CA2032766A1 - Hollow acid-free acrylate polymeric microspheres having multiple small voids - Google Patents
Hollow acid-free acrylate polymeric microspheres having multiple small voidsInfo
- Publication number
- CA2032766A1 CA2032766A1 CA002032766A CA2032766A CA2032766A1 CA 2032766 A1 CA2032766 A1 CA 2032766A1 CA 002032766 A CA002032766 A CA 002032766A CA 2032766 A CA2032766 A CA 2032766A CA 2032766 A1 CA2032766 A1 CA 2032766A1
- Authority
- CA
- Canada
- Prior art keywords
- microspheres
- acrylate
- hollow
- sensitive adhesive
- diameter
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J133/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Adhesives based on derivatives of such polymers
- C09J133/04—Homopolymers or copolymers of esters
- C09J133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
- C09J133/08—Homopolymers or copolymers of acrylic acid esters
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J109/00—Adhesives based on homopolymers or copolymers of conjugated diene hydrocarbons
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J13/00—Colloid chemistry, e.g. the production of colloidal materials or their solutions, not otherwise provided for; Making microcapsules or microballoons
- B01J13/02—Making microcapsules or microballoons
- B01J13/06—Making microcapsules or microballoons by phase separation
- B01J13/14—Polymerisation; cross-linking
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J7/00—Adhesives in the form of films or foils
- C09J7/30—Adhesives in the form of films or foils characterised by the adhesive composition
- C09J7/38—Pressure-sensitive adhesives [PSA]
- C09J7/381—Pressure-sensitive adhesives [PSA] based on macromolecular compounds obtained by reactions involving only carbon-to-carbon unsaturated bonds
- C09J7/385—Acrylic polymers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/14—Polymer mixtures characterised by other features containing polymeric additives characterised by shape
- C08L2205/18—Spheres
- C08L2205/20—Hollow spheres
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2301/00—Additional features of adhesives in the form of films or foils
- C09J2301/30—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier
- C09J2301/302—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier the adhesive being pressure-sensitive, i.e. tacky at temperatures inferior to 30°C
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
Abstract
Docket Number: 44408CAN9A
Abstract Hollow, polymeric, acrylate, infusible, inherently tacky, solvent-insoluble, solvent-dispersible, elastomeric, nitrogen-containing, acid-free pressure-sensitive adhesive microspheres having an average diameter of at least about 1 micrometer wherein a majority of the microspheres contain multiple interior voids, a majority of the voids having a diameter of less than about 10% of the diameter of the microsphere, the total of the diameters of the voids being at least about 10% of the diameter of the microsphere.
These hollow microspheres are useful as repositionable pressure-sensitive adhesives. The invention also provides pressure-sensitive adhesives consisting essentially of such acid-free hollow microspheres. Aqueous suspensions of these microspheres, processes for their preparation, spray repositionable pressure-sensitive adhesive compositions, and pressure-sensitive adhesive coated sheet materials are also provided. Surprisingly, hollow microspheres of the invention may be used in combination with delicate substrates such as photographs without causing discoloration or damage, in comparison with prior art repositionable pressure-sensitive adhesives.
Abstract Hollow, polymeric, acrylate, infusible, inherently tacky, solvent-insoluble, solvent-dispersible, elastomeric, nitrogen-containing, acid-free pressure-sensitive adhesive microspheres having an average diameter of at least about 1 micrometer wherein a majority of the microspheres contain multiple interior voids, a majority of the voids having a diameter of less than about 10% of the diameter of the microsphere, the total of the diameters of the voids being at least about 10% of the diameter of the microsphere.
These hollow microspheres are useful as repositionable pressure-sensitive adhesives. The invention also provides pressure-sensitive adhesives consisting essentially of such acid-free hollow microspheres. Aqueous suspensions of these microspheres, processes for their preparation, spray repositionable pressure-sensitive adhesive compositions, and pressure-sensitive adhesive coated sheet materials are also provided. Surprisingly, hollow microspheres of the invention may be used in combination with delicate substrates such as photographs without causing discoloration or damage, in comparison with prior art repositionable pressure-sensitive adhesives.
Description
~2~
Doc~et Nllmber: 44408C~AN9A
HOLLOW ACID-FREE ACRYLATE POLYMERIC MICROSP~E~ES HAVING
MULTIPLE SMALL VOIDS
Field of the Invention This invention relates to hollow, polymeric, acrylate, infusible, inherently tacky, elastomeric, solvent-dispersible, solvent-insoluble, nitrogen-containing, acid-~ree microspheres, to processes for their preparation, and to their use as repositionable pressure-sensitive adhes~ves.
Back~round of the Invention Description of the Related Art Solid, inherently tacky, elastomeric microspheres are known in the art to be us~ful in repositionable pressure-sensitive adhesive applications.
As used herein, the term "repositionable" refers to the ability to be repeatedly adhered to and removed from a substrate without substantial loss of adhesion capability. Microsphere-based adhesives are thought to perform well in such applications at least in part due to their "self-cleaning" character, wherein substrate contaminants tend to be pushed aside and trapped between the microspheres as the adhesi~e is applied. Upon removal, the adhesive can then still present a relativelv uncontaminated surface for reapplication to the substrate. However, problems with microsphere loss, i.e., microsphere transfer to the substrate, and the resultant need for use of a primer or binder have been recognized in the art.
Numerous references concern the preparation and/or use of inherently tacky, elastomeric acrylate polymeric microspheres which are solid in nature. Such spheres and their use in aerosol adhesive systems having repositionable properties are disrlosed in U.S. Pat. No.
3,691,140 (Silver). These microspheres are prepared by aqueous suspension polymerization of alkyl acrylate monomers and ionic comonomer~ e.g., sodium methacrylate, ' ' ~
Doc~et Nllmber: 44408C~AN9A
HOLLOW ACID-FREE ACRYLATE POLYMERIC MICROSP~E~ES HAVING
MULTIPLE SMALL VOIDS
Field of the Invention This invention relates to hollow, polymeric, acrylate, infusible, inherently tacky, elastomeric, solvent-dispersible, solvent-insoluble, nitrogen-containing, acid-~ree microspheres, to processes for their preparation, and to their use as repositionable pressure-sensitive adhes~ves.
Back~round of the Invention Description of the Related Art Solid, inherently tacky, elastomeric microspheres are known in the art to be us~ful in repositionable pressure-sensitive adhesive applications.
As used herein, the term "repositionable" refers to the ability to be repeatedly adhered to and removed from a substrate without substantial loss of adhesion capability. Microsphere-based adhesives are thought to perform well in such applications at least in part due to their "self-cleaning" character, wherein substrate contaminants tend to be pushed aside and trapped between the microspheres as the adhesi~e is applied. Upon removal, the adhesive can then still present a relativelv uncontaminated surface for reapplication to the substrate. However, problems with microsphere loss, i.e., microsphere transfer to the substrate, and the resultant need for use of a primer or binder have been recognized in the art.
Numerous references concern the preparation and/or use of inherently tacky, elastomeric acrylate polymeric microspheres which are solid in nature. Such spheres and their use in aerosol adhesive systems having repositionable properties are disrlosed in U.S. Pat. No.
3,691,140 (Silver). These microspheres are prepared by aqueous suspension polymerization of alkyl acrylate monomers and ionic comonomer~ e.g., sodium methacrylate, ' ' ~
-2- 2~7~
in the presence of an emulsifier. The US8 of a water-soluhle, substantially oil-insoluble ionic comonomer is critical to preventing coagulation or agglomeration of the microspheres.
U.S. Pat. No. 4,166,152 (Baker et al.) describes solid, inherently tacky (meth)acrylate microspheres which are prepared ~rom non-ionic alkyl acrylate or methacrylate monomer(s) in the presence of both an emulsifier and an ionic suspension stabilizer.
Such microspheres are also disclosed in U.S. Pat. Nos.
4,495,318 and 4,598,112 (Howard). All three patents disclose utility as a "reusable adhesive".
U.S. Pat. No. 4,735,837 (Miyasaka et al.) discloses a detachable adhesive sheet having an adhesive layer containing "elastic micro-balls", wherein the microballs partially protrude from the surface of the adhesive layer. The microballs may or may not be tacky.
DE 3,544,882 A1 (Nichiban) describes crosslinked microspheres composed of 90 to 99.5 weight percent of (meth)acrylate ester and 10 to 0.5 weight percent of vinyl type monomer, e.g., acrylic acid, having a reactive functional group through which crosslinking agent. The stated purpose of the invention is to provide microspheres having a uniform particle size, and to pre~ent transfer of the adhesive.
U.S. Statutory Invention Registration H509 (Chao) discloses acrylate microparticle adhesives wherein the level of tack is varied by adjusting the type and ratio of monomers used in the starting solution. Very high tack is said to be achieved when isodecyl acrylate and 2 ethyl-hexyl acrylate are used in combination with acrylic acid, vinyl pyrrolidone, and isobornyl acrylate.
It is an object of this invention to provide an acid~free microsphere-based, repositionabls pressure-sensitive adhesive ~or use where acids would cause problems with the substrate such as discoloration, i.e., photographs.
~ ~ .
~ ~ -7 ~ ~
It is a further object of this invention to provide an elastomeric microsphere-based, repositionable pressure-sensitive adhesive which exhibits good shear adhesion, enabling the adhesive to support heavy objects.
It has now been discovered that these objects, and others, which will become apparent from the following discussion may be achieved by preparing hollow microspheres having multiple small voids which, in addition to being inherently tacky, elastomeric, infusible, solvent-insoluble, and solvent-dispersible, are also nitrogen-containing and acid-free.
Summary of the Invention This invention provides hollow, polymeric, acrylate, inherently tacky, infusible, solvent-insoluble, solvent-dispersible, elastomeric, acid-free pressure-sensitive adhesive microspheres having diameters of at least about one micrometer. A majority of the microspheres contain multiple interior voids, a majority of the voids having a diameter of less than about 10% of the diameter of the microsphere, the total of all void diameters being at least about 10% of the diameter of the microsphere. These microspheres are useful as repositionable pressure-sensitive adhesives.
The invention also provides pressure-sensitive adhesives based on the acid-free hollow microspheres, aqueous suspensions of these microspheres, procPsses for their preparation, spray repositionable pressure-sensitive adhesive compositions, and pressure-sensitive adhesive-coated sheet materials.
Repositionable pressure-sensitive adhesives based on nitrogen-containing, acid-free microspheres having multiple small voids can be used even on such delicate substrates as photographs, graphics, silk-screened printed mater, and the like, which would discolor if used with conventional, acid-containing repositionable pressure-sensitive adhesives.
:
~ ~ 3 2 ~ ~ 3 It has been discovered that increasing the amount of N-containing polar monomer results in higher shear adhesion without detrimental effect on the other pressure-sensitive adhesive properties. Thus, adhesives of the invention comprising higher, i.e., 15-25 parts of the N-containing polar monomer exhibit greater shear adhesion for a given coating wight of adhesive than prior art systems. The hollow acid-free microspheres af this invention are also highly adherent to substrates on which they are coated, and, thus, generally re~uire neither separate primer or binder material.
This invention also provides a pressure-sensitive adhesive consisting essentially of these nitrogen-containing, acid-free hollow microspheres. More specifically, the pressure-sensitive adhesive consists essentially oE hollow,polymeric, acrylate, inherently tacky, infusible, solvent-insoluble, solvent-dispersible, elastomeric, nitrogen-containing, acid-free microspheres comprising:
a) at least about 70 parts by weight of at least one alkyl methacrylate ester; and b) up to about 30 parts by weight of at least one nitrogen containing polar monomer, a majority of the microspheres having multiple interior voids~ a majority of the voids having a diameter of less than about 10% of the diameter of the microsphere, the total of all void diameters being at least about 10% of the diameter of the microsphere.
These hollow acid-free microspheres may he prepared by a two-step emulsification polymerization process comprising the step of:
a) forming a water-in-oil emulsion of an aqueous solution of nitrogen-containing polar monomer(s) in oil phase monomer(s);
b) forming a water-in-oil-in-water emulsion by dispersing the water-in-oil emulsion into an aqueous phase; and .: :
~, c) initiating polymerization preferably by application o~ heat (or radiation).
Acid-free hollow microspheres may also be prepared by a simpler ("one-step") emulsification process comprising aqueous suspension polymerization of at least one alkyl acrylate or al]~yl methacrylate ester monomer and at least one non-ionic nitrogen-containing polar monomer in the presence of at least one emulsifier which is capable of producing a water-in-oil emulsion inside the droplets, as defined below, which is substantially stable during emulsification and polymerization. soth methods produce an aqueous suspension of monomer droplets which upon polymerization become microspheres, a majority of which have multiple interior cavities that, upon drying, become voids.
The following terms have these meanings as used herein:
1. The term "droplet" means the liquid stage of the microspheres prior to the completion of polymerization.
2. The term "cavity" means a space within the walls of a droplet or microsphere when still in the suspension or dispersion medium prior to drying, and thus containing whatever medium was used.
in the presence of an emulsifier. The US8 of a water-soluhle, substantially oil-insoluble ionic comonomer is critical to preventing coagulation or agglomeration of the microspheres.
U.S. Pat. No. 4,166,152 (Baker et al.) describes solid, inherently tacky (meth)acrylate microspheres which are prepared ~rom non-ionic alkyl acrylate or methacrylate monomer(s) in the presence of both an emulsifier and an ionic suspension stabilizer.
Such microspheres are also disclosed in U.S. Pat. Nos.
4,495,318 and 4,598,112 (Howard). All three patents disclose utility as a "reusable adhesive".
U.S. Pat. No. 4,735,837 (Miyasaka et al.) discloses a detachable adhesive sheet having an adhesive layer containing "elastic micro-balls", wherein the microballs partially protrude from the surface of the adhesive layer. The microballs may or may not be tacky.
DE 3,544,882 A1 (Nichiban) describes crosslinked microspheres composed of 90 to 99.5 weight percent of (meth)acrylate ester and 10 to 0.5 weight percent of vinyl type monomer, e.g., acrylic acid, having a reactive functional group through which crosslinking agent. The stated purpose of the invention is to provide microspheres having a uniform particle size, and to pre~ent transfer of the adhesive.
U.S. Statutory Invention Registration H509 (Chao) discloses acrylate microparticle adhesives wherein the level of tack is varied by adjusting the type and ratio of monomers used in the starting solution. Very high tack is said to be achieved when isodecyl acrylate and 2 ethyl-hexyl acrylate are used in combination with acrylic acid, vinyl pyrrolidone, and isobornyl acrylate.
It is an object of this invention to provide an acid~free microsphere-based, repositionabls pressure-sensitive adhesive ~or use where acids would cause problems with the substrate such as discoloration, i.e., photographs.
~ ~ .
~ ~ -7 ~ ~
It is a further object of this invention to provide an elastomeric microsphere-based, repositionable pressure-sensitive adhesive which exhibits good shear adhesion, enabling the adhesive to support heavy objects.
It has now been discovered that these objects, and others, which will become apparent from the following discussion may be achieved by preparing hollow microspheres having multiple small voids which, in addition to being inherently tacky, elastomeric, infusible, solvent-insoluble, and solvent-dispersible, are also nitrogen-containing and acid-free.
Summary of the Invention This invention provides hollow, polymeric, acrylate, inherently tacky, infusible, solvent-insoluble, solvent-dispersible, elastomeric, acid-free pressure-sensitive adhesive microspheres having diameters of at least about one micrometer. A majority of the microspheres contain multiple interior voids, a majority of the voids having a diameter of less than about 10% of the diameter of the microsphere, the total of all void diameters being at least about 10% of the diameter of the microsphere. These microspheres are useful as repositionable pressure-sensitive adhesives.
The invention also provides pressure-sensitive adhesives based on the acid-free hollow microspheres, aqueous suspensions of these microspheres, procPsses for their preparation, spray repositionable pressure-sensitive adhesive compositions, and pressure-sensitive adhesive-coated sheet materials.
Repositionable pressure-sensitive adhesives based on nitrogen-containing, acid-free microspheres having multiple small voids can be used even on such delicate substrates as photographs, graphics, silk-screened printed mater, and the like, which would discolor if used with conventional, acid-containing repositionable pressure-sensitive adhesives.
:
~ ~ 3 2 ~ ~ 3 It has been discovered that increasing the amount of N-containing polar monomer results in higher shear adhesion without detrimental effect on the other pressure-sensitive adhesive properties. Thus, adhesives of the invention comprising higher, i.e., 15-25 parts of the N-containing polar monomer exhibit greater shear adhesion for a given coating wight of adhesive than prior art systems. The hollow acid-free microspheres af this invention are also highly adherent to substrates on which they are coated, and, thus, generally re~uire neither separate primer or binder material.
This invention also provides a pressure-sensitive adhesive consisting essentially of these nitrogen-containing, acid-free hollow microspheres. More specifically, the pressure-sensitive adhesive consists essentially oE hollow,polymeric, acrylate, inherently tacky, infusible, solvent-insoluble, solvent-dispersible, elastomeric, nitrogen-containing, acid-free microspheres comprising:
a) at least about 70 parts by weight of at least one alkyl methacrylate ester; and b) up to about 30 parts by weight of at least one nitrogen containing polar monomer, a majority of the microspheres having multiple interior voids~ a majority of the voids having a diameter of less than about 10% of the diameter of the microsphere, the total of all void diameters being at least about 10% of the diameter of the microsphere.
These hollow acid-free microspheres may he prepared by a two-step emulsification polymerization process comprising the step of:
a) forming a water-in-oil emulsion of an aqueous solution of nitrogen-containing polar monomer(s) in oil phase monomer(s);
b) forming a water-in-oil-in-water emulsion by dispersing the water-in-oil emulsion into an aqueous phase; and .: :
~, c) initiating polymerization preferably by application o~ heat (or radiation).
Acid-free hollow microspheres may also be prepared by a simpler ("one-step") emulsification process comprising aqueous suspension polymerization of at least one alkyl acrylate or al]~yl methacrylate ester monomer and at least one non-ionic nitrogen-containing polar monomer in the presence of at least one emulsifier which is capable of producing a water-in-oil emulsion inside the droplets, as defined below, which is substantially stable during emulsification and polymerization. soth methods produce an aqueous suspension of monomer droplets which upon polymerization become microspheres, a majority of which have multiple interior cavities that, upon drying, become voids.
The following terms have these meanings as used herein:
1. The term "droplet" means the liquid stage of the microspheres prior to the completion of polymerization.
2. The term "cavity" means a space within the walls of a droplet or microsphere when still in the suspension or dispersion medium prior to drying, and thus containing whatever medium was used.
3. The term "void" means an empty space completely within the walls of a polymerized microsphere.
4. The term "hollow" means containing at least one void or cavity.
5. The term "acid-free" means the monomers utilized contain no proton-donating species, specifically no carboxylic or sulphonic acid groups.
All percents, parts, and ratios described herein are by weight unless specifically stated otherwise.
Detailed Description of the Invention Alkyl acrylate or methacrylate monomers useful -` 2~2~
in preparing the hollow microspheres and pressure-sensitive adhesives of this invention are those monofunctional unsaturated acrylate or methacrylic esters of non-tertiary alkyl alcohols, the alkyl groups of which have from 4 to about 14 carbon atoms. Such acrylates are oleophilic, water emulsifiable, have restricted water solubility, and as homopolymers, generally have glass transition temperatures below about -20C. Included within this class of monomers are, for example, isooctyl acrylate, 4-methyl-2-pentyl acrylate, 2-methylbutyl acrylate, isoamyl acrylate, sec-butyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate, isodecyl methacrylate, isononyl acrylate, isodecyl acrylate, and the like, singly or in mixtures.
Preferred acrylates include isooctyl acrylate, isononyl acrylate, isoamyl acrylate, isodecyl acrylate, 2-ethylhexyl acrylate, n-butyl acrylate, sec-butyl acrylate, and mixtures thereof. Acrylate or methacrylate or other vinyl monomers which, as homopolymers, have glass transition temperatures higher than about -20C, e.g., tert-butyl acrylate, vinyl acetate, and the like, may be utilized in conjunction with one or more of the acrylate or methacrylate monomers provided that the glass transition temperature of the resultant polymer is below about -20C. When methacrylate monomer is the sole alkyl acrylate utilized, a crosslinking agent, infra, must be included.
Nitrogen-containing polar monomers suitable for copolymerization with the acrylate or methacrylate monomers to produce acid-free hollow microspheres are those nitrogen-containing polar monomers which are both somewhat oil-soluble and water-soluble, resulting in a distribution of the polar monomer between the aqueous and the oil phases.
Representative examples of suitable nitrogen-containing polar monomers include N-vinyl-2-pyrrolidone, N-vinyl caprolactam, 2-vinyl-4, 4-dimethyl-2-oxazolin-5-2 ~ c~
one (vinyl azlactone), acrylamide, t~butyl acrylamide,dimethylaminoethyl methacryla~e, and N-octyl acrylamide.
The hollow microspheres of this invention and the pressure-sensitive adhesives made therefrom comprise at least about 70 parts by weight of at least one alkyl acrylate or alkyl methacrylate ester and correspondingly, up to about 30 parts by weight o~ one or mora nitrogen-containing polar monomers. Preferred microspheres containing at least about 85 parts by weight of the alkyl acrylate, and up to about 15 parts by weight of the nitrogen-containing polar monomer. At least one nitrogen-containing polar monomer is included in the composition. For most nitrogen-containing polar monomers, incorporation of from about 1 part to about 15 parts by weight is preferred, as this ratio provides hollow microspheres with balanced pressure-sensitive adhesive properties.
Aqueous suspensions of the hollow microspheres may be prepared by a "two-step" emulsification process which first involves forming a water-in-oil emulsion of an aqueous solution of nitrogen-containing polar monomer(s) in oil phase monomer, i.e., at least one acrylate or methacrylate ester, using an emulsifier having a low hydrophilic-lipophilic balance (HLB) value.
Suitable emulsifiers are those having an HLB value below about 7, preferably in the range of about 2 to about 7.
Examples of such emulsifiers include sorbitan monooleate, sorbitan trioleate, and ethoxylated oleyl alcohol such as Brij 93, availa~le from Atlas Chemical Industries, Inc.
Thus, in this first step, oil phase monomer(s), emulsifier, a free radical initiator, and, optionally, a crosslinking monomer or monomers as defined below are combined, and an aqueous solution of all or a portion of the polar monomer(s) is agitated and poured into the oil phase mixture to form a water-in-oil emulsion. A
thickening agent, e.g., methyl cellulose may also be included in the aqueous phase of the water-in-oil ' . ~
: ~
~2~
emulsion. In the second step, a water-in-oil-in-water emulsion is formed by dispersing the water-in-oil emulsion of the first step into an a~ueous phase containing an emulsifier having an HLB ~alue above about 6. The ~queous phase may also contain any portion of the polar monomer(s) which saw not added in step one.
Examples of such emulsifiers include ethoxylated sorbitan monooleate, ethoxylated lauryl alcohol, and alkyl sulfates. In both steps, when an emulsifier is utilized, its concentration should be greater than its critical micelle concentration, which is herein defined as the minimum concentration of emulsifier necessary for the formation of micelles, i.e., submicroscopic aggregations of emulsifier molecules. Critical micelle concentration is slightly different for each emulsifier, usable concentrations ranging from about 1.0 x 10-4 to about 3.0 moles/liter. Additional detail concerning the preparation of water-in-oil-in-water emulsions, i.e., multiple emulsions, may be found in various literature references, e.g., Surfactant Systems: Their Chemist~y~
Pharmacy, & Bioloqy, (D. Attwood and A. T. Florence, Chapman & Hall Limited, New York, New York, 1983). The final process step of this method of the invention involves the application of heat or radiation to initiate polymerization of the monomers. Useful initiators are those which are normally suitable for free radical polymerization of acrylate monomers and which are oil-soluble and of very low solubility in water. However, when the nitrogen-containing polar monomer is N-vinyl pyrrolidone, the use of benzoyl peroxide as the initiator is recommended. Examples of such initiators such as zero compounds, hydroperoxides, peroxides, and the like, and photoinitiators such as benzophenone, benzoin ethyl ether, and 2,2-dimethoxy-2-phenyl acetophenone. Use of a water-soluble polymerization initiator causes formation of substantial amounts of latex. The extremely small particle size of latex particles renders any significant ~32P~
formation of latex undesirable. The initiator is generally used in an amount ranging from about 0.01 perce~t up to about 10 percent by weight of the total polymerizable composition, preferably up to about 5 percent.
Agueous suspensions of hollow acid-free microspheres may also by prepared by a "one-step"
emulsification process comprising aqueous suspension polymerization of at least one alkyl acrylate or alkyl methacrylate ester monomer and at least one nitrogen-containing polar monomer in the presence of at least one emulsifier capable of producing a water-in-oil emulsion inside the droplets which is substantially stable during emulsification and polymerization. As in the two-step emulsification process, the emulsifier is utilized in concentrations greater than its critical micelle concentration. In general, high HLB emulsifiers are required, i.e., emulsifiers having an HLB value of at least about 25, will produce stable cavity-containing droplets during the polymerization, and are suitable for use in this one-step process. Examples of such emulsifiers include alkylarylether sulfates such as sodium alkylarylether sulfate, e.g., Triton~ W/30, available from Rohm and Haas, alkylarylpolyether sulfates such as alkylarylpoly(ethylene oxide) sulfates, preferably those having up to about 4 ethyleneoxy repeat units, and alkyl sulfates such as sodium lauryl sulfate, ammonium lauryl sulfate, triethanolamine lauryl sulfate, and sodium hexadecyl sulfate, alkyl ether sulfates such as ammonium lauryl ether sulfate, and alkylpolyether sulfates such as alkyl poly(ethylene oxide) sulfates, preferably those having up to about 4 ethyleneoxy units.
Alkyl sulfates are preferred as they provide a maximum number of voids per microsphere for a minimum amount of surfactant. Polymeric stabilizer may also be present but are not necessary.
The composition may also contain a crosslinking '`' ~' ~
~2~
agent such as a multifunctional (meth)acrylate, e.g., butanediol diacrylate or hexanediol diacrylate, or other multifunctional crosslinker such as divinylbenzene. When used, crosslinker(s) is (are) added at a level o~ up to about 0.5 mole percent, preferably up to about 0.1 mole percent, of the total polymerizable composition.
The hollow acid-free microspheres of the invention are normally tacky, elastomeric, insoluble but swellable in organic solvents, and small, typically having diameters of at least about 1 micrometer, preferably in the range of about 1 to about 250 micrometers. The majority of the hollow acid-free microspheres prepared by the methods of this invention contain multiple voids, a majority of the voids having a diameter which is less than about 10~ of the diameter of the microsphere, the total of all the void diameters being at least about 10% of the diameter of the microsphere, preferably at least about 20~, more preferably, at least about 30%.
Following polymerization, an aqueous suspension of the hollow microspheres is obtained which is stable to agglomeration or coagulation under room temperature conditions. The suspension may have non-volatile solids contents of from about 10 to about 50 percent by weight.
Upon prolonged standing, the suspension separates into two phases, one phase being aqueous and substantially free of polymer, the other phase being an aqueous suspension of microspheres having multiple cavities which, upon drying, become voids. Both phases may contain a minor portion of small latex particles.
Decantation of the microsphere-rich phase provides an aqueous suspension having a non~volatile solids content on the order of about 40-50 percent which, if shaken with water, will readily redisperse. If desired, the aqueous suspension of hollow microspheres may be utilized immediately following polymerization to provide inherently tacky pressure-sensitive adhesive coatings.
. :
2 ~ 3 2 rl ~ ~
The suspension may be coated on suitable flexible or inflexible backing materials by conventional coating techniques such as knife coating or Meyer bar coating or use of an extrusion die.
Alternatively, the aqueous suspension may be coagulated with polar organic solvents such as methanol, with ionic emulsifiers having a charge opposite to that of the emulsifier used in the polymerization process, or with saturated salt solutions, o the like, followed by washing and drying. The dried hollow microspheres, with sufficient agitation, will readily disperse in common organic liquids such as ethyl acetate, tetrahydrofuran, heptane, 2-butanone, benzene, cyclohexane, and esters, although it is not possible to resuspend them in water.
Solvent dispersions of the hollow microspheres may also be coated on suitable backing materials by conventional coating techniques, as described above for aqueous suspensions.
Suitable backing materials for the aqueous or solvent based coatings include paper, plastic films, cellulose acetate, ethyl cellulose, woven or nonwoven fabric formed of synthetic or natural materials, metal, metallized polymeric film, ceramir sheet material, and the like. Primer or binders may be used, but they are not required.
Suspensions or dispersions of the hollow acid-free microspheres in a liquid medium, e.g., water or an organic liquid as described above, may be sprayed by conventional techniques without cobwebbing or may be incorporated in aerosol containers with suitable propellants such as alkanes, alkanes, or chlorofluorocarbons, e.g., Freons~. The hollow acid-free microspheres of the invention provide a repositionable pressure-sensitive adhesive, i.e., a pressure-sensitive adhesive having a degree of adhesion which permits separation, repositioning, and rebonding.
Useful aerosol formulae have a solids content ~6~7~
of from about 5% to about 20%, preferably from about 10%
to about 16%.
The pressure-sensitive adhesive properties of the acid-free hollow microspheres may be altered by addition of tackifying resin and/or plastici~er.
Preferred tackifiers for use herein include hydrogenated rosin esters commercially available from companies such as Hercules Inc., under such trade names as Foral7M 65, Foral~ 85, and Foral~ 105. Other useful tackifiers include those based on t-butyl styrene. Useful plasticizers include dioctyl phthalate, 2-ethyl hexyl phosphate, tricresyl phosphate, and the like.
It is also within the scope of this invention to include various other components, such as pigments, fillers, stabilizers, or various polymeric additives.
These and other aspects of the invention are illustrated by the following examples which should not be viewed as limiting in scope.
Test Methods Peel Adhesion Peel adhesion is the force required to remove a coated flexible sheet material from a test panel measured at a specific angle and rate of removal. In the examples, this force is expressed in grams per centimeter (cm) width of coated sheet. The procedure followed is:
A strip 1.27 cm in width of the coated sheet is applied to the horizontal surface of a clean glass test plate with at least 12.7 lineal cm in firm contact. A 2 kg hard rubber roller is used to apply the strip. The free end of the coated strip is doubled back nearly touching itself so the angle of removal will be 180.
The free and is attached to the adhesion tester scale.
The glass test plate is clamped in the jaws of a tensile testing machine which is capable of moving the plate away from the scale at a constant rate of 2.3 meters per minute. The scale reading in grams is recorded as the .
?J~2~
tape is peeled from the glass surface. The data is reported as the average of the range of numbers observed during the test.
Shear Strength The shear strength is a measure of the cohesiveness or internal strength of an adhesive. It is based upon the amount of force required to pull an adhesive strip from a standard flat surface in a direction parallel to the surface to which is has been affixed with a definite pressure. It is measured in minutes required to pull a standard area of adhesive coated sheet material ~rom a stainless steel test panel ~nder stress of a constant, standard load.
The tests were conducted on strips of coated sheet material applied to a stainless steel panel such that a 1.27 cm by 1.27 cm portion of each strip was in firm contact with the panel with one end portion of the tape being free. The panel with the coated strip attached was held in a rack such that the panel formed an angle of 178 with the extended tape free end which was tensioned by application of a force of 200 grams applied as a hanging weight from the free end of the coated strip. The 2 less than 180 is used to negate any peel forces, thus insuring that only the shear forces are measured, in an attempt to more accurately determine the holding power of the tape being tested. The tima elapsed for each coated film to separate from the test panel was recorded as the shear strength.
Example 1 In a one-liter reactor equipped with mechanical stirrer, condenser, and inlet-outlet lines for vacuum and argon, 450 grams of deionized water, 135 grams of isooctyl acrylate, 15 grams of N-vinyl-2-pyrrolidone, 0.04 gram of 1,4-butanediol diacrylate and 0.5 gram of benzoyl peroxide were changed. Vacuum was applied to . .
, ~ ~ ~c~
evacuate the reactor atmosphere, and ~he reactor was then purged with argon. The agitation was set to 400 RPM and when the initiator had dissolved 1.5 grams of ammonium lauryl sulfate (Standapol~ A, Henkel A~) were added. The temperature of the reactor was raised to 60c and maintained for 22 hours. An argon purge was maintained during the polymerization. After the 22-hour period, the suspension was allowed to cool to room temperature. The reactor was then emptied and the suspension filtered.
Optical microscopy showed hollow microspheres from about 10 to 85 micrometers in diameter suspended in water. The majority of the microspheres contained multiple inclusions at least about 2 micrometers in diameter.
Examples 2-7 These examples illustrate the use of N-vinyl 2-pyrrolidone in different amounts and with different acrylates to prepare hollow, tacky elastomeric microspheres using the type of equipment and polymerization technique outlined in Example 1. Details of the compositions are listed in Table I. For these examples the initiator was benzoyl peroxide (0.5 gram) and the surfactant was ammonium lauryl sulfate (1.5 grams). All polymerizations produced aqueous suspensions of hollow microspheres. The microspheres contained multiple inclusions at least about 2 microns in diameter.
:, 2~7~
Table I
Example Monomers 2 135 g isooctyl acrylate 15 g N-vinyl-2-pyrrolidone 0.08 g 1,4-butanediol diacrylate 3 127.5 g isooctyl acrylate 22.5 g N-vinyl-2-pyrrolidone 0.04 g 1,4-butanediol diacrylate 4 112.5 g isooctyl acrylate 37.5 g N-vinyl-2-pyrrolidone 0.04 g 1,4 butanediol diacrylate 105 g isooctyl acrylate 45 g N-vinyl-2-pyrrolidone 0.04 g 1,4-butanediol diacrylate 6 135 g 2-ethylhexyl acrylate 15 g N-vinyl-2-pyrrolidone 7 67.5 g isooctyl acrylate 75 g n-butyl acrylate 7.5 g N-vinyl-2-pyrrolidone 0.08 g trimethylolpropane trimethacrylate Examples 8-13 These examples illustrate the use of different N-containing polar monomers to prepare hollow tacky microspheres. The equipment and technique used to prepare the microsphere suspensions were similar to those described in Example 1. In these examples the initiator used was benzoyl peroxide (0.5 gram) except for Example 9 where 0.5 g of 2,2'-azobis(2,4-di.methylpentane nitrile), available from DuPont as Vazo~-52 initiator was used.
- :: - , , ~. .:
~. . ..
,,: : :
~ ~ ~ 2 7 1~,9 ~
The surfactant in all examples was ammonium lauryl sulfate (1.5 grams) except for Example 12 where 1.0 g of sodium cetyl sulfate was used. Monomer compositions are shown in Table II.
Table II
Example Monomers 8 135 g isooctyl acrylate 15 g vinyl caprolactam 0.04 g 1,4-butanediol diacrylate 9 135 g isooctyl acrylate 15 g 2-vinyl-4,4-dimethyl-2-oxazolin-5-one 0.08 g divinyl benzene 144 g isooctyl acrylate 6 g dimethylaminoethyl methacrylate 0.04 g 1,6-hexanediol diacrylate 11 141 isooctyl acrylate 9 g octyl acrylamide 0.02 g tetraethylene glycol dimethacrylate 12 120 g 2-ethylhexyl acrylate 15 g n-butyl acrylate 7.5 g N-vinyl~2-pyrrolidone 7.5 g 2-vinyl-4,4-dimethyl-2-oxazolin-5-one 0.02 g trimethylolpropane trimethacrylate 13 127.5 g isodecyl acrylate 22.5 N-vinyl caprolactam 0.08 g divinyl benzene Example 14 The microspheres of Example 1 were coagulated :
r and dispersed in isopropanol at 12 wt% solids. the solvent dispersion was coated on 100# weight white paper and dried. The microsphere pressure sensitive adhesive dry coating weight was 18 g/m2. The microsphere coated paper and an acid-sensitive substrate were repeatedly attached to each other and separated. A 90 peel adhesion of 67.3 g/cm was recorded. Adhesion and removability were good. No transfer of microspheres or damage to the acid sensitive substrate was observed.
Example 15 to 21 Microspheres prepared in the examples shown in Table III were coagulated and dispersed in isopropanol or isopropanol/heptane mixtures and coated on a 37-micron chick poly(ethylene terephthalate) film. The coatings were dried in an oven at 65C for 10 minutes and left in a constant humidity (50% relative humidity) and temperature (22.2C) room overnight. The coated samples were tested for peel adhesion and shear strength.
Results are shown in Table III. Examples 16, 17, 19, and 20 show excellent shear performance. Examples 16 and 17, which have high levels of the N-containing polar monomer show exceptional shear performance for a repositionable adhesive.
Table III
~ Coatlng Peel Shear Microsphere Weight Adhesion Strength ExampleExample ~g/cm) (g~cm)(minutes) 1 5 124.3 6.0 16 3 5 191.3>3,000.0 17 5 5 105.6>3,000.0 18 7 9 69.2 11.0 19 ~ 7 259~632~0 9 5 205.4493.5 21_ 10 7 152.5 7.5 :
All percents, parts, and ratios described herein are by weight unless specifically stated otherwise.
Detailed Description of the Invention Alkyl acrylate or methacrylate monomers useful -` 2~2~
in preparing the hollow microspheres and pressure-sensitive adhesives of this invention are those monofunctional unsaturated acrylate or methacrylic esters of non-tertiary alkyl alcohols, the alkyl groups of which have from 4 to about 14 carbon atoms. Such acrylates are oleophilic, water emulsifiable, have restricted water solubility, and as homopolymers, generally have glass transition temperatures below about -20C. Included within this class of monomers are, for example, isooctyl acrylate, 4-methyl-2-pentyl acrylate, 2-methylbutyl acrylate, isoamyl acrylate, sec-butyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate, isodecyl methacrylate, isononyl acrylate, isodecyl acrylate, and the like, singly or in mixtures.
Preferred acrylates include isooctyl acrylate, isononyl acrylate, isoamyl acrylate, isodecyl acrylate, 2-ethylhexyl acrylate, n-butyl acrylate, sec-butyl acrylate, and mixtures thereof. Acrylate or methacrylate or other vinyl monomers which, as homopolymers, have glass transition temperatures higher than about -20C, e.g., tert-butyl acrylate, vinyl acetate, and the like, may be utilized in conjunction with one or more of the acrylate or methacrylate monomers provided that the glass transition temperature of the resultant polymer is below about -20C. When methacrylate monomer is the sole alkyl acrylate utilized, a crosslinking agent, infra, must be included.
Nitrogen-containing polar monomers suitable for copolymerization with the acrylate or methacrylate monomers to produce acid-free hollow microspheres are those nitrogen-containing polar monomers which are both somewhat oil-soluble and water-soluble, resulting in a distribution of the polar monomer between the aqueous and the oil phases.
Representative examples of suitable nitrogen-containing polar monomers include N-vinyl-2-pyrrolidone, N-vinyl caprolactam, 2-vinyl-4, 4-dimethyl-2-oxazolin-5-2 ~ c~
one (vinyl azlactone), acrylamide, t~butyl acrylamide,dimethylaminoethyl methacryla~e, and N-octyl acrylamide.
The hollow microspheres of this invention and the pressure-sensitive adhesives made therefrom comprise at least about 70 parts by weight of at least one alkyl acrylate or alkyl methacrylate ester and correspondingly, up to about 30 parts by weight o~ one or mora nitrogen-containing polar monomers. Preferred microspheres containing at least about 85 parts by weight of the alkyl acrylate, and up to about 15 parts by weight of the nitrogen-containing polar monomer. At least one nitrogen-containing polar monomer is included in the composition. For most nitrogen-containing polar monomers, incorporation of from about 1 part to about 15 parts by weight is preferred, as this ratio provides hollow microspheres with balanced pressure-sensitive adhesive properties.
Aqueous suspensions of the hollow microspheres may be prepared by a "two-step" emulsification process which first involves forming a water-in-oil emulsion of an aqueous solution of nitrogen-containing polar monomer(s) in oil phase monomer, i.e., at least one acrylate or methacrylate ester, using an emulsifier having a low hydrophilic-lipophilic balance (HLB) value.
Suitable emulsifiers are those having an HLB value below about 7, preferably in the range of about 2 to about 7.
Examples of such emulsifiers include sorbitan monooleate, sorbitan trioleate, and ethoxylated oleyl alcohol such as Brij 93, availa~le from Atlas Chemical Industries, Inc.
Thus, in this first step, oil phase monomer(s), emulsifier, a free radical initiator, and, optionally, a crosslinking monomer or monomers as defined below are combined, and an aqueous solution of all or a portion of the polar monomer(s) is agitated and poured into the oil phase mixture to form a water-in-oil emulsion. A
thickening agent, e.g., methyl cellulose may also be included in the aqueous phase of the water-in-oil ' . ~
: ~
~2~
emulsion. In the second step, a water-in-oil-in-water emulsion is formed by dispersing the water-in-oil emulsion of the first step into an a~ueous phase containing an emulsifier having an HLB ~alue above about 6. The ~queous phase may also contain any portion of the polar monomer(s) which saw not added in step one.
Examples of such emulsifiers include ethoxylated sorbitan monooleate, ethoxylated lauryl alcohol, and alkyl sulfates. In both steps, when an emulsifier is utilized, its concentration should be greater than its critical micelle concentration, which is herein defined as the minimum concentration of emulsifier necessary for the formation of micelles, i.e., submicroscopic aggregations of emulsifier molecules. Critical micelle concentration is slightly different for each emulsifier, usable concentrations ranging from about 1.0 x 10-4 to about 3.0 moles/liter. Additional detail concerning the preparation of water-in-oil-in-water emulsions, i.e., multiple emulsions, may be found in various literature references, e.g., Surfactant Systems: Their Chemist~y~
Pharmacy, & Bioloqy, (D. Attwood and A. T. Florence, Chapman & Hall Limited, New York, New York, 1983). The final process step of this method of the invention involves the application of heat or radiation to initiate polymerization of the monomers. Useful initiators are those which are normally suitable for free radical polymerization of acrylate monomers and which are oil-soluble and of very low solubility in water. However, when the nitrogen-containing polar monomer is N-vinyl pyrrolidone, the use of benzoyl peroxide as the initiator is recommended. Examples of such initiators such as zero compounds, hydroperoxides, peroxides, and the like, and photoinitiators such as benzophenone, benzoin ethyl ether, and 2,2-dimethoxy-2-phenyl acetophenone. Use of a water-soluble polymerization initiator causes formation of substantial amounts of latex. The extremely small particle size of latex particles renders any significant ~32P~
formation of latex undesirable. The initiator is generally used in an amount ranging from about 0.01 perce~t up to about 10 percent by weight of the total polymerizable composition, preferably up to about 5 percent.
Agueous suspensions of hollow acid-free microspheres may also by prepared by a "one-step"
emulsification process comprising aqueous suspension polymerization of at least one alkyl acrylate or alkyl methacrylate ester monomer and at least one nitrogen-containing polar monomer in the presence of at least one emulsifier capable of producing a water-in-oil emulsion inside the droplets which is substantially stable during emulsification and polymerization. As in the two-step emulsification process, the emulsifier is utilized in concentrations greater than its critical micelle concentration. In general, high HLB emulsifiers are required, i.e., emulsifiers having an HLB value of at least about 25, will produce stable cavity-containing droplets during the polymerization, and are suitable for use in this one-step process. Examples of such emulsifiers include alkylarylether sulfates such as sodium alkylarylether sulfate, e.g., Triton~ W/30, available from Rohm and Haas, alkylarylpolyether sulfates such as alkylarylpoly(ethylene oxide) sulfates, preferably those having up to about 4 ethyleneoxy repeat units, and alkyl sulfates such as sodium lauryl sulfate, ammonium lauryl sulfate, triethanolamine lauryl sulfate, and sodium hexadecyl sulfate, alkyl ether sulfates such as ammonium lauryl ether sulfate, and alkylpolyether sulfates such as alkyl poly(ethylene oxide) sulfates, preferably those having up to about 4 ethyleneoxy units.
Alkyl sulfates are preferred as they provide a maximum number of voids per microsphere for a minimum amount of surfactant. Polymeric stabilizer may also be present but are not necessary.
The composition may also contain a crosslinking '`' ~' ~
~2~
agent such as a multifunctional (meth)acrylate, e.g., butanediol diacrylate or hexanediol diacrylate, or other multifunctional crosslinker such as divinylbenzene. When used, crosslinker(s) is (are) added at a level o~ up to about 0.5 mole percent, preferably up to about 0.1 mole percent, of the total polymerizable composition.
The hollow acid-free microspheres of the invention are normally tacky, elastomeric, insoluble but swellable in organic solvents, and small, typically having diameters of at least about 1 micrometer, preferably in the range of about 1 to about 250 micrometers. The majority of the hollow acid-free microspheres prepared by the methods of this invention contain multiple voids, a majority of the voids having a diameter which is less than about 10~ of the diameter of the microsphere, the total of all the void diameters being at least about 10% of the diameter of the microsphere, preferably at least about 20~, more preferably, at least about 30%.
Following polymerization, an aqueous suspension of the hollow microspheres is obtained which is stable to agglomeration or coagulation under room temperature conditions. The suspension may have non-volatile solids contents of from about 10 to about 50 percent by weight.
Upon prolonged standing, the suspension separates into two phases, one phase being aqueous and substantially free of polymer, the other phase being an aqueous suspension of microspheres having multiple cavities which, upon drying, become voids. Both phases may contain a minor portion of small latex particles.
Decantation of the microsphere-rich phase provides an aqueous suspension having a non~volatile solids content on the order of about 40-50 percent which, if shaken with water, will readily redisperse. If desired, the aqueous suspension of hollow microspheres may be utilized immediately following polymerization to provide inherently tacky pressure-sensitive adhesive coatings.
. :
2 ~ 3 2 rl ~ ~
The suspension may be coated on suitable flexible or inflexible backing materials by conventional coating techniques such as knife coating or Meyer bar coating or use of an extrusion die.
Alternatively, the aqueous suspension may be coagulated with polar organic solvents such as methanol, with ionic emulsifiers having a charge opposite to that of the emulsifier used in the polymerization process, or with saturated salt solutions, o the like, followed by washing and drying. The dried hollow microspheres, with sufficient agitation, will readily disperse in common organic liquids such as ethyl acetate, tetrahydrofuran, heptane, 2-butanone, benzene, cyclohexane, and esters, although it is not possible to resuspend them in water.
Solvent dispersions of the hollow microspheres may also be coated on suitable backing materials by conventional coating techniques, as described above for aqueous suspensions.
Suitable backing materials for the aqueous or solvent based coatings include paper, plastic films, cellulose acetate, ethyl cellulose, woven or nonwoven fabric formed of synthetic or natural materials, metal, metallized polymeric film, ceramir sheet material, and the like. Primer or binders may be used, but they are not required.
Suspensions or dispersions of the hollow acid-free microspheres in a liquid medium, e.g., water or an organic liquid as described above, may be sprayed by conventional techniques without cobwebbing or may be incorporated in aerosol containers with suitable propellants such as alkanes, alkanes, or chlorofluorocarbons, e.g., Freons~. The hollow acid-free microspheres of the invention provide a repositionable pressure-sensitive adhesive, i.e., a pressure-sensitive adhesive having a degree of adhesion which permits separation, repositioning, and rebonding.
Useful aerosol formulae have a solids content ~6~7~
of from about 5% to about 20%, preferably from about 10%
to about 16%.
The pressure-sensitive adhesive properties of the acid-free hollow microspheres may be altered by addition of tackifying resin and/or plastici~er.
Preferred tackifiers for use herein include hydrogenated rosin esters commercially available from companies such as Hercules Inc., under such trade names as Foral7M 65, Foral~ 85, and Foral~ 105. Other useful tackifiers include those based on t-butyl styrene. Useful plasticizers include dioctyl phthalate, 2-ethyl hexyl phosphate, tricresyl phosphate, and the like.
It is also within the scope of this invention to include various other components, such as pigments, fillers, stabilizers, or various polymeric additives.
These and other aspects of the invention are illustrated by the following examples which should not be viewed as limiting in scope.
Test Methods Peel Adhesion Peel adhesion is the force required to remove a coated flexible sheet material from a test panel measured at a specific angle and rate of removal. In the examples, this force is expressed in grams per centimeter (cm) width of coated sheet. The procedure followed is:
A strip 1.27 cm in width of the coated sheet is applied to the horizontal surface of a clean glass test plate with at least 12.7 lineal cm in firm contact. A 2 kg hard rubber roller is used to apply the strip. The free end of the coated strip is doubled back nearly touching itself so the angle of removal will be 180.
The free and is attached to the adhesion tester scale.
The glass test plate is clamped in the jaws of a tensile testing machine which is capable of moving the plate away from the scale at a constant rate of 2.3 meters per minute. The scale reading in grams is recorded as the .
?J~2~
tape is peeled from the glass surface. The data is reported as the average of the range of numbers observed during the test.
Shear Strength The shear strength is a measure of the cohesiveness or internal strength of an adhesive. It is based upon the amount of force required to pull an adhesive strip from a standard flat surface in a direction parallel to the surface to which is has been affixed with a definite pressure. It is measured in minutes required to pull a standard area of adhesive coated sheet material ~rom a stainless steel test panel ~nder stress of a constant, standard load.
The tests were conducted on strips of coated sheet material applied to a stainless steel panel such that a 1.27 cm by 1.27 cm portion of each strip was in firm contact with the panel with one end portion of the tape being free. The panel with the coated strip attached was held in a rack such that the panel formed an angle of 178 with the extended tape free end which was tensioned by application of a force of 200 grams applied as a hanging weight from the free end of the coated strip. The 2 less than 180 is used to negate any peel forces, thus insuring that only the shear forces are measured, in an attempt to more accurately determine the holding power of the tape being tested. The tima elapsed for each coated film to separate from the test panel was recorded as the shear strength.
Example 1 In a one-liter reactor equipped with mechanical stirrer, condenser, and inlet-outlet lines for vacuum and argon, 450 grams of deionized water, 135 grams of isooctyl acrylate, 15 grams of N-vinyl-2-pyrrolidone, 0.04 gram of 1,4-butanediol diacrylate and 0.5 gram of benzoyl peroxide were changed. Vacuum was applied to . .
, ~ ~ ~c~
evacuate the reactor atmosphere, and ~he reactor was then purged with argon. The agitation was set to 400 RPM and when the initiator had dissolved 1.5 grams of ammonium lauryl sulfate (Standapol~ A, Henkel A~) were added. The temperature of the reactor was raised to 60c and maintained for 22 hours. An argon purge was maintained during the polymerization. After the 22-hour period, the suspension was allowed to cool to room temperature. The reactor was then emptied and the suspension filtered.
Optical microscopy showed hollow microspheres from about 10 to 85 micrometers in diameter suspended in water. The majority of the microspheres contained multiple inclusions at least about 2 micrometers in diameter.
Examples 2-7 These examples illustrate the use of N-vinyl 2-pyrrolidone in different amounts and with different acrylates to prepare hollow, tacky elastomeric microspheres using the type of equipment and polymerization technique outlined in Example 1. Details of the compositions are listed in Table I. For these examples the initiator was benzoyl peroxide (0.5 gram) and the surfactant was ammonium lauryl sulfate (1.5 grams). All polymerizations produced aqueous suspensions of hollow microspheres. The microspheres contained multiple inclusions at least about 2 microns in diameter.
:, 2~7~
Table I
Example Monomers 2 135 g isooctyl acrylate 15 g N-vinyl-2-pyrrolidone 0.08 g 1,4-butanediol diacrylate 3 127.5 g isooctyl acrylate 22.5 g N-vinyl-2-pyrrolidone 0.04 g 1,4-butanediol diacrylate 4 112.5 g isooctyl acrylate 37.5 g N-vinyl-2-pyrrolidone 0.04 g 1,4 butanediol diacrylate 105 g isooctyl acrylate 45 g N-vinyl-2-pyrrolidone 0.04 g 1,4-butanediol diacrylate 6 135 g 2-ethylhexyl acrylate 15 g N-vinyl-2-pyrrolidone 7 67.5 g isooctyl acrylate 75 g n-butyl acrylate 7.5 g N-vinyl-2-pyrrolidone 0.08 g trimethylolpropane trimethacrylate Examples 8-13 These examples illustrate the use of different N-containing polar monomers to prepare hollow tacky microspheres. The equipment and technique used to prepare the microsphere suspensions were similar to those described in Example 1. In these examples the initiator used was benzoyl peroxide (0.5 gram) except for Example 9 where 0.5 g of 2,2'-azobis(2,4-di.methylpentane nitrile), available from DuPont as Vazo~-52 initiator was used.
- :: - , , ~. .:
~. . ..
,,: : :
~ ~ ~ 2 7 1~,9 ~
The surfactant in all examples was ammonium lauryl sulfate (1.5 grams) except for Example 12 where 1.0 g of sodium cetyl sulfate was used. Monomer compositions are shown in Table II.
Table II
Example Monomers 8 135 g isooctyl acrylate 15 g vinyl caprolactam 0.04 g 1,4-butanediol diacrylate 9 135 g isooctyl acrylate 15 g 2-vinyl-4,4-dimethyl-2-oxazolin-5-one 0.08 g divinyl benzene 144 g isooctyl acrylate 6 g dimethylaminoethyl methacrylate 0.04 g 1,6-hexanediol diacrylate 11 141 isooctyl acrylate 9 g octyl acrylamide 0.02 g tetraethylene glycol dimethacrylate 12 120 g 2-ethylhexyl acrylate 15 g n-butyl acrylate 7.5 g N-vinyl~2-pyrrolidone 7.5 g 2-vinyl-4,4-dimethyl-2-oxazolin-5-one 0.02 g trimethylolpropane trimethacrylate 13 127.5 g isodecyl acrylate 22.5 N-vinyl caprolactam 0.08 g divinyl benzene Example 14 The microspheres of Example 1 were coagulated :
r and dispersed in isopropanol at 12 wt% solids. the solvent dispersion was coated on 100# weight white paper and dried. The microsphere pressure sensitive adhesive dry coating weight was 18 g/m2. The microsphere coated paper and an acid-sensitive substrate were repeatedly attached to each other and separated. A 90 peel adhesion of 67.3 g/cm was recorded. Adhesion and removability were good. No transfer of microspheres or damage to the acid sensitive substrate was observed.
Example 15 to 21 Microspheres prepared in the examples shown in Table III were coagulated and dispersed in isopropanol or isopropanol/heptane mixtures and coated on a 37-micron chick poly(ethylene terephthalate) film. The coatings were dried in an oven at 65C for 10 minutes and left in a constant humidity (50% relative humidity) and temperature (22.2C) room overnight. The coated samples were tested for peel adhesion and shear strength.
Results are shown in Table III. Examples 16, 17, 19, and 20 show excellent shear performance. Examples 16 and 17, which have high levels of the N-containing polar monomer show exceptional shear performance for a repositionable adhesive.
Table III
~ Coatlng Peel Shear Microsphere Weight Adhesion Strength ExampleExample ~g/cm) (g~cm)(minutes) 1 5 124.3 6.0 16 3 5 191.3>3,000.0 17 5 5 105.6>3,000.0 18 7 9 69.2 11.0 19 ~ 7 259~632~0 9 5 205.4493.5 21_ 10 7 152.5 7.5 :
Claims (18)
1. Hollow, polymeric, acrylate, inherently tacky, infusible, solvent-insoluble, solvent-dispersible, elastomeric, nitrogen-containing, acid-free pressure-sensitive adhesive microspheres having an average diameter of at least about 1 micrometer wherein a majority of said microspheres contain multiple interior voids, a majority of said voids having a diameter of less than about 10% of the diameter of the microsphere, the total of the void diameters being at least about 10% of the diameter of said hollow microsphere.
2. Hollow, polymeric, acrylate, inherently tacky, infusible, solvent-insoluble, solvent-dispersible elastomeric, nitrogen-containing, acid free pressure-sensitive adhesive microspheres having an average diameter of at least about 1 micrometer wherein a majority of said microspheres contain multiple interior voids, a majority of said voids having a diameter of less than about 10% of the diameter of the microsphere, the total of the void diameters being at least about 20% of the diameter of said hollow microsphere.
3. Hollow, polymeric, acrylate, inherently tacky, infusible, solvent-insoluble, solvent-dispersible, elastomeric, nitrogen-containing, acid-free pressure-sensitive adhesive microspheres having an average diameter of at least about 1 micrometer wherein a majority of said microspheres contain multiple interior voids, a majority of said voids having a diameter of less than about 10% of the diameter of the microsphere, the total of the void diameters being at least about 30% of the diameter of said hollow microsphere.
4. Hollow, polymeric, acrylate, inherently tacky, infusible, solvent-insoluble, solvent-dispersible, elastomeric, nitrogen-containing, acid free pressure-sensitive adhesive microspheres according to claim 1 comprising:
a) at least about 70 parts be weight of at least one alkyl acrylate or alkyl methacrylate ester, and b) correspondingly, up to about 30 parts by weight of at least one nitrogen-containing polar monomer.
a) at least about 70 parts be weight of at least one alkyl acrylate or alkyl methacrylate ester, and b) correspondingly, up to about 30 parts by weight of at least one nitrogen-containing polar monomer.
5. Hollow, polymeric, acrylate, inherently tacky, infusible, solvent-insoluble, solvent-dispersible, elastomeric, nitrogen-containing, acid-free pressure-sensitive adhesive microspheres according to claim 1 comprising:
a) at least about 85 parts by weight of at least one alkyl acrylate or alkyl methacrylate ester, and b) correspondingly, up to about 15 parts by weight of at least one nitrogen-containing polar monomer.
a) at least about 85 parts by weight of at least one alkyl acrylate or alkyl methacrylate ester, and b) correspondingly, up to about 15 parts by weight of at least one nitrogen-containing polar monomer.
6. The hollow acid-free microspheres of claim 4 wherein the alkyl acrylate is selected from the group consisting of isooctyl acrylate, 2-ethylhexyl acrylate, isononyl acrylate, isoamyl acrylate, isodecyl acrylate and butyl acrylate.
7. The hollow acid-free microspheres of claim 6 wherein the nitrogen-containing polar monomer is selected from the group consisting of N-vinyl-2-pyrrolidone, N-vinyl caprolactam, 2-vinyl-4,4-dimethyl-2-oxazolin-5-one, dimethylaminoethyl methacrylate, acrylamide, t-butyl acrylamide and N-octyl acrylamide.
8. A particulate pressure-sensitive adhesive consisting essentially of the hollow acid-free microspheres of claim 1.
9. A particulate pressure-sensitive adhesive consisting essentially of the hollow acid-free microspheres of claim 4.
10. A particulate pressure-sensitive adhesive consisting essentially of the hollow microspheres of claim 7.
11. A repositionable spray pressure-sensitive adhesive comprising the hollow microspheres of claim 1 and a liquid medium therefor.
12. A repositionable spray pressure-sensitive adhesive according to claim 11 further comprising a propellant selected from the group consisting of alkanes, alkenes, and chlorofluorocarbons.
13. A sheet material having coated on at least a portion thereof the pressure-sensitive adhesive of claim 8.
14. An aqueous suspension comprising the hollow microspheres of claim 1.
15. A process for preparing the aqueous suspension of claim 14 comprising the steps of:
a) forming a water-in oil emulsion of a water phase selected from the group consisting of water and aqueous solutions of at least one nitrogen-containing polar monomer in at least one oil phase monomer selected from the group consisting of alkyl acrylate and alkyl methacrylate esters;
b) forming a water-in-oil-in-water emulsion by dispersing the water-in-oil emulsion into an aqueous phase containing an emulsifier having a hydrophilic-lipophilic balance value of at least about 6; and c) initiating polymerization by means of exposure to enegy selected from heat and radiation.
a) forming a water-in oil emulsion of a water phase selected from the group consisting of water and aqueous solutions of at least one nitrogen-containing polar monomer in at least one oil phase monomer selected from the group consisting of alkyl acrylate and alkyl methacrylate esters;
b) forming a water-in-oil-in-water emulsion by dispersing the water-in-oil emulsion into an aqueous phase containing an emulsifier having a hydrophilic-lipophilic balance value of at least about 6; and c) initiating polymerization by means of exposure to enegy selected from heat and radiation.
16. A process according to claim 15 wherein the water-in-oil emulsion further comprises an emulsifier having a hydrophilic-lipophilic balance value of less than about 7.
17. A process for preparing the aqueous suspension of claim 14 comprising the steps of:
a) forming droplets by mixing together i) at least one monomer selected from alkyl acrylate esters and alkyl methacrylate esters, ii) at least one nitrogen-containing polar monomer, and, iii) at least one emulsifier which is capable of producing a water-in-oil emulsion inside said droplets, said emulsion being substantially stable during emulsification and polymerization.
b) initiating polymerization by means of exposure to energy selected from heat and radiation.
a) forming droplets by mixing together i) at least one monomer selected from alkyl acrylate esters and alkyl methacrylate esters, ii) at least one nitrogen-containing polar monomer, and, iii) at least one emulsifier which is capable of producing a water-in-oil emulsion inside said droplets, said emulsion being substantially stable during emulsification and polymerization.
b) initiating polymerization by means of exposure to energy selected from heat and radiation.
18. A process according to claim 19 wherein said emulsifier has an HLB value of at least about 25.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/485,630 US4968562A (en) | 1990-02-27 | 1990-02-27 | Hollow acid-free acrylate polymeric microspheres having multiple small voids |
| US485,630 | 1990-02-27 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2032766A1 true CA2032766A1 (en) | 1991-08-28 |
Family
ID=23928873
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002032766A Abandoned CA2032766A1 (en) | 1990-02-27 | 1990-12-20 | Hollow acid-free acrylate polymeric microspheres having multiple small voids |
Country Status (10)
| Country | Link |
|---|---|
| US (1) | US4968562A (en) |
| EP (1) | EP0444354B1 (en) |
| JP (1) | JP3317977B2 (en) |
| KR (1) | KR910021455A (en) |
| AU (1) | AU628706B2 (en) |
| BR (1) | BR9100129A (en) |
| CA (1) | CA2032766A1 (en) |
| DE (1) | DE69026927T2 (en) |
| DK (1) | DK0444354T3 (en) |
| ES (1) | ES2086385T3 (en) |
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1990
- 1990-02-27 US US07/485,630 patent/US4968562A/en not_active Expired - Lifetime
- 1990-12-19 DE DE69026927T patent/DE69026927T2/en not_active Expired - Fee Related
- 1990-12-19 EP EP90313880A patent/EP0444354B1/en not_active Expired - Lifetime
- 1990-12-19 DK DK90313880.8T patent/DK0444354T3/en active
- 1990-12-19 ES ES90313880T patent/ES2086385T3/en not_active Expired - Lifetime
- 1990-12-20 CA CA002032766A patent/CA2032766A1/en not_active Abandoned
-
1991
- 1991-01-09 AU AU69283/91A patent/AU628706B2/en not_active Ceased
- 1991-01-14 BR BR919100129A patent/BR9100129A/en not_active IP Right Cessation
- 1991-02-26 KR KR1019910003091A patent/KR910021455A/en not_active Application Discontinuation
- 1991-02-26 JP JP03088591A patent/JP3317977B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| US4968562A (en) | 1990-11-06 |
| AU6928391A (en) | 1991-08-29 |
| AU628706B2 (en) | 1992-09-17 |
| BR9100129A (en) | 1991-10-22 |
| ES2086385T3 (en) | 1996-07-01 |
| EP0444354A3 (en) | 1992-01-02 |
| EP0444354B1 (en) | 1996-05-08 |
| DE69026927D1 (en) | 1996-06-13 |
| JP3317977B2 (en) | 2002-08-26 |
| JPH04216888A (en) | 1992-08-06 |
| EP0444354A2 (en) | 1991-09-04 |
| KR910021455A (en) | 1991-12-20 |
| DK0444354T3 (en) | 1996-09-23 |
| DE69026927T2 (en) | 1996-11-28 |
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Legal Events
| Date | Code | Title | Description |
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| EEER | Examination request | ||
| FZDE | Discontinued |