Water extended polyester resin

Claim 2

The dispersion of claim 2 wherein the monomer is styrene.

Claim 3

A water in oil emulsion of a polyester resin comprising: a. an unsaturated polyester which is the reaction product of a polycarboxylic acid and a polyol, b. a vinyl monomer cross-linking agent, c. water, and d. ammonium carbonate-carbamate.

Claim 4

The emulsion of claim 4 wherein the polyester has an acid number of from 30 to 60.

Claim 5

The emulsion of claim 5 wherein the ammonium carbonate-carbamate is present in a neutralization equivalence range of from 1.2 to 0.8.

Claim 6

The emulsion of claim 6 wherein the water comprises 50 to 80 weight percent based on the polyester-monomer-water mixture.

Claim 7

The emulsion of claim 4 wherein the monomer is styrene.

Claim 8

The emulsion of claim 8 wherein the styrene comprises from 30 to 70 weight percent based on the polyesterstyrene mixture.

Claim 9

The emulsion of claim 7 wherein the polyester is the esterification product of an unsaturated aliphatic dicarboxylic acid and a carboxylic acid selected from i. a saturated aromatic dicarboxylic acid, ii. a mixture of saturated aromatic dicarboxylic acids with saturated aromatic monocarboxylic acids, iii. a mixture of saturated aromatic dicarboxylic acids with saturated aliphatic monocarboxylic acids, and iv. mixtures thereof, and a polyol selected from diols and mixtures of diols with up to 20 percent by weight of alcohols selected from triols and monocarboxylic acid alcohols.

Claim 10

The emulsion of claim 10 wherein the equivalence ratio of total polycarboxylic acid to total polyol is in the range of from 2.0 to 2.6:2.0, respectively.

Claim 11

The emulsion of claim 11 wherein the equivalence ratio of total polyacid to total polyol is about 2.1:2.0.

Claim 12

The emulsion of claim 11 wherein the equivalence ratio of saturated aromatic dicarboxylic acid to unsaturated aliphatic dicarboxylic acid is in the range of from 0.7:1.3 to 1.2:1.8, respectively.

Claim 13

The emulsion of claim 13 wherein the equivalence ratio of saturated aromatic dicarboxylic acid to unsaturated aliphatic dicarboxylic acid is about 1.0 to 1.0, respectively.

Claim 14

The emulsion of claim 10 wherein the carboxylic acid is a mixture of saturated aromatic dicarboxylic acid and saturated aromatic monocarboxylic acid.

Claim 15

The emulsion of claim 15 wherein the equivalence ratio of saturated aromatic dicarboxylic acid to saturated aromatic monocarboxylic acid is about 0.95:0.05.

Claim 16

A water in oil emulsion of a polyester resin comprising: a. unsaturated polyester having an acid number from 30 to 60 which is the esterification product of an unsaturated aliphatic dicarboxylic acid and a carboxylic acid selected from: i. a saturated aromatic dicarboxylic acid, ii. a mixture of saturated aromatic dicarboxylic acids with saturated aromatic monocarboxylic acids, iii. a mixture of saturated aromatic dicarboxylic acids with saturated aliphatic monocarboxylic acids, iv. mixtures thereof, and a polyol selected from diols and mixtures of diols with up to 20 percent by weight of alcohols selected from triols and monocarboxylic acid alcohols, and wherein the equivalence ratio of saturated aromatic dicarboxylic acid to unsaturated aliphatic dicarboxylic acid is in the range of from 0.7:1.3 to 1.2:1.8, and wherein the equivalence ratio of total polycarboxylic acid to total polyol is in the range of from 2.0 to 2.6:2.0, respectively; b. styrene in the amount of from 30 to 70 weight percent based upon the polyester resin-styrene mixture; c. water in the amount of from 50 to 80 weight percent based upOn the polyester-monomer-water mixture; and d. ammonium carbonate-carbamate present in a neutralization equivalence range of from 1.2 to 0.8.

Claim 17

The emulsion of claim 17 wherein the unsaturated aliphatic dicarboxylic acid is selected from maleic acid, fumaric acid and itaconic acid.

Claim 18

The emulsion of claim 18 wherein the saturated aromatic dicarboxylic acid is selected from isophthalic, terephthalic and phthalic acid.

Claim 19

The emulsion of claim 19 wherein the saturated monocarboxylic acids are selected from benzoic, o-toluic, m-toluic, p-toluic acids.

Claim 20

The emulsion of claim 20 wherein the diols are selected from alkyleneglycols having from two to eight carbon atoms.

Claim 22

The method of claim 22 wherein said ammonium carbonate-carbamate is mixed in an amount of from 1.2 to 0.8 neutralization equivalence range.

Claim 23

The method of claim 23 wherein the polyester resin has an acid number of from 30 to 60.

Claim 24

The method of claim 22 wherein the water is present in an amount of from 50 to 80 percent based on the polyester-monomer-water mixture.

Claim 25

The method of claim 25 wherein the vinyl monomer is styrene present in an amount of from 30 to 70 weight percent based on the polyester-styrene content of the mixture.

Claim 26

The method of claim 26 wherein the polyester comprises the esterification product of a saturated aromatic dicarboxylic acid, an unsaturated aliphatic dicarboxylic acid and a polyol.

Claim 27

The method of claim 27 wherein the aromatic acid is selected from phthalic, isophthalic and terephthalic acids, the unsaturated aliphatic acid is selected from maleic, fumaric and itaconic acids, and the polyols are selected from ethylene and propylene glycols.

Claim 28

The method of claim 27 wherein the polyester additionally comprises a monocarboxylic acid in an amount up to an equivalence ratio of about 1:10 relative to the dicarboxylic acid present.

Claim 29

The method of claim 29 wherein the monocarboxylic acid is selected from benzoic and toluic acids.

Claim 30

The method of claim 30 wherein the water is present in an amount from 55 to 65 weight percent of the polyester-monomer-water mixture.

Claim 31

A process for making a cross-linked water extended polyester resin comprising: a. reacting a polycarboxylic acid with a polyol to form a polyester, with the proviso that at least one of the two polyester reactants contains an ethylenically unsaturated group capable of cross-linking in the presence of a vinyl monomer cross-linking agent, b. combining the polyester with a vinyl monomer cross-linking agent and water to form a mixture, c. admixing the mixture in the presence of an amount of an ammonium carbonate-carbamate emulsifying agent effective to form a water in oil emulsion of the water and unpolymerized polyester resin, and d. thereafter polymerizing the result to form a solid water extended polyester resin.

Claim 32

The process of claim 32 wherein the emulsifying agent is present in a neutralization equivalence range of from 0.8 to 1.2.

Claim 33

The process of claim 33 wherein the water comprises a major portion of the emulsion.

Claim 34

The process of claim 34 wherein the water is present in an amount up to 80 weight percent based on the resin, cross-linking agent and water.

Claim 35

The process of claim 35 wherein the polyester is unsaturated.

Claim 36

The process of claim 36 wherein the monomer is styrene and is present in an amount of from 30 to 70 weight percent based upon the total resin.

Claim 37

In the process of claim 37, the Polycarboxylic acid comprising a saturated aromatic dicarboxylic acid and an unsaturated aliphatic dicarboxylic acid, the polyol comprising an acyclic aliphatic diol, the equivalence ratio of saturated aromatic dicarboxylic acid to unsaturated aliphatic dicarboxylic acid being in the range of 0.7:1.3 to 1.2:1.8, respectively.

Claim 38

The process of claim 38 wherein the equivalence ratio of total dicarboxylic acid to total diol is in the range of from 2.0:2.0 to 2.6:2.0, respectively.

Claim 39

The process of claim 39 wherein a saturated monocarboxylic acid, present in an equivalence ratio with respect to the saturated dicarboxylic acid of up to 1.0:10.0, is additionally reacted with the diol to form the polyester resin.