Multistage Polymer Particles for Latex Paint Durability
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Solution Overview
Problem
Latex paints often exhibit inferior coating properties such as decreased durability and adhesion compared to solvent-based paints, lacking excellent blocking resistance, water resistance, and scrub resistance.
Innovation Solution
Development of multistage polymers comprising a first stage copolymer derived from soft ethylenically-unsaturated monomers, phosphorus-containing monomers, and acetoacetoxy monomers, and a second stage polymer derived from hard ethylenically-unsaturated monomers, forming multilayer particles with a significant difference in glass transition temperatures, which are used in aqueous compositions including additives for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If latex paints are used instead of solvent-based paints, then volatile organic compounds are reduced and cleanup is easier, but coating durability and adhesion deteriorate
Solution Approach 1:
The patent employs composite particles consisting of a core shell polymer containing phosphorus-containing functional groups and a surface layer polymer. This composite structure combines the benefits of latex paints (low VOC) with improved durability and adhesion properties, resolving the contradiction between environmental friendliness and coating performance.
Solution Approach 2:
The invention creates particles with non-uniform composition where the core and surface layers have different functional properties. The core provides adhesion enhancement through phosphorus-containing groups while the surface layer maintains the latex paint characteristics, allowing different regions of the particle to fulfill different functional requirements.
2Object-generated harmful factors
If latex paints are used instead of solvent-based paints, then volatile organic compounds are reduced and cleanup is easier, but blocking resistance deteriorates
Solution Approach 1:
The composite particle structure with phosphorus-containing functional groups in the core shell polymer enhances blocking resistance while maintaining low VOC content. The specific composition and structure of the composite particles provide the necessary strength for blocking resistance without requiring solvent-based formulations.
3Object-generated harmful factors
If latex paints are used instead of solvent-based paints, then volatile organic compounds are reduced and cleanup is easier, but water resistance deteriorates
Solution Approach 1:
The patent utilizes composite particles with specifically designed core and surface layers that work together to provide water resistance. The phosphorus-containing functional groups in the core shell polymer contribute to water resistance while maintaining the water-based formulation benefits of latex paints.
4Object-generated harmful factors
If latex paints are used instead of solvent-based paints, then volatile organic compounds are reduced and cleanup is easier, but scrub resistance deteriorates
Solution Approach 1:
The composite particle structure with enhanced surface properties provides improved scrub resistance. The combination of core shell polymer with phosphorus-containing groups and surface layer polymer creates a more durable coating that can withstand scrubbing while maintaining low VOC content.
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 multistage polymers improve the durability, adhesion, and resistance properties of latex paints, including blocking resistance, water resistance, and scrub resistance, comparable to solvent-based paints, while maintaining low volatile organic compounds.
Implementation Method 1
multistage polymers that comprise (i) a first stage comprising a first copolymer having a first theoretical glass-transition temperature (Tg), and (ii) a second stage comprising a second polymer having a second theoretical Tg, wherein the second theoretical Tg is at least 40° C. greater than the first theoretical Tg
Data Source
AI summary
Provided are multistage polymers that comprise (i) a first stage comprising a first copolymer having a first theoretical Tg, the first copolymer being derived from a soft ethylenically-unsaturated monomer, a phosphorus-containing monomer, and an acetoacetoxy monomer; and (ii) a second stage comprising a second polymer having a second theoretical Tg, the second polymer being derived from one or more hard ethylenically-unsaturated monomers. The multistage polymers can be in the form of multilayer particles that comprise (i) a first layer comprising the first copolymer; and (ii) a second layer surrounding at least a portion of the first layer comprising the second polymer. Also provided are aqueous compositions including one or more of the multistage polymers (or multilayer particles) described herein, as well as methods for making the multistage polymers (or multilayer particles) described herein.