S. C. Johnson Commercial Markets, Inc.

Johnson Polymer, Inc.

John P Wiruth

Paul E Sandvick

Frederick C Hansen

Glenn C Calhoun

Dean R Hellwig

Kevin M Andrist

Steven M Hurley

Dennis M Wilson

D Sunil Jayasuriya

Matthew G Lee

John E Blasko

Stephen J Maccani

H Thomas Mills, Jr

Kurt A Hessenius

Gregory R Peterson

A continuous bulk polymerization and esterification process includes continuously charging into a reaction zone at least one ethylenically unsaturated acid-functional monomer and at least one linear or branched chain alkanol having greater than 11 carbon atoms. The process includes maintaining a flow rate through the reaction zone sufficient to provide an average residence time of less than 60 minutes and maintaining a temperature in the reaction zone sufficient to produce a polymeric product incorporating at least some of the alkanol as an ester of the polymerized ethylenically unsaturated acid-functional monomer. The polymeric product is used in various processes to produce water-based compositions including emulsions and dispersions such as oil emulsions, wax dispersions, pigment dispersions, surfactants and coatings which contain the polymeric product. A polymeric surfactant includes at least one ethylenically unsaturated acid-functional monomer which has been radically incorporated into the polymeric surfactant and at least one ester of the incorporated ethylenically unsaturated acid-functional monomer which has a linear or branched chain alkyl group with greater than 11 carbon atoms. The molar critical micelle concentration of the polymeric surfactant is less than 1.0&#xd7;10moles/liter. Aqueous 2 percent solutions of certain polymeric surfactants have a surface tension of less than 45 mN/m at 30&#xb0; C. and exhibit a decrease in surface tension of at least 5 mN/m as the temperature warms from 30&#xb0; C. to 50&#xb0; C.

Continuous bulk polymerization and esterification process and compositions including the polymeric product

A continuous bulk polymerization and esterification process includes continuously charging into a reaction zone at least one ethylenically unsaturated acid-functional monomer and at least one linear or branched chain alkanol having greater than 11 carbon atoms. The process includes including maintaining a flow rate through the reaction zone sufficient to provide an average residence time of less than 60 minutes and maintaining a temperature in the reaction zone sufficient to produce a polymeric product incorporating at least some of the alkanol as an ester of the polymerized ethylenically unsaturated acid-functional monomer. The polymeric product is used in various processes to produce water-based compositions including emulsions and dispersions such as oil emulsions, wax dispersions, pigment dispersions, surfactants and coatings which contain the polymeric product. A polymeric surfactant includes at least one ethylenically unsaturated acid-functional monomer which has been radically incorporated into the polymeric surfactant and at least one ester of the incorporated ethylenically unsaturated acid-functional monomer which has a linear or branched chain alkyl group with greater than 11 carbon atoms. The molar critical micelle concentration of the polymeric surfactant is less than 1.0&times;10 moles/liter. Aqueous 2 percent neutralized solutions of certain polymeric surfactants have a surface tension of less than 45 mN/m at 30&deg; C. and exhibit a decrease in surface tension of at least 5 mN/m as the temperature warms from 30&deg; C. to 50&deg; C.

Continuous bulk polymerization and esterification process

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Racine, WI, United States of America

John P Wiruth