Acrylate emulsion composition and method for producing acrylate emulsion

Abstract

The invention provides an acrylate emulsion composition and a manufacturing method of an acrylate emulsion. The acrylate emulsion composition comprises a plurality of monomers, wherein the monomers comprise methyl methacrylate, butyl acrylate and styrene; a polymerization initiator, wherein the polymerization initiator comprises ammonium persulfate; a main emulsifier, wherein the main emulsifier comprises dioctyl sodium sulfosuccinate; and a secondary emulsifier, wherein the secondary emulsifier comprises potassium stearate. By adding the specific auxiliary emulsifier, the solid content of the acrylate emulsion is increased.

Description

Technical Field

[0001] This invention relates to an acrylic emulsion composition and a method for manufacturing an acrylic emulsion, particularly to an acrylic emulsion composition with high solids content and a method for manufacturing an acrylic emulsion. Background Technology

[0002] Emulsion polymerization involves dispersing monomers in water to form an emulsion using an emulsifier and mechanical stirring. A polymerization initiator is then added to initiate the polymerization reaction. This method offers rapid polymerization, readily yielding polymers with high degrees of polymerization, i.e., emulsion polymers, which produce stable emulsions.

[0003] However, the solid content of emulsions produced by existing emulsion polymerization methods is generally no more than 35%, resulting in low production efficiency. Furthermore, the water content of emulsions produced by existing methods is relatively high, which increases the energy and cost required for subsequent drying processes.

[0004] In view of this, there is an urgent need to provide an acrylic emulsion composition and a method for manufacturing an acrylic emulsion, so as to increase the solid content of the acrylic emulsion and reduce the water content of the acrylic emulsion. Summary of the Invention

[0005] One embodiment of the present invention provides an acrylic emulsion composition, which increases the solid content of the acrylic emulsion and reduces the water content of the acrylic emulsion by adding a co-emulsifier.

[0006] Another aspect of the present invention is to provide a method for manufacturing an acrylate emulsion, which improves the chemical stability of the acrylate emulsion by controlling specific monomer addition methods and times.

[0007] According to one aspect of the present invention, an acrylate emulsion composition is provided, comprising a plurality of monomers, wherein the monomers include methyl methacrylate, butyl acrylate, and styrene; a polymerization initiator, wherein the polymerization initiator includes ammonium persulfate; a primary emulsifier, wherein the primary emulsifier includes dioctyl sodium sulfosuccinate; and a secondary emulsifier, wherein the secondary emulsifier includes potassium stearate. The acrylate emulsion composition is 100 parts by weight, the primary emulsifier is 1 to 4 parts by weight, and the secondary emulsifier is 0.1 to 1 part by weight.

[0008] According to one embodiment of the present invention, the above-mentioned acrylate emulsion composition further includes a pH adjuster and a chain transfer agent, wherein the acrylate emulsion composition is 100 parts by weight, the pH adjuster is 0.5 parts by weight to 2.5 parts by weight, and the chain transfer agent is 0.02 parts by weight to 0.04 parts by weight.

[0009] According to one embodiment of the present invention, the mass ratio of methyl methacrylate to butyl acrylate is 5:1 to 7:1.

[0010] According to one embodiment of the present invention, the acrylate emulsion composition comprises 100 parts by weight, methyl methacrylate comprises 35 to 45 parts by weight, butyl acrylate comprises 7 to 9 parts by weight, and styrene comprises 1 to 3 parts by weight.

[0011] According to one embodiment of the present invention, the above-mentioned acrylate emulsion composition is 100 parts by weight, and the polymerization initiator is 0.5 to 1.5 parts by weight.

[0012] According to another aspect of the present invention, a method for manufacturing an acrylic emulsion is provided. The method includes mixing a primary emulsifier and water to obtain an emulsifying solvent; heating the emulsifying solvent to a first temperature; adding a polymerization initiator to the emulsifying solvent to obtain a first solution, wherein the polymerization initiator comprises ammonium persulfate; adding methyl methacrylate and butyl acrylate to the first solution to obtain a second solution, wherein the addition time of methyl methacrylate and butyl acrylate is 2 hours to 4 hours; heating the second solution to a second temperature, wherein the second temperature is higher than the first temperature; adding styrene to the second solution to obtain a third solution; and adding a secondary emulsifier to the third solution to obtain an acrylic emulsion, wherein the secondary emulsifier comprises potassium stearate.

[0013] According to one embodiment of the present invention, the first temperature is 40°C to 70°C, and the second temperature is 60°C to 80°C.

[0014] According to one embodiment of the present invention, after adding styrene to the second solution, the above method further includes a stirring step, wherein the stirring speed of the stirring step is 200 rpm to 450 rpm.

[0015] According to one embodiment of the present invention, the second solution undergoes a reaction for 1 to 3 hours.

[0016] According to one embodiment of the present invention, the third solution is subjected to a reaction for 0.5 hours to 2 hours.

[0017] The acrylic emulsion composition and manufacturing method of the present invention utilize specific co-emulsifiers to increase the solid content and reduce the water content of the acrylic emulsion. Furthermore, by controlling specific monomer addition methods and timing, the chemical stability and process uptime of the acrylic emulsion are improved. Detailed Implementation

[0018] The manufacture and use of embodiments of the present invention are discussed in detail below. However, it will be understood that the embodiments provide many applicable inventive concepts that can be implemented in a wide variety of specific contexts. The specific embodiments discussed are for illustrative purposes only and are not intended to limit the scope of the invention.

[0019] As used in this invention, “around,” “about,” “approximately,” or “substantially” generally mean within 20 percent, 10 percent, or 5 percent of the stated value or range.

[0020] As described above, this invention provides an acrylic emulsion composition and a method for manufacturing an acrylic emulsion. By adding specific co-emulsifiers, the solid content of the acrylic emulsion is increased, and the water content is reduced. Furthermore, by controlling specific monomer addition methods and times, the chemical stability of the acrylic emulsion and the process uptime are improved.

[0021] The acrylate emulsion composition of the present invention comprises a variety of monomers, polymerization initiators, primary emulsifiers, and secondary emulsifiers. In some embodiments, the monomers comprise at least methyl methacrylate, butyl acrylate, and styrene. In some embodiments, the mass ratio of methyl methacrylate to butyl acrylate is from about 5:1 to about 7:1. Controlling the mass ratio of methyl methacrylate to butyl acrylate within the aforementioned range can prevent methyl methacrylate from undergoing self-polymerization during the emulsion polymerization reaction, thus affecting the reactivity of the emulsion polymerization reaction.

[0022] In some embodiments, the acrylate emulsion composition comprises 100 parts by weight of methyl methacrylate, about 35 parts by weight to about 45 parts by weight of methyl methacrylate, about 7 parts by weight to about 9 parts by weight of butyl acrylate, and about 1 part by weight to about 3 parts by weight of styrene. The content of each monomer must be controlled within the aforementioned range to obtain an acrylate emulsion with better chemical stability after the emulsification polymerization reaction.

[0023] In some embodiments, the polymerization initiator comprises ammonium persulfate (APS). This invention utilizes ammonium persulfate to replace the commonly used potassium persulfate, thereby increasing the reaction rate of the emulsion polymerization reaction and providing a recombination system with better mechanical stability, thus improving the physical properties and chemical stability of the acrylate emulsion. In some embodiments, based on 100 parts by weight of the acrylate emulsion composition, the polymerization initiator is approximately 0.5 parts by weight to approximately 1.5 parts by weight. Controlling the amount of polymerization initiator within the aforementioned range allows for a better reaction rate in the emulsion polymerization reaction.

[0024] In some embodiments, the primary emulsifier comprises sodium dioctyl sulfosuccinate, which provides good emulsion mechanical stability. In the foregoing embodiments, based on 100 parts by weight of the acrylate emulsion composition, the primary emulsifier is approximately 1 part by weight to approximately 4 parts by weight, preferably approximately 2 parts by weight to approximately 3 parts by weight. Controlling the amount of primary emulsifier within the foregoing range can prevent gelation reactions during the emulsification polymerization process.

[0025] In some embodiments, the co-emulsifier comprises potassium stearate to reduce the water content of the acrylate emulsion and increase the solids content. In the foregoing embodiments, based on 100 parts by weight of the acrylate emulsion composition, the co-emulsifier is approximately 0.1 parts by weight to approximately 1 part by weight. By controlling the amount of co-emulsifier within the foregoing range, the water content of the acrylate emulsion can be appropriately controlled, thereby improving the subsequent drying rate.

[0026] In some embodiments, the acrylate emulsion composition further comprises water, wherein the water is about 35 to about 45 parts by weight based on 100 parts by weight of the acrylate emulsion composition.

[0027] In some embodiments, the acrylate emulsion composition may selectively include a pH adjuster and a chain transfer agent. In some embodiments, the pH adjuster may be sodium hydroxide, wherein based on 100 parts by weight of the acrylate emulsion composition, the pH adjuster is present in amounts from about 0.5 parts by weight to about 2.5 parts by weight. Controlling the amount of pH adjuster within the aforementioned range allows the reaction to proceed at a specific pH environment. In some embodiments, the chain transfer agent may be a thiol, wherein based on 100 parts by weight of the acrylate emulsion composition, the chain transfer agent is present in amounts from about 0.02 parts by weight to about 0.04 parts by weight. Controlling the chain transfer agent within the aforementioned range allows control over the degree of polymerization of the resulting polymer.

[0028] This invention also provides a method for manufacturing an acrylic emulsion to obtain an acrylic emulsion with high solids content, thereby reducing the water content of the acrylic emulsion, increasing the drying speed, and reducing energy consumption. It should be understood that "high solids content" refers to a solids content of 45% or more, for example, 45% to 50%.

[0029] The following describes the manufacturing process of an acrylic emulsion. First, distilled water and a primary emulsifier are mixed and stirred for approximately 1 to 2 hours to obtain an emulsifying solvent. In some specific examples, the primary emulsifier may be sodium dioctyl sulfosuccinate. In some embodiments, the emulsifying solvent may selectively include a pH adjuster (e.g., sodium hydroxide) and a chain transfer agent (e.g., thiol). In some embodiments, the stirring speed in the aforementioned stirring step is approximately 200 rpm to approximately 450 rpm. This specific range of stirring speeds improves the stability of the resulting acrylic emulsion.

[0030] Next, the emulsifying solvent is heated to a first temperature, and a polymerization initiator is added to obtain a first solution. In some embodiments, the first temperature is from about 40°C to about 70°C, preferably 65°C. In some specific examples, the polymerization initiator may be ammonium persulfate. Adding ammonium persulfate at the first temperature within the aforementioned range helps to give the subsequently prepared emulsion better stability.

[0031] Then, methyl methacrylate and butyl acrylate are continuously added to the first solution, and the reaction is carried out for about 1 hour to about 3 hours to obtain a second solution. In some embodiments, the addition time is about 2 hours to about 4 hours. The addition time must be controlled within the aforementioned range to control the molecular weight of the obtained polymer and the reaction rate of the polymerization reaction, thereby controlling the chemical stability of the subsequently prepared emulsion. This avoids the generation of heat of reaction due to the polymerization reaction of a large number of monomers, which would affect the stability of the emulsion.

[0032] After the above-mentioned reaction time is completed, the second solution is heated to a second temperature, and styrene is added all at once to obtain a third solution. The reaction is then continuously stirred for about 0.5 hours to about 2 hours. In some embodiments, the second temperature is higher than the first temperature, and the second temperature is about 60°C to about 80°C. Controlling the reaction time and the second temperature within the aforementioned range allows the subsequently prepared emulsion to have better physical properties. In some embodiments, the stirring speed during the aforementioned stirring reaction is about 200 rpm to about 450 rpm. This specific range of stirring speeds allows for better stability of the prepared acrylate emulsion.

[0033] After the above reaction is completed, a co-emulsifier is added to the third solution to obtain an acrylic emulsion. In some embodiments, the co-emulsifier is potassium stearate. By adding the co-emulsifier, the solids content of the acrylic emulsion can be increased, thereby improving the emulsion production efficiency. Furthermore, high-solids acrylic emulsions have lower water content, resulting in faster subsequent drying and lower energy consumption. In addition, high-solids acrylic emulsions can reduce unit transportation and storage costs.

[0034] Based on the above, the present invention provides an acrylic emulsion composition and a method for manufacturing an acrylic emulsion. By adding specific co-emulsifiers, the solid content of the acrylic emulsion is increased, and the water content is reduced. Furthermore, by controlling specific monomer addition methods and times, the chemical stability of the acrylic emulsion and the process uptime are improved, thus better meeting the needs of industrial production.

[0035] Although the present invention has been disclosed above with reference to various embodiments, it is not intended to limit the present invention. Those skilled in the art can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

Claims

1. An acrylic emulsion composition, characterized in that, Include: Multiple monomers, wherein the multiple monomers include methyl methacrylate, butyl acrylate and styrene; A polymerization initiator, wherein the polymerization initiator comprises ammonium persulfate; Primary emulsifier, wherein the primary emulsifier comprises sodium dioctyl sulfosuccinate; and The secondary emulsifier comprises potassium stearate, and based on 100 parts by weight of the acrylate emulsion composition, the primary emulsifier comprises 1 to 4 parts by weight, and the secondary emulsifier comprises 0.1 to 1 part by weight.

2. The acrylate emulsion composition according to claim 1, characterized in that, Also includes: pH adjuster; and Chain transfer agent, wherein the acrylate emulsion composition comprises 100 parts by weight, the pH adjuster comprises 0.5 to 2.5 parts by weight, and the chain transfer agent comprises 0.02 to 0.04 parts by weight.

3. The acrylate emulsion composition according to claim 1, characterized in that, The mass ratio of methyl methacrylate to butyl acrylate is 5:1 to 7:

1.

4. The acrylate emulsion composition according to claim 1, characterized in that, Based on the acrylate emulsion composition being 100 parts by weight, the methyl methacrylate being 35 to 45 parts by weight, the butyl acrylate being 7 to 9 parts by weight, and the styrene being 1 to 3 parts by weight.

5. The acrylate emulsion composition according to claim 1, characterized in that, Based on the acrylate emulsion composition being 100 parts by weight, the polymerization initiator being 0.5 to 1.5 parts by weight.

6. A method for manufacturing an acrylic emulsion, characterized in that, Include: Mix the primary emulsifier and water to obtain an emulsified solvent; Heating the emulsified solvent to a first temperature; A polymerization initiator is added to the emulsifying solvent to obtain a first solution, wherein the polymerization initiator comprises ammonium persulfate; Methyl methacrylate and butyl acrylate are added to the first solution to obtain a second solution, wherein the addition time of methyl methacrylate and butyl acrylate is 2 to 4 hours; The second solution is heated to a second temperature, wherein the second temperature is greater than the first temperature; Styrene is added to the second solution to obtain a third solution; as well as A secondary emulsifier is added to the third solution to obtain the acrylate emulsion, wherein the secondary emulsifier comprises potassium stearate.

7. The method for manufacturing an acrylic emulsion according to claim 6, characterized in that, The first temperature is 40°C to 70°C, and the second temperature is 60°C to 80°C.

8. The method for manufacturing an acrylic emulsion according to claim 6, characterized in that, Also includes: After the styrene is added to the second solution, a stirring step is performed, and the stirring speed of the stirring step is 200 rpm to 450 rpm.

9. The method for manufacturing an acrylic emulsion according to claim 6, characterized in that, The second solution is reacted for 1 to 3 hours.

10. The method for manufacturing an acrylic emulsion according to claim 6, characterized in that, The third solution undergoes a reaction for 0.5 to 2 hours.