阅读说明：本技术 聚合物颗粒、微球和聚硅氧烷颗粒的水性分散体 (Aqueous dispersion of polymer particles, microspheres and polysiloxane particles ) 是由 J·C·勃林 I·尔雅兹斯 B·K·哈格曼 P·R·哈希 Y·刘 P·S·马宗达 E·A 于 2019-10-22 设计创作，主要内容包括：本发明涉及一种漆组合物,其包含以下的水性分散体：a)平均粒径在80nm到500nm的范围内的聚合物颗粒；b)粒径在1μm到20μm的范围内的聚合有机交联微球；c)粒径在1μm到30μm的范围内的聚硅氧烷颗粒；d)流变改性剂；e)折射率>1.9的不透明白色颜料；和f)小于10重量％的低T-g聚氨酯。本发明的组合物给予涂层优异的耐磨光性。(The present invention relates to a paint composition comprising an aqueous dispersion of: a) polymer particles having an average particle diameter in the range of 80nm to 500 nm; b) polymeric organically cross-linked microspheres having a particle size in the range of 1 μm to 20 μm; c) polysiloxane particles having a particle size in the range of 1 μm to 30 μm; d) a rheology modifier; e) refractive index>1.9 of an opaque white pigment; and f) a low T of less than 10% by weight g A polyurethane. The compositions of the present invention impart excellent burnish resistance to the coating.)

1. A paint composition comprising an aqueous dispersion of:

a) z polymer particles having an average particle size in the range of 80nm to 500 nm;

b) polymeric organically cross-linked microspheres having an average particle diameter in the range of 1 μm to 20 μm;

c) polysiloxane particles having an average particle diameter in the range of 1 μm to 30 μm;

d) a rheology modifier;

e) an opaque white pigment having a refractive index >1.9 at a pigment volume concentration in the range of 1 to 30, with the proviso that when the pigment volume concentration of the opaque white pigment is less than 10, the paint composition comprises a non-white colorant in the range of 5 to 20 weight percent solids, based on the weight of the paint composition; and

f) less than 10 wt.% T, based on the weight of the polymer particles_g<Polyurethane at 0 ℃;

wherein the concentration of the polymer particles and the crosslinked microspheres is in a range of 10 wt% to 65 wt%, based on the weight of the paint composition;

wherein the weight to weight ratio of the polymer particles to the crosslinked microspheres is in the range of 1.1:1 to 20: 1; the concentration of the polysiloxane particles ranges from 0.05 wt% to 5 wt% based on the weight of the paint composition; and the concentration of the rheology modifier is in the range of 0.1 wt% to 5 wt% based on the weight of the paint composition.

2. The paint composition of claim 1, wherein the polysiloxane is a linear polymer represented by the following structure:

wherein each R⁴Independently is C₁-C₃₀Alkyl, O-C₁-C₆Alkyl or H, provided that at least one R is⁴Is C₁-C₃₀An alkyl group; each R⁵Independently is C₁-C₃₀Alkyl, H or Si (R)⁶)₃(ii) a Wherein each R⁶Independently is C₁-C₆An alkyl group; and n is 4 to 10,000.

3. The paint composition of claim 1, wherein a) the polymer particles are T_g<Acrylic polymer particles at 20 ℃; and b) the polymeric organically cross-linked microsphere packageContaining T_gA first stage crosslinked polymer at 20 ℃ or less; and T_g>A second stage at 30 ℃; wherein the polymeric organic microspheres have a median weight average particle size in the range of 2 μm to 15 μm.

4. The paint composition of claim 2, wherein the weight to weight ratio of polymeric particles to crosslinked microspheres is in the range of 1.3:1 to 10: 1; the polymer particles comprise at least 30 wt% of structural units of one or more methacrylate and/or acrylate monomers, based on the weight of the polymer particles; wherein each R⁴Independently methyl or ethyl.

5. The paint composition of claim 4, wherein the polymer particles further comprise from 0.05 to 12 weight percent structural units of a monomer having a ketone functional group, based on the weight of the polymer particles and the polymeric organic microspheres, and the composition further comprises from 0.1 to less than 10 weight percent of a dihydrazide of a polyamine crosslinker, based on the weight of the polymer particles and the polymeric organic microspheres.

6. The lacquer composition of claim 4, wherein the refractive index>1.9 the opaque white pigment is TiO with a PVC in the range of 12 to 22₂(ii) a Wherein each R⁴Independently a methyl group.

7. The paint composition of claim 5, wherein at least 50 weight percent of the first stage of the crosslinked microspheres comprise structural units of butyl acrylate and a multi-ethylenically unsaturated nonionic monomer, wherein the weight to weight ratio of butyl acrylate to the multi-ethylenically unsaturated nonionic monomer is in the range of 99.5:0.5 to 90: 10; wherein the second stage comprises a methyl methacrylate homopolymer.

8. The paint composition of claim 2, wherein the polymeric organic crosslinked microspheres have an average particle size in the range of 2 μ ι η to 15 μ ι η, wherein the polymeric organic microspheres are functionalized with 0.05% to 5% by weight of structural units of a compound of formula I, based on the weight of the microspheres:

or a salt thereof; wherein R is H or CH₃Wherein R is¹And R²Each independently is H or CH₃Provided that there are no two adjacent CR' s²CR¹Each of which is substituted with methyl; each R³Independently is a straight or branched chain C₂-C₆An alkylene group; m is 1 to 10 and n is 0 to 5, with the proviso that when m is 1, n is 1 to 5; x is 1 or 2; and y is 1 or 2; and x + y is 3.

9. The lacquer composition of claim 1, wherein the refractive index>1.9 the opaque white pigment is TiO with a PVC in the range of 1 to 10₂(ii) a Wherein the paint composition further comprises a non-white colorant in the range of 5 to 20% by weight solids and an inorganic extender having a refractive index in the range of 1.0 to 1.9 of less than 15PVC, based on the weight of the paint composition.

10. The composition of claim 2, further comprising one or more additives selected from the group consisting of: coalescents, surfactants, dispersants, biocides, opacifying polymers, colorants, waxes, defoamers, and neutralizers.

Background

The present invention relates to a paint composition comprising an aqueous dispersion of polymer particles (latex), microspheres and polysiloxane particles; the paint composition is suitable for preparing coatings with improved burnish resistance.

Achieving the performance attributes of semi-gloss coatings with traditional matte-coat gloss is a far reaching goal and has not been achieved to date. Matte coatings are desirable for their ability to mask surface defects of the substrate. Control of gloss, which is critical in the design of these low gloss decorative paints, is accomplished with matting agents (also known as extenders or delusterants) which are inorganic particles of calcium carbonate, silica, clay, talc, and the like.

Matting agents reduce gloss by increasing the surface roughness of the film; unfortunately, conventional matting agents compromise the durability and performance of the resulting film. Thus, the high flow areas do not use matte coatings due to poor burnish resistance (an unnecessary increase in gloss/gloss due to rubbing or grinding). Accordingly, it would be advantageous to design matte coating compositions that form coatings with improved burnish resistance.

Disclosure of Invention

The present invention addresses the need in the art by providing a paint composition comprising an aqueous dispersion of:

a) z polymer particles having an average particle size in the range of 80nm to 500 nm;

b) polymeric organically cross-linked microspheres having an average particle diameter in the range of 1 μm to 20 μm;

c) polysiloxane particles having an average particle diameter in the range of 1 μm to 30 μm;

d) a rheology modifier;

e) an opaque white pigment having a refractive index >1.9 at a pigment volume concentration in the range of 1 to 30, with the proviso that when the pigment volume concentration of the opaque white pigment is less than 10, the paint composition comprises a non-white colorant in the range of 5 to 20 weight percent solids, based on the weight of the paint composition; and

f) less than 10 wt.% T, based on the weight of the polymer particles_g<Polyurethane at 0 ℃;

wherein the concentration of the polymeric particles and the crosslinked microspheres is in the range of 10 wt% to 65 wt% based on the weight of the paint composition;

wherein the weight to weight ratio of the polymer particles to the crosslinked microspheres is in the range of 1.1:1 to 20: 1; the concentration of the polysiloxane particles is in the range of 0.05 to 5% by weight based on the weight of the paint composition; and the concentration of the rheology modifier is in the range of 0.1 wt% to 5 wt% based on the weight of the paint composition.

The present invention addresses a need in the art by providing a composition that imparts an burnish resistance to a matte finish semi-gloss painted substrate.

Detailed Description

The present invention is a paint composition comprising an aqueous dispersion of:

a) z polymer particles having an average particle size in the range of 80nm to 500 nm;

b) polymeric organically cross-linked microspheres having an average particle diameter in the range of 1 μm to 20 μm;

c) polysiloxane particles having an average particle diameter in the range of 1 μm to 30 μm;

d) a rheology modifier;

e) an opaque white pigment having a refractive index >1.9 at a pigment volume concentration in the range of from 1 to 30, with the proviso that when the pigment volume concentration of the opaque white pigment is less than 10, the paint composition comprises a non-white colorant in the range of from 5 to 20 weight percent solids, based on the weight of the paint composition; and

f) less than 10 wt.% T, based on the weight of the polymer particles_g<Polyurethane at 0 ℃.

Wherein the concentration of the polymeric particles and the crosslinked microspheres is in the range of 10 wt% to 65 wt% based on the weight of the paint composition;

wherein the weight to weight ratio of the polymer particles to the crosslinked microspheres is in the range of 1.1:1 to 20: 1; the concentration of the polysiloxane particles is in the range of 0.05 to 5% by weight based on the weight of the paint composition; and the concentration of the rheology modifier is in the range of 0.1 wt% to 5 wt% based on the weight of the paint composition.

The polymer particles are preferably acrylic, which means that they comprise at least 30% by weight, based on the weight of the polymer particles, of structural units of one or more methacrylate monomers, such as methyl methacrylate and ethyl methacrylate, and/or one or more acrylate monomers, such as methyl acrylate, ethyl acrylate, butyl acrylate, 2-propylheptyl acrylate and 2-ethylhexyl acrylate. The acrylic polymer may further include a structural unit of an ethylenically unsaturated carboxylic acid monomer (such as methacrylic acid, acrylic acid, and itaconic acid) or a salt thereof, and a structural unit of a phosphoric acid monomer (such as phosphoethyl methacrylate) or a salt thereof.

The polymer particles may also include other structural units other than acrylate or methacrylate monomers, such as styrene and vinyl acetate. The polymer particles are preferably film-forming below room temperature; and preferably T calculated by Fox's equation_g<20 deg.C, more preferably<15℃。

Preferably, the polymeric particles further comprise from 0.05 wt%, more preferably from 0.5 wt% to 12 wt%, more preferably to 5 wt%, structural units of a monomer having a ketone functional group, including acetoacetoxyethyl methacrylate (AAEM) or diacetone acrylamide (DAAM), based on the weight of the polymeric particles and polymeric organic microspheres.

If the polymer particles are functionalized as building blocks of monomers having ketone functionality, the paint composition advantageously includes 0.1 wt.%, preferably 0.2 wt.%, and more preferably 0.5 wt.% to 10 wt.%, and preferably to 5 wt.% of dihydrazide or polyamine crosslinking agent, based on the weight of the polymer particles and microspheres. Examples of polyamine crosslinkers include diamines such as 3,3' - (ethane-1, 2-diylbis (oxy)) bis (propan-1-amine); 4, 9-dioxadodecane-1, 12-diamine; 4, 9-dioxadodecane-1, 12-diamine; 4, 7-dioxadodecane-1, 10-diamine; and 4,7, 10-trioxatridecane-1, 13-diamine. Commercial examples of polyamines are polyetheramines such as JEFFAMINE D-230, JEFFAMINE D-400, JEFFAMINE D-2000, JEFFAMINE M-600, JEFFAMINE M-1000, JEFFAMINE ED-600, JEFFAMINE ED-900, T-403, and JEFFAMINE T-3000 polyetheramines. When the monomer having ketone functionality is DAAM, the composition preferably includes a dihydrazide crosslinker, such as adipic Acid Dihydrazide (ADH), Carbodihydrazide (CDH), Sebacic Dihydrazide (SDH), Valine Dihydrazide (VDH), isophthalic dihydrazide (ISODH), and eicosadihydrazide (ICODH). Preferably, the crosslinking agent for the DAAM functionalized polymer particles is a dihydrazide, more preferably ADH.

The term "structural unit" is used herein to describe the residue of the monomer after polymerization. For example, the structural units of methyl methacrylate are shown below:

wherein the dashed lines indicate the points of attachment of the structural units to the polymer backbone.

The concentration of the polymer particles is preferably in the range of 10 wt%, more preferably 15 wt% to 35 wt%, more preferably to 30 wt%, and most preferably to 25 wt%, based on the weight of the paint composition. Preferably, the z-average particle size of the polymer particles is in the range of from 100nm to 300nm, more preferably to 250nm as measured using a Brookhaven BI90 particle analyser or similar dynamic light scattering apparatus.

The polymeric organically crosslinked microspheres preferably comprise a low T_gFirst stage (. ltoreq.20 ℃, preferably<10 ℃ and more preferably<0 ℃, as calculated by fox equation) polymer that is crosslinked to provide resilience and does not diffuse to the substrate; and high T_gA second stage (. gtoreq.30 ℃, preferably more than 50 ℃ as calculated by the Fox equation) to provide microspheres that are not film-forming at room temperature. Preferably, at least 50 wt.%, more preferably at least 70 wt.%, and most preferably at least 90 wt.% of the crosslinked first stage comprises I) methyl acrylate, butyl acrylate, or ethyl acrylate, or a combination thereof; and II) structural units of a polyethylenically unsaturated nonionic monomer exemplified below, in a I: II w/w ratio in the range of from 99.5:0.5 to 90: 10; preferably, the methyl methacrylate comprises at least 60 wt.%, more preferably at least 80 wt.%, and most preferably at least 90 wt.% of the second stage.

Average particle diameter (technically, median weight average particle diameter, D) of the polymeric organic crosslinked microspheres₅₀) In the range of 2 μm, preferably 4 μm to 20 μm, preferably 15 μm, as measured using a disk centrifuge photometric sedimentometer as described below. Aqueous dispersions of crosslinked microspheres can be prepared in a variety of ways, including those described in U.S. patent publication 2013/0052454; US 4,403,003; US7,768,602; and those of US7,829,626.

In a preferred method of preparing an aqueous dispersion of polymerized organically cross-linked multistage microspheres (preferred method a), an aqueous dispersion of first microspheres comprising structural units of a first monoethylenically unsaturated nonionic monomer is contacted under polymerization conditions with a first stage monomer comprising, based on the weight of the first stage monomer: a) from 0.05 to 5% by weight of a polymerizable organophosphate or salt thereof; and b)70 to 99.95 wt% of a second monoethylenically unsaturated non-ionic monomer to grow first microspheres to form an aqueous dispersion of organophosphate-functionalized second microspheres, wherein the first microspheres have a particle size in the range of 1 to 15 μm and the second microspheres have a particle size in the range of 1.1 and 20 μm; and wherein the polymerizable organophosphate is represented by the structure of formula I:

or a salt thereof; wherein R is H or CH₃Wherein R is¹And R²Each independently is H or CH₃Provided that there are no two adjacent CR' s²CR¹Each of which is substituted with methyl; each R³Independently is a straight or branched chain C₂-C₆An alkylene group; m is 1 to 10 and n is 0 to 5, with the proviso that when m is 1, n is 1 to 5; x is 1 or 2; and y is 1 or 2; and x + y is 3. The resulting microspheres prepared by this method are preferably functionalized with 0.05 to 5 wt% of structural units of formula I or salts thereof, based on the weight of the microsphere.

When n is 0, x is 1 and y is 2, the polymerizable organophosphate or salt thereof is represented by the structure of formula II:

preferably, R¹And R²Is H, and R¹And R²The other of (A) is CH₃(ii) a More preferably, each R²Is H and each R¹Is CH₃(ii) a m is preferably 3, and more preferably 4; to preferably 8 and more preferably to 7. The phosphoesters of Sipomer PAM-100, Sipomer PAM-200 and Sipomer PAM to 600 are in compounds of formula IIExamples of compounds commercially available within the scope.

In another aspect, wherein n is 1; m is 1; r is CH₃；R¹And R²Each is H; r³-(CH₂)₅-; x is 1 or 2; y is 1 or 2; and x + y ═ 3, the polymerizable organophosphate or salt thereof is represented by the structure of formula III:

a commercially available compound within the scope of formula III is Kayamer PM-21 phosphate.

In this method, the first microspheres preferably comprise 90 to 99.9 wt% structural units of a monoethylenically unsaturated nonionic monomer, examples of which include acrylates such as methyl acrylate, ethyl acrylate, butyl acrylate, and 2-ethylhexyl acrylate; methacrylates such as methyl methacrylate, n-butyl methacrylate, t-butyl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, acetoacetoxyethyl methacrylate, and urea methacrylate; acrylonitrile; acrylamides, such as acrylamide and diacetone acrylamide; styrene; and vinyl esters, such as vinyl acetate. Although it is possible that the first microspheres comprise structural units of a carboxylic acid monomer (such as methacrylic acid or acrylic acid), preferably the first microspheres comprise less than 5 wt.%, more preferably less than 3, and most preferably less than 1 wt.% structural units of a carboxylic acid monomer based on the weight of the microspheres. The first microspheres more preferably comprise structural units of an acrylate or methacrylate or a combination of acrylate and methacrylate.

As described herein, the first microspheres are advantageously made of a weight average molecular weight (M)_w) An aqueous dispersion of oligomeric seed in the range of 800g/mol, preferably 1000g/mol to 20,000g/mol, preferably to 10,000g/mol and most preferably to 5000g/mol, the weight average molecular weight as determined by size exclusion chromatography using polystyrene standards. The average diameter of the oligomeric seed is 200n, as described hereinm, more preferably 400nm, and most preferably 600nm to 8000nm, preferably to 5000nm, more preferably to 1500nm, and most preferably to 1000nm, as determined by disk centrifugation of DCP. The oligomer seed has a structure of a chain transfer agent such as an alkylmercaptan, and examples thereof include n-dodecylmercaptan, 1-hexanethiol, 1-octanethiol and 2-butanethiol.

The aqueous dispersion of oligomeric seed and hydrophobic initiator is advantageously contacted with a first monoethylenically unsaturated monomer; alternatively, the monomer may be swelled into an oligomeric seed followed by the addition of a hydrophobic initiator. The hydrophobic initiator is preferably added in the form of an aqueous dispersion. As used herein, hydrophobic initiator refers to an initiator having a water solubility in the range of 5ppm, preferably 10ppm to 10,000ppm, preferably to 1000ppm and more preferably to 100 ppm. Examples of suitable hydrophobic initiators include, for example, t-amyl peroxy-2-ethylhexanoate (water solubility at 20 ℃ C.: 17.6mg/L) or t-butyl peroxy-2-ethylhexanoate (water solubility at 20 ℃ C.: 46 mg/L). The degree of swelling (seed growth) can be controlled by the monomer to seed ratio. Examples of suitable monoethylenically unsaturated nonionic monomers include acrylic esters such as ethyl acrylate, butyl acrylate, and 2-ethylhexyl acrylate; methacrylates such as methyl methacrylate, n-butyl methacrylate, t-butyl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, acetoacetoxyethyl methacrylate, and urea methacrylate; acrylonitrile; acrylamides, such as acrylamide and diacetone acrylamide; styrene and vinyl esters, such as vinyl acetate.

Formation of microspheres from oligomeric seeds provides an effective way to control the particle size distribution of the microspheres. Preferably, the coefficient of variation of the first and second microspheres as determined by DCP is less than 25%, more preferably less than 20%, more preferably less than 15% and most preferably less than 10%. Preferably, the concentration of the gel formed during the preparation of the aqueous dispersion of second microspheres is preferably less than 0.5 wt%, more preferably less than 0.2 wt%, more preferably less than 0.1 wt% and most preferably less than 0.05 wt% based on the weight of the aqueous dispersion. Dispersions of microspheres with low coefficients of variation ultimately result in coatings with reliable and reproducible performance in end-use applications. In contrast, microspheres with a coefficient of variation greater than 30% give coatings with unreliable and unpredictable properties.

Preferably, D of the first microspheres₅₀The particle size is 2.5 μm, more preferably 3.0 μm, preferably to 12 μm, more preferably to 10 μm, and most preferably to 8.5 μm.

In a preferred method of preparing an aqueous dispersion of microspheres functionalized with a polymerizable organophosphate ester of structure I, an aqueous dispersion of first microspheres is contacted under polymerization conditions and in the presence of an emulsifying surfactant (such as a phosphate or alkylbenzene sulfonate or sulfate) with a first stage monomer comprising from 0.05 wt%, preferably from 0.1 wt% and more preferably from 0.2 wt% to 5 wt%, preferably to 3 wt%, more preferably to 2 wt%, and most preferably to 1 wt%, of a polymerizable organophosphate ester of structure I or a salt thereof, based on the weight of the first stage monomer; and 70 wt%, more preferably 80 wt%, and most preferably 90 wt% to 99.95 wt%, preferably 99.8 wt% of a second monoethylenically unsaturated nonionic monomer. The first microspheres increase in volume (grow out) to form an aqueous dispersion of organophosphate functionalized second microspheres having a particle size in the range of 1.1 μm, and preferably 2.5 μm, preferably 3.5 μm to 20 μm, and preferably to 15 μm.

The first stage monomer preferably also comprises a polyethylenically unsaturated nonionic monomer, preferably at a concentration in the range of from 0.1 weight percent, more preferably 1 weight percent, and most preferably from 2 weight percent to 15 weight percent, more preferably to 10 weight percent, and most preferably to 8 weight percent, based on the weight of the first stage monomer. Examples of suitable polyethylenically unsaturated nonionic monomers include allyl methacrylate, allyl acrylate, divinylbenzene, trimethylolpropane trimethacrylate, trimethylolpropane triacrylate, butanediol (1,3) dimethacrylate, butanediol (1,3) diacrylate, ethylene glycol dimethacrylate, and ethylene glycol diacrylate. The inclusion of these polyethylenically unsaturated nonionic monomers is particularly preferred where further fractionation of the functionalized second microspheres is desired.

The first stage monomer as well as the second microspheres preferably comprise structural units of carboxylic acid monomers that are substantially absent. As used herein, substantially absent structural units of carboxylic acid monomers means less than 5 wt.%, preferably less than 3 wt.%, more preferably less than 1 wt.%, and most preferably less than 0.2 wt.% structural units of carboxylic acid monomers (such as methacrylic acid or acrylic acid) based on the weight of the microsphere.

The second microspheres preferably comprise from 90 wt% to 98 wt% structural units of a second monoethylenically unsaturated nonionic monomer, which may be the same or different from the first monoethylenically unsaturated nonionic monomer. It is further preferred that the ketone functional monomer be included in the second monoethylenically unsaturated monomer in the same concentration ranges as described for the phosphoric acid functional polymer particles. It is understood that "monomer" refers to one or more monomers.

Preferably, the aqueous dispersion of first microspheres is contacted with an excess of polymerizable organophosphate (or salt thereof) under polymerization conditions such that the resulting dispersion of organophosphate-functionalized second microspheres comprises unreacted organophosphate ester. The presence of unreacted (residual) polymerizable organophosphate or salt thereof is particularly advantageous if further fractionation of the second microspheres is desired. For example, it may be desirable to prepare T as calculated by the Fox equation_gA dispersion of second microspheres at less than 25 ℃, followed by further fractionation of the second microspheres with residual organophosphate and additional monoethylenically unsaturated nonionic monomer (a second stage ethylenically unsaturated nonionic monomer) (which may be the same as or different from the first stage monoethylenically unsaturated nonionic monomer) to produce microspheres having a T_gDomains less than 25 ℃ and T_gA dispersion of domain organophosphate functionalized third microspheres greater than 50 ℃.

In the case of the use of an initiator/redox couple, it has been found that the first pK of the remaining polymerizable organophosphate is lower if the pH is higher than the pH_aThe polymerization is carried out at a high pH of at least one unit, then the gel is further processedA significant reduction in formation occurs. Preferably, the polymerization step for preparing the aqueous dispersion of third microspheres is performed at a pH of at least 3, more preferably at least 4, more preferably at least 5 and most preferably at least 6 to preferably 12, more preferably to 10 and most preferably to 8. Thus, the polymerizable organophosphate used to prepare the aqueous dispersion of third microspheres is preferably present predominantly in the form of a salt, preferably such as a lithium, sodium, potassium, trialkylammonium or ammonium salt.

Additional polymerizable organophosphate may be added in further fractionation of the second microspheres, preferably within the desired pH range using an initiator redox/couple. It is especially preferred to prepare microspheres using a salt of formula II wherein each R is²Is H, and each R¹Is CH₃Or each R²Is CH₃And each R¹Is H; or formula III.

The aqueous dispersion of polymeric microspheres produced by preferred method a comprises crosslinked microspheres functionalized to have 0.05 to 5 weight percent structural units of formula I based on the weight of the microspheres.

In another preferred method of preparing an aqueous dispersion of polymerized multi-stage crosslinked microspheres (preferred method B), an aqueous dispersion of first microspheres (prepared as described in preferred method a) is contacted with a first stage monomer comprising 70 to 100 weight percent of a second monoethylenically unsaturated nonionic monomer to grow the first microspheres to form an aqueous dispersion of second microspheres, as described above, except that the polymerization is carried out in the presence of a nonionic polyalkylene oxide of a distyryl or tristyryl phenol or an anionic polyalkylene oxide salt of a distyryl or tristyryl phenol. The nonionic polyalkylene oxide or anionic polyalkylene oxide salt of distyryl or tristyryl phenol is represented by the compound of formula IV:

wherein each R' is independently C₁-C₄An alkyl group; r¹' is H, CH₂CR＝CH₂、CH＝CHCH₃Or 1-phenethyl- (R')_p(ii) a Each R²' is independently H, allyl, methyl, acrylate, methacrylate, or-CH₂CHR³OX; each R³' is independently H, methyl or ethyl; m is 0 to 5; n is 6 to 40; p is 0,1 or 2; and O-X is hydroxyl, methoxy, sulfate or phosphate. Preferably, R¹'is 1-phenethyl- (R')_n；R²' preferably H, CH₃Or an allyl group; m is preferably 0,1 or 2; n is 10 to 20; p is 0; and O-X is a sulfate or phosphate group. More preferred polyethylene oxide salts of tristyrylphenol are represented by the formula V:

wherein X is-SO₃H、-SO₃Y、-H₂PO₃、-HPO₃Y or-PO₃Y₂Wherein Y is Li⁺、Na⁺、K⁺Or NH₄ ⁺. An example of a commercially available compound having the formula II is Solvay Soprophor 4D/384 ammonium salt of a polyarylphenyl ether sulfate.

Another preferred oxirane salt of distyrylphenol or tristyrylphenol is represented by the compound of formula VI, where m is non-zero.

Where n is preferably from 12 to 18. A commercial example of a compound of formula VI is the E-Sperse RS-1684 reactive surfactant. Another example of a polyethylene oxide salt of distyrylphenol is represented by the formula VII:

a commercial example of a compound of formula IV is Hitenol AR-1025 reactive surfactant.

A subclass of compounds of structure IV (m ═ 0) can be prepared by reacting distyryl or tristyryl phenols with alkylene oxides (ethylene oxide, 1, 2-propylene oxide or 1, 2-butylene oxide) in the presence of a base such as an alkali or alkaline earth metal hydroxide, carbonate or bicarbonate, or an alkali metal hydride; this intermediate can then be neutralized to the corresponding diol, methoxylated with a methyl halide, chlorosulfonated with a sulfonyl chloride or phosphorylated with polyphosphoric acid. The compounds of formula VI can be prepared in the same manner except that the distyryl or tristyryl phenol is first reacted with an epihalohydrin, such as epichlorohydrin, in the presence of a base to form the corresponding monoglycidyl ether of the distyryl or tristyryl phenol, which is then reacted with an alkylene oxide.

Preferably, the aqueous dispersion of first microspheres is contacted with a salt of a compound of formula V or an excess of a compound of formula VI or a salt of formula VII under polymerization conditions such that the resulting dispersion of second microspheres preferably comprises a salt of a compound of formula V or an unreacted salt of a compound of formula VI. The presence of a salt of a compound of formula V, VI or VII is particularly advantageous if the second microspheres are further fractionated. For example, it may be desirable to prepare T as calculated by the Fox equation_gA dispersion of second microspheres less than 25 ℃, followed by further fractionation of the second microspheres under polymerization conditions with a salt of a compound of formula V, VI or VII and additional monoethylenically unsaturated nonionic monomer (a second stage monoethylenically unsaturated nonionic monomer) (which may be the same as or different from the first stage monoethylenically unsaturated nonionic monomer) to produce T_gDomains less than 25 ℃ and T_gA dispersion of third microspheres of domains greater than 50 ℃.

Preferably, the polymerization step for preparing the aqueous dispersion of third microspheres is performed at a pH of at least 3, more preferably at least 4, more preferably at least 5 and most preferably at least 6 to preferably 12, more preferably to 10 and most preferably to 8.

Additional compounds of formula IV, in particular salts of compounds of formula IV, may be added in the further fractionation of the second microspheres, preferably in the desired pH range in case an initiator/coupling agent is used.

The particle size and particle size distribution of the microspheres formed by preferred method B are similar to the distribution obtained by preferred method a.

It is also possible and sometimes preferred to prepare compositions having microspheres of different sizes, each microsphere having a low coefficient of variation; such formulations may be prepared, for example, from D₅₀Aqueous dispersion of microspheres having a particle size of 8 μm and D₅₀Blending of aqueous dispersions of microspheres with a particle size of 12 μm results in a coefficient of variation for each dispersion<20% to form a bimodal dispersion of microspheres with two modes of controlled particle size.

In a preferred aspect, the aqueous dispersion of polymeric microspheres produced by preferred method B comprises crosslinked microspheres functionalized to have 0.01 to 5 weight percent structural units of the compound of formula VI, based on the weight of the microspheres; in another preferred aspect, the composition further comprises 0.01 wt%, preferably 0.05 wt%, more preferably 0.1 wt%, and most preferably 0.2 wt% to 5 wt%, preferably to 3 wt%, more preferably to 2 wt%, and most preferably to 1 wt% of a compound of structure V, based on the weight of the microspheres.

Preferably, the polymeric organic microspheres functionalized with structural units of the compound of formula I, formula VI or formula VII and the composition further comprising the compound of formula V comprise substantially no phosphoethyl methacrylate (PEM), i.e. less than 0.09 wt%, more preferably less than 0.05 wt%, more preferably less than 0.01 wt%, and most preferably 0 wt% of structural units of the PEM, based on the weight of the polymeric organic microspheres.

The weight to weight ratio of the polymer particles to the crosslinked microspheres is in the range of 1.1:1, preferably 1.3:1, and more preferably 1.5:1 to 20:1, more preferably to 10:1, more preferably to 5:1, and most preferably to 3: 1.

Polysiloxanes are linear and/or branched polymers comprising repeating units of Si-O-Si groups and Si-alkyl groups; the polysiloxane optionally comprises, for example, Si-O-alkyl, Si-O-aryl, Si-OH, Si-H and/or Si-O-trialkylsilyl groups. Preferably, the polysiloxane is a linear polymer represented by the following structure:

wherein each R⁴Independently is C₁-C₃₀Alkyl, O-C₁-C₆Alkyl or H, provided that at least one R is⁴Is C₁-C₃₀An alkyl group; each R⁵Independently is C₁-C₃₀Alkyl, H or Si (R)⁶)₃(ii) a Wherein each R⁶Independently is C₁-C₆An alkyl group; and n is 4, preferably 10 to 10,000, preferably to 5000. Preferably, each R⁴Independently is C₁-C₆Alkyl, more preferably ethyl or methyl, and most preferably methyl; preferably, each R⁵Is H; and preferably R⁶Is methyl.

D of polysiloxane Polymer particles as measured by a Malvern particle size Analyzer 3000 particle size Analyzer₅₀The average particle size is in the range of 1 μm, preferably 2 μm to 20 μm, more preferably to 15 μm, and most preferably to 10 μm.

The rheology modifier can be any thickener capable of controlling the viscosity of the formulation to a desired level. Preferably, the concentration of rheology modifier is in the range of 0.2 wt%, more preferably 0.5 wt% to preferably 3, more preferably to 2 wt% based on the weight of the composition. Examples of suitable rheology modifiers include hydrophobically modified ethylene oxide urethane polymers (HEUR), hydroxyethyl cellulose (HEC), alkali swellable polymers (ASE), and hydrophobically modified alkali swellable polymers (HASE).

The composition further comprises a refractive index>1.9 opacifying pigments, preferably TiO₂. For dark base paint compositions, TiO₂(iii) a Pigment Volume Concentration (PVC) of between 1 and 10; in such compositions, the paint also includes from 5% to 20% by weight solids of a non-white colorant, based on the weight of the paint composition. The colorant may be organic or inorganic; examples of the organic colorant include phthalocyanine blue, phthalocyanineGreen, monoanilide yellow, benzidine yellow, benzimidazolone yellow, heterocyclic yellow, DAN orange, quinacridone magenta, quinacridone violet, organic reds including metallized azo reds and non-metallized azo reds. Inorganic colorants include carbon black, lampblack, black iron oxide, yellow iron oxide, brown iron oxide, and red iron oxide.

For non-dark base paint compositions, the preferred TiO is₂Is in the range of 12, more preferably 15 to 25, more preferably to 22. TiO 2₂The PVC is defined by the following equation:

PVC_(TiO2)＝(TiO₂solid volume/total solid volume) x 100

Wherein "total solids volume" includes TiO₂Extender (if present), polymer particles and microspheres, and other solids (e.g., opaque polymers) that make up the volume of the final dried coating.

Preferably, TiO as measured using a Brookhaven BI90 particle analyzer₂The particles have a z-average particle size in the range of 200nm, more preferably 250nm to 400nm, more preferably to 350nm, and most preferably to 300 nm.

The composition of the invention also comprises less than 10 wt%, more preferably less than 5, more preferably less than 1 wt%, and most preferably 0 wt% of polyurethane, more specifically dispersed polyurethane particles.

In another aspect, the compositions of the present invention comprise a non-white colorant at a concentration in the range of 5 weight percent, preferably 10 weight percent to 20 weight percent solids and substantially no inorganic extender having a refractive index in the range of 1.0 to 1.9. As used herein, "substantially absent" refers to any extender having a refractive index within the specified range that is less than 15, preferably less than 5, more preferably less than 1, and most preferably 0 PVC. Examples of extenders not substantially present in the composition include silica, silicates and aluminosilicates such as talc, clay, mica and sericite; CaCO₃(ii) a Nepheline syenite; feldspar; wollastonite; kaolinite; dicalcium phosphate; and diatomaceous earth.

The compositions of the present invention are conveniently prepared by mixing together an aqueous dispersion of polymer particles (i.e., latex) with an aqueous dispersion of polymeric organically cross-linked microspheres, an aqueous dispersion of a polysiloxane, a slurry or powder of an opaque white pigment, and a rheology modifier. Other additives may also be included in the composition, such as coalescing agents, surfactants, dispersants, biocides, other opacifying pigments, such as opacifying polymers, colorants, waxes, defoamers, and neutralizing agents.

The compositions of the present invention provide a means of preparing matte finish coatings having the burnish resistance of semi-gloss paints.

Examples of the invention

Molecular weight determination of acrylic oligomer seed

The dispersion of acrylic oligomer seeds (0.1g) was dissolved in tetrahydrofuran (THF, 8g, HPLC grade) and then filtered through a 0.45 μm PTFE filter. Size Exclusion Chromatography (SEC) was performed on a liquid chromatograph equipped with an Agilent (Agilent) model 1100 isocratic pump, vacuum degasser, variable injection size autosampler, and Agilent 1100HPLC G1362A refractive index detector. Data were processed using Agilent chemical workstation version B.04.03 and Agilent GPC-Addon version B.01.01. GPC separation was carried out using a GPC column set composed of two PLgel Mixed D columns (300X 7.5mm ID, 5 μm) and a guard column (50X 7.5mm ID, 5 μm) at a flow rate of 1 mL/min using THF as an eluent. Ten polystyrene standards were fitted with a 1 st order fit calibration curve. Weight average molecular weight (M) of the standards_w) The following were used: 630; 1,370, respectively; 2,930, respectively; 4,900; 10,190; 22,210, respectively; 50,550, respectively; 111,400, respectively; 214,700, respectively; and 363,600. Data was collected using a Refractive Index (RI) detector.

DCP particle size setting method for acrylic oligomer seeds and microspheres

Particle size and distribution were measured using a disk centrifuge photometric sedimentometer (DCP, pregrieville, louisiana) by separation mode of centrifugation and sedimentation via sucrose gradient. By adding 1 to 2 drops of oligomer seed dispersion or microsphere dispersion to 10mL Deionized (DI) water containing 0.1% sodium lauryl sulfate, then injecting 0.1mL sample into a fill with 15g/mSamples were prepared in a rotating disk of L sucrose gradient. For oligomer seeds, a 0-4% sucrose gradient disk rotating at 10,000rpm was used, and 596-nm polystyrene calibration standards were injected prior to injection of the samples. For microspheres, a 2% -8% sucrose gradient disk spinning at 3,000rpm was used, and a 9- μm polystyrene calibration standard was injected before injecting the sample. The median weight average (D) was calculated using the algorithm of the instrument₅₀) Particle size and Coefficient of Variation (CV).

Method for testing burnish resistance

Each coating was drawn down on a Leneta black vinyl card using a 3 mil Bird applicator and then dried at 25 c and 50% relative humidity for 7 days. After the drying period, the initial gloss values were measured at three different sections on the membrane using a BYK Micro-Tri-gloss meter. The buffing test was performed using a Gardner abrasion tester. The grinding boat was wrapped with four layers of fresh cheesecloth and placed on top of the coating. The coating was scrubbed with an abrasive boat wrapped with cheesecloth for 500 cycles. After 500 cycles were completed, the gloss values of the coatings were measured on the same three parts. The average change in Δ 85 ° gloss is reported.

Intermediate example 1-preparation of an aqueous Dispersion of acrylic beads to which phosphate ester is added

An aqueous dispersion of acrylic oligomer seeds (33% solids, 67 butyl acrylate/18 n-dodecyl mercaptan/14.8 methyl methacrylate/0.2 methacrylic acid) was prepared essentially as described in US 8,686,096 examples 1 and 5 (columns 19 and 20), with median weight average particle size (D), as determined by DCP₅₀) 885nm and a coefficient of variation of 5%, and a weight average molecular weight of 2532 g/mol. This seed was used to prepare microspheres for all examples and comparative examples described herein.

An initiator emulsion was prepared by combining deionized water (4.9g), Rhodacal DS-4 branched alkylbenzene sulfonate (DS-4, 0.21g, 22.5% aqueous solution), 4-hydroxy-2, 2,6, 6-tetramethylpiperidine (4-hydroxy TEMPO, 0.4g, 5% aqueous solution), tert-amyl peroxy-2-ethylhexanoate (TAPEH, 5.42g, 98% active) in separate vials, then emulsifying with a homogenizer at 15,000rpm for 10 minutes. The initiator emulsion was then added to the acrylic oligomer seed (4.2g, 32% solids) dispersion in another vial and mixed for 60 minutes. A cast monomer emulsion (cast ME) was prepared by combining deionized water (109.5g), Solvay Sipomer PAM-600 phosphate of PPG monomethacrylate (PAM-600, 2.18g, 60% active), DS-4(4.13g, 22.5% solution), 4-hydroxy TEMPO (0.2g, 5% aqueous solution), n-butyl acrylate (BA, 234.8g), and allyl methacrylate (ALMA, 15.1g) in separate flasks. To a 5-L round bottom flask (reactor) equipped with a stirrer, condenser and temperature probe was added deionized water (1575 g). The reactor was heated to 70 ℃, after which the initiator and oligomer seed mixture was added to the reactor and the shot ME was fed into the reactor over 15 minutes. After an induction period of 30 minutes, the resulting exotherm caused the reactor temperature to rise to 80 ℃.

A first monomer emulsion (ME1, prepared by combining deionized water (328.5g), PAM-600(6.5g), DS-4(12.4g, 22.5% solution), 4-hydroxy TEMPO (0.6g, 5% aqueous solution), BA (738.7g), and ALMA (47.2 g)) was then fed into the reactor over 55 minutes. After 20 minutes of holding, the NH was turned off within 3 minutes₄OH (0.8g, 28% aqueous solution) was fed to the reactor.

The reactor temperature was cooled to and maintained at 75 ℃ after which the FeSO was cooled₄·7H₂O (11g, 0.15% aqueous solution) and EDTA tetrasodium salt (2g, 1% aqueous solution) were mixed and added to the reactor. A second monomer emulsion (ME2) was prepared by combining deionized water (90g), DS-4(3.2g, 22.5% solution), PAM-600(2.20g), methyl methacrylate (MMA, 250.0g), and ethyl acrylate (EA, 10.5g) in separate flasks. ME2, t-butyl hydroperoxide solution (t-BHP, 1.44g (70% aqueous solution) in 100g water) and erythorbic acid (IAA, 1.05g in 100g water) were fed to the reactor over 45 minutes. The remaining monomer was then flushed by feeding a solution of t-BHP (2.54g (70% aqueous solution) in 40g of water) and IAA (1.28g in 40g of water) into the reactor over 20 minutes. The resulting dispersion was filtered through a 45- μm sieve; the gel remaining on the sieve was collected and dried (655 ppm). Analysis of the filtrate percent solids (32.8%),Coefficient of variation (<20%) and particle size (8.7 μm as measured by DCP).

Intermediate example 2 preparation of Silicone Dispersion 1

DOWSIL 3-3602PDMS (225.0g, kinematic viscosity 80,000 centistokes (cSt) measured at 25 ℃), Polystep A-16-22 sodium salt of branched alkyl benzene sulfonic acid (A-16-22, 8.1g, 22.0% aqueous solution) and deionized water (9.6g) were added to a plastic cup (1L size designed for a fast mixer DAC 600 FVZ). The plastic cup was capped and placed in the mixer and the cup was mixed at 2350rpm for 2 minutes. Additional deionized water (57.4g) was added to the cup, which was then mixed in the mixer for an additional 2 minutes. The silicone dispersion 1 was analyzed for percent solids (75.5%) and particle size (4.6 μm as measured by a Malvern particle size analyzer 3000 particle size analyzer).

Intermediate example 3 preparation of Silicone Dispersion 2

DOWSIL SFD-12PDMS (225.0g, kinematic viscosity 4000cSt, measured at 25 ℃), A-16-22(8.1g, 22.0% aqueous solution) and deionized water (9.7g) were added to a 1-L plastic cup (designed for a fast mixer DAC 600FVZ mixer). The plastic cup was capped and placed in the mixer and the cup was mixed at 2350rpm for 2 minutes. Additional deionized water (54.4g) was added to the cup, which was then mixed in the mixer for an additional 2 minutes. The silicone dispersion 2 was analyzed for percent solids (75.2%) and particle size (3.3 μm as measured by a Malvern particle size analyzer 3000 particle size analyzer).

Intermediate example 4 preparation of Silicone Dispersion 3

Mixing XIAMERET at 3500rpm using a fast mixer DAC 150FVZ mixer^TMOFX-5563 fluid (4g), TERGITOL^TM15-S-40 surfactant (10g) and UCON^TM75-H-90000 Lubricants (4g) for 30 seconds. (XIAMERET, TERGITOL and UCON are trademarks of Dow Chemical Company or Its subsidiary (The Dow Chemical Company or Its arts Affilates.)

A portion of this mixture (12.6g) was combined with α, ω -hydroxy-terminated polydimethylsiloxane (35g, kinematic viscosity 2 million cSt) and glass beads (16g, 3mm diameter). The contents were mixed at 3500rpm for 2 minutes and then allowed to cool to room temperature; mixing was then repeated for 2 minutes. Water (2.5g) was then added to the mixture and the contents were mixed at 3500rpm for 1 minute. Additional water (19.7g) was added in three portions, each addition followed by mixing at 3500rpm for 30 seconds; the resulting dispersion (68% solids) had a volume average median diameter of 3.5 μm as measured by a Malvern Masterizer 3000 particle analyzer.

Comparative example 1 preparation of a paint without polyorganosiloxane

Mixing RHOPLEX^TMVSR-1049LOE acrylic emulsion (194.99g) and intermediate example 1 acrylic beads (116.99g) were mixed together in a 0.5-L vessel with overhead stirring for 2 minutes, followed by slow addition of Kronos 4311TiO₂(131.42 g). Mixing was continued for 5 minutes, after which Texanol coalescing agent (5.19g) and BYK-022 defoamer (0.13g) were slowly added to the mixture. Mixing is continued for 2 to 3 minutes, at which point the stirring speed is increased; then ACRYSOL was added slowly^TMRM-2020NPR rheology modifier (14.15g) followed by addition of ACRYSOL under high speed stirring^TMRM-8W rheology modifier (2.23g) and water (42.50 g); then 28% aqueous ammonia (0.11g) was added and mixing was continued for an additional 5 to 10 minutes. The final mixture is a paint containing the colored microspheres. (ACRYSOL and RHOPLEX are trademarks of the Dow chemical company or its subsidiary companies.)

Comparative example 2 preparation of a lacquer with Water-soluble polyorganosiloxane

Will DOWSIL^TM402LS polyorganosiloxane (0.20g) was added with stirring to a portion of the formulation of comparative example 1 (70.0 g). Since this polyorganosiloxane is water soluble, no dispersion of discrete particles is formed.

Comparative example 3-preparation of a paint with polyorganosiloxane particles < 1-micron size

ROSILK is added^TM2000 polyorganosiloxane (0.454g, D)₅₀Particle size 0.5 μm) was added to a portion (70.0g) of the formulation of comparative example 1 after stirring.

EXAMPLE 1 preparation of a paint with a size of >1- μm polyorganosiloxane

Silicone dispersion 1(0.27g) was post-added to a portion of the comparative example 1 formulation (70.0g) with stirring.

EXAMPLE 2 preparation of polyorganosiloxane paints with a size >1- μm

Silicone dispersion 2(0.27g) was post-added to a portion of the comparative example 1 formulation (70.0g) with stirring.

Example 3-preparation of a paint with polyorganosiloxane microspheres >1- μm size

Silicone dispersion 3(0.30g, 4 μm) was post-added to a portion of the comparative example 1 formulation (70.0g) with stirring.

Table 1 illustrates the effect of polyorganosiloxane additives on burnish resistance. The additive refers to a polyorganosiloxane additive. In all examples where additives were used, the weight percent of the additive was 1 weight percent based on the binder solids and acrylic beads.

TABLE 1 burnish resistance data

Paint ID	Additive agent	Δ 85 ° (average)	std
				Comparative example 1	Is free of	10.2	0.4
Comparative example 2	DOWSILTM402LS	3.1	0.3
				Comparative example 3	ROSILKTM2000	3.6	0.3
Example 1	Silicone Dispersion 1	1.0	0.2
				Example 2	Silicone Dispersion 2	0.5	0.0
Example 3	Silicone Dispersion 3	1.0	0.2

The results show that in the case of silicone particle sizes >1 μm, the burnish resistance is significantly improved in the presence of the silicone dispersion. Notably, the molecular weight of the silicone additive did not have any significant effect on burnish resistance, indicating that various polysiloxanes are effective as long as the particle size is >1 μm.