Resin dispersion, coating materials, laminates, and process for production of the same

Abstract

To provide an aqueous dispersion of a resin wherein dispersed particles are stable with fine particle sizes and whereby bleeding out is suppressed, which is thus useful as e.g. a surface treating agent, an adhesive or a coating material for a polyolefin substrate. A resin dispersion having, dispersed in water with a 50% particle diameter of at most 0.5 μm, a polymer (C) having a hydrophilic polymer (B) or an acidic group bonded to a propylene/α-olefin copolymer (A) as a copolymer of propylene with an α-olefin other than propylene, wherein the copolymer (A) has a propylene content of at least 50 mol % and less than 100 mol %, and the copolymer (A) has a weight average molecular weight Mw of at least 10,000 and a molecular weight distribution Mw/Mn of at most 3.5; and the resin dispersion has a surfactant content of at most 15 parts by weight per 100 parts by weight of the polymer (C); and a coating material or laminate, made by using such a dispersion.

1 . A resin dispersion having, dispersed in water with a 50% particle diameter of at most 0.5 μm, a polymer (C) having a hydrophilic polymer (B) or an acidic group bonded to a propylene/α-olefin copolymer (A) as a copolymer of propylene with an α-olefin other than propylene, wherein:
 the copolymer (A) has a propylene content of at least 50 mol % and less than 100 mol %, and the copolymer (A) has a weight average molecular weight Mw of at least 10,000 and a molecular weight distribution Mw/Mn of at most 3.5; and   the resin dispersion has a surfactant content of at most 15 parts by weight per 100 parts by weight of the polymer (C).   
   
   
       2 . The resin dispersion according to  claim 1 , wherein the copolymer (A) is produced by means of a single-site catalyst. 
   
   
       3 . The resin dispersion according to  claim 1  or  2 , wherein the copolymer (A) is a propylene/butene copolymer. 
   
   
       4 . The resin dispersion according to any one of  claims 1  to  3 , wherein the copolymer (A) has a melting point Tm of at most 100° C. and a heat of crystal fusion ΔH of at most 60 J/g. 
   
   
       5 . The resin dispersion according to any one of  claims 1  to  4 , wherein the copolymer (A) elutes at least 95% at a temperature of at most 60° C. in temperature rising elution fractionation. 
   
   
       6 . The resin dispersion according to any one of  claims 1  to  5 , wherein the copolymer (A) contains substantially no chlorine. 
   
   
       7 . The resin dispersion according to any one of  claims 1  to  6 , wherein the polymer (C) is dispersed in water with a 50% particle diameter of at most 0.3 μm. 
   
   
       8 . The resin dispersion according to any one of  claims 1  to  7 , wherein the polymer (C) has a hydrophilic polymer (B) bonded to the copolymer (A) in a ratio of (A):(B)=100:1 to 100:500 (weight ratio) or has an acidic group bonded to the copolymer (A). 
   
   
       9 . The resin dispersion according to any one of  claims 1  to  8 , wherein the polymer (C) has a hydrophilic polymer (B) bonded to the copolymer (A). 
   
   
       10 . The resin dispersion according to  claim 9 , wherein the polymer (C) is a graft copolymer having a hydrophilic polymer (B) graft-bonded to the copolymer (A). 
   
   
       11 . The resin dispersion according to  claim 9  or  10 , wherein the polymer (C) has from 0.01 to 5 mmol of a hydrophilic polymer (B) bonded per 1 g of the copolymer (A). 
   
   
       12 . The resin dispersion according to any one of  claims 9  to  11 , wherein the hydrophilic polymer (B) is a polyether resin. 
   
   
       13 . The resin dispersion according to any one of  claims 9  to  12 , wherein the hydrophilic polymer (B) has at least one reactive group per one molecule. 
   
   
       14 . The resin dispersion according to  claim 13 , wherein the hydrophilic polymer (B) has an amino group as the reactive group. 
   
   
       15 . The resin dispersion according to any one of  claims 1  to  14 , which contains substantially no surfactant. 
   
   
       16 . A coating material containing the resin dispersion as defined in any one of  claims 1  to  15 . 
   
   
       17 . A laminate having formed on a thermoplastic resin-molded product (F) a layer comprising a polymer (C) having a hydrophilic polymer (B) or an acidic group bonded to a propylene/α-olefin copolymer (A) as a copolymer of propylene with an α-olefin other than propylene, wherein the copolymer (A) has a propylene content of at least 50 mol % and less than 100 mol %, and the copolymer (A) has a weight average molecular weight Mw of at least 10,000 and a molecular weight distribution Mw/Mn of at most 3.5; and the surfactant content is at most 15 parts by weight per 100 parts by weight of the polymer (C). 
   
   
       18 . A laminate having a resin layer formed by applying and heating the resin dispersion as defined in any one of  claims 1  to  15  or the coating material as defined in  claim 16 , on a thermoplastic resin-molded product (F). 
   
   
       19 . A process for producing a laminate, which comprises applying and heating the resin dispersion as defined in any one of  claims 1  to  15  or the coating material as defined in  claim 16 , to form a resin layer on a thermoplastic resin-molded product (F).