DISPERSION OF A (METH)ACRYLATE ADDITION POLYMER IN AN ORGANIC LIQUID

Abstract: The present invention pertains to a dispersion in an organic liquid of a (meth)acrylate based addition polymer stabilized by a graft copolymer of a polybutadiene with particular monomer components grafted thereon. The pre­ sent invention also pertains to a coating composition based upon such dispersion and to a process of coating a substrate with the coating com­ position. Finally, the present invention relates to a process for the pre­ paration of the stabilizer of the disperion.

Description: The present invention relates generally to a dispersion in an organic liquid of a (meth)acrylate addition polymer. By (meth)acrylate addition polymer is it meant acrylate and/or methacrylate based addition polymer, as further described below. Such dispersions are generally known from EP-A-0172589, which is hereby incorporated by reference herein for all purposes. These well-known dispersions, however, are not suitable for use in, for example, certain basecoat/clearcoat systems as further described below. According to the present invention, such dispersions are stabilized with a special stabilizer to make them suitable for this particular use. To this end, the present invention provides for a dispersion in an organic liquid of a (meth)acrylate addition polymer, characterized in that per 100 parts by weight of the addition polymer, the dispersion contains 5-100 parts by weight of a dispersion stabilizer, the dispersion stabilizer comprising a graft copolymer composed of: (1) 10-60 parts by weight of a polybutadiene built up from at least 60% by weight butadiene-1,3; with grafted to it (2) 10-70 parts by weight of a first monomer mixture consisting of (a) 20-60 mole% of a styrene, (b) 20-70 mole% of an hydroxyalkyl methacrylate having 2 to 6 carbon atoms in the alkyl group, and (c) 0-40 mole% of a different monoethylenically unsaturated compound; and (3) 0-60 parts by weight of a second monomer mixture consisting of (a) 20-60 mole% of a styrene, (b) 30-80 mole% of a (cyclo)alkyl methacrylate having 1-12 carbon atoms in the (cyclo)alkyl group, and (c) 0-40 mole% of a different monoethylenically unsaturated compound, wherein the total of the parts by weight of the polybutadiene, the first monomer mixture and the second monomer mixture is 100. In the aformentioned formulations, by a styrene is it meant styrene and methyl styrenes such as a-methyl styrene, ortho-methyl styrene, meta-methyl styrene and/or para-methyl styrene. As examples of suitable different monoethylenically unsaturated compounds may be mentioned monovinyl aromatic hydrocarbons such as vinyl toluene and vinyl naphthalene; (meth)acrylic esters such as methyl methacrylate, ethyl acrylate, ethyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 4-hydroxybutyl acrylate, 6-hydroxyhexyl acrylate, p-hydroxycyclohexyl acrylate, 8-hydroxyoctyl acrylate, 2-methoxyethyl methacrylate, 2-ethoxy ethyl methacrylate, ethoxymethyl methacrylate, glycidyl methacrylate, butyl methacrylate, 2-ethylhexyl acrylate, n-dodecyl acrylate and n-hexadecyl acrylate; (meth)acrylamides; and other compounds such as vinyl chloride, vinyl acetate and vinyl propionate. Of course, by the use of the terminology "different", for the first monomer mixture the hydroxyalkyl methacrylates having 2 to 6 carbon atoms in the alkyl group should be excluded from the above list of different monoethylenically unsaturated compounds, while for the second monomer mixture (cyclo)alkyl methacrylates having 1-12 carbon atoms in the (cyclo)alkyl group should likewise be excluded. Also, ethylenically unsaturated monocarboxylic acids and amino-group containing esters thereof are not considered suitable different monoethylenically unsaturated compounds in the present dispersion stabilizers other than in minor amounts, generally less than 20 mole%, and more preferably less than 10 mole%, of the total monomers. It should be noted that somewhat similar dispersion stabilizers are described in EP-A-0238108, which is hereby incorporated by reference for all purposes. These stabilizers, however, are utilized in aqueous dispersions and are not suitable for use in the present dispersions in organic liquids. The dispersions according to the present invention distinguish themselves from the well-known dispersions (without the dispersion stabilzer) in that they display excellent stability, particularly when used in combination with "solution" resins such as polyesters, polyacrylates or polyurethanes. In a preferred embodiment, the dispersion stabilizer should comprise 10-60 parts by weight of the second monomer mixture. It is believed that the presence of the second monomer mixture increases the hydrophobic part of the stabilizer to improve the stability of the dispersion, more particularly the stability vis à vis shearing forces, as may for instance be found in a closed circuit. In more preferred embodiments, the first monomer mixture consists of: (a) 30-60 mole% of a styrene, (b) 30-70 mole% of a hydroxyalkyl methacrylate having 2 to 6 carbon atoms in the alkyl group, and (c) 0-20 mole% of a different monoethylenically unsaturated compound, while the second monomer monomer mixture consists of: (a) 30-60 mole% of a styrene, (b) 30-70 mole% of a (cyclo)alkyl methacrylate having 1-12 carbon atoms in the (cyclo)alkyl group, and (c) 0-20 mole% of a different monoethylenically unsaturated compound. Also in more preferred embodiments, the polybutadiene is built up from at least 80% by weight butadiene-1,3, with the remainder of the polybutadiene being built up from a different ethylenically unsaturated component such as, for example, styrene, acrylonitrile or isoprene. Additionally, the polybutadiene preferably should have a number average molecular weight of 2000-6000, since below this little stabilization takes place and above this the viscosity of the polybutadiene becomes too high, increasing the risk of full gelation. The copolymerization of the monomer mixtures for the dispersion stabilizer according to the present invention is generally carried out in random order with the aid of a radical initiator in an amount of 1-12% by weight, more preferably 2-10% by weight (calculated on the weight of the polybutadiene), in an organic solvent, at a temperature of 60°C to 150°C, more preferably 80°C to 110°C, and under an atmosphere of inert gas such as nitrogen. As a radical intiator, it is preferred that use be made of di-t-butyl peroxide, dibenzoyl peroxide or a substituted dibenzoyl peroxide, such as di(2-methylbenzoyl)peroxide and di(2,4-dichlorobenzoyl)peroxide. Suitable organic solvents include ether group containing alcohols such as propylene glycol monopropyl ether, propylene glycol monobutyl ether, propylene glycol monoisopropyl ether, propylene glycol monoisobutyl ether, diethylene glycol monobutyl ether and dipropylene glycol monomethyl ether, or esters of these alcohols such as the acetic or propionic esters, or mixtures of such esters and alcohols containing 1-4 carbon atoms. It is preferred that first 10-70 parts by weight of the first monomer mixture be copolymerized in the presence of 10-60 parts by weight of the polybutadiene, after which 0-60 parts by weight of the second monomer mixture are copolymerized in the presence of the resulting reaction product. Alternatively, the second monomer mixture can first be polymerized in the presence of the polybutadiene, after which the first monomer mixture is copolymerized in the presence of the resulting reaction product. In both cases, the total parts by weight of the first monomer mixture, second monomer mixture and polybutadiene is 100. A suitable process comprises preparing the stabilizer in a concentration of 30-50% by weight in the organic solvent. If desired, the resulting solution or dispersion may be diluted with a solvent such as ethanol, optionally at elevated temperature, to a solids content of, for example, 10% by weight. As a rule, a bluish dispersion of the stabilizer will be obtained with a mean particle size of 100-250 nm (determined by dynamic light scattering). In this process, it is believed that the hydrophobic part of the stabilizer (the polybutadiene with optionally the second monomer mixture grafted thereon) is insoluble in the indicated dispersing agent - it is stabilized by the hydrophilic part (the first monomer mixture) of the stabilizer solvated by the dispersing agent. The dispersion of the (meth)acrylate addition polymer is produced by the polymerization of the monomers for the (meth)acrylate addition polymer in the presence of the dispersion stabilizer. Preferably, per 100 parts by weight of the resulting addition polymer, the resulting dispersion contains 5-100 parts by weight of the dispersion stabilizer. As suitable (meth)acrylate monomers for the (meth)acrylate addition polymer may be mentioned (cyclo)alkyl(meth)acrylates of which the (cyclo)alkyl group contains 1-24 carbon atoms, particular examples of which may be found in previously incorporated EP-A-0238108. Optionally, the aforementioned (meth)acrylate monomers may be mixed with one or more other ethylenically unsaturated monomers such as hydroxy-functional or epoxy-functional (meth)acrylates and other examples which may also be found in previously incorporated EP-A-0238108 As a further option, use may be made of small amounts (generally less than 10% by weight and, more preferably when utilized from 0,5-5% by weight, based upon the monomers) of suitable polyfunctional monomers, as still further found in previously incorporated EP-A-0238108. The use of a small amount of these polyfunctional monomers will result in full or partial cross-linking of the polymer micro particles. Polymerization of the monomers referred to above is carried out with the aid of a radical initiator in a polar organic diluent. As organic diluent is preferably used mainly an alcohol containing 1-4 carbon atoms, more preferably ethanol. On conclusion of the dispersion polymerization, the polar organic diluent may be replaced wholly or in part with a different, optionally less polar and/or less volatile diluent by adding a different diluent to the reaction product after the entire or part of the polar organic diluent is distilled off. It is preferred that the polymerization reaction should be carried out under an atmosphere of an inert gas, such as nitrogen, and preferably under reflux using 0,1-5% by weight (based on the weight of the monomers) of a radical initiator such as an organic peroxide (e.g., dilauroyl peroxide, dibenzoyl peroxide) or an azo compound (e.g., azobisisobutyronitrile, azobiscyanovaleric acid). The dispersions according to the present invention may be employed as coating compositions alone or in combination with acrylate resins, polyester resins or alkyd resins, the coating composition also containing a curing agent such as a melamine resin or a polyisocyanate which may be blocked or not. It s preferred that the dispersions should be used in amounts of 5-40% by weight of the solids content of the final coating composition. The dispersions according to the present invention may be applied to a substrate in any desirable manner, such as by roller coating, spraying, brushing, sprinkling, flow coating, dipping, electrostatic spraying or electrophoresis. As suitable substrates may be mentioned wood, metal and synthetic materials. Curing may be carried out at ambient temperature after evaporation of the solvent, or at higher temperatures in the range of, for example, 60°C to 160°C, in a baking oven and over a period of 10 to 60 minutes. The dispersions of the addition polymer according to the present invention are extremely suitable for coating compositions of a high-gloss metallic appearance. To this end the compositions according to the present invention are used in the base coat along with so-called non-leafing aluminum paste or some other metallic pigment. In addition, the base coat may contain the usual additives and adjuvants, such as other pigments, dispersing agents, colorants, organic solvents and accelerators for the curing reaction. In order to obtain a high gloss with such metallic pigment containing coatings, a second clearcoat may be applied over the pigmented coating. This dual coat system is referred to as a basecoat/clearcoat system. The composition of the clearcoat is generally a solvent-borne baking lacquer of a conventional acrylate/melamine composition. This system may be cured in a baking oven for 20-30 minutes at a temperature of 130°C to 150°C. Also a clearcoat can be applied, for instance a so-called two-component system based on an acrylate/polyisocyanate composition which can be cured in a baking oven for 20-30 minutes at a temperature of 60°C to 80°C. The use of a dispersion according to the invention has the advantage that the orientation of the pigment particles required for the metallic effect is retained during re-spraying with the clear coat, as a high solids content of the base coat (≧ 40% by weight) may be realised with such dispersions. Such an orientation is expressed in flop value. The invention will be further described in the following comparative examples. In these examples the mean particle size of the dispersion is determined by dynamic light scattering, the dispersion being diluted with ethanol to a solids content of about 0,1% by weight. The viscosity is determined with a Brookfield viscometer. The hydroxyl number is expressed in mg KOH/g. The solids content is determined in accordance with ASTM method 1644-59 with heating at 130°C over a period of 30 minutes. The flop is measured with the M.A.T. (Metallic Appearance Tester), a flop ≧ 30 being high and a flop of 20 low. For an automotive lacquer 30 would be an acceptable flop value, and 20 would clearly be unacceptable. Examples Preparation of Stabilizer A In a 3-l flask fitted with a stirrer, a thermometer, a reflux condenser, and a dropping funnel are homogeneously mixed: 351 g of polybutadiene having a number average molecular weight of 2800 and a hydroxyl number of 46,4, and composed of 20% of vinyl-1,2, 60% of trans-1,4, and 20% of cis-1,4 polybutadiene 1063,5 g of propylene glycol methylether acetate (PGMA) The dropping funnel is filled with a homogeneous mixture of: 156 g of styrene 195 g of hydroxyethyl methacrylate 42,1 g of dibenzoyl peroxide (50% by weight in dicyclohexyl phthalate) After deaeration the contents of the flask and the dropping funnel are brought under a nitrogen atmosphere. The contents of the flask are heated to 90°C, whereupon the contents of the dropping funnel are introduced into the flask over a period of 1 hour, the contents of the flask being kept at 90°C. After the dropping funnel has been emptied, the temperature of the contents of the flask is kept at 90°C for another 5 hours. Obtained is a dispersion of Stabilizer A in PGMA having a solids content of 40% by weight with a viscosity of 2,6 Pa.s. Preparation of Stabilizer B Step I In a 2-l flask fitted with a stirrer, a thermometer, a reflux condenser, and a dropping funnel are homogeneously mixed: 200 g of polybutadiene having a number average molecular weight of 2800 and a hydroxyl number of 46,6, and composed of 20% of vinyl-1,2, 60% of trans-1,4, and 20% of cis-1,4 polybutadiene 454 g of propylene glycol methylether acetate (PGMA) 151 g of ethanol The dropping funnel is filled with a homogeneous mixture of: 88,9 g of styrene 111,1 g of hydroxyethyl methacrylate 20,0 g of dibenzoyl peroxide (50% by weight in dicyclohexyl phthalate) After deaeration the contents of the flask and the dropping funnel are brought under a nitrogen atmosphere. The contents of the flask are heated to reflux temperature (90°C). Next, the contents of the dropping funnel are introduced into the flask over a period of 1 hour, the contents of the flask being kept at 90°C. After the dropping funnel has been emptied, the contents of the flask are kept at 90°C for another 5 hours. Step II Added to the reaction product of Step I in the flask are: 114 g of propylene glycol methylether acetate (PGMA) 38 g of ethanol The dropping funnel is filled with a homogeneous mixture of: 49,5 g of styrene 38,1 g of methyl methacrylate 12,4 g of hydroxyethyl methacrylate 8 g of dibenzoyl peroxide (50% by weight in dicyclohexyl phthalate) After deaeration the contents of the flask and the dropping funnel are brought under a nitrogen atmosphere. Over a period of 30 minutes the contents of the dropping funnel are introduced into the flask while the reflux temperature of the contents of the flask (= 90°C) is maintained. After the dropping funnel has been emptied, the contents of the flask are kept at 90°C for a further 5 hours. Obtained is a dispersion of Stabilizer B in PGMA having a solids content of 40% by weight. The viscosity is 1,16 Pa.s. Preparation of Stabilizer C Step I of the preparation of Stabilizer B is repeated. Step II Added to the reaction product of Step I in the flask are: 229 g of PGMA 76 g of ethanol The dropping flask is filled with a homogeneous mixture of 99 g of styrene 76,2 g of methyl methacrylate 24,8 g of hydroxyethyl methacrylate 16 g of dibenzoyl peroxide (50% by weight in dicyclohexyl phthalate) Over a period of 1 hour the contents of the dropping funnel are introduced into the flask while the contents of the flask are maintained at their reflux temperature (= 90°C). After the dropping funnel has been emptied, the contents of the flask are kept at 90°C for another 5 hours. Obtained is a dispersion of Stabilizer C in PGMA having a solids content of 40% by weight. The viscosity is 1,7 Pa.s. Preparation of Stabilizer D Step I In a 2-l flask fitted with a stirrer, a thermometer, a reflux condenser, and a dropping funnel are homogeneously mixed: 200 g of polybutadiene having a number average molecular weight of 2800 and a hydroxyl number of 46,6, and composed of 20% of vinyl-1,2, 60% of trans-1,4, and 20% of cis-1,4 polybutadiene 604 g of PGMA The dropping funnel is filled with a homogeneous mixture of: 88,9 g of styrene 111,1 g of hydroxyethyl methacrylate 16 g of dibenzoyl peroxide (50% by weight in dicyclohexyl phthalate) After deaeration the contents of the flask and the dropping funnel are brought under a nitrogen atmosphere. The contents of the flask are heated to 90°C, whereupon the contents of the dropping funnel are introduced into the flask over a period of 1 hour, the contents of the flask being kept at 90°C. After the dropping funnel has been emptied, the contents of the flask are kept at 90°C for another 5 hours. Step II To the reaction product of Step I in the flask are added: 304 g of PGMA The dropping funnel is filled with a homogeneous mixture of: 92,6 g of styrene 99,0 g of methyl methacrylate 8,4 g of methacrylamide 16 g of dibenzoyl peroxide (50% by weight in dicyclohexyl phthalate) After deaeration the contents of the flask and the dropping funnel are brought under a nitrogen atmosphere. Over a period of 30 minutes the contents of the dropping funnel are introduced into the flask, while its contents are kept at 90°C. After the dropping funnel has been emptied, the contents of the flask are kept at 90°C for a further 5 hours. Obtained is a dispersion of Stabilizer D in PGMA having a solids content of 40% by weight. The viscosity is 4,7 Pa.s. Example 1 Into a 2-l flask fitted with a thermometer, a stirrer, a reflux condenser, and a dropping funnel are weighed: 125 g of stabilizer A (40% by weight in PGMA) 675 g of ethanol The dropping funnel is filled with a homogeneous mixture of: 107,1 g of butyl acrylate 84,2 g of methyl methacrylate 3,80 g of trimethylol propane triacrylate 4,88 g of azobisisobutyronitrile After deaeration the contents of the flask and the dropping funnel are brought under a nitrogen atmosphere. The contents of the flask are heated with stirring to reflux temperature (78°C). The contents of the dropping funnel are introduced into the flask over a period of 2 hours, the temperature being kept at 78°C. After the addition of the monomer mixture the contents of the flask are kept at 78°C for another 5 hours. After the reaction mixture has been cooled, 300 g of PGMA are added and the ethanol is distilled off under reduced pressure until the dispersion has a solids content of 40% by weight. Viscosity : 17 Pa.s Particle size : 115 nm Example 2 Into a 2-l flask fitted with a thermometer, a stirrer, a reflux condenser, and a dropning funnel are weighed: 187,5 g of stabilizer A (40% by weight in PGMA) 675 g of ethanol The dropping funnel is filled with a homogeneous mixture of: 72,65 g of 2-ethylhexyl acrylate 78,9 g of methyl methacrylate 15,4 g of hydroxyethyl methacrylate 3,34 g of trimethylol propane triacrylate 4,7 g of azobisisobutyronitrile After deaeration the contents of the flask and the dropping funnel are brought under a nitrogen atmosphere. The contents of the flask are heated with stirring to reflux temperature (78°C). At this temperature the contents of the dropping funnel are introduced into the flask over a period of 2 hours. After total addition of the contents of the dropping funnel the contents of the flask are kept at 78°C for another 5 hours. After the reaction mixture has been cooled, 262,5 g of PGMA are added and the ethanol is distilled off under reduced pressure until the dispersion has a solids content of 40% by weight. Viscosity : 4 Pa.s Particle size : 110 nm Example 3 Into a 2-l flask fitted with a thermometer, a stirrer, a reflux condenser, and a dropping funnel are weighed: 156,25 g of Stabilizer B (40% by weight in PGMA) 675 g of ethanol The dropping funnel is filled with a homogeneous mixture of: 77,85 g of 2-ethylhexyl acrylate 84,5 g of methyl methacrylate 16,5 g of hydroxyethyl methacrylate 3,6 g of trimethylol propane triacrylate 5,0 g of azobisisobutyronitrile After deaeration the contents of the flask and the dropping funnel are brought under a nitrogen atmosphere. The contents of the flask are heated with stirring to reflux temperature (78°C). While kept at this temperature, the contents of the dropping funnel are introduced into the flask over a period of two hours. After total addition of the contents of the dropping funnel, the contents of the flask are kept at 78°C for another 5 hours. After the reaction 281,25 of PGMA are added, followed by distilling off of the ethanol under reduced pressure until the dispersion has a solids content of 40% by weight. Viscosity : 0,77 Pa.s Particle size : 125 nm Example 4 Into a 2-l flask fitted with a stirrer, a thermometer, a reflux condenser, and a dropping funnel are weighed: 187,5 g of Stabilizer C (40% by weight in PGMA) 850 g of ethanol The dropping funnel is filled with a homogeneous mixture of: 72,65 g of 2-ethylhexyl acrylate 78,9 g of methyl methacrylate 15,4 g of hydroxyethyl methacrylate 3,34 g of trimethylol propane triacrylate 4,7 g of azobisisobutyronitrile The contents of both the flask and the dropping funnel are brought under N₂, after which the contents of the flask are heated to reflux temperature (78°C). Next, the contents of the dropping funnel are added at a constant rate to those of the flask over a period of 2 hours. Next, the contents of the flask are kept at 78°C for another 5 hours. Following the reaction 262,5 g of PGMA are added, after which the ethanol is distilled off under reduced pressure until the dispersion has a solids content of 40% by weight. Viscosity : 0,67 Pa.s Particle size : 132 nm Example 5 Into a 2-l flask fitted with a stirrer, a thermometer, a reflux condenser, and a dropping funnel are weighed: 187,5 g of Stabilizer D (40% by weight in PGMA) 850 g of ethanol The dropping funnel is filled with a homogeneous mixture of: 72,1 g of ethylhexyl acrylate 78,4 g of methyl methacrylate 15,3 g of hydroxyethyl methacrylate 4,15 g of methacrylamide 5,1 g of azobisisobutyronitrile 47,5 g of ethanol The contents of both the flask and the dropping funnel are brought under an N₂ atmosphere, after which the flask is heated to reflux temperature (78°C). Next, the contents of the dropping funnel are added at a constant rate to those of the flask over a period of 2 hours at a temperature of 78°C. Then the contents of the flask are stirred for a further 2 hours at 78°C, after which another 1 g of azobisisobutyronitrile in 50 g of ethanol is added to the contents of the flask over a period of 30 minutes. Subsequently, the contents of the flask are kept at 78°C for another 2 hours. Following the reaction 262,5 g of PGMA are added, after which the ethanol is distilled off under reduced pressure until the dispersion has a solids content of 40% by weight. Viscosity : 0,63 Pa.s Particle size : 128 nm All the dispersions in propylene glycol methylether acetate of the Examples 1 through 5 are used in the preparation of base coat compositions consisting of the following components: 19,2 g of aluminium paste (available under the trademark 5000 AR ex Silberline) 37,6 g of polyacrylate resin, prepared from butyl methacrylate, styrene, hydroxyethyl methacrylate, 2-ethylhexyl acrylate, and n-octyl mercaptan. Said acrylate resin has the following characteristics; - OH number : 134 - average molecular weight: 2500 - solids content : 75% by weight in butyl acetate 16,2 g of polymer dispersion as described in the Examples 1 through 5 (solids content 40% by weight in PGMA) 2 g of cellulose acetobutyrate 25 g of methoxylated methyl melamine The base coat compositions are brought to spraying consistency (efflux time of 25 sec. in Ford cup no. 3) with butyl acetate. The solids contents of the base coats then is ≧ 40% by weight. In addition, base coats of the above composition are prepared which instead of the aforementioned acrylate resin contain a polyester resin prepared from isophthalic acid, adipic acid, neopentyl glycol, trimethylol propane and hexahydrophthalic acid. This polyester had the following characteristics: OH number : 98 acid number : 40 average molecular weight : 2000 solids content : 65% by weight in butyl acetate After diluting to spraying consistency (25 sec. efflux time in Ford cup 3), the solids content of this series of base coats is again above 40% by weight. Also, a base coat composition is prepared having the following conventional composition: The solids content of such a base coat composition is 11,8% by weight at spraying consistency (25 sec. efflux time in Ford cup 3). The base coat coating compositions are sprayed onto steel test panels in a film thickness of 15-20 µm (in the dry state). The resulting test panels are predried for 5 minutes in a baking oven at a temperature of 60°C. Next, these test panels are partially covered up and the uncovered part is re-sprayed with a clear coat (in a film thickness of 40-45 µm in the dry state). This clear coat is a so-called bi-component acrylate/polyisocyanate coating composition, the polyisocyanate being the adduct of 3 moles of hexamethylene diisocyanate to 1 mole of water. After curing in a baking oven for 20 minutes at 120°C a metallic coat of high gloss is obtained, with an excellent resistance both to organic solvents and water. Of the metallic coats the flop of both the base coat and the base coat provided with clear coat is measured (see Table I). The decrease of the flop by the application of the clear coat is a measure of the softening of the base coat by the clear coat, thus reducing the flop. The flop values of the base coats based on the dispersions according to the invention (Examples 1 through 5) are all very high. The decrease of the flop by the application of the clear coat is small, so that a high flop of about 30 is maintained.

Claims: A dispersion in an organic liquid of a (meth)acrylate addition polymer, characterized in that per 100 parts by weight of the addition polymer the dispersion contains 5-100 parts by weight of a dispersion stabilizer, the dispersion stabilizer comprising a graft polymer composed of: (1) 10-60 parts by weight of a polybutadiene built up from at least 60% by weight butadiene-1,3; with grafted to it (2) 10-70 parts by weight of a first monomer mixture consisting of (a) 20-60 mole% of a styrene, (b) 20-70 mole% of an hydroxyalkyl methacrylate having 2 to 6 carbon atoms in the alkyl group, and (c) 0-40 mole% of a different monoethylenically unsaturated compound; and (3) 0-60 parts by weight of a second monomer mixture consisting of (a) 20-60 mole% of a styrene, (b) 30-80 mole% of a (cyclo)alkyl methacrylate having 1-12 carbon atoms in the (cyclo)alkyl group, and (c) 0-40 mole% of a different monoethylenically unsaturated compound, wherein the parts by weight of the polybutadiene, the first monomer mixture and the second monomer mixture is 100. A dispersion according to claim 1, wherein the dispersion stabilizer comprises 10-60 parts by weight of the second monomer mixture. A dispersion according to claims 1 or 2, characterized in that the first monomer mixture consists of: (a) 30-60 mole% of a styrene, (b) 30-70 mole% of a hydroxyalkyl methacrylate having 2 to 6 carbon atoms in the alkyl group, and (c) 0-20 mole% of a different monoethylenically unsaturated compound. A dispersion according to claims 1-3, characterized in that the second monomer mixture consists of: (a) 30-60 mole% of a styrene, (b) 30-70 mole% of a (cyclo)alkyl methacrylate having 1 to 12 carbon atoms in the (cyclo)alkyl group, and (c) 0-20 mole% of a different monoethylenically unsaturated compound. A dispersion according to claims 1-4, characterized in that the polybutadiene is built up from at least 80% by weight of butadiene-1,3. A dispersion according to claims 1-5, characterized in that the polybutadiene has a number average molecular weight of 2000-6000. A process for the preparation of the dispersion stabilizer of the dispersion of claims 1-6, characterized in that the first monomer mixture is copolymerized in the presence of the polybutadiene in an organic solvent at a temperature of 60°C-150°C, use being made of a radical initiator in an amount of 1-12% by weight calculated on the polybutadiene. A process for the preparation of the dispersion stabilizer of claims 1 -6, characterized in that the first and second monomer mixtures are copolymerized, in random order, in the presence of the polybutadiene in an organic solvent at a temperature of 60°C-150°C, use being made of a radical initiator in an amount of 1-12% by weight calculated on the polybutadiene. A coating composition based on a dispersion according to any one of the claims 1-6. A process for coating a substrate with a coating composition, characterized in that use is made of a composition according to any one of the claims 1-6 and 9.

Inventors: BUTER, ROELOF
Applicants: AKZO N.V.
Application year: 1989
Main classification: C08F2
IPC codes: C08F2, C09D133, C09D151, C08F279, C08L33, C08L51