High solids, low viscosity thermosetting phenolic/epoxy coating system

Claim 2

A curable coating composition having a viscosity of between 100 and 1000 cps comprising: (a) a normally liquid phenolic component consisting essentially of alkyl dimethylol phenol of the structure: ##STR4## where R is an alkyl group containing 1-16 carbon atoms in the para or ortho position and where the methylol groups are in the 2 remaining ortho and para positions; (b) a normally liquid phenolic component consisting essentially of an alkylene phenol of the structure: ##STR5## where R 1 and R 2 are methyl or hydrogen, x is 1 or 2 and R 3 is an alkyl group containing 1-16 carbon atoms; (c) a normally liquid 1,2 - epoxy component consisting of an aliphatic epoxy compound, an epoxy compound containing aromaticity or mixtures thereof and having an epoxy equivalent of between 130 and 200; (d) 3-25% of the combined weight of (a), (b), (c) and (d) of a non-volatile polyol; (e) less than 25% of the combined volume of (a), (b), (c), (d) and (e) of a non-reactive organic solvent; and (f) an amine catalyst

Claim 3

The composition of claim 1 where the R 3 group of component (b) is methyl and is ortho to the phenolic hydroxy and where the R and CH 2 OH groups of component (a) are para and ortho respectively to the phenolic hydroxy.

Claim 4

The composition of claim 2 where R 1 and R 2 are hydrogen.

Claim 5

The composition of claim 3 where R of component (a) is an aliphatic alkyl group with 1-16 carbon atoms.

Claim 6

The composition of claim 3 where the component (c) is a mixture of epoxy compounds containing aromaticity with an aliphatic epoxy compound.

Claim 7

The composition of claim 2 where the viscosity of the composition is between 300 and 800 cps.

Claim 8

The composition of claim 1 where the weight percentages excluding solvent are 20 to 70% for component (a); 5-60% for component (b); 5-60% for component (c); 5-25% for component (d).

Claim 9

The composition of claim 4 where the weight percent composition excluding solvent is 20 to 70% component (a); 5-60% component (b); 5-60% component (c); 10-20% component (d); and where the viscosity of the resulting composition is between 100 and 500 cps.

Claim 10

A curable coating composition having a viscosity of between 100 and 1500 cps comprising: (a) a normally liquid phenolic component consisting essentially of alkyl dimethylol phenol of the structure: ##STR6## where R is an alkyl group containing 1-16 carbon atoms in the ortho or para position and where the methylol groups are in the 2 remaining ortho and para positions: (b) a normally liquid phenolic component consisting essentially of an alkylene phenol of the structure: ##STR7## where R 1 and R 2 are methyl or hydrogen, x is 1 or 2 and R 3 is an alkyl group containing 1-16 carbon atoms; (c) a normally liquid, 1,2 - epoxy component consisting of an aliphatic epoxy compound, an epoxy compound containing aromaticity or mixtures thereof and having an epoxy equivalent of between 130 and 200; (d) a composition prepared by the partial reaction of a hydroxy-containing polyester and an oxirane containing compound where said composition contains both hydroxy and oxirane groups; (e) less than 25% of the combined volume of (a), (b), (c), (d) and (e) of a non-reactive organic solvent; and (f) an amine catalyst.

Claim 11

A curable coating composition having a viscosity of between 100 and 1500 cps comprising: (a) a normally liquid phenolic component consisting essentially of alkyl dimethylol phenol of the structure: ##STR6## where R is an alkyl group containing 1-16 carbon atoms in the ortho or para position and where the methylol groups are in the 2 remaining ortho and para positions: (b) a normally liquid phenolic component consisting essentially of an alkylene phenol of the structure: ##STR7## where R 1 and R 2 are methyl or hydrogen, x is 1 or 2 and R 3 is an alkyl group containing 1-16 carbon atoms; (c) a normally liquid, 1,2 - epoxy component consisting of an aliphatic epoxy compound, an epoxy compound containing aromaticity or mixtures thereof and having an epoxy equivalent of between 130 and 200; (d) a composition prepared by the partial reaction of a hydroxy-containing polyester and an oxirane containing compound where said composition contains both hydroxy and oxirane groups; (e) less than 25% of the combined volume of (a), (b), (c), (d) and (e) of a non-reactive organic solvent; and (f) an amine catalyst.

Claim 12

The composition of claim 9 where the R 3 group or component (b) is methyl and is ortho to the phenolic hydroxy and where the R and CH 2 OH groups of component (a) are para and ortho respectively to the phenolic hydroxy.

Claim 13

The composition of claim 10 where R 1 and R 2 are hydrogen.

Claim 14

The composition of claim 11 where R of component (a) is an aliphatic alkyl group with 1-16 carbon atoms.

Claim 15

The composition of claim 12 where the weight percent composition excluding solvent is 20 to 70% component (a); 5-60% component (b); 5-60% component (c) where part of (c) is used in the preparation of component (d); 5-25% hydroxy-containing polyester as component (d) at least part of which is prereacted with at least part of component (c);

Claim 16

The composition of claim 13 where component (d) is present in an amount of 10-18%.

Claim 17

The composition of claim 1 wherein (b) is obtained from phenol, formaldehyde, and o-cresol.

Claim 18

The composition of claim 1 wherein R 3 of (b) contains in the chain ester or nitrile or sulfone or ether group.

Claim 19

The composition of claim 1 wherein the alkylene bridge of (b) is ortho or para to the phenolic hydroxy.

Claim 20

The composition of claim 1 wherein the alkylene bridge of (b) is ortho to the phenolic hydroxy.

Claim 21

The composition of claim 1 wherein said amine includes triethanolamine or triethylamine or triethylenediamine.

Claim 22

A thermoset composition obtained by baking a substrate coated with the composition of claim 4 at 350°-450° F. until cured.