Aqueous polyester dispersions of stabilized viscosity, their preparation and their use as binders for water-thinnable coatings

Claim 2

A viscosity-stabilized aqueous polyester dispersion comprising: a) an acid-functional polyester resin, b) at least one neutralizing agent for the polyester resin a, the amount of said neutralizing agent present being sufficient to convert from 10 to 200% of the amount of substance of acid groups in the polyester resin a into salt groups, the neutralizing agent being at least one selected from the group consisting of ammonia, organic amines, alkali metal hydroxides and alkaline earth metal hydroxides, c) optionally, an organic auxiliary solvent, d) an alkali-stabilized aqueous silica dispersion present in an amount such that the mass of SiO 2 present in said silica dispersion is from 0.1 to 50% of the mass of said polyester resin a, and e) water.

Claim 3

A viscosity-stabilized aqueous polyester dispersion as claimed in claim 1, wherein the polyester resin a is obtained by polycondensation of a mixture comprising one or more polyfunctional organic hydroxy compounds aa and one or more polyfunctional organic carboxylic acids ab, each of which independently of the other have an average functionality of from 1.3 to 2.5.

Claim 4

A viscosity-stabilized aqueous polyester dispersion as claimed in claim 1, wherein the polyester resin a has been modified during its preparation with at least one compound selected from the group consisting of polyfunctional isocyanates, epoxy resins and saturated and unsaturated fatty acids.

Claim 5

A viscosity-stabilized aqueous polyester dispersion as claimed in claim 1, wherein said polyester resin a comprises an acrylic-modified polyester resin which is prepared by emulsion polymerization of one or more olefinically unsaturated monomers in the presence of a water-soluble alkyd resin, the mass fraction of the alkyd resin in the mass of the modified polyester being from 30 to 80% and the mass fraction originating from the olefinically unsaturated monomers being from 20 to 70% in the mass of the modified polyester.

Claim 6

A process for preparing a viscosity-stabilized aqueous polyester dispersion as claimed in claim 1, comprising: mixing an alkali-stabilized aqueous silica dispersion d, neutralizing agent b, polyester resin a and water e and, optionally organic auxiliary solvent c.

Claim 7

A process as claimed in claim 5, wherein the aqueous silica dispersion d is prepared by hydrolysis of one or more alkoxysilanes with water.

Claim 8

A process as claimed in claim 5, further wherein said mixing includes: admixing said alkali-stabilized aqueous silica dispersion d with an amount of said neutralizing agent b which is selected such that from 10 to 200% of the amount of substance of the dissociable protons of the acid groups of the polyester resin a can be neutralized or bound, and subsequently emulsifiying the polyester a in said dispersion d.

Claim 9

A process as claimed in claim 5, wherein said mixing includes: admixing said aqueous silica dispersion d with an amount of said neutralizing agent b which is selected such that from 10 to 200% of the amount of substance of the dissociable protons of the acid groups of the polyester resin a can be neutralized or bound, and subsequently emulsifying said dispersion in the polyester resin a, which optionally may have been partially dissolved in said organic auxiliary solvent c.

Claim 10

A process as claimed in claim 5, wherein said mixing includes: dispersing said aqueous silica dispersion d in the polyester resin a, which optionally may have been partially dissolved in said organic auxiliary solvent c, to form a mixture; subsequently emulsifying said mixture, directly or inversely, in said water e, containing said neutralizing agent b, the amount of said neutralizing agent b being selected such that from 10 to 200% of the amount of substance of the dissociable protons of the acid groups of the polyester resin a can be neutralized or bound.

Claim 11

A binder for a coating composition comprising a viscosity-stabilized aqueous polyester dispersion as claimed in claim 1.

Claim 12

A viscosity-stabilized aqueous polyester dispersion as claimed in claim 1, wherein said polyester resin has an acid number of between 10 and 200 mg/g.

Claim 13

A viscosity-stabilized aqueous polyester dispersion as claimed in claim 1, wherein said polyester resin is modified with at least one of (i) an acrylic monomer, (ii) by incorporation of a urethane structure or epoxy resin, or (iii) with drying or nondrying fatty acids.

Claim 14

A viscosity-stabilized aqueous polyester dispersion as claimed in claim 1, wherein said auxiliary organic solvent is included and comprises an alcohol or an ether alcohol selected from the group consisting of a monoalkyl ether of ethylene glycol, diethylene glycol, propylene glycol and dipropylene glycol.

Claim 15

A viscosity-stabilized aqueous polyester dispersion as claimed in claim 1, wherein the amount of said neutralizing agent converts 40 to 70% of the acid groups in the polyester resin a into salt groups.

Claim 16

A viscosity-stabilized aqueous polyester dispersion as claimed in claim 1, wherein the average particle size of the silica in said aqueous silica dispersion is from 5 to 130 nm, and said aqueous silica dispersion has a mass fraction of solids of from 10 to 80%.

Claim 17

A method for preparing a viscosity-stabilized aqueous polyester dispersion as claimed in claim 1, comprising: obtaining the polyester resin a by polycondensation of a mixture comprising one or more polyfunctional organic hydroxy compounds aa and one or more polyfunctional organic carboxylic acids ab, each of which independently of the other have an average functionality of from 1.3 to 2.5; and mixing said resin with components b, d, e, and optionally c.

Claim 18

A method for preparing an aqueous polyester dispersion as claimed in claim 1, comprising at least one of the following: 1a) adding the neutralizing agent to said aqueous silica dispersion and said polyester resin, which optionally may be partially dissolved in said organic auxiliary solvent, and emulsifying the resultant into a dispersion; 1b) adding said neutralizing agent to said aqueous silica dispersion, and emulsifying the resultant dispersion in said polyester resin, which optionally may have been partially dissolved in said organic auxiliary solvent; 1c) emulsifying said aqueous silica dispersion in the polyester resin, which optionally may be partially dissolved in said organic auxiliary solvent, and subsequently emulsifying the resultant mixture directly; 1d) inversely adding water containing the neutralizing agent to said aqueous silica dispersion and said polyester resin, which optionally may be partially dissolved in said organic auxiliary solvent, and emulsifying the resultant into a dispersion; 1e) neutralizing the polyester resin in whole or in part with the neutralizing agent and then processing the resultant further in accordance with 1a), 1b), 1c) or 1d).

Claim 19

An aqueous polyester dispersion prepared using a process comprising at least one of the following: 1a) adding a neutralizing agent to an aqueous silica dispersion and a polyester resin, which optionally may be partially dissolved in an organic auxiliary solvent, and emulsifying the resultant into a dispersion; 1b) adding a neutralizing agent to an aqueous silica dispersion, and emulsifying the resultant dispersion in a polyester resin, which optionally may have been partially dissolved in an organic auxiliary solvent; 1c) emulsifying an aqueous silica dispersion in a polyester resin, which optionally may be partially dissolved in an organic auxiliary solvent, and subsequently emulsifying the resultant mixture directly; 1d) inversely adding water containing a neutralizing agent to an aqueous silica dispersion and a polyester resin, which optionally may be partially dissolved in an organic auxiliary solvent, and emulsifying the resultant into a dispersion; 1e) neutralizing a polyester resin in whole or in part with a neutralizing agent and then processing the resultant further in accordance with 1a), 1b), 1c) or 1d), wherein in each case, said polyester resin comprises: a) an acid-functional polyester resin, said neutralizing agent comprises: b) at least one neutralizing agent for the polyester resin a, the amount of said neutralizing agent present being sufficient to convert from 10 to 200% of the amount of substance of acid groups in the polyester resin a into salt groups, the neutralizing agent being at least one selected from the group consisting of ammonia, organic amines, alkali metal hydroxides and alkaline earth metal hydroxides, said aqueous silica dispersion comprising: d) an alkali-stabilized aqueous silica dispersion present in an amount such that the mass of SiO 2 in silica present in said silica dispersion is from 0.1 to 50% of the mass of said polyester resin a.

Claim 20

An aqueous polyester dispersion prepared using a process comprising at least one of the following: 1a) adding a neutralizing agent to an aqueous silica dispersion and a polyester resin, which optionally may be partially dissolved in an organic auxiliary solvent, and emulsifying the resultant into a dispersion; 1b) adding a neutralizing agent to an aqueous silica dispersion, and emulsifying the resultant dispersion in a polyester resin, which optionally may have been partially dissolved in an organic auxiliary solvent; 1c) emulsifying an aqueous silica dispersion in a polyester resin, which optionally may be partially dissolved in an organic auxiliary solvent, and subsequently emulsifying the resultant mixture directly; 1d) inversely adding water containing a neutralizing agent to an aqueous silica dispersion and a polyester resin, which optionally may be partially dissolved in an organic auxiliary solvent, and emulsifying the resultant into a dispersion; 1e) neutralizing a polyester resin in whole or in part with a neutralizing agent and then processing the resultant further in accordance with 1a), 1b), 1c) or 1d), wherein in each case, said polyester resin comprises: a) an acid-functional polyester resin, said neutralizing agent comprises: b) at least one neutralizing agent for the polyester resin a, the amount of said neutralizing agent present being sufficient to convert from 10 to 200% of the amount of substance of acid groups in the polyester resin a into salt groups, the neutralizing agent being at least one selected from the group consisting of ammonia, organic amines, alkali metal hydroxides and alkaline earth metal hydroxides, said aqueous silica dispersion comprising: d) an alkali-stabilized aqueous silica dispersion present in an amount such that the mass of SiO 2 in silica present in said silica dispersion is from 0.1 to 50% of the mass of said polyester resin a.