Aqueous epoxy ester emulsions
First Claim
1. A nongelled hydroxy ester copolymer composition substantially free of oxirane functionality comprising an acidic copolymer-epoxy resin hydroxy ester reaction product produced by esterifying an acidic copolymer with an epoxy resin in the presence of amine catalyst in amounts larger than 2% by weight of reactants subjected to esterification to avoid a useless gel, the epoxy resin being a mixture containing at least 5% by weight of aromatic polyether which is difunctional in oxirane functionality which is consumed by reaction with the acidic copolymer and the acidic copolymer being a solution copolymer of monoethylenically unsaturated monomers comprising at least about 20% of monoethylenically unsaturated carboxylic acid, based on the total weight of monomers, the epoxy resin mixture constituting at least about 40% of the total resin solids content and providing oxirane functionality in a stoichiometric deficiency with respect to carboxyl functionality in the acidic copolymer of from 1:
- 2 to 1;
20, at least a portion of the carboxyl functionality in the copolymer-epoxy resin hydroxy ester reaction product being reacted with a base to render the reaction product self-emulsifiable in water.
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Abstract
Sanitary coatings based on self-emulsifiable epoxy ester copolymers are produced by esterifying a solvent-soluble carboxyl polymer with an epoxy resin in an organic resin and in the presence of at least about 2% amine catalyst to provide a carboxyl-functional epoxy polymer which can be reacted with a base and dispersed into water.
74 Citations
43 Claims
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1. A nongelled hydroxy ester copolymer composition substantially free of oxirane functionality comprising an acidic copolymer-epoxy resin hydroxy ester reaction product produced by esterifying an acidic copolymer with an epoxy resin in the presence of amine catalyst in amounts larger than 2% by weight of reactants subjected to esterification to avoid a useless gel, the epoxy resin being a mixture containing at least 5% by weight of aromatic polyether which is difunctional in oxirane functionality which is consumed by reaction with the acidic copolymer and the acidic copolymer being a solution copolymer of monoethylenically unsaturated monomers comprising at least about 20% of monoethylenically unsaturated carboxylic acid, based on the total weight of monomers, the epoxy resin mixture constituting at least about 40% of the total resin solids content and providing oxirane functionality in a stoichiometric deficiency with respect to carboxyl functionality in the acidic copolymer of from 1:
- 2 to 1;
20, at least a portion of the carboxyl functionality in the copolymer-epoxy resin hydroxy ester reaction product being reacted with a base to render the reaction product self-emulsifiable in water. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 34, 35, 36)
- 2 to 1;
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14. Process for preparing a self-emulsifiable epoxy ester copolymer mixture which comprises esterifying a solvent-soluble carboxy-functional polymer comprising polymerized ethylenically unsaturated monomers with an epoxy resin which is a mixture comprising aromatic polyethers containing oxirane functionality, at least 5% of the aromatic polyethers being constituted by diepoxide, the mixture of aromatic polyethers constituting at least 40% of the total resin solids content and providing oxirane functionality in a stoichiometric deficiency with respect to carboxyl functionality in the carboxyl-functional polymer of from 1:
- 2 to 1;
20, the esterification being carried out in organic solvent medium in the presence of greater than 2% of an amine esterification catalyst, based on the weight of the reactants subjected to esterification, and at an elevated temperature sufficient to cause the oxirane functionality to react with the carboxyl functionality until the oxirane functionality is substantially entirely consumed and reaching at least a portion of the carboxyl functionality in the resultant polymer-epoxy resin hydroxy ester reaction product with a base to render the reaction product self-emulsifiable in water. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 37, 38)
- 2 to 1;
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30. A process for producing a water-dispersed nongelled emulsion of an epoxy resin ester copolymer containing by weight at least about 40% epoxy resin esterified with an acidic copolymer, the process steps comprising:
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esterifying epoxy resin with acid functional copolymer in the presence of at least about 4% by weight amine esterification catalyst based on reactants and carried out in an organic solvent medium, wherein said acid functional copolymer comprises copolymerized ethylenically unsaturated monomers including between 30% and 70% by weight monoethylenically unsaturated carboxylic acid whereby the acidic copolymer contains 4 to 10 carboxyl groups per epoxy resin oxirane groups and said epoxy resin ester copolymer contains non-esterified carboxyl groups; reacting at least a portion of the non-esterified carboxyl groups on said epoxy resin ester copolymer with volatile amine base and dispersing the epoxy resin ester copolymer in water to provide a nongelled emulsion. - View Dependent Claims (31, 32, 33)
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39. A composition suitable for sanitary can coatings consisting essentially of a self-emulsified mixture substantially free of oxirane groups including a hydroxy ester copolymer containing carboxyl groups at least some of which, sufficient to achieve self-emulsification in water, are neutralized by volatile amine;
- which composition is the product of the reaction of;
(A) an acidic addition copolymer having an acid number greater than 150 comprising a copolymer of monoethylenically unsaturated monomers selected from the group consisting of styrene, vinyl toluene, acrylic acid esters, methacrylic acid esters, acrylic acid and methacrylic acid containing at least about 30% by weight of acrylic or methacrylic acid based on the total weight of monomers; (B) a mixture containing (bispenol-A)-epichlorohydrin polyether epoxy resin including at least 5% by weight of polyether epoxy resin containing oxirane groups and at least 25% by weight of said (bisphenol-A)polyether being terminated with bisphenol-A and devoid of oxirane groups, said mixture comprising at least 40% of the total resin solids and containing sufficient oxirane groups to provide a ratio of oxirane groups to carboxyl of 1;
2 to 1;
20; andconducted in the presence of a tertiary amine in amounts larger than 2% by weight of reactants subjected to esterification. - View Dependent Claims (40, 41, 42, 43)
- which composition is the product of the reaction of;
Specification