Polymer Dispersions

25
Polymer Dispersions and Their Industrial Applications Edited by Dieter Urban and Koichi Takamura Polymer Dispersions and Their Industrial Applications. Edited by Dieter Urban and Koichi Takamura Copyright © 2002 Wiley-VCH Verlag GmbH & Co. KGaA ISBNs: 3-527-30286-7 (Hardback); 3-527-60058-2 (Electronic)

Transcript of Polymer Dispersions

Page 1: Polymer Dispersions

Polymer Dispersions and Their Industrial ApplicationsEdited by Dieter Urban and

Koichi Takamura

Polymer Dispersions and Their Industrial Applications. Edited by Dieter Urban and Koichi TakamuraCopyright © 2002 Wiley-VCH Verlag GmbH & Co. KGaA

ISBNs: 3-527-30286-7 (Hardback); 3-527-60058-2 (Electronic)

Page 2: Polymer Dispersions

edited by Dieter Urban andKoichi Takamura

Polymer Dispersions and Their Industrial Applications

Polymer Dispersions and Their Industrial Applications. Edited by Dieter Urban and Koichi TakamuraCopyright © 2002 Wiley-VCH Verlag GmbH & Co. KGaA

ISBNs: 3-527-30286-7 (Hardback); 3-527-60058-2 (Electronic)

Page 3: Polymer Dispersions

IV

Editors

Dr. Dieter UrbanDr. Koichi TakamuraBASF Corp.11501 Steele Creek RoadCharlotte, NC 28273, USA

Cover photograph Scanning electron micrograph of a hollow sphere created by the deposition of 7.9 µm polystyrene particles on a nitrogen bubble during their preparation in the microgravity environment of the Space Shuttle Challenger (courtesy of the Emulsion Polymers Institute, Lehigh University,Bethlehem, PA, USA).

This book was carefully produced. Never-theless, editors, authors and publisher do not warrant the informationcontained therein to be free of errors. Readers are advised to keep in mind thatstatements, data, illustrations, proceduraldetails or other items may inadvertently be inaccurate.

Library of Congress Card No.: applied for

British Library Cataloguing-in-Publication DataA catalogue record for this book is available from the British Library.

Die Deutsche Bibliothek – CIP Cataloguing-in-Publication DataA catalogue record for this publication is available from Die Deutsche Bibliothek

© 2002 Wiley-VCH Verlag GmbH, WeinheimAll rights reserved (including those oftranslation into other languages). No part of this book may be reproduced in any form – by photoprinting, micro-film, or any other means – nor transmittedor translated into a machine language without written permission from the publishers. Registered names, trademarks,etc. used in this book, even when notspecifically marked as such, are not to beconsidered unprotected by law.

Printed in the Federal Republic of Germany Printed on acid-free paper

Typesetting TypoDesign Hecker GmbH, LeimenPrinting betz-druck GmbH, DarmstadtBinding Großbuchbinderei J. SchäfferGmbH & Co. KG, Grünstadt

ISBN 3-527-30286-7

Polymer Dispersions and Their Industrial Applications. Edited by Dieter Urban and Koichi TakamuraCopyright © 2002 Wiley-VCH Verlag GmbH & Co. KGaA

ISBNs: 3-527-30286-7 (Hardback); 3-527-60058-2 (Electronic)

Page 4: Polymer Dispersions

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Contents

Preface XIII

1 Introduction 1

1.1 Names and Definitions 1

1.2 Properties of Polymer Dispersions 3

1.3 Important Raw Materials 8

1.4 Commercial Importance of Polymer Dispersions 10

1.5 Manufacturers of Polymer Dispersions 12

References 14

2 Synthesis of Polymer Dispersions 15

2.1 Introduction 15

2.2 Chemistry 17

2.2.1 Mechanism of Emulsion Polymerization 17

2.2.2 Major Monomers 23

2.2.3 Functional Monomers 26

2.2.4 Surfactants 27

2.2.5 Initiator Systems 30

2.2.6 Other Ingredients 32

2.3 Manufacturing Processes 34

2.3.1 Types of Process 34

2.3.2 Influence of Process Conditions on Polymer/Colloidal Properties 37

2.3.3 Equipment Considerations 39

2.3.4 Safety Considerations 40

References 40

3 Characterization of Aqueous Polymer Dispersions 41

3.1 Introduction 41

3.2 Polymer Dispersions 42

3.2.1 General Characterization of Dispersions 42

3.2.2 Characterization of Polymer Particles 48

3.2.3 Residual Volatiles 56

3.2.4 Aqueous Phase Analysis 57

Polymer Dispersions and Their Industrial Applications. Edited by Dieter Urban and Koichi TakamuraCopyright © 2002 Wiley-VCH Verlag GmbH & Co. KGaA

ISBNs: 3-527-30286-7 (Hardback); 3-527-60058-2 (Electronic)

Page 5: Polymer Dispersions

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3.3 Polymer Films 58

3.3.1 Film Formation 59

3.3.2 Macroscopic Characterization of Polymer Films 60

3.3.3 Microscopic Characterization of Polymers 68

References 72

4 Applications in the Paper Industry 75

4.1 Introduction 75

4.2 The Paper Industry 76

4.3 Surface Sizing 79

4.4 Paper Coating 81

4.4.1 Coating Techniques 84

4.4.2 Pigments used in Coating Colors 86

4.4.3 Co-binders and Thickeners used in Coating Colors 87

4.4.4 Binders used in Coating Colors 90

4.4.5 Test Methods 97

4.5 Concluding Remarks 100

Acknowledgments 100

References 101

5 Applications for Printing Inks 103

5.1 Introduction 103

5.1.1 Flexographic Ink 104

5.1.2 Gravure Ink 106

5.2 Ink Composition 106

5.2.1 Pigment Dispersion 108

5.2.2 Emulsion Vehicle 109

5.2.3 Solution Vehicle 112

5.2.4 Waterborne Wax Emulsions and Powders 113

5.2.5 Ink Additives 113

5.3 Physical Properties and Test Methods 114

5.3.1 Typical Properties 114

5.3.2 Application Tests 115

5.3.3 Test Method Abstracts 115

5.4 Inks for Flexible Substrates (Films) 117

5.4.1 Surface Print Film 118

5.4.2 Lawn and Garden Bags 118

5.5 Inks for Paper Board Substrates 118

5.5.1 Folding Cartons 118

5.5.2 Direct Print Corrugated Packages 119

5.5.3 Pre-print Corrugated Packages 119

5.6 Inks for Poly-coated Board 120

5.6.1 Milk Cartons 120

5.6.2 Cup and Plate 120

5.7 Inks for Paper Products 120

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Contents VII

5.7.1 Multiple Wall Bags 121

5.7.2 Gift Wrap and Envelopes 121

5.7.3 Newspapers 121

5.7.4 Towel and Tissue 122

References 122

6 Applications for Decorative and Protective Coatings 123

6.1 Introduction 123

6.1.1 Market Overview 123

6.1.2 Coating Industry Trends 124

6.1.3 Coatings Provide Decoration and Protection 124

6.2 Overview of Coating Formulations 125

6.2.1 Volume Solids and Pigment Volume Content 125

6.2.2 Polymer Matrix 127

6.2.3 Film Formation 128

6.2.4 Typical Polymer Compositions 129

6.2.5 Pigments, Extenders, and Additives 132

6.3 Decorative Coatings 137

6.3.1 Emulsion Polymers in Decorative Coatings 137

6.3.2 Polymer Compositions used for Emulsion-based Decorative Coatings 137

6.3.3 Regional Distinctions in Decorative Coatings 138

6.3.4 Market Size of Decorative Coatings 138

6.4 Interior Decorative Coatings 139

6.4.1 Key Performance Features 139

6.4.2 Interior Decorative Coating Formulations 140

6.4.3 Standard Application and Performance Tests 142

6.5 Exterior Decorative Coatings 146

6.5.1 Key Performance Features 146

6.5.2 Exterior Decorative Coating Formulations 147

6.5.3 Standard Application and Performance Tests 147

6.6 Elastomeric Wall Coatings 149

6.6.1 Key Performance Features 149

6.6.2 Typical Elastomeric Wall Coating Formulations 150

6.6.3 Standard Application and Performance Tests 151

6.7 Primer Coatings 151

6.7.1 Key Performance Features 152

6.7.2 Primer Formulations 152

6.7.3 Standard Application and Performance Tests 153

6.8 Protective and Industrial Coatings 154

6.8.1 Copolymers used in Protective and Industrial Coatings 154

6.8.2 Market Size 155

6.8.3 Industrial Maintenance Coatings 155

6.8.4 Key Performance Features 155

6.8.5 Formulation Characteristics for Industrial Maintenance Coatings 156

6.8.6 Standard Application and Performance Tests 156

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6.9 Traffic Marking Paints 158

6.9.1 Description of Traffic Paint Market 158

6.9.2 Key Performance Features 159

6.9.3 Typical Traffic Paint Formulation 159

6.9.4 Standard Application and Performance Tests 159

References 161

7 Applications for Automotive Coatings 163

7.1 Introduction 163

7.1.1 History of Automotive Coating 164

7.2 Automotive Coating Layers 166

7.2.1 Electrocoat 170

7.2.2 Primer 172

7.2.3 Basecoat 173

7.3 Properties of Water-borne Binders used for Automotive Coatings 176

7.3.1 Emulsion Polymers 176

7.3.2 Microgels 177

7.3.3 Miniemulsions 177

7.3.4 Selection of Monomers, Initiators, and Surfactants 178

7.3.5 Secondary Acrylic Dispersions 179

7.3.6 Secondary Polyurethane Dispersions 179

7.4 Rheology 181

7.5 Crosslinking 183

7.6 Application Properties 185

7.6.1 Metallic Effect 186

7.7 Environmental Aspects and Future Trends 186

References 187

8 Applications in the Adhesives and Construction Industries 191

8.1 Introduction 191

8.2 Pressure-sensitive Adhesives 193

8.2.1 Self-adhesive Labels 194

8.2.2 Self-adhesive Tapes 207

8.2.3 Test Methods 210

8.3 Laminating Adhesives 217

8.3.1 Flexible Packaging 217

8.3.2 Glossy Film Lamination 219

8.3.3 Furniture and Automotive 222

8.4 Construction Adhesives 224

8.4.1 Floor-covering Adhesives 224

8.4.2 Sub-floor and Wall Mastics 231

8.4.3 Sealants 233

8.4.4 Ceramic Tile Adhesives 238

8.4.5 Polymer-modified Mortars 241

8.4.6 Waterproofing Membranes 244

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Contents IX

8.4.7 Elastomeric Roof Coatings 247

Acknowledgments 250

References 251

9 Applications in the Carpet Industry 253

9.1 Introduction 253

9.2 History of Carpet 253

9.3 Present Day Carpet Business 255

9.4 Carpet Backing Binders 256

9.5 Carpet Laminating 259

9.5.1 Background 259

9.5.2 Carpet Terminology 260

9.5.3 Back-coating Applications 261

9.5.4 Back-coating Formulations and Ingredients 262

9.5.5 Industry Issues 264

References 266

10 Non-wovens Application 267

10.1 Introduction 267

10.2 Manufacturing Systems 270

10.2.1 Web Formation 271

10.2.2 Web Consolidation 272

10.3 Polymer Dispersions for Chemical Bonding 273

10.4 Application Test Methods 275

References 281

11 Applications in the Leather Industry 283

11.1 Introduction 283

11.2 Market Situation 284

11.3 Leather Finishing 286

11.3.1 Modern Finishing 287

11.3.2 General Construction of Finishing Coats 287

11.3.3 Spray Dyeing 287

11.3.4 Grain Impregnation 287

11.3.5 Base Coat 287

11.3.6 Pigment Coat 288

11.3.7 Top Coat 288

11.4 Application Methods 288

11.4.1 Spraying 289

11.4.2 Roll Coating 289

11.4.3 Curtain Coater 289

11.5 Binders 291

11.5.1 Polyacrylate Dispersions 291

11.5.2 Polybutadiene Dispersions 291

11.5.3 Polyurethane Dispersions 292

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11.6 Production of Selected Leather Articles 292

11.6.1 Shoe Upper Leather 292

11.6.2 Apparel Leather 293

11.6.3 Automotive Leather 294

11.6.4 Furniture Leathers 295

11.7 Test Methods in Leather Finishing 296

11.7.1 Flexing Endurance 297

11.7.2 Rub-fastness 298

11.7.3 Dry and Wet Adhesion 299

11.7.4 Fastness to Ironing 299

11.7.5 Hot Air Fastness 299

11.7.6 Aging resistance 299

11.7.7 Fogging test 300

11.7.8 Light-fastness 300

11.7.9 Hot light aging 300

References 300

12 Applications for Asphalt Modification 301

12.1 Introduction 301

12.2 Hot Mix Asphalt Paving 303

12.2.1 Asphalt Specification 304

12.2.2 In-line Injection (Pump-in) 311

12.3 Paving with Asphalt Emulsion 313

12.3.1 Applications of Asphalt Emulsions 314

12.3.2 Asphalt Emulsion Tests 317

12.3.3 Polymer Honeycomb Structure in Cured Asphalt Emulsion 317

12.3.4 Asphalt Emulsion Residue Characterization 319

12.3.5 Application Tests for Chip Seal and Microsurfacing 321

12.4 Eco-efficiency Analysis 323

12.5 Concluding Remarks 326

Acknowledgement 326

References 326

13 Applications of Redispersible Powders 329

13.1 Introduction 329

13.2 Manufacturing of Redispersible Powders 330

13.3 Dry Mortar Technology 332

13.4 Markets and Application Areas of Redispersible Powders 333

13.4.1 Adhesives for Ceramic Tiles 334

13.4.2 Tile Grouts 340

13.4.3 Exterior Insulation and Finish Systems and Top Coats 341

13.4.4 Self-leveling Underlayments 345

13.4.5 Patch and Repair Mortars 346

13.4.6 Waterproof Membranes 350

13.5 Summary 353

Page 10: Polymer Dispersions

Contents XI

References 354

14 Applications for Modification of Plastic Materials 355

14.1 Introduction 355

14.2 Emulsion Polymerization and Isolation Technology 356

14.2.1 Isolation Technology 357

14.3 Processing Aids 358

14.3.1 Processing Aids for PVC 359

14.3.2 Processing Aids for Other Resins 366

14.4 Impact Modifiers 367

14.4.1 Impact Modifiers for PVC 368

14.4.2 Engineering Resins 375

Acknowledgment 378

References 379

15 Applications for Dipped Goods 383

15.1 Introduction 383

15.2 Polymers Used by the Dipping Industry 384

15.3 Principles of Dipping 385

15.4 Dipping Synthetic Polymer Emulsions in Practice 386

15.4.1 Former Design 386

15.4.2 Mix Design 388

15.4.3 Coagulant 390

15.4.4 The Dipping Process 390

15.5 The Testing of Synthetic Gloves 395

15.5.1 Non-safety-critical Gloves 395

15.5.2 Safety-critical Gloves 396

References 398

Index 399

Page 11: Polymer Dispersions

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Preface

Aqueous polymer dispersions are important raw materials used in a variety of in-dustrial processes. They consist of very small polymer particles dispersed in waterand appear as milky fluids. When finally processed and providing the function forwhich they were selected, they are barely visible. Polymer dispersions are used toprotect metal, wood, and leather against water and microorganisms, and are used asbinders for pigments, fillers, and fibers and to finish the surfaces of metal, wood orpaper. Protecting, binding, and finishing are the essential effects achieved by use ofpolymer dispersions.

In most applications the water will be evaporated and a functional polymer re-mains. This can be hard or tacky, plastic or elastic, transparent or opaque. Accord-ingly, they are used for coatings or as adhesives, for binders or foams, for clear coatvarnishes or opacifiers. It is even possible to reconcile these classically contradictoryproperties by proper design of a single dispersion or by mixing several.

Even small amounts of polymer dispersion are able to improve considerably theproperties of different binders, e.g. starch, bitumen, or cement.

The huge variety of applications continues into the area of solid plastic materials –impact modifiers are added to improve the properties of plastic materials. Dippinggoods, e.g. gloves, and latex foams for mattresses are polymeric materials which aremade directly from polymer dispersions.

Finally, there are also applications in which polymer dispersions remain in theirliquid form – they are used as drug carriers, in medical diagnosis, and in liquid soap.

This book focuses on the applications of aqueous polymer dispersions. The chap-ters on synthesis and characterization should be regarded as an introduction andshould aid understanding of the applications. The applications of aqueous polymerdispersions have developed differently, both historically and regionally. Regulatoryissues have contributed to these differences. The strongest development of polymerdispersions occurred in Europe and North America in the middle of the 20th centu-ry. The differences between these two regions are emphasized.

We are specially grateful to all the authors who helped us make this global com-parison and acknowledge the authors’ companies, for approving and supporting thiswork.

Charlotte, North Carolina, USA Dieter UrbanKoichi Takamura

Polymer Dispersions and Their Industrial Applications. Edited by Dieter Urban and Koichi TakamuraCopyright © 2002 Wiley-VCH Verlag GmbH & Co. KGaA

ISBNs: 3-527-30286-7 (Hardback); 3-527-60058-2 (Electronic)

Page 12: Polymer Dispersions

XV

List of Authors

Peter Blanpain7834 Covey Chase DriveCharlotte, NC 28210, USA

Dr. Mary BurchRohm & Haas Company727 Norristown RoadSpring House, PA 19477, USA

Dr. Chuen-Shyong ChouRohm & Haas CompanyRt. 413 and Old Rt. 13Bristol, PA 19007, USA

Dr. Dieter DistlerBASF AktiengesellschaftGKD - B1D-67056 Ludwigshafen, Germany

Dr. Johannes Peter DixBASF AktiengesellschaftEVL/I – G100D-67056 Ludwigshafen, Germany

Dr. Luke EganBASF Corporation11501 Steele Creek RoadCharlotte, NC 28273, USA

Dr. Onno GraalmannBASF Nederland B.V.Westervoortsedijk 71NL-6827 AV Arnhem, The Netherland

Dr. Sunitha GrandheeBASF Corporation26701 Telegraph RoadSouthfield, MI 48034, USA

Richard GrovesSynthomer LTDCentral Road, Templefields, Harlow, Essex, CM20 2BH, UK

Dr. Christoph HahnerWacker Polymer Systems, L. P.3301 Sutton Road Adrian, MI 49221, USA

Dr. Do Ik LeeThe Dow Chemical Company1604 BuildingMidland, MI 48674, USA

Dr. Hermann Lutz Wacker Polymer Systems GmbH&CoKGJohannes-Hees-Str. 24D-84489 Burghausen, Germany

Dr. Werner KirchnerBASF AktiengesellschaftEV/CS – H201D-67056 Ludwigshafen, Germany

Andrew LanhamSynthomer Ltd.Central Road, Templefields, Harlow, Essex, CM20 2BH, UK

Dr. Brough RicheyRohm & Haas Company727 Norristown RoadSpring House, PA 19477, USA

Dr. Jürgen Schmidt-ThümmesBASF AktiengesellschaftGKD/S – B1D-67056 Ludwigshafen, Germany

Dr. Elmar SchwarzenbachBASF AktiengesellschaftEDP/MB – H201D-67056 Ludwigshafen, Germany

Richard ScottBASF Corporation475 Reed Road NWDalton, GA 30720, USA

Polymer Dispersions and Their Industrial Applications. Edited by Dieter Urban and Koichi TakamuraCopyright © 2002 Wiley-VCH Verlag GmbH & Co. KGaA

ISBNs: 3-527-30286-7 (Hardback); 3-527-60058-2 (Electronic)

Page 13: Polymer Dispersions

XVI

J. Arthur SmithBASF Nederland B.V.Westervoortsedijk 71NL-6827 AV Arnhem, The Netherland

K. SpenceleySynthomer Ltd.Central Road, Templefields, Harlow, Essex, CM20 2BH, UK

Barna SzaboFlint Ink Corporation4600 Arrowhead DriveAnn Arbor, MI 48105, USA

Dr. Koichi TakamuraBASF Corporation11501 Steele Creek RoadCharlotte, NC 28273, USA

Jim TangerBASF Corporation11501 Steele Creek RoadCharlotte, NC 28273, USA

Michael A. TaylorBASF Corporation11501 Steele Creek RoadCharlotte, NC 28273, USA

Dr. Dieter UrbanBASF Corporation11501 Steele Creek RoadCharlotte, NC 28273, USA

Dr. Jane E. WeierRohm & Haas CompanyRt. 413 and Old Rt. 13Bristol, PA 19007, USA

Dr. Harm WieseBASF AktiengesellschaftGKD/N – B1D-67056 Ludwigshafen, Germany

Marilyn WolfBASF Corporation11501 Steele Creek RoadCharlotte, NC 28273, USA

Page 14: Polymer Dispersions

Color Plates XVII

Fig. 4-7 Effect of coated paper on offset printing.

Uncoated grade,supercalendered

Coated grade,supercalendered

Fig. 1-3Particle morphologies.

Raspberry structure

Core/shell structure

Acorn structure

Color Plates

Polymer Dispersions and Their Industrial Applications. Edited by Dieter Urban and Koichi TakamuraCopyright © 2002 Wiley-VCH Verlag GmbH & Co. KGaA

ISBNs: 3-527-30286-7 (Hardback); 3-527-60058-2 (Electronic)

Page 15: Polymer Dispersions

XVIII Color Plates

Fig. 12-15 Photo-micrograph demon-strating spontaneousformation of polymernetwork upon curingof the CRS-2 asphaltemulsion modifiedwith 3 % cationic SBRlatex.

Fig. 8-9 Schematic representation of PSA label coater.

Releaseliner

SteamDryerCoating head

Unwind Rewind

Laminatingstation

Backing

Fig. 4-8 Effect of coated paper on rotogravure printing.

Coatedgravurepaper

Uncoatedgravurepaper

Latex PolymerNetwork

50 µm

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399

aabrasion cohesion test Esso (ACTE) 323abrasion resistance 115, 332accelerators 389acorn structure 5acrylates 90acrylic adhesive 220acrylic dispersions 6, 12, 90, 108, 130 f., 142,

154, 193 ff., 217, 273 f., 285, 291, 358acrylic esters 90, 94additives 78, 132, 240, 332 f., 355adhesion 191 ff., 299, 330, 332, 338 f., 339adhesion level 210adhesion-elongation 238adhesive raw materials 192adhesives 191 ff., 334agglomeration number 28aggregates 332aging resistance 299American Standards (ANSI) 335analytical ultracentrifuge 51antifoam agents 6, 114, 136, 202antifreeze agents 235anti-sag 334apparel leather 284, 293applications tests 97 f., 114 f., 142 ff., 147 f.,

151, 156 f., 159 f., 168 ff., 210 ff., 221 f., 228 ff., 232, 237 f., 240, 246 f., 249, 261, 275 ff., 296 ff., 304 ff., 321, 335 ff., 368, 395 ff.

aqueous 1aqueous flexo news ink 121aqueous ink 104aqueous phase analysis 57asphalt binder 304asphalt composition 310asphalt consumption 301asphalt emulsion 302, 303, 313 ff.– anionic 315– application 314

– cationic 315– cured 318– ductility 317– elastic recovery 317– latex modified 318– medium-setting 313– modification 301– penetration 317– properties 309– rapid-setting 313– slow-setting 313– softening point 317– specification 304– tests 317– torsion recovery 317automotive coating 163 ff., 176 f., 183– appearance 169– basecoat 167– clearcoat 167– crosslinking 183– electrocoat 167– emulsion polymers 176– formulation 168– function of ingredients 168– function 167– layer 167– main ingredients 168– microgels 177– miniemulsions 177– performance 169– primer 167– standard tests 169automotive leather 284, 294average degree of polymerization 195

bback-coating of carpets 259, 262bally flexometer 297barrier coatings 7basecoat 173 ff., 287, 344

Index

Polymer Dispersions and Their Industrial Applications. Edited by Dieter Urban and Koichi TakamuraCopyright © 2002 Wiley-VCH Verlag GmbH & Co. KGaA

ISBNs: 3-527-30286-7 (Hardback); 3-527-60058-2 (Electronic)

Page 17: Polymer Dispersions

400 Index

bending beam rheometer 306, 308bimodal 5binder 78, 84 ff., 127, 253, 291, 332– natural 90 f.– paints 127– sole binder 90– styrene-acrylate 96 f.– styrene-butadiene 95, 97– synthetic 90 f.binding strength 87, 92 ff.biocides 6, 135, 203biodegradability 6blistering 93 ff.block resistance 116board 92branching 18brightness 84, 86, 93butadiene 9, 90, 94 f.butadiene-styrene copolymers 11, 90, 256 ff.,

273 f., 285, 291, 303 ff.butadiene-acrylonitrite copolymers 385 ff.butyl acrylate 90

ccalcium carbonate 86 f.calender 85 f.capillary hydrodynamic fractionation 53capillary water absorption 345carboxylated styrene/butadiene (XSB)

dispersions 6, 90, 256 ff., 273 f.carboxylic acid 26carboxymethylcellulose 88, 90carpet 253carpet backcoating 259carpet backing 253carpet backing binders 253, 256, 258– carboxylated styrene-butadiene 256– cold SB (styrene-butadiene) 256– high solids styrene-butadiene latex

(HSL) 256– hot SB (styrene-butadiene) 256– natural latex 256carpet laminating 259, 263 f.– adhesive scrim coat 263– pre-coat 263– unitary backing 264carpet production 255carpet terminology 260cement 333cementitious topcoats 345centrifugation 51ceramic tile adhesives 238 ff., 332 ff.chain entanglement 21chain transfer 18

chain transfer agent 32, 178, 198characterization 41 ff.chelating agent 34chemical bonding 273chemical reacting adhesives 192chemical resistance 116china clay 86chip seal 316, 321– application test 321coagulant dipping 386coagulants 390coagulation 3coagulum 37coagulum grit 42coating 205coating color 81, 85, ff.– co-binder thickeners 87– pigments 86– sheet-fed offset 86coating layers 166coating of carpets 261coating support materials 205coating weight of adhesives 207co-binder 84, 87 ff.coefficient of friction 116colloid mill 313color 65concrete 242, 346 ff.– maintenance 347– rehabilitation 349– repair 347 f.construction adhesives 224construction industries 191contaminants 36conversion 22conversion process 363– melt rheology 363conversion-time curve 23core-shell modifiers 373core-shell structure 4 f.core-shell impact modifier 376core-shell particle 71corona discharge 118corona-pretreated film 218corrosion inhibitor 114CPVP 126cracking 336crinkle resistance 116critical micelle concentration

(CMC) 19, 27critical PVC 126critical surface tension 65cross-linking 4, 9, 21, 33, 70, 113, 167, 183 f.,

220

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Index 401

cup and plate inks 120curtain coater 289 f.

ddecorative coatings 123 ff., 137, 139defoamer 6, 114, 136, 202degradation time 360delaminating 336delamination resistance 221density 43diafiltration 58dialysis 58differential scanning calorimetry 60dilatancy 45dipped gloves 388dipped goods 383dipping 384 ff.– forms 386– mix design 388– polymers 384– practical aspects 386– principles 385– process 383, 390 ff.direct print corrugated inks 119disc centrifuge 53dispersing aids 133, 235dispersion 1dissolution 66double-sided adhesive tapes 209Dougherty-Krieger equation 47dry adhesion 299dry mix mortars 333, 352dry mortar technology 332– pre-mixed 332– pre-packed 332– redispersible powders 332drying test 116dwell time 212dynamic light scattering 49dynamic mechanical analysis 63 f.dynamic shear rheometry (DSR) 306

eE.I.F. systems 342e-coat 170eco-efficiency analysis 323efflux time 44elastic modulus 62elastic recovery 237elasticity 6elastomeric roof coatings 247elastomeric wall coating 149 f.– application tests 151– formulation 150

electric double layer 26electrical tapes 208electrocoat 170 ff.electrokinetics 56electrolytes 33electrophoretic mobility 56elongation at break 6, 63elpo 170embrittlement 299emission measurement 230– chamber method 230emulsified asphalts 302emulsifier coverage 55emulsifiers 9emulsion polymerization 3, 16, 17, 20, 330,

356– at atmospheric pressure 16– at high pressures 16– mechanism 17emulsion 1emulsion polymers 15– synthesis 15emulsion vehicle 109engineering resins 375environmental impact 325equipment 39ethene 8, 10ethylene/vinyl acetate copolymers 6, 90,

330 ff.extenders 132extensibility 361exterior decorative coating 146 ff.– application tests 148– exterior exposure testing 148– formulations 147– performance tests 147– standard application tests 147exterior insulation and finish systems

(E.I.F.S.) 332exterior insulation systems 341exterior thermal insulation compounds

(E.T.I.C.S.) 332

ffastness 299fatigue cracking 306Fikentscher’s K-value 195, 360fillers 86, 202film formation 128 f.– coalescing agent 129– latex 128film forming emulsion polymer 117film morphology 70film whitening 67

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402 Index

finish systems 341finishing 287finishing coats 287flexibility 332, 336, 338– mortar 338flexible 217, 330, 336– packaging 217flexing endurance 297flexographic 103– ink formulation 107– printing press 105flexural strength 332flocculation techniques 57flock lining 394floor-covering adhesives 224flow behavior 44flow curve 44flow, Newtonian 45flow, pseudoplastic 45foam backing 257foam impregnation 274foaming 6foaming behavior 48fogging test 300foil duct tapes 208folding carton inks 118food packaging 7form 386– dipping 386form cleaning 391– dipping 391formulation 86 f., 107, 117 ff., 141, 147 ff.,

150, 152 f., 156 f., 168, 171, 199 ff., 203 f.,219, 224, 227 f., 233, 236, 239, 243, 245, 249,263 f., 274, 388

free radical 18free-radical polymerization 25freeze-thaw 116, 245, 336– stability 48functional monomers 26furniture automotive 222furniture leathers 295fusion promotion 359

ggas chromatography 56gas permeation 68gel effect 21gel fraction 67gel permeation chromatography 69glass transition temperature 1, 6, 60, 94,

128, 154, 195, 288, 338, 357gloss 65, 93, 99, 112gloss enamel 142

glossy film lamination 219glove dipping 391, 393– batch process 393– continuous process 391gloves 384, 391 ff.– dipping 391– disposable 391– fabric supported 394– polymeric 391– protective 396– testing 395– unsupported 392gradient polymer elution chromato-

graphy 69grain impregnation 287gravure 103– ink 106– ink formulation 107– printing press 106– roll 206Green Label certification 227– of adhesives 227green strength development 230

hheat distortion temperature (HDT) 356heat resistance 116heat sensitivity 33Helio test 100high float emulsions 314hot light aging 300hot mix asphalt 302 f.hydration 337hydrodynamic particle diameter 50hydrophobicity 332

iimpact behavior 376impact modification 370impact modifiers 11, 367, 373, 375– non-weatherable 375– weatherable core shell 373impact performance 369, 372impact resistance 367impurities 35 f.induction period 21industrial maintenance coatings 155 ff.– application tests 156, 158– formulation 157– performance tests 156– salt spray testing 158inisurf 9initiation 18initiator 9, 31, 178

Page 20: Polymer Dispersions

Index 403

– half-life 31– thermal decomposition 32– thermally dissociating 31initiator systems 30– half-life 30– peroxides 30– persulfate 30ink 93– absorption 93– additives 113– color strength 114– composition 106– for films 117– jet papers 81– splitting 97 ff.in-line injection 311interior decorative coating 139 ff.– adhesion test 144– application tests 142– block resistance 145– formulation 140 f.– freeze-thaw stability 142– heat age stabilitiy 142– interior flat coatings 140– performance test 145– print resistance test 145– scrub test 144– stability heat age test 142– stain resistance test 144– wall coatings enamels 140interior enamels 140internal surface area 3interparticle crosslinking 67, 70intrinsic viscosity 69isolation technology 356 f.

jjoint filling compositions 233

kkaolin clay 86, 87

llaboratory reactors 15laminating adhesives 217 f., 222laser light scattering 49latex 3– definition 3– paints 125lawn and garden bag inks 118layers 166– automotive coatings 166leather 283, 291– binder 291

– structure 283leather articles 292leather finishing 285 f., 296– test methods 296leather industry 283leather production 284letterpress 103life-cycle analysis 324light-fastness 300light transmission 49liquid soaps 7loaded wheel test (LWT) 322loss modulus 63low film forming temperature 112low temperature cracking 306lubrication 364

mmanufactures 12manufacturing processes 34– batch 34– continuous 34– plug-flow continuous reactor 34– semi-batch 35Maron plot 55masking tapes 209mastic products 231mechanical characterization 62mechanical stability 48medical diagnosis 7melt homogeneity 359melt rheology 363melt strength 361melt viscosity 362membrane filtration techniques 58membranes 350 f.– waterproof 350 f.metallic effect 186metallic flog (MF) index 182micellar nucleation 20micelles 19microgels 70, 177microorganisms 6, 203– protection against 203microscopic characterization 68microsurfacing 316, 321– application test 321– pavement 320Mie scattering 4milk carton ink 120milk carton wet rub 116mineral topcoats 344miniemulsions 177

Page 21: Polymer Dispersions

404 Index

minimum film formation temperature(MFFT) 59, 128

model system 17modified fretting 323modifier shell effects 372modulus of elasticity 336moisture vapor transmission 247molecular weight 69, 127, 357monomer 23 f., 94monomers 23, 25 f.– butadiene 24– concentration 21– diene 24– fox equation 23– functional 26– major 23– polymer design 25– polymer properties 23– vinyl monomer 24mortar 239, 241 ff., 348 ff.mottling 93, 99multiple wall bags 121– inks 121

nnatural adhesives 192natural rubber latex 11, 303needlepunched carpet 255neoprene latex 303newspapers 121– inks 121non-weatherable impact modifiers 375non-weatherable PVC formulations 374non-woven manufacturing systems 270non-wovens 267 ff.– application tests 275– applications 268– binders 273– standard test methods 276notch sensitivity 370

oOEM coatings 164offset printing 82, 85, 93 ff.– rotogravure printing 93– sheet-fed 85 f.– web offset printing 93offset test 99oligomeric radicals 20opacifying aids 134– hollow sphere particles 134– TiO2 134opacity 82, 86, 93open time 113, 230

optical characterization 65organic pigments 107original equipment manufacturers

(OEM) 164– coatings 164

pP&I test 99packaging tapes 208paint formulations 125paints 127– binder 127paper coating 76, 79, 81, 84– coating colors 84– coating techniques 84paper gloss 84paper industry 75 f.paper machine 78paper products 120– inks 120paper properties 78paperboard coatings 75particle morphology 70particle size 48, 94 f.particle size distribution 52, 94, 331– dispersion/redispersion 331particle surface 54patch mortar 346paving 303, 313peel resistance 229– measurement 229peel strength 196, 210 ff.peel value 197performance grading 304 f.permanent deformation 306permanent paper label 203permeability 7permeation 66pH 43photon correlation spectroscopy 49pick strength 93– see binding strengthpigments 82 ff., 109, 132, 202– coat 288– dispersion 108– dispersion stability 104– extender 132– surface treatment 109– volume content of paints (PVC) 125 f.plastic materials 355– modification 355plasticizer 201, 286– migration 286plastics production 10

Page 22: Polymer Dispersions

Index 405

plywood on lumber shear test 232polyacrylate dispersions 194, 291– leather-finishing 291polyacrylates 11polybutadiene dispersions 291polychloroprene adhesives 225poly-coated board 120polyken probe tack 214polymer characterization 68polymer colloids 1polymer compositions 129– binder 129– styrene-butadiene copolymers 129polymer corporation 131– acrylic copolymers 131– specialty monomers 131polymer design 25polymer dispersion 2 f., 10 ff., 41, 273– characterization 41– chemical bonding 273– commercial importance 10– definition 3– manufactures 12– names 2– properties 3– suppliers 13– synthesis 15polymer films 58polymer isolation technology 357polymer modified cement concrete

(PCC) 349polymer strength 6polymer/cement ratio 337– flexibility 337polymeric impact modifiers 355polymeric modifiers 358– classification 358– processing aids 358polymeric gloves 397– standard test 397polymerizable surfactants 30polymer-modified asphalt 309polymer-modified mortars 241polyolefins 10polystyrene 10polystyrene dispersions 7polyurethane adhesives 223polyurethane dispersions 7, 170, 172, 175,

179 ff., 191, 217 f., 222 f., 285, 288, 292polyurethanes 110polyvinyl acetate 90polyvinyl alcohol 88 ff., 332polyvinyl chloride 10porosity 93

pre-mixed 332pre-packed 332pre-print corrugated inks 119pressure sensitive adhesives 193, 205, 207,

210– test methods 210pressurized aging vessel (PAV) 304primer 172 f.– composition 173– formulations 152 f.– polymers used 172– requirements 172– surfacer 172primer coating 151 ff.– application tests 153– marker stain resistance 153– stain blocking 153print bonding 274printability 93printability tests 99printing 103printing inks 103, 115– tests 115printing processes 92, 103probe tack method 214process aids 355process conditions 37– branching 37– crosslinking 37– monomer/polymer concentration 37– number of particles 38– temperature 38processing aids 359 ff.– effect 366– for PVC 359– for resins 366– types 364product resistance 116propagation 18propagation rate 21propene 9 f.protective coatings 123, 154protective colloid 6, 9protective films 209protective gloves 384pulp 77 ff.pulp suspension 79pump-in 311PVC durables 373PVC formulations 371– for building products 371

Page 23: Polymer Dispersions

406 Index

qquasielastic light scattering 49quick-stick 213

rraspberry structure 4, 5rate of polymerization 19, 21raw hide production 285raw materials 8reactive monomers 9recycling 10redispersible powders 329, 332, 339– adhesion 339– building materials 329– building/construction industry 329– dry mix mortar technology 329– premixed 329– pre-packed 329repair mortar 241, 346, 350residual volatiles 56residue characterization 319resin 104– support 110resinated pigments 109resistance to flow 237re-solubility 112reverse gravure 205re-wetting 116rheology control agent 181roll coating 289 f.rolling ball 215roof coating 248rosin fumarate ester 110rosin fumarates 104rotating thin film oven test (RTFOT) 304rotogravure printing 82 f., 86, 94, 99rubber milk 3rub-fastness 298rub test – metal corrugator 116rutting 306

ssafety 40– capacity limitation 40– design pressure 40– relief devices 40sand 333saturation 274scale-up criteria 15scrim coat 262sealant 233 f., 236 f.– production 237– slurries 351– tensile stress values 236

– types 235seed polymer 39seeded emulsion polymerization 20seeded processes 29selected conversion processes 364self-adhesive articles 210– labels 194, 205– products 199– tapes 207self-leveling underlayments (SLU) 345serum separation techniques 57shear strength 198, 210, 216, 229– measurement 216shear thinning 45shear value 197shoe upper leather 292shotcrete process 350silane-based coupling 235size press 79sizing agent 78, 80– low molecular weight 80– polymeric 80slot-die coating 207SLU 345, 347– abrasion resistance 347– surface 347slurry seal 316soap titration 55solids content 42solubility parameters 67solution polymers 113solution vehicles 112solvent based ink 103soy protein 90 f.spray drying 330, 357– emulsion polymerization 330spray-dry process 331spray dyeing 287spray machine 289spraying 289stability 47starch 79 ff., 88, 90 f.static light scattering 51steady shear viscosity profile 182steam cracker products 8storage modulus 63storage stability 48stress-strain measurements 62styrene 10, 90, 94styrene-butadiene dispersions 6, 90, 129,

204, 217, 256 ff., 273 f.styrene-butadiene rubber (SBR) latex 227,

256 ff., 303 ff.sub-floor mastics 231

Page 24: Polymer Dispersions

Index 407

superpave binder specification 305superpave performance grade 304surface-active materials 27surface print inks 118surface sizing 76, 79 ff.surface tension 43surface tension of films 117surface treatment 108, 314– of pigments 109surfactant 27 ff., 114– physical properties 27– structural influences on properties 28surfmer 9swelling 66synthetic additives 78synthetic adhesives 192

ttack 6, 195, 210, 213tackifying resins 200tack measurement method 214tanning 283tensile strength 63termination 18test methods 97 f., 114 f., 142 ff., 147 f., 151,

156 f., 159 f., 168 ff., 210 ff., 221 f., 228 ff.,232, 237 f., 240, 246 f., 249, 261, 275 ff., 296 ff., 304 ff., 335 ff., 368, 395 ff.

thermoset coatings 183thick bed mortar technique 334thickeners 7, 84 ff., 133, 235, 390– anionic 235– dipping compounds 390thickening 201thin bed mortar technique 334thixotropy 45tile adhesives 240– test methods 240tile grouts 332, 334, 340 f.– ANSI Standards 341– EN Standards 341titanium dioxide 84, 86, 132 f., 147, 160,

202top coats 288, 341, 344torque rheometry 360toughness 63, 367towel and tissue ink 122traffic marking paints 158 ff.– application tests 159 f.– dry-through time 159– formulation 160– no-pick-up test 160– retro-reflectance 160transmission electron microscopy 70

transparency 6, 65tufted carpet 254 ff.

uunitary coating 264

vvario gravure 206vinyl acetate copolymers 6, 11, 90, 130, 141,

273 f., 330 ff.vinyl chloride 10vinylidene chloride 7viscosity 5 f., 45, 96, 182– dilatant 6– pseudoplastic 5– shear rate 5– thixotropic 5viscosity, Zahn efflux cup 117volatile organic compounds (VOC) 165, 258

wwall coatings 139wall mastics 231water based ink 103water impermeability 332water loss of green concrete 248water resistance 117water uptake 67water-borne binders 176– aqueous polyurethane dispersions 179– for automotive coating 179, 181– rheology control agents (RCA) 181– secondary acrylic dispersions 179water-borne coatings 163– applicaton properties 185water-borne emulsion polymers 124waterproofing membranes 244, 250, 350waterproofing sealing 351waterproofing system 350water-soluble binders 185– properties 185water-soluble oligomers 4wax emulsions 113weatherability 374weatherable impact modifiers 373web consolidation 272– chemical bonding 272– mechanical bonding 272– thermal bonding 272web formation 271– dry-laid 271– spun-laid 271– wet-laid 271wet adhesion 299

Page 25: Polymer Dispersions

408 Index

wet finishing 286wet pick strength 94 ff.wet track abrasion test (WTAT) 322wetting 65wetting agents 201wetting aids 136white-point temperature 60workability 332work of fracture 63woven carpet 254 f.

yyellowing 94, 299Young’s modulus 62

zzeta potential 56Zosel tack measurement 215