High solids polyester resin-based coating composition and method of making same

Claim 2

An hydroxyl-bearing, polyester resin suitable for combination with a cross-linking agent to form a heat-curable, film-forming composition comprising at least about 90% by weight solids, said polyester resin being the condensation reaction product obtained by the heating of (a) an aliphatic diol having about 4 to about 9 carbon atoms with (b) a cyclic dicarboxylic acid or anhydride thereof and (c) a mono carboxylic fatty acid having between about 8 and about 20 carbon atoms in a reaction mixture in which said (a) is present in an amount sufficient to provide hydroxyl groups in excess of the carboxyl groups from said acids and which has a system functionality between about 1.6 and about 1.8, the molar ratio of said (b) to said (c) being between about 4:1 and about 1.5:1.

Claim 3

The polyester resin of claim 1 wherein said monocarboxylic fatty acid is present as a mixture of hydroxyl-bearing mono- and di-esters having an average hydroxyl functionality between about 1.4 and about 1.8, said mixture being obtained by the reaction of (d) an aliphatic triol with a member selected from the group consisting of oils and said monocarboxylic fatty acids, the molar ratio of said (a) to the total triol from said (d) and said oils being between about 2.5:1 and about 7.5:1, and said (a), said (d), and the triol from said oils combined providing said excess of said hydroxyl groups.

Claim 4

The polyester resin of claim 2 wherein said oil is soybean, sunflower, safflower, olive, walnut or palm oil or mixtures thereof.

Claim 5

The polyester resin of claim 3 wherein said triol has 3 to about 7 carbon atoms.

Claim 6

The polyester resin of claim 2 wherein said reaction mixture is heated at a temperature at which there is substantially no ester interchange between said diol and said triol.

Claim 7

The polyester resin of claim 2 in which said reaction mixture further comprises (e) an unsaturated aliphatic dicarboxylic acid or anhydride thereof in an amount which improves adhesion of said film-forming composition to a substrate up to about 14% by weight of the total weight of reactants charged.

Claim 8

The polyester resin of claim 6 wherein said (e) has about 4 to about 10 carbon atoms.

Claim 9

The polyester resin of claim 6 wherein said (e) is present in an amount between about 10% and about 14% by weight of the weight of reactants charged.

Claim 10

The polyester resin of claim 2 wherein said heating of said reaction mixture is continued until a solids acid number thereon below about 20 is obtained.

Claim 11

A polyester resin solution comprising the polyester resin of claim 2 and a solvent therefor, said solution having a Gardner-Holdt viscosity not greater than about Z2 at about 90% by weight solids.

Claim 12

A heat-curable, film-forming composition comprising the polyester resin of claim 2, a cross-linking agent reactive with hydroxyl groups and having 2-6 reactive sites per molecule, and a solvent therefor, said cross-linking agent being present in an amount sufficient to react with substantially all of said hydroxyl groups of said polyester resin.

Claim 13

The cured film obtained by heating said composition of claim 11 to a temperature sufficient to copolymerize said polyester resin and said cross-linking agent.

Claim 14

The polyester resin of claim 1 wherein said reaction mixture further comprises (e) an unsaturated aliphatic dicarboxylic acid or anhydride thereof in an amount which improves adhesion of said film-forming composition to a substrate up to about 14% by weight of the total weight of reactants charged, said (a) providing hydroxyl groups in excess of said (b), (c) and (e) combined.

Claim 15

The polyester resin of claim 13 wherein said (e) has about 4 to about 10 carbon atoms.

Claim 16

The polyester resin of claim 13 wherein said (e) is present in an amount between about 10% and about 14% by wt. of the weight of reactants charged.

Claim 17

The polyester resin of claim 1 wherein said heating is continued until a reaction mixture solids acid number below about 20 is obtained.

Claim 18

A polyester resin solution comprising the polyester resin of claim 1 and a solvent therefor, said solution having a Gardner-Holdt viscosity not greater than about Z2 at about 90% by weight solids.

Claim 19

A heat-curable, film-forming composition comprising the polyester resin of claim 1, a cross-linking agent reactive with hydroxyl groups and having 2-6 reactive sites per molecule, and a solvent therefor, said cross-linking agent being present in an amount sufficient to react with substantially all of said hydroxyl groups of said polyester resin.

Claim 20

The cured film obtained by heating the composition of claim 18 to copolymerize said polyester resin and said cross-linking agent.

Claim 21

A polyester resin having an average of about, but less than, 2 pendant hydroxyl groups per molecule, and being suitable for combination with a cross-linking agent to form a heat-curable, film-forming composition comprising at least about 90% by weight solids, said polyester resin being the condensation reaction product obtained by heating (a) an aliphatic diol having about 4 to about 9 carbon atoms with (b) a cyclic dicarboxylic acid or anhydride thereof and (c) a monocarboxylic fatty acid having between about 8 and about 20 carbon atoms in a reaction mixture for a time sufficient to obtain a reaction mixture solids acid number below about 20, said (a) being present in said reaction mixture in an amount sufficient to provide hydroxyl groups in excess of the carboxyl groups from said acids, said reaction mixture having a system functionality between about 1.6 and about 1.8, the molar ratio of said (b) to said (c) being between about 4:1 and about 1.5:1.

Claim 22

A polyester resin having an average of about, but less than, 2 pendant hydroxyl groups per molecule, and being suitable for combination with a cross-linking agent to form a heat-curable, film-forming composition comprising at least about 90% by weight solids, said polyester resin being the condensation reaction product obtained by heating (a) an aliphatic diol having about 4 to about 9 carbon atoms with (b) a cyclic dicarboxylic acid or anhydride thereof and (c) a monocarboxylic fatty acid having between about 8 and about 20 carbon atoms in a reaction mixture for a time sufficient to obtain a reaction mixture solids acid number below about 20, said (a) being present in said reaction mixture in an amount sufficient to provide hydroxyl groups in excess of the carboxyl groups from said acids, said reaction mixture having a system functionality between about 1.6 and about 1.8, the molar ratio of said (b) to said (c) being between about 4:1 and about 1.5:1.

Claim 23

The polyester resin of claim 20 wherein said monocarboxylic fatty acid is present as a mixture of hydroxyl-bearing mono- and di-esters having an average hydroxyl functionality between about 1.4 and about 1.8, said mixture being obtained by the reaction of (d) an aliphatic triol with a member selected from the group consisting of oils and said monocarboxylic fatty acids, the molar ratio of said (a) to the total triol from said (d) and said oils being between about 2.5:1 and about 7.5:1, and said (a), said (d) and the triol from said oils combined providing said excess of said hydroxyl groups.

Claim 24

The polyester resin of claim 21 wherein said reaction mixture is heated at a temperature at which there is substantially no ester interchange between said diol and said triol.

Claim 25

The polyester resin of claim 21 in which said reaction mixture further comprises (e) an unsaturated aliphatic dicarboxylic acid or anhydride thereof having from about 4 to about 10 carbon atoms per molecule, said (e) being present in an amount which provides improved adhesion of said film-forming composition to a substrate up to about 14% by weight of the total weight of reactants charged.

Claim 26

A polyester resin solution comprising the polyester resin of claim 21 and a solvent therefor, said solution having a Gardner-Holdt viscosity not greater than about Z2 at about 90% by weight solids.

Claim 27

A heat-curable, film-forming composition comprising the polyester resin of claim 21, an aminoplast resin reactive with hydroxyl groups and having 2-6 reactive sites per molecule and a solvent therefor, said resin being present in an amount sufficient to react with substantially all of said hydroxyl groups of said polyester resin.

Claim 28

The composition of claim 25 wherein said aminoplast resin is a material selected from the group consisting of melamines and ureas having pendant alkoxy and alkylol substituents available for reaction with said hydroxyl groups of said polyester resin, said alkoxy and said alkylol substituents having from 1-4 carbon atoms.

Claim 29

The cured film obtained by heating the composition of claim 25 to copolymerize said polyester resin and said aminoplast resin.

Claim 30

The polyester resin of claim 20 wherein said reaction mixture further comprises (e) an unsaturated aliphatic dicarboxylic acid or anhydride thereof having from about 4 to about 10 carbon atoms per molecule, said (e) being present in an amount which improves adhesion of said film-forming composition to a substrate up to about 14% by weight of the total weight of reactants charged.

Claim 31

A polyester resin solution comprising the polyester resin of claim 20 and a solvent therefor, said solution having a Gardner-Holdt viscosity not greater than about Z2 at about 90% by weight solids.

Claim 32

A heat-curable, film-forming composition comprising the polyester resin of claim 20, an aminoplast resin reactive with hydroxyl groups and having 2-6 reactive sites per molecule, and a solvent therefor, said aminoplast resin being present in an amount sufficient to react with substantially all of said hydroxyl groups of said polyester resin.

Claim 33

The composition of claim 30 wherein said aminoplast resin is a material selected from the group consisting of melamines and ureas having pendant alkoxy and alkylol substituents available for reaction with said hydroxyl groups of said polyester resin, said alkoxy and said alkylol substituents having from 1-4 carbon atoms.

Claim 34

The cured film obtained by heating the composition of claim 30 to copolymerize said polyester resin and said aminoplast resin.

Claim 35

An hydroxyl-bearing, polyester resin having an average of about, but less than, 2 hydroxyl groups per molecule and an average molecular weight of about 900 to about 1100, said polyester resin being capable of forming, in combination with an aminoplast resin, a heat-curable, film-forming composition comprising at least about 90% by weight solids and, in combination with a solvent therefor, a solution having a Gardner-Holdt viscosity not greater than about Z2 at about 90% by weight solids, said polyester resin being the condensation reaction product obtained by heating (a) an aliphatic diol which is a material selected from the group consisting of: neopentyl glycol; 1,6 hexane diol; diethylene glycol; dipropylene glycol; 1,5 pentane diol; 2 ethyl-1,3 hexane diol; 1,4 and 1,3 butane diol; cyclohexane dimethanol; and trimethyl-1,6 hexane diol, and mixtures thereof with (b) a cyclic dicarboxylic acid or anhydride thereof, said (b) being a material selected from the group consisting of: methyl tetrahydrophthalic acid; hexahydrophthalic acid; tetrahydrophthalic acid; phthalic acid; cyclohexane dicarboxylic acid; and methyl hexahydrophthalic acid, and mixtures thereof, and (c) a monocarboxylic fatty acid which is a material selected from the group consisting of pelargonic, linoleic, oleic, palmitic, stearic, highly refined tall oil acids, mixtures of the fatty acids from soybean oil, lauric acid, myristic acid, 2-ethyl hexoic acid, isonononoic acids, and mixtures thereof, in a reaction mixture comprising said (a), (b), and (c) for a time sufficient to obtain a reaction mixture solids acid number below about 20, said (a) being present in an amount sufficient to provide hydroxyl groups in excess of the carboxyl groups from said acids to provide said reaction mixture with a system functionality between about 1.6 and about 1.8, the molar ratio of said (b) to said (c) being between about 4:1 and about 1.5:1.

Claim 36

An hydroxyl-bearing, polyester resin having an average of about, but less than, 2 hydroxyl groups per molecule and an average molecular weight of about 900 to about 1100, said polyester resin being capable of forming, in combination with an aminoplast resin, a heat-curable, film-forming composition comprising at least about 90% by weight solids and, in combination with a solvent therefor, a solution having a Gardner-Holdt viscosity not greater than about Z2 at about 90% by weight solids, said polyester resin being the condensation reaction product obtained by heating (a) an aliphatic diol which is a material selected from the group consisting of: neopentyl glycol; 1,6 hexane diol; diethylene glycol; dipropylene glycol; 1,5 pentane diol; 2 ethyl-1,3 hexane diol; 1,4 and 1,3 butane diol; cyclohexane dimethanol; and trimethyl-1,6 hexane diol, and mixtures thereof with (b) a cyclic dicarboxylic acid or anhydride thereof, said (b) being a material selected from the group consisting of: methyl tetrahydrophthalic acid; hexahydrophthalic acid; tetrahydrophthalic acid; phthalic acid; cyclohexane dicarboxylic acid; and methyl hexahydrophthalic acid, and mixtures thereof, and (c) a monocarboxylic fatty acid which is a material selected from the group consisting of pelargonic, linoleic, oleic, palmitic, stearic, highly refined tall oil acids, mixtures of the fatty acids from soybean oil, lauric acid, myristic acid, 2-ethyl hexoic acid, isonononoic acids, and mixtures thereof, in a reaction mixture comprising said (a), (b), and (c) for a time sufficient to obtain a reaction mixture solids acid number below about 20, said (a) being present in an amount sufficient to provide hydroxyl groups in excess of the carboxyl groups from said acids to provide said reaction mixture with a system functionality between about 1.6 and about 1.8, the molar ratio of said (b) to said (c) being between about 4:1 and about 1.5:1.

Claim 37

The polyester resin of claim 33 wherein said monocarboxylic acid is present as a mixture of hydroxyl-bearing mono- and di-esters obtained by the reaction of (d), an aliphatic triol having 3 to about 7 carbon atoms with a material selected from the group consisting of oils and said monocarboxylic fatty acids, said mixture of said mono- and di-esters having an average hydroxyl functionality between about 1.4 and about 1.8, the molar ratio of said (a) to the total triol from said (d) and said oils being between about 2.5:1 and about 7.5:1, said (a), said (d), and the triol from said oils combined providing said excess of said hydroxyl groups.

Claim 38

The polyester resin of claim 34 wherein said oil is soybean, sunflower, safflower, olive, walnut or palm oil, or mixtures thereof.

Claim 39

The polyester resin of claim 35 wherein said triol is trimethylol ethane, trimethylol propane, trimethylol butane, hexane triol or glycerine.

Claim 40

The polyester resin of claim 36 wherein said reaction mixture further comprises (e) an unsaturated aliphatic dicarboxylic acid, or anhydride thereof, which is a material selected from the group consisting of maleic, fumaric, itaconic and citraconic acid, and mixtures thereof, said (e) being present in an amount between about 10% and about 14% by wt. of the weight of reactants charged.

Claim 41

A heat-curable, film-forming composition comprising the polyester resin of claim 34, an aminoplast resin which is a material selected from the group consisting of melamines and ureas having at least two pendant alkoxy and alkylol substituents per molecule having from 1 to 4 carbon atoms, and a solvent therefor, said aminoplast resin being present in an amount sufficient to react with substantially all of said hydroxyl groups of said polyester resin.

Claim 42

A cured film obtained by the heating of said composition of claim 38 to a temperature sufficient to copolymerize said polyester and aminoplast resins.

Claim 43

The polyester resin of claim 33 wherein said reaction mixture further comprises (e) an unsaturated aliphatic dicarboxylic acid, or anhydride thereof, which is a material selected from the group consisting of maleic, fumaric, itaconic and citraconic acid, and mixtures thereof, said (e) being present in an amount between about 10% and about 14% by wt. of the weight of reactants charged.

Claim 44

A heat-curable, film-forming composition comprising the polyester resin of claim 33, an aminoplast resin which is a material selected from the group consisting of melamines and ureas having at least two pendant alkoxy and alkylol substituents per molecule having 1 to 4 carbon atoms, and a solvent therefor, said aminoplast resin being present in an amount sufficient to react with substantially all of said hydroxyl groups of said polyester resin.

Claim 45

A cured film obtained by the heating of said composition of claim 40 to copolymerize said polyester and aminoplast resins.