COMPOSITE DISPERSION, METHOD OF PRODUCING THE SAME, AND ARTICLES MADE THEREFROM

The instant invention is a composite dispersion, method of producing the same, and articles made therefrom. The composite dispersion according to the instant invention comprises (1) a first seed dispersion comprising (a) a first internal phase; and (b) an external phase, and (2) a second internal phase; wherein the composite dispersion comprises more than 60 percent by the combined weight of the first internal phase and the second internal phase, and the composite dispersion has a viscosity of less than 10,000 cP measured by RV4 spindle at 20 rpm at greater than 60 weight percent total internal phase, and wherein the composite dispersion has a bimodal particle size distribution and a particle size ratio (P2/P1) in the range of 2 to 200. The first internal phase comprises a first hydrophobic material selected from the group consisting of alkyd, silicone, polyolefin, polyurethane, epoxy, emulsion polymer, and polyester. The external phase comprises water. The second internal phase comprises a second hydrophobic material selected from the group consisting of alkyd, silicone, polyurethane prepolymer, epoxy, and polyester. The process for producing a composite dispersion according to the instant invention comprises the steps of: (1) selecting a first internal phase comprising a first hydrophobic material selected from the group consisting of alkyd, silicone, polyolefm, polyurethane, epoxy, emulsion polymer, polyester; (2) selecting an external phase comprising water; (3) contacting the first hydrophobic material with the external phase; (4) thereby producing a first seed dispersion; (5) contacting the first seed dispersion and a second internal phase comprising a second hydrophobic material selected from the group consisting of alkyd, silicone, polyurethane prepolymer, epoxy, polyester; (6) thereby forming the composite dispersion, wherein the composite dispersion comprises more than 60 percent by the combined weight of the first internal phase and the second internal phase, and wherein the composite dispersion has a viscosity of less than 10,000 cP measured by RV4 spindle at 20 rpm at greater than 60 weight percent total internal phase, and wherein the composite dispersion has a bimodal particle size distribution and a particle size ratio (P2/P1) in the range of 2 to 200. The articles according to the instant invention comprise the inventive composite dispersion.