Hydroxylic acrylate copolymer process for its preparation, and coating agent based on the acrylate

Abstract

The invention relates to a hydroxylic acrylate copolymer which contains a proportion of copolymerized monomers having at least 2 double bonds, and to the process for the preparation of the acrylate copolymer. The invention also relates to coating agents which contains acid-curable binders, organic solvents and, if appropriate, pigments, fillers and conventional assistants and additives and which contain, as the essential binder, the hydroxylic acrylate copolymer and an alkylated melamine/formaldehyde resin. The invention also relates to coating agents which, as the essential binders, contain the hydroxylic acrylate copolymer in one or more different polyfunctional isocyanates.

Description

The invention relates to a hydroxylic acrylate copolymer produced by copolymerization of acrylates having at least 2 olefinically unsaturated (sic) double bonds, hydroxylic monomers and further olefinically unsaturated monomers.

EP-A No. 103,199 has disclosed an acrylate copolymer of the abovementioned type. EP-A No. 103,199 has also disclosed the processing of the copolymer of the abovementioned type with a suitable crosslinking agent to give a coating agent. An etherified amine/formaldehyde resin is mentioned inter alia as a crosslinking agent.

Moreover, EP-A No. 64,338 has disclosed an acid-curable coating agent based on an acrylate copolymer and a melamine/formaldehyde resin.

It is the object of the present invention to provide a crosslinkable acrylate copolymer and coating agents which are based on the crosslinkable acrylate copolymer and have an improved fastness to gasoline and an improved resistance to long-term exposure to water or steam.

The object is achieved by a hydroxylic acrylate copolymer of the abovementioned type, which has been obtained from

(a.sub.1) 10 to 60% by weight, preferably 15 to 60% by weight, of hydroxylic esters of acrylic/methacrylic acid, having 2 to 14 carbon atoms in the alkali radical, (a.sub.2) 3 to 25% by weight, preferably 5 to 20% by weight, of monomers having at least 2 polymerizable olefinically unsaturated (sic) double bonds, and (a.sub.3) 15 to 82% by weight, preferable 40 to 70% by weight, of further polymerizable monomers having one olefinically unsaturated (sic) double bond, the sum of components a.sub.1, a.sub.2 and a.sub.3 being 100% by weight.

Compounds of the general formula ##STR1## where R=H or CH.sub.3,

X=O, N or S n=2 to 8, can advantageously be used as the component a.sub.2.

Examples of such compounds are hexanediol diacrylate, hexanediol dimethacrylate, glycol diacrylate, glycol dimethacrylate, butanediol diacrylate, butanediol dimethacrylate and similar compounds.

The component a.sub.2 can advantageously also be a reaction product of a carboxylic acid having a polymerizable olefinically unsaturated (sic) double bond and glycidyl acrylate and/or glycidylmethacrylate, or a polycarboxylic acid or unsaturated monocarboxylic acid esterified with an unsaturated alcohol.

Moreover, the component a.sub.2 can advantageously be a reaction product of a polyisocyanate and an unsaturated alcohol or amine. The reaction product of one mol of hexamethylene diisocyanate and 2 mol of allyl alcohol may be mentioned as an example.

Another advantageous component a.sub.2 is a diester of polyethylene glycol and/or polypropylene glycol of a mean molecular weight of less than 1500, preferably less than 1000, and acrylic and/or methacrylic acid. According to the invention, acrylates having more than 2 ethylenically unsaturated (sic) double bonds, for example trimethylolpropane triacrylate or trimethylolpropane trimethacrylate, can also be used as the component a.sub.2. Of course, combinations of these polyunsaturated monomers can also be used.

The component a.sub.1 can especially be a hydroxyalkyl ester of acrylic and/or methacrylic acid, having a primary hydroxyl group, for example hydroxyethyl acrylate, hydroxypropyl acrylate, hydroxybutyl acrylate, hydroxyamyl acrylate, hydroxyhexyl acrylate, hydroxyoctyl acrylate and the corresponding methacrylates.

Advantageously, the component a.sub.1 can at least partially be a reaction product of one mol of hydroxyethyl acrylate and/or hydroxyethyl methacrylate and, on average, 2 mol of .epsilon.-caprolactone.

Advantageously, up to 75% by weight, and particularly preferably up to 50% by weight, of the component a.sub.1 can also be a hydroxylic acrylic and/or methacrylic acid ester with a secondary hydroxyl group, in particular a reaction product of acrylic and/or methacrylic acid and the glycidyl ester of a carboxylic acid having a tertiary .alpha.-carbon atom. 2-Hydroxypropyl acrylate, 2-hydroxybutyl acrylate, 3-hydroxybutyl acrylate and the corresponding methacrylates may be mentioned as examples.

The choice of the further polymerizable monomers of component a.sub.3 is not particularly critical. These can be chosen from the group comprising styrene, vinyltoluene, acrylic acid, methacrylic acid, alkyl esters of acrylic and methacrylic acid, alkoxyethyl acrylates and aryloxyethyl acrylates and the corresponding methacrylates, and the esters of maleic and fumaric acids. Examples of these are methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, ssopropyl acrylate, isobutyl acrylate, pentyl acrylate, isoamyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, octyl acrylate, 3,5,5-trimethylhexyl acrylate, decyl acrylate, dodecyl acrylate, hexadecyl acrylate, octadecyl acrylate, octadecenyl acrylate, pentyl methacrylate, isoamyl methacrylate, hexyl methacrylate, 2-ethylbutyl methacrylate, octyl methacrylate, 3,5,5-trimethylhexyl methacrylate, decyl methacrylate, dodecyl methacrylate, hexadecyl methacrylate, octadecyl methacrylate, alkoxyethyl acrylates or methacrylates, such as butoxyethyl acrylate or butoxyethyl methacrylate, methyl methacrylate, ethyl methacrylate, propyl methacrylate, isopropyl methacrylate, butyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, acrylonitrile, methacrylonitrile, vinyl acetate, vinyl chloride and phenoxyethyl acrylate. Other monomers can be used, unless they cause undesirable properties of the copolymer.

The invention also relates to a process for the preparation of an acrylate copolymer as claimed in any of claims 1 to 11, which comprises copolymerizing, for its preparation,

(a.sub.1) 10 to 60% by weight, preferably 15 to 60% by weight, of hydroxylic esters of acrylic and/or methacrylic acid, having 2 to 14 carbon atoms in the alkyl radical, (a.sub.2) 3 to 25% by weight, preferably 5 to 20% by weight, of monomers having at least 2 polymerizable olefinically unsaturated (sic) double bonds and (a.sub.3) 15 to 82% by weight, preferably 40 to 70% by weight, of further polymerizable monomers having one olefinically unsaturated (sic) double bond, in an organic solvent with the addition of polymerization initiators and polymerization regulators to give a precrosslinked, ungelled product, the sum of the components a.sub.a, a.sub.2 and a.sub.3 being 100% by weight.

Care must be taken in order to obtain a precrosslinked, but ungelled copolymer. Surprisingly, a clear, transparent, ungelled solution of a branched copolymer can be prepared by means of suitable polymerization conditions. The use of monomers having at least 2 ethylenically unsaturated groups causes precrosslinking of the copolymer molecules, but due to the special reaction conditions according to the invention this nevertheless does not lead to gelled products. These special reaction conditions comprise carrying out the polymerization at temperatures from 80.degree. to 130.degree. C., preferably 90.degree. to 120.degree. C., at a relatively low polymerized solids content of about 50% by weight. Furthermore, it is necessary to use suitable initiators and, depending on the proportion of difunctional monomer, at least 0.5% by weight, but preferably at least 2.5% by weight, of a polymerization regulator (chain stopper), for example mercapto compounds. The choice of the initiator depends on the proportion of the difunctional monomers used. In the case of a low proportion, the initiators conventional for such temperatures, for example peroxy esters, can be used. In the case of a higher proportion of difunctional monomer, initiators such as azo compounds are preferably employed. After the polymerization, the polymer solution is concentrated to the desired solids content, preferably solids contents of 60% by weight, by distilling off the solvent. When adjusted to a solids content of 50% by weight, the clear copolymer solutions thus obtained have a viscosity of 0.4 to 10 dPas.

Surprisingly, measurements on the acrylate copolymer solutions by means of photon-correlation spectroscopy do not indicate any microgel content.

The invention also relates to a coating agent which contains a binder, organic solvents, if appropriate pigments, fillers and conventional assistants and additives and, if appropriate, is curable by means of a catalyst and which, as the essential binder, contains the acrylate copolymer according to the invention as claimed in one or more of claims 1 to 11 and a binder suitable for cross-linking the former.

The invention relates to a coating agent which is curable by means of acid and, as the essential binder, contains

(A) 55 to 90% by weight, preferably 70 to 80% by weight, of the acrylate copolymer according to the invention and

(B) 10 to 45% by weight, preferably 20 to 30% by weight, of a melamine/formaldehyde resin having a mean molecular weight from 250 to 1000 and a degree of a methylolation of at least 0.65, preferably 0.9 to 1, which resin is etherified with monoalcohols having 1 to 4 carbon atoms and/or monoethers of diols having 2 to 7 carbon atoms in total, to an extent of at least 80 mol %, preferably 90 to 100 mol %, based on the maximum possible etherification, the sum of the binders (A) and (B) being 100% by weight.

Preferably, 25 to 40% by weight of the component a.sub.1 is used, the sum of components a.sub.1, a.sub.2 and a.sub.3 being 100% by weight.

The melamine/formaldehyde resin used as the binder (B) can have been etherified with, for example, methanol, ethanol, propanol and butanol. Hexakis-(methoxy)-methylmelamine is very suitable. Of course, the component B can also consist of urea/formaldehyde and benzoguanamine formaldehyde resins.

Before they are used, the coating agents according to the invention are mixed with an acid catalyst, in order to reduce the curing temperature and to accelerate curing. The catalyst is used in a quantity of 1 to 5% by weight, preferably 1.5 to 3.5% by weight, based on the solids content of binders (A) and (B). Sulfonic acid compounds, in particular p-toluene sulfonic acid, are particularly suitable. Mixtures of catalysts can also be employed.

To extend the pot life to 6 to 24 hours after the addition of the catalyst, the coating agent advantageously contains a quantity of a nitrogen-containing compound, equivalent to the quantity of acid, or a part of this quantity, depending on the desired extension of the pot life.

An extension of the pot life can advantageously also be obtained by an addition of 5 to 35% by weight, based on the solids content of binder, of one or more alcohols, of which ethanol, butanol and mixtures thereof are preferred.

The invention also relates to a process for the preparation of an acid-curable coating agent, which comprises copolymerizing, for the preparation of an hydroxylic acrylate copolymer,

(A)

(a.sub.1) 10 to 60% by weight, preferably 15 to 60% by weight, of hydroxylic esters of acrylic and/or methacrylic acid, having 2 to 14 carbon atoms in the alkyl radical, (a.sub.2) 3 to 25% by weight, preferably 5 to 20% by weight, of monomers having at least 2 polymerizable olefinically unsaturated (sic) double bonds and (a.sub.3) 15 to 82% by weight, preferably 40 to 70% by weight, of further polymerizable monomers having one olefinically unsaturated (sic) double bond, in an organic solvent with the addition of polymerization initiators and polymerization regulators to give a precross-linked, ungelled product, the sum of the components a.sub.1, a.sub.2 and a.sub.3 being 100% by weight, and processing this copolymer (A) in a proportion of 55 to 90% by weight, preferably 70 to 80% by weight, with

(B) 10 to 45% by weight, preferably 20 to 30% by weight, of a melamine/formaldehyde resin having a molecular weight from 250 to 1000 and a degree of methylolation of at least 0.65, preferably 0.9 to 1, which resin is etherified with monoalcohols of 1 to 4 carbon atoms and/or monoethers of diols having 2 to 7 carbon atoms in total, to an extent of at least 80 mol %, preferably 90 to 100 mol %, based on the maximum possible etherification, and with organic solvents and, if appropriate, pigments and conventional assistants and additives, by mixing and, if necessary, dispersing to give a coating composition, the sum of binders (A) and (B) being 100% by weight.

The invention also relates to a coating agent which, as the essential binder, contains the acrylate copolymer

(A) according to the invention and

(B) one or more different polyfunctional isocyanates, with the proviso that the ratio of the isocyanate groups and hydroxyl groups is within the range from 0.3:1 to 3.5:1.

Examples of polyfunctional isocyanates, which can be used for crosslinking the hydroxylic copolymers, are 2,4-toluylene diisocyanate, 2,6-toluylene diisocyanate, 4,4'-diphenylmethane diisocyanate, hexamethylene diisocyanate, 3,5,5-trimethyl-1-isocyanato-3-isocyanatomethylcyclohexane, m-xylylene diisocyanate, p-xylylene diisocyanate, tetramethylene diisocyanate, cyclohexane-1,4-diisocyanate, 4,4'-diisocyanatodiphenyl ether, 2,4,6-triisocyanatotoluene and 4,4',4"-triisocyanatotriphenylmethane. The polyisocyanates can be linked to give prepolymers of higher molecular weight. Adducts of toluylene diisocyanate and trimethylolpropane, a biuret formed from 3 molecules of hexamethylene diisocyanate, and the trimers of hexamethylene diisocyanate and 3,5,5-trimethyl-1-isocyanato-3-isocyanatomethylcyclohexane may be mentioned here.

In the case of the acrylate copolymers crosslinked with isocyanate groups, preferably 15 to 40% by weight of component a.sub.1 are used, the sum of components a.sub.1, a.sub.b and a.sub.3 being 100% by weight.

The invention also relates to a process for the preparation of the coating agent, which comprises copolymerizing, for the preparation of the acrylate copolymer,

(A)

(a.sub.1) 10 to 60% by weight, preferably 15 to 60% by weight, of hydroxylic esters of acrylic and/or methacrylic acid, having 2 to 14 carbon atoms in the alkyl radical, (a.sub.2) 3 to 25% by weight, preferably 5 to 20% by weight, of monomers having at least 2 polymerizable olefinically unsaturated (sic) double bonds and (a.sub.3) 15 to 82% by weight, preferably 40 to 70% by weight, of further polymerizable monomers having one olefinically unsaturated (sic) double bond, in an organic solvent with the addition of polymerization initiators and polymerization regulators to give a pre-crosslinked, ungelled product, the sum of components a.sub.1, a.sub.2 and a.sub.3 being 100% by weight, and processing this copolymer (A) with

(B) one or more different polyfunctional isocyanates and with organic solvents and, if appropriate, pigments and conventional assistants and additives, by mixing and, if necessary, dispersing to give a coating composition, with the proviso that the ratio of the isocyanate groups and hydroxyl groups is within the range from 0.3:1 to 3.5:1.

In the process according to the invention, one or more catalysts in a quantity of 0.01 to 1% by weight, based on the solids content of the reacting components, can be used. The preferred catalysts used are amines, for example dimethylethanolamine. When catalysts are added the curing temperature can be reduced and curing can be accelerated. The isocyanate curing according to the invention can be carried out at temperatures as low as room temperature. At very high temperatures, the addition of a catalyst is unnecessary.

The coating agents according to the invention can be cured at low temperatures, for example at 20.degree. to 80.degree. C., and are therefore employed particularly for automobile finish repairs.

The invention also relates to a process for the preparation of a coating, wherein an acid catalyst in a quantity of 1 to 5% by weight, preferably 1.5 to 3.5% by weight, based on the solids content of binders (A) and (B), is admixed to a coating agent as claimed in claim 18 or 19, the mixture obtained is applied in the form of a film to a substrate by spraying, flooding, dipping, rolling, knife application or brushing and a film is cured at temperatures from 20.degree. to 80.degree. C. to give a firmly adhering coating.

The invention also relates to a process for the preparation of a coating, wherein a coating agent crosslinked in claim 21 or 22, to which a catalyst may have been admixed, is applied in the form of a film to a substrate by spraying, flooding, dipping, rolling, knife application or brushing and the film is cured to give a firmly adhering coating. The invention also relates to substrates coated by a process according to the invention.

The invention is explained in more detail below by reference to illustrative embodiments.

(A) Preparation of copolymers according to the invention (Binder A)

In the examples which follow, all percentage figures relate to parts by weight, unless otherwise stated. The solids content values were determined in a circulating-air oven after 1 hour at 130.degree. C. The viscosities were determined in a cone-and-plate viscometer.

1 Preparation of acrylate resin I

360 parts of butyl acetate and 180 parts of methoxypropyl acetate are introduced into a 3 l kettle.

The solvent mixture is heated to 110.degree. C. Within 3 hours, the following are metered in uniformly:

Solution 1: 300 parts of methyl methacrylate 250 parts of styrene 150 parts of hexanediol diacrylate 250 parts of butanediol monoacrylate 50 parts of n-butyl acrylate 45 parts of mercaptoethanol Solution 2: 350 parts of butyl acetate 30 parts of azobisisobutyronitrile 175 parts of methoxypropyl acetate

The polymerization is then completed during a further 3 hours at 110.degree. C. A solids content of 50.5% is reached. About 340 parts of solvent are distilled off in vacuo at 60.degree.-70.degree. C. The clear, colorless acrylate resin solution has a solids content of 60.6%, an acid number of 0.1, an OH number of 97 and a viscosity of 2.0 dPas at 23.degree. C. at a solids content adjusted to 50% with ethylglycol acetate.

2 Preparation of acrylate resin II

360 parts of butyl acetate and 180 parts of methoxypropyl acetate are introduced into a 3 l kettle.

The solvent mixture is heated to 110.degree. C. Within 3 hours, the following are metered in uniformly:

Solution 1: 300 parts of methyl methacrylate 150 parts of styrene 150 parts of hexanediol diacrylate 400 parts of hydroxyethyl methacrylate 45 parts of mercaptoethanol Solution 2: 350 parts of butyl acetate 30 parts of azobisisobutyronitrile 175 parts of methoxypropyl acetate.

The polymerization is then completed during a further 3 hours at 110.degree. C. A solids content of 50.5% is reached. About 340 parts of solvent are distilled off in vacuo at 60.degree.-70.degree. C. The clear, colorless acrylate resin solution has a solids content of 61.4%, an acid number of 0.4, and an OH number of 173 and a viscosity of 6.6 dPas at 23.degree. C. at a solids content adjusted to 50% with ethyl glycol acetate.

3. Preparation of acrylate resin III

360 parts of butyl acetate and 180 parts of methoxypropyl acetate are introduced into a 3 l kettle.

The solvent mixture is heated to 110.degree. C. Within 3 hours, the following are metered in uniformly:

Solution 1: 300 parts of methyl methacrylate 150 parts of styrene 150 parts of hexanediol diacrylate 150 parts of hydroxyethyl methacrylate 250 parts of butanediol monoacrylate 45 parts of mercaptoethanol Solution 2. 350 parts of butyl acetate 30 parts of azobisisobutyronitrile 175 parts of methoxypropyl acetate (sic).

The polymerization is then completed during a further 3 hours at 110.degree. C. A solids content of 49.8% is reached. About 340 parts of solvent are distilled off in vacuo at 60.degree.-70.degree. C. The clear, colorless acrylate resin solution has a solids content of 60.9%, an acid number of 0.3, and an OH number of 162 and a viscosity of 3.8 dPas at 23.degree. C. at a solids content adjusted to 50% with ethylglycol acetate.

4. Preparation of acrylate resin IV

240 parts of butyl acetate, 120 parts of methoxypropyl acetate and 10 parts of tert.-butylperoxy 2-ethylhexanoate are introduced into a 3 l kettle.

The solvent mixture and a part of the required quantity of initiator are heated to 110.degree. C. Within 3 hours, the following are metered in uniformly:

Solution 1: 300 parts of methyl methacrylate 250 parts of styrene 75 parts of hexanediol diacrylate 75 parts of hydroxyethyl methacrylate 250 parts of butanediol monoacrylate 50 parts of n-butyl acrylate 35 parts of mercaptoethanol

Within 3.5 hours, the following are metered in uniformly:

Solution 2: 240 parts of butyl acetate 35 parts of tert.-butylperoxy 2-ethylhexanoate 120 parts of methoxypropyl acetate.

The polymerization is then completed during a further 3 hours at 110.degree. C. The clear, colorless acrylate resin solution has a solids content of 61.5%, an acid number of 4.1, and an OH number of 130 and a viscosity of 4.8 dPas at 23.degree. C. at a solids content adjusted to 50% with ethylglycol acetate

5. Preparation of acrylate resin V

360 parts of of butyl acetate, 180 parts of methoxypropyl acetate and 10 parts of tert.-butylperoxy 2-ethylhexanoate are introduced into a 3 l kettle.

The solvent mixture is heated to 110.degree. C. Within 3 hours, the following are metered in uniformly:

Solution 1: 300 parts of methyl methacrylate 250 parts of styrene 75 parts of hexamethylene-bis-methacrylamide 75 parts of hydroxyethyl methacrylate 250 parts of butanediol monoacrylate 50 parts of n-butyl acrylate 35 parts of mercaptoethanol

Within 3.5 hours, the following are metered in uniformly:

Solution 2: 350 parts of butyl acetate 35 parts of tert.-butylperoxy 2-ethylhexanoate 175 parts of methoxypropyl acetate

The polmerization is then completed during a further 3 hours at 110.degree. C. The solids content of 50.9% is reached. About 340 parts of solvent are distilled off in vacuo at 60.degree.-70.degree. C. The clear, colorless acrylate resin solution has a solids content of 61.5%, an acid number of 3.1, an OH number of 130 and a viscosity of 3.6 dPas at 23.degree. C. at a solids content adjusted to 50% with ethylglycol acetate.

6. Preparation of acrylate resin VI

361 parts of butyl acetate and 181 parts of ethylglycol acetate are introduced into a 3 l kettle.

The solvent mixture is heated to 110.degree. C. Within 3 hours, the following are metered in uniformly:

Solution 1: 300 parts of methyl methacrylate 250 parts of styrene 150 parts of ethylene glycol dimethacrylate 250 parts of butanediol monoacrylate 50 parts of n-butyl acrylate 45 parts of mercaptoethanol Solution 2: 350 parts of butyl acetate 30 parts of azobisiobutyronitrile (sic) 175 parts of ethyl glycol acetate.

The polymerization is then completed during a further 3 hours at 110.degree. C. A solids content of 48.9% is reached. About 340 parts of solvent are distilled off in vacuo at 60.degree.-70.degree. C. The clear, colorless acrylate resin solution has a solids content of 59.1%, an acid number of 1.6, an OH number of 97 and a viscosity of 6.5 dPas at 23.degree. C. at a solids content adjusted to 50% with ethylglycol acetate.

7. Preparation of acrylate resin VII

361 parts of butyl acetate and 181 parts of ethyl glycol acetate are introduced into a 3 l kettle. The solvent mixture is heated to 110.degree. C. Within 3 hours, the following are metered in uniformly: Solution 1: 300 parts of methyl methacrylate 150 parts of styrene 150 parts of hexanediol diacrylate 250 parts of butanediol monoacrylate 150 parts of a 1 : 2 reaction product of 2-hydroxyethyl acrylate and caprolactone, as described below 45 parts of mercaptoethanol Solution 2: 350 parts of butyl acetate 30 parts of ethylglycol acetate 175 parts of ethylglycol acetate

The polymerization is then completed during a further 3 hours at 110.degree. C. A solids content of 50.3% is reached. About 340 parts of solvent are distilled off in vacuo at 60.degree.-70.degree. C. The clear, colorless acrylate resin solution has a solids content of 60.1%, an acid number of 0.7, an OH number of 122 and a viscosity of 7.4 dPas at 23.degree. C. originally and a viscosity of 2.2 dPas at a solids content adjusted to 50% with ethylglycol acetate.

Reaction product of 2-hydroxyethyl acrylate and caprolactone

A commercially available reaction product, prepared from one mol of hydroxyethyl acrylate and, on average, 2 mol of .epsilon.-caprolactone, was used.

(B) Preparation of tinting pastes for pigmented top coats

White tinting paste P1

______________________________________Acrylate resin I 32.0 partsTitanium dioxide, rutile 53.0 partsAnti-settling agent(Salt of a higher-molecular polycarboxylic 1.0 partacid, 52% in higher-boiling aromatics)Xylene 4.3 partsSolvent mixture 6.7 parts(6:4 xylene/butyl acetate)Treated montmorrillonite 2.0 parts(10% in solvent naphtha/propylene carbonate/soya lecithin 85:4:1)Pyrogenic silica 1.0 part 100.0 parts______________________________________

The items are successively stirred up in a dissolver and then dispersed for 20 minutes in a commercially available laboratory sand mill (10 .mu.m fineness)

Yellow tinting paste P2

______________________________________Acrylate resin I 67.3 partsAnthrapyrimidine yellow (CI Y 108, 68,420) 15.0 partsSolvent mixture 15.0 parts(6:4 xylene/butyl acetate)Triethylenetetramine 0.2 partXylene 2.5 parts 100.0 parts______________________________________

The items are stirred up successively in a dissolver and then dispersed for 60 minutes in a commercially available laboratory and sand mill (10 .mu.m fineness).

White tinting paste P3 with extraneous binder

______________________________________Solvent mixture (xylene/butyl acetate) 5.4 partsCommercially available OH-copolymer, 31.1 partsOH number 150 based on solids, 60% in 2:1xylene/ethylglycol acetate, viscosity(50% in xylene) 450-750 mPasAnti-settling agent 1.0 part(Salt of a higher-molecular polycarboxylicacid, 52% in higher-boiling aromatics)Treated montmorrillonite 2.0 parts(10% in solvent naphtha/propylene carbonatesoya lecithin 85:4:1)Pyrogenic silica 0.5 partTitanium oxide, rutile 60.0 parts 100.0 parts______________________________________

The items are stirred up successively in the dissolver and then dispersed for 20 minutes in a commercially available laboratory sand mill (10 .mu.M fineness).

Green tinting paste

______________________________________Acrylate resin I 38.6 partsTitanium dioxide, rutile 10.7 partsYellow pigment (Y34, C.I. 77,603) 4.2 partsYellow pigment (Y34, C.I. 77,600) 10.5 partsGreen pigment (G7, C.I. 74,260) 0.5 partsButanol 23.2 partsTetraline 4.6 partsButyl acetate 7.7 parts 100.0 parts______________________________________

The items are stirred up successively in a dissolver and then dispersed for 20 minutes in a commercially available laboratory sand mill (10 .mu.m fineness).

Red tinting paste

______________________________________Acrylate resin I 46.3 partsRed pigment (R104, C.I. 77,605) 44.2 partsWetting and dispersing additive 1.0 part(Partial amide and ammonium salt of a higher-molecular unsaturated polycarboxylic acid, combinedwith an organically modified siloxane copolymer)Ethylglycol acetate 8.5 parts 100.0 parts______________________________________

The items are stirred up successively in a dissolver and then dispersed for 20 minutes in a commerically available laboratory sand mill (10 .mu.m fineness).

(C) Preparation of top coats

In the examples which follow, testing of the coatings is carried out as follows:

The pendulum hardness is determined by the Konig method.

Resistance to premium gasoline (FAM standard gasoline DIN 51,604) and xylene

A small cellulose sheet (diameter about 35 mm) impregnated with the particular solvent is placed for the indicated time upon the coating (knife-coated on glass in the viscosity as obtained) and covered. The film is examined for softening and marking.

Damp heat resistance

A phosphated steel sheet with the conventional structure (cathodic electrocoat primer, epoxy filler, top coat) is exposed for the indicated period to a humidity-saturated atmosphere at 40.degree. C.

After one hour of regeneration time, the test sheet is examined for blisters and loss of gloss.

Sticking test

One hour after forced drying of the coating, a strip of crepe adhesive tape is stuck on, firmly pressed on and left for one hour. After the adhesive tape has been torn off, the coating is examined for markings.

EXAMPLE 1

Formulation of a white top coat

______________________________________Acrylate resin I 43.5 partsWhite tinting paste P1 34.3 partsHexakis-(methoxymethyl)-melamine 7.7 partsXylene 13.8 partsCommercially available silicone oil (5%) 1.0 partPyridine salt of p-toluenesulfonic acid(20%) 5.7 parts______________________________________

Adjustment diluent: xylene (18 sec DIN 4)

EXAMPLE 2

Formulation of a yellow top coat

______________________________________Acrylate resin I 69.1 partsYellow tinting paste P2 14.0 partsHexakis-(methoxymethyl)-melamine 12.0 partsXylene 4.9 partsCommercially available silicone oil (5%) 1.0 partPyridine salt of p-tolulenesulfonic acid(20%) 8.5 parts______________________________________

Adjustment diluent

xylene (18 sec DIN 4)

With forced drying (30 minutes at 60.degree. C.), the following property level is reached (unless otherwise stated, the exposure tests were carried out one hour after removal from the drying oven).

______________________________________ White coat Yellow coat______________________________________Layer thickness 35 .mu.m 33 .mu.mPendulum hardness 1 hour after 55 sec 50 secdryingAfter 48 hours 108 sec 97 secResistance to a premium no marking no markinggasoline and xylene (duration after 24 hrsof exposure 5 minutes in each no softening no softeningcase)Sticking test (1 hour stressed no marking no markingwith adhesive tape)______________________________________

EXAMPLE 3

Formulation of a white top coat

______________________________________Acrylate resin II 36.8 partsHexakis-(methoxymethyl)-melamine 7.3 partsWhite tinting paste P3 29.4 partsButyl acetate 7.6 partsButanol 15.0 partsCommercially available silicone oil (5%) 1.0 partp-toluenesulfonic acid (40%) 2.9 parts______________________________________

Adjustment diluent

methoxypyropyl acetate (18 sec DIN 4)

With forced drying (30 minutes at 60.degree. C.), the following property level is reached (unless otherwise stated, the exposure tests were carried out 1 hour after removal from the drying oven).

______________________________________Layer thickness 32 .mu.mPendulum hardness 1 hour after drying 95 secafter 48 hours 111 secResistance to premium gasoline and xylene no marking,(duration of exposure 5 minutes in each case) no softeningSticking test (1 hour stressed with adhesive no markingtape)______________________________________

With drying at 20.degree. C. (room temperature), the following property level is reached:

______________________________________Resistance to premium gasoline and xylene no marking,after 3 days (duration of exposure 5 minutes no softeningin each case)Exposure to damp heat, 260 hours at 40.degree. C. no blisters, good gloss retention______________________________________

EXAMPLE 4

Formulation of a white top coat

______________________________________Acrylate resin III 39.4 partsHexakis-(methoxymethyl)-melamine 7.4 partsWhite tinting paste P3 29.4 partsMethoxypropyl acetate 3.0 partsButanol 15.0 partsTetraline 3.0 partsCommercially available silicone oil (5%) 1.0 partp-toluenesulfonic acid (40%) 1.8 part______________________________________

Adjustment diluent

methoxypropyl acetate (18 sec DIN 4)

With forced drying (30 minutes at 60.degree. C.), the following property level is reached (unless otherwise stated, the exposure tests were carried out 1 hour after removal from the drying oven).

______________________________________Layer thickness 35 .mu.mPendulum hardness 1 hour after drying 91 secafter 4 days 126 secResistance to premium gasoline and xylene no marking,(duration of exposure 5 minutes in each case) no softening______________________________________

With drying at 20.degree. C. (room temperature), the following property level is reached:

______________________________________Layer thickness 33 .mu.mPendulum hardness after 48 hours 81 secAfter 24 hours: resistance to premium no marking,gasoline no softeningResistance to xylene slight mark-(5 minutes exposure in each case) ingAfter 48 hours no marking,Resistance to premium gasoline no softeningResistance to xylene no marking, no softeningExposure to damp heat, 260 hours at 40.degree. C. no blisters, slight dulling______________________________________

EXAMPLE 5

Formulation of a white top coat

______________________________________Acrylate resin IV 39.7 partsHexakis-(methoxymethyl)-melamine 7.3 partsWhite tinting paste P3 29.4 partsButyl acetate 4.8 partsButanol 15.0 partsCommercially available silicone oil (5%) 1.0 partp-toluenesulfonic acid (40%) 2.8 parts______________________________________

Adjustment diluent

xylene (18 sec DIN 4)

With forced drying (30 minutes at 60.degree. C.), the following product level is reached (unless otherwise stated, the exposure tests were carried out 1 hour after removal from the drying oven).

______________________________________Layer thickness 36 .mu.mPendulum hardness 1 hour after drying 70 secafter 24 hours 77 secResistance to premium gasoline and xylene no marking,(duration of exposure 5 minutes in each case) no softening______________________________________

EXAMPLE 6

Formulation of a white top coat

______________________________________Acrylate resin 38.6 partsHexakis-(methoxymethyl)-melamine 7.3 partsWhite tinting paste P3 29.4 partsButyl acetate 5.9 partsButanol 15.0 partsCommercially available silicone oil (5%) 1.0 partp-toluenesulfonic acid (40%) 2.8 parts______________________________________

Adjustment diluent

xylene (18 sec DIN 4)

With forced drying (30 minutes at 60.degree. C.), the following property level is reached (unless otherwise stated, the exposure tests were carried out 1 hour after removal from the drying oven).

______________________________________Layer thickness 33 .mu.mPendulum hardness 1 hour after drying 85 secafter 24 hours 98 secafter 14 days 155 secResistance to premium gasoline and xylene no marking,(duration of exposure 5 minutes in each case) no softening______________________________________

EXAMPLE 7

Formulation of a clear coating

______________________________________Acrylate resin 68.1 partsHexakis-(methoxymethyl)-melamine 10.2 partsXylene 13.2 partsCommercially available silicone oil (5%) 1.0 partPyridine salt of p-toluenesulfonic acid(20%) 7.5 parts______________________________________

Adjustment diluent

xylene (18 sec DIN 4)

With forced drying (30 minutes at 60.degree. C.), the following property level is reached (unless otherwise stated the exposure tests were carried out 1 hour after removal from the drying oven).

______________________________________ Clear coating______________________________________Layer thickness 32 .mu.mPendulum hardness 1 hour after drying 95 secafter 48 hours 111 secResistance to premium gasoline and xylene no marking,(duration of exposure 5 minutes in each case) no softeningSticking test (1 hour stressed with adhesive no markingtape:)______________________________________

EXAMPLE 8

Formulation of a white top coat

______________________________________Acrylate resin VII 42.0 partsHexakis-(methoxymethyl)-melamine 7.7 partsWhite tinting paste P3 30.8 partsButanol 15.6 partsCommercially available silicone oil (5%) 1.0 partp-toluenesulfonic acid (40%) 2.9 parts______________________________________

Adjustment diluent

xylene (18 sec DIN 4)

With forced drying (30 minutes at 60.degree. C.), the following property level is reached (unless otherwise stated, the exposure tests were carried out 1 hour after removal from the drying oven):

______________________________________Layer thickness 32 .mu.mPendulum hardness 1 hour after drying 81 secafter 6 days 87 secResistance to premium gasoline and xylene slight mark-(duration of exposure 5 minutes in each case) ingAfier 48 hours no marking no softening______________________________________

EXAMPLE 9

Formulation of a red top coat

______________________________________Acrylate resin III 29.7 partsPolyisocyanate 26.5 parts(75%, triisocyanate from trimethylol-propane with 3 mol of toluylene diiso-cyanate, in ethyl acetate)Red tinting paste 25.0 partsButyl acetate 18.75 partsEthylene diamine 0.05 part(10% in isopropanol)propanol)(sic) 100.0 parts______________________________________

EXAMPLE 10

Formulation of a green top coat

______________________________________Acrylate resin I 40.9 partsPolyisocyanate 18.3 parts(75%, triisocyanate from trimethylol-propane with 3 mol of toluylenediisocyanate, in ethyl acetate)Green tinting paste 31.3 partsButyl acetate 9.4 partsEthylenediamine 0.1 part(10% in isopropanol) 100.0 parts______________________________________

With forced drying (30 minutes at 60.degree. C.), the following property level is reached:

______________________________________ Example 9 Example 10______________________________________Layer thickness 40 .mu.m 42 .mu.mPendulum hardness6 hours after removal 53 sec 63 sec24 hours after removal 137 sec 126 secfrom the drying ovenResistance to premium gaso- no marking, no marking,line and xylene (5 minutes no softening no softeningexposure in each case, 6 hoursafter removal from the dryingoven)______________________________________

EXAMPLE 11

Formulation of a green top coat

______________________________________Acrylate resin I 45.8 partsPolyisocyanate 13.4 parts(Triisocyanate from 3 mol ofhexamethylene diisocyanate,trimerized, 90% in 1:1 butylaceate/solvent naphtha)Green tinting paste 31.2 partsButyl acetate 9.52 partsEthylene diamine 0.08 part(10% in isopropanol) 100.00 parts______________________________________

With forced drying (20 minutes at 120.degree. C.), the following property level is reached:

______________________________________Layer thickness 40 .mu.mPendulum hardness6 hours after removal 90 secfrom the drying oven24 hours after removal 125 secfrom the drying ovenResistance to premium gasoline no marking(5 minutes exposure, 6 hours no softeningafter removal from the dryingoven)Resistance to xylene, very slight5 minutes exposure in each case marking, very6 hours after removal slight soften-from the drying oven ing;24 hours after removal no marking,from the drying oven no softening______________________________________

Pot life in a DIN 4 flow cup, rise from 20 seconds to 52 seconds in 24 hours.

The acrylate resins I and III are examined by photocorrelation spectroscopy for a content of microgel particles. The result of the examination is that there is no analytical indication of a microgel content. The resin solutions were examined by means of a Coulter Model N 4 sub-micron partical (sic) analyzer of Curtin Matheson Scientific Inc., Detroit, Mich., USA.

Claims

1. A hydroxylic acrylate copolymer comprising a precrosslinked, ungelled reaction product of

about 10 to about 60 percent of a hydroxyalkyl acrylate or methacrylate monomer (a.sup.1) having from 2 to 14 carbons in the hydroxyalkyl group;

about 5 to about 20 percent of an unconjugated diolefinic monomer (a.sup.2), the olefinic groups being at the two termini of the monomer;

about 15 to about 82% of a monoolefinic monomer (a.sup.3) selected from the group consisting of styrene, vinyl toluene, acrylic acid, methacrylic acid and the alkyl, alkoxyethyl or aryloxyethyl ester of acrylic acid, methacrylic acid, maleic acid or fumaric acid;

wherein all percentages are by weight relative to the weight of the copolymer and said copolymer is dissolvable in a saturated organic ester solvent, produces a viscosity of about 0.4 to about 10 dPas when dissolved in an alkyl acetate solvent at a solids content of about 50 percent by weight, and exhibits no microgel content in solution.

2. The copolymer according to claim 1 wherein monomer (a.sup.1) is from about 15 to about 60 percent by weight, monomer (a.sup.2) is from about 5 to about 20 percent by weight, and monomer (a.sup.3) from about 40 to about 70 percent by weight.

3. The copolymer according to claim 1 wherein the monomer (a.sup.2) has the general formula

CH.sub.2 .dbd.CRC(O)X(CH.sub.2).sub.n XC(O)CR.dbd.CH.sub.2

R being H or CH.sub.3 ; X being O, NH or S; and n being an integer from 2 to 8.

4. A copolymer according to claim 3 wherein monomer (a.sup.2) is the reaction product of an unsaturated carboxylic acid and glycidyl acrylate or glycidyl methacrylate, or mixtures thereof.

5. A copolymer according to claim 2 wherein monomer (a.sup.2) is the ester reaction product of an olefinic alcohol and a polycarboxylic acid or an unsaturated monocarboxylic acid.

6. A copolymer according to claim 2 wherein the monomer (a.sup.2) is the reaction product of polyiscyanate and an olefinic alcohol or amine compound.

7. A copolymer according to claim 2 wherein the monomer (a.sup.2) is a diester formed by reacting diol selected from the group consisting of polyethylene glycol, polypropylene glycol, and mixtures thereof, with an olefinic carboxylic acid selected from the group consisting of acrylic acid, methacrylic acid, and mixtures thereof, said monomer (a.sup.2) having a mean molecular weight of less than 1500.

8. A copolymer according to claim 7 wherein said monomer (a.sup.2) has a mean molecular weight of less than 1000.

9. A copolymer according to claim 1 wherein monomer (a.sup.1) contains a primary hydroxyl group.

10. A copolymer according to claim 1 wherein monomer (a.sup.1) is at least partially comprised of the reaction product of 2 mol of epsilon-caprolactone and 1 mol of hydroxyethyl acrylate or hydroxyethyl methacrylate.

11. A copolymer according to claim 1 wherein monomer (a.sup.1) is comprised of up to 75% by weight of a hydroxyalkyl acrylate or methacrylate having a secondary hydroxyl group.

12. A copolymer according to claim 1 wherein monomer a.sup.1 is a reaction product of glycidyl ester of a carboxylic acid having a tertiary alpha carbon atom and acrylic acid, methacrylic acid, or mixtures thereof.

13. A precrosslinked, ungelled copolymer according to claim 1, produced by the process comprising:

combining monomers a.sup.1, a.sup.2 and a.sup.3 at said relative weight percents, polymerization initiator, at least 0.5 percent by weight of total solids of a polymerization regulator, and an inert organic solvent to form a mixture, the total monomeric a.sup.1, a.sup.2 and a.sup.3 content in the mixture being from about 40 to about 65 percent by weight relative to the total weight of the mixture; and

heating the mixture of about 80.degree. C. to about 130.degree. C. for a period of time sufficient to complete polymerization and product the copolymer.

14. The copolymer produced according to claim 13 wherein said initiator is selected from the group consisting of a peroxy ester compound and an azo compound.

15. The copolymer produced according to claim 13 wherein said azo compound is azobisisobutyronitrile.

16. The copolymers produced according to claim 13 wherein the heating is carried out at a temperature of about 90.degree.-120.degree. C.

17. The copolymer produced according to claim 13 wherein the polymerization regulator comprises at least about 2.5% by weight of the reactants.

18. The copolymer produced according to claim 13 wherein the polymerization regulator is a mercapto-containing compound.

19. The copolymer produced according to claim 18 wherein the polymerization regulator is mercaptoethanol.

20. The copolymer produced according to claim 13 wherein the percentage of monomer (a.sup.1) is from about 15 to 60 percent, the percentage of monomer (a.sup.2) is from about 5 to about 20 percent, and the percentage of monomer (a.sup.3) is from about 40 to about 70 percent.