Reactive surfactant composition for emulsion polymerization

Abstract

The present invention is concerned with a reactive surfactant composition for emulsion polymerization, which is able to micronize the particle diameter of a polymer emulsion and to reduce the addition amount of the reactive surfactant composition to be used. The reactive surfactant composition for emulsion polymerization of the present invention contains a reactive anionic surfactant (component A) represented by the following formula (I), the component A being satisfied with the following requirement R: wherein AO represents an alkyleneoxy group having a carbon number of 3 or more and 18 or less; EO represents an ethyleneoxy group; p represents an integer of 1 or more and 15 or less; m′ represents an integer of 0 or more; n′ represents an integer of 0 or more; W represents a hydrogen ion or a cation; and plural kinds of AOs may coexist. Requirement R: An average addition molar number m of AO is a number of 1 or more and 50 or less; an average addition molar number n of EO is a number of 0 or more and 200 or less; and when in the component A, a component having an addition molar number of AO of (m−3) or less is defined as (component A-1), and a component having an addition molar number of AO of (m+2) or more is defined as (component A-2), X in the following formula (I) is less than 30, provided that when m is less than 3, (m′=0) is defined as (component A-1): X={(molar number of component A-1)+(molar number of component A-2)}÷(molar number of component A)×100  (I).

1 .- 7 . (canceled) 
     
     
         8 . A method of emulsion polymerization using a reactive surfactant composition, wherein the reactive surfactant composition comprises a reactive anionic surfactant (component A) represented by the following formula (1), and the component A is satisfied with the following requirement R: 
       
         
           
           
               
               
           
         
         wherein AO represents an alkyleneoxy group having a carbon number of 3 or more and 18 or less; EO represents an ethyleneoxy group; p represents an integer of 1 or more and 15 or less; m′ represents an integer of 0 or more; n′ represents an integer of 0 or more; M +  represents a hydrogen ion or a cation; and plural kinds of AOs may coexist, and 
         Requirement R: an average addition molar number m of AO is a number of 1 or more and 50 or less; an average addition molar number n of EU is a number of 0 or more and 200 or less; and when in the component A, a component having an addition molar number of AO of (m−3) or less is defined as (component A-1), and a component having an addition molar number of AO of (m+2) or more is defined as (component A-2), X in the following formula (I) is less than 30, provided that when m is less than 3, (m′=0) is defined as (component A-1):
   X={(molar number of component A-1)+(molar number of component A-2)}÷(molar number of component A)×100  (I).
 
 
       
     
     
         9 . A method of producing a polymer emulsion, comprising subjecting a radical polymerizable monomer to emulsion polymerization in the presence of a reactive surfactant composition wherein the reactive surfactant composition comprises a reactive anionic surfactant (component A) represented by the following formula (1), and the component A is satisfied with the following requirement R: 
       
         
           
           
               
               
           
         
         wherein AO represents an alkyleneoxy group having a carbon number of 3 or more and 18 or less; EO represents an ethyleneoxy group; p represents an integer of 1 or more and 15 or less; m′ represents an integer of 0 or more; n′ represents an integer of 0 or more; M +  represents a hydrogen ion or a cation; and plural kinds of AOs may coexist, and 
         Requirement R: an average addition molar number m of AO is a number of 1 or more and 50 or less; an average addition molar number n of EO is a number of 0 or more and 200 or less; and when in the component A, a component having an addition molar number of AO of (m−3) or less is defined as (component A-1), and a component having an addition molar number of AO of (m+2) or more is defined as (component A-2), X in the following formula (I) is less than 30, provided that when m is less than 3, (m′=0) is defined as (component A-1):
   X={(molar number of component A-1)+(molar number of component A-2)}÷(molar number of component A)×100  (I).
 
 
       
     
     
         10 . A coating material composition comprising the polymer emulsion obtained by the production method according to  claim 9 . 
     
     
         11 . A method of producing a polymer coating film foimed of the coating material composition according to  claim 10 . 
     
     
         12 . A method of producing a reactive anionic surfactant, comprising the following steps (i) to (iii), the reactive anionic surfactant being represented by the following formula (1) and being satisfied with the following requirement R (provided that in the requirement R, when n is 0, then the step (ii) is not performed):
 Step (i): a step of adding an alkylene oxide having a carbon number of 3 or more and 18 or less to a compound represented by the following formula (2) in the presence of an aluminum-magnesium complex oxide catalyst to thereby obtain a compound represented by the following formula (3);   Step (ii): a step of adding ethylene oxide to the compound represented by the following formula (3) in the presence of an alkali catalyst to thereby obtain a compound represented by the following formula (4); and   Step (iii): a step of sulfating the compound represented by the following formula (4) with a sulfating agent and neutralizing with a basic substance:   
       
         
           
           
               
               
           
         
         wherein AO represents an alkyleneoxy group having a carbon number of 3 or more and 18 or less; EO represents an ethyleneoxy group; p represents an integer of 1 or more and 15 or less; m′ represents an integer of 0 or more; n′ represents an integer of 0 or more; M +  represents a hydrogen ion or a cation; and plural kinds of AOs may coexist: and 
         Requirement R: an average addition molar number m of AO is a number of 1 or more and 50 or less; an average addition molar number n of EO is a number of 0 or more and 200 or less; and when in the compound represented by the formula (1) (component A), a component having an addition molar number of AO of (m−3) or less is defined as (component A-1), and a component having an addition molar number of AO of (m+2) or more is defined as (component A-2), X in the following formula (I) is less than 30, provided that when m is less than 3, (m′=0) is defined as (component A-1):
   X={(molar number of component A-1)+(molar number of component A-2)}÷(molar number of component A)×100  (I).
 
 
       
     
     
         13 . The method of emulsion polymerization according to  claim 8 , wherein in the formula (1), m′ is an integer of 1 or more and an integer of 100 or less. 
     
     
         14 . The method of emulsion polymerization according to  claim 8 , wherein in the formula (1), m′ is an integer of 2 or more and an integer of 50 or less. 
     
     
         15 . The method of emulsion polymerization according to  claim 8 , wherein in the formula (1), n′ is an integer of 1 or more and an integer of 400 or less. 
     
     
         16 . The method of emulsion polymerization according to  claim 8 , wherein in the formula (1), n′ is an integer of 2 or more and an integer of 200 or less. 
     
     
         17 . The method of emulsion polymerization according to  claim 8 , wherein in the formula (1), the carbon number of the alkyleneoxy group represented by AO is 8 or less. 
     
     
         18 . The method of emulsion polymerization according to  claim 8 , wherein in the requirement R, m is 2 or more and 20 or less. 
     
     
         19 . The method of emulsion polymerization according to  claim 8 , wherein in the requirement R, m is 3 or more and 10 or less. 
     
     
         20 . The method of emulsion polymerization according to  claim 8 , wherein in the requirement R, n is 1 or more and 150 or less. 
     
     
         21 . The method of emulsion polymerization according to  claim 8 , wherein in the requirement R, (m+n) is {3≤(m+n)≤100}. 
     
     
         22 . The method of emulsion polymerization according to  claim 8 , wherein in the formula (I), X is 10 or more and 29 or less. 
     
     
         23 . The method of producing a polymer emulsion according to  claim 9 , wherein the use amount of the reactive surfactant composition for emulsion polymerization is 0.1% by mass or more and 10% by mass or less relative to the total amount of the radical polymerizable monomer. 
     
     
         24 . A polymer emulsion obtained by the production method according to  claim 9 , wherein an average particle diameter of the polymer emulsion is 30 nm or more and 500 nm or less. 
     
     
         25 . A polymer emulsion obtained by the production method according to  claim 9 , wherein a viscosity of the polymer emulsion is 10 mPa·s or more and 50,000 mPa·s or less.