Curable oil-in-water emulsions, methods of preparing the same and uses thereof

Abstract: Provided is a curable, oil-in-water emulsion which comprises an aqueous medium having substantially homogeneously emulsified therein a non-aqueous substantially homogeneous emulsifiable composition comprising a mixture of an unblocked polyisocyanate crosslinking agent and a surface active isocyanate reactive material. Also provided is a method of producing such curable, oil-in-water emulsion, as well as the use thereof in a variety of coatings applications.

Description: The present invention relates to curable, oil-in-water emulsions comprising an aqueous medium which contain an unblocked polyisocyanate crosslinker and a surface active isocyanate reactive material. The present invention also relates to methods of preparing such curable emulsions, as well as uses thereof particularly in coatings applications. Isocyanate crosslinked systems are in general well known. As an example, polyurethane films can be formed from coating compositions based upon polyols and polyisocyanate crosslinking agents. Polyurethane coatings can be formulated to provide fast curing characteristics, as well as a desirable combination of abrasion resistance, flexibility, adhesion, chemical resistance and appearance characteristics in the resulting films. Due to the reactivity of isocyanates with active hydrogen containing compounds, including water, polyurethane coatings have historically been formulated as two-component organic solvent based systems. One-component systems, both organic solvent based and waterborne (see GB1530021 and GB1530022), have also been formulated by blocking of the isocyanate groups via well-known blocking agents. Despite the excellent films which can be achieved with some of these systems, and particularly the two-component organic solvent based systems, the coatings industry is under great pressure to reduce the environmentally undesirable emission of volatile organic compounds (VOC), which includes the organic solvent media as well as the common blocking agents. One means of doing so, of course, would be to exchange some or all of the liquid organic solvent medium with water. Unfortunately, the switch from organic solvents to water is neither a simple nor straightforward matter, particularly in the case of common isocyanate crosslinkers which are not only reactive with water, but are also hydrophobic and non-dispersible. Several approaches to lowering the VOC of polyurethane coatings are discussed N.T. Cullen, "Low-VOC Polyurethane Coatings: Current Successes and Promising Developments," American Paint & Coatings Journal , August 19, 1991, pp. 44-49 and 64. One such approach has been to preform a water-dispersible film-forming polyurethane polymer by reacting a polyisocyanate with a hydrophilic reactive component, then dispersing the so-preformed hydrophilic polymer in water. A variation on this approach disclosed in GB1162409 is to preform the polyurethane polymer in situ in the aqueous medium with the aid of non-reactive surfactants. A still further variation on this approach is described in EP-A-0369389, in which a lower molecular weight water-dispersible prepolymer containing residual isocyanate functionality is first formed by reaction of a mixture of isocyanates with a polyol chain containing hydrophilic groups, after which the prepolymer is dispersed in water and chain extended or crosslinked. Upon application of these preformed polymer systems to a substrate, films are formed primarily via physical drying mechanisms due to evaporation of the liquid medium (water). While such preformed polyurethane systems can significantly reduce emitted VOC's, they often can suffer from application and stability problems. In addition, films produced from such systems can suffer from poor water resistance due to the hydrophilic nature of the preformed polymers or surfactants remaining after cure. In another approach disclosed in GB-A-2018796 and US4663377, an emulsifiable polyisocyanate mixture comprising (a) a hydrophilic isocyanate functional oligomer and (b) a polyisocyanate, is produced by partially reacting a polyisocyanate with, for example, a hydrophilic polyether alcohol. Curable coating and adhesive compositions can be formed by combining these polyisocyanate emulsions with separate aqueous resins. The emulsifiable polyisocyanate mixtures of these references, however, suffer from low isocyanate content which results from the destruction of some of the isocyanate groups when the polyisocyanate is allowed to partially react with the polyether, as well as the destruction of some of the isocyanate groups due to the reaction with water upon and after emulsification. Predictably, a low isocyanate content would severely reduce the ability of these polyisocyanate mixtures to function as efficient crosslinkers in coating compositions. In addition, these polyisocyanate emulsions suffer from stability problems due to the reaction of isocyanate groups with water, particularly those on the hydrophilic component (a). In a similar approach disclosed in US5202377, an emulsifiable polyisocyanate mixture comprising (a) a hydrophilic tertiary isocyanate functional oligomer and (b) a polyisocyanate having tertiary isocyanate groups, is produced by partially reacting a polyisocyanate containing tertiary isocyanate groups with a hydrophilic polyether. Coating compositions can be formed by combining (i) these polyisocyanate emulsions with (ii) separate aqueous solutions, emulsions or dispersions of film-forming polymers containing isocyanate-reactive functionality. These emulsifiable mixtures are said to produce more stable emulsions than those of US4663377 due to the lower reactivity of tertiary isocyanate groups. Despite the lower reactivity of the tertiary isocyanate groups, coatings produced from these emulsions may still suffer from low isocyanate content as well as stability problems. EPO 654,055 B1 discloses a water-thinable coating material containing A) 40 to 95% by weight of a binder vehicle which contains OH-groups as an aqueous dispersion of a polymer resin, B) 60-5% by weight of one or more polyisocyanates containing more than one free isocyanate group and C) optionally one or more additional binder vehicles customary pigments, extenders and/or customary lacquer additives and adjuvant substances. Still another approach to reducing the VOC of isocyanate crosslinked systems is found in US5075370 (corresponding to DE 3829587 A1). This reference generically discloses an aqueous coating composition comprising an aqueous solution and/or dispersion of a surface active isocyanate reactive resin (anionic olefinic polyol) into which a specific relatively low viscosity liquid unblocked polyisocyanate crosslinker is emulsified. The disclosed aqueous coating compositions are produced by emulsifying the isocyanate crosslinker into the aqueous solution and/or dispersion of the isocyanate reactive resin. It has, however, been found that, when systems were prepared in accordance with the teachings of US5075370 (emulsification of the isocyanate into the aqueous resin solution/dispersion), that the isocyanates do not properly incorporate into the resin solution/dispersion nor is an acceptable emulsion produced. After a short period of time a two phase system results, and films obtained from such systems display poor appearance characteristics, are hazy, contain microblisters, and have little or no gloss. It is the object of the present invention to provide a curable, oil-in-water-emulsion and a method of producing the same which avoids the above mentioned drawbacks. This object is solved by the emulsion of independent claim 1, the method of independent claim 14, the coating composition of independent claim 27, the clear coat according to independent claim 28, the method of coating a substrate according to independent claim 29 and the article coated with a cured film according to independent claim 30. Further advantageous features, aspects and details of the invention are evident from the dependent claims, the description and the examples. The claims are to be understood as a first non-limiting approach to define the invention in general terms. It has surprisingly been discovered that superior results are obtainable when, in contrast to the procedure of US5075370, a curable oil-in-water emulsion is prepared by a process which includes the step of contacting a non-aqueous substantially homogeneous emulsifiable composition with water as its last step. In contrast to the systems of the above mentioned art, the emulsions prepared by the process of the present invention are substantially homogeneous. On standing, they do not separate into two phases and have a relatively long pot life before gelation. When cured, films obtained from curable emulsions prepared in accordance with the present invention have surprisingly improved physical and appearance characteristics over films from curable systems prepared in accordance with the process of US5075370. Furthermore, by proper selection of the emulsion components, films can be obtained which possess outstanding clarity and gloss, and contain minimal or no microblisters. In accordance with the broadest aspects of the present invention, there is provided a curable, oil-in-water emulsion comprising an aqueous medium having substantially homogeneously emulsified therein a non-aqueous substantially homogeneous emulsifiable composition comprising a mixture of an unblocked polyisocyanate crosslinking agent and a surface active isocyanate reactive material. Optionally, such curable, oil-in-water emulsion may also comprise one or more of a neutralizing agent for rendering the surface active isocyanate material water-dispersible, a relatively minor amount of an organic solvent, a cure catalyst, and other well known auxiliaries and additives suited for the particular end use. The present invention further provides a method of producing such curable, oil-in-water emulsion comprising the steps of: (a) admixing the components of the non-aqueous emulsifiable composition as described above; and thereafter (b) contacting such emulsifiable composition and an aqueous medium in proportions and under conditions so as to result in a substantially homogeneous, oil-in-water emulsion. The present invention still further provides a method for coating a substrate by applying such substantially homogeneous, curable oil-in-water emulsion onto a substrate and, thereafter, curing said emulsion either at ambient or elevated temperatures depending upon the components and ultimate end use. Finally, the present invention provides an article coated with a cured film derived from such a substantially homogeneous, curable, oil-in-water emulsion. Advantages of the various aspects of the present invention include the following: (1) the emulsifiable compositions of the invention are substantially homogenous, a property which facilitates the formation of substantially homogeneous curable emulsions; (2) the curable emulsions of the present invention are substantially homogenous and do not separate into two phases; (3) the curable emulsions of the present invention have a long pot life prior to gelation thereby providing a longer time period in which to coat a substrate; (4) the curable emulsions of the present invention can be formulated to cure efficiently at room temperature, making it usable in situations where ambient cure is necessary, such as in automotive refinish applications; (5) the curable emulsions of the present invention can also be formulated to cure at elevated temperatures, making them suitable for use in high performance coating applications; (6) the curable emulsions of the present invention have reduced VOC emission and, therefore, are particularly suitable for use in situations where environmental concerns or regulatory requirements preclude the use of high VOC solvent based systems; and (7) by proper component selection, films can be obtained from the curable emulsions which possess excellent appearance, physical and resistance characteristics, even comparable to that of organic solvent based systems. These and other features and advantages of the present invention will be more readily understood by those skilled in the art from a reading of the following detailed description. As indicated above, the present invention provides, in its broadest concept, a non-aqueous emulsifiable composition comprising a substantially homogeneous mixture of: (1) an unblocked polyisocyanate crosslinking agent; and (2) a surface active isocyanate reactive material. The Unblocked Polyisocyanate Crosslinking Agent Polyisocyanate crosslinking agents are generally well known in the art and have been extensively used in coating compositions in a monomeric, oligomeric and/or polymeric form. To function as an effective crosslinking agent, the polyisocyanate must have at least two reactive isocyanate groups. As suitable polyisocyanate crosslinking agents for use in the present invention may be mentioned any liquid or solid organic polyisocyanate containing at least two reactive isocyanate groups. In addition, such polyisocyanate crosslinking agents should in and of themselves be substantially hydrophobic and non-dispersible in water. Suitable polyisocyanate crosslinking agents may contain aliphatically, cycloaliphatically, araliphatically and/or aromatically bound isocyanate groups. Mixtures of polyisocyanates are also suitable. Particularly preferred are those polyisocyanates containing aliphatically, cycloaliphatically and/or araliphatically bound polyisocyanates including, but not limited to, the following specific examples: hexamethylene diisocyanate; 2,2,4-trimethylhexamethylene diisocyanate; 2,4,4-trimethylhexamethylene diisocyanate; meta-α,α,α',α'-tetramethylxylylenediisocyanate (commercially available under the trade designation m-TMXDI® aliphatic isocyanate from Cytec Industries Incorporated, West Paterson, New Jersey); para-α,α,α',α'-tetramethylxylylenediisocyanate (available under the trade designation p-TMXDI® aliphatic isocyanate from Cytec Industries Incorporated, West Paterson, New Jersey); 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl cyclohexane (isophorone diisocyanate, abbreviated as IPDI); bis(4-isocyanatocyclohexyl)methane (hydrogenated MDI); biuret derivatives of various diisocyanates including, for example, hexamethylene diisocyanate (commercially available under the trade designation Desmodur® N of Miles Inc., Pittsburgh, Pennsylvania); uretdione derivatives of various diisocyanates including, for example, hexamethylene diisocyanate and IPDI; isocyanurate derivatives of various diisocyanates including, for example, hexamethylene diisocyanate (commercially available under the trade designation Desmodur® N 3390 of Miles Inc., Pittsburgh, Pennsylvania) and IPDI (commercially available under the trade designation IPDI® T 1890 polyisocyanate of Huls America, Inc., Piscataway, N.J.); and urethane adducts of diisocyanates with polyols such as, for example, ethylene glycol, propylene glycol, neopentyl glycol, trimethylolpropane, pentaerythritol and the like, as well as oligomeric and polymeric polyols. The preferred polyisocyanate crosslinking agents are those having at least one non-primary isocyanate group, and especially such polyisocyanates which are derivatives (e.g., urethane adducts, isocyanurates, biurets, uretidiones) obtained from diisocyanates having at least one non-primary isocyanate group (e.g., TMXDI and IPDI). Particularly preferred are the urethane diisocyanate/polyol adducts, more preferably those having an NCO content of at least 10 wt% (on a 100% solids basis), and especially those wherein the diisocyanate contains at least one non-primary isocyanate group. Particularly preferred are such urethane adducts having an average NCO functionality of greater than 2, and especially the diisocyanate/trimethylolpropane adducts. An especially preferred example of such is the 3:1 meta-α,α,α',α'-tetramethylxylylenediisocyanate/trimethylolpropane adduct commercially available under the trade designation CYTHANE® 3160 aliphatic polyisocyanate of Cytec Industries Incorporated, West Paterson, New Jersey, which has the following properties: Non-Volatiles (% by wt) 80 NCO Content (% by wt on Solution) 11 Solvent (1:1) Butyl Acetate/Methyl Ethyl Ketone Viscosity, 25°C (mPa @ 80%) 12,000-15,000 Another example of a diisocyanate/trimethylolpropane adduct is a 3:1 IPDI/trimethylolpropane adduct commercially available under the trade designation SPENLITE® P 25-A4-60 aliphatic urethane prepolymer of Reichhold Chemicals, Research Triangle Park, North Carolina. The Surface Active Isocyanate Reactive Material The surface active isocyanate reactive material contains both (i) functionality capable of reacting with isocyanate groups, as well as (ii) hydrophilizing functionality capable of rendering the surface active isocyanate reactive material water dipersible. In this manner, in the curable emulsions the reactive material acts as a surfactant for emulsifying the isocyanate crosslinkers, and in the final film the surface active material is incorporated into the crosslinked network by virtue of its reactivity with the isocyanate crosslinkers, leading to improved water resistance. The preferred surface active isocyanate reactive material is polymeric in nature, with the hydrophilizing groups and isocyanate reactive functionality being incorporated into the polymer via appropriate monomer selection or subsequent modification. As examples of such may be mentioned olefinic copolymers based on carboxyfunctional ethylenically unsaturated monomers and hydroxyfunctional ethylenically unsaturated monomers; polyesters based on polybasic carboxylic acids and polyhydric alcohols; polyurethanes based on polyisocyanates, polyhydric alcohols and hydroxy acids; polyepoxy esters; and the like. Especially preferred for use in the present invention are the olefinic copolymers. Isocyanate reactive functionality, as utilized herein, refers to functionality which is reactive with isocyanate groups under cure conditions of the curable emulsions. Such isocyanate reactive functionality is generally well known to those skilled in the coatings art and includes, most commonly, active hydrogen containing functionality such as hydroxyl and amino groups. Hydroxyl is typically utilized as the isocyanate reactive functionality in coatings and is preferred for use in the present invention. Hydrophilizing functionality is also generally well known to those skilled in the coatings art and includes, most commonly, anion generating, cation generating and hydrophilic non-ionic functionality. By anion generating and cation generating is meant functionality such as carboxyl (anion generating) or amino (cation generating) which, when appropriately neutralized, becomes hydrophilic in nature. Hydrophilic non-ionic functionality is, in and of itself, hydrophilic in nature. The amount of hydrophilizing functionality present in the isocyanate reactive material should, upon at least partial neutralization of the anion generating or cation generating groups (if present), be sufficient to render the isocyanate reactive material water-dispersible. Besides the aforementioned carboxyl groups, other examples of suitable groups which generate anions upon neutralization include sulfonic and phosphoric groups. Besides the aforementioned amino groups (substituted and unsubstituted), other examples of suitable groups which generate cations upon neutralization may be mentioned substituted and unsubstituted sulphonate groups, and substituted and unsubstituted phosphite groups. As examples of suitable hydrophilic non-ionic functionality may be mentioned amine oxide, phosphine oxide, alkyl or aryl phosphate, and polyether (polyethylene oxide). Preferred hydrophilizing groups for most applications are those which generate anions upon neutralization and, particularly, the carboxyl and sulfonic groups. Especially preferred are carboxyl groups. When coating compositions are formulated from the emulsifiable compositions of the present invention, it is especially preferred that the polyisocyanate crosslinker and the surface active isocyanate reactive material comprise the primary film-forming components of the coating. In such a case, the surface active isocyanate reactive material should possess the following characteristics: a number average molecular weight (Mn) of from 1000 to 50000, and preferably from 1000 to 12000; an acid number of from 15 to 150 mg KOH/g resin, preferably from 20 to 70 mg KOH/g resin, and especially from 20 to 35 mg KOH/g resin; and an amount of hydroxyl groups of from 2.5 wt% to 6 wt%, preferably from 3 wt% to 5 wt%, and especially from 3.5% to 4.5 wt% (100% solids basis). In addition, for ambient cure systems the surface active isocyanate reactive material should have a low glass transition temperature (Tg), preferably below 0°C Particularly preferred surface active isocyanate reactive materials comprise copolymers of (meth)acrylic acid, hydroxyalkyl (meth)acrylates and, optionally, other free-radically polymerizable monomers which, when polymerized, meet the above characteristics. As exemplified by the previously incorporated references, production of such copolymers is well-known to those skilled in the relevant art and need not be discussed further. It should be noted that, for applications such as electrodeposition, the common hydrophilizing functionality is cation generating. Especially preferred in this case are amino groups, and similar constraints to those set forth above (with the exception of acid number being exchanged for amine equivalency) would apply to the surface active isocyanate reactive materials utilized in forming curable emulsions for this application. Although the polyisocyanate crosslinker and the surface active isocyanate reactive material can be present in the emulsifiable compositions in varying amounts, when these components comprise the primary film-forming components of a subsequently formed coating, it is preferred that they be present in the emulsifiable compositions in amounts such that the NCO:NCO reactive functionality ratio is in the range of from 0.5:1 to 2:1, and especially in the range of from 0.8:1 to 1.2:1. Optional Ingredients As indicated earlier, the emulsifiable compositions may also comprise additional ingredients such as, for example, neutralizing agents for rendering the surface active isocyanate material water-dispersible, cure catalysts and relatively minor amounts of an organic solvent. When an anion generating group is present on the isocyanate reactive material, any base may be used as the neutralizing agent to produce an anionic surface active material. Normally, a base capable of converting a carboxyl group to a carboxylate anion is used as the neutralizing agent, including organic and inorganic bases such as sodium and potassium hydroxide, sodium and potassium carbonate, and amines such as ammonia, primary, secondary and tertiary amines. Tertiary amines and ammonia are preferred. Similarly, when a cation generating group is present on the isocyanate reactive material, any acid may be used as the neutralizing agent to produce a cationic surface active material. As discussed in further detail below, when utilized the neutralizing agents may be present in the emulsifiable composition, the aqueous medium into which the emulsifiable composition is emulsified or both. In any case, the total amount of neutralizing agent must at least be sufficient to render the surface active isocyanate reactive material water dispersible. Cure catalysts for isocyanates are well known to those skilled in the relevant coatings art. When cure catalysts are utilized, preferred are organometallic catalysts and, particularly, organotin compounds such as dibutyltin di-2-ethylhexoate, dibutyltin diisooctyl maleate, dibenzyltin di-2-ethylhexoate, dibutyltin dilaurate, dimethyltin dilaurate, tetrabutyl diacetoxy distannoxane, tetramethyl diacetoxy distannoxane, tetrapropyl diacetoxy distannoxane, dibutyltin dichloride, and the like. In another preferred embodiment, no additional such cure catalyst is added, particularly when an amine is utilized as the neutralizing agent for an anion generating group on the isocyanate reactive material. The organic solvents present in the emulsifiable compositions are generally those present in the various components. For example, many coatings components are not commercially available on a 100% solids basis but are rather a somewhat lower solids content in an appropriate solvent. Preferably, no other organic solvent is or need be added to the emulsifiable compositions (or emulsions) to achieve acceptable results. Depending on their end use, the emulsifiable compositions of the present invention may also comprise other well known auxiliaries and additives typically utilized in the coatings industry including, for example, foam inhibitors, levelling aids, pigments, pigment dispersing aids, dyes, UV absorbers and other stabilizing additives, and the like. These other additives are well known to those skilled in the relevant art and need not be discussed further. Process for Preparing the Curable Emulsions and the Curable Emulsions So Prepared As mentioned above, the substantially homogeneous, curable, oil-in-water emulsions in accordance with the present invention are produced by the steps of: (a) admixing the components of the non-aqueous emulsifiable composition as described above; and thereafter (b) contacting such emulsifiable composition and an aqueous medium in proportions and under conditions so as to result in a substantially homogeneous, oil-in-water emulsion. As is evident, a key aspect to obtaining improved results is to first prepare the emulsifiable composition, then to subsequently mix the emulsifiable composition and the aqueous medium so as to result in a substantially homogenous oil-in-water emulsion. The emulsions can be prepared by any number of well known techniques, but are preferably prepared by adding the aqueous medium, either continuously or in portions, to the emulsifiable composition under mixing conditions until phase inversion occurs. Additional aqueous medium can then be added to adjust the emulsions to the desired solids content and viscosity. In the aforementioned procedure, the neutralizing agent (if utilized) may comprise a portion of the emulsifiable composition (preneutralization of the surface active isocyanate reactive material) and/or a portion of the aqueous medium (neutralization during emulsification). In either case, sufficient neutralizing agent should be present in total in order to render the surface active isocyanate reactive material water-dispersible. The aqueous medium may comprise solely water or may, as indicated above, comprises other components such as the neutralizing agent. Other than the neutralizing agent, the aqueous medium may also include any one of a number of other auxiliaries and additives common to the end use, as well as minor amounts of water-miscible organic solvents to ease emulsification or adjust viscosity, although this is not preferred. It is preferred that any such additional ingredients be incorporated into the emulsifiable compositions; in other words, it is preferred that the aqueous medium comprise solely water, or comprise water and a neutralizing agent. Via the above procedure, substantially homogenous, curable, oil-in-water emulsions can be produced which may find use in a variety of fields including, for example, coatings and adhesives applications. Without being bound by any structure or theory, it is believed that the superior properties of such emulsions and films from such emulsions are the direct result of a unique microstructure in the emulsion achievable via the order of addition described above. Coating Compositions A primary utility of the curable emulsions of the present invention is in the coatings industry, for example, in automotive original equipment manufacturing (OEM), industrial maintenance, electrodeposition and, particularly, ambient temperature cure automotive refinish applications. It is also usable in architectural, coil, can, plastic and wood coating applications. The curable emulsion may be utilized in clearcoat applications, or may contain a pigment for other applications. An especially preferred application for the curable emulsions of the present invention is as an ambient temperature cure, automotive refinish clearcoat. Coatings obtained from the curable emulsions of the present invention may be applied to a variety of substrates in any desirable manner, such as by roller coating, spraying, brushing, sprinkling, flow coating, dipping, electrostatic spraying and electrophoresis. Depending on the ultimate end use, coatings may be formulated as ambient or elevated temperature cure systems. For example, for refinish coatings applications the coatings will be formulated for ambient cure, whereas for automotive original equipment manufacturing (OEM) applications the coatings will be formulated for cure at elevated temperatures of, typically, 125°C. The foregoing more general discussion of the invention will be further exemplified by the following specific examples offered by way of illustration and not limitation of the above-described invention. EXAMPLES EXAMPLE 1 Production of Surface Active Isocyanate Reactive Material Urethane grade propylene glycol monomethyl ether acetate (655 g) was added to a 5 liter reactor equipped with a stirrer, a reflux condenser, and a thermocouple under a blanket of nitrogen and heated in an oil bath to 90°C. A monomer feed mixture (1725 g total) consisting of butyl acrylate (48.38 wt %), 2-hydroxyethyl acrylate (21.07 wt %), methyl methacrylate (20.46 wt %), acrylic acid (6.16 wt %), 2,2'-azobis-2-methylbutyronitrile (2.97 wt %), and 1-octanethiol (0.96 wt %) was added to the reactor using a piston metering pump over a period of 235 minutes. During this period, the temperature of the reaction mixture reached a maximum of 101°C. After an additional 40 minutes, 10.3 g of a 20 wt% solution of 2,2'-azobis-2-methylbutyronitrile in urethane grade propylene glycol monomethyl ether acetate was charged and the reaction mixture was stirred at a temperature of 92°C to 98°C for an additional 86 minutes to produce a carboxyfunctional isocyanate reactive material as the reaction product. The solids content of the product was 72.0 wt % by the pan solids method (heating 1.00 g of sample in an aluminum dish at 105°C for 1 hour). The material had an acid number of 28 mg KOH/g resin (by titration). The amount of hydroxyl groups, after correcting for the acidity of the product, was 3.5 wt % (100% solids basis). By High Pressure Size Exclusion Chromatography (HPSEC), the number averaged molecular weight of the product was 7,200 relative to a polystyrene standard, with a polydispersity of 2.5. Production of Curable Emulsion A To 6.8 g of the surface active isocyanate reactive material produced above were added, under stirring, the following components in the listed order to produce an emulsifiable composition: 0.25 g triethylamine, 0.41 g of a 10 wt % solution of dibutyltin dilaurate in urethane grade propylene glycol monomethyl ether acetate, and 4.0 g of CYTHANE® 3160 aliphatic polyisocyanate resin (80 wt% solids in a mixture of 1:1 methyl ethyl ketone/normal butyl acetate). To this emulsifiable composition were added, at room temperature, eight portions of water (15.5 g total), with the resulting mixture being stirred after each addition to give a substantially homogeneous oil-in-water curable emulsion. Curable Emulsion A contained 30 wt % of non-volatiles and an NCO/OH equivalent ratio of 1:1. Volatile organic compounds (VOC) were present at a level not more than 0.4536 kg/3.78 l (1.0 lb/gal.) Curable Emulsion A displayed an opalescent appearance, bluish tint and uniform consistency, and had a gel time of more than 8 hours. Production of Curable Emulsions B, C and D Curable Emulsions B, C and D were produced in a manner identical to Curable Emulsion A with the ingredients listed below. The NCO/OH equivalent ratio of each was 1:1. CURABLE EMULSION: B C D Surface Active Material (g) 6.8 6.8 6.8 Triethylamine (g) 0.25 0.25 0.25 10% Dibutyltin Dilaurate solution in propyleneglycol monomethyl ether acetate (g) 0.42 0.37 ---- 1% Dibutyltin Dilaurate solution in propyleneglycol monomethyl ether acetate (g) ---- ---- 0.14 Polyisocyanate (g) SPENLITE® P25-A4-60 5.7 ---- ---- IPDI® T1890 ---- 3.5 ---- DESMODUR® N 3390 ---- ---- 2.2 Water (g) (Added Last) 14.5 13.8 13.6 GEL TIME (Hours) 8+ 2.5 4.0 APPEARANCE Milky Milky Milky TINT Bluish ----- ----- CONSISTENCY Uniform Uniform Slightly Gritty Drawdowns of Curable Emulsions A-D were made on BONDERITE® 100 ED-11 primed steel panels, a product of Advanced Coating Technologies, Southfield, MI., using a #52 wire cator applicator. Wet films of 100 to 300 µm thickness corresponding to a dry film thickness 25 to 75 µm were obtained. The films were cured either at room temperature (TABLE 1, COATINGS E, F, G and H) or at a super ambient temperature (TABLE 2, COATINGS I, J and K) as indicated below to produce high gloss coatings. Appearance, film properties, and resistance properties of the coatings are summarized in TABLE 1 and TABLE 2. PROPERTIES OF SUPERAMBIENT TEMPERATURES CURED COATINGS FROM CURABLE EMULSION A Film Thickness (mils) 1.4 Film Thickness (mm) 0.036 NCO/OH Ratio 1:1 COATINGS I J K Cure 30 MIN./120°C 30 MIN./60°C 30 MIN./60°C Followed by 7 Days at Room Temp. Knoop Hardness 14.8 3 11.5 MEK Rubs (Mar/Remove) 200+ 60/200+ 200+ EXAMPLE 2 Curable Emulsion L was prepared in a manner and with ingredients identical to Emulsion A, except that the water and triethylamine were combined first, then added to a mixture of the remaining ingredients. The NCO/OH equivalent ratio was 1:1. A drawdown of Curable Emulsion L was prepared in accordance with the procedure set forth in Example 1, and the film obtained was cured for 10 days at room temperature to a film thickness of 0.038 mm (1.5 mils). The resulting dried film was clear with no grit, blisters or pinholes, possessed a Knoop Hardness of 5.0, and withstood 200+ MEK double rubs. COMPARATIVE EXAMPLE 1 A surface active isocyanate reactive material was produced in an identical manner to that set forth in EXAMPLE 1 except that the solvent used was butyl acetate. This material was dispersed in a water/ammonia solution by following the procedure disclosed in column 8, lines 27 to 40 of the previously incorporated US5075370. The butyl acetate was removed by adding the hydroxyfunctional material to water and azeotroping the volatiles. Occasionally, an amount of water equal to the amount of water azeotroped was added back into the mixture. The azeotroping procedure was repeated until all the butyl acetate was removed. The pH of the remainder was 7, so it was not necessary to add additional ammonia solution. The resulting aqueous product had a solids level of 25.8%. In the manner taught by US5075370, an attempt was made to prepare a curable emulsion by adding the ingredients in the amounts shown below: (1) Aqueous Product (g) 20.5 (2) Water (g) 3.38 (3) 10% Dibutyltin Dilaurate solution in propyleneglycol monomethyl ether acetate 0.42 (4) CYTHANE® 3160 (80% Solids) (g) 4.0. The above aqueous product and additional water were combined first and, thereafter, the polyisocyanate ingredient and the cure catalyst were added. The NCO/OH equivalent ratio was 1:1 and the level of the non-volatiles was 30 weight %. An attempt was made to admix the above ingredients by hand-stirring and also by using a high shear air stirrer. Both methods, however, produced a milky-white two phase system with an appreciable amount of grit. When the stirring was stopped, two distinct layers were obtained. Because of the two phase nature of the formulation, it was not possible to make a drawdown thereof. COMPARATIVE EXAMPLE 2 The water dispersed carboxyfunctional material "G" was prepared by repeating the procedure disclosed in column 8, lines 8 to 40 of the previously incorporated US5075370. The aqueous product obtained in this manner had a solids level of 24.2%. In the manner taught by US5075370, an attempt was made to prepare a curable emulsion by adding the ingredients in the amounts shown below: (1) Aqueous Product (g) 14.5 (2) Water (g) 3.5 (3) DESMODUR® N3390 polyisocyanate (50% solids in Solvesso 100) (g) 4.0 The aqueous product and additional water were combined first and, thereafter, the polyisocyanate ingredient was added. The NCO/OH equivalent ratio was 1:1 and the level of the non-volatiles was 25 weight %. While the resulting emulsion (EMULSION M) did not gel, it was a non-uniform and unstable emulsion which gave a heavy precipitate on standing 1 to 2 hours at room temperature. Two drawdowns of Emulsion M were prepared as in Example 1 and cured as set forth in Table 3. Appearance, film properties and resistance properties of the resulting films are summarized in TABLE 3. PROPERTIES OF FILMS PREPARED ACCORDING TO US5075370 Film Thickness (mils) 1.40 Film Thickness (mm) 0.025 NCO/OH Ratio 1:1 COATINGS N O Cure 9 Days at Room Temp. 30 Min./125°C Film Appearance Hazy Microblisters Hazy Microblisters MEK Rubs (Mar/Remove) 200+ 200+ Gloss 60° 14 4 20° 3 1 As can be seen from the results of Comparative Examples 1 and 2, neither acceptable emulsions nor films could be achieved by following the disclosure of US5075370.

Claims: A curable, oil-in-water emulsion comprising an aqueous medium, an unblocked polyisocyanate crosslinking agent and a surface active isocyanate reactive material, characterized in that the emulsion comprises the aqueous medium having substantially homogeneously emulsified therein a non-aqueous substantially homogeneous emulsifiable composition comprising a mixture of the unblocked polyisocyanate crosslinking agent and the surface active isocyanate reactive material. The curable, oil-in-water emulsion of claim 1, characterized in that the unblocked polyisocyanate crosslinking agent has at least two reactive isocyanate groups and/or contains at least one non-primary isocyanate group, and/or is in and of itself substantially hydrophobic and non-dispersible in water. The curable, oil-in-water emulsion of claim 2, characterized in that the unblocked polyisocyanate crosslinking agent comprises a urethane adduct of a diisocyanate containing at least one non-primary isocyanate group with a polyol. The curable, oil-in-water emulsion of claim 3, characterized in that the polyol is trimethylolpropane. The curable, oil-in-water emulsion of claim 2, characterized in that the unblocked polyisocyanate crosslinking agent comprises an isocyanurate derivative of a diisocyanate containing at least one non-primary isocyanate group. The curable, oil-in-water emulsion of claim 3, characterized in that the diisocyanate is meta-α,α,α',α'-tetramethylxylylenediisocyanate. The curable, oil-in-water emulsion of one of claims 3 to 5, characterized in that the diisocyanate is isophorone diisocyanate. The curable, oil-in-water emulsion of one of the preceding claims, characterized in that the surface active isocyanate reactive material contains isocyanate reactive functionality, hydrophilizing functionality and/or is polymeric in nature. The curable, oil-in-water emulsion of claim 8, characterized in that the hydrophilizing functionality is anionic. The curable, oil-in-water emulsion of claims 8 or 9, characterized in that the emulsion further comprises a neutralizing agent for the hydrophilizing functionality. The curable, oil-in-water emulsion of one of the preceding claims, characterized in that no cure catalyst is added. The curable, oil-in-water emulsion of one of the preceding claims, characterized in that the surface active isocyanate reactive material possesses the following characteristics: a number averaged molecular weight of from 1000 to 50000, an acid number of from 15 to 150 mg KOH/g resin, and an amount of hydroxyl groups of from 2.5 wt% to 6 wt% (on a 100% solids basis). The curable, oil-in-water emulsion of one of the preceding claims, characterized in that the unblocked polyisocyanate crosslinking agent and the surface active isocyanate reactive material are present in amounts such that isocyanate:isocyanate reactive functionality ratio is in the range of from 0.5:1 to 2:1. A method of producing a substantially homogeneous, curable, oil-in-water emulsion comprising the steps of: (a) admixing (1) an unblocked polyisocyanate crosslinking agent and (2) a surface active isocyanate reactive material, to produce a non-aqueous, substantially homogenous, emulsifiable composition; and thereafter (b) contacting the emulsifiable composition and an aqueous medium in proportions and under conditions so as to result in a substantially homogeneous, oil-in-water emulsion. The method of claim 14, characterized in that the unblocked polyisocyanate crosslinking agent has at least two reactive isocyanate groups and/or contains at least one non-primary isocyanate group, and/or is in and of itself substantially hydrophobic and non-dispersible in water. The method of claim 15, characterized in that the unblocked polyisocyanate crosslinking agent comprises a urethane adduct of a diisocyanate containing at least one non-primary isocyanate group with a polyol. The method of claim 16, characterized in that the polyol is trimethylolpropane. The method of one of claims 15 to 17, characterized in that the unblocked polyisocyanate crosslinking agent comprises an isocyanurate derivative of a diisocyanate containing at least one non-primary isocyanate group. The method of claim 16 or 17, characterized in that the diisocyanate is meta-α,α,α',α'-tetramethylxylylenediisocyanate. The method of one of claims 16 to 19, characterized in that the diisocyanate is isophorone diisocyanate. The method of one of claims 14 to 20, characterized in that the surface active isocyanate reactive material contains isocyanate reactive functionality, hydrophilizing functionality and/or is polymeric in nature. The method of claim 21, characterized in that the hydrophilizing functionality is anionic. The method of claim 21 or 22, characterized in that the emulsion further comprises a neutralizing agent for the hydrophilizing functionality. The method of one of claims 14 to 23, characterized in that no cure catalyst is added. The method of one of claims 14 to 24, characterized in that the surface active isocyanate reactive material possesses the following characteristics: a number averaged molecular weight of from 1000 to 50000, an acid number of from 15 to 150 mg KOH/g resin, and an amount of hydroxyl groups of from 2.5 wt% to 6 wt% (on a 100% solids basis). The method of one of claims 14 to 25, characterized in that the unblocked polyisocyanate crosslinking agent and the surface active isocyanate reactive material are present in amounts such that isocyanate:isocyanate reactive functionality ratio is in the range of from 0.5:1 to 2:1. A coating composition comprising the curable, oil-in-water emulsion as set forth in any one of claims 1-13, or the curable oil-in-water emulsion produced by the method of any one of claims 14-26. An ambient temperature curable, automotive refinish clearcoat comprising the curable, oil-in-water emulsion as set forth in any one of claims 1-13, or the curable oil-in-water emulsion produced by the method of any one of claims 14-26. A method of coating a substrate comprising the steps of: (a) applying to the substrate the coating composition of claim 27 or claim 28, and thereafter (b) curing the so-applied coating. An article coated with a cured film derived from the curable, oil-in-water emulsion as set forth in any one of claims 1-13, or the curable oil-in-water emulsion produced by the method of any one of claims 14-26.

Inventors: FIORI DENISE ELIZABETH, QUINN RICHARD J, FIORI, DENISE ELIZABETH, QUINN, RICHARD J.
Applicants: CYTEC TECH CORP, CYTEC TECHNOLOGY CORP.
Application year: 1995
Main classification: C08G18
IPC codes: B01J13, C08G18, B05D7, C09D175, C08F2, C08J5