Coating powder.

0001The present invention relates to a coating powder and more specifically, it concerns a coating powder which is excellent in blocking resistance and capable of resulting a coating with improved weather resistance, hardness and other coating properties, as well as excellent appearance.

0002Coating powder containing no or substantially no volatile components have been widely used for the coating of metallic materials in an automobile, an electric appliance and other industries. However, the coating is, in general, not so good in appearance as compared with those of solvent type coating compositions. In order to improve the said coating appearance at least to the same level as obtained with a solvent type coating composition, it is believed that a higher degree of thermal flowability should be given to the coating powder by using, for example, a comparatively low molecular weight polymer or a low Tg polymer as a binder resin or by adding a plasticizer to the coating powder. In those cases, an additional problem is always encountered such that the coating powder is liable to become solid during storage thereof, resulting the so-called blocking, and in extreme case, thus solidified material can hardly be re-pulverized and used as a coating powder.

0003Thus, in a coating powder, the requirements of having improved appearance and improved blocking resistance are contrary to each other and actual use of such coating powder has been markedly limited on that account.

0004Attempts have been made to prevent or decrease the occurence of undesired blocking by the addition of inorganic microparticles as colloidal silica, siloxane and the like with a coating powder. However, since an excess amount of such additive may cause the loss in gloss of the coating and often exert harmful influence on the film properties as water resistance and the like, the employable amount of such additive is practically limitted to at most 0.1 % by weight of the total solid, which is quite insufficient for the intended blocking resistance.

0005Under the circumstances, has long been desired a coating powder which, without relying on inorganic microparticles, is free from blocking during storage, has an improved thermal flowability and capable of resulting a coating with excellent appearance which is comparable with those of conventional solvent type coating compositions.

0006The principal object of the invention is therefore to provide such coating powder. A further object of this invention is to provide a coating powder which can be applied in a thicker coating without the fear of sagging but still result a coating with improved weather resistance, hardness and other desirable properties, as well as excellent coating appearance and blocking resistance.

0007According to the invention, the aforesaid and other objects of the invention are attained with a coating powder consisting essentially of (a) a binder resin, (b) a hardener, (c) crosslinked polymer particles and (d) other optional additives as pigments, levelling agent, UV absorber and anti-oxidant.

0008The present invention has been made on the basis of the finding that when the crosslinked polymer particles hereinunder mentioned are added as a constituting component of coating powder, the aforesaid objects of the invention can be fully attained therewith.

0009The crosslinked polymer particles used in the invention are polymer particles with a mean diameter of 0.01 to 10µ, three-dimentionally crosslinked, which are substantially insoluble in organic solvents and cannot be melted at an elevated temperature as high as baking temperature.

0010Any of the known polymer materials for coating use may be satisfactorily used, providing being three-dimentionally crosslinked to give the particles with a mean grain diameter of 0.01 to 10,u.. However, from the preparation easiness and practical sense of view, preferable members are acrylic resin, epoxy resin, polyester resin and melamine resin.

0011The crosslinked acrylic resin particles may be prepared by emulsion-polymerizing a mixture of ethylenically unsaturated comonomers including at least one crosslinking comonomer in an aqueous medium by a conventional method, and then removing water from the emulsion by, for example, solvent substitution, centrifugation, filtering or drying. Any known emulsifier and/or dispersing agent may be used in the emulsion polymerization. An amphoteric ionizable group containing emulsifier is particularly preferable, since the crosslinked acrylic resin particles with a uniform particle size distribution may be easily obtained therewith. Examples of ethylenically unsaturated comonomers used for the production of the crosslinked acrylic resin particles include methyl (meth) acrylate, ethyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, 2-ethyl hexyl (meth) acrylate, styrene, α-methyl styrene, vinyl toluene, t-butyl styrene, ethylene, propylene, vinyl acetate, vinyl propionate, acrylonitrile, methacrylonitrile, dimethylaminoethyl (meth) acrylate and the like. Two or more comonomers may be combined. Crosslinking comonomers include a monomer having at least two ethylenically unsaturated bonds in the molecule and the combination of two different monomers having mutually reactive groups. Monomers having at least two polymerization sites may typically be represented by esters of a polyhydric alcohol with an ethylenically unsaturated monocarboxylic acid, esters of an ethylenically unsaturated monoalcohol with a polycarboxylic acid and aromatic compounds having at least two vinyl substituents.

0012Specific examples thereof include ethylene glycol diacrylate, ethylene glycol dimethacrylate, triethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, 1,3-butylene glycol dimethacrylate, trimethylolpropane triacrylate, trimethylolpropane trimethacrylate, 1,4-butanediol diacrylate, neopentyl glycol diacrylate, 1,6-hexanediol diacrylate, pentaerythritol diacrylate, pentaerythritol triacrylate, pentaerythritol tetracrylate, pentaerythritol dimethacrylate, pentaerythritol trimethacrylate, pentaerythritol tetramethacrylate, glycerol diacrylate, glycerol allyloxy dimethacrylate, 1,1,1-tris (hydroxy methyl) ethane diacrylate, 1,1,1-tris (hydroxymethyl) ethane triacrylate, 1,1,1-tris (hydroxymethyl) ethane dimethacrylate, 1,1,1-tris (hydroxymethyl) ethane trimethacrylate, 1,1,1-tris (hydroxymethyl)_propane diacrylate, 1,1,1-tris (hydroxymethyl) propane triacrylate, 1,1,1-tris (hydroxymethyl) propane dimethacrylate, 1,1,1-tris(hydroxymethyl) propane trimethacrylate, triallyl cyanurate, triallyl isocyanurate, triallyl tirmellitate, diallyl phthalate, diallyl terephthalate and divinyl benzene.

0013Combinations of two monomers having mutually reactive groups may be used in place of, or in addition to monomers having two or more polymerization sites. For example, monomers having a glycidyl group such as glycidyl acrylate or methacrylate may be combined with carboxyl group-containing monomers such as acrylic, methacrylic or crotonic acid.

0014Also, hydroxyl group-containing monomers such as 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, hydroxybutyl (meth) acrylate, allyl alcohol or methallyl alcohol may be combined with isocyanate group-containing monomers such as vinyl isocyanate or isopropenyl isocyanate. Other combinations will be apparent to those skilled in the art.

0015Monomer mixtures forming the crosslinked acrylic resin particles may contain monomers having a functional group which may react with the crosslinking agent.

0016Examples of such monomers include acrylic acid, methacrylic acid, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, hydroxybutyl (meth) acrylate, allyl alcohol, methallyl alcohol, acrylamide, methacrylamide and the like. The crosslinked acrylic resin particles may be of uniform structure or multilayer structure.

0017Crosslinked epoxy resin particles may be obtained by first preparing an epoxy resin in a conventional way as, for example, by a solution polymerization and the like, effecting a crosslinking reaction in the post emulsification step and removing an aqueous medium from the reaction system.

0018Since the preparation procedures per se are well known in the art, the details are omitted herein.

0019The base coating powder to which the aforesaid crosslinked polymer particles are added in this invention are conventional ones comprising (a) a binder resin, (b) a hardener and (d) other optional additives as pigments, levelling agent, UV adsorber, anti-oxidant and the like.

0020As the binder resin, any of the known resins which are solid at a room temperature and are excellent in fluidity and film-forming properties at a heat melted state may be satisfactorily used and, however, particulary preferable members are acrylic resin, polyester resin and epoxy resin. They should preferably have such reactive groups as glycidyl, carboxyl, hydroxyl group and the like or other groups capable of producing such groups at an elevated temperature.

0021As the hardener, any of the compounds or resins having two or more groups which are reactive with the aforesaid reactive groups of the binder resin may be satisfactorily used. Thus, the binder resin and the hardener are properly selected to react with each other at a fixing stage under heated conditions. Examples of such combinations are as follows.

0022When glycidyl group containing binder resin is used, the hardener is selected from a dicarboxyl acid, a diamine, a carboxyl group containing resin and the like; at the time of hydroxyl group containing binder resin, the hardener is selected from a melamine resin, a blocked polyisocyanate compound and the like; and at the time of carboxyl group containing binder resin, the hardener is selected from a polyglycidyl compound, a glycidyl group containing resin and the like.

0023It is, of course, possible to use more than one binder resins and/or hardeners as desired.

0024In this invention, the aforesaid crosslinked polymer particles are added to the base coating powder at an appropriate stage in the preparation of said powder.

0025For example, when the coating powder is prepared by a dry method wherein the solid binder resin, hardener and other additives are mixed and milled in a kneader to give pellets, which are then pulverized and shieved, the aforesaid crosslinked polymer particles may be added to the coating powder at any stage of said mixing and milling, pulverizing and shieving steps. When the coating powder is prepared by a wet process comprising dissolving or dispersing a solid binder resin, hardener, and other additives in an appropriate solvent and spray-drying the same, the aforesaid crosslinked polymer particles may be advantageously dispersed in said spray-drying solution or dispersion to obtain the present coating powder. At the time when a self- curing type binder resin is selected, the hardener may be dispensed with as might be well understood.

0026The most characteristic features of the invention reside in the point that a flowable resin and crosslinked polymer particles having no or substantially no fluidity at an elevated temperature are combined together, thereby attaining the objects of improved coating appearance and improved blocking resistance liable to occure with the use of said flowable resin in a coating composition. Thus, in the present invention, both of the conflicting natures of coating appearance and blocking resistance are well balanced by the combination of fluidity characteristics of said binder resin and of crosslinked polymer particles.

0027If the crosslinked polymer particles are of no fluidity nature, the binder resin may be safely selected from a wider range of resins including the members having good fluidity, which have not been used in a coating powder area from the fear of undesirable sagging. There is of course a certain degree of allowable range in the fluidity of crosslinked polymer particles from the standview of blocking resistance of coating powder capable of resulting a coating with excellent appearance.

0028With respect to said fluidity nature of crosslinked polymer particles, the inventors have found that the polymer particles should preferably have the characteristics of 0 to 5 mm flow in the following thermal fluidity test.

0029Thermal fluidity test: <ul id="ul0001" list-style="none"><li>1 g of crosslinked polymer particles are pressed under 10 t/cm² pressure to form a pellet with a diameter of 2 cm, thus obtained pellet is fixed on a polished steel plate with a double faced tape, the plate is held at an inclination of 45 degrees and heated at 150 °C for 15 minutes. The flow distance of said pellet on the plate surface is measured and used as a fluidity index.</li></ul>

0030The crosslinked polymer particles should preferably have a mean grain diameter of 0.01 to 10µ. This is because if the mean grain diameter of said polymer particles exceeds over the limit of 10µ, there is a tendency of chemical seeding in a coating, and if the mean grain diameter is less than 0.01µ, it is unable to expect the aforesaid effects of the invention.

0031The crosslinked polymer particles should be added to the base coating powder in an amount of 0.1 to 30 % by weight, preferably 0.1 to 10 % and most preferably 0.1 to 5 % by weight, of the total solid. This is because if the amount of said polymer particles is less than 0.1 % by weight, there is no substantial effect in the improvement of blocking resistance, whereas if the amount of said polymer particles exceeds over the limit of 30 % by weight, there is a tendency that coating appearance be lowered.

0032From the standview of coating appearance alone, the most preferable range of said polymer particles is in a range of 0.1 to 5 % by weight of the total solid.

0033The invention shall be now more fully explained in the following Examples. Unless otherwise being stated, all parts and % are by weight.

Reference Example 1

Preparation of amphoteric ionizable group containing polyester resin

0034Into a 2 liters flask fitted with a stirrer, a nitrogen gas inlet, a thermoregulator, a condenser and a decanter, were placed 134 parts of bishydroxy ethyl taurine, 130 parts of neopentyl glycol, 236 parts of azelaic acid, 186 parts of phthalic anhydride and 27 parts of xylene and the mixture was heated, while removing the formed water azeotropically with xylene.

0035The temperature was raised to 190°C in about 2 hours from the commencement of reflux, and the reaction was continued, while stirring and continuing dehydration, until the resinous acid value based on carboxyl groups reached 145. The reaction mixture was then allowed to cool to 140°C, dropwise added with 314 parts of Cardura E-10 (versatic acid glycidyl ester, trademark of Shell Co.) in 30 minutes at 140°C and the combined mixture was reacted at the same temperature for 2 hours to obtain an amphoteric ionizable group containing polyester resin, whose acid value was 59 and hydroxyl value was 90. Number average molecular weight of the polyester resin was 1054.

Reference Example 2

0036Preparation of crosslinked polymer particles (G-l) Into a 1 liter flask fitted with a stirrer, a condenser and a thermoregulator, were placed 282 parts of deionized water, 10 parts of the amphoteric ionizable group containing polyester resin obtained in Reference Example 1 and 0.75 part of dimethyl ethanol amine and the mixture was heated under stirring to 80 °C to get a clear solution. To this, a solution of 4.5 parts of azobiscyanovaleric acid in a mixture of 45 parts of deionized water and 4.3 parts of dimethyl ethanol amine was added and then a monomer mixture of 70.7 parts of methyl methacrylate, 94.Z parts of n-butyl acrylate, 70.7 parts of styrene, 30 parts of 2-hydroxyethyl acrylate and 4.5 parts of ethylene glycol dimethacrylate was dropwise added in 60 minutes. Thereafter, a solution of 1.5 parts of azobiscyanovaleric acid in 15 parts of deionized water and 1.4 parts of dimethyl ethanol amine was added and the combined mixture was reacted at 80°C for 60 mintues to obtain an emulsion having a non-volatile content of.45 %, pH 7.2 and a viscosity of 92 cps (at 25°C). This emulsion was subjected to a spray-drying to obtain crosslinked polymer particles (G-1) having a mean grain diameter of 0.8µ. Ther thermal fluidity test was carried out according to the procedures as stated hereinbefore, and the flow distance (hereinafter merely referred as fluidity) was determined as 1 mm.

0037A part of said emulsion was added with xylene, and the mixture was heated under reduced pressure while removing water azeotropically with xylene to obtain a xylene dispersion (S-1) of crosslinked polymer particles.

Reference Example 3

0038Preparation of crosslinked polymer particles (G-2) Into a flask fitted with a stirrer and a thermometer, were placed 200 parts of deionized water, 6 parts of sodium dodecyl benzene sulfonate and 8 parts of polyethylene glycol (molecular weight 4000). To this solution, 60 parts (on solid basis) of butyrated melamine formaldehyde resin were added and dispersed therein so as to give an emulsion having a mean particle size of 0.2_AL. Thus obtained emulsion was adjusted to pH 3.8 with 0.5 N-HC1 aqueous solution, gradually heated to 80°C and maintained at this temperature for 6 hours to obtain a dispersion of crosslinked polymer particles.

0039The dispersion was then subjected to spray-drying to obtain the crosslinked polymer particles (G-2), whose fluidity was 1 mm.

Reference Example 4

0040Preparation of crosslinked polymer particles (G-3) Into a reaction vessel fitted with a stirrer and a thermometer, were placed 60 parts (on solid basis) of Epicoat 1001 (epoxy resin, manufactured by Shell Chem. Co.) and 4 parts of dicyandiamide and the mixture was heated at 150°C for 2 hours.

0041At the stage wherein no fluid mass was observed, the content was allowed to cool, pulverized and shieved to obtain crosslinked polymer particles (G-3) having a mean grain diameter of 2µ. The fluidity was 0 mm in substance.

Reference Example 5

0042Preparation of crosslinked polymer particles (G-4) Into a flask fitted with a stirrer and a thermometer, were placed 200 parts of deionized water, 6 parts of sodium dodecyl benzene sulfonate and 4 parts of polyvinyl alcohol. To this, 70 parts of long oil alkyd (prepared by a conventional method from 90 parts of soy bean oil, 28 parts of phthalic anhydride, 17 parts of pentol and 1 part of maleic anhydride) and 2 parts of cobalt naphthenate were added and the mixture was emulsified. The mixture was heated, while introducing air, at 80°C for 8 hours to obtain a dispersion of crosslinked polymer particles. The dispersion was then subjected to spray-drying to obtain the crosslinked polymer particles (G-4), whose fluidity was 4.5 mm.

Reference Example 6

Preparation of acrylic resin [I]

0043Into a flask fitted with a dropping funnel, a stirrer and a thermometer, were placed 80 parts of xylene and the temperature was raised to 130°C. To this, a solution of 30 parts of glycidyl methacrylate, 10 parts of methyl methacrylate, 30 parts of styrene, 20 parts of n-butyl methacrylate, 10 parts of n-butyl methacrylate and.2 parts of azobisisobutyronitrile was dropwise added at a constant speed in 3 hours.

0044After completion of said addition, the combined mixture was maintained at the same temperature for 30 mintues, added dropwise a solution of 0.5 part of t-butyl peroxy benzoate in 20 parts of xylene in 1 hour. Thereafter, the mixture was maintained at 130°C for 2 hours and xylene was removed by a vacuum distillation to obtain an acrylic resin [I].

Reference Example 7

Preparation of acrylic resin solution [II]

0045Into a flask fitted with a dropping funnel, a stirrer and a thermometer, were placed 80 parts of xylene and the temperature was raised to 130°C. To this, a solution of 20 parts of N-n-butoxymethyl acrylamide, 10 parts of 2-hydroxyethyl metahcrylate, 20 parts of methyl methacrylate, 30 parts of styrene, 10 parts of n-butyl methacrylate, 10 parts of n-butyl acrylate and 2 parts of azobisisobutyronitrile was dropwise added from the dropping funnel at a constant speed in 3 hours. After completion of said addition, the mixture was maintained at the same temperature for 30 minutes and then added dropwise with a solution of 0.5 part of t-butyl peroxybenzoate in 20 parts of xylene in 1 hour. Thereafter, the combined mixture was maintained at 130°C for 2 hours to obtain an acrylic resin xylene solution [II].

Reference Example 8

0046To a flask as used in Reference Example 2, were placed 232 parts of deionized water, 10 parts of the polyester resin obtained in Reference Example 1, and 0.75 part of dimethyl ethanolamine. The mixture was stirred at 80°C to make a solution. To the solution, were added a solution of 10 parts of azobiscyanovaleric acid and 0.26 part of dimethyl ethanolamine in 20 parts of deionized water. Then, a monomer mixture consisting of 108 parts of methyl methacrylate and 27 parts of ethylene glycol dimethacrylate was added dropwise over 60 minutes. The mixture was stirred for additional 60 minutes at 80°C.

0047A solution of 0.5 part of azobiscyanovaleric acid and 0.3 part of dimethyl ethanolamine in 25 parts of water was added again to the reaction mixture. Then, a monomer mixture consisting of 9.5 parts of styrene, 20 parts of methyl methacrylate, 14 parts of n-butyl acrylate and 6 parts of ethylene glycol dimethacrylate was added dropwise over 60 minutes. A solution of 1.5 parts of azobiscyanovaleric acid and 1.4 parts of dimethyl ethanolamine in 15 parts of deionized water was added and the mixture was stirred for 60 minutes at 80°C. An emulsion having a non-volatile content of 45 %, a pH of 7.2 and a viscosity of 105 cps (25°C) was obtained.

0048Upon subjecting to a spray-drying, the crosslinked acrylic resin particles (G-5) having a mean diameter of 1.0µ were obtained.

Example 1

0049100 parts of the acrylic resin [I] obtained in Reference Example 6, 24 parts of decane dicarboxylic acid, 30 parts of titanium oxide and 1 part of tiodaflow (levelling agent, trademark of Monsanto Chem.), were dry-mixed in a Henschel mixer (manufactured by Mitsui Miike Seisakusho). Next, the mixture was melt-kneaded in Co-kneader PR-46 (manufactured by Bus in Switzerland) at 100°C and then allowed to cool. The solid mass was pulverized in a hammer mill and shieved with a 150 mesh wire screen.

0050To thus obtained powder, 5 parts of the crosslinked polymer particles (G-1) obtained in Reference Example 2 were added and mixed well to obtain a coating powder (A).

Example 2

0051The same procedures as stated in Example 1 were repeated excepting reducing the amount of crosslinked polymer particles (G-1) to 0.2 part, to obtain a coating powder (B).

Example 3

0052The same procedures as stated in Example 1 were repeated excepting increasing the amount of crosslinked polymer particles (G-1) to 20 parts, to obtain a coating powder (C).

Comparative Example 1

0053The same procedures as stated in Example 1 were repeated and however, the crosslinked polymer particles (G-l) were not added. Thus obtained powder was referred to as coating powder (D) hereinunder.

Comparative Example 2

0054The same procedures as stated in Example 1 were repeated excepting increasing the amount of crosslinked polymer particles (G-l) to 35 parts to obtain a coating powder (E).

Example 4

0055In a Henschel mixer (manufactured by Mitsui t4iike Seisakusho), 100 parts of the acrylic resin [I] obtained in Reference Example 6, 24 parts of decane dicarboxylic acid, 30 parts of titanium oxide, 1 part of Modaflow and 10 parts of the crosslinked polymer particles (G-l) were mixed well and the mixture was then melt-kneaded in a Co-Kneader PR-46 (manufactured by Bus in Switzerland) at 100°C. Thereafter, the mixture was allowed to cool and the solid mass was then pulverized in a hammer mill, and shieved with a 150 mesh wire screen to obtain a coating powder (F).

Example 5

0056In a Henschel mixer, 100 parts of Krelan U-502 (polyester resin, trademark of Bayer A.G.), 36 parts of Kakenate PW 4403 N (blocked isocyanate, trademark of Takeda Yakuhin K.K.), 40 parts of titanium oxide and 1 part of Acronal 4F (levelling agent, trademark of BASF) were dry-mixed and the mixture was then melt-kneaded in a Co-kneader PR-46 at 100°C. After cooling, the solidified mass was pulverized in a hammer mill and shieved with a 150 mesh wire screen. To thus obtained powder, 3 parts of the crosslinked polymer particles (G-2) obtained in Reference Example 3 were mixed well to obtain a coating powder (G).

Comparative Example 3

0057The same procedures as stated in Example 5 were repeated and however, the crosslinked polymer particles were not added, to obtain a coating powder (H).

Example 6

0058The same procedures as stated in Example 4 were repeated excepting substituting the following for the materials shown in Example 4. 100 parts of Epicoat 1001 (epoxy resin, trademark of Shell), 6 parts of dicyandiamide, 40 parts of titanium oxide, 1 part of Modaflow and 10 parts of crosslinked polymer particles (G-3) obtained in Reference Example 4. The powder thus obtained was referred to as coating powder (I) hereinunder.

Comparative Example 4

0059The same procedures as stated in Example 6 were repeated and however, the crosslinked polymer particles (G-3) were not used, to obtain a coating powder (J).

Example 7

0060In a paint shaker, 40 parts of titanium oxide were dispersed in the acrylic resin xylene solution [II] obtained in Reference Example 7 (100 parts as solid). Then, Modaflow (1 part) and xylene dispersion (S-1) of crosslinked polymer particles (5 parts as solid) were added to obtain a coating composition. This was then subjected to spray-drying to obtain a coating powder (K).

Example 8

0061The same procedures as stated in Example 6 were repeated excepting substituting the crosslinked polymer particles (G-4) for the crosslinked polymer particles (G-3). Thus obtained coating powder was referred to (L) hereinunder.

Example 9

0062The same procedures as stated in Example 6 were repeated excepting substituting the crosslinked polymer particles (G-5) for the crosslinked polymer particles (G-3). Thus obtained coating powder was referred to as M hereinunder. Thus obtained coating powders A to M were evaluated as follows.

1) Blocking resistance test:

0063The test powder was storred at 40°C for 1 month and thereafter, the flow property of the coating powder was evaluated. <ul id="ul0002" list-style="none"><li>excellent ... no substantial change in flow property</li><li>good ... certain re-pulverizable masses</li><li>no good ... many un-pulverizable masses</li></ul>

2) Coating appearance and properties:

0064The test powder was applied on to a soft steel plate previously treated with a zinc phosphate bath, to a film thickness of 30 to 40µ by an electrostatic coating and the coating was baked at 180°C for 20 minutes.

0065The coating appearance was visually evaluated.

0066Pencil hardness test was carried out according to the standard JIS method.

0067Weather resistance test was conducted by using Sunshine weather-O-meter (400 hours illumination).

0068The test results are shown in the following Table 1. <tables id="tabl0001" num="0001"><img file="EP0250183A2_D0001.tif" /></tables>