Aqueous coating composition from aminoplast and reaction product of tertiary amine and polymer containing randomly distributed epoxy groups

Claim 2

A water-borne thermosetting coating composition consisting essentially of: (A) 50-97 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000; reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equilvalents, per equivalent of epoxy group of said epoxy polymer of (A), of a tertiary amine selected from the group consistinng of R 1 R 2 R 3 N, pyridine, N-methylpyrrole, N-methyl pyrrolidine, N-methyl morpholine, and mixtures thereof and where R 1 and R 2 are hydroxy-substituted or unsubstitued mono-valent alkyl groups containing one or two carbon atoms and R 3 is a hydroxy-substituted or unsubstituted mono-valent alkyl group containing 1-4 carbon atoms; and (C) 3-50 parts by weight, based on the weight of components (A) plus (C), of an alkylated aminealdehyde resin, an alkylated amide-aldehyde resin or mixtures thereof; dissolved or dispersed in water and an organic liquid or mixture of such liquids wherein the water and said organic liquid are in a ratio of from 70:30 to 90:10 and said coating composition having a pH of 10 or above.

Claim 3

The composition of claim 1 wherein components (A), (B), and (C) comprise about 0.1-50% by weight of the coating composition.

Claim 4

The composition of claim 2 wherein said epoxy polymer comprises 65-85 parts by weight and said resin 15-35 parts by weight based on the combined weights of these two components.

Claim 5

The composition of claim 1 wherein the tertiary amine R 1 R 2 R 3 N is selected from the group consisting of: trimethyl amine, dimethyl ethanol amine, methyl diethanol amine, diethyl methyl amine, ethyl methyl ethanol amine, dimethyl benzyl amine, dimethyl propyl amine, dimethyl ethyl amine, dimethyl 3-hydroxy-1-propyl amine, dimethyl 2-hydroxy-1-propyl amine, dimethyl 1-hydroxy-2-propyl amine, and mixtures thereof.

Claim 6

The composition of claim 2 wherein said tertiary amine is trimethyl amine, dimethyl ethanol amine or mixtures thereof.

Claim 7

The composition of claim 3 wherein said tertiary amine is selected from the group consisting of: trimethyl amine, dimethyl ethanol amine, methyl diethanol amine, ethyl methyl ethanol amine, dimethyl propyl amine, dimethyl 3-hydroxy-1-propyl amine, dimethyl 2-hydroxy-1-propyl amine, dimethyl 1-hydroxy-2-propyl amine, diethyl methyl amine, and mixtures thereof.

Claim 8

The composition of claim 2 wherein the alkylated amine-aldihyde resin is hexamethylol melamine alkylted with 1-6 alkanol molecules containing 1-6 atoms.

Claim 9

A water-borne thermosetting coating composition consisting essentially of: (A) 50-97 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1, 2-epoxy groups per moleculy and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000, reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of R 1 R 2 R 3 N, pyridine, N-methylpyrrole, N-methyl pyrrolidine, N-methyl morpholine, and mixtures thereof wherein R 1 and R 2 are hydroxy substituted or unsubstituted mono-valent alkyl groups containing one or two carbon atoms and R 3 is a hydroxy substituted or unsubstituted mono-valent alkyl group containing 1-4 carbon atoms; and (C) 3-50 parts by weight, based on the weight of components (A) plus (C), of an alkylated amine-aldehyde resin, an alkylated amide-aldehyde resin or mixtures thereof; dissolved or dispersed in water and an organic liquid or mixture of such liquids wherein the water and said organic liquid are in a ratio of from 70:30 to 90:10, said coating composition also containing an acid catalyst selected from the group consisting of: phosphoric acid, its mono- and di- esters formed with aliphatic, cycloaliphatic, and aromatic alcohols, citric acid, para-toluenesulfonic acid, and mixtures thereof, in a quantity sufficient to lower the pH of the composition to between 7.5 and 12.

Claim 10

A water-borne thermosetting coating composition consisting essentially of: (A) 50-97 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1, 2-epoxy groups per moleculy and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000, reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of R 1 R 2 R 3 N, pyridine, N-methylpyrrole, N-methyl pyrrolidine, N-methyl morpholine, and mixtures thereof wherein R 1 and R 2 are hydroxy substituted or unsubstituted mono-valent alkyl groups containing one or two carbon atoms and R 3 is a hydroxy substituted or unsubstituted mono-valent alkyl group containing 1-4 carbon atoms; and (C) 3-50 parts by weight, based on the weight of components (A) plus (C), of an alkylated amine-aldehyde resin, an alkylated amide-aldehyde resin or mixtures thereof; dissolved or dispersed in water and an organic liquid or mixture of such liquids wherein the water and said organic liquid are in a ratio of from 70:30 to 90:10, said coating composition also containing an acid catalyst selected from the group consisting of: phosphoric acid, its mono- and di- esters formed with aliphatic, cycloaliphatic, and aromatic alcohols, citric acid, para-toluenesulfonic acid, and mixtures thereof, in a quantity sufficient to lower the pH of the composition to between 7.5 and 12.

Claim 11

The composition of claim 8 wherein components (A), (B), and (C) comprise about 0.1-50% by weight of the coating composition.

Claim 12

The composition of claim 9 wherein the alkylated amine-aldehyde resin is hexamethoxymethyl melamine.

Claim 13

The composition of claim 8 wherein the tertiary amine R 1 R 2 R 3 N is selected from the group consisting of: trimethyl amine, dimethyl ethanol amine, methyl diethanol amine, diethyl methyl amine, ethyl methyl ethanol amine, dimethyl benzyl amine, dimethyl propyl amine, dimethyl ethyl amine, dimethyl 3-hydroxy-1-propyl amine, dimethyl 2-hydroxy-1-propyl amine, dimethyl 1-hydroxy-2-propyl amine, and mixtures thereof.

Claim 14

The composition of claim 8 wherein said tertiary amine is selected from the group consisting of trimethyl amine, dimethyl ethanol amine, pyridine, N-methylpyrrole, N-methyl pyrrolidine, N-methyl morpholine, and mixtures thereof.

Claim 15

The composition of claim 8 wherein said epoxy polymer is a polymer of an epoxy-functional monomer selected from the group consisting of glycidyl acrylate, glycidyl methacrylate, and allyl glycidyl ether and at least one α,β-ethylenically unsaturated monomer selected from the group consisting of styrene, C 1 -C 8 alkyl acrylate, C 1 -C 8 alkyl methacrylate, vinyl acetate, and mixtures of one or more of these α,β-ethylenically unsaturated monomers with at least one of: acrylonitrile, methacrylonitrile, acrylamide, methacrylamide, hydroxyethyl acrylate, hydroxypropyl acrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, acrylic acid, methacrylic acid, and itaconic acid.

Claim 16

The composition of claim 13 wherein said polymer has the composition of styrene/methyl methacrylate/C 1 -C 8 alkyl acrylate or C 2 -C 8 alkyl methacrylate/hydroxyethyl acrylate, hydroxypropyl acrylate, hydroxyethyl methacrylate or hydroxypropyl methacrylate/glycidyl methacrylate in the weight ratios, based on the polymer, of 30-50/20-30/30-50/5-10/5-30%.

Claim 17

The composition of claim 14 wherein said polymer has an epoxy equivalent of 750-1250 wherein there is also present an acid in sufficient quantity to lower the pH of the composition to between 7.5 and 12.

Claim 18

A water-borne thermosetting coating composition consisting essentially of: (A) 65-85 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000; reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy polymer of (A), of a tertiary amine selected from the group consisting of: trimethyl amine, diethyl methyl amine, dimethyl ethyl amine, dimethyl ethanol amine, methyl diethanol amine, ethyl methyl ethanol amine, dimethyl propyl amine, dimethyl 3-hydroxy-1-propyl amine, dimethyl 2-hydroxy-1-propyl amine, dimethyl 1-hydroxy-2-propyl amine, and mixtures thereof; and (C) 15-35 parts by weight, based on the weight of components (A) plus (C), of an alkylated amine-aldehyde resin, an alkylated amide-aldehyde resin or mixtures thereof; wherein components (A), (B) and (C) comprise about 1-40% by weight of the coating composition and the remainder is comprised of water and an organic liquid or mixtures of such liquids in a ratio of from 70:30 to 90:10 and said coating composition having a pH of 10 or above.

Claim 19

A water-borne thermosetting coating composition consisting essentially of: (A) 65-85 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000; reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy polymer of (A), of a tertiary amine selected from the group consisting of: trimethyl amine, diethyl methyl amine, dimethyl ethyl amine, dimethyl ethanol amine, methyl diethanol amine, ethyl methyl ethanol amine, dimethyl propyl amine, dimethyl 3-hydroxy-1-propyl amine, dimethyl 2-hydroxy-1-propyl amine, dimethyl 1-hydroxy-2-propyl amine, and mixtures thereof; and (C) 15-35 parts by weight, based on the weight of components (A) plus (C), of an alkylated amine-aldehyde resin, an alkylated amide-aldehyde resin or mixtures thereof; wherein components (A), (B) and (C) comprise about 1-40% by weight of the coating composition and the remainder is comprised of water and an organic liquid or mixtures of such liquids in a ratio of from 70:30 to 90:10 and said coating composition having a pH of 10 or above.

Claim 20

A water-borne thermosetting coating composition consisting essentially of: (A) 70-80 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000; reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of trimethyl amine, dimethyl ethanol amine, and mixtures thereof; and (C) 20-30 parts by weight, based on the weight of components (A) plus (C), of a partially methylated hexamethylol melamine crosslinking agent wherein components (A), (B), and (C) comprise about 20-30% by weight of the coating composition and the remainder is comprised of water and organic liquid or mixtures of such liquids in a ratio of from 70:30 to 90:10 and said coating composition also contains sufficient phosphoric acid to lower the pH to between 7.5 and 10.

Claim 21

A water-borne thermosetting coating composition consisting essentially of: (A) 70-80 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000; reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of trimethyl amine, dimethyl ethanol amine, and mixtures thereof; and (C) 20-30 parts by weight, based on the weight of components (A) plus (C), of a partially methylated hexamethylol melamine crosslinking agent wherein components (A), (B), and (C) comprise about 20-30% by weight of the coating composition and the remainder is comprised of water and organic liquid or mixtures of such liquids in a ratio of from 70:30 to 90:10 and said coating composition also contains sufficient phosphoric acid to lower the pH to between 7.5 and 10.

Claim 22

A water-borne thermosetting coating composition consisting essentially of: (A) 50-65 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000; reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of trimethyl amine, dimethyl ethanol amine, and mixtures thereof; and (C) 35-50 parts by weight, based on the weight of components (A) plus (C), of a partially methylated hexamethylol melamine crosslinking agent, wherein components (A), (B), and (C) comprise about 30-40% by weight of the coating composition and the remainder is comprised of water and an organic liquid or mixtures of such liquids in a ratio of from 70:30 to 90:10 and said coating composition also contains sufficient phosphoric acid to lower the pH to between 6 and 8.

Claim 23

A water-borne thermosetting coating composition consisting essentially of: (A) 50-65 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000; reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of trimethyl amine, dimethyl ethanol amine, and mixtures thereof; and (C) 35-50 parts by weight, based on the weight of components (A) plus (C), of a partially methylated hexamethylol melamine crosslinking agent, wherein components (A), (B), and (C) comprise about 30-40% by weight of the coating composition and the remainder is comprised of water and an organic liquid or mixtures of such liquids in a ratio of from 70:30 to 90:10 and said coating composition also contains sufficient phosphoric acid to lower the pH to between 6 and 8.

Claim 24

A water-borne thermosetting coating composition consisting essentially of: (A) 65-80 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000; reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of trimethyl amine, dimethyl ethanol amine, and mixtures thereof; and (C) 20-35 parts by weight, based on the weight of components (A) plus (C), of a mixture of alkylated amine-aldehyde resins consisting of a fully alkylated and a partially methylated hexamethylol melamine in a weight ratio range of from 1:2 to 2:1 wherein components (A), (B), and (C) comprise about 20-30% by weight of the coating composition and the remainder is comprised of water and an organic liquid or mixtures of such liquids in a ratio of from 70:30 to 90:10 and said coating composition also contains sufficient phosphoric acid to lower the pH to between 7.5 and 10.

Claim 25

A water-borne thermosetting coating composition consisting essentially of: (A) 65-80 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000; reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of trimethyl amine, dimethyl ethanol amine, and mixtures thereof; and (C) 20-35 parts by weight, based on the weight of components (A) plus (C), of a mixture of alkylated amine-aldehyde resins consisting of a fully alkylated and a partially methylated hexamethylol melamine in a weight ratio range of from 1:2 to 2:1 wherein components (A), (B), and (C) comprise about 20-30% by weight of the coating composition and the remainder is comprised of water and an organic liquid or mixtures of such liquids in a ratio of from 70:30 to 90:10 and said coating composition also contains sufficient phosphoric acid to lower the pH to between 7.5 and 10.

Claim 26

A water-borne thermosetting coating composition consisting essentially of: (A) 65-85 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1, 2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography using a polystyrene standard, of 25,000-75,000, reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of: trimethyl amine, diethyl methyl amine, dimethyl ethyl amine, dimethyl ethanol amine, methyl diethanol amine, ethyl methyl ethanol amine, dimethyl propyl amine, dimethyl 3-hydroxy-1-propyl amine, dimethyl 2-hydroxy-1-propyl amine, dimethyl 1-hydroxy-2-propyl amine, N-methyl pyrrolidine, and mixtures thereof; and (C) 15-35 parts by weight, based on the weight of components (A) plus (C), of an alkylated amine-aldehyde resin, an alkylated amide-aldehyde resin or mixtures thereof; wherein components (A), (B), and (C) comprise about 1-40% by weight of the coating composition and the remainder is comprised of water and an organic liquid or mixtures of such liquids in a ratio of from 70:30 to 90:10, said coating composition also containing an acid catalyst selected from the group consisting of: phosphoric acid, its mono- and di-esters formed with aliphatic, cylcoaliphatic, and aromatic alcohols, citric acid, para-toluenesulfonic acid, and mixtures thereof, in a quantity sufficient to lower the pH of the composition of between 7.5 and 12.

Claim 27

A water-borne thermosetting coating composition consisting essentially of: (A) 65-85 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1, 2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography using a polystyrene standard, of 25,000-75,000, reacted to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of: trimethyl amine, diethyl methyl amine, dimethyl ethyl amine, dimethyl ethanol amine, methyl diethanol amine, ethyl methyl ethanol amine, dimethyl propyl amine, dimethyl 3-hydroxy-1-propyl amine, dimethyl 2-hydroxy-1-propyl amine, dimethyl 1-hydroxy-2-propyl amine, N-methyl pyrrolidine, and mixtures thereof; and (C) 15-35 parts by weight, based on the weight of components (A) plus (C), of an alkylated amine-aldehyde resin, an alkylated amide-aldehyde resin or mixtures thereof; wherein components (A), (B), and (C) comprise about 1-40% by weight of the coating composition and the remainder is comprised of water and an organic liquid or mixtures of such liquids in a ratio of from 70:30 to 90:10, said coating composition also containing an acid catalyst selected from the group consisting of: phosphoric acid, its mono- and di-esters formed with aliphatic, cylcoaliphatic, and aromatic alcohols, citric acid, para-toluenesulfonic acid, and mixtures thereof, in a quantity sufficient to lower the pH of the composition of between 7.5 and 12.

Claim 28

A thermosetting coating composition, which is infinitely dilutable with water, consisting essentially of: (A) 50-97 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000, reacted, to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of R 1 R 2 R 3 N, pyridine, N-methylpyrrole, N-methyl pyrrolidine, N-methyl morpholine, and mixtures thereof wherein R 1 and R 2 are hydroxy substituted or unsubstituted mono-valent alkyl groups containing one or two carbon atoms and R 3 is a hydroxy substituted or unsubstituted mono-valent alkyl group containing 1-4 carbon atoms; and (C) 3-50 parts by weight, based on the weight of components (A) plus (C), of an alkylated amine-aldehyde resin, an alkylated amide-aldehyde resin or mixtures thereof.

Claim 29

A thermosetting coating composition, which is infinitely dilutable with water, consisting essentially of: (A) 50-97 parts by weight, based on the weight of components (A) plus (C), of an epoxy polymer containing, on the average, 10-150 randomly distributed 1,2-epoxy groups per molecule and having a weight average molecular weight, determined by gel permeation chromatography, using a polystyrene standard, of 25,000-75,000, reacted, to the substantially complete consumption of the epoxy groups with (B) an aqueous solution of about 1-1.25 equivalents, per equivalent of epoxy group of said epoxy resin of (A), of a tertiary amine selected from the group consisting of R 1 R 2 R 3 N, pyridine, N-methylpyrrole, N-methyl pyrrolidine, N-methyl morpholine, and mixtures thereof wherein R 1 and R 2 are hydroxy substituted or unsubstituted mono-valent alkyl groups containing one or two carbon atoms and R 3 is a hydroxy substituted or unsubstituted mono-valent alkyl group containing 1-4 carbon atoms; and (C) 3-50 parts by weight, based on the weight of components (A) plus (C), of an alkylated amine-aldehyde resin, an alkylated amide-aldehyde resin or mixtures thereof.