Vinylidene chloride polymer latices

Claim 2

A vinylidene halide copolymer latex comprising an internal phase of vinylidene halide copolymer particles homogeneously dispersed within an external aqueous phase, said vinylidene halide copolymer particles comprising the copolymerizate of: (A) vinylidene halide as the principal copolymerized comonomer; (B) from about 0.2 to about 5 percent by weight of an ethylenically unsaturated sulfated monomer represented by the structural formula: ##STR10## wherein R is at least one member selected from the group consisting of hydrogen and hydrocarbyl, R' represents a hydrocarbylene group, n is an integer having a value of at least one, and M is a cation; (C) from about 0.5% to 25% by weight of a hydroxyalkyl ester of an alpha, beta-ethylenically unsaturated carboxylic acid; and (D) up to 40 percent by weight of an ethylenically unsaturated monomer other than copolymerized comonomers (A), (B) and (C).

Claim 3

The latex according to claim 1 wherein the copolymer contains (on a copolymer weight basis) vinylidene chloride (A) as the major copolymerized comonomer, from about 0.25% to about 2.5% copolymerized sulfated monomer (B), from about 2% to about 20% hydroxyalkyl ester of an alpha, beta-ethylenically unsaturated carboxylic acid and at least 4% to less than 25% by weight copolymerized comonomer (D).

Claim 4

The latex according to claim 2 wherein the copolymer particles have an average particle size of less than 0.25 micron and the latice contains (on a copolymer dry weight basis) between 0.25% to 1.5% non-polymerizable surfactant.

Claim 5

The latex according to claim 3 wherein copolymerized comonomers (A), (B) and (C) comprise about 85% to about 95% of the copolymer weight with the balance of the copolymer weight being comprised of copolymerized comonomer (D).

Claim 6

The latex according to claim 1 wherein the copolymerized monomers comprises from about 70% to about 95% vinylidene chloride, from about 3% to about 15% hydroxyalkyl acrylate and hydroxyalkyl methacrylate, from about 0.5% to about 2% sulfated monomer, the latice is stabilized with at least one non-polymerizable surfactant selected from the group consisting of anionic surfactant and non-ionic surfactant with the total anionic and non-ionic surfactant concentration in said latice (on a dry copolymer weight basis) ranging from 0.35% to 1.0% and the copolymer average particle size ranges from about 0.1 to about 0.2 microns.

Claim 7

The latex according to claim 5 wherein the total water-soluble salt content of the latice is less than 0.5% of the copolymer dry weight, the copolymer comprises less than 3% by weight copolymerized monomers which contain acid and acid salt moieties and the hydroxyalkyl acrylate and hydroxyalkyl methacrylate consists essentially of hydroxyalkyl groups containing from 1 to 3 carbon atoms inclusive.

Claim 8

The latex according to claim 6 wherein the sulfated monomer formula, R represents either hydrogen or lower alkyl group of 1 to 4 carbon atoms inclusive, R' represents a saturated alkylene group of 2 to 4 carbon atoms inclusve, n has a value of 1 to 5 inclusive and M represents a fugative cation having a boiling point of less than 30° C. at 760 mm pressure.

Claim 9

The latex according to claim 6 which contains on a copolymerized comonomer weight basis from about 75% to about 87% vinylidene chloride, from about 5% to about 10% hydroxyalkyl ester (C) monomer with the hydroxypropyl and hydroxyethyl esters of methacrylic acid and acrylic acid comprising at least 75% by weight of the total copolymerized monomer (C) weight, and from about 7% to about 13% by weight copolymerized monomer (D).

Claim 10

The latex according to claim 8 wherein a major weight portion of copolymerized monomer (D) is comprised of alkyl esters of an alpha, beta-ethylenically unsaturated, monocarboxylic acid in which the alkyl ester of said monomer (D) contains from 1 to 8 carbon atoms inclusive.

Claim 11

The latex according to claim 8 wherein at least 75% by weight of monomer (D) is comprised of alkyl acrylates or alkyl methacrylates or a mixture of an alkyl acrylate and alkyl methacrylate in which the alkyl ester groups of the alkyl acrylate and alkyl methacrylate are characterized as containing from 1 to 8 carbon atoms inclusive.

Claim 12

A vinylidene halide copolymer composition comprising the copolymerizate of: (A) vinylidene halide as the principal copolymerized comonomer; (B) from about 0.2 to about 5 percent by weight of copolymerized ethylenically unsaturated sulfated monomer represented by the structural formula: ##STR11## wherein R is at least one member selected from the group consisting of hydrogen and hydrocarbyl, R' represents a hydrocarbylene group, n is an integer having a value of at least one, and M is a cation; (C) from about 0.5 to 25 percent by weight of copolymerized hydroxyalkyl ester of an alpha, beta-ethylenically unsaturated carboxylic acid; and (D) up to 40 percent by weight of copolymerized ethylenically unsaturated monomer other than copolymerized comonomers (A), (B) and (C).

Claim 13

A vinylidene halide copolymer composition comprising the copolymerizate of: (A) vinylidene halide as the principal copolymerized comonomer; (B) from about 0.2 to about 5 percent by weight of copolymerized ethylenically unsaturated sulfated monomer represented by the structural formula: ##STR11## wherein R is at least one member selected from the group consisting of hydrogen and hydrocarbyl, R' represents a hydrocarbylene group, n is an integer having a value of at least one, and M is a cation; (C) from about 0.5 to 25 percent by weight of copolymerized hydroxyalkyl ester of an alpha, beta-ethylenically unsaturated carboxylic acid; and (D) up to 40 percent by weight of copolymerized ethylenically unsaturated monomer other than copolymerized comonomers (A), (B) and (C).

Claim 14

The composition according to claim 11 wherein said composition comprises on a copolymerized comonomer weight basis from about 75% to about 87% vinylidene chloride, from about 0.25% to about 2.5% sulfated monomer (B), from about 5% to about 15% copolymerized hydroxyalkyl monomer (C) and at least 4% copolymerized monomer (D).

Claim 15

The composition according to claim 12 wherein the composition contains at least one unpolymerized surfactant selected from the group consisting of anionic surfactant and non-ionic surfactant with the total amount of said surfactant in the composition on a copolymer dry weight basis ranging from about 0.35% to about 1% and the composition contains (on a copolymer dry weight basis) less than 1% water-soluble salt contaminants.

Claim 16

The composition according to claim 12 wherein the copolymer contains from about 4% to about 15% by weight copolymerized alkyl ester of an alpha, beta-ethylenically unsaturated acid wherein the alkyl esters are at least one member selected from the group consisting of alkyl acrylate and alkyl methacrylate in which the alkyl group contains from 1 to 8 carbon atoms inclusive.

Claim 17

The composition according to claim 14 wherein the copolymerized sulfated monomer (B) comprises more than 0.5%, but less than 2% of the copolymer weight, R represents hydrogen or methyl, R' represents ethylene or propylene and n is an integer of 1 to 5 inclusive.

Claim 18

The composition according to claim 15 wherein at least 75% by weight of copolymerized hydroxyalkyl ester (C) comprises at least one copolymerized monomer or copolymerized monomer mixture of monomers of a member selected from the group consisting of hydroxyethyl acrylate and hydroxypropyl methacrylate.

Claim 19

The composition according to claim 15 wherein the non-polymerizable surfactant consists essentially of a combination of at least two anionic surfactants having different critical micelle concentration in a total amount ranging from about 0.4% to about 0.8% of the copolymer weight.

Claim 20

The composition according to claim 17 wherein the composition contains less than 0.3% by weight water-soluble salt contaminants on a copolymer dry weight basis.

Claim 21

In a method for preparing a vinylidene halide copolymer latex wherein pre-emulsified vinylidene halide and other copolymerizable monomers are continuously or intermittently feed into a copolymerization zone and copolymerized to a vinylidene halide copolymer latex, the improvement which comprises: (I) preparing an aqueous comonomer pre-emulsion comprised of: (A) vinylidene halide as the principal copolymerized comonomer; (B) from about 0.2 to about 5 percent by weight of an ethylenically unsaturated sulfated monomer represented by the structural formula: ##STR12## wherein R is at least one member selected from the group consisting of hydrogen and hydrocarbyl, R' represents a hydrocarbylene group, n is an integer having a value of at least one, and M is a cation; (C) from about 0.5 to 25 percent by weight of a hydroxyalkyl ester of an alpha, beta-ethylenically unsaturated carboxylic acid; and (D) up to 40 percent by weight of an ethylenically unsaturated monomer other than copolymerized comonomers (A), (B) and (C); with said comonomers being emulsified by a combination of at least two different emulsifiers characterized as having different critical micelle concentration, said emulsifier being at least one member selected from the group consisting of anionic surfactants and non-ionic surfactants with the total amount of said emulsifier in said pre-emulsion being sufficient to provide a vinylidene halide copolymer particles of an average particle size less than 0.25 micron at an emulsifier concentration (based on the comonomer total weight) ranging from about 0.35% to about 1%; (II) copolymerizing said pre-emulsified comonomers to provide a vinylidene halide latice containing copolymer particles of an average particle size less than 0.25 micron.

Claim 22

In a method for preparing a vinylidene halide copolymer latex wherein pre-emulsified vinylidene halide and other copolymerizable monomers are continuously or intermittently feed into a copolymerization zone and copolymerized to a vinylidene halide copolymer latex, the improvement which comprises: (I) preparing an aqueous comonomer pre-emulsion comprised of: (A) vinylidene halide as the principal copolymerized comonomer; (B) from about 0.2 to about 5 percent by weight of an ethylenically unsaturated sulfated monomer represented by the structural formula: ##STR12## wherein R is at least one member selected from the group consisting of hydrogen and hydrocarbyl, R' represents a hydrocarbylene group, n is an integer having a value of at least one, and M is a cation; (C) from about 0.5 to 25 percent by weight of a hydroxyalkyl ester of an alpha, beta-ethylenically unsaturated carboxylic acid; and (D) up to 40 percent by weight of an ethylenically unsaturated monomer other than copolymerized comonomers (A), (B) and (C); with said comonomers being emulsified by a combination of at least two different emulsifiers characterized as having different critical micelle concentration, said emulsifier being at least one member selected from the group consisting of anionic surfactants and non-ionic surfactants with the total amount of said emulsifier in said pre-emulsion being sufficient to provide a vinylidene halide copolymer particles of an average particle size less than 0.25 micron at an emulsifier concentration (based on the comonomer total weight) ranging from about 0.35% to about 1%; (II) copolymerizing said pre-emulsified comonomers to provide a vinylidene halide latice containing copolymer particles of an average particle size less than 0.25 micron.

Claim 23

The method according to claim 19 wherein the pre-emulsified comonomer comprises from about 75% to about 87% vinylidene chloride, about 0.5 to about 2% sulfated monomer, about 5% to about 15% hydroxyalkyl monomer (C) with hydroxyethyl or hydroxypropyl ester of methacrylic acid or acrylic acid or mixtures thereof comprising at least 75% by weight of the total copolymerized monomer (C) weight, from about 5% to about 15% monomer (D) wherein at least 75% by weight copolymerized monomer (D) is comprised of alkyl acrylate or alkyl methacrylate or a combination of alkyl acrylate and alkyl methacrylate which have alkyl ester groups of 1 to 8 carbon atoms inclusive.

Claim 24

The method according to claim 20 wherein the copolymerized latex contains less than 0.3% by weight water-soluble salt contaminants (copolymer dry solids weight basis), the emulsifier concentration ranges from about 0.4% to about 0.8%, and in the sulfated monomer (B) R represents hydrogen or methyl, R' represents ethylene or propylene and n is an integer of 1 to 5 inclusive.