Continuous bulk polymerization and esterification process and compositions

Abstract

A continuous bulk polymerization and esterification process includes continuously charging into a reaction zone at least one ethylenically unsaturated acid-functional monomer and at least one linear or branched chain alkanol having greater than 11 carbon atoms. The process includes maintaining a flow rate through the reaction zone sufficient to provide an average residence time of less than 60 minutes and maintaining a temperature in the reaction zone sufficient to produce a polymeric product incorporating at least some of the alkanol as an ester of the polymerized ethylenically unsaturated acid-functional monomer. The polymeric product is used in various processes to produce water-based compositions including emulsions and dispersions such as oil emulsions, wax dispersions, pigment dispersions, surfactants and coatings which contain the polymeric product. A polymeric surfactant includes at least one ethylenically unsaturated acid-functional monomer which has been radically incorporated into the polymeric surfactant and at least one ester of the incorporated ethylenically unsaturated acid-functional monomer which has a linear or branched chain alkyl group with greater than 11 carbon atoms. The molar critical micelle concentration of the polymeric surfactant is less than 1.0×10−2 moles / liter. Aqueous 2 percent solutions of certain polymeric surfactants have a surface tension of less than 45 mN / m at 30° C. and exhibit a decrease in surface tension of at least 5 mN / m as the temperature warms from 30° C. to 50° C.

Description

FIELD OF THE INVENTION The present invention relates to a bulk polymerization and esterification process for maximizing the conversion of an aliphatic alkanol to an ester in a radically-initiated polymerization of an ethylenically unsaturated acid-functional monomer, to the polymeric products produced by the process, to polymeric products, to processes for preparing emulsions and dispersions utilizing the polymeric products, and to overprint varnishes (OPVs), inks, coatings, surfactants, adhesives, paints, primers, and floor polishes containing the polymeric products. BACKGROUND OF THE INVENTION Conventional solvent-based industrial finishes and coatings have presented many problems to date. Organic solvents can pollute the workplace and environment. In addition, many organic solvents are readily ignited, toxic, expensive, and lower the quality of finishes, and they can add undesirable colors to an otherwise colorless finish. As a replacement for these solvent-based finishes, the ...

AI Technical Summary

Benefits of technology

Still another object of the invention is to provide a process for improving the viscosity profile of an aqueous pigment dispersion which includes adding the polymeric product of the continuous bulk polymerization and esterification process to an aqueous pigment dispersion.

Problems solved by technology

Conventional solvent-based industrial finishes and coatings have presented many problems to date.

Organic solvents can pollute the workplace and environment.

In addition, many organic solvents are readily ignited, toxic, expensive, and lower the quality of finishes, and they can add undesirable colors to an otherwise colorless finish.

One of the most enduring and difficult problems in preparing and utilizing high solids coatings is the selection and control of viscosity.

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