Process for preparation of thermosetting resinous compositions

Claim 2

A PROCESS FOR THE PREPARATION OF THERMOSETTING RESINOUS COMPOSITIONS WHICH COMPRISES HOMOPOLYMERIZING OR COPOLYMERIZING (B) AND A,B-ETHYLENICALLY UNSATURATED MONOMER CAPABLE OF RELEASING AN ISOCYANATE GROUP UNDER HEATING OR A MIXTURE OF SAID A,B-ETHYLENICALLY UNSATURATED MONOMER AND OTHER UNSATURATED MONOMER COPOLYMERIZABLE THEREWITH IN WATER AT A TEMPERATURE LOWER THAN THE ISOCYANATE-RELEASING TEMPERATURE IN THE PRESENCE OF (A) A WATER-SOLUBLE RESIN HAVING AN ACID GROUP OF AN ACID VALUE OF 5 TO 3000 NEUTRALIZED WITH A BASIC SUBSTANCE AND BEING FREE OF A GROUP CAPABLE OF RELEASING AN ISOCYANATE GROUP UNDER HEATING, TO THEREBY OBTAIN AN AQUEOUS POLYMER DISPERSION, SAID UNSATURATED MONOMER OR MONOMER MIXTURE BEING COPOLYMERIZED WITH THE WATER-SOLUBLE RESIN WHEN THE LATTER HAS AN UNSATURATED BOND, AND BEING HOMOPOLYMERIZED IN THE CASE OF AN UNSATURATED MONOMER OR COPOLYMERIZED IN THE CASE OF A MONOMER MIXTURE WHEN THE WATER-SOLUBLE RESIN HAS NO UNSATURATED BOND, THE CONTENT OF SAID ISOCYANATE GROUPS BEING FROM 0.05 TO 10% BY WEIGHT BASED ON THE TOTAL NON-VOLATILE SOLIDS, AT LEAST ONE OF SAID COMPONENTS (A) AND (B) CONTAINING ACTIVE HYDROGEN-CONTAINING GROUPS IN COMPONENTS (A) AND (B) BEING WITHIN THE RANGE OF FROM 0.3 TO 0.5, AND THE NON-VOLATILE COMPONENT WEIGHT RATIO OF COMPONENT (A) TO COMPONENT (B) BEING WITHIN A RANGE OF FROM 10:90 TO 95:5.

Claim 3

A process according to claim 1 wherein the amount of the Alpha , Beta -ethylenically unsaturated monomer capable of releasing an isocyanate group under heating is 2 to 40% by weight based on the total non-volatile components.

Claim 4

A process according to claim 1 wherein the Alpha , Beta -ethylenically unsaturated monomer capable of releasing an isocyanate group under heating is a member selected from the group consisting of (1) amine imide monomers, (2) polyisocyanates in which one of the isocyanate groups is reacted with an Alpha , Beta -ethylenically unsaturated monomer having an active hydrogen-containing group and the remaining isocyanate groups are blocked with an active hydrogen-containing compound, and (3) vinyl isocyanate compounds blocked with an active hydrogen-containing compound.

Claim 5

A process according to claim 1 wherein the water-soluble resin is a member selected from the group consisting of alkyd resins, acrylic resins, maleic oil resins nd epoxy ester resins, each having an acid value of 5 to 300.

Claim 6

A process for the preparation of powdery thermosetting resinous compositions which cOmprises homopolymerizing or copolymerizing (b) an Alpha , Beta -ethylenically unsaturated monomer capable of releasing an isocyanate group under heating or a mixture of said Alpha , Beta -ethylenically unsaturated monomer and other unsaturated monomer copolymerizable therewith in water at a temperature lower than the isocyanate-releasing temperature in the presence of (a) a water-soluble resin having an acid group of an acid value of 5 to 300 neutralized with a basic substance and being free of a group capable of releasing an isocyanate group under heating, to thereby obtain an aqueous polymer dispersion, said unsaturated monomer or monomer mixture being copolymerized with the water-soluble resin when the latter has an unsaturated bond, and being homopolymerized in the case of an unsaturated monomer or copolymerized in the case of a monomer mixture when the water-soluble resin has no unsaturated bond, the content of said isocyanate groups being from 0.05 to 10% by weight based on the total non-volatile solids, at least one of said components (a) and (b) containing active hydrogen-containing groups and the ratio of said active hydrogen-containing groups in components (a) and (b) being within the range of from 0.3 to 0.5, and the non-volatile component weight ratio of component (a) to component (b) being within the range of from 10:90 to 95:5, and spray-drying the so obtained aqueous polymer dispersion at a temperature lower than the isocyanate-releasing temperature.

Claim 7

A process for the preparation of powdery thermosetting resinous compositions which cOmprises homopolymerizing or copolymerizing (b) an Alpha , Beta -ethylenically unsaturated monomer capable of releasing an isocyanate group under heating or a mixture of said Alpha , Beta -ethylenically unsaturated monomer and other unsaturated monomer copolymerizable therewith in water at a temperature lower than the isocyanate-releasing temperature in the presence of (a) a water-soluble resin having an acid group of an acid value of 5 to 300 neutralized with a basic substance and being free of a group capable of releasing an isocyanate group under heating, to thereby obtain an aqueous polymer dispersion, said unsaturated monomer or monomer mixture being copolymerized with the water-soluble resin when the latter has an unsaturated bond, and being homopolymerized in the case of an unsaturated monomer or copolymerized in the case of a monomer mixture when the water-soluble resin has no unsaturated bond, the content of said isocyanate groups being from 0.05 to 10% by weight based on the total non-volatile solids, at least one of said components (a) and (b) containing active hydrogen-containing groups and the ratio of said active hydrogen-containing groups in components (a) and (b) being within the range of from 0.3 to 0.5, and the non-volatile component weight ratio of component (a) to component (b) being within the range of from 10:90 to 95:5, and spray-drying the so obtained aqueous polymer dispersion at a temperature lower than the isocyanate-releasing temperature.

Claim 8

A process for the preparation of thermosetting resinous compositions which comprises homopolymerizing or copolymerizing (b) an Alpha , Beta -ethylenically unsaturated monomer being free of a group capable of releasing an isocyanate group under heating or a mixture of said Alpha , Beta -ethylenically unsaturated monomer and an Alpha , Beta -ethylenically unsaturated monomer capable of releasing an isocyanate group under heating in water at a temperature lower than the isocyanate-releasing temperature in the presence of (a) a water-soluble resin having an acid group of an acid value of 5 to 300 neutralized with a basic substance and containing a group capable of releasing an isocyanate group under heating, to thereby obtain an aqueous polymer dispersion, said unsaturated monomer or monomer mixture being copolymerized with the water-soluble resin when the latter has an unsaturated bond, and being homopolymerized in the case of an unsaturated monomer or copolymerized in the case of a monomer mixture when the water-soluble resin has no unsaturated bond, the content of said isocyanate groups being from 0.15 to 10% by weight based on the total non-volatile solids, at least one of said components (a) and (b) containing active hydrogen-containing groups and the ratio of said active hydrogen-containing groups in components (a) and (b) being within the range of from 0.3 to 0.5, and the non-volatile component weight ratio of component (a) to component (b) being within a range of from 10:90 to 95.:5.

Claim 9

A process for the preparation of thermosetting resinous compositions which comprises homopolymerizing or copolymerizing (b) an Alpha , Beta -ethylenically unsaturated monomer being free of a group capable of releasing an isocyanate group under heating or a mixture of said Alpha , Beta -ethylenically unsaturated monomer and an Alpha , Beta -ethylenically unsaturated monomer capable of releasing an isocyanate group under heating in water at a temperature lower than the isocyanate-releasing temperature in the presence of (a) a water-soluble resin having an acid group of an acid value of 5 to 300 neutralized with a basic substance and containing a group capable of releasing an isocyanate group under heating, to thereby obtain an aqueous polymer dispersion, said unsaturated monomer or monomer mixture being copolymerized with the water-soluble resin when the latter has an unsaturated bond, and being homopolymerized in the case of an unsaturated monomer or copolymerized in the case of a monomer mixture when the water-soluble resin has no unsaturated bond, the content of said isocyanate groups being from 0.15 to 10% by weight based on the total non-volatile solids, at least one of said components (a) and (b) containing active hydrogen-containing groups and the ratio of said active hydrogen-containing groups in components (a) and (b) being within the range of from 0.3 to 0.5, and the non-volatile component weight ratio of component (a) to component (b) being within a range of from 10:90 to 95.:5.

Claim 10

A process according to claim 5 wherein the amount of the Alpha , Beta -ethylenically unsaturated monomer capable of releasing an isocyanate group under heating, which is contained in the component (a) or the components (a) and (b) is 2 to 40% by weight based on the total non-volatile components.

Claim 11

A process according to claim 6 wherein the Alpha , Beta -ethylenically unsaturated monomer capable of releasing an isocyanate group under heating is a member selected from the group consisting of (1) amine imide monomers, (2) polyisocyanates in which one of the isocyanate groups is reacted with an Alpha , Beta -ethylenically unsaturated monomer having an active hydrogen-containing group and the remaining isocyanate groups are blocked with an active hydrogen-containing compound, and (3) vinyl isocyanate compounds blockeD with an active hydrogen-containing compound.

Claim 12

A process according to claim 6 wherein the water-soluble resin is a member selected from the group consisting of alkyd resins, acrylic resins, maleic oil resins and epoxy ester resins, each having an acid value of 5 to 300 and containing a group capable of releasing an isocyanate group under heating.

Claim 13

A process for the preparation of powdery thermosetting resinous compositions which comprises homopolymerizing or copolymerizing (b) an Alpha , Beta -ethylenically unsaturated monomer being free of a group capable of releasing an isocyanate group under heating or a mixture of said Alpha , Beta -ethylenically unsaturated monomer and an Alpha , Beta -ethylenically unsaturated monomer capable of releasing an isocyanate group under heating in water at a temperature lower than the isocyanate-releasing temperature in the presence of (a) a water-soluble resin having an acid group of an acid value of 5 to 300 neutralized with a basic substance and containing a group capable of releasing an isocyanate group under heating, to thereby obtain an aqueous polymer dispersion, said unsaturated monomer or monomer mixture being copolymerized with the water-soluble resin when the latter has an unsaturated bond, and being homopolymerized in the case of an unsaturated monomer or copolymerized in the case of a monomer mixture when the water-soluble resin has no unsaturated bond, the content of said isocyanate groups being from 0.05 to 10% by weight based on the total non-volatile solids, at least one of said components (a) and (b) containing active hydrogen-containing groups and the ratio of said active hydrogen-containing groups in components (a) and (b) being within the range of from 0.3 to 0.5, and the non-volatile component weight ratio of component (a) to component (b) being within a range of from 10:90 to 95:5, and spray-drying the so obtained aqueous polymer dispersion at a temperature lower than the isocyanate-releasing temperature.

Claim 14

A process for the preparation of powdery thermosetting resinous compositions which comprises homopolymerizing or copolymerizing (b) an Alpha , Beta -ethylenically unsaturated monomer being free of a group capable of releasing an isocyanate group under heating or a mixture of said Alpha , Beta -ethylenically unsaturated monomer and an Alpha , Beta -ethylenically unsaturated monomer capable of releasing an isocyanate group under heating in water at a temperature lower than the isocyanate-releasing temperature in the presence of (a) a water-soluble resin having an acid group of an acid value of 5 to 300 neutralized with a basic substance and containing a group capable of releasing an isocyanate group under heating, to thereby obtain an aqueous polymer dispersion, said unsaturated monomer or monomer mixture being copolymerized with the water-soluble resin when the latter has an unsaturated bond, and being homopolymerized in the case of an unsaturated monomer or copolymerized in the case of a monomer mixture when the water-soluble resin has no unsaturated bond, the content of said isocyanate groups being from 0.05 to 10% by weight based on the total non-volatile solids, at least one of said components (a) and (b) containing active hydrogen-containing groups and the ratio of said active hydrogen-containing groups in components (a) and (b) being within the range of from 0.3 to 0.5, and the non-volatile component weight ratio of component (a) to component (b) being within a range of from 10:90 to 95:5, and spray-drying the so obtained aqueous polymer dispersion at a temperature lower than the isocyanate-releasing temperature.