Claims
- 1. A continuous, high temperature polymerization process for preparing a free radically polymerized epoxy-functional polymeric product comprising:
(a) continuously charging into a reactor monomer(s) consisting essentially of:
(i) at least one epoxy-functional acrylic monomer; (ii) optionally at least one non-functional monomer which is a non-functional free radical polymerizable monomer; and (b) maintaining an effective temperature in the reactor for an effective period of time to cause polymerization of the monomers to produce a polymeric product, such that the polymeric product is formed substantially free of gel particles.
- 2. The continuous, high temperature polymerization process of claim 1, wherein (a) further comprises continuously charging into the reactor:
(i) from about 1 percent to 100 percent by weight of at least one epoxy-functional acrylic monomer based on the total weight of the monomers; (ii) from 0 percent to about 99 percent by weight of at least one non-functional monomer selected from the group consisting of non-functional acrylate monomers, non-functional methacrylate monomers, non-functional styrenic monomers and combinations thereof based on the total weight of the monomers; and (iii) at least one free radical polymerization initiator.
- 3. The continuous, high temperature polymerization process of claim 2, wherein (a) further comprises continuously charging into the reactor a solvent in an amount up to 40 percent by weight of the total weight of the monomers.
- 4. The continuous, high temperature polymerization process of claim 1, wherein the effective temperature is from about 160° to about 270° C., and the effective period of time for residence of the monomers within the reactor is less than 60 minutes.
- 5. The continuous, high temperature polymerization process of claim 1, wherein the epoxy-functional acrylic monomer is glycidyl methacrylate.
- 6. The continuous, high temperature polymerization process of claim 1, wherein the monomers further comprise at least one non-functional methacrylate monomer, at least one non-functional acrylate monomer, and at least one non-functional styrenic monomer.
- 7. The continuous, high temperature polymerization process of claim 1, wherein the monomers further comprise at least two different non-functional methacrylate monomers and at least one non-functional acrylate monomer.
- 8. The continuous, high temperature polymerization process of claim 1, wherein the monomers further comprise at least two different non-functional methacrylate monomers, at least one non-functional acrylate monomer, and at least one non-functional styrenic monomer.
- 9. The continuous, high temperature polymerization process of claim 1, wherein the monomers consist essentially of epoxy-functional acrylic monomer(s) and non-functional styrenic monomer(s).
- 10. The continuous, high temperature polymerization process of claim 2, wherein the free radical polymerization initiator is di-t-amyl peroxide.
- 11. A continuous, high temperature polymerization process for preparing a free radically polymerized epoxy-functional polymeric product comprising;
(a) continuously charging into a reactor monomer(s) consisting essentially of:
(i) at least one epoxy-functional acrylic monomer; (ii) at least one non-functional monomer selected from the group consisting of non-functional acrylate monomers, non-functional methacrylate monomers, and combinations thereof; and (b) maintaining an effective temperature in the reactor for an effective period of time to cause polymerization of the monomers to produce a polymeric product, such that the polymeric product is formed substantially free of gel particles.
- 12. The continuous, high temperature polymerization process of claim 11, wherein (a) further comprises continuously charging into the reactor at least one solvent.
- 13. The continuous, high temperature polymerization process of claim 11, wherein (a) further comprises continuously charging into the reactor at least one free radical polymerization initiator.
- 14. The continuous, high temperature polymerization process of claim 11, wherein the effective temperature is from about 175° C. to about 250° C., and wherein the effective period of time for residence of the monomers within the reactor is less than 15 minutes.
- 15. The continuous, high temperature polymerization process of claim 11, wherein (a) further comprises continuously charging into the reactor at least one non-functional styrenic monomer.
- 16. The continuous, high temperature polymerization process of claim 11, wherein the monomers further comprise at least two different non-functional acrylate monomers or nonfunctional methacrylate monomers.
- 17. The continuous, high temperature polymerization process of claim 16, wherein the monomers further comprise at least two different non-functional methacrylate monomers and at least one non-functional acrylate monomer.
- 18. The continuous, high temperature polymerization process of claim 11, wherein the monomers further comprise at least three non-functional methacrylate monomers.
- 19. The continuous, high temperature polymerization process of claim 11, wherein (a) further comprises continuously charging into the reactor:
(i) about 15 percent to about 60 percent by weight of at least one epoxy-functional acrylic monomer based on the total weight of the monomers; (ii) up to about 85 percent by weight of at least one non-functional monomer selected from the group consisting of non-functional acrylate monomers, non-functional methacrylate monomers, and combinations thereof based on the total weight of the monomers; (iii) about 0.0005 to about 0.06 moles of at least one free radical polymerization initiator per mole of monomers; (iv) 0 percent to about 25 percent by weight of at least one non-functional styrenic monomer based on the total weight of the monomers; and (v) 0 percent to about 15 percent by weight of solvent based on the total weight of the monomers.
- 20. The continuous, high temperature polymerization process of claim 11, wherein the epoxy-functional acrylic monomer is glycidyl methacrylate.
- 21. The continuous, high temperature polymerization process of claim 19, wherein the non-functional methacrylate and non-functional acrylate monomers are selected from the group consisting of methyl methacrylate, butyl methacrylate, butyl acrylate, isobutyl methacrylate, cyclohexyl methacrylate, isobornyl methacrylate and combinations thereof.
- 22. The continuous, high temperature polymerization process of claim 21, further comprising at least one non-functional styrenic monomer.
- 23. A powder coating composition, comprising:
(a) the polymeric product made according to the process of claim 1; and (b) other materials sufficient to form a powder coating composition when combined with the polymeric product.
- 24. A powder coating composition, comprising:
(a) the polymeric product made according to the process of claim 11; and (b) other materials sufficient to form a powder coating when combined with the polymeric product.
- 25. A powder coating composition, comprising:
(a) a polymeric product, the polymeric product consisting essentially of:
(i) about 1 percent to 100 percent by weight of at least one epoxy-functional acrylic monomer based on the total weight of the monomers; (ii) optionally From 0 percent to about 99 percent by weight of a at least one non-functional monomer which is a non-functional free radical polymerizable monomer, such that the monomers are polymerized into the polymeric product, such that the polymeric product comprises at least 40 percent by weight of polymerized epoxy-functional monomers; (b) other materials sufficient to form a powder clear coating when combined with the polymeric product, wherein the powder clear coating composition exhibits a Delta b value of 1.2 or less at standard conditions.
- 26. A powder coating composition, comprising:
(a) a polymeric product, the polymeric product consisting essentially of:
(i) about 15 percent to about 60 percent by weight of at least one epoxy-functional acrylic monomer based on the total weight of the monomers; (ii) up to 85 percent by weight of at least one non-functional monomer selected from the group consisting of non-functional acrylate monomers, non-functional methacrylate monomers and combinations thereof based on the total weight of the monomers, such that the monomers are polymerized into the polymeric product; and (iii) 0 to about 25 percent by weight of at least one non-functional styrenic monomer based on the total weight of the monomers, such that the polymeric product comprises at least 40 percent by weight of polymerized epoxy-functional monomers; (b) other materials sufficient to form a powder clear coating when combined with the polymeric product, wherein the powder clear coating composition exhibits a Delta b value of 1.2 or less at standard conditions.
- 27. A liquid coating composition, comprising:
(a) the polymeric product made according to the process of claim 1; and (b) other materials sufficient to form a liquid coating composition when combined with the polymeric product.
- 28. A liquid coating composition, comprising:
(a) the polymeric product made according to the process of claim 11; and (b) other materials sufficient to form a liquid coating composition when combined with the polymeric product.
- 29. A liquid coating composition, comprising:
(a) a polymeric product, the polymeric product consisting essentially of:
(i) about 1 percent to 100 percent by weight of at least one epoxy-functional acrylic monomer based on the total weight of (he monomers; (ii) optionally from 0 percent to about 99 percent by weight of at least one non-functional monomer which is a non-functional free radical polymerizable monomer, such that the monomers are polymerized into the polymeric product; and (b) other materials sufficient to form a liquid clearcoating when combined with the polymeric product, wherein the liquid coating composition exhibits a Delta b value of 1.2 or less at standard conditions.
- 30. A liquid clear coating composition, comprising:
(a) a polymeric product, the polymeric product consisting essentially of:
(i) about 15 percent to about 60 percent by weight at least one epoxy-functional acrylic monomer based on the total weight of the monomers; (ii) up to 85 percent by weight of at least one non-functional monomer selected from the group consisting of non-functional acrylate monomers, non-functional methacrylate monomers and combinations thereof based on the total weight of the monomers; (iii) 0 to about 25 percent by weight of at least one non-functional styrenic monomer based on the total weight of the monomers, such that the monomers are polymerized into the polymeric product; and (b) other materials sufficient to form a liquid clear coating when combined with the polymeric product, wherein the liquid coating composition exhibits a Delta b value of 1.2 or less at standard conditions.
- 31. A continuous, high temperature polymerization process for preparing a free radically polymerized epoxy-functional polymeric product comprising:
(a) continuously changing into a reactor monomers consisting essentially of:
(i) at least one epoxy-functional acrylic monomer; (ii) at least one non-functional methacrylate monomer; (iii) at least one non-functional acrylate monomer; and (b) maintaining an effective temperature in the reactor for an effective period of time to cause polymerization of the monomers to produce a polymeric product, wherein the acrylate monomer is added in a sufficient amount such that at least 60 percent of the total functional and non-functional methacrylate monomers are incorporated into the polymeric product.
- 32. The continuous, high temperature polymerization process of claim 31, wherein (a) further comprises continuously charging into the reactor at least one free radical polymerization initiator.
- 33. The continuous, high temperature polymerization process of claim 31, wherein (a) further comprises continuously charging into the reactor at least one non-functional styrenic monomer.
- 34. The continuous, high temperature polymerization process of claim 31, wherein (a) further comprises continuously charging into the reactor at least one solvent.
- 35. The continuous, high temperature polymerization process of claim 31, wherein a homopolymer of each nonfunctional acrylate monomer has a Tg of less than or equal to 30° C.
- 36. The continuous, high temperature polymerization process of claim 31, wherein a homopolymer of each non-functional acrylate monomer has a Tg of greater than 30° C.
- 37. The continuous, high temperature polymerization process of claim 31, wherein (a) further comprises continuously charging into the reactor:
(i) about 15% to about 60% by weight of at least one epoxy-functional acrylic monomer based on the total weight of the monomers; (ii) up to about 60% by weight of at least one non-functional methacrylate monomer based on the total weight of the monomers; (iii) tip to about 25% by weight of at least one non-functional acrylate monomer based on the total weight of the monomers; (iv) about 0.0005 to about 0.06 moles of at least one free radical polymerization initiator per mole of monomers; (v) up to about 25% by weight of at least one non-functional styrenic monomer based on the total weight of the monomers; and (vi) up to about 15% by weight of solvent based on the total weight of the monomers.
- 38. The continuous, high temperature polymerization process of claim 37, wherein the epoxy-functional acrylic monomer is glycidyl methacrylate.
- 39. The continuous, high temperature polymerization process of claim 38, wherein the non-functional acrylate monomer is selected from the group consisting of cyclohexyl acrylate, isoborynl acrylate, and combinations thereof.
- 40. The continuous, high temperature polymerization process of claim 38, wherein the non-functional methacrylate monomers are selected from the group consisting of methyl methacrylate, butyl methacrylate, isobutyl methacrylate, cyclohexyl methacrylate, isobornyl methacrylate, and combinations thereof.
- 41. The continuous, high temperature polymerization process of claim 37, further comprising at least one non-functional styrenic monomer.
- 42. A powder coating composition, comprising:
(a) the polymeric product made according to the process of claim 31; and (b) other materials sufficient to form a powder coating composition when combined with the polymeric product.
- 43. A liquid coating composition, comprising:
(a) the polymeric product made according to the process of claim 31; and (b) other materials sufficient to form a liquid coating composition when combined with the polymeric product.
- 44. A powder clear coating composition, comprising:
(a) a polymeric product, the polymeric product consisting essentially of:
(i) about 15 percent to about 60 percent by weight of at least one epoxy-functional acrylic monomer based on the total weight of the monomers; (ii) up to 60 percent by weight of at least one non-functional methacrylate monomer based on the total weight of the monomers; (iii) up to 25 percent by weight of at least one non-functional acrylate monomer, such that the monomers are polymerized into the polymeric product such that the polymeric product comprises at least 40 percent by weight of polymerized epoxy-functional monomers; (b) other materials sufficient to form a powder clear coating composition when combined with the polymeric product, wherein the powder clear coating composition exhibits a Delta b value of 1.2 or less at standard conditions.
- 45. A liquid coating composition, comprising:
(a) a polymeric product, the polymeric product consisting essentially of:
(i) about 15% to about 60% by weight at least one epoxy-functional acrylic monomer based on the total weight of the monomers; (ii) tip to 85% by weight of at least one non-functional monomer selected from the group consisting of non-functional acrylate monomers, non-functional methacrylate monomers and combinations thereof based on the total weight of the monomers; and (iii) tip to 25% by weight of at least one non-functional acrylate monomer, such that the monomers are polymerized into the polymeric product; (b) other materials sufficient to form a liquid clear coating composition when combined with the polymeric product, wherein the liquid clear coating composition exhibits a Delta b value of 1.2 or less at standard conditions.
Parent Case Info
[0001] This application claims priority from U.S. patent application Ser. No. 09/354,350, filed Jul. 14, 1999, the entire contents of which are hereby incorporated by reference.
Divisions (1)
|
Number |
Date |
Country |
Parent |
09614619 |
Jul 2000 |
US |
Child |
10429548 |
May 2003 |
US |