Polymer Dispersions

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)

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)

Polymer Dispersions and Their Industrial Applications

edited by Dieter Urban and Koichi Takamura

IV

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)

Editors Dr. Dieter Urban Dr. Koichi Takamura

BASF Corp. 11501 Steele Creek Road Charlotte, NC 28273, USA

This book was carefully produced. Nevertheless, editors, authors and publisher do not warrant the information contained therein to be free of errors. Readers are advised to keep in mind that statements, data, illustrations, procedural details or other items may inadvertently be inaccurate. Library of Congress Card No.:

applied for British Library Cataloguing-in-Publication Data

A catalogue record for this book is available from the British Library. Die Deutsche Bibliothek – CIP Cataloguingin-Publication Data

A catalogue record for this publication is available from Die Deutsche Bibliothek © 2002 Wiley-VCH Verlag GmbH, Weinheim All rights reserved (including those of translation into other languages). No part of this book may be reproduced in any form – by photoprinting, microfilm, or any other means – nor transmitted or translated into a machine language without written permission from the publishers. Registered names, trademarks, etc. used in this book, even when not specifically marked as such, are not to be considered unprotected by law.

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).

Cover photograph

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

TypoDesign Hecker GmbH,

Leimen Printing betz-druck GmbH, Darmstadt Binding Großbuchbinderei J. Schäffer

GmbH & Co. KG, Grünstadt ISBN 3-527-30286-7

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)

Contents Preface

XIII

1

Introduction

1.1 1.2 1.3 1.4 1.5

Names and Definitions 1 Properties of Polymer Dispersions 3 Important Raw Materials 8 Commercial Importance of Polymer Dispersions Manufacturers of Polymer Dispersions 12 References 14

1

10

2

Synthesis of Polymer Dispersions 15

2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.3 2.3.1 2.3.2 2.3.3 2.3.4

Introduction 15 Chemistry 17 Mechanism of Emulsion Polymerization 17 Major Monomers 23 Functional Monomers 26 Surfactants 27 Initiator Systems 30 Other Ingredients 32 Manufacturing Processes 34 Types of Process 34 Influence of Process Conditions on Polymer/Colloidal Properties Equipment Considerations 39 Safety Considerations 40 References 40

3

Characterization of Aqueous Polymer Dispersions 41

3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4

Introduction 41 Polymer Dispersions 42 General Characterization of Dispersions 42 Characterization of Polymer Particles 48 Residual Volatiles 56 Aqueous Phase Analysis 57

37

V

VI

Contents

3.3 3.3.1 3.3.2 3.3.3

Polymer Films 58 Film Formation 59 Macroscopic Characterization of Polymer Films Microscopic Characterization of Polymers 68 References 72

60

4

Applications in the Paper Industry 75

4.1 4.2 4.3 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.5

Introduction 75 The Paper Industry 76 Surface Sizing 79 Paper Coating 81 Coating Techniques 84 Pigments used in Coating Colors 86 Co-binders and Thickeners used in Coating Colors Binders used in Coating Colors 90 Test Methods 97 Concluding Remarks 100 Acknowledgments 100 References 101

5

Applications for Printing Inks 103

5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 5.3.1 5.3.2 5.3.3 5.4 5.4.1 5.4.2 5.5 5.5.1 5.5.2 5.5.3 5.6 5.6.1 5.6.2 5.7

Introduction 103 Flexographic Ink 104 Gravure Ink 106 Ink Composition 106 Pigment Dispersion 108 Emulsion Vehicle 109 Solution Vehicle 112 Waterborne Wax Emulsions and Powders 113 Ink Additives 113 Physical Properties and Test Methods 114 Typical Properties 114 Application Tests 115 Test Method Abstracts 115 Inks for Flexible Substrates (Films) 117 Surface Print Film 118 Lawn and Garden Bags 118 Inks for Paper Board Substrates 118 Folding Cartons 118 Direct Print Corrugated Packages 119 Pre-print Corrugated Packages 119 Inks for Poly-coated Board 120 Milk Cartons 120 Cup and Plate 120 Inks for Paper Products 120

87

Contents

5.7.1 5.7.2 5.7.3 5.7.4

Multiple Wall Bags 121 Gift Wrap and Envelopes Newspapers 121 Towel and Tissue 122 References 122

121

6

Applications for Decorative and Protective Coatings 123

6.1 6.1.1 6.1.2 6.1.3 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.4 6.4.1 6.4.2 6.4.3 6.5 6.5.1 6.5.2 6.5.3 6.6 6.6.1 6.6.2 6.6.3 6.7 6.7.1 6.7.2 6.7.3 6.8 6.8.1 6.8.2 6.8.3 6.8.4 6.8.5 6.8.6

Introduction 123 Market Overview 123 Coating Industry Trends 124 Coatings Provide Decoration and Protection 124 Overview of Coating Formulations 125 Volume Solids and Pigment Volume Content 125 Polymer Matrix 127 Film Formation 128 Typical Polymer Compositions 129 Pigments, Extenders, and Additives 132 Decorative Coatings 137 Emulsion Polymers in Decorative Coatings 137 Polymer Compositions used for Emulsion-based Decorative Coatings 137 Regional Distinctions in Decorative Coatings 138 Market Size of Decorative Coatings 138 Interior Decorative Coatings 139 Key Performance Features 139 Interior Decorative Coating Formulations 140 Standard Application and Performance Tests 142 Exterior Decorative Coatings 146 Key Performance Features 146 Exterior Decorative Coating Formulations 147 Standard Application and Performance Tests 147 Elastomeric Wall Coatings 149 Key Performance Features 149 Typical Elastomeric Wall Coating Formulations 150 Standard Application and Performance Tests 151 Primer Coatings 151 Key Performance Features 152 Primer Formulations 152 Standard Application and Performance Tests 153 Protective and Industrial Coatings 154 Copolymers used in Protective and Industrial Coatings 154 Market Size 155 Industrial Maintenance Coatings 155 Key Performance Features 155 Formulation Characteristics for Industrial Maintenance Coatings 156 Standard Application and Performance Tests 156

VII

VIII

Contents

6.9 6.9.1 6.9.2 6.9.3 6.9.4

Traffic Marking Paints 158 Description of Traffic Paint Market 158 Key Performance Features 159 Typical Traffic Paint Formulation 159 Standard Application and Performance Tests 159 References 161

7

Applications for Automotive Coatings 163

7.1 7.1.1 7.2 7.2.1 7.2.2 7.2.3 7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.4 7.5 7.6 7.6.1 7.7

Introduction 163 History of Automotive Coating 164 Automotive Coating Layers 166 Electrocoat 170 Primer 172 Basecoat 173 Properties of Water-borne Binders used for Automotive Coatings Emulsion Polymers 176 Microgels 177 Miniemulsions 177 Selection of Monomers, Initiators, and Surfactants 178 Secondary Acrylic Dispersions 179 Secondary Polyurethane Dispersions 179 Rheology 181 Crosslinking 183 Application Properties 185 Metallic Effect 186 Environmental Aspects and Future Trends 186 References 187

8

Applications in the Adhesives and Construction Industries 191

8.1 8.2 8.2.1 8.2.2 8.2.3 8.3 8.3.1 8.3.2 8.3.3 8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6

Introduction 191 Pressure-sensitive Adhesives 193 Self-adhesive Labels 194 Self-adhesive Tapes 207 Test Methods 210 Laminating Adhesives 217 Flexible Packaging 217 Glossy Film Lamination 219 Furniture and Automotive 222 Construction Adhesives 224 Floor-covering Adhesives 224 Sub-floor and Wall Mastics 231 Sealants 233 Ceramic Tile Adhesives 238 Polymer-modified Mortars 241 Waterproofing Membranes 244

176

Contents

8.4.7

Elastomeric Roof Coatings Acknowledgments 250 References 251

247

9

Applications in the Carpet Industry 253

9.1 9.2 9.3 9.4 9.5 9.5.1 9.5.2 9.5.3 9.5.4 9.5.5

Introduction 253 History of Carpet 253 Present Day Carpet Business 255 Carpet Backing Binders 256 Carpet Laminating 259 Background 259 Carpet Terminology 260 Back-coating Applications 261 Back-coating Formulations and Ingredients 262 Industry Issues 264 References 266

10

Non-wovens Application 267

10.1 10.2 10.2.1 10.2.2 10.3 10.4

Introduction 267 Manufacturing Systems 270 Web Formation 271 Web Consolidation 272 Polymer Dispersions for Chemical Bonding Application Test Methods 275 References 281

11

Applications in the Leather Industry 283

11.1 11.2 11.3 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5 11.3.6 11.3.7 11.4 11.4.1 11.4.2 11.4.3 11.5 11.5.1 11.5.2 11.5.3

Introduction 283 Market Situation 284 Leather Finishing 286 Modern Finishing 287 General Construction of Finishing Coats Spray Dyeing 287 Grain Impregnation 287 Base Coat 287 Pigment Coat 288 Top Coat 288 Application Methods 288 Spraying 289 Roll Coating 289 Curtain Coater 289 Binders 291 Polyacrylate Dispersions 291 Polybutadiene Dispersions 291 Polyurethane Dispersions 292

273

287

IX

X

Contents

11.6 11.6.1 11.6.2 11.6.3 11.6.4 11.7 11.7.1 11.7.2 11.7.3 11.7.4 11.7.5 11.7.6 11.7.7 11.7.8 11.7.9

Production of Selected Leather Articles 292 Shoe Upper Leather 292 Apparel Leather 293 Automotive Leather 294 Furniture Leathers 295 Test Methods in Leather Finishing 296 Flexing Endurance 297 Rub-fastness 298 Dry and Wet Adhesion 299 Fastness to Ironing 299 Hot Air Fastness 299 Aging resistance 299 Fogging test 300 Light-fastness 300 Hot light aging 300 References 300

12

Applications for Asphalt Modification 301

12.1 12.2 12.2.1 12.2.2 12.3 12.3.1 12.3.2 12.3.3 12.3.4 12.3.5 12.4 12.5

Introduction 301 Hot Mix Asphalt Paving 303 Asphalt Specification 304 In-line Injection (Pump-in) 311 Paving with Asphalt Emulsion 313 Applications of Asphalt Emulsions 314 Asphalt Emulsion Tests 317 Polymer Honeycomb Structure in Cured Asphalt Emulsion 317 Asphalt Emulsion Residue Characterization 319 Application Tests for Chip Seal and Microsurfacing 321 Eco-efficiency Analysis 323 Concluding Remarks 326 Acknowledgement 326 References 326

13

Applications of Redispersible Powders

13.1 13.2 13.3 13.4 13.4.1 13.4.2 13.4.3 13.4.4 13.4.5 13.4.6 13.5

Introduction 329 Manufacturing of Redispersible Powders 330 Dry Mortar Technology 332 Markets and Application Areas of Redispersible Powders 333 Adhesives for Ceramic Tiles 334 Tile Grouts 340 Exterior Insulation and Finish Systems and Top Coats 341 Self-leveling Underlayments 345 Patch and Repair Mortars 346 Waterproof Membranes 350 Summary 353

329

Contents

References

354

14

Applications for Modification of Plastic Materials 355

14.1 14.2 14.2.1 14.3 14.3.1 14.3.2 14.4 14.4.1 14.4.2

Introduction 355 Emulsion Polymerization and Isolation Technology 356 Isolation Technology 357 Processing Aids 358 Processing Aids for PVC 359 Processing Aids for Other Resins 366 Impact Modifiers 367 Impact Modifiers for PVC 368 Engineering Resins 375 Acknowledgment 378 References 379

15

Applications for Dipped Goods 383

15.1 15.2 15.3 15.4 15.4.1 15.4.2 15.4.3 15.4.4 15.5 15.5.1 15.5.2

Introduction 383 Polymers Used by the Dipping Industry 384 Principles of Dipping 385 Dipping Synthetic Polymer Emulsions in Practice 386 Former Design 386 Mix Design 388 Coagulant 390 The Dipping Process 390 The Testing of Synthetic Gloves 395 Non-safety-critical Gloves 395 Safety-critical Gloves 396 References 398 Index 399

XI

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)

Preface Aqueous polymer dispersions are important raw materials used in a variety of industrial processes. They consist of very small polymer particles dispersed in water and appear as milky fluids. When finally processed and providing the function for which they were selected, they are barely visible. Polymer dispersions are used to protect metal, wood, and leather against water and microorganisms, and are used as binders for pigments, fillers, and fibers and to finish the surfaces of metal, wood or paper. Protecting, binding, and finishing are the essential effects achieved by use of polymer dispersions. In most applications the water will be evaporated and a functional polymer remains. This can be hard or tacky, plastic or elastic, transparent or opaque. Accordingly, they are used for coatings or as adhesives, for binders or foams, for clear coat varnishes or opacifiers. It is even possible to reconcile these classically contradictory properties by proper design of a single dispersion or by mixing several. Even small amounts of polymer dispersion are able to improve considerably the properties 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. Dipping goods, e.g. gloves, and latex foams for mattresses are polymeric materials which are made directly from polymer dispersions. Finally, there are also applications in which polymer dispersions remain in their liquid 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 chapters on synthesis and characterization should be regarded as an introduction and should aid understanding of the applications. The applications of aqueous polymer dispersions have developed differently, both historically and regionally. Regulatory issues have contributed to these differences. The strongest development of polymer dispersions occurred in Europe and North America in the middle of the 20th century. The differences between these two regions are emphasized. We are specially grateful to all the authors who helped us make this global comparison and acknowledge the authors’ companies, for approving and supporting this work. Charlotte, North Carolina, USA

Dieter Urban Koichi Takamura

XIII

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)

List of Authors Peter Blanpain

Dr. Christoph Hahner

7834 Covey Chase Drive Charlotte, NC 28210, USA

Wacker Polymer Systems, L. P. 3301 Sutton Road Adrian, MI 49221, USA

Dr. Mary Burch

Rohm & Haas Company 727 Norristown Road Spring House, PA 19477, USA Dr. Chuen-Shyong Chou

Rohm & Haas Company Rt. 413 and Old Rt. 13 Bristol, PA 19007, USA Dr. Dieter Distler

BASF Aktiengesellschaft GKD - B1 D-67056 Ludwigshafen, Germany Dr. Johannes Peter Dix

BASF Aktiengesellschaft EVL/I – G100 D-67056 Ludwigshafen, Germany Dr. Luke Egan

BASF Corporation 11501 Steele Creek Road Charlotte, NC 28273, USA Dr. Onno Graalmann

BASF Nederland B.V. Westervoortsedijk 71 NL-6827 AV Arnhem, The Netherland Dr. Sunitha Grandhee

BASF Corporation 26701 Telegraph Road Southfield, MI 48034, USA Richard Groves

Synthomer LTD Central Road, Templefields, Harlow, Essex, CM20 2BH, UK

Dr. Do Ik Lee

The Dow Chemical Company 1604 Building Midland, MI 48674, USA Dr. Hermann Lutz

Wacker Polymer Systems GmbH&CoKG Johannes-Hees-Str. 24 D-84489 Burghausen, Germany Dr. Werner Kirchner

BASF Aktiengesellschaft EV/CS – H201 D-67056 Ludwigshafen, Germany Andrew Lanham

Synthomer Ltd. Central Road, Templefields, Harlow, Essex, CM20 2BH, UK Dr. Brough Richey

Rohm & Haas Company 727 Norristown Road Spring House, PA 19477, USA Dr. Jürgen Schmidt-Thümmes

BASF Aktiengesellschaft GKD/S – B1 D-67056 Ludwigshafen, Germany Dr. Elmar Schwarzenbach

BASF Aktiengesellschaft EDP/MB – H201 D-67056 Ludwigshafen, Germany Richard Scott

BASF Corporation 475 Reed Road NW Dalton, GA 30720, USA

XV

XVI

J. Arthur Smith

BASF Nederland B.V. Westervoortsedijk 71 NL-6827 AV Arnhem, The Netherland K. Spenceley

Synthomer Ltd. Central Road, Templefields, Harlow, Essex, CM20 2BH, UK Barna Szabo

Flint Ink Corporation 4600 Arrowhead Drive Ann Arbor, MI 48105, USA Dr. Koichi Takamura

BASF Corporation 11501 Steele Creek Road Charlotte, NC 28273, USA Jim Tanger

BASF Corporation 11501 Steele Creek Road Charlotte, NC 28273, USA Michael A. Taylor

BASF Corporation 11501 Steele Creek Road Charlotte, NC 28273, USA Dr. Dieter Urban

BASF Corporation 11501 Steele Creek Road Charlotte, NC 28273, USA Dr. Jane E. Weier

Rohm & Haas Company Rt. 413 and Old Rt. 13 Bristol, PA 19007, USA Dr. Harm Wiese

BASF Aktiengesellschaft GKD/N – B1 D-67056 Ludwigshafen, Germany Marilyn Wolf

BASF Corporation 11501 Steele Creek Road Charlotte, NC 28273, USA

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) Color Plates

Color Plates Fig. 1-3

Particle morphologies.

Raspberry structure

Core/shell structure

Acorn structure

Uncoated grade, supercalendered

Coated grade, supercalendered

Fig. 4-7

Effect of coated paper on offset printing.

XVII

XVIII

Color Plates

Coated gravure paper

Uncoated gravure paper

Fig. 4-8

Effect of coated paper on rotogravure printing.

Coating head

Steam Dryer Laminating station Release liner

Schematic representation of PSA label coater.

Backing

Fig. 8-9

Unwind

Rewind

Latex Polymer Network

Photomicrograph demonstrating spontaneous formation of polymer network upon curing of the CRS-2 asphalt emulsion modified with 3 % cationic SBR latex.

Fig. 12-15

50 µm

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)

Index a abrasion cohesion test Esso (ACTE) 323 abrasion resistance 115, 332 accelerators 389 acorn structure 5 acrylates 90 acrylic adhesive 220 acrylic dispersions 6, 12, 90, 108, 130 f., 142, 154, 193 ff., 217, 273 f., 285, 291, 358 acrylic esters 90, 94 additives 78, 132, 240, 332 f., 355 adhesion 191 ff., 299, 330, 332, 338 f., 339 adhesion level 210 adhesion-elongation 238 adhesive raw materials 192 adhesives 191 ff., 334 agglomeration number 28 aggregates 332 aging resistance 299 American Standards (ANSI) 335 analytical ultracentrifuge 51 antifoam agents 6, 114, 136, 202 antifreeze agents 235 anti-sag 334 apparel leather 284, 293 applications 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 1 aqueous flexo news ink 121 aqueous ink 104 aqueous phase analysis 57 asphalt binder 304 asphalt composition 310 asphalt consumption 301 asphalt 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 317 automotive 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 169 automotive leather 284, 294 average degree of polymerization 195

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

399

400

Index bending beam rheometer 306, 308 bimodal 5 binder 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, 203 biodegradability 6 blistering 93 ff. block resistance 116 board 92 branching 18 brightness 84, 86, 93 butadiene 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

c calcium carbonate 86 f. calender 85 f. capillary hydrodynamic fractionation 53 capillary water absorption 345 carboxylated styrene/butadiene (XSB) dispersions 6, 90, 256 ff., 273 f. carboxylic acid 26 carboxymethylcellulose 88, 90 carpet 253 carpet backcoating 259 carpet backing 253 carpet 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 256 carpet laminating 259, 263 f. – adhesive scrim coat 263 – pre-coat 263 – unitary backing 264 carpet production 255 carpet terminology 260 cement 333 cementitious topcoats 345 centrifugation 51 ceramic tile adhesives 238 ff., 332 ff. chain entanglement 21 chain transfer 18

chain transfer agent 32, 178, 198 characterization 41 ff. chelating agent 34 chemical bonding 273 chemical reacting adhesives 192 chemical resistance 116 china clay 86 chip seal 316, 321 – application test 321 coagulant dipping 386 coagulants 390 coagulation 3 coagulum 37 coagulum grit 42 coating 205 coating color 81, 85, ff. – co-binder thickeners 87 – pigments 86 – sheet-fed offset 86 coating layers 166 coating of carpets 261 coating support materials 205 coating weight of adhesives 207 co-binder 84, 87 ff. coefficient of friction 116 colloid mill 313 color 65 concrete 242, 346 ff. – maintenance 347 – rehabilitation 349 – repair 347 f. construction adhesives 224 construction industries 191 contaminants 36 conversion 22 conversion process 363 – melt rheology 363 conversion-time curve 23 core-shell modifiers 373 core-shell structure 4 f. core-shell impact modifier 376 core-shell particle 71 corona discharge 118 corona-pretreated film 218 corrosion inhibitor 114 CPVP 126 cracking 336 crinkle resistance 116 critical micelle concentration (CMC) 19, 27 critical PVC 126 critical surface tension 65 cross-linking 4, 9, 21, 33, 70, 113, 167, 183 f., 220

Index cup and plate inks 120 curtain coater 289 f.

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

electric double layer 26 electrical tapes 208 electrocoat 170 ff. electrokinetics 56 electrolytes 33 electrophoretic mobility 56 elongation at break 6, 63 elpo 170 embrittlement 299 emission measurement 230 – chamber method 230 emulsified asphalts 302 emulsifier coverage 55 emulsifiers 9 emulsion polymerization 3, 16, 17, 20, 330, 356 – at atmospheric pressure 16 – at high pressures 16 – mechanism 17 emulsion 1 emulsion polymers 15 – synthesis 15 emulsion vehicle 109 engineering resins 375 environmental impact 325 equipment 39 ethene 8, 10 ethylene/vinyl acetate copolymers 6, 90, 330 ff. extenders 132 extensibility 361 exterior decorative coating 146 ff. – application tests 148 – exterior exposure testing 148 – formulations 147 – performance tests 147 – standard application tests 147 exterior insulation and finish systems (E.I.F.S.) 332 exterior insulation systems 341 exterior thermal insulation compounds (E.T.I.C.S.) 332

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

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

401

402

Index finish systems 341 finishing 287 finishing coats 287 flexibility 332, 336, 338 – mortar 338 flexible 217, 330, 336 – packaging 217 flexing endurance 297 flexographic 103 – ink formulation 107 – printing press 105 flexural strength 332 flocculation techniques 57 flock lining 394 floor-covering adhesives 224 flow behavior 44 flow curve 44 flow, Newtonian 45 flow, pseudoplastic 45 foam backing 257 foam impregnation 274 foaming 6 foaming behavior 48 fogging test 300 foil duct tapes 208 folding carton inks 118 food packaging 7 form 386 – dipping 386 form cleaning 391 – dipping 391 formulation 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 18 free-radical polymerization 25 freeze-thaw 116, 245, 336 – stability 48 functional monomers 26 furniture automotive 222 furniture leathers 295 fusion promotion 359

g gas chromatography 56 gas permeation 68 gel effect 21 gel fraction 67 gel permeation chromatography 69 glass transition temperature 1, 6, 60, 94, 128, 154, 195, 288, 338, 357 gloss 65, 93, 99, 112 gloss enamel 142

glossy film lamination 219 glove dipping 391, 393 – batch process 393 – continuous process 391 gloves 384, 391 ff. – dipping 391 – disposable 391 – fabric supported 394 – polymeric 391 – protective 396 – testing 395 – unsupported 392 gradient polymer elution chromatography 69 grain impregnation 287 gravure 103 – ink 106 – ink formulation 107 – printing press 106 – roll 206 Green Label certification 227 – of adhesives 227 green strength development 230

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

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

Index – half-life 31 – thermal decomposition 32 – thermally dissociating 31 initiator systems 30 – half-life 30 – peroxides 30 – persulfate 30 ink 93 – absorption 93 – additives 113 – color strength 114 – composition 106 – for films 117 – jet papers 81 – splitting 97 ff. in-line injection 311 interior 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 140 interior enamels 140 internal surface area 3 interparticle crosslinking 67, 70 intrinsic viscosity 69 isolation technology 356 f.

j joint filling compositions

233

k kaolin clay

86, 87

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

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

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

403

404

Index minimum film formation temperature (MFFT) 59, 128 model system 17 modified fretting 323 modifier shell effects 372 modulus of elasticity 336 moisture vapor transmission 247 molecular weight 69, 127, 357 monomer 23 f., 94 monomers 23, 25 f. – butadiene 24 – concentration 21 – diene 24 – fox equation 23 – functional 26 – major 23 – polymer design 25 – polymer properties 23 – vinyl monomer 24 mortar 239, 241 ff., 348 ff. mottling 93, 99 multiple wall bags 121 – inks 121

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

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

optical characterization 65 organic pigments 107 original equipment manufacturers (OEM) 164 – coatings 164

p P&I test 99 packaging tapes 208 paint formulations 125 paints 127 – binder 127 paper coating 76, 79, 81, 84 – coating colors 84 – coating techniques 84 paper gloss 84 paper industry 75 f. paper machine 78 paper products 120 – inks 120 paper properties 78 paperboard coatings 75 particle morphology 70 particle size 48, 94 f. particle size distribution 52, 94, 331 – dispersion/redispersion 331 particle surface 54 patch mortar 346 paving 303, 313 peel resistance 229 – measurement 229 peel strength 196, 210 ff. peel value 197 performance grading 304 f. permanent deformation 306 permanent paper label 203 permeability 7 permeation 66 pH 43 photon correlation spectroscopy 49 pick strength 93 – see binding strength pigments 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 355 plasticizer 201, 286 – migration 286 plastics production 10

Index plywood on lumber shear test 232 polyacrylate dispersions 194, 291 – leather-finishing 291 polyacrylates 11 polybutadiene dispersions 291 polychloroprene adhesives 225 poly-coated board 120 polyken probe tack 214 polymer characterization 68 polymer colloids 1 polymer compositions 129 – binder 129 – styrene-butadiene copolymers 129 polymer corporation 131 – acrylic copolymers 131 – specialty monomers 131 polymer design 25 polymer 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 15 polymer films 58 polymer isolation technology 357 polymer modified cement concrete (PCC) 349 polymer strength 6 polymer/cement ratio 337 – flexibility 337 polymeric impact modifiers 355 polymeric modifiers 358 – classification 358 – processing aids 358 polymeric gloves 397 – standard test 397 polymerizable surfactants 30 polymer-modified asphalt 309 polymer-modified mortars 241 polyolefins 10 polystyrene 10 polystyrene dispersions 7 polyurethane adhesives 223 polyurethane dispersions 7, 170, 172, 175, 179 ff., 191, 217 f., 222 f., 285, 288, 292 polyurethanes 110 polyvinyl acetate 90 polyvinyl alcohol 88 ff., 332 polyvinyl chloride 10 porosity 93

pre-mixed 332 pre-packed 332 pre-print corrugated inks 119 pressure sensitive adhesives 193, 205, 207, 210 – test methods 210 pressurized aging vessel (PAV) 304 primer 172 f. – composition 173 – formulations 152 f. – polymers used 172 – requirements 172 – surfacer 172 primer coating 151 ff. – application tests 153 – marker stain resistance 153 – stain blocking 153 print bonding 274 printability 93 printability tests 99 printing 103 printing inks 103, 115 – tests 115 printing processes 92, 103 probe tack method 214 process aids 355 process conditions 37 – branching 37 – crosslinking 37 – monomer/polymer concentration 37 – number of particles 38 – temperature 38 processing aids 359 ff. – effect 366 – for PVC 359 – for resins 366 – types 364 product resistance 116 propagation 18 propagation rate 21 propene 9 f. protective coatings 123, 154 protective colloid 6, 9 protective films 209 protective gloves 384 pulp 77 ff. pulp suspension 79 pump-in 311 PVC durables 373 PVC formulations 371 – for building products 371

405

406

Index

q quasielastic light scattering quick-stick 213

49

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

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

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

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

t tack 6, 195, 210, 213 tackifying resins 200 tack measurement method 214 tanning 283 tensile strength 63 termination 18 test 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 183 thick bed mortar technique 334 thickeners 7, 84 ff., 133, 235, 390 – anionic 235 – dipping compounds 390 thickening 201 thin bed mortar technique 334 thixotropy 45 tile adhesives 240 – test methods 240 tile grouts 332, 334, 340 f. – ANSI Standards 341 – EN Standards 341 titanium dioxide 84, 86, 132 f., 147, 160, 202 top coats 288, 341, 344 torque rheometry 360 toughness 63, 367 towel and tissue ink 122 traffic marking paints 158 ff. – application tests 159 f. – dry-through time 159 – formulation 160 – no-pick-up test 160 – retro-reflectance 160 transmission electron microscopy 70

transparency 6, 65 tufted carpet 254 ff.

u unitary coating

264

v vario gravure 206 vinyl acetate copolymers 6, 11, 90, 130, 141, 273 f., 330 ff. vinyl chloride 10 vinylidene chloride 7 viscosity 5 f., 45, 96, 182 – dilatant 6 – pseudoplastic 5 – shear rate 5 – thixotropic 5 viscosity, Zahn efflux cup 117 volatile organic compounds (VOC) 165, 258

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

407

408

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

y 322

yellowing 94, 299 Young’s modulus 62

z zeta potential 56 Zosel tack measurement

215