Stable acrylic copolymer dispersions

Abstract: Stable aqueous acrylic resin dispersions are made from a dispersion in water of the reaction product of a carboxylic acid-containing acrylic resin and a diglycidyl ether of a polyoxyalkylene glycol.

Description: Field of the Invention The field of art to which this invention is directed is stable aqueous dispersions of acrylic polymers. Background to the Invention Acrylic ester resin emulsions are well known, having been made commercially for at least 30 years. Such emulsions are made by polymerizing acrylic ester monomer in water using nonionic and anionic surfactants as emulsifiers. Emulsions of this type have been used to manufacture various types of coatings, e.g. exterior and interior house paints. Such emulsions have found limited utility in industrial applications due to the lack of resistance properties, e.g. water resistance, which industrial coatings require. As described in US-A-4,177,177, polymer emulsions have been made by the emulsion polymerization of monomers, referred to hereinabove; by the direct emulsification of an organic-solvent solution of the polymer in water using an oil-in-water type emulsifier; by the inversion emulsification of an organic-solvent polymer solution by adding water to the polymer solution using an oil-in-water emulsifier which can act also as a water-in-oil emulsifier; by emulsification by neutralization wherein acid groups in the polymer are neutralized with a base, e.g. an amine, and the salted polymer is emulsified in water. In addition to the conventional nonionic and anionic surfactants, various kinds of compounds have been used as dispersants in forming aqueous dispersions of various polymers. One particularly useful dispersant for epoxide resins is described in FR-A-2,319,417 and US-A-4,315,044. This dispersant is the diglycidyl ether of polyoxyalkylene glycols, made from the reaction of epichlorohydrin and the glycol. In US-A-3,305,601, organic solvent solutions of acrylic resins containing carboxylic acid functionality are blended with epoxy resins and are cured to form tough, thermoset coatings. US-A-2,954,358 discloses a surface coating composition that comprises (a) 40 to 95 parts by weight of a linear thermoplastic copolymer of (1) 1 to 10 mole percent of acrylic acid or methacrylic acid, the copolymer being present either in the acid form or as a salt of ammonium hydroxide or of a water-soluble amine and (2) 90 to 99 mole percent of at least one alkyl ester of one of said acids, and (b) 5 to 6 parts by weight of an aliphatic polyepoxide in an aqueous system, the polyepoxide being one, in particular, that contains at least two vic-epoxy groups in which the epoxy oxygen atom is attached to adjacent carbon atoms. Due to environmental concerns, there is an ongoing effort to decrease or eliminate the use of organic solvents in protective and ornamental coatings and to formulate coatings in aqueous systems which have properties equal to or better than the organic solvent systems. Summary of the Invention This invention is directed to acrylic resins. In one aspect, this invention pertains to stable aqueous acrylic resin dispersions. In another aspect, this invention relates to a process for preparing stable aqueous acrylic resin dispersions. In still another aspect, this invention pertains to thermosetting coating compositions made from the stable aqueous acrylic resin dispersions and epoxy resins. The stable aqueous resin dispersion of this invention is made up of an aqueous medium having dispersed therein the reaction product of an acrylic resin having an acid value of from 10 to 150 and a diglycidyl ether of a polyoxyalkylene glycol, wherein said polyoxyalkylene glycol is a block copolymer of ethylene oxide and propylene oxide with the polyoxypropylene blocks in the middle of terminal polyoxyethylene blocks. The stable aqueous resin dispersion of this invention when blended with epoxy resins is useful in the formulation of coatings which cure under ambient conditions or when heated to elevated temperatures. Description of preferred embodiments The acrylic resins useful in this invention include copolymers of ethylenically unsaturated polymerizable monomers wherein at least one monomer is a polymerizable acid, i.e. a monomer containing a carboxylic acid group. The term "acrylic resins" as used herein is intended to cover copolymers of monomers wherein from 25 up to 100 weight percent of the monomers are acrylic monomers. Examples of acrylic monomers useful in this invention are the acrylic and methacrylic esters wherein the ester group contains from 1 to 18 carbon atoms. Specific examples of such monomers are methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, 2-ethylhexyl acrylate, nonyl acrylate, hydroxyethyl acrylate, hydroxypropyl acrylate, hydroxyethyl methacrylate, and hydroxypropyl methacrylate. Other useful acrylic monomers are acrylonitrile, methacrylonitrile, acrylic acid, and methacrylic acid. Other monomers which are useful in this invention are monomers copolymerizable with acrylic monomers such as styrene, vinyl toluene, dimethyl maleate, diethyl fumarate, dibutyl maleate, and half esters of maleic or fumaric acid, e.g. ethyl acid maleate and butyl acid fumarate. Additional monomers are maleic acid, fumaric acid and itaconic acid. The acrylic resins useful in this invention contain as one of the monomer components one or more acid monomers in an amount sufficient for the acrylic resin to have an acid value of from 10 to 150. This amount of acid monomer is from 1.5 to 23 weight percent of the total monomer weight. The preferred acid value is from 75 to 85 with the amount of monomer, e.g. acrylic acid, being from 9 to 11 weight percent. Preferred monomers useful in this invention are acrylic and methacrylic acid, acrylic or methacrylic esters wherein the ester group contains 1 to 4 carbon atoms, and styrene or vinyl toluene. The most preferred monomers are acrylic acid, butyl acrylate, and styrene. The acrylic resins used in this invention are wellknown compositions and are prepared by solution polymerization techniques using free-radical catalyst. Such procedures are described in US-A-3,305,601. Organic solvents used to prepare the acrylic resins are, preferably, those which are substantially watermiscible, either in the form of a single polar compound or as a mixture which can include non-polar constituents. Suitable organic solvents, either alone or in admixture, include hydroxyethyl acetate, 2-ethoxyethyl acetate, propylene glycol monomethyl ether, propylene glycol monoethyl ether, 2-propoxyethanol, ethylene glycol monobutyl ether and diethylene glycol monobutyl ether. Additional solvents include ketones, such as methyl ethyl ketone and methyl isobutyl ketone. Non-polar solvents which can be included as a minor constituent of the organic solvent component include aliphatic and aromatic hydrocarbons, such as naphtha, heptane, hexane, mineral spirits, toluene and xylene. The acrylic resin solutions useful in this invention are generally those which have a viscosity of less than 10,000 cps (mPa.s) at 200°F (93°C) and a solids content of from 25 to 80 percent. Preferably, the viscosity will be less than 5000 cps (mPa.s) at 200°F (93°C) and the solids content will be from 40 to 80 weight percent. The diglycidyl ether of a polyoxyalkylene glycol useful in this invention is the diglycidyl ether of block copolymers of ethylene oxide and propylene oxide wherein the polyoxypropylene block is in the middle with the polyoxyethylene blocks being in the terminal positions. Such polyoxyalkylene glycols have molecular weights of from 4,000 to 20,000 and are derived from 50 to 90 weight percent ethylene oxide and from 10 to 50 weight percent propylene oxide. The diglycidyl ethers are prepared by reacting the polyoxyalkylene glycol with epichlorohydrin using a Lewis acid catalyst, followed by dehydrohalogenation with caustic. Such diglycidyl ethers are described in detail in FR-A-2,319,417. The amount of diglycidyl ether used in this invention is from 2 to 10 weight percent, preferably from about 5 to 7 weight percent, wherein said weight percentages are based on the weight of acrylic resin and diglycidyl ether. The acrylic resin and the diglycidyl ether are reacted by mixing the two components with or without a carboxy epoxy catalyst and applying heat until the glycidyl groups react with the carboxylic acid groups of the acrylic resin. Generally, the reaction is conducted at a temperature of from 225°F (107°C) to 300°F (149°C) for from 1 to 4 hours. Preferably, a small amount of a basic catalyst, such as an alkali metal hydroxide, carbonate or organic - acid salt, or a tertiary amine is used. Alternatively, the monomers used to prepare the acrylic resin can be polymerized in the presence of the diglycidyl ether of the polyoxyalkylene glycol. In preparing the compositions of this invention, water is added to the acrylic resin-diglycidyl ether reaction product with stirring to form first a water-in-oil emulsion which inverts to an oil-in-water emulsion or dispersion. The solids content of the acrylic resin-diglycidyl ether reaction product and organic solvent, prior to the addition of water, is from 40 to 80 weight percent. Sufficient water is added to bring about the inversion to the oil-in-water state. Generally, this amount of water will be sufficient to reduce the solids content of the dispersion to from 30 to 55 weight percent. The viscosity of the dispersions is 5000 to 17,000 cps (mPa.s) at 25°C. Additional water can be added to the dispersion for viscosity adjustment if necessary. The emulsification or dispersion process is conducted at room temperature up to 200°F (93°C). Preferably, the process is conducted at from 150° to 180°F (66° to 82°C). Aqueous dispersions of the acrylic resin can be made using the diglycidyl ether of a polyoxyalkylene glycol as the dispersing agent without co-reacting the resin and diglycidyl ether. However, such dispersions are inferior in stability to those made according to this invention. The aqueous acrylic dispersions of this invention are used in combination with epoxy resins for formulating thermosetting coatings which cure under ambient conditions as well as when heated. Useful epoxy resins are the wellknown polyglycidyl ethers of polyhydric phenols which are made by the reaction of polyhydric phenols with epichlorohydrin. Examples of such epoxy resins are those derived from resorcinol, p,p'-dihydroxy diphenyl, p,p'- dihydroxydiphenyl propane (commonly called bisphenol A), p,p'-dihydroxydiphenyl ethane and novolak resins. Generally, such epoxy resins have epoxide equivalent weights of from 110 to 400. Preferred epoxy resins for use in this invention are those based on bisphenol A having epoxide equivalent weights of from 175 to 350, most preferably from 180 to 220. Other epoxy resins which can be used in this invention are polyglycidyl esters, i.e. reaction products of epichlorohydrin and polybasic acids, e.g. azelic acid, dimer acids of fatty acids, adipic acid, sebacic acid and the phthalic acids. Other epoxy resins are those made by the epoxidation of unsaturated hydrocarbons, e.g. 3,4-epoxy-6- methyl cyclohexane carboxylate. In formulating the coating compositions, resins are blended with the acrylic dispersions in amounts based on epoxide equivalents and carboxylic acid equivalents. Generally, the equivalent ratios will be from 0.5 to 1.5 epoxide equivalents per each carboxylic acid equivalent. Preferably the ratios will be from 0.75 to 1.25 to 1, and most preferably, 1 to 1. Blends of the aqueous acrylic resin dispersions and epoxy resins when used as coating compositions are curable at room temperature or by heating up to a temperature of 150°C or higher. Preferably, the compositions are used in room temperature curing formulations. In addition to epoxy resins, the acrylic resin dispersions can be blended with other polyfunctional reactants, e.g. aminoplast resins, phenolplast resins or blocked polyisocyanates. When formulated into coatings, the aqueous acrylic dispersions and crosslinking agents can contain other components conventionally used in coating technology, e.g. pigments, flow-control aids, and thickeners. The following examples illustrate the invention in greater detail, Examples 5 to 8 being given for the purpose of comparison. Parts and percentages, unless otherwise designated, are parts and percentages by weight. Example 1 To a suitable reactor were added 4951 parts of 2- propoxy ethanol. To a monomer addition tank were added 5955 parts of styrene, 4597 parts of butyl acrylate and 1466 parts of acrylic acid. After thorough mixing, 241 parts of 2,2'-azobis(isobutyronitrile) were added. Heat and agitation were applied to the reactor and the temperature was raised to 200°F (93°C). The monomer solution was then added over a period of 3 hours while keeping the temperature at 200°F (93°C). The addition tank was flushed with 200 parts of 2-propoxyethanol which was added to the reactor. The temperature was held at 200-210°F (93 - 99°C) for 1 hour. Di-tertiary butyl peroxide, 65.6 parts, was then added. The temperature was raised to 255-265°F (124 - 129°C) and was held at this temperature range for 3 hours to complete the polymerization reaction. The temperature was lowered to 200-210°F (93 - 99°C) and the acrylic polymer solution was filtered through a 10 µm filter press and into containers. The acrylic polymer solution had a Gardner-Holdt viscosity of Z₈ at 25°C and 70 percent solids. Example 2 To a suitable reactor were added 201 parts of the acrylic polymer solution of Example 1, 9.5 parts of the diglycidyl ether of Pluronic F88 (BASF - Wyandotte) and 0.02 part of sodium benzoate. Pluronic F88 is a block copolymer of ethylene oxide and propylene oxide with the polyoxypropylene block in the middle with terminal polyoxyethylene blocks. The copolymer contains 80 weight percent ethylene and 20 weight percent propylene and has an average molecular weight of 10,800. Heat and agitation were applied raising the temperature to 280°F (138°C). The temperature was held at 275-280°F (135 - 138°C) for 1 hour and was cooled to 160°F (71°C). Deionized water, 74.2 parts, was then added over a period of one hour and 30 minutes with the temperature dropping to 125°F (52°C). A creamy smooth water-in-oil emulsion first formed which inverted to an oil-in-water emulsion. Additional deionized water, 54.4 parts, was added over 28 minutes. An additional 16 parts of deionized water were added to adjust the solids content to 43 percent. The resulting dispersion had a viscosity of 160 cps (mPa.s) at 25°C, measured with a Brookfield viscometer, No. 1 spindle at 20 rpm. After 25 days at room temperature, the dispersion had very slight solvent separation and a small amount of settling. Example 3 Using the same procedure described in Example 2, 930 parts of the acrylic polymers solution described in Example 1 were mixed with 43.9 parts of the diglycidyl ether described in Example 2, and 0.09 part of sodium benzoate. After heating at 280°F (138°C) for 1 hour, 343.2 parts of deionized water were added to form first a water-in-oil emulsion which inverted to an oil-in-water emulsion. Additional water, 126.5 parts, was added bringing the solids content to 49.33 percent. The viscosity at 25°C was 9810 cps (mPa.s), No. 5 spindle at 20 rpm. After 15 days at room temperature, the dispersion exhibited slight solvent separation which could easily be stirred in. A portion of the dispersion was reduced to 45.9 percent solids with additional water. The viscosity at 25°C was 1290 cps (mPa.s). After 15 days, the dispersion exhibited soft settling which could easily be stirred in. Example 4 To a suitable reactor were added 846 parts of ethylene glycol monobutyl ether. To a monomer addition vessel were added 768.8 parts of methyl methacrylate, 976.5 parts of butyl methacrylate, 330.0 parts of hydroxypropyl methacrylate, 174.8 parts of methacrylic acid and 118.5 parts of cumene hydroperoxide. Approximately, 20 percent of the monomer-catalyst mixture was added to the reactor, and heat and agitation were applied. When the temperature reached 300°F (149°C), addition of monomer-catalyst solution was begun. The addition was completed in 3 hours and 5 minutes with the temperature at 310°F (154°C). Heating was continued for 2 hours holding the temperature at 300-310°F (149-154°C). The diglycidyl ether of the polyoxyalkylene glycol described in Example 2, 151.2 parts, was then added along with 0.3 part of sodium benzoate. The temperature was held at 300°F (149°C) for 1 hour and 20 minutes. The resulting acrylic resin solution had a viscosity (Gardner-Holdt at 25°C) greater than Z₈ at 70 percent solids and an acid value, solids basis of 50.3. To another reactor were added 996 parts of the acrylic resin solution. Heat agitation were applied and the temperature was raised to 160°F (71°C). Deionized water was then added, first forming a water-in-oil emulsion, followed by inversion to an oil-in-water emulsion. A total of 673 parts of water were added. The resulting stable dispersion at 41.5 percent solids had a viscosity of 18,500 cps (mPa.s) at 25°C. Several dispersions were made using the diglycidyl ether of Example 2 as the dispersant. These dispersions differed from Examples 2, 3, and 4 in that the dispersant was not co-reacted with carboxylic acid groups of the acrylic copolymer. The details of these are given in the following Examples 5, 6 and 7. Example 5 (Comparison) To a suitable reactor were added 1102.5 parts of the acrylic polymer solution described in Example 1 and 52.1 parts of the diglycidyl ether described in Example 2. Heat was applied raising the temperature to 205°F (96°C) in order to dissolve the diglycidyl ether. The temperature was then lowered to 180°F (82°C), and 288.3 parts of deionized water were added over 58 minutes. A water-in-oil emulsion was formed initially followed by inversion to an oil-in-water dispersion. Additional deionized water, 230.9 parts, was added over 30 minutes. A smooth dispersion having a viscosity of 312 cps (mPa.s) at 53 percent solids was formed. The dispersion separated badly overnight forming a bottom layer. Example 6 (Comparison) Using the same procedure described in Example 5, 925 parts of the acrylic polymer solution described in Example 1 and 43.7 parts of the diglycidyl ether described in Example 2 were blended together and heated to 215°F (102°C) to melt out and dissolve the diglycidyl in the acrylic solution. When solution was obtained, the temperature was dropped to 180°F (82°C). A total of 435.5 parts of deionized water were added to form an oil-in-water dispersion having a viscosity at 25°C of 1220 cps (mPa.s), No. 5 spindle at 20 rpm. The solids content was 52.8 percent. After 6 days at room temperature, the dispersion exhibited hard settling which could be stirred in. After 18 days, there was solvent separation and hard settling which could be stirred in. After 4 months, the settling could not be stirred in. Example 7 (Comparison) Using the same procedure described in Example 5, a dispersion was made using 978 parts of the acrylic solution described in Example 1, 46.2 parts of the diglycidyl ether described in Example 2, and 376.2 parts of deionized water. The resulting oil-in-water dispersion had a viscosity at 25°C of 1920 cps (mPa.s), No. 5 spindle at 20 rpm and a solids content of 52.8 percent. After 14 days at room temperature, the dispersion had separated with a solvent layer on top. The dispersion could be reformed with stirring. Example 8 (Comparison) As shown by this example, an acrylic resin containing carboxylic acid groups is salted with an amine and dispersed in water. To a suitable reactor were added 1299 parts of 2- propoxyethanol and 575 parts of xylene. To the monomer addition tanks attached to the reactor were added 911 parts of acrylic acid, 3,703 parts of styrene, 2858 parts of butyl acrylate and 150 parts of 2,2'-azobis(isobutyronitrile). Agitation was begun and the reactor temperature was raised to 200°F (93°C). The monomer-catalyst solution was then added over a 4 hour period while keeping the temperature at 200-210°F (93-99°C). When the addition was completed, the temperature was held at 200-210°F (93-99°C) for 1 hour. Di-tertiary butyl peroxide, 40 parts, was then added, the temperature was raised to 255-265°F (124-129°C) and was held within this range for 1 hour. The temperature was then lowered to 180-190°F (82-88°C), and 527 parts of triethylamine were slowly added over a 30 minute period with the temperature at 180-190°F (82-88°C). After the addition was completed, the temperature was held at 180-190°F (82- 88°C) for 1 hour. Deionized water, 7072 parts, heated to 180-190°F (82- 88°C), was then added over a 1 hour period. The temperature was then lowered to 150°F (66°C) and 400 parts of deionized water were added over a 10 minute period. After 30 minutes with the temperature at 150°F (66°C), the dispersion was transferred to a storage tank for viscosity equilibration. The viscosity of the dispersion when transferred was 600,000 to 900,000 cps (mPa.s) at 42 percent solids. After 5 to 7 days the viscosity dropped to 10,000-25,000 cps (mPa.s). Example 9 Coating compositions were prepared by blending the acrylic resin dispersions of Examples 2, 3 and 4 with the diglycidyl ether of bisphenol A having an epoxide equivalent weight of 190. Coating compositions were also prepared from Example 8, the acrylic dispersion made by amine salting of the carboxylic acid groups, and the diglycidyl ether of bisphenol A. In Table 1, are listed the acrylic resin dispersion by Example number, the equivalents of carboxylic acid and epoxy used in each formulation, and the catalyst used in the formulation. The catalysts were triethylamine (TEA), tetramethylammonium hydroxide (TMAH) at 25 percent solids in methanol, tetraethylene diamine (DABCO) at 25 percent in ethylene glycol monopropyl ether and 1,5- diazobicyclo-4,3-non-5-ene (DBN). The percent catalyst is the amount of catalyst, active basis, based on the weight of acrylic resin dispersion solids and epoxy resin. Films were prepared from the acrylic resin dispersionepoxy resin blends using a 3 mil (25.4µm) Byrd applicator on glass panels. The films were cured at room temperature. The evaluation of the films is shown in Tables 2 and 3. Example 10 To a suitable reactor were added 567 parts of 2- propoxyethanol, 94.3 parts of the diglycidyl ether of Pluronic F88 described in Example 2 and 1.9 parts of sodium benzoate. To a monomer addition funnel were added 681.9 parts of styrene, 526.4 parts of butyl acrylate, 167.9 parts of acrylic acid, and 27.7 parts of 2,2'- azobis(isobutyronitrile). Heat and agitation were applied to the reactor and the temperature was raised to 200°F (93°C). The monomer solution was then slowly added over a period of 3 hours with the temperature being held between 190 and 255°F (88 - 124°C). The monomer addition funnel was flushed with 23.1 parts of 2-propoxyethanol which was added to the reactor. Di-tertiary butyl peroxide, 7.5 parts, and 39.2 parts of 2-propoxyethanol were then added, the temperature was raised to 255°F (124°C) and was held at 250- 270°F (121 - 132°C) for 3 hours. An additional 7.5 parts of ditertiary butyl peroxide were added and heating was continued for 1 hour and 45 minutes at 250°F (121°C). The resulting polymer solution had a solids content of 70.61 percent and an acid value of 74.69. To a suitable reactor were added 932.6 parts of the above described polymer solution. Heat and agitation were applied and when the temperature reached 160°F (71°C), the addition of 328.6 parts of deionized water was begun. All of the water was added in one hour and 30 minutes with the temperature being held at 130-180°F (54-82°C). Additional water, 29.9 parts, was added and stirred in followed by the addition of 146 parts of water. The resulting dispersion, at 42.39 percent solids, had a viscosity of 13,800 cps (mPa.s) at 25°C, No. 5 spindle, 20 RPM. After 3 months, the dispersion was stable and the viscosity was 16,766 cps (mPa.s). Example 11 Using the same procedure described in Example 10, a polymer solution was prepared by adding catalyst-monomer mixture of 197.0 parts of methyl methacrylate, 525.4 parts of butyl methacrylate, 277.2 parts of butyl acrylate, 289 parts of hydroxypropyl methacrylate, 25 parts of methacrylic acid and 55.7 parts of 2,2'-azobis(isobutyronitrile) to 544.8 parts of 2-propoxyethanol, 86.8 parts of the diglycidyl ether of Pluronic F88 and 1.2 parts of sodium benzoate and heating at 200-245°F (93 - 118°C) for 5 hours. After the addition of 54.6 parts of 2-propoxyethanol, the resulting polymers solution had a solids content of 68.75 percent and an acid value of 16.8. An aqueous dispersion was prepared by adding 327.8 parts of deionized water to 930.4 parts of the above described polymer solution using the procedure described in Example 10. The dispersion had a viscosity of 13,000 cps (mPa.s) at 51.4 percent solids. After three months, the dispersion was stable with a viscosity of 14,200 cps (mPa.s). Example 12 A copolymer solution, 300 parts, made from 36.84 percent styrene, 36.84 percent butyl acrylate, 15.03 percent hydroxypropyl methacrylate and 11.29 percent acrylic acid at 72.17 percent solids in 2-butoxy ethanol was added to a reactor along with 6.7 parts of the diglycidyl ether of Pluronic F88 and 0.03 parts of sodium benzoate. Heat and agitation were applied raising the temperature to 280°F (138°C), and holding it at 280°F (138°C) for one hour. The temperature was then lowered to 170°F (77°C), and 114.4 parts of deionized water were added slowly forming a water-in-oil emulsion. After the addition of 25.3 parts of water, the emulsion inverted to an oil-in-water emulsion. The emulsion was then reduced to a solids content of 45.7 percent with additional water. The viscosity was 14,133 cps (mPa.s) at 25°C. The dispersion was stable after 3 months with no separation. It will of course be understood that the present invention has been described above purely by way of example and that modifications of detail can be made within the scope of the invention.

Claims: A stable aqueous acrylic resin dispersion comprising (A) an aqueous medium and (B) the reaction product of (a) from 90 to 98 weight percent of an acrylic resin having an acid value of from 10 to 150, and (b) from 2 to 10 weight percent of a diglycidyl ether of a polyoxyalkylene glycol wherein said polyoxyalkylene glycol is a block copolymer of ethylene oxide and propylene oxide with the polyoxypropylene block in the middle with terminal polyoxyethylene blocks, and wherein said weight percentages are based on the weight of (a) and (b). The dispersion of claim 1 wherein the acid value of the acrylic resin is from 75 to 85. The dispersion of claim 1 or 2 wherein the polyoxyalkylene glycol contains from 50 to 90 weight percent polyoxyethylene blocks and from 10 to 50 weight percent polyoxypropylene blocks, and wherein the polyoxyalkylene glycol has a molecular weight of from 4,000 to 20,000. The dispersion of claim 1, 2 or 3 wherein the diglycidyl ether of the polyoxyalkylene glycol is present in the amount of from 5 to 7 weight percent. The dispersion of any of claims 1 to 4 wherein the acrylic resin is a copolymer of acrylic or methacrylic acid, an acrylic or methacrylic ester wherein the ester group contains 1 to 4 carbon atoms, and styrene or vinyl toluene. The dispersion of claim 5 wherein the acrylic resin is a copolymer of acrylic acid, butyl acrylate, and styrene. A process for preparing a stable aqueous acrylic resin dispersion which comprises: (A) reacting an acrylic resin in the amount of from 90 to 98 weight percent and having an acid value of from 10 to 150 with from 2 to 10 weight percent of a diglycidyl ether of a polyoxyalkylene glycol wherein said polyoxyalkylene glycol is a block copolymer of ethylene oxide and propylene oxide with the polyoxypropylene block in the middle with terminal polyoxyethylene blocks, for a time sufficient to react the glycidyl groups of the diglycidyl ether with the acid groups of the acrylic resin; and (B) adding sufficient water with agitation to the reaction product of (A) to form first a water-in-oil emulsion followed by inversion to an oil-in-water emulsion. The process of claim 7 wherein the acrylic resin and the diglycidyl ether of the polyoxyalkylene glycol are reacted at a temperature of from 225°F (107°C) to 300°F (149°C). The process of claim 7 or 8 wherein the acid value of the acrylic resin is from 75 to 85. The process of claim 7, 8 or 9 wherein the polyoxyalkylene glycol contains from 50 to 90 weight percent polyoxyethylene blocks and from 10 to 50 weight percent polyoxypropylene blocks, and wherein the polyoxyalkylene glycol has a molecular weight of from 4,000 to 20,000. The process of any of claims 7 to 10 wherein the diglycidyl ether of the polyoxyalkylene glycol is present in the amount from 5 to 7 weight percent. The process of any of claims 7 to 11 wherein the acrylic resin is a copolymer of acrylic acid or methacrylic acid, acrylic or methacrylic ester wherein the ester group contains 1 to 4 carbon atoms, and styrene or vinyl toluene. The process of claim 12 wherein the acrylic resin is a copolymer of acrylic acid, butyl acrylate, and styrene. The process of any of claims 7 to 13 wherein the reaction product of the acrylic resin and the diglycidyl ether of the polyoxyalkylene glycol is prepared by polymerizing acrylic monomers in the presence of the diglycidyl ether of the polyoxyalkylene glycol. A curable composition comprising a blend of the stable dispersion of any of claims 1 to 6 , or the stable dispersion prepared by the process of any of the claims 7 to 14,and an epoxy resin. The curable composition of claim 15 wherein the epoxy resin is a polyglycidyl ether of a polyhydric phenol. The curable composition of claim 16 wherein the polyhydric phenol is p,p'-dihydroxydiphenyl propane.

Inventors: MILLER MICHAEL M, MILLER, MICHAEL M.
Applicants: SHELL INT RESEARCH, SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1991
Main classification: C08J3
IPC codes: C08L33, C08L71, C08J3, C08G81