The Use of Tristyrylphenol Alkoxylate Sulfosuccinates in Emulsion Polymerization and Coatings

Abstract

Disclosed are the use of novel surfactants for the synthesis of emulsion polymer latexes, particularly those used in paints, coatings, and pressure sensitive adhesives. The surfactant compositions for emulsion polymer latexes comprise sterically bulky surfactants whose composition comprises at least one alkoxylated polyaryl substituted aromatic sulfosuccinate compound. The novel surfactants provide for the production of stable, small particle size distribution emulsion polymer latexes. The resulting latexes, when formulated into latex paint, impart improvements in water resistance as measured by film opacity, blister resistance and improved leveling characteristics, and when formulated into pressure sensitive adhesives, provide improved water resistance characteristics as measured by film opacity.

We claim: 
     
         1 . A pressure-sensitive adhesive comprising polymeric latex particles that comprise
 (i) a surfactant of one or more compounds defined by formula (I),   
       
         
           
           
               
               
           
         
         or a salt thereof, wherein
 one of G and G 1  is —SO 3 M and the other is hydrogen, wherein M is hydrogen or a metal cation selected from Li + , Na + , or K + ; 
 R is —OH or —R 1 ; wherein 
 each R 1  is independently -L-R 2 , wherein
 R 2  is 
 
 
       
       
         
           
           
               
               
           
         
         
           
              wherein q is a mixture of 1, 2, and 3;
 each L is independently —(OCH(CH 3 )CH 2 ) n —(OCH 2 CH 2 ) m —* or —(OCH 2 CH 2 ) m —(OCH(CH 3 )CH 2 ) n —*, wherein R 2  is attached to L at the *; and 
 
           
           n and m are each between 0 and 100, provided that at least one of m and n is greater than or equal to 1; and 
         
         (ii) a polymerization product of radical-polymerizable monomers wherein the radical-polymerizable monomers comprise (a) acrylic acid, methacrylic acid, or a mixture thereof in an amount of from greater than about 0 to about 2% by weight based on all monomers, and (b) additional monomers selected from the group consisting of vinyl monomers, acrylate monomers, methacrylate monomers, and mixtures thereof. 
       
     
     
         2 . The pressure-sensitive adhesive of  claim 1 , wherein the polymeric latex particles have a mean diameter of between about 50 nm and about 300 nm. 
     
     
         3 . The pressure-sensitive adhesive of  claim 2 , wherein the polymeric latex particles have a mean diameter of less than about 175 nm. 
     
     
         4 . The pressure-sensitive adhesive of  claim 2 , wherein the polymeric latex particles have a mean diameter of greater than about 75 nm. 
     
     
         5 . The pressure-sensitive adhesive of  claim 1 , wherein the surfactant is a compound according to formula (II), 
       
         
           
           
               
               
           
         
         or a salt thereof. 
       
     
     
         6 . The pressure-sensitive adhesive of  claim 1 , wherein the surfactant is a compound according to formula (III), 
       
         
           
           
               
               
           
         
         or a salt thereof, wherein both R 1  groups are the same. 
       
     
     
         7 . The pressure-sensitive adhesive of  claim 1 , wherein R 1  is —(OCH(CH 3 )CH 2 ) n —(OCH 2 CH 2 ) m —R 2 . 
     
     
         8 . The pressure-sensitive adhesive of  claim 1 , wherein R 1  is —(OCH 2 CH 2 ) m —(OCH(CH 3 )CH 2 ) n —R 2 . 
     
     
         9 . The pressure-sensitive adhesive of  claim 1 , wherein R 1  is —(OCH 2 CH 2 ) m —R 2 . 
     
     
         10 . The pressure-sensitive adhesive of  claim 1 , wherein the surfactant is defined by:
 a. R is —OH, G is —SO 3 Na, G 1  is hydrogen, m is 16, n is 0, and q is a mixture of 1, 2, and 3;   b. R is —OH, G is —SO 3 Na, G 1  is hydrogen, m is 4, n is 0, and q is a mixture of 1, 2, and 3;   c. R is —OH, G is —SO 3 Na, G 1  is hydrogen, m is 16, n is 1.5, and q is a mixture of 1, 2, and 3;   d. R is R 1 , G is —SO 3 Na, G 1  is hydrogen, m is 8, n is 0, and q is a mixture of 1, 2, and 3;   e. R is —OH, G is —SO 3 Na, G 1  is hydrogen, m is 8, n is 0, and q is a mixture of 1, 2, and 3; or   f. R is —OH, G is —SO 3 Na, G 1  is hydrogen, m is 7, n is 8, and q is a mixture of 1, 2, and 3;   or a salt thereof.   
     
     
         11 . A latex paint, comprising polymeric latex particles that comprise a polymerization product of radical-polymerizable monomers and a surfactant of one or more compounds, wherein the surfactant of one or more compounds is defined by formula (I), 
       
         
           
           
               
               
           
         
         or a salt thereof, wherein
 one of G and G 1  is —SO 3 M and the other is hydrogen, wherein M is hydrogen or a metal cation selected from Li + , Na + , or K + ; 
 R is —OH, —R 1 , or —R 3 ; wherein
 each R 1  is -L-R 2 , wherein
 R 2  is 
 
 
 
       
       
         
           
           
               
               
           
         
         
           
             
                wherein q is a mixture of 1, 2, or 3, 
               each L is independently —(OCH(CH 3 )CH 2 ) n —(OCH 2 CH 2 ) m —* or —(OCH 2 CH 2 ) m —(OCH(CH 3 )CH 2 ) n —*, wherein R 2  is attached to L at the *; and 
               n and m are each between 0 and 100, provided that at least one of m and n is greater than or equal to 1; and 
             
             R 3  is -L-OR 4  or C 1-30  alkoxy, wherein —OR 4  is attached to L at the * and R 4  is hydrogen or C 1-4  alkyl, and 
           
           wherein the radical-polymerizable monomers comprise: 
           (a) acrylic acid, methacrylic acid, or a mixture thereof in an amount of from greater than about 0 to about 2% by weight based on all monomers, and 
           (b) additional monomers selected from the group consisting of vinyl monomers, acrylate monomers, methacrylate monomers, and mixtures thereof, 
         
       
     
     
         12 . The latex paint of  claim 11 , wherein the polymeric latex particles have a mean diameter of between about 50 nm and about 300 nm. 
     
     
         13 . The latex paint of  claim 12 , wherein the polymeric latex particles have a mean diameter of less than about 175 nm. 
     
     
         14 . The latex paint of  claim 12 , wherein the polymeric latex particles have a mean diameter of greater than about 75 nm. 
     
     
         15 . The latex paint of  claim 11 , wherein the surfactant is a compound according to formula (II), 
       
         
           
           
               
               
           
         
         or a salt thereof. 
       
     
     
         16 . The latex paint of  claim 11 , wherein the surfactant is a compound according to formula (III), 
       
         
           
           
               
               
           
         
         or a salt thereof, wherein both R 1  groups are the same. 
       
     
     
         17 . The latex paint of  claim 11 , wherein R 1  is —(OCH(CH 3 )CH 2 ) n —(OCH 2 CH 2 ) m —R 2 . 
     
     
         18 . The latex paint of  claim 11 , wherein R 1  is —(OCH 2 CH 2 ) m —(OCH(CH 3 )CH 2 ) n —R 2 . 
     
     
         19 . The latex paint of  claim 11 , wherein R 1  is —(OCH 2 CH 2 ) m —R 2 . 
     
     
         20 . The latex paint of  claim 11 , wherein the surfactant is defined by:
 a. R is —OH, G is —SO 3 Na, G 1  is hydrogen, m is 16, n is 0, and q is a mixture of 1, 2, and 3;   b. R is —OH, G is —SO 3 Na, G 1  is hydrogen, m is 4, n is 0, and q is a mixture of 1, 2, and 3;   c. R is —OH, G is —SO 3 Na, G 1  is hydrogen, m is 16, n is 1.5, and q is a mixture of 1, 2, and 3;   d. R is R 1 , G is —SO 3 Na, G 1  is hydrogen, m is 8, n is 0, and q is a mixture of 1, 2, and 3;   e. R is —OH, G is —SO 3 Na, G 1  is hydrogen, m is 8, n is 0, and q is a mixture of 1, 2, and 3; or   f. R is —OH, G is —SO 3 Na, G 1  is hydrogen, m is 7, n is 8, and q is a mixture of 1, 2, and 3;   or a salt thereof.