Bio-based Acrylate Polymer Latex for Waterborne Coatings
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Solution Overview
Problem
Existing polymer dispersions struggle to achieve a balanced application profile, often compromising one coating property while improving another, and are primarily based on fossil-derived monomers, which contributes to carbon footprint concerns.
Innovation Solution
Aqueous polymer latexes are developed through emulsion polymerization using a composition of isobutyl acrylate, 2-methylbutyl acrylate, and isoamyl acrylate, which can be sourced from biological origins, providing improved whitening resistance, flexibility, and reduced fossil carbon demand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polymer dispersions are based on conventional fossil-derived monomers to achieve good coating properties, then coating performance is maintained, but carbon footprint and environmental impact increase
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating bio-based monomers (isobutyl acrylate, isoamyl acrylate, 2-methylbutyl acrylate) in specific proportions (20-90 wt%) into the polymer latex, replacing conventional fossil-derived monomers while maintaining coating performance characteristics
Solution Approach 2:
The patent creates a composite polymer system combining multiple monomer types (acrylate, methacrylate, and vinyl aromatic monomers) with specific bio-based components to achieve both environmental sustainability and balanced coating properties including hardness, flexibility, and weathering resistance
2Adaptability or versatility
If polymer composition is modified to improve one coating property, then that property is enhanced, but other coating properties deteriorate significantly
Solution Approach 1:
The patent optimizes multiple composition parameters simultaneously by controlling the ratios of different monomers (isobutyl acrylate 20-90 wt%, methacrylate monomers 5-50 wt%, vinyl aromatic monomers 5-50 wt%) to achieve a balanced application profile where no single property is compromised
Solution Approach 2:
The patent develops a multi-component polymer system where isobutyl acrylate provides flexibility, methacrylate monomers contribute hardness and blocking resistance, and vinyl aromatic monomers enhance weathering resistance, creating a synergistic composite that balances all coating properties
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The polymer latexes exhibit a well-balanced application profile with enhanced flexibility, weathering resistance, scrub resistance, and thickening efficiency, while significantly reducing fossil carbon usage in their production.
Implementation Method 1
aqueous polymer latexes of film-forming copolymers obtainable by aqueous emulsion polymerisation of ethylenically unsaturated monomers
Data Source
AI summary
The present invention relates to aqueous polymer latexes of film-forming copolymers which are suitable as binders in waterborne coating compositions, and are obtainable by aqueous emulsion polymerisation of ethylenically unsaturated monomers M, which comprise •20 to 95% by weight, based on the total amount of monomers M, of at least one monomer M1, which is selected from isobutyl acrylate and isoamyl acrylate and mixtures thereof; •0 to 55% by weight, based on the total amount of monomers M, of at least one monomer M2, which is selected from ethyl acrylate, n-propyl acrylate, n-butyl acrylate, n-pentyl acrylate, C6-C20-alkyl esters of acrylic acid and C5-C20-alkyl esters of methacrylic acid and mixtures thereof; •5 to 50% by weight, based on the total amount of monomers M, of at least one monomer M3, which is selected from tert-butyl acrylate, C1-C4-alkyl esters of methacrylic acid, C5-C20-cycloalkyl esters of acrylic acid, C5-C20-cycloalkyl esters of methacrylic acid, C5-C20-cycloalkylmethyl esters of acrylic acid, C5-C20-cycloalkylmethyl esters of methacrylic acid, where cycloalkyl in the aforementioned monomers is mono-, bi- or tricyclic and where 1 or 2 CH2 moieties of cycloalkyl may be replaced by O and where cycloalkyl may be unsubstituted or carry 1, 2, 3 or 4 methyl groups, and monovinyl aromatic monomers and mixtures thereof; •0.05 to 4% by weight, based on the total amount of monomers M, of least one monomer M4, which is selected from monoethylenically unsaturated monomers having an acidic group; where the total amount of monomers M1 and M2 is in the range from 45 to 95% by weight, in particular 50 to 90% by weight, especially 55 to 85% by weight based on the total amount of ethylenically unsaturated monomers M, and where the total amount of monomers M1, M2 and M3 is at least 90% by weight, in particular at least 95% by weight, based on the total amount of ethylenically unsaturated monomers M.