Polyester resins based on fatty acids that have a short oil length, aqueous dispersions and associated coatings

• US 9,624,339 B2
• Filed: 09/23/2011
• Issued: 04/18/2017
• Est. Priority Date: 09/27/2010
• Status: Active Grant

• Current Assignee: Arkema France (Arkema)
• Original Assignee: Arkema France (Arkema)
• Inventors: Herve, Grgoire, Beurdeley, Patricia, Kurczak, Michael
• Primary Examiner(s): Yoon, Tae H
• Application Number:
  US13/876,222
• Publication Number:
  US 20130197152A1
• Time in Patent Office: 2,034 Days
• Field of Search: 5282953, 5282955, 523502, 524513
• CPC Class Codes: C08G 63/00 Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule polyester-amides C08G69/44; polyester-imides C08G73/16
• CPC Class Codes: C08G 63/48 by unsaturated higher fatty oils or their acids; by resin acids
• CPC Class Codes: C08J 3/05 from solid polymers
• CPC Class Codes: C08L 2201/50 Aqueous dispersion, e.g. containing polymers with a glass transition temperature (Tg) above 20°C
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 67/08 Polyesters modified with higher fatty oils or their acids, or with resins or resin acids
• CPC Class Codes: C09D 167/00 Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain based on polyester-amides C09D177/12; based on polyester-imides C09D179/08; Coating compositions based on derivatives of such polymers
• CPC Class Codes: C09D 167/08 Polyesters modified with higher fatty oils or their acids, or with natural resins or resin acids

Abstract

The invention relates to a polyester resin which is based on at least one fatty acid, with a zero oil length (0%) or an oil length of between 0 and 35%, with a weight ratio of oxidizable fatty acids (monoacids), relative to the overall fatty acids, of 0 or greater than 0 and ranging up to 1, and which is based on an acid component comprising, in addition to said fatty acid, from 30% to 85% by weight, relative to the total weight of said resin, of rosin and/or of derivatives thereof bearing at least one carboxylic acid function.

Claims

1. An aqueous resin dispersion comprising at least one polyester resin derived from:

at least one fatty acid, and

an acid component comprising, in addition to said fatty acid, from 45% to 75%, relative to the total weight of said resin, of rosin and/or rosin derivatives bearing at least one carboxylic acid function,

said acid component comprising at least one acid containing at least one carboxylic acid function and having an overall functionality of 2 to 3, selected from the group consisting of saturated polyacids, ethylenically unsaturated polyacids, and hydroxy acids, wherein said polyacid comprises at least on C36 fatty acid dimer and/or C54 fatty acid trimer;

wherein said resin has an oil length from 0% to 35%, and has a weight ratio of oxidizable fatty monoacids relative to the overall fatty acids from 0 to 1;

wherein said resin comprises less than 5% by weight aromatic compound in addition to the rosin and/or rosin derivatives bearing at least one carboxylic acid function,

said aqueous resin dispersion further comprising at least one surfactant selected from the group consisting of;

anionic surfactant, nonionic surfactant, and at least one surfactant having both anionic and nonionic functional units, and with an overall surfactant weight ratio relative to said resin from 2% to 15%;

whereby said resin is dispersed in water without need for organic solvent and in the absence of groups that make the resin self-dispersing.

2. The aqueous resin dispersion of claim 1, wherein said acid component comprises at least two acids, with at least one chosen from saturated polyacids and at least another chosen from unsaturated polyacids.

3. The aqueous resin dispersion of claim 1 wherein the oxidizable unsaturation content of said resin is from zero (0) to 0.25 mmol of oxidizable double bonds per g of dry resin.

4. The aqueous resin dispersion of claim 1 wherein said resin is derived from an alcohol component comprising at least one polyol having polyol functionality from 2 to 10.

5. The aqueous resin dispersion of claim 1 wherein said oil length is greater than 0 and less than 35%, said acid component including at least one oxidizable fatty monoacid.

6. The aqueous resin dispersion of claim 5, wherein the oxidizable unsaturation content of said resin is greater than 0 and up to 0.25 mmol of oxidizable double bonds per g of dry resin.

7. The aqueous resin dispersion of claim 5 wherein said fatty acid is selected from the group consisting of fatty acids of soybean oil, sunflower oil, tall oil (TOFA), castor oil, dehydrated castor oil, linseed oil, and rapeseed oil, said fatty acids being in acid form or in the form of triglyceride esters of fatty acids, or of corresponding stand oils of fatty acid oils.

8. The aqueous resin dispersion of claim 5 wherein, said acid component comprises a polyacid comprising at least one C36 fatty acid dimer and/or C54 fatty acid trimer and wherein said resin is further derived from a polyol comprising at least one glycerol and/or pentaerythritol and/or dipentaerythritol oligomer.

9. The aqueous resin dispersion of claim 1 wherein said polyester is an alkyd resin with an oil content greater than 0%.

10. The aqueous resin dispersion of claim 1 wherein said resin has a zero oil content (0%) and said fatty acid is selected from non-oxidizable fatty acids with a corresponding content of oxidizable unsaturations that is 0 mmol per g of dry resin or wherein said resin has an oil content up to 5% and wherein said acid component further comprises as a minor component an oxidizable fatty acid, such that said resin has said oil content of no more than 5%.

11. The aqueous resin dispersion of claim 10, wherein said non-oxidizable fatty acid is selected from the group consisting of saturated fatty acids, fatty acids that are initially oxidizable which have been hydrogenated, and Fatty acid oligomers.

12. The aqueous resin dispersion of claim 10 wherein said resin is derived from an alcohol component comprising a glycerol oligomer, and as non-oxidizable fatty acid a C36 fatty acid dimer and/or a C54 fatty acid trimer which are hydrogenated or non-hydrogenated.

13. An aqueous resin dispersion comprising a mixture, of a first aqueous resin dispersion according to claim 1 and at least one second resin dispersion different from the first, this second resin dispersion being selected from the group consisting of alkyd dispersions, acrylic and styrene acrylic dispersions and emulsions, saturated and unsaturated polyester dispersions and polyurethane dispersions.

14. A process for preparing an aqueous resin dispersion according to claim 1 comprising a step of emulsification, at a temperature of from 30 to 90°

C. of said resin by phase inversion in a reactor stirred via a dual-flow stirring system.

15. A coating composition comprising as binder at least one aqueous resin dispersion according to claim 1.

16. The coating composition as claimed in claim 15 wherein said coating is selected from the group consisting of decorative industrial coatings, and anticorrosion coatings.

17. A coating composition comprising an aqueous resin dispersion according to claim 1, and further comprising a siccativating agent and wherein said resin of said aqueous resin dispersion has an oil length (content) up to 25%.