US4532294A — Superior high solids coatings

Claim 1

Independent Claim 188 words

An improved process for forming acrylic copolymer resins suitable for electrostatic spraying in high solids coatings containing at least 50 wt.% solids which comprises contacting under polymerizing conditions a polymerization mixture comprising at least one hydroxy-substituted alkyl(meth)acrylate monomer and at least one non-hydroxy substituted alkyl(meth)acrylate monomer in the presence of a free radical initiator and a solvent therefor, said solvent being employed in an amount of from about 10 to 70 wt.% of the polymerization mixture, and said solvent comprising at least one normally liquid ester selected from the group consisting of compounds having the formula: ##STR6## wherein R 1 is a straight or branched chain alkyl of 1 to 6 carbon atoms, and R 2 is a straight or branched chain alkyl of 1 to 7 carbon atoms, with the proviso that R 1 and R 2 together contain from 6 to 11 carbon atoms, said hydroxy-substituted alkyl(meth)acrylate monomer comprising from about 5 to 30 wt.% of the total monomers charged to said polymerization reaction, and said non-hydroxy substituted alkyl(meth)acrylate monomer comprising from about 5 to 95 wt.% of the total monomers charged to said polymerization reaction.

Claim 2

Dependent Claim 188 words

An improved process for forming acrylic copolymer resins suitable for electrostatic spraying in high solids coatings containing at least 50 wt.% solids which comprises contacting under polymerizing conditions a polymerization mixture comprising at least one hydroxy-substituted alkyl(meth)acrylate monomer and at least one non-hydroxy substituted alkyl(meth)acrylate monomer in the presence of a free radical initiator and a solvent therefor, said solvent being employed in an amount of from about 10 to 70 wt.% of the polymerization mixture, and said solvent comprising at least one normally liquid ester selected from the group consisting of compounds having the formula: ##STR6## wherein R 1 is a straight or branched chain alkyl of 1 to 6 carbon atoms, and R 2 is a straight or branched chain alkyl of 1 to 7 carbon atoms, with the proviso that R 1 and R 2 together contain from 6 to 11 carbon atoms, said hydroxy-substituted alkyl(meth)acrylate monomer comprising from about 5 to 30 wt.% of the total monomers charged to said polymerization reaction, and said non-hydroxy substituted alkyl(meth)acrylate monomer comprising from about 5 to 95 wt.% of the total monomers charged to said polymerization reaction.

Claim 3

Dependent Claim 55 words

The process of claim 1 wherein said hydroxy-substituted alkyl(meth)acrylate monomer comprises a member selected from the group consisting of monomers of the formula: ##STR7## wherein R 4 is hydrogen or methyl and R 5 and R 6 are independently selected from the group consisting of hydrogen and alkyl of from 1 to 6 carbon atoms.

Claim 4

Dependent Claim 40 words

The process according to claim 1 wherein said non-hydroxy substituted alkyl(meth)acrylate monomer comprises at least one monomer of the formula: ##STR8## wherein R 7 is alkyl of from 1 to 6 carbon atoms and R 8 is hydrogen or methyl.

Claim 5

Dependent Claim 63 words

The process according to claim 1 wherein ester solvent is employed in admixture with at least one alkyl-substituted benzene solvent in which the alkyl substituent(s) contain a total of at least 2 carbon atoms when the benzene ring is monoalkyl substituted and contains a total of at least 3 carbon atoms when the benzene ring is substituted by two or more alkyl groups.

Claim 6

Dependent Claim 107 words

The process according to claim 4 wherein said alkyl-substituted benzene solvent comprises at least 1 aromatic compound of the formula: ##STR9## wherein p is an integer of from 1 to 4, and X is in each instance in which it appears independently selected from the group consisting of straight and branched-chain alkyl of from 1 to 4 carbon atoms, with the proviso that when p is 1, X must contain at least 2 carbon atoms and with the further proviso that when p is 2 or higher, the X groups must contain a total of at least 3 carbon atoms, and mixtures of the foregoing aromatic compounds.

Claim 7

Dependent Claim 22 words

The process according to claim 1 wherein said polymerization reaction is effected for a time of from about 0.5 to 10 hours.

Claim 8

Dependent Claim 30 words

The process according to claim 1 wherein the acrylic polymer produced in said polymerization reaction is characterized by a weight average molecular weight of from about 2,000 to about 12,000.

Claim 9

Dependent Claim 72 words

The process according to claim 1 wherein said normally liquid ester solvent comprises at least one member selected from the group consisting of alkyl acetates having a total of from 5 to 7 carbon atoms in the alkyl moiety, alkyl propionates having a total of from 4 to 6 carbon atoms in the alkyl moiety and alkyl butyrates having a total of from 3 to 5 carbon atoms in the alkyl moiety.

Claim 10

Dependent Claim 87 words

A polymerizable composition comprising a mixture of acrylic resin monomers and from about 10 to 70 wt.% of a solvent comprising at least one normally liquid ester selected from the group consisting of compounds having the formula: ##STR10## wherein R 1 is a straight or branched chain alkyl of 1 to 6 carbon atoms, and R 2 is a straight or branched chain alkyl of 1 to 7 carbon atoms, with the proviso that R 1 and R 2 together contain from 6 to 11 carbon atoms.

Claim 11

Dependent Claim 87 words

A polymerizable composition comprising a mixture of acrylic resin monomers and from about 10 to 70 wt.% of a solvent comprising at least one normally liquid ester selected from the group consisting of compounds having the formula: ##STR10## wherein R 1 is a straight or branched chain alkyl of 1 to 6 carbon atoms, and R 2 is a straight or branched chain alkyl of 1 to 7 carbon atoms, with the proviso that R 1 and R 2 together contain from 6 to 11 carbon atoms.

Claim 12

Dependent Claim 177 words

A polymerizable composition suitable for application after polymerization to a surface by electrostatic spraying as a high solids coating which comprises (a) from about 30 to 90 wt.% of a monomer mixture comprising (i) at least one hydroxy-substituted alkyl(meth)acrylate in an amount of from about 5 to 30 wt.% of said monomer mixture; (ii) at least one non-hydroxy substituted alkyl(meth)acrylate monomer in an amount of from about 5 to 95 wt.% of said monomer mixture; and (iii) at least one free radical polymerization initiator in an amount of from about 0.5 to 6 wt.% of said monomer mixture; and (b) from about 10 to 70 wt.% of a polymerization solvent comprising at least one normally liquid ester selected from the group consisting of compounds having the formula: ##STR11## wherein R 1 is a straight or branched chain alkyl of 1 to 6 carbon atoms, and R 2 is a straight or branched chain alkyl of 1 to 7 carbon atoms, with the proviso that R 1 and R 2 together contain from 6 to 11 carbon atoms.

Claim 13

Dependent Claim 177 words

A polymerizable composition suitable for application after polymerization to a surface by electrostatic spraying as a high solids coating which comprises (a) from about 30 to 90 wt.% of a monomer mixture comprising (i) at least one hydroxy-substituted alkyl(meth)acrylate in an amount of from about 5 to 30 wt.% of said monomer mixture; (ii) at least one non-hydroxy substituted alkyl(meth)acrylate monomer in an amount of from about 5 to 95 wt.% of said monomer mixture; and (iii) at least one free radical polymerization initiator in an amount of from about 0.5 to 6 wt.% of said monomer mixture; and (b) from about 10 to 70 wt.% of a polymerization solvent comprising at least one normally liquid ester selected from the group consisting of compounds having the formula: ##STR11## wherein R 1 is a straight or branched chain alkyl of 1 to 6 carbon atoms, and R 2 is a straight or branched chain alkyl of 1 to 7 carbon atoms, with the proviso that R 1 and R 2 together contain from 6 to 11 carbon atoms.

Claim 14

Dependent Claim 32 words

The polymerizable composition of claim 10 wherein said monomer mixture further comprises from about 5 to 30 Wt.% of at least one monovinyl aromatic hydrocarbon containing from 8 to 12 carbon atoms.

Claim 15

Dependent Claim 231 words

Low viscosity acrylic resins, suitable for electrostatic spraying as a coating containing at least 50 wt.% solids upon a surface, which comprise resins formed by polymerization of from about 30 to 90 wt.% of an acrylic monomer mixture in the presence of from about 10 to 70 wt.% of a polymerization solvent comprising at least one normally liquid ester selected from the group consisting of compounds having the formula: ##STR12## wherein R 1 is a straight or branched chain alkyl of 1 to 6 carbon atoms, and R 2 is a straight or branched chain alkyl of 1 to 7 carbon atoms, with the proviso that R 1 and R 2 together contain from 6 to 11 carbon atoms, said acrylic monomer mixture comprising (i) at least one hydroxy-substituted alkyl(meth)acrylate in an amount of from about 5 to 30 wt.% of said monomer mixture; (ii) at least one non-hydroxy substituted alkyl(meth)acrylate monomer in an amount of from about 5 to 95 wt.% of said monomer mixture; and (iii) at least one free radical polymerization initiator in an amount of from about 0.5 to 6 wt.% of said monomer mixture, said acrylic resin being characterized by weight average molecular weights of from about 2,500 to 10,000, by kinematic viscosities of up to 6,000 cs and by weight average molecular weight to number average molecular weight ratios of from about 1 to 5.

Claim 16

Dependent Claim 231 words

Low viscosity acrylic resins, suitable for electrostatic spraying as a coating containing at least 50 wt.% solids upon a surface, which comprise resins formed by polymerization of from about 30 to 90 wt.% of an acrylic monomer mixture in the presence of from about 10 to 70 wt.% of a polymerization solvent comprising at least one normally liquid ester selected from the group consisting of compounds having the formula: ##STR12## wherein R 1 is a straight or branched chain alkyl of 1 to 6 carbon atoms, and R 2 is a straight or branched chain alkyl of 1 to 7 carbon atoms, with the proviso that R 1 and R 2 together contain from 6 to 11 carbon atoms, said acrylic monomer mixture comprising (i) at least one hydroxy-substituted alkyl(meth)acrylate in an amount of from about 5 to 30 wt.% of said monomer mixture; (ii) at least one non-hydroxy substituted alkyl(meth)acrylate monomer in an amount of from about 5 to 95 wt.% of said monomer mixture; and (iii) at least one free radical polymerization initiator in an amount of from about 0.5 to 6 wt.% of said monomer mixture, said acrylic resin being characterized by weight average molecular weights of from about 2,500 to 10,000, by kinematic viscosities of up to 6,000 cs and by weight average molecular weight to number average molecular weight ratios of from about 1 to 5.

Claim 17

Dependent Claim 72 words

The low viscosity acrylic resins of claim 12 wherein said acrylic monomer mixture additionally comprises from about 5 to 30 wt.% of at least one monovinyl aromatic hydrocarbon containing from 8 to 12 carbon atoms, and either (i) from about 2 to 5 wt.% of acrylic acid, or (ii) from about 3 to 10 wt.% of at least one member selected from the group consisting of vinylchloride, acrylonitrile, methacrylonitrile and vinyl acetate.

Claim 18

Dependent Claim 37 words

The process according to claims 1, 2, 3, 4, 6 or 7 wherein said normally liquid ester comprises a member selected from the group consisting of pentyl acetates, hexyl acetates, heptyl acetates, octyl acetates and mixtures thereof.

Claim 19

Dependent Claim 32 words

The polymerizable composition according to claim 9 wherein said normally liquid ester comprises a member selected from the group consisting of pentyl acetates, hexyl acetates, heptyl acetates, octyl acetates and mixtures thereof.

Claim 20

Dependent Claim 34 words

The polymerizable composition according to claims 10 or 11 wherein said normally liquid ester comprises a member selected from the group consisting of pentyl acetates, hexyl acetates, heptyl acetates, octyl acetates and mixtures thereof.

Claim 21

Dependent Claim 36 words

The low viscosity acrylic resins according to claims 12 or 13 wherein said normally liquid ester comprises a member selected from the group consisting of pentyl acetates, hexyl acetates, heptyl acetates, octyl acetates and mixtures thereof.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1988-07-29	1989-01-28	1989-07-30	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1992-07-29	1993-01-28	1993-07-30	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1996-07-29	1997-01-28	1997-07-30	$7700.00	Window Closed / Lapsed

Superior high solids coatings

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