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1. WO2010074750 - MINI-EMULSIONS AND LATEXES THEREFROM

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WE CLAIM:

1. A process for the preparation of a latex composition comprising: a. forming an oil phase comprising an alkyd, a drier, and at least one ethylenically unsaturated monomer, wherein the oil phase solubilizes the drier; b. combining the oil phase with an aqueous phase, wherein the aqueous phase comprises a surfactant, to form a pre-emulsion; c. homogenizing the pre-emulsion thereby forming a miniemulsion, wherein the drier is solubilized in the oil phase; d. initiating the polymerization by adding a free radical initiator, thereby polymerizing the at least one ethylenically unsaturated monomer in the miniemulsion and forming a latex polymer emulsion having latex polymer particle sizes in the range of 40 nm to 700 nm.

2. The process of claim 1 , wherein the drier is a metallic drier.

3. The process of claim 1, wherein the drier is selected from the group consisting of cobalt, zirconium, manganese, calcium, zinc, copper, barium, vanadium, cerium, iron, potassium, strontium, aluminum, bismuth and lithium compounds.

4. The process of claim 1, wherein the alkyd is a C12-C22 oil-based alkyd having an iodine value greater than 120.

5. The process of claim 1, wherein the alkyd is selected from the group consisting of vegetable oil, C12-C22 oil-based alkyds, coconut oil, fish oil, linseed oil, rung oil, castor oil, cottonseed oil, safflower oil, sunflower oil, soybean oil, and tall oil, and

6. The process of claim 1 , wherein the drier is present in the oil phase in the range of 0.05 weight percent to 0.50 weight percent, based on the total weight of the alkyd.

7. The process of claim 1, wherein the alkyd has an iodine level greater than 120.

8. The process of claim 1, wherein the ratio of the alkyd to the total monomer present in the oil phase is 40: 60 to 60:40.

9. The process of claim 1 wherein the surfactant is a surfactant selected from the group consisting of cationic, anionic, nonionic or polymeric surfactant, or a mixture thereof.

9. The process of claim 1 wherein the amount of surfactant is from about 0.5 to 5.0 percent by weight based on the total weight of the monomer and alkyd.

10. The process of claim 1 wherein the ethylenically unsaturated monomer is selected from the group consisting of vinyl monomers, acrylic monomers, allylic monomers, acrylamides, acrylonitriles N-vinyl amides, N-allyl amines mono- and dicarboxylic unsaturated acids and vinyl ethers. Vinyl esters may be used and may include vinyl acetate, vinyl propionate, vinyl butyrates, vinyl neodeconate and similar vinyl esters; vinyl halides include vinyl chloride, vinyl fluoride and vinylidene chloride; vinyl aromatic hydrocarbons include styrene, a-methyl styrene, and similar lower alkyl styrenes. Acrylic monomers include monomers such as alkyl esters of acrylic or methacrylic acid having an alky portion containing between 1 to 12 carbon atoms as well as aromatic derivatives of acrylic and methacrylic acid. Useful acrylic monomers may include, for example, acrylic and methacrylic acid esters of aliphatic alcohol having C1 to Ci2: methyl acrylate, and methacrylate, ethyl acrylate and methacrylate, butyl acrylate and methacrylate, propyl acrylate and methacrylate, 2-ethyl hexyl acrylate and methacrylate, cyclohexyl acrylate and methacrylate, decyl and dodecyl acrylate and methacrylate, isodecylacrylate and methacrylate, and benzyl acrylate and methacrylate; poly(propylene glycol) acrylates and methacrylates, poly(ethylene glycol) acrylates and methacrylates and their ethers of alcohols containing from 1 to 18 carbon atoms.

11. A product of the process of claim 1.

12. The product of claim 11, wherein the volatile organic content is less than 50 grams/liter.

13. A process for the preparation of a mini-emulsion comprising: a. forming an oil phase comprising an alkyd, a drier, and at least one ethylenically unsaturated monomer, wherein the oil phase solubilizes the drier; b. combining the oil phase with an aqueous phase, wherein the aqueous phase comprises a surfactant to form a pre-emulsion;

c. homogenizing the pre-emulsion at high shear thereby forming a miniemulsion, wherein the drier is solubilized in the oil phase; and wherein the average particle size of the monomer particles and the alkyd is in the range of 40 nanometers to 700 nanometers.

14. A latex pre-emulsion, said pre-emulsion comprising: a. an oil phase comprising an alkyd, a drier, and at least one ethylenically unsaturated monomer, wherein the drier is dissolved in the oil phase; b. an aqueous phase, wherein the aqueous phase comprises a surfactant; and wherein the oil phase and aqueous phase are blended at high shear to form average particle sizes in the range of 40 run to 700 nm.

15. A latex polymer particle, comprising; a drier associated with an alkyd in the latex polymer particle, said latex polymer particle formed from a free radical polymerization of a latex pre-emulsion comprising: a. an oil phase comprising an alkyd, a drier, and at least one ethylenically unsaturated monomer, wherein the drier is dissolved in the oil phase; b. an aqueous phase, wherein the aqueous phase comprises a surfactant; and c. wherein the oil phase and aqueous phase are blended at high shear to form average particle sizes in the range of 40 nm to 700 nm.