RESIN EMULSION COMPOSITION, AND PROCESS OF OBTAINING SAME

Abstract

The present invention relates to aqueous resin emulsions containing at least a non-ionic surfactant of general formula R.sub.1(A.sub.1O).sub.n(A.sub.2O).sub.x(A.sub.3O).sub.yR.sub.2, obtained by the phase inversion emulsification process. In particular, the invention relates to aqueous resin emulsions commonly used in solvent-based paints, such as, for example, alkyd resins. Said emulsions are stabilized by non-ionic and anionic surfactant compositions which promote the inversion of the water-oil to oil-water phases in the presence of low water content, enabling water-oil type emulsions to be obtained with high productivity and high solids content, even in low shear conditions.

Claims

1. A resin emulsion composition, characterized by comprising at least a resin, water and at least a non-ionic surfactant of formula I:
R.sub.1(A.sub.1O).sub.1(A.sub.2O).sub.x(A.sub.3O).sub.yR.sub.2(I) wherein R.sub.1 is a saturated or unsaturated carbon chain containing 1-22 carbons A.sub.1O is an alkylene oxide homopolymer or block or random copolymer A.sub.2O is an alkylene oxide block or random copolymer having a composition different to A.sub.1 and A.sub.3 A.sub.3O is an alkylene oxide homopolymer or block or random copolymer x varies from 1 to 30 n varies from 1 to 100 y varies from 0 to 100 R.sub.2 is hydrogen or a saturated or unsaturated carbon chain containing 1-22 carbons wherein said resin emulsion composition is obtained by the phase inversion emulsification process and inverts phases in an organic phase concentration from 30 to 90%, especially between 60-80%.

2. The resin emulsion composition as claimed in claim 1, characterized wherein the resin is a polymer.

3. The resin emulsion composition as claimed in claim 1, characterized by comprising a single resin or mixture of two or more resins.

4. The resin emulsion composition as claimed in claim 1, characterized wherein the resin is a long oil alkyd resin.

5. The resin emulsion composition as claimed in claim 1, characterized by comprising solvent-free resins, and/or resins in aromatic and aliphatic solvent solutions, such as esters, alcohols, glycols and derivatives thereof, especially turpentine.

6. The resin emulsion composition as claimed in claim 1, characterized wherein R1 is of vegetable or petrochemical origin.

7. The resin emulsion composition as claimed in claim 1, characterized wherein the non-ionic surfactants are mixtures of surfactant of formula I and conventional alkoxylate surfactants, containing 10-100% of the surfactant of formula I.

8. The resin emulsion composition as claimed in any of claims 1 to 7, characterized by comprising at least an anionic surfactant.

9. The resin emulsion composition as claimed in claim 8, characterized wherein the anionic surfactants can be derived from alkyl ether carboxylates, alkyl aryl sulfonates, alkyl sulfonates, alkyl ether sulfates, phosphate esters, semi or diester of sulfosuccinates, sulfated or sulfonated oils, such as castor oil, or sulfonated fat, alkyl or alkylene sulfates, neutralized with alkaline metal bases, especially sodium and potassium, and amines, especially tertiary amines, including hydroxyalkyl amines, especially alkanol amine s.

10. The resin emulsion composition as claimed in claim 8 or 9, characterized wherein the non-ionic/anionic surfactants ratio varies between 5 and 95%.

11. The resin emulsion composition as claimed in all the prior claims, characterized by containing a concentration of organic phase surfactants from 0.1 to 20%, preferably from 6 to 12%.

12. The resin emulsion composition as claimed in all the prior claims, characterized wherein the resins containing anionic sites are neutralized with alkaline metal bases, especially sodium and potassium, and amines, especially tertiary amines, including hydroxyalkyl amines, especially alkanolamines, the degree of neutralization of the anionic sites varying from 0-150%.

13. The resin emulsion composition as claimed in claim 1, characterized wherein the emulsion contains stable droplets having average sizes less than 500 nm.

14. The resin emulsion composition as claimed in any of claims 1 to 13, characterized by being employed in coating formulations applied in the construction industry, architectural paints, industrial paints, paints and varnishes for packaging in general.

15. A process of obtaining the resin emulsion composition as defined in claims 1 to 13, characterized by using conventional stirring systems, with stirring speeds under 1500 rpm and phase inversion emulsification method.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0010] The present invention relates to aqueous resin emulsions containing compositions of optimized non-ionic and anionic surfactants to generate stable emulsions with reduced droplet or particulate sizes, high solids and high process productivity, even under mild shear conditions, conventional stirring equipment and low overall concentration of surfactants by way of the phase inversion emulsification method.

[0011] The aqueous resin emulsions comprised in the present invention contain at least a resin, water and at least a non-ionic surfactant of formula I:

R.sub.1(A.sub.1O).sub.n(A.sub.2O).sub.x(A.sub.3O).sub.yR.sub.2(I)

[0012] wherein

[0013] R.sub.1 is a saturated or unsaturated carbon chain containing 1-22 carbons

[0014] A.sub.1O is an alkylene oxide homopolymer or block or random copolymer

[0015] A.sub.2O is an alkylene oxide block or random copolymer having a composition different to A.sub.1 and A.sub.3

[0016] A.sub.3O is an alkylene oxide homopolymer or block or random copolymer

[0017] x varies from 1 to 30

[0018] n varies from 1 to 100

[0019] y varies from 0 to 100

[0020] R.sub.2 is hydrogen or a saturated or unsaturated carbon chain containing 1-22 carbons

[0021] In a preferred embodiment of the resin emulsion composition according to the present invention, the emulsions obtained present an organic phase content from 30 to 90%, preferably between 60-80%.

[0022] In a preferred embodiment of the resin emulsion composition according to the present invention, appropriate resins for emulsification include all types of suitable polymers that are commonly used in coatings, for example, paints and adhesives, being obtained by polymerization methods known in the art. Said polymers include, but not limited to, acrylic, vinyl, epoxy, cellulose and polyester resins and derivatives thereof. Especially, the present invention is suitable for the emulsification of alkyd resins and derivatives thereof, both for air or forced drying, with oil lengths in the range of 10 to 100%, preferably 30 to 80% and especially 45 to 55%.

[0023] In a preferred embodiment of the resin emulsion composition according to the present invention, the resins or polymers used may comprise a single resin or mixture of two or more resins.

[0024] In a preferred embodiment of the resin emulsion composition according to the present invention, it is possible to use solvent-free resins, resins containing low residual solvent content or resins in solution by using a suitable solvent. Said solvents include, but are not limited to, aromatic and aliphatic compounds, esters, alcohols, glycols and derivatives thereof. Preferably, the solvents used comprise the family of petroleum naphthas, especially turpentine.

[0025] In a preferred embodiment, the resin emulsion composition according to the present invention is characterized wherein the non-ionic surfactants comprise only the non-ionic surfactant of formula I.

[0026] In a preferred embodiment, the resin emulsion composition according to the present invention is characterized wherein the non-ionic surfactants are mixtures of a surfactant of formula I and convention alkoxylate surfactants containing at least 10% of the surfactant of formula I.

[0027] Notably, it is desirable to use combinations of non-ionic surfactants of formula (I) with anionic surfactants, such as alkyl ether carboxylates, alkyl aryl sulfonates, phosphate esters, alkyl ether sulfates, semi or diester of sulfosuccinates, sulfated or sulfonated oils, such as castor oil, or sulfonated fat, alkyl or alkylene sulfates, or a mixture of at least two of such anionic surfactants. These well-known classes of anionic surfactants are furnished as acidulates, or include counter-ions to render them nearer neutral. In this invention, it is possible to use neutralized anionic surfactants or to include neutralizing agents in the compositions. Suitable counter-ions include those derived from alkaline metals, especially from sodium and potassium (adequately furnished as hydroxide or carbonate) and, especially for sodium and potassium (adequately furnished as hydroxide or carbonate) and, especially ether carboxylates, amines, especially tertiary amines, including hydroxyalkyl amines, especially alkanolamines. Neutralization at the point of use or in situ during emulsification can be performed by using a suitable base such as a hydroxide or alkaline metal carbonate or amines, especially alkanolamines. The amount of neutralizing agent used is sufficient to achieve a desired pH level in the product emulsion. Preferably, the pH of the end emulsion is within the range of 3 to 10, more preferably, 5 to 9. Therefore, another preferred embodiment of the resin emulsion composition according to the present invention, comprises the use of at least an anionic surfactant.

[0028] In a preferred embodiment of the resin emulsion composition according to the present invention, the surfactants employed in the emulsification of resins by the phase inversion method are mixtures of non-ionic and anionic surfactants.

[0029] In a preferred embodiment of the resin emulsion composition according to the present invention, the anionic surfactants may be derived from alkyl ether carboxylates, alkyl aryl sulfonates, alkyl sulfonates, alkyl ether sulfates, phosphate esters, semi or diester of sulfosuccinates, sulfated or sulfonated oils, such as castor oil, or sulfonated fat, alkyl or alkylene sulfates, neutralized with alkaline metal bases, especially sodium and potassium, and amines, especially tertiary amines, including hydroxyalkyl amines, especially alkanolamines.

[0030] In a preferred embodiment of the resin emulsion composition according to the present invention, the ratio of non-ionic/anionic surfactants varies between 5 and 95%, preferably the ratio of non-ionic/anionic surfactants varies between 25 and 75% by weight.

[0031] In a preferred embodiment of the resin emulsion composition according to the present invention, the overall concentration of organic phase surfactants varies from 0.1 to 20%, preferably from 4 to 15%, and especially from 6 to 12% by weight.

[0032] In a preferred embodiment of the resin emulsion composition according to the present invention, the resins employed that contain active anionic sites can be neutralized with neutralizing agents to adjust the pH of the emulsion during or after the formation up to a suitable level, usually not strongly acidulated or alkaline, preferably present in the range from 0 to 150%, more preferably 40 to 110%, expressed as a percentage of the acid value of the resin.

[0033] In a preferred embodiment of the resin emulsion composition according to the present invention, others materials, for example, process additives, may be added in the aqueous phase or in the organic phase, prior to emulsification, to facilitate the emulsification process. Process additives include foam-inhibiting agents or foam eliminators, which when used will preferably be present in the range of 0.01 to 2% by mass of the emulsion; rheology modifiers, which when used, will preferably be present in the range of 0.5% to 20%, more preferably 0.5 to 10%, and especially 0.5 to 3% by weight of the emulsion; electrolytes which when used to control an inversion mechanism, will preferably be present in the range of 1 mmol.1.sup.1 to 100 mmol.1.sup.1 of emulsion.

[0034] In a preferred embodiment of the resin emulsion composition according to the present invention, the resin emulsions obtained contain stable droplets having average sizes less than 500 nm.

[0035] In a preferred embodiment of the resin emulsion composition according to the present invention, the process of obtaining the aqueous resin emulsions uses stirring speeds under 1500 rpm, conventional stirring systems and phase inversion emulsification method.

[0036] In a preferred embodiment of the resin emulsion composition according to the present invention, the resin emulsions obtained are employed in coating formulations applied in the construction industry, architectural paints, industrial paints, paints and varnishes for packaging in general.

[0037] The invention is illustrated by the non-limiting examples.

EXAMPLE 1

[0038] 200 g of alkyd resin (long in oil, based on soybean oil with a length of 60%) was added in a round-bottom flask partially immersed in a thermostatically-controlled bath at a temperature of 70 C. Once the temperature was stabilized, 4.0 g of KOH (solution at 45%) was added. Once completely dissolved, a composition of surfactants (22.0 g) according to the invention was added. Once fully dissolved in the water at the temperature of 70 C., it was slowly added, at a stirring speed of 230 rpm, until the point of inversion, determined as the point at which it is possible to disperse a sample of the emulsion in water. The solids content of the emulsion was determined at this time, the value of 75% being obtained. After this step, the remainder of the water to attain the solids content of 65% was added quickly. After this, the emulsion was cooled to ambient temperature.

EXAMPLE 2

[0039] 200 g of alkyd resin (long in oil, based on soybean oil with a length of 60%) diluted with turpentine solvent at 80% of solids was added in a round-bottom flask at ambient temperature. Thereafter, 4.0 g of KOH (solution at 45%) was added. Once fully dissolved, the composition of surfactants (13.0 g) according to the invention was added. Once fully dissolved, the water was slowly added at a stirring speed of 230 rpm, up until the point of inversion, determined as the point where it is possible to disperse a sample of the emulsion in water. The organic phase concentration at this time was 67% (by mass). After this step, the remainder of the water to attain the organic phase concentration of 65% by mass was added quickly.

RESULTS

[0040] The results are described in the following table:

TABLE-US-00001 Example 1 Example 2 Organic phase concentration 65% 65% Viscosity (cPs) 200 514 Size of particle (nm; D50) 220 207