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Patent 2261485 Summary

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(12) Patent Application: (11) CA 2261485
(54) English Title: EPOXY RESIN AND HYBRID POWDER COATING COMPOSITIONS
(54) French Title: COMPOSITIONS POUR REVETEMENT EN POUDRE EN RESINE EPOXYDIQUE OU EN RESINE HYBRIDE
Status: Dead
Bibliographic Data
(51) International Patent Classification (IPC):
  • C09D 163/00 (2006.01)
  • B05D 3/02 (2006.01)
  • B05D 7/24 (2006.01)
  • C08G 59/50 (2006.01)
  • C08G 59/58 (2006.01)
  • C09D 5/03 (2006.01)
  • C09D 167/00 (2006.01)
(72) Inventors :
  • WEISS, JORN VOLKER (Germany)
  • WENNING, ANDREAS (Germany)
(73) Owners :
  • DEGUSSA-HULS AKTIENGESELLSCHAFT (Germany)
(71) Applicants :
  • HULS AKTIENGESELLSCHAFT (Germany)
(74) Agent: FETHERSTONHAUGH & CO.
(74) Associate agent:
(45) Issued:
(22) Filed Date: 1999-02-12
(41) Open to Public Inspection: 1999-08-16
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data:
Application No. Country/Territory Date
19806225.7 Germany 1998-02-16

Abstracts

English Abstract





Disclosed is an epoxy resin or hybrid resin-based
powder coating composition, which comprises, as a hardener,
a mixture of (a) a salt of a polycarboxylic acid (other than
isophthalic acid, terephthalic acid and phthalic acid) and
an amine or guanidine, such as the salt between pyromellitic
acid and 2-phenylimidazoline, and (b) a polycarboxylic acid,
preferably selected from the group consisting of cyanuric
acid, ethylenediaminetetraacetic acid, isophthalic acid,
terephthalic acid, 1,2,3,4-butanetetracarboxylic acid,
trimellitic acid and trimesic acid. The coating composition
is useful for producing a semi-gloss to matt coating layer.


Claims

Note: Claims are shown in the official language in which they were submitted.




THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A powder coating composition which comprises:
an epoxy resin or a carboxyl-functional polyester
resin mixed with an epoxy resin, and
as a hardener, a physical mixture consisting of:
a) a salt of:
a1) an aliphatic, cycloaliphatic, araliphatic
or aromatic polycarboxylic acid other than isophthalic acid,
terephthalic acid and phthalic acid, with
a2) an amine of the formula:

Image ~~Image~~Image

(wherein R1, R2 and R3 are identical or different and are each
2,2,6,6-tetramethylpiperidin-4-yl or an aliphatic,
cyclo-aliphatic, araliphatic or aromatic hydrocarbon radical having
1 - 20 carbon atoms, in which one or more CH2 groups in a C
chain may be replaced by O, CH-OH or NR4 where R4 is C1-6-alkyl
or one or more terminal methyl groups may be replaced by a
dialkylamino group having 1 to 6 carbon atoms in each alkyl.
group or R1 and R2 together with the N atom to which they are
attached form a conjoint ring in which one CH2 group may be
replaced by O, NR4, R1 and R2 in the formula C) may also be
hydrogen or R1, R2 and R3 in the formula A) are each


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-CH2-CH2- attached via a conjoint N atom, and n is 3 - 11) or
a3) a guanidine compound of the formula:

Image

(wherein R5, R6, R7, R8 and R9 independently of one another
are identical or different and are an aliphatic, cycloaliphatic,
araliphatic or aromatic hydrocarbon radical having 1 - 9 carbon
atoms or hydrogen or R6 and R7 together or R8 and R9 together
with the N atom to which they are attached form a conjoint ring
which may include an oxygen atom as heteroatom), and
b) an aliphatic, cycloaliphatic, araliphatic or
aromatic polycarboxylic acid, in a ratio a) : b) of from 99 : 1
to 1 : 99.

2. The powder coating composition as claimed in claim 1,
wherein the polycarboxylic acid a1) is a tri- or tetracarboxylic
acid.

3. The powder coating composition as claimed in claim 2,
wherein the tri- or tetracarboxylic acid is aliphatic or
cycloaliphatic.

4. The powder coating composition as claimed in claim 3,
wherein the aliphatic or cycloaliphatic tri- or tetracarboxylic
acid is 1,2,3,4-butanetetracarboxylic acid, ethylenediamine-tetraacetic
acid, nitrilotriacetic acid, cyclopentanetetra-carboxylic
acid, citric acid or aconitic acid.


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5. The powder coating composition as claimed in claim 2,
wherein the tri- or tetracarboxylic acid is aromatic.
6. The powder coating composition as claimed in claim 5,
wherein the aromatic tri- or tetracarboxylic acid is cyanuric
acid, trimellitic acid or trimesic acid.
7. The powder coating composition as claimed in claim 5,
wherein the aromatic tri- or tetracarboxylic acid is
pyro-mellitic acid.
8. The powder coating composition as claimed in claim 1,
wherein the polycarboxylic acid a1) is an aliphatic or
cyclo-aliphatic polycarboxylic acid.
9. The powder coating composition as claimed in claim 8,
wherein the polycarboxylic acid a1) is an aliphatic or
cyclo-aliphatic di-, tri- or tetracarboxylic acid.
10. The powder coating composition as claimed in claim 1,
wherein the polycarboxylic acid a1) is cyanuric acid,
2,2,4-(2,4,4)-trimethyladipic acid, 1,2,3,4-butanetetracarboxylic
acid, ethylenediaminetetraacetic acid, diethylenetriamine-pentaacetic
acid, nitrilotriacetic acid, hexahydrophthalic acid,
hexahydroisophthalic acid, hexahydroterephthalic acid,
pyro-mellitic acid, trimellitic acid, trimesic acid, cyclopentane-
tetracarboxylic acid, citric acid, aconitic acid or
2,6-naphthalenedicarboxylic acid.
11. The powder coating composition as claimed in any one
of claims 1 to 10, wherein the salt a) is of the amine of the



-21-



formula A), B) or C).

12. The powder coating composition as claimed in claim 11,
wherein the amine has the formula A).

13. The powder coating composition as claimed in claim 12,
wherein in the formula A), R1, R2 and R3 are each C1-20 alkyl,
phenyl or cyclohexyl or the amine is N-methylmorpholine,
N,N-dimethylpiperazine, 2,2,6,6-tetramethyl-4-dimethylamino-piperidine,
N,N,N',N'-tetramethylhexamethylenediamine or
1,4-diazabicyclo[2.2.2]octane.

14. The powder coating composition as claimed in claim 11,
wherein the amine has the formula C) in which R1 and R2 are each
hydrogen, C1-6-alkyl, or phenyl.

15. The powder coating composition as claimed in any one
of claims 1 to 10, wherein the salt a) is of the guanidine
compound of the formula D).

16. The powder coating composition as claimed in any one
of claims 1. to 10, wherein the salt a) is of N,N-dimethylcyclo-hexylamine,
N,N-dimethylaniline, N-methylmorpholine,
N,N'-dimethylpiperazine, 2,2,6,6-tetramethyl-4-dimethylamino-piperidine,
N,N-dimethyloctadecylamine, 1,8-diazabicyclo[5.4.0]-
undec-7-ene, N,N,N',N'-tetramethylhexamethylenediamine,
1,4-diazabicyclo[2.2.2]octane, 2-phenylimidazoline,
2-methyl-imidazoline, 2,4-dimethylimidazoline, 2-ethyl-4-methylimidazoline,
tetramethylguanidine, tetramethylcyclohexylguanidine,
N,N',N"-triphenylguanidine or N,N'-dicyclohexyl-4-morpholine-carboxamide.


-21-



17. The powder coating composition as claimed in
claim 1, wherein the salt a) is of pyromellitic acid as the
polycarboxylic acid a1) and 2-phenylimidazoline as the amine
a2).

18. The powder coating composition as claimed in any
one of claims 1 to 1.7, wherein the salt is formed with 0.5 - 3
mols of the amine a2) or the guanidine compound a3) per mol. of
the polycarboxylic acid a1) or its anhydride.

19. The powder coating composition as claimed in any
one of claims 1 to 1.8, wherein the polycarboxylic acid b) is
cyanuric acid, 2,2,4(2,4,4)-trimethyladipic acid,
1,2,3,4-butanetetracarboxylic acid, ethylenediaminetetraacetic acid,
diethylenetriaminepentaacetic acid, nitrilotriacetic acid,
isophthalic acid, terephthalic acid, phthalic acid,
hexahydrophthalic acid, hexahydroisophthalic acid, hexahydroterephthalic
acid, pyromellitic acid, trimellitic acid, trimesic acid,
cyclopentanetetracarboxylic acid, citric acid, aconitic acid
or 2,6-naphthalenedicarboxylic acid.

20. The powder coating composition according to claim 1,
wherein the hardener is a mixture of a salt of pyromellitic
acid and 2-phenylimidazoline, and a polycarboxylic acid
selected from the group consisting of cyanuric acid,
ethylene-diaminetetraacetic acid, isophthalic acid, terephthalic acid,
1,2,3,4-butanetetracarboxylic acid, trimellitic acid and
trimesic acid.



-22-



21. The powder coating composition as claimed in any one
of claims 1. to 20, which comprises the hardener in an amount
of 2 - 14% by weight based on the epoxy resin or the
carboxyl-functional. polyester resin mixed with the epoxy resin.

22. The powder coating composition as claimed in any one
of claims 1 to 21, wherein the epoxy resin has a melting point
of 60 - 150°C and contains on average more than one 1,2-epoxide
group per molecule.

23. The powder coating composition as claimed in any one
of claims 1 to 22, wherein the epoxy resin is based on a
reaction product of bisphenol A and epichlorohydrin and has an
epoxide equivalent weight of 400 - 3,000.

24. The powder coating composition as claimed in any one
of claims 1 to 23, which comprises the carboxyl-functional
polyester resin mixed with the epoxy resin, wherein the
carboxyl-functional polyester resin has a melting point of
60 - 160°C, an acid number of 10 - 150 mg of KOH/g and an OH
number of below 10 mg of KOH/g.

25. A method of forming a semi-glossy to matt coating
layer on a substrate, which comprises:
applying the powder coating composition as defined
in any one of claims 1 to 24 on the substrate, and
curing the powder coating composition at a
temperature of 150 - 220°C.

-23-

Description

Note: Descriptions are shown in the official language in which they were submitted.



CA 02261485 1999-02-12
EPOXY RESIN AND HYBRID POWDER COATING COMPOSITIONS
The invention relates to epoxy (EP) resin or hybrid
powder coating compositions.
DE-A 23 24 696 describes a process for producing matt
coatings by curing epoxy resins with salts of aromatic poly-
carboxylic acids, especially pyromellitic acid and cyclic
amidines.
DE-A 44 00 931 describes salts of pyromel.litic acid
and guanidines as hardeners for matt epoxy and hybrid coatings.
DE-A 44 03 225 describes salts of pyromellitic acid
and tertiary amines which can be used to produce matt epoxy
and hybrid coatings.
It is also known that only salts of cyclic amidines
with trimell.itic and/or pyromellitic acid are suitable for
producing matt EP powder coatings. In contrast, the corres-
ponding salts of phthalic, isophthal.ic and terephthal.ic acid
cure with EP resins to give glossy films.
An essential factor in the above prior art is that
it is not the individual components but their reaction
products, i. e., the salts, that are employed. Since the salts
comprise pyromell.itic acid, hardeners of this type are
relatively highly priced for high-quality epoxy and hybrid
coatings. Another disadvantage is the yellowing of the
coatings.
It is also known that by simultaneous use of the
individual hardeners, namely the amine component and the pol.y-
carboxylic acid, surfaces with the same degree of matting are
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CA 02261485 1999-02-12
obtained as when the salt-form matt hardener consisting of the
same individual components is employed. Since there is no
need to prepare salts, these hardeners are less expensive.
However, surface texturing and poor physical properties are
found in coatings produced with such hardeners, as well as poor
reproducibility of the matt effect.
Such physical. mixtures of amine component and pol.y-
carboxylic acid are described, for example, in EP-A 0 504 183.
Physical mixtures of salts and polycarboxylic acids
were described for the first time in DE-A 44 00 929 and
DE-A 44 03 129. The salts are reaction products of phthalic,
isophthalic and terephthalic acids with guanidines or amines.
Pyromellitic and/or trimellitic acid are employed as the
polycarboxyl.ic acids. The overtaking stability of coatings
comprising such mixtures is disadvantageous.
To improve the yellowing resistance on overtaking of
both glossy and matt EP powder coatings based on salts of
cyclic amidines with aromatic polycarboxylic acids,
DE 1.96 30 450 employs as its hardener component phosphoric acid
salts in a mixture with the polycarboxylic acids. However,
preparation of these complex hardeners is difficult. Fluctua-
tions in the reaction conditions can lead to a different
structure of the salt mixtures and hence to different coating
results.
A major object of the present invention, therefore,
is to provide a hardener essentially free from the disadvantages
listed above and further provide a novel EP or hybrid powder
- 2 -
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CA 02261485 1999-02-12
coating composition, which comprises the hardener, by a simple
preparation process, and which is suitable for preparing semi-
glossy to matt coatings with a high level. of quality.
Surprisingly, it has been found that, as the hardener
component, a physical mixture of an aliphatic, cycloaliphatic,
araliphatic or aromatic polycarboxyl.ic acid with a salt of an
aliphatic, cycloaliphatic, aral.iphatic or aromatic poly-
carboxylic acid and an amine is particularly effective for the
above-mentioned purpose, provided that the pol.ycarboxylic acid
of the salt is other than isophthalic acid, terephthalic acid
and phthalic acid.
The present invention provides an epoxy resin or
hybrid powder coating composition which comprises, as a
hardener, a physical mixture of:
a) a salt of:
al) an aliphatic, cycloaliphatic, araliphatic
or aromatic polycarboxylic acid other than isophthal.ic acid,
terephthal.ic acid and phthalic acid, and
a2) an amine of the formula:
(CH2 ) n
R2
Rl i iR3
R N~N
2 , o r HN / N
R1
A) B) C)
(wherein Rl, R2 and R3 are identical or different and are each
2,2,6,6-tetramethylpiperidin-4-yl or an aliphatic, cyclo-
aliphatic, araliphatic or aromatic hydrocarbon radical. havingl -
20 carbon atoms, in which one or more CH2 groups in the C chain
- 3 -
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CA 02261485 1999-02-12
may be replaced by O, CH-OH or NR4 where R4 is Cl-6-alkyl or
one or more terminal methyl. groups may be replaced by a dialkyl
amino group having 1 to 6 carbon atoms in each alkyl. group or
R1 and R2 together with the N atom to which they are attached
form a ring in which one CH2 group may be replaced by O or NR4,
Rl and R2 in the formula C) may be hydrogen or Rl, R2 and R3 in
the formula A) are each -CH2-CH2- attached via a conjoint N
atom, and n is 3 - 11.) or
a3) a guanidine compound of the formula:
R6 ~ N-- C-N~R8
R ~ NI \R9
\R5
D)
(wherein R5, R6, R7, R8 and R9 independently of one another are
identical or different and are an aliphatic, cycloaliphatic,
araliphatic, aromatic hydrocarbon radical. having 1 - 9 C atoms
or hydrogen, or R6 and R7 or R8 and R9 together with the N atom
to which they are attached form a ring which may include an
oxygen atom) and
b) an aliphatic, cycloaliphatic, aral.iphatic or
aromatic polycarboxylic acid, in a ratio a):b) of from 99:1 to
1:99.
The salts a) which can be employed in accordance with
the invention comprise aliphatic, cycloal.iphatic, araliphatic
or aromatic polycarboxylic acids. Isophthalic acid,
terephthalic acid and phthalic acid are expressly excluded. In
place of the acids, if desired, their anhydrides may be
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CA 02261485 1999-02-12
employed for forming the salts (component al). Examples of the
polycarboxylic acids are cyanuric acid, 2,2,4(2,4,4)-trimethyl-
adipic acid, 1,2,3,4-butanetetracarboxylic acid, ethyl.ene-
diaminetetraacetic acid, diethylenetriaminepentaacetic acid,
nitrilotriacetic acid, hexahydrophthal.ic acid (i. e., cyclo-
hexane-1,2-dicarboxyl.ic acid), hexahydroisophthalic acid (i. e.,
cyclohexane-1,3-dicarboxylic acid), hexahydroterephthalic acid
(i. e., cyclohexane-1,4-dicarboxylic acid), pyromell.itic acid,
trimellitic acid, trimesic acid, cycl.opentanetetracarboxyl.ic
acid, citric acid, aconitic acid and 2,6-naphthalenedicarboxylic
acid. When mixtures of the polycarboxylic acids are employed,
any desired combinations are possible. One preferred group of
the polycarboxylic acids are tri- and tetracarboxylic acids.
Another preferred group of the polycarboxyl.ic acids are
aliphatic or cycl.oaliphatic polycarboxylic acids. Particularly
preferred are tetracarboxylic acids, especially pyromellitic
acid. Cyanuric acid may not be called as a polycarboxylic acid
in a strict sense, but it can be used according to the invention
just as a pol.ycarboxylic acid.
The salts of the polycarboxylic acids comprise, as
their amine component a2) and/or a3), nitrogen compounds
capable of forming salts, represented by the formulae A)-D).
Preferred are those amines of the formula C) in which R1 and R2
are each hydrogen, Cl-6-alkyl or phenyl. In the formula A),
R1, R2 and R3 are preferably C1-20 alkyl, phenyl or cycl.ohexyl
or two of them with the N atom to which they are attached form
optionally substituted morphol.ine, piperazine or piperidine
ring. Examples of specific compounds of the formulae A)-C) are
- 5 -
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CA 02261485 1999-02-12
N,N-dimethylcyclohexylamine, N,N-dimethylaniline, N-methyl-
morphol.ine, N,N'-dimethyl.piperazine, 2,2,6,6-tetramethyl-4-
dimethylaminopiperidine, N,N-dimethyloctadecylamine, 1,8-
diazabicyclo[5.4.0]undec-7-ene, N,N,N',N'-tetramethylhexa-
methylenediamine, 1,4-diazabicyclo[2.2.2]octane, 2-phenyl-
imidazoline, 2-methyl.imidazoline, 2,4-dimethylimidazoline and
2-ethyl.-4-methylimidazoline. Examples of specific compounds
of the formula D) are tetramethylguanidine, tetramethylcyclo-
hexyl.guanidine, N,N',N"-triphenylguanidine and N,N'-dicyclo-
1.0 hexyl-4-morpholinecarboxamide. The basic N content of the salts
may be generally 0.01 - 30 mmol/g and the carboxyl. group content
may be generally 1 - 35 mmol/g.
The salts a) may be formed by reacting the pol.y-
carboxylic acids or their anhydrides al) with 0.5 - 3 mols of
the amines a2) or the guanidine compounds a2).
Components b) that are suitable for use are aliphatic,
cycloaliphatic, aral.iphatic or aromatic polycarboxylic acids.
Examples that may be mentioned are cyanuric acid, 2,2,4(2,4,4)-
trimethyladipic acid, 1,2,3,4-butanetetracarboxylic acid,
20 ethylenediaminetetraacetic acid, diethylenetriaminepentaacetic
acid, nitril.otriacetic acid, hexahydrophthalic acid, hexahydro-
isophthalic acid, hexahydroterephthalic acid, pyromellitic
acid, trimel.litic acid, trimesic acid, cyclopentanetetra-
carboxylic acid, citric acid and 2,6-naphthalenedicarboxylic
acid. Isophthalic acid, terephthalic acid and phthalic acid
may also be employed. When mixtures of the polycarboxylic
acids are employed, any desired combinations are possible.
- 6 -
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CA 02261485 1999-02-12
The hardeners of the invention comprising components
a) and b) may be prepared in two stages, where in the first
stage the salt is formed in a solvent and when this process
has ended the solvent is removed. In a second step, one or
more aliphatic, cycloaliphatic, araliphatic or aromatic poly-
carboxylic acids are physically admixed.
Some of the salts a) are known. In addition, they
are not a subject of the invention. They are prepared in a
known manner, for example, by adding the amine/guanidine
1.0 component a2/a3, in portions, to the pol.ycarboxylic acid in a
boiling solution in water or ethanol. After the end of this
addition, heating is continued for about one hour or more.
Subsequently, the solvent is removed by distillation. For
quantitative removal of the solvent the reaction mixture is
dried in a vacuum drying oven at 60°C for about 1.0 h. Then
the aliphatic, cycl.oal.iphatic, araliphatic or aromatic poly-
carboxylic acids are admixed. The salts a) are composed of 1
mol of the polycarboxylic acid and 0.5 - 3 mol. of the compounds
A)-D). The composition of the hardener mixture a) and b) of
20 the invention consists of 99 - l.s, preferably 90 - l0a by
weight of the salt a) and 1 - 99~, preferably 10 - 90~ by
weight of the polycarboxylic acid b).
The hardener mixture a) and b) of the invention is
combined with epoxy resins or hybrid resins. Hybrids are
carboxyl-functional polyester resins that have been mixed with
epoxy resins.
To prepare the coating compositions of the invention,
the hardeners are employed in amounts effective to work as
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CA 02261485 1999-02-12
hardeners, for example, 2 - 14% by weight based on the sum of
the starting resins. The polyepoxy resins used are well.-known
in the art and are generally solid, resinous substances which
melt in the range 60 - 150°C, preferably 70 - 110°C, and
contain on average more than one 1.,2-epoxide group per
molecule. In principle, suitable compounds are all those
containing more than one 1.,2-epoxide group per molecule.
Examples are polyepoxides, such as polyglycidyl ethers of
aromatic or aliphatic compounds containing two or more active
hydrogen atoms. These include resorcinol., hydroquinone,
pyrocatechol, bisphenol A, bisphenol. F, glycerol., pentaerythri-
tol, mannitol, sorbitol and trimethylolpropane. Preference is
given, however; to customary commercial EP resins, as are
obtained by reacting bisphenol. A or bisphenol F with epichloro-
hydrin. Very particular preference is given to EP resins based
on the reaction between bisphenol A and epichlorohydrin and
having an EP equivalent weight of 400 - 3,000, preferably 800 -
1,000.
The carboxyl-functional polyester resins are
polyester polycarboxylic acids which are prepared from polyols
and polycarboxylic acids or derivatives thereof. The melting
point of these acidic polyesters lies generally within the
range of 60 - 160°C, preferably 80 - 120°C; their acid number
varies from 10 - 150 mg of KOH/g, preferably 30 - 60 mg of
KOH/g. The OH numbers are normally below 10 mg of KOH/g.
The polyester polycarboxylic acids that are to be
employed may be prepared using polycarboxylic acids, such as
oxalic, adipic, 2,2,4(2,4,4)-trimethyladipic, azelaic, sebacic,
_ g -
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CA 02261485 1999-02-12
decanedicarboxylic, dodecanedicarboxylic, fumaric, phthalic,
isophthalic, terephthalic, trimel.litic and pyromel.litic acid,
for example. Examples of pol.yols used for the acidic poly-
esters are as follows: ethylene glycol, 1,2- and 1,3-propane-
diol, 1,2-, 1,3-, 1-4- and 2,3-butanediol., 1,5-pentanediol,
3-methyl-1,5-pentanediol, neopentyl glycol, 1,12-dodecanediol,
2,2,4(2,4,4)-trimethyl.-1,6-hexanediol, trimethyl.olpropane,
glycerol, pentaerythritol, 1.,4-bishydroxymethylcyclohexane,
cyclohexane-1,4-diol, diethylene glycol, triethylene glycol
and dipropylene glycol.. It is of course also possible to react
hydroxyl.-containing polyesters, which are prepared by known
methods from polycarboxylic acids and polyols, with poly-
carboxylic acids and/or polycarboxylic anhydrides to give the
polyester polycarboxylic acids.
In the case of the exclusive use of the customary
commercial EP resins based on bisphenol A (+ epichlorohydrin),
the amount of the hardener is usually 2 - 1.4% by weight. In
the case where mixtures of the epoxy resins and the polyester
pol.ycarboxylic acids are used, the proportion is guided by
the acid number of the carboxyl polyester. For example, at an
acid number of 30 - 50 mg of KOH/g, the weight ratio of EP
resin to carboxyl polyester is usually from 60 . 40 to 80 . 20,
preferably 70 . 30. The amount of the hardener mixture a) + b)
in these EP resin/carboxyl polyester mixtures is usually
2 - 14~ by weight. Before or after they are mixed, the
hardener components are preferably ground to an average
particle size of less than 100 um, preferably less than 40 um.
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CA 02261485 1999-02-12
To prepare the powder coating material, the binders may first
of al.l be mixed with a leveling agent, pigment and/or filler
and with W stabilizers and antioxidants and the mixture may
be homogenized in an extruder at about 100°C. After the
extruded mass has cooled to room temperature, it may be ground
into a powder coating material. whose average particle size is
normally about 30 - 100 um, preferably 40 - 80 um.
The coating compositions of the invention are suit-
able for preparing coating materials, especially for powder
1.0 coatings having semi-glossy to matt surfaces. The amounts of
the individual. powder coating binder components can be varied
extensively.
The application of powder coatings based on the
coating compositions of the invention to appropriate substrates
can take place by the known methods, such as, for example, by
electrostatic powder spraying, fluidized-bed sintering or
electrostatic fluidized-bed sintering. Following the applica-
tion of the powder coating by one of these techniques, the
coated substrates are cured by heating at temperatures of 1.50 -
20 220°C. The curing often takes about 30 - 8 minutes. The
coating films produced in this way are notable for very good
leveling, good to very good mechanical properties and a matt
surface, it being possible to adjust the degree of gloss as
desired within a wide range.
The examples which follow are intended to elucidate
the invention further.
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CA 02261485 1999-02-12
A Preparing the hardener mixtures employed in the process of
the invention
General preparation procedure
The amine (a2 and/or a3) is added in portions to the
pol.ycarboxyl.ic acid al), which is heated with from 6 to 10
times the amount of ethanol and/or water to the boiling point
of the solvent. After the end of the addition of amine,
heating is continued for about 1 h more. Then the solvent is
removed, generally by distillation. For quantitative removal.
of the solvent the reaction product is subsequently after-
treated at about 60°C in a vacuum drying oven. The salt a) is
then physically mixed with the polycarboxyl.ic acid b).
The hardeners listed in Table 1 below were prepared
by the general. preparation procedure.
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CA 02261485 1999-02-12
Table 1 : Hardener mixtures
ExampleHardener Characteristic
mixture data
com ition


A Salt e) PolycyrboxylicN contentCOON
and b)


content


PolyutboxylfeAminel9uanidine( 3 by weightJmmoll9JJmmoUpJ
geld (!i based


(! by weightlby weight) on salts


1 a) 16.5 PMA 53.5 PI 20 CYA 10.50 7.58


1 b) 46.5 PMA 53.5 PI 51 CYA 15.51 13.73


1 c 46.5 PMA 53.5 PI 63 CYA 17.33 15.97


2 a) 63.5 PMA 36.5 PI 10 CYA 6.82 9.07


2 b) 63.5 PMA 36.5 PI 20 CYA 8.65 10.64


2 c 63.5 PMA 36.5 PI 50 CYA 14.12 15.77


3 a) 46.5 PMA 53.5 PI 10 EDTA 7.27 4.66


3 b) 46.5 PMA 53.5 Pt 40 EDTA 7.13 7.67


3 c 46.5 PMA 53.5 PI 60 EDTA 7.03 9.68


4 s) 63.5 PMA 36.5 PI 10 EDTA 5.18 8.11


4 b) 63.5 PMA 36.5 PI 20 EOTA 5.37 8.73


4 c) 63.5 PMA 36.5 PI 30 EDTA 5.55 9.35


5 a) 46.5 PAAA 53.5 PI t 0 IA 6.59 4.50


5 b) 46.5 PMA 53.5 PI 30 IA 5.12 6.17


5 c! 46.5 PMA 53.5 Pt 80 IA 1 46 10.36


6 a) 63.5 PMA 36.5 PI 10 IA 4.50 7.95


6 b 63.5 PMA 36.5 PI 50 IA 2.50 9.77


7 a) 46.5 PMA 53.5 PI 20 TA 5.86 5.34


7 b 46.5 PMA 53.5 PI 55 TA 3.29 8.27


8 a) 63.5 PMA 36.5 PI 20 TA 4.00 8.40


8 b1 63.5 PMA 36.5 PI 50 TA 2.50 9.T7


9 a) 46.5 PMA 53.5 PI 10 BTA 6.59 5.0


9 b d6.5 PMA 53.5 PI 20 BTA 5.86 6.34


10 al 63.5 PMA 36.5 PI 10 ATA 4.50 8.45


10 b) 63.5 PMA 36.5 PI 20 8TA 4.00 9.41


10 c 63.5 PMA 36.5 PI 40 BTA 3.00 11.33


11 a) 46.5 PMA 53.5 P) 10 TMA 6.59 4 72


11 b) d6.5 PMA 53.5 PI 20 TMA 5.86 5 78


11 c) 46.5 PMA 53.5 PI 40 TMA 4.39 7 91


1 i 46.5 PMA 53.5 PI 70 TMA 2.20 11 09


12 a) 63.5 PMA 36.5 PI 10 TMA 4.50 8.17


12 b! 63.5 PMA 36.5 PI 50 TMA 2.50 10.89


13 a) 46.5 PMA 53.5 PI 10 TMSA 6.59 4.72


13 b) 46.5 PMA 53.5 PI 40 TMSA 4 39 7.91


13 c 46.5 PMA 53.5 PI 60 TMSA 2.93 10.03
I


I 14 63.5 PMA 36.5 P1 10 TMSA 4.50 8.17
a)


14 b) 63.5 PMA 36.5 PI 40 TMSA 3.00 10.21


14 c 63.5 PMA 36.5 P1 60 TMSA 2.00 11.56


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CA 02261485 1999-02-12
Key:


BTA: 1,2,3,4-butanetetracarboxylic
acid


CYA: cyanuric acid


IA: isophthalic acid


PI: 2-phenylimidazoline


PMA: pyromellitic acid


TMA: trimellitic acid


TMSA: trimesic acid


TA: terephthalic acid


1 o EDTA: ethylenediaminetetraacetic
acid


B Epox~,r resin
Bisphenol A was the basis of the epoxy resin compound employed in the Use
Examples. It has the following characteristic data:
Table 2: Characteristic data of the epoxy resin
Example B 1


Characteristic data


E uivalent wei ht 900 - 1000


j E oxide value 0.1 - 0.111


H drox I value 0.34


Meltin ran a 96 - 104C


C Epoxy resin powder coating composition
To prepare the epoxy resin powder coating compositions of the invention the
ground starting materials - hardener, epoxy resin and leveling agent
masterbatch ( log by weight of leveling agent based on polymeric butyl
2 o acrylates is homogenized in the melt with the epoxy resins and the melt is
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CA 02261485 1999-02-12
comminuted after it has so~dified) - were intimately mixed in an edge runner
mill with the white pigment (Ti02) and the mixture was then homogenized in
an extruder at from 90 to 110°C. After cooling, the extrudate was
fractionated
and ground in a pin mill to a particle size < 100 Nm (Coatings Examples).
The powder prepared as described above was applied to degreased and
optionally pretreated steel panels using an electrostatic powder spraying unit
at 60 kV and the panels were baked in a laboratory drying oven operating
with air circulation.
The abbreviations in the tables below have the following meanings:
1o LT - Layer thickness in Nm
CH - Crosshatch test
(DIN 53 151 )
GG fi0°Q = Gardner gloss (ASTM-D 5233)
EI - Erichsen indentation in mm (DIN 53 15fi)
BI dir. - Ball impact direct in inch'Ib
YI - Yellowness index
The coating formulations were calculated in accordance with the following
scheme:
by weight EP = epoxide
B - C = EP B = % by weight of binder
20 C = % by weight of crosslinker
B = 100 - A A = % by weight of adjuvants
X40% by weight white pigment (Ti02 ) , 0 . 5~
by weight leveling agent]
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CA 02261485 1999-02-12
Table 3: Coatings Examples
ExampleCrosslinkarCunn9 Mechanical
ac- data


cording
to



C ~' by 'CJmin LT CH GG 60'GEI BI YI
weight) dir.


1 3.5 A 200112 48 - 0 18 - 8.0-9.5>80 7.2
t a) 57 19


2 3.5 A 200H 60 - 0 19 - 9.0 50 8.0
t b) 2 76 20


3 3.5 A 200112 75 - 0 24 - 9.5 50 9.1
1 c 85 26


4 5.0 A 200115 69 - 1 9 7.0 >80 13.8
2 a) 71


5.0 A 200/15 89 - 0 12 - 7.0 >80 132
2 b) 104 13


6 5.0 A 200/15 64 - 0 25 - 8.5-9.5>80 8.9
2 a 82 26


7 3.5 A 200/15 76 - 1 15 - 7.5-9.5>80 18.4
3 a) 89 16


8 3.5 A 200!15 61 - 1 10 6.5-B.040 17.2
3 b 78


9 5.OA4a) 200115 84-99 0-1 6-7 7.0 >80 17.9


5.0 A 200/15 48 - 1 - 7 - 7.5 >80 15~
4 b) 61 2 8


11 5.0 A 20dt 53 - 1 7 - 7.0 >80 17.1
4 c 5 72 8


12 3.5 A 200/15 67 - 1 17 - 9.0 >80 17.4
5 a) 92 18


13 3.5 A 200115 57 - 0 19 8.5-9.060 14.8
5 b) 72


14 3.5 A 200!25 63 - 0 31 - 8.5 60 13 2
5 c) 77 32


t5 5.OA6a) 200115 59-72 0 5 8.0 >BO 15.1


16 5 0 A 200!15 77 - 1 25 - 9.0 >80 13.0
6 b) 103 26


17 3.5 A 200115 76 - 1 19 8Ø5 >80 12.8
7 a) 65


18 3.SA7b 200125 75-91 0-1 16-17 9.0 60 12.7


19 5.0 A 200115 10 - 1 8 8.0-0.5>80 11.6
8 a) 55


5.0 A 200115 50 - 1 31 - 9.0 >80 11.0
8 b 62 34


21 3.5 A 200115 76 - 0 14 8.0 60 18.0
9 a) 90


22 3.5 A 20W15 82 - 0 12 6.5-7.060 18.4
9 b 92 1 13


23 5.0 A 200/15 57 - 0 - 6 - 7.5-0.5>80 13.6
10 a) 64 1 7


24 5.0 A 200!15 78 - 1 7 - 6.5-7.0>80 16.2
10 b) 82 9


5.0 A 200115 36 . t 12 - 7.5-8.0>80 13.
10 c) 5p 15 t


26 3.5 A 200/15 47 - 0 16 - 8.0-8.5>80 13.9
11 a) 62 17


27 3.5 A 200115 67 - 1 14 - 6.0 >80 14.7
11 b) 80 15


28 3.5 A 200115 77 - 0 20 7.5 60 10.6
11 c 88


29 5.0 A 200/15 44 - 1 6 8.0 >80 12.5
12 a) 58


5 0 A 200/15 48 - 1 30 - 8.5-9.0>80 10.1
12 b) 68 31


31 3.5 A 200/15 58 - 0 - 17 8.0-8.580 16.3
13 a) 81 1


32 3.5 A 200125 72 - 1 11 4.0-7.040 15.0
13 c) 92


33 5.0 A 200115 77 - 0 5 7.0-7.5>80 14.5
14 a) 91


34 5.0 A 200r25 90 - 0 8 6.0 >80 13.1
14 b 105 1


D Carboxyl-containing pol~resters
To prepare a hybrid powder coating composition the carboxyl-containing
polyesters described below were employed, having the following characteri-
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CA 02261485 1999-02-12
stic data:
Table 4: Characteristic data of the acidic polyester
Example D 1


Characteristic data


Acid number 30 mg of KOH/


Meltin ran a 78 - 81 C


Glass transition tem erature 64 C


E Hybrid powder coating examples
The preparation of the raw materials, and also the preparation and ap-
plication of the coatings, is as in C. The hybrid powder coatings comprise
epoxy resin and polyesterpolycarboxylic acids in a ratio of 75 : 25, 40% by
mass white pigment (Ti02) and 1 % by mass leveling agent.
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CA 02261485 1999-02-12
Table 5: Coatings Examples
Example,CrossllnkerCuring Mechanical
ac- data


eordlnq
to



E f t by 'Gmin LT GG 60' EI 81
weight: 4 dir.
~


1 5.0 A 2 200115 60 16 7.07.5>60
b -
74


2 7.5 A 3 20011 55 13 6.5-9.5>80
a) S -
80


3 3.5 A 3 200115 59 12 6.57.040
b) -
75


d J.5 A 3 200115 44 12 3.55.570
c 65


5 5.0 A 4 200V15 44 9 7.0-7.5>80
a) 84


6 5.0 A 4 200Y15 48 9 8.0 >60
b -
59


7 5.0 A 6 200115 55 10 xØ8.5>60
a -
6r!


8 5.0 A 8 20W15 81 18 7 5-8.0>80
s -
72


9 3.5 A 11 200115 58 18 9.0 70
a) -
66


10 J.5 A 11 20W 55 1 tl 9.5 70
b) 15 -
69


11 3.5 A 11 200115 57 19 9.5 80
c .
t)D


12 3.5 A 17 200115 60 15 9Ø9.5>80
a) -
73


13 3.5 A 13 200115 59 15 9.0 >80
b) -
74


14 3.5 A 13 200!15 5 t 16 9 0.9.570
c -
70


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O.Z. 5290
23443-671

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Administrative Status

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Administrative Status

Title Date
Forecasted Issue Date Unavailable
(22) Filed 1999-02-12
(41) Open to Public Inspection 1999-08-16
Dead Application 2002-02-12

Abandonment History

Abandonment Date Reason Reinstatement Date
2001-02-12 FAILURE TO PAY APPLICATION MAINTENANCE FEE

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $300.00 1999-02-12
Registration of a document - section 124 $100.00 1999-02-24
Registration of a document - section 124 $50.00 2001-01-31
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
DEGUSSA-HULS AKTIENGESELLSCHAFT
Past Owners on Record
HULS AKTIENGESELLSCHAFT
WEISS, JORN VOLKER
WENNING, ANDREAS
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Abstract 1999-02-12 1 22
Description 1999-02-12 17 608
Claims 1999-02-12 6 210
Cover Page 1999-08-24 1 29
Assignment 2001-01-31 55 3,857
Assignment 1999-02-12 4 150
Correspondence 1999-03-16 1 26
Correspondence 1999-04-09 1 55
Correspondence 1999-09-27 1 1
Correspondence 2001-04-04 4 175