Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Mixing of two or more solid polymers; mixing of solid...
Reexamination Certificate
2000-10-31
2003-01-21
Sellers, Robert E. L. (Department: 1712)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Mixing of two or more solid polymers; mixing of solid...
C525S108000, C525S111000, C525S117000, C525S118000, C525S125000, C525S131000, C525S166000, C525S176000, C525S207000, C525S404000, C525S407000, C525S438000, C525S454000
Reexamination Certificate
active
06509417
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a multi-component coating composition. More particularly, the invention relates to a multi-component coating composition comprising a fatty acid modified glycidyl-containing component and a hydroxy-functional polymer.
BACKGROUND AND SUMMARY OF THE INVENTION
There are a wide variety of multi-component coating compositions available for finishing substrates. Typically, the components are mixed together before application and then the resulting composition is applied by conventional techniques, such as spraying, roll coating, curtain coating, dipping, or flow coating, and the composition is cured at ambient or at elevated temperatures. These compositions are used to originally finish or to refinish such articles as farm, industrial, and construction equipment, automobiles, and trucks, and to paint structures such as bridges, buildings, appliances, metal furniture, such as cabinets and shelves, and the like.
Numerous patents disclose such coating compositions. For example, European Patent Application 0 123 793 discloses a two-component coating composition with one component having an anhydride ring that is opened with an amine and a second component containing glycidyl groups. Finishes formed from such compositions are not useful for articles exposed to high humidity, such as farm, industrial, and construction equipment, automobiles, trucks, and structures such as bridges and buildings, since the finishes whiten and blister on exposure to high humidity, and exhibit recoat lifting when refinished within several days after the original finish has been applied.
U.S. Pat. No. 3,136,736 and British Patent No. 994,881 disclose coating compositions comprising polyepoxides and maleic anhydride copolymers, but do not teach or suggest the use of fatty acid modified glycidyl-containing components or of hydroxy-functional polymers.
U.S. Pat. No. 4,732,791 describes a coating composition comprising olyepoxides, a monomeric anhydride curing agent, and a low number average molecular weight hydroxyl group-containing polyfunctional material. However, the composition described must be heated to cure, contains monomeric anhydrides rather than polymeric anhydrides, and does not teach or suggest the use of fatty acid modified glycidyl-containing components.
U.S. Pat. No. 5,057,555 describes a coating composition comprising a polyepoxide, polymeric anhydride, and a polymer with multiple hydroxyl groups, but does not teach or suggest the use of fatty acid modified glycidyl-containing components. These coating compositions have higher viscosities than the coating compositions of the present invention and a shorter shelf-life. U.S. Pat. No. 5,270,362 suggests the use of a low molecular weight hydroxy-functional polyester to reduce the viscosity of such coating compositions, but does not suggest the use of fatty acid modified glycidyl-containing components. The compositions disclosed in the '362 patent have a shorter shelf-life than those of the present invention.
U.S. Pat. No. 5,977,255 discloses a coating composition comprising a polyepoxy compound crosslinked with an amine-functional organosilicon, but does not teach or suggest the use of fatty acid modified glycidyl-containing components. This composition has an improved shelf-life and lowered viscosity, but is not curable at ambient temperatures in contrast to the composition of the present invention.
U.S. Pat. No. 5,977,255 discloses a coating composition comprising a polyepoxy with polymeric acid anhydride group in the form of a half-ester. This composition exhibits improved stability and good reactivity, but is not curable at ambient temperatures in contrast to the presently claimed composition.
There is a need for a coating composition, such as that of the present invention, that cures at ambient temperatures and provides a high quality finish that is useful as an exterior finish or refinish for industrial, agricultural, and construction equipment, and the like, that exhibits superior adhesion to the substrate, excellent weatherability, for example, humidity resistance, and that has a pleasing appearance.
Furthermore, advantageously the presently claimed coating composition may optionally employ a two-component system whereas three different polymers or components are required in some of the previously described coating compositions, such as the coating composition described in U.S. Pat. No. 5,057,555. Also, elimination of the polymeric anhydride, as is possible with the compositions of the present invention, produces lower viscosity coatings. Lowered viscosity results in better sprayability, and reduces the amount of environmentally hazardous volatile organic compounds required as less organic solvent may be used to obtain a coating composition with the desired viscosity.
In one embodiment of the present invention a coating composition having a hard, glossy and tack-free finish is provided. The coating composition comprises about 20 to about 80 percent by weight of reactive binder components wherein the binder components comprise:
(a) 0 to about 24 percent based on the binder weight of an anhydride acrylic polymer having at least two reactive anhydride groups and comprising the product of polymerization of monomers of an ethylenically unsaturated anhydride or an ethylenically unsaturated dicarboxylic acid and monomers selected from the group consisting of C
1
-C
8
alkyl methacrylate, C
1
-C
8
alkyl acrylate, vinyl monomers and mixtures thereof, the acrylic polymer having a weight average molecular weight of about 2,000 to about 50,000;
(b) about 5 to about 50 percent based on the binder weight of a fatty acid modified glycidyl component having hydroxy functionality and at least two reactive glycidyl groups and at least two reactive unsaturation groups; and
(c) about 5 to about 60 percent based on the binder weight of a polymeric component containing multiple hydroxy groups selected from the group consisting of acrylic polyols, polyester polyols, polyesterurethane polyols, polyether polyols, acrylourethane polyols and any mixtures thereof and having a weight average molecular weight of about 3,000 to about 20,000. The coating composition further comprises about 0.1 to about 15 percent based on the binder weight of a catalyst having the capacity to be incorporated into the polymer, a maximum of about 25 percent based on the binder weight of an aromatic vinyl, and about 20 to about 80 percent by weight of a solvent.
In another embodiment of the invention the glycidyl component is selected from the group consisting of a polyglycidyl ether of a low molecular weight polyol, an epoxy resin of epichlorohydrin and bisphenol A, a polyglycidyl ester of polyacids, polyglycidyl ethers of isocyanurates, a glycidyl methacrylate or a glycidyl acrylate containing acrylic polymer, and mixtures thereof.
In yet another embodiment of the invention the glycidyl polymeric component is modified with a fatty acid selected from the group consisting of a dehydrated caster oil fatty acid, a tall oil fatty acid, a soya oil fatty acid, a linseed oil fatty acid, and a coconut fatty acid.
In another embodiment of the invention the anhydride acrylic polymer contains about 0.1 to about 50 percent by weight of monomers selected from the group consisting of styrene acrylonitrile, methacrylonitrile and mixtures thereof.
In an alternate embodiment of the invention the anhydride acrylic polymer consists essentially of about 20 to about 40 percent by weight, based on the weight of the acrylic polymer, of methyl methacrylate, styrene, or mixtures thereof, about 35 to about 55 percent by weight of an alkyl methacrylate or an alkyl acrylate having 2-4 carbon atoms in the alkyl group and about 5 to about 55 percent by weight of polymerizable ethylenically unsaturated anhydride or ethylenically unsaturated dicarboxylic acid.
In still another embodiment of the invention the polymeric component containing multiple hydroxy groups is a polymer comprising polymerized monomers of a hydroxy alkyl methacrylate or an hydroxy alkyl acryl
O'Dell William G.
Wetzel Wylie H.
Lilly Industries, Inc.
Sellers Robert E. L.
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