RESIN COMPOSITION FOR PAINT

Abstract: This improved resin compsn. contains a compsn. prepd. by graft polymerisation of a chlorinated polyolefin and an esterified unsatd. carbxylic acid, an esterified prod.of a ungrafted unsatd. carboxylic acid and an alcohol, and a urethane prepolymer compsn.. The urethane prepolymer compsn. is the reaction prod. of a polyol and an isocyanate monomer or its deriv.. The wt. ratio of the solid part of the esterified graft polymer compsn. to the solid part of the urethane prepolymer compsn. lies between 10:90-90:10. The chlorinated polyolefin is chosen from monomers or co-polymers of ethylene, propylene, 1-butene-3-methyl -1-butene. The unsatd. carboxylic acid contains a max. is 15C and at least one double-bond and is chosen from bifunctional carboxylic acids or their anhdyrides. The resin compsn. is produced by mixing a compsn. prepd. by graft polymerisation of a chlorinated polyolefin with an unsatd. carboxylic acid in a solvent and esterifying all of the unsatd. carboxylic acid in the system, wtih a urethane polymer in a solid ratio of 90:10 to 10:90..

Description: The present invention relates to a modified chlorinated polyolefin type coating resin composition. More particularly, the present invention relates to a novel valuable coating composition which can be applied as a primer to a variety of materials, and a process for the preparation of this coating composition. BACKGROUND ART Various resin lacquers have been developed and utilized as surface coating materials for motor vehicles and the like. However, these lacquers have merits and demerits and have poor general-purpose properties. Recently, however, a modified chlorinated polyolefin lacquer has been developed and utilized as a lacquer having an excellent solvent resistance and general-purpose properties. As typical instances of the prior art, there can be mentioned Japanese Unexamined Patent Publication No. 58-176207 and Japanese Unexamined Patent Publication No. 60-1214. The latter Japanese Unexamined Patent Publication No. 60-1214 teaches that, in order to overcome defects of a chlorinated polyethylene lacquer having an excellent weatherability, chemical resistance, flame resistance, resistance against thermal aging, flexibility, sanitary characteristics, and electric characteristics, a modified chlorinated polyethylene formed by graft-polymerizing an unsaturated carboxylic acid or an anhydride thereof to chlorinated polyethylene is used. Chlorinated polyethylene per se has a poor adhesiveness to metals and alloys such as iron, aluminum and steel, polar polymers and inorganic materials such as mica and glass, but a modified chlorinated polyethylene formed by graft-polymerizing an unsaturated carboxylic acid to chlorinated polyethylene, has an improved adhesiveness to these materials. However, this modified chlorinated polyolefin lacquer is defective in that the storage stability of the lacquer is poor because the graft polymer is crystallized at low temperatures. In this lacquer, the unsaturated carboxylic acid or its anhydride is left unreacted at the reaction step. In practice, it is difficult to completely remove the residual unsaturated carboxylic acid or anhydride from the lacquer. The unreacted unsaturated carboxylic acid produces a smell at the coating operation and this problem of smell generation is considered to be not negligible when carrying out the coating operation. The invention disclosed in the above-mentioned Japanese Unexamined Patent Publication No. 60-1214 relates to a reaction process in which any remaining unreacted unsaturated carboxylic acid is controlled as much as possible. Nevertheless, even if this process is adopted, it is impossible to completely remove the smell-producing unreacted unsaturated carboxylic acid from the coating composition. Apart from this problem of smell generation, an improvement of the poor storage stability owing to crystallization of the graft polymer at low temperatures is not attained by either this prior invention or the invention of the above-mentioned Japanese Unexamined Patent Publication No. 58-176207. Moreover, the coating compositions of these prior art techniques still have an unsatisfactory gasoline resistance, which is especially important for a primer for motor vehicles. In accordance with the present invention, there is provided a coating resin composition comprising: (a) the esterification product of a monohydric or polyhydric alcohol with: (i) a graft copolymer of a chlorinated polyolefin, having a degree of chlorination of 10 to 50% and 1 to 20 wt.%, based on the chlorinated polyolefin, of a monobasic or dibasic, unsaturated carboxylic acid or its corresponding anhydride, and with (ii) the remaining ungrafted unsaturated carboxylic acid or anhydride in the grafting reaction system of (i), wherein the alcohol is used in an amount of 0.5 to 2 equivalents for each equivalent of carboxyl groups of the unsaturated carboxylic acid, and (b) a urethane prepolymer which is a reaction product of a polyol and an isocyanate monomer or a derivative thereof, wherein the weight ratio of the solids of component (a) to the solids of component (b) is in the range from 10:90 to 90:10. Furthermore, in accordance with the present invention, there is provided a process for the preparation of a coating resin composition, which comprises reacting 100 parts of a chlorinated polyolefin having a degree of chlorination of 10-50% with 1 to 20% by weight of an unsaturated carboxylic acid or an anhydride thereof in a reaction solvent so that the proportion of the non volatile portion in the reaction system is adjusted to 10 to 50% by weight, mixing 100 parts of the obtained unsaturated carboxylic acid-grafted chlorinated polyolefin with a monohydric or polyhydric alcohol in an amount of 0.5 to 2 equivalents to the carboxyl groups of the unsaturated carboxylic acid to esterify the grafted unsaturated carboxylic acid and the ungrafted unsaturated carboxylic acid in the grafting reaction system, separately forming a urethane prepolymer by reaction of a polyol with an isocyanate, and mixing the composition of the grafting and esterification reaction system with the composition of the prepolymer-forming reaction system so that the weight ratio of the solids of the grafting and esterification reaction system to the solids of the prepolymer-forming reaction system is in the range of from 90/10 to 10/90. The first characteristic feature of the present invention resides in that, after an unsaturated carboxylic acid is graft-polymerized to a chlorinated polyolefin, esterification is carried out with an alcohol. By this esterification, not only the grafted unsaturated carboxylic acid but also the unsaturated carboxylic acid left unreacted at the grafting step is esterified. Accordingly, the volatilization temperature of the unsaturated carboxylic acid is elevated and, hence, the problem of smell generation, which has been a hindrance to the operation, can be prevented. The second characteristic feature of the present invention resides in that by the above-mentioned esterification, there can be unexpectedly attained an effect of improving the compatibility of the modified chlorinated polyolefin coating composition and, hence, a known urethane prepolymer composition which is used as a primer for a polyolefin material, for example as disclosed in Japanese Unexamined Patent Publication No. 60-186538 can be effectively mixed with this modified chlorinated polyolefin coating composition. By this mixing, the crystallization temperature of the modified chlorinated polyolefin resin can be lowered and, hence, the storage stability of this resin at low temperatures can be improved while retaining the excellent characteristics of this resin. Although the storage of conventional lacquers in winter requires a warm storehouse, in the case of the coating composition of the present invention, such a special measure becomes unnecessary. The gasoline resistance is prominently improved by the synergistic effect of the esterified modified chlorinated polyolefin resin with the urethane prepolymer. Furthermore, the adhesion characteristics of both compositions to various materials can be fully achieved without interference. Thus, it has been confirmed that the coating composition of the present invention shows an excellent adhesion to not only polyolefin materials but also non-polar resins, polar resins such as polyamides, PBT, PET, polyphenylene oxide, RIM, SMC, BMC, FRP and ABS, metals such as iron, aluminum, copper, lead, zinc, tin and nickel, alloys such as stainless steel and brass, and other inorganic substances. Preferably, the chlorination degree of the chlorinated polyolefin used in the present invention 20 to 40%. As typical instances of the polyolefin, there can be mentioned homopolymers and copolymers of ethylene, propylene, 1-butene and 3-methyl-1-butene. The carbon number of the unsaturated carboxylic acid is preferably not more than 15. In view of the effect of improving the gasoline resistance, a dibasic acid or an anhydride thereof is preferred as the unsaturated carboxylic acid. The amount of the unsaturated carboxylic acid is 1 to 20% by weight, preferably 5 to 15% by weight, based on the chlorinated polyolefin. If the amount of the unsaturated carboxylic acid is smaller than 1% by weight, the solvent resistance is insufficient, and if the amount of the unsaturated carboxylic acid exceeds 20% by weight, the adhesion to a polyolefin material is degraded, and since the solution becomes gelatious, the composition is not preferred as a lacquer. As the alcohol for the esterification, there can be mentioned monohydric alcohols such as methanol and ethanol and polyhydric alcohols such as ethylene glycol and glycerol. These alcohols may be used singly or in the form of mixtures of two or more thereof. As the polyol for formation of the urethane prepolymer, there may be used polyols having at least two OH groups in the molecule, such as polyethylene glycol, polytetramethylene glycol, and OH group-containing isoprene. As the isocyanate, there may be used isocyanate monomers and derivatives such as hexamethylene diisocyanate (HMDI), tolylene isocyanate (TDI), and diphenylmethane diisocyanate (MDI). Preferably, the polyol and isocyanate are incorporated in amounts such that the molar ratio of the OH groups to the NCO groups is in the range of from 10/1 to 10/7. The unsaturated carboxylic acid-grafted chlorinated polyolefine should be mixed with the urethane prepolymer so that the weight ratio of the solids of the composition of the esterified graft polymer and esterification product to the solids of the urethane prepolymer composition is in the range of from 10/90 to 90/10, preferably from 60/40 to 90/10. If this mixing ratio is in the range of from 10/90 to 60/40, the adhesion to a polyolefin material is relatively low. Preferably, the grafting reaction is carried out by using a radical polymerization initiator in which the half-value period at 100°C is 0.1 to 20 hours. An organic peroxide in which the half-value period at 100°C is 0.2 to 10 hours is especially preferred as the initiator. For example, there can be mentioned benzoyl peroxide, dilauryl peroxide, and diacetyl peroxide. In order to shorten the reaction time and reduce the manufacturing cost, preferably an amine such as triethylamine or an organic tin compound such as dibutyltin dilaurate is used as a urethanation catalyst for the urethane prepolymer-forming reaction. The resin composition of the present invention obtained under the above-mentioned conditions has the following excellent characteristics as a lacquer, especially as a primer. 1. The solvent resistance is good. 2. A high gasoline resistance is attained. 3. The storage stability at low temperatures is good. 4. Smell generation is controlled. 5. A good adhesion is achieved to not only polyolefin materials but also metals and polar group-containing plastic materials. 6. The steps for synthesizing the resin are very simple (vacuum removal of the residual monomer is not necessary). 7. All the pigments may be used as in case of ordinary coloring lacquers, and coloration of the resin composition is possible. Samples used for Examples 1 through 7 according to the present invention and Comparative Examples 1 through 3 were prepared according to the following processes. Production Examples A through E are examples illustrating the production of unsaturated carboxylic acid-grafted chlorinated polyolefin composition samples by the grafting reaction or by the grafting and esterification reaction. Production Example A A 4-neck flask equipped with a stirring rod, a thermometer and a cooling condenser, and having a capacity of 1000 ml was charged with 210 g of xylene and 90 g of chlorinated polypropylene having a chlorination degree of 29%, and the mixture was heated with stirring. When the temperature was elevated to 80°C, 5.4 g of maleic anhydride was added and uniformly dissolved. Then, 0.3 g of B.P.O. was added and the mixture was maintained at 85 to 90°C for 3 hours. Then, 0.3 g of B.P.O. was further added and the mixture was maintained at the same temperature for 3 hours. The temperature was then lowered to 80°C and 350 g of toluene and 7 g of ethyl alcohol were added, and the mixture was maintained at 80 to 85°C for 5 hours to complete the reaction. In Production Examples B, C, D and E, synthesis was carried out in the same manner as described above in Production Example A. The components used in these Production Examples are shown in Table I. Production Example F through H are examples illustrating the production of urethane prepolymer composition samples. These samples were prepared according to the following procedures. Production Example F A 4-neck flask equipped with a stirring rod, a thermometer and a cooling condenser, and having a capacity of 1000 ml was charged with 263 g of toluene and 80.7 g of liquid polyisoprene having at least two OH groups in the molecule and the mixture was heated with stirring. When the temperature was elevated to 80°C, 6.1 g of 4,4'-diphenylmethane diisocyanate was added and 0.3 g of a 10% toluene solution of dibutyltin dilaurate was added. The temperature was then elevated to 90°C and this temperature was maintained for 4 hours to complete the reaction. In Production Examples G and H, synthesis was carried out in the same manner as described above in Production Example F. The components used in these Production Examples are shown in Table 11. Production Example F Production Example G Production Example H OH-containing polyisoprene 23.1 34.7 PTMG 1000 12.3 MDI 1.74 1.74 0.86 10% Toluene solution of dibutyltin dilaurate 0.09 0.09 0.04 Toluene 75.1 40.4 86.8 Total 100.03 100.03 100.0 OH/NCO 10/5 10/3.3 10/2.5 The above-mentioned samples (Production Examples A through H) were mixed at a predetermined ratio (shown in Table III), and the mixture was blended at room temperature for about 10 to about 30 minutes by using an ordinary stirrer such as a disperser to form a homogeneous composition. Test plates were prepared according to the following procedures. 1. Substrate: substrate used in the example 2. Pretreatment: degreasing and wiping with IPA 3. Primer: the above composition 4. Coating method: air-spray coating 5. Coating thickness: 15 µm 6. Setting: 15 minutes (room temperature) 7. Top-coating: 1) Two-pack urethane lacquer: R-263 (supplied by Nippon Bee Chemical) 2) Coating method: air-spray coating method 3) Coating thickness: 35 µm 4) Baking conditions: 90°C x 30 minutes The test plates obtained in Examples 1 through 7 and Comparative Examples 1 through 3 were tested according to specific methods. The conditions and results are summarized in Table III. In Table III, mark "o" indicates that the plate passed the test, mark "x" indicates that the plate did not pass the test, and mark "▵" indicates that the plate narrowly passed the test. The tests were carried out in the same manner as in the Example and Comparative Examples except that a one-pack melamine baking type lacquer was used as the top-coating lacquer. The obtained results were substantially the same as those shown in Table III. Solvent Resistance Test Results of Coating Compositions of Examples and Comparative Examples The solvent resistance test was carried out according to the method shown in Table III and the test was conducted until the critical value was obtained. The obtained results are shown in Table IV. From these results, it is seen that the coating resin composition of the present invention has a remarkably superior gasoline resistance to the modified chlorinated polyolefin (Comparative Example 2) and the esterification product thereof (Comparative Example 1), and therefore, the coating resin composition of the present invention is superior. Volatile Oil Resistance Gasoline Resistance Example 1 more than 24 hours more than 24 hours Example 2 more than 24 hours more than 24 hours Comparative Example 1 more than 24 hours 16 hours Comparative Example 2 more than 24 hours 16 hours

Claims: A coating resin composition comprising: (a) the esterification product of a monohydric or polyhydric alcohol with: (i) a graft copolymer of a chlorinated polyolefin, having a degree of chlorination of 10 to 50% and 1 to 20 wt.%, based on the chlorinated polyolefin, of a monobasic or dibasic, unsaturated carboxylic acid or its corresponding anhydride, and with (ii) the remaining ungrafted unsaturated carboxylic acid or anhydride in the grafting reaction system of (i), wherein the alcohol is used in an amount of 0.5 to 2 equivalents for each equivalent of carboxyl groups of the unsaturated carboxylic acid, and (b) a urethane prepolymer which is a reaction product of a polyol and an isocyanate monomer or a derivative thereof, wherein the weight ration of the solids of component (a) to the solids of component (b) is in the range from 10:90 to 90:10. A resin composition as claimed in claim 1, wherein the urethane prepolymer is a reaction product of the polyol and the isocyanate monomer in amounts such that the molar ratio of OH groups to NCO groups is in the range from 10:1 to 10:7. A resin composition as claimed in claim 1 or claim 2, wherein the weight ratio of the solids of the composition of the esterified graft polymer and the esterification product to the solids of the urethane prepolymer composition is in the range of from 60/40 to A resin composition as claimed in any preceding claim, wherein the chlorinated polyolefin is a chlorination product of a polyolefin selected from homopolymers and copolymers of ethylene, propylene, 1-butene and 3-methyl-1-butene. A resin composition as claimed in any preceding claim, wherein the unsaturated carboxylic acid has up to 15 carbon atoms. A resin composition as claimed in claim 5, wherein the unsaturated carboxylic acid component is a dibasic carboxylic acid or an anhydride thereof. A process for the preparation of a coating resin composition, which comprises reacting 100 parts of a chlorinated polyolefin having a degree of chlorination of 10-50% with 1 to 20% by weight of an unsaturated carboxylic acid or an anhydride thereof in a reaction solvent so that the proportion of the non volatile portion in the reaction system is adjusted to 10 to 50% by weight, mixing 100 parts of the obtained unsaturated carboxylic acid-grafted chlorinated polyolefin with a monohydric or polyhydric alcohol in an amount of 0.5 to 2 equivalents to the carboxyl groups of the unsaturated carboxylic acid to esterify the grafted unsaturated carboxylic acid and the ungrafted unsaturated carboxylic acid in the grafting reaction system, separately forming a urethane prepolymer by reaction of a polyol with an isocyanate, and mixing the composition of the grafting and esterification reaction system with the composition of the prepolymer-forming reaction system so that the weight ratio of the solids of the grafting and esterification reaction system to the solids of the prepolymer-forming reaction system is in the range of from 90/10 to 10/90. A preparation process according to claim 7, wherein the molar ration of OH groups of the polyol to the NCO groups of the isocyanate in the prepolymer-forming reaction system is in the range of from 10/1 to 10/7. A preparation process according to claim 7 or claim 8, wherein the grafting reaction is carried out using a radical polymerization initiator in which the half-value period at 100°C is 0.1 to 20 hours.

Inventors: ASATO, IKUO, FUKUYAMA, ISAO, INOUE, AKIRA, NAGATANI, TOSHIKAZU
Applicants: NIPPON BEE CHEMICAL CO., LTD., SAKAI CHEMICAL INDUSTRIAL COMPANY LTD.
Application year: 1986
Main classification: C09D175
IPC codes: C09D151, C08F255, C09D175