Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
  • C08L33/04—Homopolymers or copolymers of esters
  • C08L33/14—Homopolymers or copolymers of esters of esters containing halogen, nitrogen, sulfur, or oxygen atoms in addition to the carboxy oxygen
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F8/00—Chemical modification by after-treatment
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
  • C09D133/04—Homopolymers or copolymers of esters
  • C09D133/14—Homopolymers or copolymers of esters of esters containing halogen, nitrogen, sulfur or oxygen atoms in addition to the carboxy oxygen

Definitions

• the present invention generally relates to polyvinyl polymers and their various uses, such as coating compositions and molded products.
• Polyvinyl polymers such as polyvinyl butyrals have been used since the 1930s in various compositions, such as lacquers, primers for metals and anti-corrosive paints, printing inks, temporary binders, adhesives and as films for shatterproof safety glass.
• lacquers primers for metals and anti-corrosive paints
• printing inks temporary binders
• adhesives as films for shatterproof safety glass.
• Ri and R 2 are independently H, substituted or unsubstituted Ci to C 12 alkyl, substituted or unsubstituted C ⁇ to C 1 aryl, substituted or unsubstituted C to C 22 aral yl, substituted or unsubstituted C ⁇ to C ⁇ alkaryl, substituted, unsubstituted C to C 14 carbocyclyl or a combination thereof, and wherein Z is H, or -COOH and Y is -COOH, halo, unsubstituted phen
• the present invention is also directed to a method of producing a coating on a substrate comprising: (i) applying a layer over a substrate surface of a coating composition comprising:
• Ri and R 2 are independently H, substituted or unsubstituted Ci to C 12 alkyl, substituted or unsubstituted C 6 to C 14 aryl, substituted or unsubstituted C 7 to C 22 aralkyl, substituted or unsubstituted C 6 to C 14 alkaryl, substituted, unsubstituted C 4 to C carbocyclyl or a combination thereof, and wherein Z is H, or -COOH and Y is -COOH, halo, unsubstituted phenyl or
• the present invention is further directed to a method of producing a multi-coat system on a substrate comprising:
• Ri and R 2 are independently H, substituted or unsubstituted Ci to C 12 alkyl, substituted or unsubstituted C 6 to Cu aryl, substituted or unsubstituted C 7 to C 22 aralkyl, substituted or unsubstituted C & to C 14 alkaryl, substituted, unsubstituted C 4 to Ct 4 carbocyclyl or a combination thereof, and wherein Z is H, or -COOH and Y is -COOH, halo, unsubstituted phenyl
• the present invention is also directed to a method of producing a molded article, such as a safety helmet, said method comprising:
• composition comprising: (a) an acetoacetylated polyvinyl polymer having the formula:
• R-i and R 2 are independently H, substituted or unsubstituted Ci to C 12 alkyl, substituted or unsubstituted C 6 to C ⁇ 4 aryl, substituted or unsubstituted C 7 to C 22 aralkyl, substituted or unsubstituted C 6 to C ⁇ 4 alkaryl, substituted, unsubstituted C 4 to C 14 carbocyclyl or a combination thereof, and wherein Z is H, or -COOH and Y is -COOH, halo, unsubstituted
• Low VOC coating composition means a coating composition that includes in the range of from 0.1 kilograms (1.0 pounds per gallon) to 0.72 kilograms (6.0 pounds per gallon), preferably from 0.3 kilograms (2.6 pounds per gallon) to 0.6 kilograms (5.0 pounds per gallon) and more preferably from 0.34 kilograms (2.8 pounds per gallon) to 0.53 kilograms (4.4 pounds per gallon) of the solvent per liter of the coating composition. All VOC's determined under the procedure provided in ASTM D3960.
• High solids composition means a coating composition having solid component of above 30 percent, preferably in the range of from 35 to 90 percent and more preferably in the range of from 40 to 80 percent, all in weight percentages based on the total weight of the composition.
• GPC weight average molecular weight means a weight average molecular weight measured by utilizing gel permeation chromatography, such as high performance liquid chromatograph (HPLC) supplied by Hewlett-Packard, Palo Alto, California. Unless stated otherwise, polystyrene standards were employed and tetrahydrofuran was used as the liquid phase.
• HPLC high performance liquid chromatograph
• Tg glass transition temperature measured in °C determined by DSC (Differential Scanning CalorimeuN).
• (Metn)acry ⁇ a ⁇ e means acrylate and methacrylate.
• Polymer solids or “composition solids” means a polymer or composition in its dry state.
• Ambient cure condition is defined as the temperature range of 12°C to 45°C (55°F to 110°F) and a humidity range of 15% to 90% that is present in the spraying area.
• Acetoacetylated Polyvinyl Polymer suitable for producing the acetoacetylated polyvinyl polymers of the present invention is represented by the following formula (I):
• (I) wherein (m) ranges from about 1.5 mole percent to about 85 mole percent, preferably from about 36 mole percent to about 68 mole percent, and more preferably from about 40 mole percent to about 64 mole percent, (n) ranges from about 0 mole percent to about 20.5 mole percent, preferably from about 1 mole percent to about 6 mole percent, and more preferably from about 2 mole percent to about 4 mole percent and (o) ranges from about 13 mole percent to about 98.5 mole percent, preferably from about 32 mole percent to about 63 mole percent, and more preferably from about 34 mole percent to about 55 mole percent. All the foregoing mole percentages are based on the sum of (m), (n) and (o) being 100.
• Ri and R 2 are independently H, substituted or unsubstituted Ci to C 12 alkyl, substituted or unsubstituted C ⁇ to C ⁇ 4 aryl, substituted or unsubstituted C to C 22 aralkyl, substituted or unsubstituted C ⁇ to C alkaryl, substituted, unsubstituted C 4 to C- ⁇ 4 carbocyclyl or a combination thereof, said substituents being independently selected from the group consisting of Ci to C 12 alkoxy, acyl, carooxyi, ⁇ erivative of carboxyl, sulfonyl, derivative of sulfonyl, cyano, and halo.
• Ri examples include propyl, phenyl and alkyl-substituted phenyl (preferably tolyl and xylyl).
• R 2 examples include methyl, ethyl, propyl, butyl and phenyl. More preferred is polyvinyl butyral having R-i as propyl and R 2 as methyl.
• More preferred polyvinyl polymers having Ri as propyl and R 2 as methyl are typically supplied in the form of fine grained free flowing powder by Clariant Corporation, Charlotte, North Carolina under the trademark Mowital ® .
• Some examples of polyvinyl butyrals suitable for use in the present invention include Mowital ® B20H [(m) at 49 to 55 mole percent, (n) at 1 to 5 mole percent and (o) at 40 to 46 mole percent], B30T [(m) at 41 to 46 mole percent, (n) at 1 to 5 mole percent and (o) at 49 to 55 mole percent] and B30H [(m) at 50 to 55 mole percent, (n) at 1 to 5 mole percent and (o) at 40 to 46 mole percent].
• polyvinyl polymers suitable for use in the present invention can include copolymers of vinyl acetates with one or more of the following comonomers:
• Monocarboxylic acids such as acrylic, methacrylic, crotonic acids, preferably acrylic, methacrylic acids
• Ethylenically unsaturated dicarboxylic acids such as maleic, fumaric, itaconic acids, preferably maleic acid;
• Anhydride monomers such as, maleic anhydride
• Glycidyl-containing monomers such as allylglycidyl ether, glycidyl (meth) acrylate, preferably glycidyl (meth) acrylate;
• Halogen-containing monomers such as vinyl chloride, vinyl fluoride and vinyl bromide, preferably vinyl chloride;
• Phosphate derivatives preferably vinyl phosphate, and vinyl diphosphate.
• the aforedescribed polymers containing both vinyl acetate and one or more of the aforedescribed comonomers, are conventionally prepared by the hydrolysis ofthe vinyl acetate groups to vinyl alcohol groups followed by reaction, in the presence of acid catalyst, such as phosphoric acid or hydrochloric acid, with one or more aldehydes, such as acetaldehyde, propanaldehyde, butyraldehyde, or a combination thereof to produce the polyvinyl polymer of the following formula (II):
• R 1 ; R 2 (m), (n) and (o) are the same as those stated in the formula (I) above and wherein Z is H, or-COOH and Y is -COOH, halo, unsubstituted phenyl or a combination thereof and (x) ranges from about 0.5 to about 6 mole percent, preferably from about 1 mole percent to about 5 mole percent, more preferably from about 2 mole percent to about 4 mole percent, sum of (m), (n), (o) and (x) being 100.
• the physical and chemical properties of the resulting polyvinyl polymer can be controlled.
• the degree of polymerization can also influence the thermal and mechanical properties of the resulting polyvinyl polymer.
• properties of a coating such as, hardness, toughness, elasticity and water resistance of a resulting coating composition can be suitably adjusted.
• a composition containing the resulting acetoacetylated polyvinyl polymer not only has desired substrate adhesion, but it also has lower solution viscosity. As a result, the VOC of the resulting composition can be lowered without adversely affecting coating properties.
• the acetoacetylated polyvinyl polymer of the present invention results from the substitution of about 10 mole percent to about 90 mole percent, preferably of about 15 mole percent to about 55 mole percent, more preferably of about 25 mole percent to about 50 mole percent of hydroxy ethylenyl (o) groups on the polyvinyl polymer backbone of the formula (I) with acetoacetate groups.
• the resulting acetoacetylated polyvinyl polymer of the present invention has the following formula (III):
• (p) ranges from about 12 mole percent to about 87 mole percent, preferably from about 5 mole percent to about 45 mole percent and more preferably from about 7 mole percent to about 35 mole percent; and (q) ranges from about 1 mole percent to about 88 mole percent, preferably from about 5 mole percent to about 40 mole percent and more preferably from about 10 mole percent to about 30 mole percent. All the foregoing mole percentages are based on the sum of (m), (n), (p) and (q) being 100.
• the acetoacetylated polyvinyl polymer of the present invention can also result from the substitution of about 10 mole percent to about 90 mole percent, preferably of about 15 mole percent to about 55 mole percent, more preferably of about 25 mole percent to about 50 mole percent of hydroxy ethylenyl groups (o) on the polyvinyl polymer backbone of the formula (II) with acetoacetate groups.
• the resulting acetoacetylated polyvinyl polymer of the present invention has the following formula (IV):
• the GPC weight average molecular weight of the acetoacetylated polyvinyl polymer of formulas (III) and (IV) ranges from about 10,000 to about 300,000, preferably from about 20,000 to about 200,000, more preferably from about 30,000 to about 120,000.
• the Tg of the acetoacetylated polyvinyl polymer ranges from about 0°C to about 150°C, preferably from about 20°C to about 90°C, more preferably from about 40°C to about 60°C as determined by DSC.
• the acetoacetylated polyvinyl polymers of formulas (III) and (IV) are produced by contacting the aforedescribed polyvinyl polymer of formulas (I) or (II) with Ci to C- ⁇ 2 alkyl acetoacetate, preferably t-butyl acetoacetate, to convert about 10 mole percent to about 90 mole percent of hydroxyl on said polyvinyl polymer into acetoacetate groups.
• the foregoing contacting step preferably takes place at a temperature ranging from about 75°C to about 135°C, preferably from about 80°C to about 125°C and more preferably from about 90°C to about 120°C.
• the suitable process is a solution process in which polyvinyl polymer is first dissolved in a solvent, such as butyl acetate, n-methyl pyrolidone, methyl ethyl ketone, methyl propyl ketone, methyl amyl ketone; or a combination thereof followed by contacting the polyvinyl polymer solution with Ci to C 12 alkyl acetoacetate.
• a solvent such as butyl acetate, n-methyl pyrolidone, methyl ethyl ketone, methyl propyl ketone, methyl amyl ketone; or a combination thereof
• a solvent such as butyl acetate, n-methyl pyrolidone, methyl ethyl ketone, methyl propyl ketone, methyl amyl ketone; or a combination thereof
• the resulting acetoacetylated polyvinyl polymer can be separated into a free flowing powder or stored as a solution
• a clear extruded film of the acetoacetylated polyvinyl polymer can be laminated to glass panels, such as those used in automotive windshields, to produce shatter-resistant safety glass.
• the composition of the present invention includes the acetoacetylated polyvinyl polymer of the present invention solubilized in the solvent described earlier.
• the acetoacetylated polyvinyl polymer can also be provided in the form of a dried powder.
• the amount of the acetoacetylated polyvinyl polymer utilized in the present invention typically ranges from about 3 weight percent to about 100 weight percent, preferably from about 35 weight percent to about 70 weight percent, more preferably from about 40 weight percent to about 45 weight percent, all weight percentages based on the total weight of composition solids.
• the composition can further contain from about 0.1% to 50% by weight, based on the total weight of composition solids, of an acrylic polymer having a GPC weight average molecular weight of about 1 ,000 to 35,000.
• the acrylic polymers are prepared from one or more monomers in the following group, such as, for example, acrylic ester monomer including methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, decyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, lauryl (meth)acrylate, isobornyl (meth)acrylate, isodecyl (meth)acrylate, oleyl (meth)acrylate, palmityl (meth)acrylate, stearyl (meth)acrylate, hydroxyethyl (meth)acrylate, acetoacetoxy ethyl (meth)acrylate, and hydroxypropyl
• Acrylic acid methacrylic acid, crotonic acid, itaconic acid, fumaric acid, maleic acid, monometlyl itaconate, monomethyl fumarate, monobutyl fumarate, maleic anhydride, 2- acrylamido-2-methyl-1-propanesulfonic acid, sodium vinyl sulfonate, and phosphoethyl methacrylate.
• composition of the present invention can also contain from about 0.01% to 40% by weight, based on the total weight of composition solids, of a polyester polymer which is the esterification product of an aliphatic or aromatic dicarboxylic acid, a p ⁇ lyol having at least three reactive hydroxyl groups, a diol, an aromatic or aliphatic cyclic anhydride and a cyclic alcohol.
• a polyester polymer which is the esterification product of an aliphatic or aromatic dicarboxylic acid, a p ⁇ lyol having at least three reactive hydroxyl groups, a diol, an aromatic or aliphatic cyclic anhydride and a cyclic alcohol.
• a polyester polymer which is the esterification product of an aliphatic or aromatic dicarboxylic acid, a p ⁇ lyol having at least three reactive hydroxyl groups, a diol, an aromatic or aliphatic cyclic anhydride and a cyclic alcohol.
• the composition can optionally contain, in the range of from 0.1 weight percent to 50 weight percent of a modifying resin, such as a well- known non-aqueous dispersion (NAD), all percentages being based on the total weight of composition solids.
• a modifying resin such as a well- known non-aqueous dispersion (NAD)
• the non-aqueous dispersion-type polymer is prepared by dispersion polymerizing at least one vinyl monomer in the presence of a polymer dispersion stabilizer and an organic solvent.
• the polymer dispersion stabilizer may be any of the known stabilizers used commonly in the field of non-aqueous dispersions.
• the composition can include in the range of from 2 weight percent to 10 weight percent, preferably in the range of 3 weight percent to 8 weight percent, more preferably 3.5 weight percent to 6 weight percent of zinc tetroxychromate, wherein all weight ranges are based on the weight of the composition.
• Zinc tetroxychromate supplied by Rockwood Chemicals, Beltsville, Maryland, under the trademark J-1345 Basic zinc chromate can be used in the present invention.
• the coating composition can include in the range of from
• phosphoric acid is kept separate from the composition and it is mixed with the composition just prior to use.
• the composition of the present invention can also contain conventional additives, such as pigments, stabilizers, rheology control agents, flow agents, toughening agents and fillers. Selection of such additional additives will, obviously, depend on the intended use ofthe coating composition.
• a layer of the composition is typically applied over a substrate by conventional techniques, such as spraying, electrostatic spraying, roller coating, dipping or brushing.
• the layer of the composition then dries under ambient conditions in the range of 10 minutes to 4 hours, preferably in the range of 30 minutes to 60 minutes to form a coating on the substrate having the desired coating properties. It is understood that the actual drying time depends upon the thickness of the applied layer or the presence or absence of suitable drying devices, such as fans that assist in continuously flowing air over the coated substrate to accelerate the dry rate.
• the composition applied as a wash primer layer having a thickness in the range of from 6 micrometers to 25 micrometers over a metal substrate, such as automotive body, dries in 10 to 60 minutes under ambient conditions in the absence of any suitable drying.
• baking the coated substrate at a temperature of about 60°C for about 30 minutes may further accelerate the dry rate.
• the foregoing baking step is particularly useful under OEM (Original Equipment Manufacture) conditions.
• the composition can be conventionally produced in the form of a free flowing powder, which can be conventionally applied over a substrate through a fluidized bed.
• aqueous slurry of the powder can be utilized, which can then be conventionally applied over a substrate.
• An applied layer of the powder can then be typically subjected to elevated temperatures to melt the powder and form a coating on the substrate.
• the present invention is also directed to a method of producing a multi-coat system, preferably multi-coat automotive OEM or refinish systems that includes the coating composition of the present invention as a wash primer.
• a layer of the composition of the present invention is applied over a bare metal substrate to produce a wash primer coating by using the steps described earlier.
• the wash primer coating is then followed by the conventional application of a coating of a conventional base coating composition, which can be pigmented, followed by the conventional application of a coating of a conventional clear coating composition.
• an additional coating from a conventional primer coating composition can be applied over the wash primer coating before the application of the layer of the base coating composition.
• composition of the present invention is suitable for use as coating compositions, especially in wash primers or primers, for automotive OEM and refinish industries; industrial coatings, such as coiled coatings; flow agent in powder coatings; paper lacquers, plastic surface finishes; spot-weldable paints; strippable packaging lacquers; wood sealing varnishes; zinc-rich primers; flexographic inks; gravure inks; inkjet inks; thermo-transfer inks; temporary binders for abrasives, ceramics, metal powder pellets; rheology agents in adhesives and hot-melt adhesives; binders for sand papers; candle coatings; impregnating agent for card packaging material, welding rods, underwater welding rods, particle boards, such as orientated strand boards; coating compositions for magnetic recording tapes; adhesives for laminated printed circuit boards; safety helmets for work and sports; shatter-resistant safety glass; binders for extruded, stamped, or molded floor panels and insulating boards; as thermoset and
• composition of the present invention is also suitable for use as coating compositions on: Woven or non-woven cellulosic or non-cellulosic fabrics; leather or non-leather goods, such as shoes, boots, sandals, sneakers, gloves, hats and upholstery; various sports and athletics related footwear, such as sneakers, running shoes, roller blade shoes; foot ball shoes; sports and recreation equipment, such as golf clubs, balls, tees, skis, jet skis, wet bikes, snowmobiles, skates, hockey rink surfaces, hockey pucks and hockey sticks, bowling alley lanes, bowling pins and balls; fake fruits and dry flowers; fiber optics; packaging materials, such as bottles, beverage cases, food bags and boxes; finger nails and fake finger nails; safety glass, shatter-proof glass and eye wear glasses; plasticizer migration resistant coating over vinyl surfaces; furniture, including lawn furniture; roof and roof tiles; textured and soft-feel wall coverings; toys, such as Nerf ® balls; light fixtures and bulbs; communications equipment, such as phones, pagers and fax
• the coating from the composition of the present invention may be used as durable long life traffic markings on road surfaces, including reflective road markings.
• woven mats or fibrous mats of the high strength materials such as floe, pulp, fibrids, micropulp, and a combination thereof described below, can be impregnated with the coating composition of the present invention and then conventionally compression molded, extruded or pultrusion molded to produce a variety of products, such as light weight ladders, and crash resistant safety helmets, such as those described in US Patent Nos.
• Floe comprises generally short fibers made by cutting continuous filament fibers into short lengths without significant fibrillation; and the lengths of short fibers can be of almost any length, but typically they vary from about 1 mm to 12 mm for a reinforcing fiber and up to several centimeters for a staple fiber that is spun into a yarn, such as 1.5 mm Kevlar ® 6F561 Floe supplied by DuPont Company of Wilmington, Delaware.
• Short fibers suitable for use in the present invention are the reinforcing fibers disclosed in US Patent No. 5,474,842, which is incorporated herein by reference.
• Pulp can be made by refining fibers to fibrillate the short pieces of the fiber material. Pulp can be also made by casting a polymerizing solution of polymer material and grinding and refining the solution, once solidified. Such a process is disclosed in US Patent No. 5,028,372. Pulp particles differ from short fibers by having a multitude of fibrils or tentacles extending from the body of each pulp particle such as Kevlar ® 1 F361 supplied by DuPont Company of Wilmington, Delaware. These fibrils or tentacles provide minute hair-like anchors for reinforcing composite materials and cause the pulp to have a very high surface area.
• Fibrids are substantially sheet-like structures, which can be made in accordance with the process disclosed in US Patent Nos. 5,209,877;
• the process includes adding a solution of organic polymer, with vigorous agitation, to a liquid, which is a non-solvent for the polymer and is miscible with the solvent of the solution, to cause coagulation of fibrids; the coagulated fibrids are wet milled and separated from the liquid; the separated fibrids are dried, by means appropriate, to yield clumps of fibrids having a high surface area; and the clumps are opened to yield a particulate fibrid product.
• the Product Information brochure identified as H-67192 10/98 published DuPont Canada Inc. in Mississauga, Ontario, Canada illustrates the film like physical structure of typical fibrids known as F20W DuPont fibrids.
• Micropulp having a volume average length ranging from 0.01 micrometers to 100 micrometers, preferably ranging from 1 micrometer to 50 micrometers and more preferably from ranging from 0.1 micrometers to 10 micrometers are also suitable for use in the present invention.
• the aforementioned floe, fibrid, pulp or micropulp suitable for use in the present invention can be made from organic fibers from aliphatic polyamides, polyesters, polyacrylonitriles, polyvinyl alcohols, polyolefins, polyvinyl chlorides, polyvinylidene chlorides, polyurethanes, polyfluorocarbons, phenolics, polybenzimidazoles, polyphenylenetriazoles, polyphenylene sulfides, polyoxadiazoles, polyimides, aromatic polyamides, or a mixture thereof. More preferred polymers are made from aromatic polyamides, polybenzoxadiazole, polyben-zimidazole, or a mixture thereof. Still more preferred organic fibers are aromatic polyamides ((p-phenylene terephthalamide), poly(m-phenylene isophthalamide), or a mixture thereof).
• aromatic polyamide organic fibers disclosed in US Patent Nos. 3,869,430; 3,869,429; 3,767,756; and 2,999,788, all of which are incorporated herein by reference, are preferred.
• aromatic polyamide organic fibers and various forms of these fibers are available from DuPont Company, Wilmington, Delaware under the trademark Kevlar ® fibers, such as Kevlar ® Aramid Pulp, 1 F543, 1.5 mm Kevlar ® Aramid Floe 6F561 , DuPont Nomex ® aramid Fibrids F25W.
• Kevlar ® fibers such as Kevlar ® Aramid Pulp, 1 F543, 1.5 mm Kevlar ® Aramid Floe 6F561 , DuPont Nomex ® aramid Fibrids F25W.
• Other suitable commercial polymer fibers include:
• Zylon ® PBO-AS Poly(p-phenylene-2,6-benzobisoxazole) fiber
• Zylon ® PBO-HM Poly(p-phenylene-2,6-benzobisoxazole)
• Dyneema ® SK60 and SK71 ultra high strength polyethylene fiber all supplied by Toyobo, Japan.
• Celanese Vectran ® HS pulp, EFT 1063-178 supplied by Engineering Fibers Technology, Shelton, Connecticut.
• CFF Fibrillated Acrylic Fiber supplied by Sterling Fibers Inc, Pace, Florida.
• Tiara Aramid KY-400S Pulp supplied by Daicel Chemical Industries, Ltd, 1 Teppo-Cho, Sakai City Japan.
• the organic fibers suitable for use in the present invention can also include natural fibers, such as cellulose, cotton and wool fibers.
• the non-volatile content of polymer solutions was measured by removing the solvent of a polymer sample in down draft oven at 110°C. A known quantity of the polymer was mixed with tricresyl phosphate and acetone, and placed in a down draft oven maintained at 110 ⁇ 10 °C for one hour. The weight of the residue was used to calculate the wt% solids.
• the mole percentages of groups on the acetoacetylated polyvinyl polymer samples were determined through a Bruker DRX-400 NMR spectrometer equipped with a 10 mm broad banded probe.
• the polymer samples were vacuum dried at 50°C, dissolved in deuterated methanol at approximately 5-10 weight percent and run through the spectrometer at about 34°C using a 30 second relaxation delay and a 90° flip pulse to insure quantitation.
• the coated panels were tested for dry, wet and recovered adhesion. For dry adhesion a cross cut and a grid hatch were made on the panel, tape was applied and removed. The panel was then given two ratings. The first rating was from a visual scale of 0 to 10 based on the amount of coating removed, 0 being total failure and 10 being no coating removed. The second rating was the point-of-failure that occurred as describer above.
• the panels were then placed in a humidity cabinet maintained in compliance with ASTM D-1735-02 for 96 hours. The panels were removed from the humidity cabinet and the wet adhesion was measured within one hour. The panels were then stored at 25°C and 50% relative humidity for 24 hours and then retested to measure the recovered adhesion.
• Example 1 To a glass reactor equipped with an agitator, condenser, and under nitrogen atmosphere, 500 parts of Pioloform ® LL4150 (GPC weight average molecular weight about 35,000) polyvinyl butyral supplied by Wacker GmbH, Kunststoff, Germany were added to 611 parts of methyl ethyl ketone. The solution was heated to 75°C and 80.8 parts of t-butyl acetoacetate were added over a period of several minutes. The batch was held 3 hours at 75°C and then cooled to produce acetoacetylated polyvinyl butyral of formula (III) above wherein (p) was 28 and (q) was 8.
• Pioloform ® LL4150 GPC weight average molecular weight about 35,000
• the polymer was isolated by precipitation into cold water, (0.473 liter (1 pint) of water to 150g of polymer solution), filtered, washed with cold water, filtered, and dried at room temperature under vacuum at room temperature for about 7 hours, and then under vacuum at about 55°C for about 7 hours.
• Example 2 To a glass reactor equipped with an agitator, condenser, and under nitrogen atmosphere, 500 parts of Pioloform ® LL4150 (GPC weight average molecular weight about 35,000) polyvinyl butyral supplied by Wacker Polymer System were added to 611 parts of methyl ethyl ketone. The solution was heated to 75°C and 255.9 parts of t-butyl acetoacetate were added over a period of several minutes. The batch was held for 3 hours at 75°C and then cooled to produce acetoacetylated polyvinyl butyral wherein (p) was 14 and (q) was 22. The polymer was isolated by ... precipitation into cold water, (0.473 liter. (1 pint) of water to 1.50g of polymer solution), filtered, washed twice with cold water, filtered, and dried at room temperature under vacuum at room temperature for about 7 hours, and then under vacuum at about 55°C for about 7 hours.
• Pioloform ® LL4150 GPS weight
• Example 3 To a glass reactor equipped with an agitator, condenser, distillation head, and under nitrogen atmosphere, 500 parts of Pioloform ® LL4150 (GPC weight average molecular weight about 35,000) polyvinyl butyral supplied by Wacker GmbH, Kunststoff, Germany were added to 611 parts of n-methyl pyrrolidone. The solution was heated to 130°C and 255.9 parts of t-butyl acetoacetate were added over a period of several minutes. The batch was held for 3 hours at 130°C and then cooled to produce acetoacetylated polyvinyl butyral of formula (III) above wherein (p) was 9 and (q) was 27.
• Pioloform ® LL4150 GPC weight average molecular weight about 35,000
• the polymer was isolated by precipitation in cold water, (0.473 liter (1 pint) of water to 150g of polymer solution), filtered, washed with cold water, filtered, and dried at room temperature under vacuum at room temperature for about 7 hours, and then under vacuum at about 55°C for about 7 hours. Final sample weight percent solids was 98.2%.
• Example 4 To a glass reactor equipped with an agitator, condenser, distillation head, and under nitrogen atmosphere, 150 parts of Mowital ® B20H (GPC weight average molecular weight of about 35, 000 to 45,000) polyvinyl butyral supplied by Clariant Corporation were added to 606 parts of n- methyl pyrolidone. The solution was heated to 190°C to remove any low boiling solvent. The solution was then cooled to between 140°C and 145°C and 25.6 parts of t-butyl acetoacetate were added over a period of several minutes.
• Mowital ® B20H GPC weight average molecular weight of about 35, 000 to 45,000
• the batch was held 30 minutes at temperature and then was heated to about 195°C to remove t-butanol by-product to produce acetoacetylated polyvinyl butyral of formula (III) above wherein (p) is 39 and (q) is 4.
• the polymer was isolated by precipitation into cold water, (0.473 liter (1 pint) of water to 150g of polymer solution), filtered, and dried under vacuum at 45°C.
• Example 5 To a glass reactor equipped with an agitator, condenser, distillation head, and under nitrogen atmosphere, 200 parts of Mowital ® B20H (GPC weight average molecular weight of about 35, 000 to 45,000) polyvinyl butyral supplied by Clariant Corporation were added to 606 parts of n- methyl pyrolidone. The solution was heated to 190°C to remove any low boiling solvent. The solution was then cooled to between 140°C and 145°C and 68.2 parts of t-butyl acetoacetate were added over a period of several minutes.
• Mowital ® B20H GPC weight average molecular weight of about 35, 000 to 45,000
• the batch was held 30 minutes at temperature and then was heated to about 195°C to remove t-butanol by-product to produce acetoacetylated polyvinyl butyral of formula (111) above wherein (p) is 32 and (q) is 11.
• the polymer was isolated by precipitation into cold water, (0.473 liter (1 pint) of water to 150g of polymer solution), filtered, and dried under vacuum at 45°C.
• Example 6 To a glass reactor equipped with an agitator, condenser, distillation head, and under nitrogen atmosphere, 200 parts of Mowital ® B20H (GPC weight average molecular weight of about 35, 000 to 45,000) polyvinyl butyral supplied by Clariant Corporation were added to 606 parts of n- methyl pyrolidone. The solution was heated to 190°C to remove any low boiling solvent. The solution was then cooled to between 140°C and 145°C and 102.3 parts of t-butyl acetoacetate were added over a period of several minutes.
• Mowital ® B20H GPC weight average molecular weight of about 35, 000 to 45,000
• the batch was held 30 minutes at temperature and then was heated to about 195°C to remove t-butanol by-product to produce acetoacetylated polyvinyl butyral of formula (III) above wherein (p) is 16 and (q) is 27.
• the polymer was isolated by precipitation into cold water, (0.473 liter (1 pint) of water to 150g of polymer solution), filtered, and dried under vacuum at 60°C.
• Example 7 To a glass reactor equipped with an agitator, condenser, distillation head, and under nitrogen atmosphere, 300 parts of Butvar ® B90 (GPC weight average molecular weight about 90,000) polyvinyl butyral supplied by Solutia Inc., Springfield, Massachusetts were added to 2000 parts of n- methyl pyrolidone. The solution was heated to 190°C to remove any low boiling solvent. The solution was then cooled to between 140°C and 145°C and 102.3 parts of t-butyl acetoacetate were added over a period of several minutes.
• Butvar ® B90 GPC weight average molecular weight about 90,000
• the batch was held 30 minutes at temperature and then was heated to about 95°C to remove t-butanol by-product and to produce acetoacetylated polyvinyl butyral of formula (III) above wherein (p) is 35 and (q) is 8.
• the polymer was isolated by precipitation into cold water, (0.473 liter (1 pint) of water to 150g of polymer solution), filtered, and dried under vacuum at 45°C.
• Example 8 To a glass reactor equipped with an agitator, condenser, distillation head, and under nitrogen atmosphere, 150 parts of Butvar ® B90 (GPC weight average molecular weight about 90,000) polyvinyl butyral supplied by Solutia Inc., Springfield, Massachusetts were added to 1000 parts of n- methyl pyrolidone. The solution was heated to 190°C to remove any low boiling solvent. The solution was then cooled to between 140°C and 145°C and 76.8 parts of t-butyl acetoacetate were added over a period of several minutes.
• Butvar ® B90 GPC weight average molecular weight about 90,000 polyvinyl butyral supplied by Solutia Inc., Springfield, Massachusetts were added to 1000 parts of n- methyl pyrolidone. The solution was heated to 190°C to remove any low boiling solvent. The solution was then cooled to between 140°C and 145°C and 76.8 parts of t-butyl acetoacetate were added over
• the batch was held ⁇ u minutes at temperature and then was heated to about 195°C to remove t-butanol by-product and to produce acetoacetylated polyvinyl butyral of formula (III) above wherein (p) is 29 and (q) is 14.
• the polymer was isolated by precipitation into cold water, (0.473 liter (1 pint) of water to 150g of polymer solution), filtered, and dried under vacuum at 45°C.
• Coating Compositions The examples, shown in Table 1 below, were prepared by sequentially adding the components in Table 1 , to compare the coating properties of unmodified polyvinyl polymer against the acetoacetylated polyvinyl polymer of the present invention. All the compositions below were adjusted to 30 weight percent solids.
• Unmodified Polyvinyl butyral (Comp. Ctng Ex. 1) showed poor adhesion to unsanded electrocoated steel panels.
• the acetoacetylated polyvinyl butyral of the present invention which contain acetoacetate groups, showed much improved adhesion to unsanded electrocoated panels. While the adhesion of these polymers to Aluminum was less than desired at low levels of acetoacetylation, it improved dramatically at higher levels of acetoacetylation (Ctng Ex. 3 vs. Ctng Ex. 1 and 2). Therefore, the acetoacetylated polyvinyl butyrals of the present invention have improved adhesion to unsanded electrocoated steel panels, without sacrificing adhesion to other substrates.
• the layers of coating compositions described in Table 3 above were applied with a draw-down bar over test panels indicated below to a dry film thickness of 13 to 25.4 micrometers (0.5 to 1.0 mil). The layers were then dried for at least 14 days and then adhesion was tested.

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