# US 7,612,132 B2 · Redispersing agents for redispersible polymer powders and redispersible polymer powders including same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,612,132 B2 - Document ID: US7612132B2 - Status: Granted - Kind: B2 - Application number: 10/570,219 - Filed: 2004-02-05 - Published: 2007-01-11 - Granted: 2009-11-03 - Earliest claimed: 2003-09-01 - Assignees: Acquos Pty Ltd - Inventors: Valentino De Fazio; Robert Mantello - Web page: https://patentgrep.com/patent/US7612132B2 ## CPC - C08J 3/12: Powdering or granulating - C04B 40/0042: {Powdery mixtures} - C08J 3/122: {Pulverisation by spraying} - C09K 23/00: Use of substances as emulsifying, wetting, dispersing, or foam-producing agents - C09K 23/12: Sulfonates of aromatic or alkylated aromatic compounds - C04B 2103/0057: {added as redispersable powders} - C08J 2325/14: with unsaturated esters - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE ## Abstract The invention relates to a redispersible polymer powder including a polymer to be redispersed and an ortho-cresol based condensation polymer or salt thereof and methods for manufacturing same. More particularly, the invention relates to the use of an ortho-cresol based condensation polymer as a redispersing aid in a redispersible polymer powder. ## Claims ### Claim 1 A redispersible polymer powder including: a polymer to be redispersed; and an ortho-cresol based condensation product or salt thereof. ### Claim 2 (depends on 1) A redispersible polymer powder according to claim 1, wherein the ortho-cresol based condensation product or salt thereof is an ortho-cresol sulfonic acid formaldehyde condensation product manufactured by a method comprising: (i) sulfonating ortho-cresol with sulfuric acid; and (ii) condensing the sulfonated ortho-cresol with formaldehyde. ### Claim 3 (depends on 2) A redispersible polymer powder according to claim 2, wherein the sulfonation step (i) is carried out under a slight excess of sulfuric acid. ### Claim 4 (depends on 2) A redispersible polymer powder according to claim 2, wherein the addition of the sulfuric acid to the ortho-cresol takes place at from 35 to 60° C. and the final sulfonation takes place at higher temperatures from 85 to 95° C. ### Claim 5 (depends on 1) A redispersible polymer powder according to claim 1, wherein the ortho-cresol based condensation product or salt thereof is an ortho-cresol sulfonic acid mixed condensation product manufactured by a method comprising: (i) sulfonating ortho-cresol with sulfuric acid; and (ii) condensing the sulfonated ortho-cresol with a compatible monomer. ### Claim 6 (depends on 5) A redispersible polymer powder according to claim 5, wherein the sulfonation step (i) is carried out under a slight excess of sulfuric acid. ### Claim 7 (depends on 5) A redispersible polymer powder according to claim 5, wherein the compatible monomer is selected from cresol, phenol, resorcinol, naphthalene, meta-cresol, para-cresol and their respective sulfonated acids. ### Claim 8 (depends on 7) A redispersible polymer powder according to claim 7, wherein the compatible monomer is phenol. ### Claim 9 (depends on 1) A redispersible polymer powder according to claim 1, wherein the ortho-cresol based condensation product or salt thereof is an alkali metal salt or the alkaline earth metal salt. ### Claim 10 (depends on 9) A redispersible polymer powder according to claim 9, wherein the ortho-cresol based condensation product is a calcium salt or sodium salt or combination thereof. ### Claim 11 (depends on 1) A redispersible polymer powder according to claim 1, wherein the ortho-cresol based condensation product or salt thereof is added at a level of from about 1% to about 30% by weight of solid ortho-cresol based condensation product or salt thereof relative to the solid polymer powder. ### Claim 12 (depends on 11) A redispersible polymer powder according to claim 11, wherein the ortho-cresol based condensation product or salt thereof is added at a level of from about 1% to about 15%. ### Claim 13 (depends on 1) A redispersible polymer powder according to claim 1, wherein the polymer to be redispersed has a glass transition below 50° C. ### Claim 14 (depends on 13) A redispersible polymer powder according to claim 13, wherein the polymer to be redispersed includes at least one flexible polymer having a glass transition below 5° C. ### Claim 15 (depends on 1) A redispersible polymer powder according to claim 1, wherein the polymer to be redispersed is selected from pure acrylic polymers, styrene-acrylic polymers, vinyl acetate copolymers with alkyl acrylate or ethylene or maleates, styrene-butadiene based polymers and combinations thereof. ### Claim 16 (depends on 15) A redispersible polymer powder according to claim 15, wherein the polymer to be redispersed includes two or more monomers selected from the group consisting of styrene, methylmethacrylate, vinyl acetate, butadiene, n-butyl acrylate, 2-ethylhexylacrylate, ethylacrylate, methylacrylate, isopropylacrylate, vinyl propionate, dibutyl maleate, ethylene, tert-butyl acrylate, methacrylic acid, acrylic acid, acrylamide, methacrylamide, and hydroxyethyl methacrylate. ### Claim 17 (depends on 1) A redispersible polymer powder according to claim 1, wherein the ortho-cresol based condensation product or salt thereof is mixed with a dispersion of the polymer to be redispersed before drying thereof and the resultant mixture is then spray dried using conventional spray drying techniques. ### Claim 18 A method for manufacturing a redispersible polymer powder including: forming a dispersion of a polymer to be redispersed and an ortho-cresol based condensation product; and drying the dispersion to form the redispersible polymer powder. ### Claim 19 (depends on 18) A method for manufacturing a redispersible polymer powder according to claim 18, wherein the dispersion of polymer to be redispersed and an ortho-cresol based condensation product or salt thereof is spray dried to form said redispersible polymer powder. ### Claim 20 (depends on 19) A method for manufacturing a redispersible polymer powder according to claim 19, wherein the dispersion is atomized using rotating disc atomization, single fluid nozzles or multi fluid nozzles and dried in a chamber using air heated from 120 to 180° C., and wherein the resultant redispersible polymer powder is collected in cyclones or filter bag houses. ### Claim 21 (depends on 18) A method for manufacturing a redispersible polymer powder according to claim 18, wherein an anti-caking agent is metered into the polymer powder while the polymer powder is suspended in the air stream. ### Claim 22 (depends on 18) A redispersible polymer powder manufactured by the method of claim 18. ### Claim 23 (depends on 1) A product including, as a binder, the redispersible polymer powder according to claim 1. ### Claim 24 (depends on 23) A product according to claim 23, said product being selected from hydraulically setting compositions, adhesives, coating compositions, synthetic resin renders, and modified building materials. ### Claim 25 (depends on 1) A method of manufacture of a product comprising a binder, said method comprising the step of incorporating a redispersible polymer powder according to claim 1 as a binder in the product. ### Claim 26 (depends on 25) The method according to claim 25, wherein the product is selected from hydraulically setting compositions, adhesives, coating compositions, synthetic resin renders, and modified building materials.