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SURFACTANT COMPOSITION AND EMULSION POLYMERIZATION PROCESS CONDUCTED IN THE PRESENCE OF THE SURFACTANT COMPOSITION

IP.com Disclosure Number: IPCOM000201487D
Publication Date: 2010-Nov-11

Publishing Venue

The IP.com Prior Art Database

Abstract

A surfactant composition comprising a reactive surfactant, an emulsion polymerization process for forming polymers suitable for use in coating applications, a polymer component formed in accordance with the emulsion polymerization process, and a coating composition comprising the polymer component are provided herein. The reactive surfactant comprises the reaction product of a) diallylamine, and b) alkylene oxide selected from the group of ethylene oxide, propylene oxide, butylene oxide, and combinations thereof. The reactive surfactant has a calculated HLB of from 7 to 11. The emulsion polymerization process for forming the polymers suitable for use in coating applications comprises the steps of providing at least one substantially water-insoluble ethylenically-unsaturated monomer in an aqueous phase, providing the surfactant composition comprising the reactive surfactant, and conducting free-radical polymerization of the at least one monomer in the presence of the surfactant composition such that the reactive surfactant undergoes copolymerization with the at least one substantially water-insoluble ethylenically-unsaturated monomer.

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SURFACTANT COMPOSITION AND EMULSION POLYMERIZATION PROCESS

CONDUCTED IN THE PRESENCE OF THE SURFACTANT COMPOSITION Background of the Invention
1. Field of the Invention
[0001]The instant invention is directed to a surfactant composition that is useful in emulsion polymerization processes for forming polymers suitable for use in coating applications. More specifically, the instant invention is directed to a surfactant composition comprising a reactive surfactant that becomes chemically bonded within the polymers after the emulsion polymerization process.
2. Description of the Related Art
[0002]Emulsion polymerization of substantially water-insoluble ethylenically-unsaturated monomers is known in the art for many purposes, including production of polymeric particles, such as latex particles, that are intended for a variety of end uses such as inclusion in coating compositions for coating and/or adhesion applications. During emulsion polymerization, small droplets of liquid monomer are provided at an elevated temperature while suspended as small spheres in an aqueous phase. It has been a common practice in the art to include a water-soluble surfactant within the aqueous phase that aids in desired maintenance of the suspended liquid monomer as small spheres, thereby influencing size and dispersibility of the resulting polymeric particles. Commonly, the water-soluble surfactants are anionic, nonionic, or mixtures of anionic and nonionic surfactants.
[0003]When the resulting polymeric particles are utilized in coating compositions for coating and/or adhesive applications, residual surfactant remaining from the production of the polymeric particles may interfere with the performance of the coating compositions. For instance, the presence of residual anionic surfactants may lead to a destabilization of the polymeric particles in

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the coating compositions and cause unwanted coagulation. Also, when applied to a substrate to form a coating and/or adhesive film, the residual anionic surfactant may interfere with the desired adhesion of the film to the substrate. The scrubability and water sensitivity of the dried film can also be adversely influenced by the presence of the residual surfactants. Additionally, residual surfactants can sometimes cause an undesirable "blooming" that leads to surface irregularities in the film once it is formed on a substrate. In view of the foregoing problems with water-soluble surfactants, a desire has arisen to replace all or some of the water-soluble surfactants with surfactants that do not give rise to the aforementioned undesirable effects.
[0004]Heretofore, in some instances it has been proposed to employ certain reactive surfactants during the emulsion polymerization process, in place of or in addition to conventional water- soluble surfactants. The reactive surfactants include functionality that enables the reactive surfactants to participate in the polymerization reaction and become...