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 (Tg) 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 (Tg) 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 . A composition, comprising:
 a copolymer derived from monomers comprising   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;   wherein the copolymer has a theoretical glass transition temperature (T g ) from −60° C. to 80° C.; and   wherein the copolymer has a number average particle size of 200 nm or less.   
     
     
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         11 . The composition according to  claim 1 , wherein the copolymer further includes lauryl (meth)acrylate. 
     
     
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         21 . The composition according to  claim 1 , 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 1 , 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 1 , 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 1 , 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 1  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 1 , 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.   
     
     
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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.   
     
     
         62 . A composition, comprising:
 a copolymer derived from monomers comprising 40% to 65% by weight of 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;   0.5 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   0.1 to 0.75% by weight of a copolymerizable surfactant which is selected from the group consisting of formula (I), (II), (III) and a salt of formula (III)   
       
         
           
           
               
               
           
         
         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; and 
         wherein the copolymer has a theoretical glass transition temperature (T g ) from −60° C. to 80° C.; and 
         wherein the copolymer has a number average particle size of 200 nm or less. 
       
     
     
         63 . The composition as claimed in  claim 62 , wherein the surfactant is according to Formula IIIa: 
       
         
           
           
               
               
           
         
         wherein R 1  is C 9 -C 15  alkyl or C 7 -C 11  alkyl-phenyl, X is H, SO 3 NH-4 and/or SO 3 Na, and m is 3 to 50. 
       
     
     
         64 . The composition according to  claim 62 , wherein the copolymer has a theoretical glass-transition temperature of from −10° C. to 40° C. 
     
     
         65 . The composition according to  claim 63 , wherein R 1  is C 10 -C 14  alkyl, X is H and/or SO 3 NH 4 , and m is 5 to 40. 
     
     
         66 . The composition according to  claim 63 , wherein m is 5 to 25. 
     
     
         67 . The composition according to  claim 63 , wherein m is 5 to 15. 
     
     
         68 . The composition according to  claim 63 , wherein m is 10. 
     
     
         69 . The composition according to  claim 63 , which further comprises 0.5% by weight to 2.5% by weight of a polyamine based on the dry weight of the copolymer and wherein the copolymerizable surfactant is present in an amount from 0.3 to 0.5% by weight.