PROCESS FOR THE PREPARATION OF A POLYETHER RESIN

Abstract: Process for the preparation of a polyether resin by reacting a diglycidyl ether of a dihydric phenol with an alcohol of formula R-C(CH₂OH)₃, R being C 1-5 -alkyl, using an equivalent ratio e OH to e epoxy > 1 and selecting P > 1.05, wherein F epoxy being the epoxy functionality of the diglycidyl ether.

Description: This invention relates to a process for the preparation of a polyether resin, to polyether resins prepared by this process, to curable coating compositions containing such resins, to a process for coating a surface by applying said composition and to the cured films obtained by this coating. Epoxy resins are well-known useful materials in the coating industry; they can be applied in combination with cross-linking agents of various types, such as amines, carboxylic compounds, amino-formaldehyde and phenol-formaldehyde resins, or they can be converted first to derivatives such as ethers, for specific applications, such as for protection of metal surfaces. For example, a process for the preparation of polyether resins as described in US-A-2,731,444 concerns reaction of an epoxy resin with an aliphatic polyhydric alcohol, using an excess of polyhydric alcohol with the resins, whereby all of the epoxide groups of the resins are reacted with part of the hydroxyl groups of the polyhydric alcohol. However, Examples 42 to 49 in this specification concern the use of an excess of polyhydric alcohol with respect to the epoxide resin with incomplete reaction of the epoxide resin to form a reaction product containing both unreacted epoxy and hydroxyl groups. This known process is carried out at a very high temperature, for example 250 °C. It is appreciated that the specification mentions reaction of all of the epoxide groups of the epoxy resin with part of the hydroxyl groups of the aliphatic polyhydric alcohols. However, a manner to achieve such a complete reaction is not disclosed. According to Example 42 an epoxy resin was reacted with tetra(hydroxymethyl)methane, using a ratio of hydroxy to epoxy of about 2 : 1. It can be calculated from this example that the epoxy group content of the polyether resin was 1.01 meq per g, corresponding to an epoxy group conversion of only 62%. Further heating of the reaction product containing both epoxy and hydroxyl groups resulted in the formation of a hard, infusible material which is hereinafter referred to as "gel". Such a gel is not suitable as a starting material for the preparation of curable coating compositions. The Applicant has amended Example 42 by using a higher ratio hydroxy to epoxy and a lower temperature, but this experiment also resulted in premature gelation. It has now surprisingly been found that by using a specific group of aliphatic polyhydric alcohols and by complying with a fundamental inequality, polyether resins can be obtained at a relatively low temperature and which are substantially free from epoxy groups without a gel being formed. Moreover, cured films prepared from polyether resins so obtained have very good properties in can and general industrial stoving application, for example a very good sterilization resistance, salt spray resistance and very good flexibility. Accordingly, the invention provides a process for the preparation of a polyether resin which process comprises reacting a diglycidyl ether of a dihydric phenol and which contains on average less than two epoxy groups per molecule and an alcohol of the general formula (A) in which R represents an alkyl group having less than 5 carbon atoms, in the presence of an etherification catalyst, until the reaction product obtained is substantially free from epoxy groups, using an equivalent ratio of greater than 1, in which e OH is the total number of hydroxy equivalents introduced by the alcohol of the general formula (A) and e epoxy is the total number of epoxy equivalents introduced by the diglycidyl ether, and selecting a value for P of greater than 1.05, P being calculated with the aid of formula (1) in which e OH and e epoxy are as defined hereinbefore and F epoxy is defined as 2a / b in which "a" and "b" are the concentrations of epoxy groups and of total end groups, respectively, in the starting diglycidyl ether. A polyether resin is substantially free from epoxy groups when it contains less than 0.15 meq epoxy groups per g of resin. The alkyl group represented by R in the general formula A is preferably a methyl or an ethyl group, the alcohol being 1,1,1-tri(hydroxymethyl)propane or 1,1,1-tri(hydroxymethyl)ethane. Preference is given to the former alcohol, because it melts at 58 °C. Therefore, this alcohol can act as a solvent which simplifies the preparation of the polyether. The latter alcohol, melting at 204 °C, does not have this advantage. The diglycidyl ether referred to hereinbefore is an epoxy resin and is preferably a diglycidyl ether of 2,2-bis(4-hydroxyphenyl)propane (DPP); the general formula of such diglycidyl ethers is in which Q represents the divalent radical obtained by removal of the two H atoms from the OH groups in the dihydric phenol and in which n may have an average value in the range of from 0 to 30. Theoretically diglycidyl ethers from a dihydric phenol have two terminal glycidyl groups per molecule, but in practice non-glycidyl terminal groups are present; these groups almost completely consist of 2,3-dihydroxypropoxy, monochlorohydroxypropoxy and hydroxyl groups. The value of "b" mentioned hereinbefore refers to the total of epoxy groups and these three non-glycidyl terminal groups. The diglycidyl ethers can be further defined by their "a" value which is the concentration of epoxy groups in the starting epoxy resin expressed in milligram equivalents per gram. Diglycidyl ethers of DPP having an "a" value from, for example, 3.5 to 6 are the so-called "liquid" epoxy resins; at room temperature the commercial products are viscous liquids. Diglycidyl ethers of DPP having an "a" value from 0.2 to 2.5 are solid resins and usually melt in the range of from 50 to 130 °C. In general, the concentration of non-glycidyl end groups increases with increasing value for n. Hence, the value for F epoxy decreases with increasing value for n, F epoxy being the ratio 2a : b. Further examples of epoxy resins having on average less than two epoxy groups per molecule are polyglycidyl ethers having on average n epoxy groups per molecule, where 1 < n ≦ 2, which ethers are the reaction product of a multifunctional polyglycidyl ether having on average x epoxy groups per molecule, where x > 2, with (x-n) mol of a monofunctional phenol per mol of the multifunctional polyglycidyl ether, as described in EP-A-0 0127 915. The process according to the present invention may schematically be represented by means of the following reaction equation: in which R is as defined as in formula (A), Q and n are as defined as hereinbefore and m may have an average value from 1 to, 10. The first requirement for preventing the formation of a gel is to select a ratio of the total number of hydroxy equivalents introduced by the alcohol of the general formula (A) to the total number of epoxy equivalents introduced by the diglycidyl ether which is greater than 1. In this manner, the chance of side reactions of epoxy groups with secondary hydroxy groups of the polyether resin and/or of the epoxy resin is smaller. Such side reactions would form branched structures which increase the danger of gel formation. Preferably, said ratio is not more than 5; the use of ratios of more than 5 is, however, not excluded. The second requirement for preventing the formation of a gel is the fundamental inequality referred to hereinbefore, i.e. P > 1.05, the value for P being calculated according to formula (1). Preferably, a value for P of not more than 3.0 and more preferably not more than 2.0 is selected. The reaction mixture obtained in the process according to the present invention contains unreacted alcohol of the general formula (A). This unreacted alcohol need not be separated from the polyether resin. However, it is preferred to separate unreacted alcohol from the polyether resin, because this results in cured film coatings having improved flexibility. The alcohol may be removed from the polyether resin by means of stripping, for example with steam, nitrogen or carbon dioxide. Examples of etherification catalysts are amines and Lewis acids, for example alkanoates and halides of iron, zinc, aluminium and boron, and alkali metal alcoholates of polyoxyalkylene polyols. According to a preferred embodiment of the present invention a stannous salt is used as an etherification catalyst. The stannous salt is preferably a salt of an alkanoic acid, particularly of those having in the range of from 2 to 30 carbon atoms per molecule. Very good results have been obtained with stannous octoate. Other preferred stannous salts are stannous halides, particularly stannous chloride. If desired the process according to the invention may be carried out in the presence of a suitable non-reactive solvent, for example hydrocarbons such as octane, nonane, decane, toluene, the three xylenes, ethylbenzene or isopropylbenzene; ethers such as 1,4-dioxane, diethyl ether of ethylene glycol, diethyl ether of diethylene glycol; chlorinated hydrocarbons such as monochlorobenzene. The process according to the present invention can be carried out at a temperature which is not critical and which may vary within wide limits, preferably in the range of from 100 °C to 250 °C and more preferably from 125 °C to 200 °C. Curable coating compositions may be prepared by addition of a cross-linking resin to the polyether resin prepared by the process according to the present invention. The amount of such cross-linking resins is usually in the range of from 5 to 50% by weight, calculated on the total of polyether resin and cross-linking resin. Examples of suitable cross-linking resins are those of the aminoplast-type, such as alkoxylated reaction products of formaldehyde with melamine or benzoguanamine. Other cross-linking agents include urea-formaldehyde resins, phenol-formaldehyde resins, and blocked polyisocyanates. Suitable catalysts which may be employed in the curable coating compositions are acids such as orthophosphoric acid or p-toluenesulphonic acid. These catalysts may be used in an amount in the range of from, 0.05 to 2% by weight, calculated on polyether resin and cross-linking resin. Other examples of suitable cross-linking resins are non-acidic polyesters of polycarboxylic acids which esters have more than one, and preferably at least two, beta-hydroxyl ester groups per molecule. When such polyesters are used, a transesterification catalyst should be present, for example transesterification-promoting metal compounds, for example, salts (e.g. octoates, acetates or naphthenates) of lead, zinc, calcium, barium and iron(III). A suitable example of a metal complex is titanium acetylacetonate. Other suitable salts, although in general less active than those mentioned above, are salts of tin(II), manganese, cobalt and dibutyltin, for example dibutyltin dilaurate. Further metal salts that can be mentioned in general are octoates and naphthenates of the alkali and alkaline earth metals, of the lanthanides, and of zirconium, cadmium, chromium, and acetylacetonate complexes of lead, zinc, cadmium, cerium, thorium and copper. Mixtures of such salts and/or complexes may be used. Metal content of the transesterification-promoting metal compounds should preferably be in the range 0.3 to 2 %w. Pigments, fillers, dispersing agents and other components known in the art of paint formulation may be added. The curable coating compositions can be applied by a variety of methods as known in the art, for example by spraying, dipping or roller coating. The coatings can be hardened by stoving, for example at temperatures from 100 to 300 °C, with curing times varying from, for example, 10 sec to 30 min. The invention will be further understood from the following examples. In each of these examples a roundbottom glass reactor was used which was equipped with an anchor stirrer, thermocouple, reflux condenser and inlet tubes. EPIKOTE is a trade name for commercial diglycidyl ethers of 2,2-bis(4-hydroxyphenyl)propane. Table 1 hereinafter states which EPIKOTE resins were used and mentions the values of "a" and "b" and "F epoxy " thereof. 1,1,1-Tri(hydroxymethyl)propane is referred to hereinafter as "TMP" and contained 22.4 meq OH per g. "Shellsol A" is a trade name for a hydrocarbon solvent having a boiling range at atmospheric pressure from 166 °C to 185 °C and containing 98% by volume of aromatic hydrocarbons. The xylene was a commercial mixture of the three xylenes. Cymel 301 is a trade name for a commercial liquid hexamethoxymethyl melamine, non-volatiles below 2% by weight. Phenodur PR 217 is a trade name for a commercial solution in butanol containing 65% by weight of a phenol-formaldehyde resin. The pigment component was red iron oxide and the filler component was ASP-100 which is a trade name for a clay. Examples 1 to 12 and Comparative Experiments A, B and C The reactor was charged with an EPIKOTE resin, TMP and a solvent and was heated until a homogeneous liquid was obtained. Then, stannous octoate was added and heating was continued at a temperature between 170 and 175 °C until the reaction product was substantially free from epoxy groups. Table 2 states which EPIKOTE resins were used, the equivalent ratio e OH : e epoxy and the value of P, calculated from this ratio and from the value of F epoxy given in table 1. Table 3 states the amount of the EPIKOTE resin, of TMP, of the solvent, which solvent was used, and the amount of stannous octoate. The reaction product obtained was cooled and further diluted with 1-methoxy-2-hydroxypropane until the diluted solution had a solids content of 50% by weight, the solids being the polyether resin and stannous octoate. Table 3 also states the time used for heating at a temperature between 170 and 175 °C, the amount of 1-methoxy-2-hydroxypropane used, the epoxy group content of the polyether resin at the end of the reaction time and the viscosity of the diluted solution at 23 °C. The epoxy group contents show that the reaction products in the Examples were substantially free from epoxy groups and that those obtained in the comparative experiments were not free therefrom. In each of the examples 1 to 12 the value of P was greater than 1.05 and a gel was not formed. In comparative experiments A, B and C the value of P was not greater than 1.05 and a gel was formed. Examples 13 to 16 The reactor was charged with an EPIKOTE resin and TMP and was heated until a homogeneous liquid was obtained. Then, stannous octoate was added and heating was continued at a temperature of 175 °C until the reaction product was substantially free from epoxy groups. Table 5 states which EPIKOTE resins were used and mentions the values of "a" and "b" and "F epoxy " thereof. Table 2 hereinbefore states which EPIKOTE resins were used, the equivalent ratio e OH : e epoxy and the value of P, calculated from this ratio and from the valve of F epoxy given in table 5. Table 3 hereinbefore states the amount of the EPIKOTE resin, of TMP and of stannous octoate. The reaction product obtained was allowed to adopt ambient temperature. The clear solid polyether resin thus obtained was dissolved in a mixture of 9 parts by weight of 1-methoxy-2-hydroxypropane and 1 part by weight of xylene to obtain a solution containing 50% by weight of solid material. The viscosity of the solution at 23 °C is given in table 3. Example 17 The reactor was charged with EPIKOTE 1007 (877 g, a = 0.570 meq per g, b = 0.824 meq per g, F epoxy = 1.38), TMP (42 g) and Shellsol A (92 g) and was heated until a homogeneous liquid was obtained, the equivalent ratio e OH : e epoxy being 1.88 and P being 1.35. Then, a solution (9.8 g) of stannous chloride dihydrate (2.45 g) in 3,6,9-trioxa-undecane was added and heating was continued for 5 h at a temperature of 160 °C until the reaction product was substantially free from epoxy groups, the epoxy group content of the polyether resin being 0.05 meq per g. The reaction product obtained was cooled and further diluted with 1-methoxy-2-hydroxypropane until the diluted solution had a solids content of 35.7% by weight. The viscosity of the diluted solution at 23 °C was 1.9 Pa.s. Example 18 The reactor was charged with EPIKOTE 1009 (624 g, a = 0.321 meq per g, b = 0.589 meq per g, F epoxy = 1.09), TMP (17 g) and Shellsol A (64 g) and was heated until a homogeneous liquid was obtained, the equivalent ratio e OH : e epoxy being 1.88 and P being 1.54. Then, a solution (6.8 g) of stannous chloride dihydrate (1.7 g) in 3,6,9-trioxa-undecane was added and heating was continued for 3 h at a temperature of 170 °C until the reaction product was substantially free from epoxy groups, the epoxy group content of the polyether resin being 0.08 meq per g. The reaction product obtained was cooled and further diluted with 1-methoxy-2-hydroxypropane until the diluted solution had a solids content of 35.7% by weight. The viscosity of the diluted solution at 23 °C was 6.9 Pa.s. In the Examples 19 to 36, 40 and 41 curable clear coating compositions were prepared and evaluated as can coatings using the following four tests. "MEK rubs" is the number of double rubs given to the cured coating with a cloth wetted with methyl ethyl ketone until the coating was wiped off. The wedge bend test is a test for flexibility and is for testing the suitability as a can coating: a coated tin plate panel is bent over a 3 mm mandrel, impacted into a wedge shape, and immersed for 3 min in an aqueous solution containing 2.5% by weight of CuSO₄ and 2.5% by weight of HCl; thereby any breaks in the film will be stained, and the staining is recorded in mm continuous staining per 10 cm total length of the panel. The scale is from 100 bad to 0 excellent. The sterilization resistance concerns immersion for 90 min at 121 °C of the coated panels in water or a 2% by weight solution of lactic acid in water. The blush of the film is judged visually. The scale is from 0 bad to 5 unaffected. The pasteurization resistance concerns immersion of the coated panels in a 1% by weight solution of lactic acid in water for 30 min at 80 °C. The blush of the film is judged visually. The scale is from 0 bad to 5 unaffected. Examples 19 to 27 Curable clear coating compositions were prepared by mixing the diluted solutions obtained in Examples 1, 3, 5, 7, 9, 10, 16, 17 and 18 with Cymel 301 in a weight ratio polyether resin to Cymel 301 of 80 : 20 until a homogeneous mixture was obtained, followed by addition of a 10% by weight solution of orthophosphoric acid in 1-methoxy-2-hydroxypropane, 0.175% by weight of H₃PO₄ calculated on the total of polyether resin and Cymel being used, and 1-methoxy-2-hydroxypropane until the curable coating composition contained 35% by weight of solids. The curable coating compositions were tested as can coating materials by applying them with a bar coater onto tin plate panels. The panels were dried for 3 min at ambient temperature. After stoving for 3 min at the temperature mentioned in table 6 hereinafter the film was 6 micrometres thick and had the following properties:- The data presented in table 6 show that the cured film had a very high sterilization and pasteurization resistance and a very good flexibility. Examples 28 to 36 Curable clear coating compositions were prepared by mixing the diluted solutions obtained in Examples 1, 3, 5, 7, 9, 10, 16, 17 and 18 with Phenodur PR 217 in a weight ratio polyether resin to phenol-formaldehyde resin of 70 : 30 until a homogeneous mixture was obtained, followed by addition of a 10% by weight solution of orthophosphoric acid in 1-methoxy-2-hydroxypropane, 0.3% by weight of H₃PO₄ calculated on the total of polyether resin and Phenodur PR 217 being used, and 1-methoxy-2-hydroxypropane until the curable coating composition contained 35% by weight of solids. The curable clear coating compositions were tested as can coating materials by applying them with a bar coater onto tin plate panels. The panels were dried for 3 min at ambient temperature. After stoving for 10 min at the temperature mentioned in table 7 hereinafter the film was 6 micrometres thick and had the properties stated in table 7 hereinafter. The data presented in table 7 show that the cured films had a very high sterilization resistance and a very good flexibility. Examples 37 to 39 Curable pigmented coating compositions were prepared by mixing polyether solution (160 g), Cymel 301 (20 g), red iron oxide (92 g), clay (8 g), butyl OXITOL (120 g, "butyl OXITOL" is a trade name for 2-butoxyethanol), butanol (50 g) and orthophosphoric acid (0.25 g) using a high speed stirrer and glass pearls for grinding of the pigment particles. Stirring was continued until the pigment particles had a size below 10 micrometres. Table 8 hereinafter states which polyether solutions were used. The curable pigmented coating compositions were tested by applying them with a bar coater onto galvanized steel panels known under the trade name of BONDER 1303. The panels were dried for 20 min at ambient temperature. After stoving for 15 min at 200 °C the film was 20 to 25 micrometres thick and had the properties stated in Table 8 hereinafter. The MEK double rubs were determined in the manner described hereinbefore. Impact strength is reverse impact strength determined according to the British Standard Falling Ball Test. An impact strength of at least 90 cm.kg is considered as very good. Salt spray resistance was determined according to ASTM-B-117-64 and is recorded as mm loss of adhesion measured from scratch after 30 days. Salt spray resistances of less than 5 mm are considered as very good. The appearance of the coatings after the salt spray test was very good to excellent. Example 40 The experiment of Example 5 was repeated with the difference that xylene (52 g) was not present and that the reaction time was not 7.0 but 6.0 h. The epoxy group content of the polyether resin was 0.06 meq/g and the content of free TMP was 5.7% by weight. The reaction product obtained was allowed to adopt ambient temperature. A first portion of the clear solid polyether resin thus obtained was dissolved in a mixture of 9 parts by weight of 1-methoxy-2-hydroxypropane and 1 part by weight of xylene to obtain a solution containing 50% by weight of solid material (solution A). This solution had a viscosity at 23 °C of 4.7 Pa.s. A second portion of the clear solid polyether resin was subjected to steam stripping for 0.5 h at a temperature of 180 °C and a pressure of 0.25 bar. The stripped polyether resin contained 3.0% by weight of free TMP and was dissolved in a mixture of 9 parts by weight of 1-methoxy-2-hydroxypropane and 1 part by weight of xylene to obtain a solution containing 50% by weight of solid material (solution B). Curable clear coating compositions and cured films were prepared from solutions A and B in the same manner as described in Examples 28 to 36. The films obtained had the properties stated in Table 9 hereinafter. Table 9 shows that removal of TMP results in an enhanced flexibility of the coating and does not affect the MEK resistance and sterilization resistance. Example 41 The reactor was charged with EPIKOTE 828 (371 g, a = 5.390 meq per g, b = 5.422 meq per g, F epoxy = 1.99) and 1,1,1-tri(hydroxymethyl)ethane (150 g, 25 meq OH per g), e OH : e epoxy being 1.88 and P being 1.13. The reactor was heated to a temperature of 140 °C, stannous octoate (2.6 g) was added and the reactor was further heated to 170 °C at which temperature a clear solution was obtained. After heating for 8 h at this temperature the reaction mixture was allowed to adopt ambient temperature. A clear solid mass was obtained which had an epoxy group content of 0.07 meq per g. The solid mass was dissolved in a mixture of 9 parts by weight of 1-methoxy-2-hydroxypropane and 1 part by weight of xylene to obtain a solution containing 50% by weight of solid material. This solution had a viscosity at 23 °C of 3.2 Pa.s. A curable clear coating composition was prepared and applied in the same manner as in Examples 19 to 27 and the cured film was prepared by stoving for 3 min at 170 °C. The film obtained had the following properties:- Comparative Experiment D The reactor was charged with EPIKOTE 828 (371 g, a = 5.390 meq/g, b = 5.422 meq/g) and tetra(hydroxymethyl)methane (171 g, 29.4 meq OH per g), e OH : e epoxy being 2.52, and was heated to 170 °C, at which temperature stannous octoate (2.7 g) was added. After keeping the mixture at 170-175 °C for 2.5 h the polyether resin formed had an epoxy group content of 1.97 meq/g. After further heating in this temperature range for 1.5 h a gel was formed. This Comparative Experiment shows that the use of tetra(hydroxymethyl)methane and of a very high ratio OH to epoxy results in the formation of a gel and not in a polyether resin which is substantially free from epoxy groups.

Claims: A process for the preparation of a polyether resin which process comprises reacting a glycidyl ether of a dihydric phenol which contains on average less than two epoxy groups per molecule and an alcohol of the general formula (A) in which R represents an alkyl group having less than 5 carbon atoms, in the presence of an etherification catalyst, until a reaction product is obtained containing less than 0.15 meq epoxy groups per g of resin using an equivalent ratio of greater than 1, in which e OH is the total number of hydroxy equivalents introduced by the alcohol of the general formula (A) and e epoxy is the total number of epoxy equivalents introduced by the diglycidyl ether, and selecting a value for P of greater than 1.05, P being calculated with the aid of formula (1) in which e OH and e epoxy are as defined hereinbefore and F epoxy is defined as 2a / b in which "a" and "b" are the concentrations of epoxy groups and of total end groups, respectively, in the starting diglycidyl ether. A process as claimed in claim 1 in which R in the general formula (A) is a methyl or an ethyl group. A process as claimed in claim 2 in which the alcohol of the general formula (A) is 1,1,1-tri(hydroxymethyl)propane. A process as claimed in any one of the preceding claims in which the dihydric phenol is 2,2-bis(4-hydroxyphenyl)propane. A process as claimed in any one of the preceding claims in which an equivalent ratio hydroxyl groups in formula (A) to epoxy groups in the diglycidyl ether of not more than 5 is used. A process as claimed in any one of the preceding claims in which a value for P of not more than 3.0 is selected. A process as claimed in any one of the preceding claims which is carried out at a temperature in the range of from 100 °C to 250 °C. Polyether resins obtainable by a process as claimed in any one of the preceding claims. A curable coating composition comprising a polyether resin as claimed in claim 8 and a cross-linking resin. A process for coating a surface which comprises applying to the surface a curable coating composition as claimed in claim 9, and curing the composition by action of heat.

Inventors: DIJKSTRA, TETTE JAN, SCHOLTEN, HENRICUS, VAN IPEREN, ROELAND
Applicants: SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1987
Main classification: C08G59
IPC codes: C09D163, C09D171, C08G59, C08G65