Method of emulsion polymerization

Abstract

A method has been disclosed of preparing ultrafine hydrophobic latex particles of polymers and copolymers by free radical emulsion polymerization in a water-based system, making use therefor, in order to polymerize or copolymerize monomers or monomer mixtures respectively, of at least one compound selected from the group consisting of dimers and cobalt complexes, acting as a chain transfer agent (CTA), wherein said latex particles have an average particle size of less than 100 nm, being more than 10% lower than if prepared in the absence of said CTA, characterized in that said polymerization is conducted in a water-based reaction in the presence of a chain transfer agent and of a surfactant, wherein said surfactant is present in a concentration versus said monomer or monomer mixture of from 5 up to 25% by weight for a non-ionic surfactant or from 0.05 up to 10% by weight for an ionic surfactant, more particularly a surfactant in a concentration below twice its critical micelle concentration.

Description

[0001] The application claims the benefit of U.S. Provisional Application No. 60 / 264,567 filed Jan. 26, 2001.[0002] The present invention relates to a method of emulsion polymerization making use therefor of a group of selected pure dimers acting as addition fragmentation chain transfer agents and of cobalt complexes as catalytic chain transfer agents (CTA's).[0003] Dimers which are often used in order to control the molecular weight in solution polymerizations are e.g. the .alpha.-methyl styrene dimer (CAS 6144-04-3 or 6362-80-7) and MMA (methyl methacrylate) dimer (CAS No. 71674-93-6 or 28261-32-7). For control of molecular weight in emulsion polymerizations only the .alpha.-methylstyrene dimer has been used by Japan Synthetic Rubber Co U.S. Pat. Nos. 5,637,644 and 5,444,118) until now.[0004] In JP-A 11-292907 e.g. Sekisui was using the .alpha.-methylstyrene dimer in a surfactant free emulsion polymerization of styrene which was resulting in the synthesis of a polymer latex having...

AI Technical Summary

Benefits of technology

[0016] It is a further object of the invention to moreover provide a (co)polymer latex, wherein said small (ultrafine) particles show a decreased degree of polydispersity (low polydispersity index).

[0079] According to the present invention said ultrafine hydrophobic latex particles of polymers and, prepared according to the method as disclosed herein, are suitable for use in printing plates for computer-to-plate or computer-to-press applications, including lithography and flexography, in silver halide based graphic, cinematographic and micrographic film materials, in medical diagnostic or recording photographic film materials, in photoresist applications and in ink-jet media. Use of said hydrophobic (co)polymer latex particles in coated layers as e.g. in materials for ink-jet applications moreover leads to the desired advantage of lower load of the layers with said surfactants and to reduction of disadvantageous "bleeding" effects, resulting therefrom. The fine polymer particles can be used as organic pigments in ink-jet media, instead of the usually employed inorganic pigments, such as silica and aluminum oxide. Using such ultrafine latices the desired gloss can be obtained with good drying characteristics. Otherwise a sharp polarity switch occurs between hydrophobic and hydrophilic states in applications where it is desired, as e.g. in printing plates, computer-to-plate and computer-to-press applications. In graphic or medical silver halide film materials transparency is very important. In order to obtain an hard scratch resistant films, such as in backing layers, polymers with a high glass transition temperature are used. In order to obtain sufficient film formation NMP (N-methyl pyrrolidone) was added. In order to improve film formation with addition of less NMP, the ultrafine latex polymers prepared according to the method of the present invention are useful. As an additional advantage use of lower amounts of NMP is environmentally more attractive and acceptable.

[0081] Application of the method of the present invention clearly illustrates that the (purified) chain transfer agent used in the water-based emulsion polymerization reaction without a prior solution polymeriza-tion reaction step is not only influencing molecular weight of the polymer, but also has a remarkable influence on the size of the latex particles thus obtained in that, according to the method of the present invention particle sizes of less than 100 nm, more preferably in the range from 10 to 90 nm and even more preferably in the range from 20 to 70 nm are easily available, wherein a reduction in particle size of at least 10%, and more preferably of more than 20% less than if prepared in the absence of said CTA has been attained. Particle sizes were always measured with a Brookhaven BI90 particle sizer.

Problems solved by technology

When longer oligomeric radicals are present in a latex particle, re-entry in the aqueous phase is difficult due to the limited water solubility.

So it is e.g. well-known that is difficult to obtain small particle sizes in emulsion polymerization, without making use of high surfactant or initiator concentrations.

In that case said high concentration of surfactant may lead to bleeding of ink and to an inferior image quality.

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