NOVOLAC BASED EPOXY RESIN CURING AGENTS FOR USE IN AQUEOUS SYSTEMS

Abstract: The instant invention is an epoxy resin curing agent based upon an epoxy novolac containing, on the average, between about 3 and 7.5 epoxy groups per molecule, in which substantially all of the epoxide groups are reacted with a polyamine wherein each primary amine hydrogen in the re­ sulting reaction product is further reacted with a monoe­ poxide or a monocarboxylic acid. The resulting epoxy resin curing agent may be used in a water based system for curing epoxide resins. The curing agent is rendered water soluble or water dispersible by salting with a conventional volatile monocarboxylic acid such as acetic, formic or propionic acid.

Description: This invention relates to epoxide resin curing agents. More particularly, this invention to novolac based polyamines which may be used to cure polyepoxides in aqueous based systems. Solvent based epoxy resin curing agent systems have been known for many years. However, these solvent systems often are quite flammable and expensive and many have disagreeable odors. Moreover, in recent years, increasingly strict regulation of environmental pollutants has led to a limitation on the types and amounts of organic solvents which can be used in epoxy resin curable sytems. The first approach to these limitations on the solvent content of coating systems was simply to employ a surfactant and emulsify or disperse existing polymeric systems in water. However, the cured products which resulted from these emulsions or dispersions often exhibited poor properties when compared to prior art solvent based systems. In particular, the chemical and water resistance of such systems was often lower because of the high levels of surfactant which were needed. Therefore, the search has continued to discover epoxy resin curing agent and curing agent systems which may be dispersed in water and which maintain the high performance levels of prior art solvent based systems. US-A-4,116,900 discloses cathodic electro deposition resin systems prepared based upon polyepoxides, polyamines and monoepoxides. While the monoepoxide and polyamine are similar to the products used in this invention, the polyepoxide utilized is quite different. Specifically, in column 3, lines 47 to 68 of U.S. 4,116,900 there is no disclosure of the use of novolac type, highly branched, highly functional epoxy resins. US-A-4,246,148 discloses an aqueous coating composition based upon an epoxy polyamine adduct end capped with monoepoxide. Again it is clear that highly functional, highly branched epoxides such as the novolac resin are not contemplated in that patent. Specifically, in column 5, lines 10 to 20, of US-A-4,246,148 a general formula is shown which clearly discloses a diepoxide, not a tri- or tetra-functional epoxide. A need remains for excellent epoxy resin curing agents which are useful in aqueous based systems. A need also remains for water-based epoxy resin curing systems which exhibit properties which are equivalent to the properties of prior art solvent-based systems. To achieve these objectives, the present invention provides a novolac based epoxy resin curing agent comprising a volatile acid salt of the reaction product of an epoxy novolac compound having, on the average, 3 to 7.5 epoxide groups per molecule, a primary-amine-containing polyamine, said polyamine containing at least 2 amine nitrogen atoms per molecule, at least 3 amine hydrogen atoms per molecule and no other groups reactive with epoxide groups, and a monoepoxide wherein substantially all the epoxy groups are reacted with the polyamines and wherein substantially all the unreacted primary amine groups in the polyamine/epoxide reaction product groups are reacted with the monoepoxide, the said curing agent containing not more than 0.5% by weight of unreacted amine. The term "volatile acid" is defined hereinafter. Basically the invention involves an ambient temperature curable coating system wherein the present curing agent is utilized to cure epoxide resins. These curing agents may be employed in aqueous systems to provide superior cured state film properties. The first component of the invention is an epoxy novolac resin. In order to ensure that the curing agents prepared according to the invention have the desired degree of branching, it is essential that the epoxy novolac resins utilized as the starting material have an average epoxy functionality of 3 to 7.5, preferably 3 to 4. In other words, the compositions of the invention should be prepared based upon a novolac containing from 3 to 7.5 phenolic hydroxyl groups. The novolac starting material is defined as the reaction product of a mono or dialdehyde (most usually formaldehyde) with a mono or polyphenolic material.Examples of the monophenolic materials which may be utilized to prepare the base novolacs useful in the invention include unsubstituted phenol and the various substituted phenols such as the cresols, alkyl and aryl substituted phenols such as p-tert-butylphenol and phenylphenol. Polyphenolic materials such as the various diphenols (including bisphenol-A) may also be utilized. The aldehydes which are utilized to form the novolac materials of the invention are predominantly formaldehyde (usually paraformaldehyde is the starting material). However, glyoxal may also be utilized, as may the higher alkyl aldehydes up to about the C₄ aldehydes. When glyoxal is employed it may be used to form a tetrafunctional novolac by reacting four moles of phenol with one mole of glyoxal. In the typical reaction scheme, paraformaldehyde is reacted with phenol under acidic conditions to prepare a polyphenolic material or novolac. This material is then reacted with epichlorohydrin and dehydrohalogenated under basic conditions to produce the epoxy novolac resin. The procedures utilized to form epoxy novolacs from novolac starting materials are well known in the art, and need not be repeated here. As stated previously, the epoxy novolac resin useful herein, must have, on the average, at least 3 epoxide groups and no more than 7.5 epoxide groups per molecule. It has been found that, when less than 3 epoxide groups are present, the desired degree of crosslink density and branching in the cured product is not obtained. As a result curing agents prepared from these materials do not have the desired degree of toughness. It has also been found that, when more highly funtional materials, i.e. having more than 7.5 epoxide groups per molecule, are prepared, it is extremely difficult to process these materials and they often gel prior to the formation of the end product. In addition, the pot life of blends of these highly functional curing agents with epoxide resins is extremely short - in most cases too short for actual practical use. Each site in the epoxy novolac which contains an epoxide group is reacted with a polyamine. The polyamines contain at least two amine nitrogen atoms per molecule, at least three amine hydrogen atoms per molecule,and no other groups which are reactive with epoxide groups. These polyamines can be aliphatic, or cycloaliphatic and contain at least two carbon atoms per molecule. In general, the preferred polyamines contain 2 to 6 amine nitrogen atoms per molecule, 3 to 8 amine hydrogen atoms, and 2 to 20 carbon atoms. Among the examples of such amines are the polyalkylenepolyamines, ethylene diamine, 1,2-propylene diamine, 1,3-propylene diamine, 1,2-butylene diamine, 1,3-butylene diamine, 1,4-butylene diamine, 1,5-pentylene diamine, 1,6-hexylene diamine, methane diamine, 1,4-diaminocyclohexane and meta-xylylene diamine. Preferred amines for use in this invention are polyamines of the formula : wherein n is 0 to 4 and R is an alkylene group containing 2 to 8 carbon atoms. Among the examples of such alkylene polyamines are ethylene diamine, diethylene triamine, triethylene tetramine, tetraethylene pentamine, pentaethylene hexamine, dipropylene triamine, tributylene tetramine, hexamethylene diamine and dihexamethylene triamine. Mixtures of amines can be used. The more preferred amines are the ethylene polyamines with the most preferred being triethylene tetramine and diethylene triamine. The final component of the agent of the invention is an end capping agent. The end capping agent should be employed in an amount sufficient to react with substantially all primary amine groups (thereby providing extended pot life) and yield an end capped adduct which is compatible with the epoxy resin which is employed. It has been found that one type of end capping agent which meets these requirements includes a monoepoxide or mixture of monoepoxides. Such monoepoxide preferably has (a) one 1,2-epoxide group per molecule and no other groups which are reactive with amine groups and (b) from 9 to 20, preferably 10 to 15, carbon atoms per molecule. Representative examples of suitable aliphatic monoepoxides for use in the end capping agent include mono -epoxidized terminally unsaturated straight chain hydrocarbons (also known as terminal olefin oxides)having from 9 to 16, preferably 11 to 14, carbon atoms and mixtures thereof, such as decylene oxide, undecylene oxide, dodecylene oxide, tridecylene oxide, tetradecylene oxide, and pentadecylene oxide, monoglycidyl ethers of aliphatic alcohols, said glycidyl ethers having 6 to 20 carbon atoms, and mixtures thereof, such as octyl glycidyl ether, nonyl glycidyl ether, decyl glycidyl ether,and dodecyl glycidyl ether; and monoglycidyl esters of saturated tertiary monocarboxylic acids, said esters having 9 to 16, preferably 11 to 14, carbon atoms, such as the glycidyl ester of versatic acid (i.e., a mixture of 9 to 11 carbon carboxylic acids used to make Cardura E), tert-octanoic acid, tert-nonanoic acid, tert-decanoic acid, tert-undecanoic acid, and tert-dodecanoic acid. Representative examples of aromatic monoepoxides, i.e., at least one aromatic ring containing compound having attached thereto an epoxy functional group and no other reactive functional groups, include the monoglycidyl ethers of monohydric aromatic alcohols such as phenol and naphthanol, alkyl substituted monoglycidyl ethers of monohydric aromatic alcohols, said alkyl groups having from 1 to 4, or more, carbon atoms, such as monoglycidyl ether of p-tert-butyl phenol and o-cresol. The preferred aromatic monoepoxide is o-cresyl glycidyl ether. Finally, oils containing up to about 24 carbon atoms per molecule and containing an unreacted epoxide group may also be used herein. Examples of such materials include epoxidized cashew nut oil. In preparing the epoxy-amine adducts of this invention, the polyepoxide resin and the polyamine are reacted under such conditions that the adduct so formed contains about 1 mole of polyamine for each epoxide group originally present in the polyepoxide resin, i.e., about one mole of polyamine is reacted with each epoxide equivalent to the polyepoxide. The reaction between the epoxy novolac, the polyamine and the monoepoxide is not difficult to carry out. Preferably the epoxy novolac is reacted with a relatively large excess of the polyamine at a temperature of 200° to 300°F (93° to 149°C). In general it is preferred that the epoxy novolac be added to the amine over a period of time, generally one to four hours. The amount of excess which is employed varies depending upon the reactivity of the various reactants which are chosen. At least 2.25 and preferably at least 3 moles and no more than 10 moles of amine are generally employed for each epoxide equivalent present in the epoxy novolac. After all the novolac has been added, the materials may be allowed to react at reaction temperature for approximately one to four hours. The preparation of adducts of polyepoxide resins and polyamines is described in further detail in US-A-4,093,594 and 4,116,900. When the adducting reaction is completed, unreacted amine, if any, is removed by vacuum distillation or by steam sparging under vacuum distillation, at temperatures not greater than 500°F (260°C). If temperatures in excess of 500°F (260°C) are employed, the adduct will discolor. The steam sparging may be conducted so as to reduce the presence of unreacted amine in the adduct to an amount not greater than 0.5% by weight, based on the weight of the adduct. If unreacted amine is present in amounts greater than 0.5%, the pot life of the mixture of the curing agent and the polyepoxide which forms upon mixing the two components described herein will be reduced substantially. Many epoxy novolac resins are supplied by the manufacturer dissolved in a ketone which will interfere with the reaction between the novolac and the amine. In such cases it is necessary to remove the ketone prior to reaction between the novolac and the amine. This may be carried out by heating the epoxy novolac under vacuum and replacing the ketone with a hydrocarbon solvent such as toluene or xylene. Since the product at this point in the reaction scheme, after the epoxide resin has reacted with the polyamine, may be extremely "heavy", it is preferred that an oxygenated solvent or co-solvent as described hereafter, such as 2-propoxy ethanol, be added to the reaction mixture to reduce its viscosity. In general 20 to 50 percent by weight of 2-propoxy ethanol or another oxygenated solvent may be added at this point to control processing viscosity. When the epoxy-amine adduct formation has been completed and the unreacted amine has been removed, the end capping agent may be reacted therewith at a temperature of 65°C to 150°C for a time sufficient to bring the reaction to completion, typically 5 minutes to 3 hours. Lower temperatures may be employed at the expense of increasing the reaction time. The maximum amount of the end capper which can be reacted with the epoxy-amine adduct is influenced by whether a monoepoxide is employed as a diluent for the epoxy resin as described hereinafter. It has been found that if too many of the reactive amine groups of the epoxy-amine adduct are defunctionalized before or during reaction with the epoxy resin, either by reaction with the monoepoxide end capping agent or by eventual reaction with the diluent which can accompany the epoxy resin, then the epoxy resin will not react to the desired extent with the end capped adduct and the cured film will be soft and exhibit poor solvent resistance. The minimum amount of end capping agent which is reacted with the epoxy-amine adduct is controlled by the improvement in wettability sought to be imparted to the coating composition and the adverse effect on pot life which the presence of primary amines would impart to the coating composition. The presence of a significant amount of primary amines on the end capped epoxy-amine adduct in an aqueous system reduces the pot life of the system to an unacceptable extent due to their high reactivity and will result in either a rapid viscosity drop or increase depending on the molecular weight of the polyepoxide employed to prepare the epoxy-amine adduct. In addition, primary amine groups in the finished product tend to form amine carbonates producing undesirable amine "sweating". Thus, the amount of end capping agent must at least be sufficient to eliminate substantially the presence of primary amines on the epoxy amine adduct. Generally the maximum amount of the encapping agent should be no more than 1.2 moles per primary amine group. After the reaction has been completed, the material may be reduced in a solvent or co-solvent for the system. In general, the amount of the solvent that is added is not mere than 45% and is typically 5 to 45% by weight based on the weight of the adduct and co-solvent, preferably no more than 40%. Examples of the solvent include ethers, alcohols, glycol ethers and ketones. The preferred solvents are the glycol ethers such as the various lower alkyl ethers or ethylene and propylene glycol. After the above product has been prepared, it is salted using a volatile acid and then dissolved in water. The degree of salting of the epoxy amine adduct is herein defined to be the number of equivalents of acid sufficient to react with the total number of amine nitrogen equivalents in the end capped epoxy-amine adduct expressed as a percentage of the total number of amine nitrogen equivalents in the system. Thus, a 15% degree of salting indicates that the end capped epoxy-amine adduct has been reacted with sufficient acid to convert 15% of the amine nitrogens present on the adduct to their corresponding salt. The particular degree of salting is selected to control, as desired, a number of factors such as cure temperature, cure speed, pot life and dispersability. As the degree of salting increases, the cure time at a fixed temperature increases along with pot life. For industrial maintenance coatings the degree of salting is selected to achieve an ambient temperature curing system and the associated reduction in pot life at the lower degrees of salting is an acceptable trade off. In general, the end capped epoxy-amine adduct is reacted with sufficient acid to achieve a degree of salting of 2 to 65%, preferably 2 to 20%. The volatile acid used herein includes both organic and inorganic acids and is defined to be an acid which will substantially completely evaporate at the temperature at which drying and curing occur. The volatile organic acids may be aliphatic, cycloaliphatic, or heterocyclic and may be saturated or unsaturated. Representative examples of volatile organic acids include acetic acid, formic acid, propionic acid, butyric acid, acrylic acid, methacrylic acid, and cyclohexanoic acid. The preferred organic acid is an aliphatic monocarboxylic acid having up to 4 carbon atoms. Representative examples of volatile inorganic acids include hydrochloric acid, hydrobromic acid, and hydrofluoric acid. The preferred acids are acetic, formic and propionic acids. The salted end capped epoxy-amine adduct, in addition to acting as the principal film forming resin of the cured composition, acts as a surfactant aiding the incorporation of the epoxy resin into the two component blend and the subsequent formation of a very small particle size emulsion. The solids content of the salted end capped epoxy-amine adduct may be reduced, prior to mixing with the second component by dilution with water. Preferably the reduced solids content is in the range of 55 to 85%, by weight. The second component of the coating system is a low molecular weight, water dispersible (either alone or in the presence of a co-solvent) epoxy resin having more than one terminal epoxide group. The epoxy resins suitable for use in the second component include the glycidyl polyethers of dihydric phenols as well as epoxy novolac resins. The dihydric phenols employed to prepare the epoxy resins are further described in U.S. Patent No. 4,246, 148. It is particularly preferred to employ those glycidyl polyethers wherein the dihydric phenol is bisphenol -A. The maximum molecular weight of the epoxy resins is limited by the fact that the amount of epoxy resin employed in the second component is usually selected to achieve stoichiometric equivalence of epoxy groups with the amine hydrogen equivalents of the end capped epoxy-amine adduct. Consequently, as the molecular weight of the epoxy resin increases, thereby increasing the epoxide equivalent weight, more of the epoxy resin is required to satisfy the stoichiometric requirement. However, the use of large amounts particularly of higher molecular weight epoxy resin is not preferred because it is water insoluble and becomes increasingly difficult to microemulsify or disperse as the amount thereof is increased. In view of the above, it is preferred to characterize the epoxy resin also in terms of its epoxide equivalent weight. Thus the epoxide equivalent weight (WPE) of the glycidyl polyethers of dihydric phenols is generally not greater than 1000, preferably from 180 to 700. As described above, the amount of epoxy resin which is present in the coating composition is preferably sufficient to achieve substantially stoichiometric equivalence with the reactive amino hydrogens on the end capped epoxy-amine adduct. In general, it is preferred to employ the epoxy resin in an amount sufficient to achieve an epoxy to reactive adduct amine hydrogen equivalent weight ratio of from 0.5 : 1.0 to 1.5: 1.0, and, preferably, from 0.9: 1.0 to 1.1:1.0. The epoxy resins which are useful herein may be either liquids or solids. In the case of liquid epoxy resins, for example the diglycidyl ethers of bisphenol -A, it is possible to prepare a dispersion of the epoxy resin in the curing agent without the need to add a co-solvent or other surfactant. In these situations the salted curing agent acts as a surfactant to disperse the liquid epoxy resin. However, where the epoxy resin is solid, even in the presence of a co-solvent, the mere mixing of the epoxy resin curing agent and the epoxy resin often will not result in a permanent dispersion. Particularly as the viscosity of the curing agent increases above 10,000 cps (mPa.s), the presence of a diluent for the epoxy resin becomes more and more preferred. More importantly, however, in order to ensure that a stable dispersion is prepared, particularly with higher molecular weight epoxy resins, the use of a non-ionic surfactant of the polyether type is particularly preferred. These surfactants are well known and need not be described further. In general, the amount of such surfactant should not exceed 10% by weight, based on the total weight of the epoxy resin and the curing agent. The co-solvent/diluent which has been described above is more particularly described in US-A-4,246,148 at columns 12 to 14. When the epoxy resin and the curing agent are mixed, the resulting coating composition generally exhibits a pot life at room temperature of 2 hours to 12 days and preferably from 3 hours to 8 days. The pot life of the coating composition is herein defined to be the elapsed time from mixing the components together until the resulting composition is no longer suitable, with normal thinning, for application by spray,brush or roll coating techniques to a substrate. The suitability for application by common techniques can be expressed in terms of the viscosity of the coating composition. Thus, the pot life of unpigmented coatings can be characterized as the elapsed time from mixing the two components to the time when the viscosity of the coating compositions drops below A₁ or increases above Z as determined by the Gardner-Holdt method. For pigmented coatings, useful applications viscosities are between 50 and 140 Kreb Units (K.U.) as determined with a Stormer viscometer. Typically the viscosity of the coating composition will increase either until the microemulsion breaks, in which case the epoxy resin settles into a separate layer accompanied by a substantial reduction in viscosity, or until crosslinking reactions take place accompanied by a substantial increase in viscosity. Coatings based on the compositions described herein can be formulated into easily handled two-package systems which blend together as easily as their solvent based counterparts. Applications properties are excellent. Application by brush, spray and roller-coating are remarkably free of bubbling and other film imperfections. The coating systems described herein also exhibit good adhesion to such widely varied substrates as galvanized metal, cold rolled steel (untreated and phosphate treated), hot rolled steel, and aluminum Flash rusting is not a problem over untreated steel and, therefore, there is no need for special additives as in some water reducible epoxy systems. Adhesion is also excellent to three and four-year old alkyd and epoxy ester enamel films. Such systems may therefore be employed for repaint purposes in food processing plants and dairies and can also be used as adhesive compositions per se. Accordingly the invention also provides coating compositions which are curable at ambient temperature and which comprise an aqueous solution or dispersion of the epoxy resin curing agent of the invention in admixture with a polyepoxide. The invention also provides a substrate coated with a cured coating composition of the invention. The substrate may for example be an article such as a metal substrate to which the coating composition is directly applied, or a substrate previously coated with another coating (for example of an alkyd or epoxy ester enamel film ) over which the coating composition of the invention is applied. As pointed out above the major advantage of the coating compositions of the invention is that they are useful in preparing solvent and chemically resistant coating compositions from aqueous based systems. These systems do not exhibit the traditional solvent related problems shown by solvent based systems and accordingly are preferred in end-use applications where nonpolluting or nonflammable coatings systems are necessary. In addition, the cured state properties of compounds made from the curing agents herein are equivalent to the properties of compounds prepared from prior art solvent based systems. The invention is additionally illustrated in connection with the following Examples which are to be considered as illustrative of the present invention. All parts and percentages in the claims as well as in the remainder of the specification are by weight unless otherwise specified. EXAMPLES Example 1 Into a reactor equipped with a mechanical agitator, sampling tube, condensor and gas inlet tube were added 1500 parts of triethylene tetramine. A nitrogen sparge was begun and the material was heated to 200°F (93 °C). There was added 750 parts of an epoxy novolac resin. The resin was based upon DEN 438 available from the Dow Chemical Corporation dissolved in acetone. In order to be useful in this invention it was necessary to strip off the acetone and dissolve the resulting epoxy novolac polymer in toluene. The resin had an average epoxy functionality of 3.6, a solids content in toluene of 84% and a weight per epoxide (WPE) of 184. The resin was added to the reactor over a 1 hour and 20 minute period while the temperature was held at about 200°F (93°C). The mixture was then held at 195°F (91°C) for approximately 50 minutes. It was then heated gradually to 440°F (227°C) over approximately 2 hours under a vacuum of 10 Torr (1333.2 Pa). The mixture was then cooled to about 300°F (149°C), the vacuum was removed, and 558 parts 2-propoxy ethanol were added to the reactor at a temperature of about 245°F (118°C). 623 parts of cresyl glycidyl ether (WPE 182) were then added to the reaction mixture over a period of approximately half an hour. The mixture was held at about 260°F (127°C) for approximately half an hour, at which point 53 parts of acetic acid and 558 parts of 2-propoxy ethanol were added to the mixture. The resulting product exhibited a Gardner Holdt 25°C viscosity of Z₃ - Z₄, a solids content of 60.7% and an acid value of 29.7. Example 2 Utilizing essentially the same procedure as in Example 1, an acetic acid salt of an ambient temperature, epoxy resin, curing agent was prepared except that instead of 3.5 equivalents of cresyl glycidyl ether, 3.29 equivalents of cresyl glycidyl ether and 0.21 equivalents of butyl glycidyl ether (WPE 167) were employed. The resulting product exhibited a Gardner Holdt 25°C. viscosity of Z₄ - Z₅, a solids content of 60.1% and an acid value of 27.8. Example 3 Utilizing essentially the same procedure as described in Example 1, an ambient temperature curable, acetic acid salt of an epxoy resin curing agent was prepared in whcih the triethylene tetramine was replaced on an equivalent basis with meta-xylylene diamine. The resulting product exhibited a Gardner Holdt 25°C. viscosity of Z₄-Z₅ at 59.9% solids and an acid value of 26.5. Example 4 Utilizing essentially the same procedure as described in Example 1, an ambient temperature curable acetic acid salt of an epoxy resin curing agent was prepared in which the triethylene tetramine was replaced on an equivalent basis with diethylene triamine. The resulting product exhibited a Gardner Holdt 25°C. viscosity of Z₂- Z₃, a solids content of 60.0% and an acid value of 30.1. Example 5 Utilizing essentially the same procedure as described in Example 1, an epoxy resin curing agent was prepared except that the acetic acid was replaced with formic acid at 2% by weight level based on the product's solids content. The resulting product exhibited a Gardner Holdt 25°C. viscosity of Z₄ - Z₅, a solids content of 60.8 and an acid value of 24.9. Example 6 Utilizing essentially the same procedure as in Example 1, an epoxy resin curing agent was prepared except that the amount of triethylene tetramine used to react with the epoxy novolac was reduced from 10.5 moles as in Example 1 to 8 moles. In addition, 50% of the 2-propoxy ethanol was replaced on a weight basis with methyl isobutyl ketone. The resulting product exhibited a Gardner Holdt 25°C.viscosity of Z₄, a solids content of 58.9% and an acid value of 27.9. Examples 7 - 10 Blends were prepared as set forth in Table I below by mixing initially the epoxy resin, aqueous dispersion in the amounts indicated with water. The epoxy resin dispersion was a bisphenol-A based polyglycidyl ether having a weight per epoxide in the range of 600-700 and a solids content of 55% water. Such an epoxy resin dispersion is available from the Celanese Specialty Resins Company under the resin number W-55-5522. After the initial epoxy resin dispersion/water blend had been prepared a second blend of the epoxy resin curing agent prepared in Example 6 a titanium dioxide pigment and water was also prepared. The resulting products were then mixed and reduced to spray viscosity by adding 35 parts of water or in the case of Example 10, 25 parts of water. The blends were then spray applied to cold rolled steel panels to a thickness of about 2 mils (0.05 mm) and allowed to cure at room temperature for one week. In Table II are shown the hours-to-failure of the various coatings when subjected to the indicated tests. As can be seen from Table II, the compositions of this invention possess excellent cured state film properties even when subjected to a variety of chemical resistance tests.

Claims: A novolac based epoxy resin curing agent comprising a volatile acid salt of the reaction product of an epoxy novolac compound having, on the average, 3 to 7.5 epoxide groups per molecule, a primary-amine-containing polyamine, said polyamine containing at least 2 amine nitrogen atoms per molecule, at least 3 amine hydrogen atoms per molecule and no other groups reactive with epoxide groups, and a monoepoxide, wherein substantially all the epoxy groups are reacted with the polyamines and wherein substantially all the unreacted primary amine groups in the polyamine/epoxide reaction product groups are reacted with the monoepoxide, the said curing agent containing not more than 0.5% by weight of unreacted amine, and the said volatile acid being such that it will evaporate substantially completely at the temperature at which drying and curing occur. The curing agent of claim 1 wherein the epoxy novolac is the epoxidized reaction product of a phenol and an aldehyde. The curing agent of claim 1 wherein the novolac is a phenol/formaldehyde based novolac. The curing agent of claim 3 wherein the phenol is at least in part bisphenol-A. The curing agent of claim 1 wherein the novolac is based at least in part on glyoxal. The curing agent of any of claims 1-5 wherein the polyamine is a polyalkylenepolyamine. The curing agent of any of claims 1-5 wherein the polyamine has the formula: wherein n is 0 to 4 and R is an alkylene or arylene group containing 2 to 8 carbon atoms. The curing agent of claim 6 or 7 wherein the amine is selected from diethylenetriamine, triethylenetetramine, tetraethylenepentamine and metaxylylene diamine. The curing agent of any of claims 1-8 wherein the monoepoxide is an aromatic monoepoxide. The curing agent of any of claims 1 to 8 wherein the monoepoxide is cresyl monoglycidyl ether or cashew nut oil monoepoxide. The curing agent of any of claims 1-10, wherein the volatile acid is selected from formic acid, acetic acid and propionic acid. An ambient temperature curable coating composition comprising an aqueous solution or dispersion of the composition of any of claims 1-11, in admixture with a polyepoxide. The composition of claim 12 wherein the polyepoxide is a polyglycidyl ether of dihydric phenol. The composition of claim 13 wherein the dihydric phenol is bisphenol-A. The composition of any of claims 12-14 wherein the polyepoxide has a weight per epoxide no greater than 1000. The composition of claim 15 wherein the polyepoxide has a weight per epoxide of 180 to 700. The composition of any of claims 12-16 wherein the ratio of the epoxy groups in the polyepoxide to reactive amine hydrogen groups in the curing agent is in the range of 0.5 to 1.0 to 1.5 to 1.0. The composition of any of claims 12-17 in admixture with a co-solvent. The composition of claim 18 wherein the co-solvent is an oxygenated solvent. The composition of claim 19 wherein the co-solvent is a glycol based ether. A substrate coated with a cured coating composition in accordance with any of claims 12-20.

Inventors: DE GOOYER, WILLIAM J
Applicants: INTEREZ, INC. (A GEORGIA CORPORATION)
Application year: 1985
Main classification: C08G59
IPC codes: C08G59, C08L63