Aqueous compositions with polyvalent metal ions and dispersed polymers

Abstract

There is provided a composition comprising (a) at least one aqueous polymer dispersion, wherein said polymer is formed from a monomer mix comprising one or more carboxylic acid functional monomers; (b) at least one swelling agent; and (c) at least one polyvalent metal ion; wherein said composition is formed by a process comprising the step of forming a preliminary admixture of said dispersion (a) with some or all of said swelling agent (b), wherein the ratio of equivalents of polyvalent metal ions in said preliminary admixture to equivalents of carboxylic acid functional groups in said preliminary admixture is 0.25 or less.

1 . A composition comprising 
 (a) at least one aqueous polymer dispersion, wherein said polymer is formed from a monomer mix comprising 5-50% by weight based on the weight of said monomer mix, of one or more carboxylic acid functional monomers;    (b) 1 to 10 parts by weight of at least one swelling agent, based on 100 parts by weight of said monomer mix; and    (c) at least one polyvalent metal ion;    wherein the ratio of equivalents of polyvalent metal ions in said composition to equivalents of carboxylic acid functional groups in said composition is 0.4 or more to 1; and    wherein said composition is formed by a process comprising the step of forming a preliminary admixture of said dispersion (a) with some or all of said swelling agent (b),    wherein said preliminary mixture contains no polyvalent metal cation or said preliminary mixture contains polyvalent metal cation in an amount such that the ratio of equivalents of polyvalent metal ions in said preliminary admixture to equivalents of carboxylic acid functional groups in said preliminary admixture is 0.25 or less to 1.    
     
     
         2 . The composition of  claim 1 , wherein said preliminary admixture further comprises one or more nonionic surfactants.  
     
     
         3 . The composition of  claim 1 , wherein said monomer mix comprises 7-15% by weight based on the weight of said monomer mix, of one or more carboxylic acid functional monomers.  
     
     
         4 . The composition of  claim 1 , wherein said ratio of equivalents of polyvalent metal ions in said composition to equivalents of carboxylic acid functional groups in said composition is 0.6 or more to 1.  
     
     
         5 . The composition of  claim 1 , wherein said ratio of equivalents of polyvalent metal ions in said composition to equivalents of carboxylic acid functional groups in said composition is 0.7 or more to 1.  
     
     
         6 . The composition of  claim 5 , wherein said preliminary mixture further comprises at least one alkali metal hydroxide; wherein said monomer mix comprises 5-15% by weight based on the weight of said monomer mix, of one or more carboxylic acid functional monomers; and wherein the ratio of equivalents of said polyvalent metal ions in said composition to equivalents of said carboxylic acid functional groups in said composition is 0.7 or more to 1.  
     
     
         7 . The composition of  claim 1 , wherein said swelling agent comprises at least one compound selected from the group consisting of plasticizers, coalescents, surfactants, and solvents.  
     
     
         8 . The composition of  claim 7 , wherein said swelling agent comprises at least one compound selected from the group consisting of plasticizers and coalescents.  
     
     
         9 . A process for forming a coated substrate, said process comprising the steps of 
 (a) applying to said substrate at least one layer of a coating material comprising the composition of  claim 1 , and    (b) drying or allowing to dry said layer.    
     
     
         10 . (canceled)  
     
     
         11 . The composition of  claim 1 , wherein said monomer mix contains no monomers with any sulfur-containing acid functional groups.  
     
     
         12 . The composition of  claim 1 , wherein said monomer mix additionally comprises one or more vinyl aromatic monomer.  
     
     
         13 . The composition of  claim 1 , wherein said monomer mix additionally comprises one or more alkyl acrylate.  
     
     
         14 . The composition of  claim 1 , wherein said monomer mix additionally comprises one or more alkyl methacrylate.  
     
     
         15 . The composition of  claim 14 , wherein said monomer mix additionally comprises one or more alkyl acrylate.  
     
     
         16 . The composition of  claim 15 , wherein said monomer mix additionally comprises one or more vinyl aromatic monomer.  
     
     
         17 . The composition of  claim 16 , wherein said monomer mix contains no monomers with any sulfur-containing acid functional groups.  
     
     
         18 . The composition of  claim 1 , wherein said monomer mix additionally comprises one or more vinyl aromatic monomer, butyl acrylate, and methyl methacrylate.  
     
     
         19 . The composition of  claim 18 , wherein said monomer mix contains no monomers with any sulfur-containing acid functional groups.