Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Patent
1982-04-23
1983-05-31
Marquis, Melvyn I.
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
252395, 523465, C08K 536
Patent
active
043861733
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
This invention relates to hot melt coating compositions which possess corrosion and rust preventive properties. More particularly, this invention relates to 100 percent solids coating compositions containing epoxy resins and rust inhibiting sulfonates, and having low melt viscosity so as to be applicable as hot melt corrosion resistant sealers. Most particularly, the corrosion preventative compositions of the invention possess outstanding adhesion to metal substrates and comprise an adduct mixture formed by reacting epoxy resins and liquid reactive elastomer, a dispersion of petroleum sulfonate complex in nonvolatile diluent oil, and microcrystalline wax.
BACKGROUND ART
Inhibiting rust formation on various metal surfaces, particularly iron-containing automotive products which are exposed to salt, is highly desirable. Various solutions for preventing rust formation have been suggested in the past. It is a well known practice to coat the under body of automobiles with materials possessing corrosion preventive properties. To this end, both in-point-of manufacture and after market applications, numerous materials and formulations have been utilized.
Most of these rust preventive corrosion compositions are based on chemically inert grease or wax-like materials. Typical of these formulations are those taught in U.S. Pat. Nos. 2,374,565, 2,430,846, 2,573,878, 2,995,532, 3,313,635, 2,746,643 and 4,150,192. In U.S. Pat. No. 3,746,643, calcium and magnesium sulfonates in a minor amount of mineral oil are taught to be useful as rust inhibitor coatings when combined with a microcrystalline wax. U.S. Pat. No. 4,150,192 teaches a sprayable hot melt rust inhibitor composite comprised of a mixture of a sulfonate, optionally a carbonate, optionally an oxidized petroleum, diluent oil, microcrystalline wax, active filler and thermoplastic resin. The composite is taught as useful for coating automobiles.
Because these prior art coating compositions are generally non-drying and lacking in cohesive strength, they can readily be removed by abrasion, impact, or elevated temperatures, and therefore require frequent inspection to determine the adequacy of the protection being afforded the coated metallic surfaces.
Elastomers have been incorporated into rust preventative compositions in an attempt to improve their cohesive strength. However, because of the extremely high viscosity of such elastomers, they can only be incorporated in a very limited quantity. The compositions containing higher levels of elastomers have a very high viscosity and cannot be sprayed unless diluted with organic solvent. However, the incorporation of such volatile solvents is undesirable for a variety of reasons, including potential fire hazard and toxicity. Epoxy resins generally have a lower viscosity than such elastomers and are known for their superior cohesive strength when used as a coating binder. However, due to the poor compatibility between epoxy resins and petroleum sulfonate complexes commonly used in rust preventative composition, epoxy resins have not been successfully blended homogeneously into such compositions.
DISCLOSURE OF INVENTION
The invention of the subject application is directed to a sprayable hot melt corrosion preventative composition and process for making the composition. The composition is characterized in that it comprises: (1) between about 10 and about 25 parts by weight of an epoxy resin-elastomer adduct mixture, (2) between about 10 and about 25 parts by weight microcrystalline wax; and (3) between about 50 and about 80 parts by weight of a dispersion of petroleum sulfonate complex in nonvolatile diluent oil. The total weight of (1), (2) and (3) is 100 parts.
In this composition the adduct mixture is formed by reacting (a) epoxy resin having a number average molecular weight (M.sub.n) between about 150 and about 2000, preferably between about 200 and about 1500, and (ii) having two or more epoxide groups per molecule and (b) reactive elastomer (i) having a number average molecular weight (M.sub.n) of
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patent: 2374565 (1945-04-01), Roden
patent: 2430846 (1947-11-01), Morgan
patent: 2573878 (1951-11-01), Schiermeier et al.
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patent: 2995532 (1961-08-01), Cantrell et al.
patent: 3313635 (1967-04-01), Wollek et al.
patent: 3746643 (1973-07-01), Rogers
patent: 4150192 (1979-04-01), Downey
Ford Motor Company
Marquis Melvyn I.
May Roger L.
Melotik Lorraine S.
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