Binder compositions and methods of preparing and using the same

Abstract

The present disclosure relates to compositions comprising a copolymer derived from a vinyl aromatic monomer, a (meth)acrylate monomer, an acid monomer, and a copolymerizable surfactant and compositions comprising the same. The (meth)acrylate monomer can be selected from a monomer having a theoretical glass transition temperature (T g ) for its corresponding homopolymer of 0° C. or less or a hydrophobic (meth)acrylate monomer. In some embodiments, the copolymer is further derived from an organosilane. The copolymers can have a theoretical glass transition temperature (T g ) from −60° C. to 80° C. and a number average particle size of 250 nm or less. The compositions can be used to prepare compositions such as coatings that have improved water resistance, blush resistance, and/or resistance to hydrostatic pressures. Methods of making the copolymers are also provided.

1 . (canceled) 
     
     
         2 . A composition, comprising:
 a copolymer derived from monomers comprising a vinyl aromatic monomer, a hydrophobic (meth)acrylate monomer, an acid monomer, an organosilane monomer, and a copolymerizable surfactant, wherein the copolymer is derived from 1% by weight or less of the organosilane monomer;   wherein the copolymer has a theoretical glass transition temperature (T g ) of −60° C. to 80° C.; and   wherein the copolymer has a number average particle size of less than 250 nm.   
     
     
         3 . The composition according to  claim 2 , wherein the hydrophobic (meth)acrylate monomer includes a C 4 -C 10 -alkyl (meth)acrylate. 
     
     
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         6 . The composition according to  claim 2 , wherein the copolymer is derived from 20%-80% by weight vinyl aromatic monomer. 
     
     
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         11 . The composition according to  claim 2 , wherein the copolymer further includes lauryl (meth)acrylate. 
     
     
         12 . The composition according to  claim 2 , wherein the acid monomer is selected from the group consisting of acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, crotonic acid, and a mixture thereof. 
     
     
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         15 . The composition according to  claim 2 , wherein the organosilane monomer is represented by the formula (R 1 )—(Si)—(OR 2 ) 3 , wherein R 1  is a C 1 -C 8  substituted or unsubstituted alkyl or a C 1 -C 8  substituted or unsubstituted alkene and R 2 , which are the same or different, each is a C 1 -C 8  substituted or unsubstituted alkyl group. 
     
     
         16 . The composition according to  claim 2 , wherein the organosilane monomer includes vinyltrimethoxysilane, vinyltriethoxysilane, vinyl tris(2-methoxyethoxysilane), vinyl triisopropoxysilane, (meth)acryloyloxypropyltrimethoxysilane, γ-(meth)acryloxypropyltrimethoxysilane, γ-(meth)acryloxypropyltriethoxysilane, or a mixture thereof. 
     
     
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         19 . The composition according to  claim 2 , further comprising an additional monomer, wherein the additional monomer includes methyl acrylate, methyl methacrylate, (meth)acrylonitrile, (meth)acrylamide, a hydroxyl (meth)acrylate, an acetoacetoxy monomer, a crosslinking monomer, or a mixture thereof. 
     
     
         20 . The composition according to  claim 2 , wherein the copolymer is derived from 5% by weight or less copolymerizable surfactant. 
     
     
         21 . The composition according to  claim 2 , wherein the copolymerizable surfactant is of formula III, or a salt thereof: 
       
         
           
           
               
               
           
         
         wherein R 1  represents a branched aliphatic hydrocarbon group, a secondary aliphatic hydrocarbon group or a branched aliphatic acyl group, AO and AO′ each independently represents an oxyalkylene group having 2 to 4 carbon atoms, R 2  and R 3  each independently represents a hydrogen atom or a methyl group, X represents a hydrogen atom or an ionic hydrophilic group, x is an integer from 0 to 12, y is 0 or 1, z is an integer from 1 to 10, m is an integer from 0 to 1,000, and n is an integer from 0 to 1,000. 
       
     
     
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         25 . The composition according to  claim 2 , wherein the copolymer includes:
 50% to 60% by weight styrene;   35% to 45% by weight of a (meth)acrylate monomer selected from butyl acrylate, ethyl hexyl acrylate, or a mixture thereof;   1% to 3% by weight of an acid monomer selected from itaconic acid, acrylic acid, or a mixture thereof;   0% to 2% by weight of an additional monomer selected from methyl methacrylate, (meth)acrylonitrile, (meth)acrylamide, an acetoacetoxy monomer, a hydroxyl (meth)acrylate, an organosilane, or a mixture thereof; and   0.05% to 2% by weight of the copolymerizable surfactant.   
     
     
         26 . The composition according to  claim 2 , wherein the copolymer has a theoretical glass-transition temperature of from −40° C. to 80° C. 
     
     
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         36 . The composition according to  claim 2 , wherein the copolymer has a number average particle size of 100 nm or less. 
     
     
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         40 . A coating comprising the composition according to  claim 2  and one or more coalescing aids. 
     
     
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         42 . The coating according to  claim 40 , wherein the coating when applied on porous walls provides a resistance to hydrostatic pressure of at least 4 psi in accordance with ASTM D7088-08. 
     
     
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         44 . The coating according to  claim 40 , wherein the coating has a blush resistance of at least 16 hours when exposed to water. 
     
     
         45 . The coating according to  claim 40 , wherein the coating is a paint, membrane, or adhesive. 
     
     
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         51 . A method of making a composition according to  claim 40 , comprising: polymerizing monomers including
 40% to 65% by weight styrene;   30% to 55% by weight of a (meth)acrylate monomer selected from butyl acrylate, ethyl hexyl acrylate, or a mixture thereof;   1% to 4% by weight of an acid monomer selected from itaconic acid, acrylic acid, or a mixture thereof;   0% to 4% by weight of an additional monomer selected from methyl methacrylate, (meth)acrylonitrile, (meth)acrylamide, an acetoacetoxy monomer, a hydroxyl (meth)acrylate, an organosilane, or a mixture thereof; and
 0.05% to 2% by weight of the copolymerizable surfactant 
   to produce a copolymer having a theoretical glass transition temperature (T g ) from −60° C. to 80° C. and a number average particle size of less than 200 microns.   
     
     
         52 . A method of making a composition according to  claim 2 , comprising: polymerizing monomers including a vinyl aromatic monomer, a hydrophobic (meth)acrylate monomer, an acid monomer, an organosilane monomer, and a copolymerizable surfactant to produce a copolymer having a theoretical glass transition temperature (T g ) of from −60° C. to 80° C. and a number average particle size of less than 250 microns,
 wherein the copolymer is derived from 1% by weight or less of the organosilane monomer. 
 
     
     
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         61 . A method, comprising:
 coating a composition comprising a copolymer derived from monomers comprising a vinyl aromatic monomer, a (meth)acrylate monomer having a theoretical glass transition temperature (T g ) for its corresponding homopolymer of 0° C. or less, an acid monomer, an organosilane monomer, and a copolymerizable surfactant to a porous wall;   wherein the copolymer has a theoretical glass transition temperature (T g ) from −60° C. to 80° C. and a number average particle size of 200 nm or less; and   wherein the coating when applied on the porous wall provides a resistance to hydrostatic pressure of at least 4 psi in accordance with ASTM D7088-08.