Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – From reactant having at least one -n=c=x group as well as...
Reexamination Certificate
2002-02-11
2003-11-11
Gorr, Rachel (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
From reactant having at least one -n=c=x group as well as...
C525S123000, C525S131000, C528S075000, C524S839000, C524S840000, C428S423100, C428S425800
Reexamination Certificate
active
06646091
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to coating compositions, crosslinked coating compositions, coated substrates, and methods for producing the coating compositions and coated substrates. More particularly, the invention relates to coating compositions including polymeric particles and crosslinking agents comprising an organic compound having an isocyanate group or a blocked isocyanate group where the polymeric particles incorporate a monoalkenyl aromatic monomer, a vinyl-containing surfactant macromonomer, and at least one acrylic monomer having a hydroxyl, amine or carboxylic acid functional group.
BACKGROUND OF THE INVENTION
Waterborne coatings are used to protect surfaces on numerous objects important to everyday life. For example, such coatings are commonly used to protect metals, wood, concrete, paper, and other important materials used in the construction of objects as diverse as homes, automobiles, bridges, retaining walls, and tin and aluminum cans.
Many surfaces such as metals are prone to oxidation, especially when exposed to salts, acids, bases, and other corrosive chemicals. Because waterborne coatings are used in a wide variety of applications and cover a wide variety of surface types, coatings that exhibit resistance to organic solvents, water, acids, salts, and other corrosive materials are highly desirable.
Although various waterborne coating compositions have been developed which show some degree of resistance to solvents and other chemicals, such coatings generally have a high cure temperature.
U.S. Pat. No. 4,814,514 and U.S. Pat. No. 4,939,283 issued to Yokota et al. disclose certain surface-active compounds which have a polymerizable allyl or methallyl group. The surface-active compounds are disclosed as being particularly useful as emulsifiers in the emulsion or suspension polymerization of various monomers such that aqueous suspensions of the polymer particles are produced.
U.S. Pat. No. 5,332,854 and U.S. Pat. No. 5,324,862 issued to Yokota et al. disclose anionic and nonionic vinyl-aromatic surfactants capable of reacting with other monomers, and thus being incorporated into polymers, during polymerization reactions.
Various vinyl aromatic surfactants referred to as Noigen RN, a nonionic surfactant, and Hitenol™ BC, an anionic surfactant, are described in a technical bulletin published by DKS International, Inc. of Tokyo, Japan. Related polymerizable anionic surfactants referred to as Hitenol™ A-10 are similarly described in another technical bulletin published by the same entity. Both publications disclose the preparation of polymers containing the surfactants.
U.S. Pat. No. 5,891,950 issued to Collins et al. disclose the preparation of water-based ink compositions containing a pigment and a polymer latex. The disclosed latex is either a non-carboxylic acid containing polymeric (polyamino) enamine latex or a mixture of a polymeric (polyamino) enamine latex and an acetoacetoxy-functional polymer latex. The polymeric (polyamino) enamine for use in the ink is disclosed as a reaction product of a surfactant-stabilized acetoacetoxy-functional polymer that may be prepared from a vinyl-containing anionic or nonionic reactive surfactant such as Hitenol™ RN, Hitenol™ HS-20, Hitenol™ A-10, and Noigen RN.
U.S. Pat. Nos. 6,060,556 and 5,998,543 issued to Collins et al. disclose the composition, preparation, and end-use of waterborne compositions prepared from water-based latexes. The water-based latexes comprise dispersed, non-carboxylic acid containing waterborne polymeric amino-functional and acetoacetoxy-functional particles. The disclosed latex can be used in a variety of coating compositions such as paints, inks, sealants, and adhesives. Preparation of a surfactant-containing acetoacetoxy-functional polymer is disclosed which may be prepared using a vinyl-containing anionic or nonionic reactive surfactant such as Hitenol™ RN, Hitenol™ HS-20, Hitenol™ A-10, and Noigen RN.
U.S. Pat. No. 6,028,155 issued to Collins et al. disclose the preparation and composition of surfactant-containing acetoacetoxy-functional polymers. The acetoacetoxy-functional polymers may be a surfactant-containing enamine-functional polymer, but is more preferably a surfactant-containing polymeric (polyamino) enamine. The disclosed non-carboxylic acid containing waterborne polymer compositions can be prepared with a high solids content while maintaining low viscosity, and the compositions are disclosed as useful in a variety of coating applications such as in paints, inks, sealants, and adhesives.
U.S. Pat. No. 5,539,073 issued to Taylor et al. discloses polymers useful in coating compositions. The polymers are prepared via free radical polymerization using ethylenically unsaturated monomers.
Various reactive anionic and nonionic surfactants are disclosed as suitable surfactants for use in the disclosed emulsion polymerization process.
U.S. Pat. No. 5,783,626 issued to Taylor et al. discloses allyl-functional polymers having pendant enamine moieties and preferably also possessing pendant methacrylate groups. The patent also discloses that amino-containing waterborne particles can be prepared by reacting propylene imine with carboxylic acid-containing latexes. Such amino-functionalized latexes were reacted with acetoacetoxyethyl methacrylate. Vinyl-containing anionic and ionic surfactants are disclosed as components which can be added to processes used for preparing the acetoacetoxy-containing polymers.
Although a number of references have disclosed polymerizable surfactants and polymers incorporating such surfactants, none of the references discloses a coating composition that comprises a crosslinking agent and a polymeric particle prepared from a vinyl-containing surfactant macromonomer that exhibits enhanced solvent resistance when crosslinked at low cure temperatures or such a coating composition which cures at faster line speeds at higher temperatures.
It would be highly desirable to have a coating composition that exhibits increased solvent resistance, chemical resistance, and hardness development at ambient cure temperatures.
SUMMARY OF THE INVENTION
The invention provides coating compositions that include polymeric particles, a crosslinking agent, and water. The polymeric particles include at least one incorporated monoalkenyl aromatic monomer, at least one incorporated vinyl-containing surfactant macromonomer, and at least one incorporated acrylic monomer. At least one incorporated acrylic monomer includes a hydroxyl functional group, or a carboxylic acid functional group. The crosslinking agent is an organic compound having at least one isocyanate group, at least one blocked isocyanate group, or at least one isocyanate group and at least one blocked isocyanate group. In one embodiment, coating compositions are provided in which the crosslinking agent is a polyisocyanate. In other coating compositions, the polymeric particles incorporate at least one acrylic monomer with a hydroxyl group and at least one acrylic monomer with a carboxylic acid functional group.
A method of preparing a coating composition includes mixing polymeric particles with a crosslinking agent to produce the coating composition. The polymeric particles include at least one incorporated monoalkenyl aromatic monomer, at least one incorporated vinyl-containing surfactant macromonomer, and at least one incorporated acrylic monomer.
At least one incorporated acrylic monomer of the polymeric particles includes a hydroxyl functional group, an amine functional group, or a carboxylic acid functional group. The crosslinking agent is an organic compound having at least one isocyanate group, at least one blocked isocyanate group, or at least one isocyanate group and one blocked isocyanate group. Preferred methods include a polyisocyanate crosslinking agent.
The invention also provides a method for preparing a coated substrate that includes coating a substrate with a coating composition according to the present invention.
The invention further provides coated substrates that include a substrate, preferab
Renner Susan L.
Taylor James W.
Bovee Warren R.
Gorr Rachel
Hamilton Neil E.
Johnson Polymer, Inc.
Rymarz Renee J.
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