Initiating system for solid polyester granule manufacture
AssigneeOrica Australia Pty Ltd
InventorsChristopher Henry Such, Barbara Aurelia Czapski, Karen Lai-On Seligman, Deepak Ajinkya, Algirdas Kazimieras Serelis
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Abstract
The invention relates generally to solid polyester granules of the type used as matting agents in paints. In particular, the invention relates to a new redox initiating system for use in a suspension polymerisation process used to manufacture the solid polyester granules, to a process for the preparation of the solid polyester granules, and to paint compositions comprising solid polyester granules.
Claims43
Use of a combination of diacyl peroxides with an aromatic amine of formula (I):
- where R1 is an optionally substituted C1-C20 alkyl group, or —(CHR′CHR′—O)nH, where n is 1 to 10 and each R′ is independently selected from H and C1-C3 alkyl;
- R2 is an optionally substituted C1-C20 alkyl group, or —(CHR′CHR′—O)nH, where n is 1 to 10 and each R′ is independently selected from H and C1-C3 alkyl;
- and
- Ar is an optionally substituted aryl group,
- as a redox initiating system in a process for the manufacture of solid polyester granules by suspension polymerisation, wherein the combination of diacyl peroxides comprises diaroyl peroxide and dialkanoyl peroxide having a diaroyl peroxide to dialkanoyl peroxide mole ratio that is equal to or greater than 1:1.
A process for the preparation of solid polyester granules comprising:
- (i) preparing a solution of unsaturated polyester and a combination of diacyl peroxides in styrene, wherein the combination of diacyl peroxides comprises diaroyl peroxide and dialkanoyl peroxide having a diaroyl peroxide to dialkanoyl peroxide mole ratio that is equal to or greater than 1:1,
- (ii) emulsifying said solution in water to provide a stabilised oil-in-water emulsion,
- (iii) adding to said emulsion an aromatic amine of formula (I):
- where R1 is an optionally substituted C1-C20 alkyl group, or —(CHR′CHR′—O)nH, where n is 1 to 10 and each R′ is independently selected from H and C1-C3 alkyl;
- R2 is an optionally substituted C1-C20 alkyl group, or —(CHR′CHR′—O)nH, where n is 1 to 10 and each R′ is independently selected from H and C1-C3 alkyl;
- and
- Ar is an optionally substituted aryl group,
- such that reaction of said aromatic amine of formula (I) with each of the diaroyl and dialkanoyl peroxides generates a radical flux capable of initiating polymerisation of the unsaturated polyester and the styrene.
A process for the preparation of solid polyester granules comprising:
- (i) preparing a solution of unsaturated polyester, and first diacyl and second diacyl peroxide in styrene, wherein the mole ratio of the first peroxide to the second peroxide is equal to or greater than 1:1,
- (ii) emulsifying said solution in water to provide a stabilised oil-in-water emulsion,
- (iii) adding to said emulsion an aromatic amine of formula (I):
- where R1 is an optionally substituted C1-C20 alkyl group, or —(CHR′CHR′—O)nH where n is 1 to 10 and each R′ is independently selected from H and C1-C3 alkyl;
- R2 is an optionally substituted C1-C20 alkyl group, or —(CHR′CHR′—O)nH where n is 1 to 10 and each R′ is independently selected from H or C1-C3 alkyl;
- and
- Ar is an optionally substituted aryl group,
- such that reaction of the aromatic amine of formula (I) with each of the first and second diacyl peroxides generates a radical flux capable of initiating polymerisation of the unsaturated polyester and the styrene, and wherein at the commencement of the polymerisation the radical flux generated by the first peroxide is greater than any radical flux generated by the second peroxide.
Use of a combination of first diacyl and second diacyl peroxides with an aromatic amine of formula (I):
- where R1 is an optionally substituted C1-C20 alkyl group, or —(CHR′CHR′—O)nH where n is 1 to 10 and each R′ is independently selected from H and C1-C3 alkyl;
- R2 is an optionally substituted C1-C20 alkyl group, or —(CHR′CHR′—O)nH where n is 1 to 10 and each R′ is independently selected from H or C1-C3 alkyl;
- and
- Ar is an optionally substituted aryl group,
- as a redox initiating system in a process for the manufacture of solid polyester granules by suspension polymerisation, wherein the mole ratio of the first peroxide to the second peroxide is equal to or greater than 1:1, wherein the first and second peroxides are each capable of reacting with the amine to generate a radical flux, and wherein at the commencement of the polymerisation the radical flux generated by the first peroxide is greater than any radical flux generated by the second peroxide.
A water-based decorative paint composition comprising binder and pigmented polyester granules, wherein the pigmented polyester granules comprise two or more differently coloured pigmented polyester granules, and wherein the paint is formulated so that the granules protrude from the surface of an applied paint film.
A water-based decorative paint film comprising pigmented polyester granules, wherein the pigmented polyester granules comprise two or more differently coloured pigmented polyester granules, and wherein the granules protrude from the surface of the paint film.
Dependencies are inferred from the claim text.