Encapsulated polymerization initiators, polymerization systems and methods using the same

• US 9,334,430 B1
• Filed: 05/29/2015
• Issued: 05/10/2016
• Est. Priority Date: 05/29/2015
• Status: Active Grant

• Current Assignee: Nippon Shokubai Company Limited
• Original Assignee: Sirrus, Inc (Nippon Shokubai Company Limited)
• Inventors: Stevenson, Peter Rulon, Palsule, Aniruddha Sudhir, Sullivan, Jeffrey M.
• Primary Examiner(s): Nguyen, Vu A
• Application Number:
  US14/725,532
• Time in Patent Office: 347 Days
• Field of Search: 428/402, 428/402.2, 428/402.21, 428/402.22, 428/402.24, 428/407
• US Class Current: 1/1
• CPC Class Codes: B01J 13/185 in an organic phase
• CPC Class Codes: C08F 222/14 Esters having no free carboxylic acid groups , e.g. dialkyl maleates or fumarates
• CPC Class Codes: C08J 3/241 Preventing premature crosslinking by physical separation of components, e.g. encapsulation
• CPC Class Codes: C08K 3/01 characterized by their specific function
• CPC Class Codes: C08K 5/0008 Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
• CPC Class Codes: C08K 5/11 of acyclic polycarboxylic acids
• CPC Class Codes: C08K 9/10 Encapsulated ingredients
• CPC Class Codes: C08L 27/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C09J 135/02 Homopolymers or copolymers of esters C09J135/06, C09J135/08 take precedence
• CPC Class Codes: C09J 4/06 Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond in combination with a macromolecular compound other than an unsaturated polymer of groups C09J159/00 - C09J187/00

Abstract

An encapsulated initiator particle includes one or more polymerization initiators encapsulated by a cured composition. The cured composition includes one or more 1,1-disubstituted alkene compounds. Polymerizable systems can include one or more encapsulated initiator particles and a polymerizable composition. The polymerizable composition can include one or more 1,1-disubstituted alkene compounds. Methods for forming an encapsulated initiator particle are also described herein.

Claims

1. An encapsulated initiator particle comprising:

an initiator matrix comprising;

a first cured composition comprising one or more 1,1-disubstituted alkene compounds; and

one or more polymerization initiators substantially encapsulated by the first cured composition and comprising spherical, non-spherical, irregular, angular, textured, or layered particles having an average granulometry of about 0.1 microns to about 1,000 microns.

2. The encapsulated initiator particle of claim 1, wherein the one or more 1,1-disubstituted alkene compounds are selected from the group consisting of methylene malonates, methylene β

-ketoesters, methylene β

-diketones, dialkyl disubstituted vinyls, dihaloalkyl disubstituted vinyls, monofunctional, difunctional or multifunctional monomers, oligomers, or polymers thereof, and combinations thereof.

3. The encapsulated initiator particle of claim 1, wherein the first cured composition comprises one or more low Tg 1,1-disubstituted alkene compounds.

4. The encapsulated initiator particle of claim 1, wherein said polymerization initiators comprise one or more alkali metal salts, alkaline earth metal salts, ammonium salts, amine salts, halides, or metal oxides.

6. The encapsulated initiator particle of claim 1 ruptures when about 0.1 psi or more of mechanical force is applied.

7. The encapsulated initiator particle of claim 1, further comprising a shell layer, wherein the shell layer surrounds and encapsulates the initiator matrix.

8. The encapsulated initiator particle of claim 7, wherein the shell layer is formed from one or more of a second cured composition formed of one or more 1,1-disubstituted alkene compounds;

a urea formaldehyde resin;

a polyvinyl alcohol;

a gelatin;

an acrylate; and

a cured oligomeric reactive monomer.

9. The encapsulated initiator particle of claim 8, wherein the 1,1-disubstituted alkene compounds of the second cured composition comprise one or more difunctional or multifunctional 1,1-disubstituted alkene compounds.

10. The encapsulated initiator particle of claim 8, wherein the shell layer comprises the second cured composition and wherein the first cured composition and the second cured composition are different.

11. The encapsulated initiator particle of claim 8, wherein the one or more 1,1-disubstituted alkene compounds of the second cured composition comprise an elevated temperature Tg 1,1-disubstituted alkene compound.

5. An encapsulated initiator particle comprising:

an initiator matrix comprising;

a first cured composition comprising one or more 1,1-disubstituted alkene compounds; and

one or more polymerization initiators substantially encapsulated by the first cured composition; and

wherein the ratio of the first cured composition to said polymerization initiators is a ratio of about 1;

1 to a ratio of about 2;

1, by weight.

12. The encapsulated initiator particle of claim 5, wherein the one or more 1,1-disubstituted alkene compounds are selected from the group consisting of methylene malonates, methylene β

-ketoesters, methylene β

-diketones, dialkyl disubstituted vinyls, dihaloalkyl disubstituted vinyls, monofunctional, difunctional or multifunctional monomers, oligomers, or polymers thereof, and combinations thereof.

13. The encapsulated initiator particle of claim 5, wherein the first cured composition comprises one or more low Tg 1,1-disubstituted alkene compounds.

14. The encapsulated initiator particle of claim 5, wherein said polymerization initiators comprise one or more alkali metal salts, alkaline earth metal salts, ammonium salts, amine salts, halides, or metal oxides.

15. The encapsulated initiator particle of claim 5 ruptures when about 0.1 psi or more of mechanical force is applied.

16. The encapsulated initiator particle of claim 5, further comprising a shell layer, wherein the shell layer surrounds and encapsulates the initiator matrix.

17. The encapsulated initiator particle of claim 16, wherein the shell layer is formed from one or more of a second cured composition formed of one or more 1,1-disubstituted alkene compounds;

a urea formaldehyde resin;

a polyvinyl alcohol;

a gelatin;

an acrylate; and

a cured oligomeric reactive monomer.

18. The encapsulated initiator particle of claim 17, wherein the 1,1-disubstituted alkene compounds of the second cured composition comprise one or more difunctional or multifunctional 1,1-disubstituted alkene compounds.

19. The encapsulated initiator particle of claim 17, wherein the shell layer comprises the second cured composition and wherein the first cured composition and the second cured composition are different.

20. The encapsulated initiator particle of claim 17, wherein the one or more 1,1-disubstituted alkene compounds of the second cured composition comprise an elevated temperature Tg 1,1-disubstituted alkene compound.