monomer selected from the group of monomer formulas consisting of;
(i) CH2═
C(R′
1)COR′
2;
(ii) R′
3OOC—
CH═
CH—
COOR′
4;
(iii) CH2═
C(R′
5)OCOR′
6;
(iv) CH2═
C(COOR′
7)CH2COOR′
8;
(v) CH3CH═
CHCOOR′
9;
(vi) R′
10C6H4CR′
11═
CHR′
11; and
(vii) R′
12CH═
CHR′
13;
wherein R′
1 is hydrogen or methyl, and R′
2 is selected from the group consisting of —
OZ′
, —
N(Z″
)(Z″
), and —
OZ′
″
OH, wherein Z′
is an alkyl group having from 8 to 18 carbon atoms;
Z″
is independently selected from the group consisting of alkyl groups having from 7 to 10 carbon atoms, dimethylamino alkyl groups having from 1 to 5 carbon atoms, and hydroxyalkyl groups having from 1 to 5 carbon atoms; and
Z′
″
is an alkyl group having from 1 to 4 carbon atoms;
R′
3 and R′
4 are independently an alkyl group having from 8 to 18 carbon atoms;
R′
5 is hydrogen or methyl and R′
6 is an alkyl group having from a to 18 carbon atoms;
R′
7 and R′
8 are independently an alkyl group having from 8 to 18 carbon atoms;
R′
9 is an alkyl group having from 8 to 18 carbon atoms, R′
10 and R′
11 are independently an alkyl group having from 1 to 2 carbon atoms;
R′
12 and R′
13 are independently selected from the group consisting of 2-pyrrolidinone, N-caprolactam, and an alkyl group having from 7 to 18 carbon atoms, with the proviso that R12 and R13 are not both 2-pyrrolidinone, are not both N-caprolactam, or are not a mixture thereof, and(b) emulsion polymerizing the monomers from (A), (B), and (C) in water at a solids level from about 20% to about 70% by weight, based on the aqueous emulsion, in the presence of a surfactant to form a copolymer having a weight average molecular weight greater than about 25,000. - View Dependent Claims (20, 21, 22)
(i) CH2═ - C(R1)COR2, wherein R1 is methyl and R2 is —
OZ′
1, wherein Z′
is an alkyl group having from 1 to 4 carbon atoms;
(ii) R3OOC—
CH═
CH—
COOR4, wherein R3 and R4 are independently an alkyl group having from 1 to 4 carbon atoms;
(iii) CH2═
C(R5)OCOR6, wherein R5 is methyl and R6 is an alkyl group having from 1 to 4 carbon atoms;
(iv) CH2═
C(COOR7)CH2COOR8, wherein R7 and R8 are independently an alkyl group having from 1 to 4 carbon atoms;
(v) CH3CH═
CHCOOR9, wherein R9 is an alkyl group having from 1 to 4 carbon atoms;
(vi) styrene; and
(vii) R12CH═
CHR13, wherein R12 and R13 are independently hydrogen or methyl.
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22. The method according to claim 19, wherein the ethylenically unsaturated monomer from (C) is selected from the group consisting of
(i) CH2═ - C(R′
1)COR′
2, wherein R′
1 is methyl, R′
2 is selected from the group consisting of —
OZ′
, —
N(Z″
)(Z″
), and —
OZ′
″
OH, wherein Z′
is an alkyl group having from 8 to 12 carbon atoms;
Z″
is independently selected from the group consisting of alkyl groups having from 8 to 10 carbon atoms, dimethylamino alkyl groups having from 1 to 3 carbon atoms, and hydroxyalkyl groups having from 1 to 3 carbon atoms; and
Z′
″
is an alkyl group having from 1 to 2 carbon atoms;
(ii) R′
3OOC—
CH═
CH—
COOR′
4, wherein R′
3 and R4 are independently an alkyl group having from 8 to 12 carbon atoms;
(iii) CH2═
C(R′
5)OCOR′
6, wherein R′
5 is methyl, and R′
6 is an alkyl group having from 8 to 12 carbon atoms;
(iv) CH2═
C(COOR′
7)CH2COOR′
8, wherein R′
7 and R′
8 are independently an alkyl group having from 8 to 12 carbon atoms;
(v) CH3CH═
CHCOOR′
9, and R′
9 is an alkyl group having from 8 to 12 carbon atoms;
(vi) R′
10C8H4CR′
11═
CHR′
11, and R′
10 and R′
11 are independently methyl; and
(vii) R′
12CH═
CHR′
13, wherein R′
12 and R′
13 are independently selected from the group consisting of 2-pyrrolidinone, N-caprolactam, and an alkyl group having from 7 to 12 carbon atoms.
- C(R′
-
23. A method for preparing an aqueous emulsion comprising a water-dispersible copolymer characterized in that films formed from said water-dispersible copolymer are dispersible in water, yet non-dispersible in aqueous solutions containing 0.5% or more of an inorganic salt, comprising the steps of:
-
(a) providing the following monomers in percentages by weight;
(A) from about 40% 25% to about 60% of acidic ethylenically unsaturated monomer;
(B) from about 10% to about 80% of ethylenically unsaturated monomer selected from the group of monomer formulas consisting of;
(i) CH2═
C(R1)COR2;
(ii) R3OOC—
CH═
CH—
COOR4;
(iii) CH2═
C(R5)OCOR8;
(iv) CH2═
C(COOR7)CH2COOR8;
(v) CH3CH═
CHCOOR9;
(vi) R10C6H4CR11═
CHR11; and
(vii) R12CH═
CHR13;
wherein R1 is hydrogen or methyl and R2 is —
OZ′
or —
N(Z″
)(Z″
), wherein Z′
is an alkyl group having from 1 to 7 carbon atoms, and Z′
is independently selected from the group consisting of hydrogen and alkyl groups having from 1 to 6 carbon atoms;
R3 and R4 are independently hydrogen or an alkyl group having from 1 to 7 carbon atoms, with the proviso that R3 and R4 are not both hydrogen;
R5 is hydrogen or methyl and R6 is an alkyl group having from 1 to 7 carbon atoms;
R7 and R8 are independently hydrogen or an alkyl group having from 1 to 7 carbon atoms, with the proviso that R7 and R8 are not both hydrogen;
R9 is an alkyl group having from 1 to 7 carbon atoms;
R10 and R11 are hydrogen; and
R12 and R13 are independently selected from the group consisting of hydrogen, —
CN, —
NHCHO, and an alkyl group having from 1 to 7 carbon atoms; and
(C) from about 10% to about 80% of ethylenically unsaturated monomer 4 selected from the group of monomer formulas consisting of;
(i) CH2═
C(R′
1)COR′
2;
(ii) R′
3OOC—
CH═
CH—
COOR′
4;
(iii) CH2═
C(R′
5)OCOR′
6;
(iv) CH2═
C(COOR′
7)CH2COOR′
8;
(v) CH3CH═
CHCOOR′
9;
(vi) R′
10C6H4CR′
11═
CHR′
11; and
(vii) R′
12CH═
CHR′
13;
wherein R′
1 is hydrogen or methyl, and R′
2 is select from the group consisting of —
OZ′
, —
N(Z″
)(Z′
), and —
OZ′
″
OH, wherein Z′
is an alkyl group having from 8 to 18 carbon atoms;
Z″
is independently selected from the group consisting of alkyl groups having from 7 to 10 carbon atoms, dimethylamino alkyl groups having from 1 to 5 carbon atoms, and hydroxyalkyl groups having from 1 to 5 carbon atoms; and
Z′
″
is an alkyl group having from 1 to 4 carbon atoms;
R′
3 and R′
4 are independently an alkyl group having from 8 to 18 carbon atoms;
R′
5 is hydrogen or methyl and R′
6 is an alkyl group having from 8 to 18 carbon atoms;
R′
7 and R′
8 are independently an alkyl group having from 8 to 18 carbon atoms;
R′
9 is an alkyl group having from 8 to 18 carbon atoms;
R′
10 and R′
11 are independently an alkyl group having from 1 to 2 carbon atoms;
R′
12 and R′
13 are independently selected from the group consisting of 2-pyrrolidinone, N-caprolactam, and an alkyl group having from 7 to 18 carbon atoms with the proviso that R12 and R13 are not both 2-pyrrolidinone, are not both N-caprolactam, or are not a mixture thereof; and
(b) neutralizing the monomers from (A), (B), and (C) in water to a level from about 2% to about 15% molar of the acidic ethylenically unsaturated monomer from (A); and
(c) emulsion polymerizing the monomers from (A), (B), and (C) at a solids level from about 20% to about 70% by weight, based on the aqueous emulsion, without a surfactant, to form a copolymer having a weight average molecular weight greater than about 25,000. - View Dependent Claims (24, 25, 26)
(i) CH2═
C(R1)COR2, wherein R1 is methyl and R2 is —
OZ′
, wherein Z′
is an alkyl group having from 1 to 4 carbon atoms;
(ii) R3OOC—
CH═
CH—
COOR4, wherein R3 and R4 are independently an alkyl group having from 1 to 4 carbon atoms;
(iii) CH2═
C(R5)OCOR6, wherein R5 is methyl and R6 is an alkyl group having from 1 to 4 carbon atoms;
(iv) CH2═
C(COOR7)CH2COOR8, wherein R7 and R8 are independently an alkyl group having from 1 to 4 carbon atoms;
(v) CH3CH═
CHCOOR8, wherein R9 is an alkyl group having from 1 to 4 carbon atoms;
(vi) styrene; and
(vii) R12CH═
CHR13, wherein R12 and R13 are independently hydrogen or methyl.
-
-
26. The method according to claim 23, wherein the ethylenically unsaturated monomer from (C) is selected from the group consisting of:
-
(i) CH2═
C(R′
1)COR′
2, wherein R′
1 is methyl, R′
2 is selected from the group consisting of —
OZ′
, N(Z″
)(Z″
), and OZ′
″
OH, wherein Z′
is an alkyl group having from 8 to 12 carbon atoms;
Z″
is independently. selected from the group consisting of alkyl groups having from 8 to 10 carbon atoms, dimethylamino alkyl groups having from 1 to 3 carbon atoms, and hydroxyalkyl groups having from 1 to 3 carbon atoms; and
Z′
″
is an alkyl group having from 1 to 2 carbon atoms;
(ii) R′
3OOC—
CH═
CH—
COOR′
4, wherein R′
3 and R′
4 are independently an alkyl group having from 8 to 12 carbon atoms;
(iii) CH2═
C(R′
5)OCOR′
6, wherein R′
5 is methyl, and R′
6 is an alkyl group having from 8 to 12 carbon atoms;
(iv) CH2═
C(COOR′
7)CH2COOR′
8, wherein R′
7 and R′
8 are independently an alkyl group having from 8 to 12 carbon atoms;
(v) CH3CH═
CHCOOR′
9, and R′
9 is an alkyl group having from 8 to 12 carbon atoms;
(vi) R′
10C6H4CR′
11═
CHR′
11, and R′
10 and R′
11 are independently methyl; and
(vii) R′
12CH═
CHR′
13, wherein R′
12 and R′
13 are independently selected from the group consisting of 2-pyrrolidinone, N-caprolactam, and an alkyl group having from 7 to 12 carbon atoms.
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Specification