WO2017117169A1 - Low bake autodeposition coatings - Google Patents

Abstract

Autodeposition coating compositions that deposit uncured coatings, on metallic surfaces of a substrate, which are curable at oven temperatures of less than 130 °C, are provided as well as autodeposition methods, compositions and components for depositing such autodeposition coatings. More particularly, the invention relates to autodeposition coatings that cure at temperatures lower than conventional autodeposition coatings, while achieving chemical and corrosion performance comparable to higher temperature cure autodeposition coatings, as well as being directed to autodeposition coating compositions possessing improved storage stability and coating thermal stability, and articles of manufacture having cured and uncured autodeposited coatings deposited thereon.

Description

LOW BAKE AUTODEPOSITION COATINGS

FIELD OF THE INVENTION

[0001.] This invention relates to autodeposition coatings on metallic surfaces of a substrate that are curable at oven temperatures of less than 130 °C, autodeposition coating compositions and components thereof useful in making autodeposition coating baths that deposit such coatings, and methods of making and using autodeposition coating compositions and coating baths, as well as articles of manufacture made therefrom. More particularly, the invention relates to autodeposition coatings that cure at temperatures lower than conventional

autodeposition coatings which provide chemical and corrosion performance comparable to higher temperature cure autodeposition coatings, as well as being directed to autodeposition coating compositions possessing improved storage stability and coating thermal stability, and articles of manufacture having cured and uncured autodeposited coatings deposited thereon.

BACKGROUND OF THE INVENTION

[0002.] Autodeposition has been in commercial use on steel for more than thirty years and is now well established for that use. For details, see for example, U.S. Pat. Nos. 3,063,877;

3,585,084; 3,592,699; 3,674,567; 3,791,431 ; 3,795,546; 4,030,945; 4,108,817; 4,178,400;

4,186,226; 4,242,379; 4,234,704; 4,636,264; 4,636,265; 4,800,106; and 5,342,694. The disclosures of all these patents are hereby incorporated by reference. Epoxy resin-based autodeposition coating systems are described in U.S. Pat. No. 4,180,603; U.S. Pat. No.

4,289,826; U.S. Pat. No. 5,500,460; U.S. Pat. No. 7,388,044 and International Publication Number WO 00/71337, the teachings of each of which are incorporated by reference.

[0003.] Autodeposition compositions are usually in the form of a liquid, usually aqueous solutions, emulsions or dispersions in which active metal surfaces of inserted articles are coated with an adherent resin or polymer film that increases in thickness the longer the metal remains in the bath, even though the liquid is stable for a long time against spontaneous precipitation or flocculation of any resin or polymer, in the absence of contact with the active metal. When used in the autodeposition process, the composition when cured forms a polymeric coating. "Active metal" is defined as metal that spontaneously begins to dissolve at a substantial rate when introduced into the liquid solution or dispersion. Such compositions, and processes of forming a coating on a metal surface using such compositions, are commonly denoted in the art, and in this specification, as "autodeposition" or "autodepositing" compositions, dispersions, emulsions, suspensions, baths, solutions, processes, methods or a like term. Autodeposition is often contrasted with electrodeposition. Although each can produce adherent films with similar performance characteristics, the dispersions from which they are produced and the mechanism by which they deposit are distinctly different. Electrodeposition requires that metal or other articles to be coated be connected to a source of direct current electricity for coating to occur. No such external electric current is used in autodeposition.

[0004.] Conventional autodeposition coatings are typically cured in two steps and require reaching a peak metal temperature (PMT) of about 200°C. This higher temperature cure coating provides improved properties such as resistance to temperatures up to about 220°C, but comes at a cost in time and energy for curing and limits the type of paints that can be applied to the uncured autodeposition coating.

[0005.] The general difficulties facing any low temperature cure autodeposition coating composition (curable at oven temperatures of 130 °C or less) have been poor performance of the cured coating with respect to corrosion resistance, chemical resistance and high temperature resistance compared to conventional higher temperature curing autodeposition coating compositions, as well as poor storage and heat stability of the coating compositions prior to application. This is reflected in the limited, if any, commercial successes of low temperature cure chemistry in the autodeposition industry.

[0006.] U.S. Pat. No. 4,575,523 and U.S. Pat. No. 6,048,443 disclose low bake cathodic ecoat compositions, but the chemistry of these compositions is unstable in autodeposition bath conditions. U.S. Pat. No. 7,388,044 discloses single component autodeposition compositions, but the coatings are generally baked above 160 °C. International patent publication

WO/2002/042008 discloses rinse compositions of metal phosphates that are said to improve anticorrosive properties of autodeposition coatings but these rinses cannot catalyze crosslinking or improve chemical resistance in the autodeposition coatings described therein. International patent publication WO/2012/174424 discloses an additive having one to two nitrogen-oxygen bonds that are said to improve autodeposition coating performance on multimetal substrates, but these additives cannot catalyze crosslinking or improve chemical resistance in the autodeposition coatings described therein, and the coatings are generally baked above 160 °C. [0007.] Thus there remains a need for lower temperature curing autodeposition coating compositions and coatings that provide corrosion resistance, chemical resistance and high temperature resistance comparable to conventional higher temperature curing autodeposition coating, as well as good storage and heat stability of the coating compositions prior to application. Applicants' invention is directed to addressing one or more of the above-described challenges.

SUMMARY OF THE INVENTION

[0008.] An object of the invention is to provide autodeposition coating chemistries, e.g. coating compositions and baths, that produce coatings on metal substrates which have cure temperature of 130 °C or below and continue to provide sufficient chemical resistance and improved corrosion resistance. Desirably the curing includes crosslinking of the uncured coating.

[0009.] In one aspect of the invention, the autodeposition coating composition comprises blocked isocyanates that may be de-blocked at lower temperatures (less than 130 °C).

[0010.] In another aspect of the invention, the aforementioned blocked isocyanates are used with an amine catalyst rinse to improve crosslinking and enhance the corrosion performance, to achieve much lower baking temperatures than the current state of art technologies.

[0011.] In another aspect of the invention, the autodeposition coating bath and the process of making the autodeposition coatings of the invention comprise in-bath additives that may prolong the storage stability and /or increase heat stability of the blocked isocyanates and /or improve corrosion performance of the cured autodeposition coatings formed according to the inventive low cure process.

[0012.] An autodeposition coating composition is provided that can be applied to a metal surface generating an uncured coating thereon and then the coating can be cured at or below 130 °C with or without a separate catalyst rinse to achieve improved chemical and corrosion performance, while possessing sufficient in-can storage stability and coating thermal stability.

[0013.] Unlike PVDC products, the inventive coatings can sustain high operating

temperatures without deterioration. While most PVDC products begin to deteriorate at aboutl20 °C, the inventive coatings have been tested to temperatures as high as about 220 °C with no visible breakdown or delamination.

[0014.] This invention provides autodeposition coating compositions useful in applications where low temperature cure processing, cured coating heat resistance and corrosion resistance, as well as autodeposition coating compatibility with lower temperature cure topcoats are required. This invention maintains autodeposition inherent advantages including environmental sustainability and simplicity. The inventive coatings and compositions are useful in application areas including pre- assembled components, rubber to metal application, vehicles, and a broad range of other industry applications where high heat curing (e.g. peak metal temperature (PMT) of greater than 130 °C) is undesirable.

[0015.] As used herein, the listed abbreviations have the following meaning: DMP: 3,5- Dimethylpyrazole; DICY: Dicyandiamide; DMI: 1 ,2-Dimethylimidazole; DEM: Diethyl malonate; DBU: l,8-Diazabicyclo[5.4.0]undece-l-ene; DBN: Diazacyclononane; MEKO:

Methylethyl ketoxime; HDI: Hexamethylene diisocyanate; IPDI: Isophorone diisocyanate; MDI: Methylene diphenyl diisocyanate; SFS: Sodium formaldehyde sulfoxylate; tBHP: tert- Butylhydroperoxide 70%; CRS: Cold rolled steel; GPC: Gel permeation chromatography.

[0016.] Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions, or defining ingredient parameters used herein are to be understood as modified in all instances by the term "about". Throughout the description, unless expressly stated to the contrary: percent, "parts of min., and ratio values are by weight or mass; the term "polymer" includes "oligomer", "copolymer", "terpolymer", and the like; the first definition or description of the meaning of a word, phrase, acronym, abbreviation or the like applies to all subsequent uses of the same word, phrase, acronym, abbreviation or the like and applies, mutatis mutandis, to normal grammatical variations thereof; the term "mole" and its variations may be applied to ions, moieties, elements, and any other actual or hypothetical entity defined by the number and type of atoms present in it, as well as to materials with well- defined neutral molecules; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description or of generation in situ within the composition by chemical reaction(s) between one or more newly added constituents and one or more constituents already present in the composition when the other constituents are added; specification of constituents in ionic form additionally implies the presence of sufficient counterions to produce electrical neutrality for the composition as a whole and for any substance added to the composition; any counterions thus implicitly specified preferably are selected from among other constituents explicitly specified in ionic form, to the extent possible; otherwise, such counterions may be freely selected, except for avoiding counterions that act adversely to an object of the invention; molecular weight (MW) is weight average molecular weight; the word "mole" means "gram mole", and the word itself and all of its grammatical variations may be used for any chemical species defined by all of the types and numbers of atoms present in it, irrespective of whether the species is ionic, neutral, unstable, hypothetical or in fact a stable neutral substance with well-defined molecules; the term "latex" is to be understood to mean a dispersion in water of polymer particles, and the terms "storage stable" or "shelf stable" are to be understood as including dispersions that show no visually detectable tendency toward phase separation or show less than 75, 50, 40, 35, 30, 25, 20, 18, 16, 14, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 % cross-linking, calculated by GPC comparison to imaged dispersions, over a period of observation of at least 72, 96, 120, 150, 200, 250, 300, 320, or preferably at least 336, hours during which the material is mechanically undisturbed and the temperature of the material is maintained at ambient room temperatures (18 to 25° C).

[0017.] For a variety of reasons, it is preferred that coating compositions according to the invention may be substantially free from many ingredients used in compositions for similar purposes in the prior art. Specifically, it is increasingly preferred in the order given,

independently for each preferably minimized ingredient listed below, that compositions according to the invention, contain no more than 1.0, 0.5, 0.35, 0.10, 0.08, 0.04, 0.02, 0.01, 0.001, or 0.0002 percent, more preferably said numerical values in grams per liter, of each of the following constituents: chromium; vinyl chloride monomer, vinylidene chloride monomer.

[0018.] The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims and equivalents thereof. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0019.] The invention relates to autodeposition compositions, useful in forming autodeposited coatings that are curable at temperatures of less than about 135°C, preferably 130°C, i.e. that cure at temperatures lower than conventional autodeposited coatings, while still providing comparable chemical and corrosion performance, as well as being directed to autodeposition coating baths, and articles of manufacture having cured and uncured autodeposited coatings deposited thereon.

[0020.] It has been found that incorporation of latent crosslinking agent with a deblocking temperature of less than 135°C that is stable at low pH into an epoxy-based autodeposition coating material is an effective way to lower the curing temperature without reducing the anti- corrosive properties of the applied coating. Using low temperature deblocking crosslinkers in autodeposition baths has been problematic due to pre-mature deblocking. Applicants discovered stabilization of the crosslinking agent in the low pH environment of compositions according to the invention provides cross-linking functionality during the curing while increasing shelf life of the autodeposition compositions.

[0021.] The invention provides a means to obtain epoxy-based autodeposition coating materials with good chemical and corrosion resistance that are curable at temperatures of less than 135°C. In one embodiment, an epoxy pre-polymer is used. The epoxy pre-polymer is combined with ethylenically unsaturated monomer that desirably may comprise hydroxy- functional monomer, to yield an epoxy-monomer blend, which may be blended with other coating components and additives. The resulting blend is then dispersed in water with surfactant and the ethylenically unsaturated monomer is polymerized (optionally in the presence of other formulation components) to yield an aqueous epoxy dispersion. Prior to being dispersed in water at least one curing agent, e.g. a crosslinking agent, is added to the blend. The curing agent must be stable in pH ranges of 1.5 to about 6, and desirably is a blocked or otherwise temporarily inactivated curing agent, preferably a blocked isocyanate. The curing agent may be added before, during or after the time the epoxy pre-polymer is combined with the ethylenically unsaturated monomer and optionally other coating components and additives provided it is added prior to the resulting blend being dispersed in water. As used herein "aqueous epoxy dispersion" means a dispersion in water of polymer particles comprising an epoxy polymer or pre-polymer and polymerized ethylenically unsaturated monomer, and may comprise other additives. "Film forming polymer molecules" found in the aqueous epoxy dispersion will be understood to mean at least the epoxy polymer or pre-polymer and polymerized ethylenically unsaturated monomer of the aqueous epoxy dispersion. The aqueous epoxy dispersion may then be used as one component of a coating bath formulation. The coating bath formulation can then be applied to an active metal substrate and cured to form a final coating.

[0022.] The present invention solves the problems of the related art by providing a process to obtain low temperature curing epoxy-based autodepositing coating materials having good chemical resistance and/or anti-corrosive properties. The invention also produces aqueous epoxy dispersions that are capable of being used as a component of an autodepositing coating bath formulation that produces autodeposited coatings on active metal surfaces, wherein the coatings are crosslinkable at temperatures of less than about 135°C. The invention also provides stable aqueous epoxy dispersions containing crosslinking agents that have a relatively long shelf life. The invention further provides a coating that may be applied using a variety of techniques such as autodeposition, spray, electrostatic, roll, and brush application.

[0023.] In one embodiment the invention comprises a process for making an aqueous epoxy dispersion, the process comprising the steps of: (a) dissolving and/or dispersing an epoxy pre- polymer with at least one ethylenically unsaturated monomer to form a mixture; (b) dispersing the mixture of step (a) in water with at least one surfactant to form a fine particle dispersion; and (c) polymerizing the at least one ethylenically unsaturated monomer contained in the fine particle dispersion to form an aqueous epoxy dispersion, wherein at least one water soluble initiator and/or at least one organic soluble initiator is added prior to step (c) and at least one latent curing agent such as, for example, a blocked isocyanate is incorporated into the mixture before the at least one ethylenically unsaturated monomer is polymerized. The type and concentration of epoxy pre-polymer and ethylenically unsaturated monomer used, as well as the type of initiator, can be varied to achieve specific performance properties such as corrosion resistance, flexibility, edge protection, and appearance properties such as gloss and smoothness.

[0024.] In another embodiment, the invention comprises an autodepositing coating composition curable at temperatures of less than about 135°C comprising one or more aqueous epoxy dispersions of the invention and at least one autodeposition accelerator component. In another embodiment, the invention comprises a process for making an autodepositing coating composition comprising combining an aqueous epoxy dispersion of the invention, water, and at least one autodeposition accelerator component.

[0025.] Depending on the relative amounts of epoxy-prepolymer and ethylenically unsaturated monomer used, a solvent may also be used in conjunction with the ethylenically unsaturated monomer to form the crude or fine particle dispersions of the present invention. Solvent, for the purposes of the present application, includes any suitable solvent other than water. A solvent component may be used as a medium for preparing the epoxy pre-polymer. The solvent may be used when combining the epoxy resin and any catalysts capable of accelerating the desired epoxy group reaction. Subsequently, the solvent may be removed by techniques known in the art. The solvent, in many cases, does not diminish the technical benefits of the final coating composition and may be left in place when the aqueous epoxy dispersion is added as a component of the final coating composition. The preferred solvents are mixtures of (i) aromatic hydrocarbons having 6 to 10 carbon atoms and (ii) ketones having 3 to 8 carbon atoms.

Particularly preferred solvents include propylene carbonate, butyl benzoate, butylene carbonate, butoxyethanol acetate and 2,2,4-trimethyl-l,3-pentanediol mono(2-methylpropanoate).

[0026.] The relative amounts of epoxy-prepolymer and ethylenically unsaturated monomer can be varied widely to yield a variety of performance attributes. Typical weight ratios of epoxy-prepolymer to ethylenically unsaturated monomer are about 90:10 to about 15:85. In one embodiment the weight ratios of epoxy-prepolymer to ethylenically unsaturated monomer are about 90:10 to about 5:95. In another embodiment, weight ratios of epoxy-pre-polymer to ethylenically unsaturated monomer are about 70:30 to about 30:70. Other desired coating components, curing agents, and additives may be added to the epoxy pre-polymer-ethylenically unsaturated monomer mixture before, during, or after it is formed. The resulting mixture of epoxy pre-polymer, ethylenically unsaturated monomer, curing agent and any other desired coating components are then dispersed in water

[0027.] The epoxy pre-polymers useful in the present invention can be based on conventional epoxy resins. Such epoxy resins are well known substances and are described, for example, in the chapter entitled "Epoxy Resins" in Volume 6 of The Encyclopedia of Polymer Science and Engineering (Second Edition). Epoxy resins are often described by the type of central organic moiety or moieties to which the 1 ,2-epoxy moieties are attached. Non-exclusive examples of such central moieties are those derived from bisphenol A, bisphenol F, novolak condensates of formaldehyde with phenol and substituted phenols, the condensates containing at least two aromatic nuclei; triazine; hydantoin; and other organic molecules containing at least two hydroxyl moieties each, in each instance with as many hydrogen atoms deleted from hydroxy moieties in the parent molecule as there are epoxy moieties in the molecules of epoxy resin. Optionally, the 1,2-epoxy moieties may be separated from the central moieties as defined above by one or more, preferably only one methylene group. Oligomers of such monomers, either with themselves or with other organic molecules containing at least two hydroxyl moieties each, may also serve as the central organic moiety.

[0028.] Non-exclusive examples of epoxy resins useful for the present invention include glycidyl ethers of a polyhydric phenol, such as bisphenol A (a particularly preferred species of polyhydric phenol), bisphenol F, bisphenol AD, catechol, resorcinol, and the like. Primarily for reasons of economy and commercial availability, it is generally preferred to utilize epoxy resins derived from bisphenol A in this invention. More particularly, epoxy moiety containing molecules utilized in this invention preferably conform to the general chemical formula:

and "n" is an integer from 0 to 50. If such epoxy resins are to be used directly as the resin component of the present invention, "n" is preferably an integer within the range from about 1- 30 so that each molecule contains at least one hydroxyl group. Commercially available epoxy resins of this type are normally mixtures of molecules having somewhat different "n" values and different numbers of epoxy groups. Preferably, the epoxy resin mixture used has a number average molecular weight in the range of from about 350 to about 5,000, more preferably in the range from about 400 to about 3000. Preferably, the average number of epoxide groups per molecule in the epoxy resin mixture is in the range from 1.7 to 2.5, more preferably in the range from 1.9 to 2.1. The epoxy resin mixture may contain resin molecules in which n=0.

[0029.] In another embodiment, the epoxy pre-polymer comprises the reaction product of aromatic polyepoxide and at least one co-reactant having one or more epoxy-reactive groups. The ratio of epoxy and epoxy reactive groups are chosen such that epoxy endgroups remain once the reaction is essentially complete. Preferred molecular equivalent weight ranges for such pre- polymers range from 450-2000 grams/equivalent epoxy based on solids. In one embodiment the co-reactant containing epoxy reactive groups also comprises ethylenic unsaturation. Such co- reactants offer one of several means to control degrees of grafting, if any, onto the epoxy pre- polymer during the radical polymerization. Non-exclusive examples of such co-reactants include unsaturated acid esters such as acrylic and methacrylic acid, and unsaturated acids and unsaturated anhydrides such as maleic acid and maleic anhydride.

[0030.] In one embodiment the pre-polymer comprises an additional monofunctional species that is capable of reacting with some of the epoxy functional groups of the pre-polymer. The resulting pre-polymer has a lower viscosity and is therefore easier to process into a dispersion with a desired particle size. Non-exclusive examples of such monofunctional species include phenol, substituted phenols such as nonylphenol, and monocarboxylic acids such as

alkylcarboxylic acids.

[0031.] At least one ethylenically unsaturated monomer is used to prepare the autodeposition coating composition. Suitable ethylenically unsaturated monomers include but are not limited to vinyl aromatic hydrocarbons such as styrene and substituted styrenes, vinyl aliphatic

hydrocarbons, ethylenically unsaturated acids such as acrylic and methacrylic acid as well as alkyl and hydroxy-alkyl esters of such acids. Non-exclusive examples include butyl acrylate, methyl methacrylate, and hydroxyethyl methacrylate. Acrylonitrile, methacrylonitrile, acrylamide, and methacrylamide are also suitable. Ethylenically unsaturated monomers with anionic functionality may be used. Anionic functional monomers, when co-polymerized into an emulsion or aqueous solution polymers, provide a "bound" source of ionic charges to effectively stabilize the emulsion polymer particles both during polymerization and subsequent formulation into autodeposition compositions. [0032.] Desirably hydroxyl functional ethylenically unsaturated monomer is used. The use of hydroxyl functional ethylenically unsaturated monomer provides for a dispersion that has greater solvent resistance when used in conjunction with hydroxyl reactive crosslinking or curing agents. The improvement in solvent resistance is observed in the applied coating after curing. The improvement stems from crosslinking between hydroxyl groups on the acrylic chain and crosslinking agent utilized in the aqueous epoxy dispersion. Non-exclusive examples of hydroxyl functional ethylenically unsaturated monomer include 2-hydroxyethyl methacrylate,

hydroxy ethyl acrylate, and hydroxy propyl methacrylate.

[0033.] The aqueous epoxy dispersions and coating compositions of the present invention may also contain one or more substances capable of reacting with the polymer end product to provide a crosslinked polymeric matrix in the cured coating. In one embodiment of the invention, at least a portion of the curing agents (sometimes referred to as crosslinking agents) only react with the epoxy dispersion end-product at the elevated temperatures typically encountered during the curing stage of the composition. Such curing agents are often referred to in the art as "latent" curing agents or hardeners because they only become activated when heated to a temperature well in excess of normal room temperature. The use of latent curing agents is preferred in the present invention so that substantial cross linking of the epoxy resin or epoxy pre-polymer may be avoided prior to and during deposition on the surface of an article. In the case of metallic articles the deposition is typically carried out at temperatures of from about 20° C. to about 60°C. However, if so desired, minor amounts of more reactive curing agents may also be present in addition to the latent curing agents so as to accomplish partial crosslinking prior to deposition on an article. In one embodiment of the invention, at least one latent curing agent such as, for example, a blocked isocyanate is incorporated into the mixture before the at least one

ethylenically unsaturated monomer is polymerized.

[0034.] Blocked isocyanates are popular latent curing agents. Most commercial products in the industry use blocked isocyanates with alcohols or lactams as blocking groups. These isocyanates generally deblock at fairly high temperatures in presence of catalysts, therefore, can ensure good shelf life for the paint formulations. Commercial blocked isocyanates that can deblock at relatively low temperatures are usually blocked with pyrozoles, oximes, phenols, malonates or amines et al. Many more blocking agents are available as discussed in [Douglas A. Wicks, Zeho W. Wicks Jr., Progress in Organic Coatings, 36 (1999) 148-172; 41 (2001) 1-83] but only a few of them have been commercialized. Because they deblock at lower temperatures, these blocked isocyanates are also more prone to deblock during transportation or storage, therefore, have inferior shelf or in-can stability. Some of them may also be prone to undergo other types of side reactions such as hydrolysis of oxime blocked isocyanates at low pHs and undesirable transesterification reactions of malonate based isocyanates. In autodeposition paint bath, due to extremely low pHs and presence of strong oxidizer and heavy metal ions, it's generally very difficult to incorporate a blocked isocyanate that can survive the harsh bath condition, and at the same time can function properly.

[0035.] In this invention, suitable blocked isocyanates can be those blocked with pyrozoles, triazoles, oximes, phenols, malonate, amines and other amine-based blocking groups. DMP- blocked isocyanates are preferred. This include DMP blocked aliphatic isocyanates such as HDI, IPDI and derivatives, as well as aromatic isocyanates. Those mixed blocked isocyanates such as DMP blocked HDI/ IPDI mixture or mixed blocked groups such as IPDI blocked with both DMP and DEM are also suitable. Desirably, typical curing temperatures for such crosslinking agents are at or below 135°C. The deblocking temperature of the latent crosslinker, i.e. the curing agent, is at least in increasing order of preference about 55, 56, 58, 60, 62, 64, 66, 68, 70, 71, 72, 74, 76, 78, 80, 82, 84, 86, 88, 90, 92, 94, 96, 98, 100, 102, 104, 106, 108, 110, 112, 114, 116, 118, 120, 122 or 124 °C and not more than in increasing order of preference about 140, 139, 138, 137, 136, 135, 134, 133, 132, 131, 130, 129, 128, 127, 126, 125 or 124°C.

[0036.] Concentration of the blocked isocyanate in aqueous epoxy dispersion ranges from 0 to 20% of total monomer prior to polymerization, desirably at least about 2, 3, 4, 5, 6, 7, 8 or 10wt.% and not more than 20, 18, 16, 14 or 12 wt.%. Typical weight ratios of blocked isocyanate to ethylenically unsaturated monomer are about 1 :99 to about 20:80. In one embodiment the weight ratios of blocked isocyanate to ethylenically unsaturated monomer are about 3:97 to about 15:85. In another embodiment, weight ratios of epoxy-pre-polymer to ethylenically unsaturated monomer are about 4:96 to about 10:90.

[0037.] In some embodiments, a stabilizer may be included in the aqueous epoxy dispersion to stabilize the lower curing blocked isocyanates in the autodeposition compositions. Strong acids generally can slow down certain urethane reactions, therefore, can somewhat extend the shelf life of certain blocked isocyanates. The preferred acids in this invention are organic acids containing sulfur or phosphorus, for example sulfonic and phosphonic acids, as some of them are also used as corrosion inhibitors or as a component of corrosion inhibitor packages.

Concentration of the strong organic acid in the mixture prior to polymerization ranges from 0 - 5%, measured as a percentage of total monomer present, i.e. 0-5 parts acid to 100 parts monomer. Desirably the amount of organic acid present ranges from about 0.05, 0.1, 0.3, 0.5, 1.0 or 1.5% and independently preferably is not more than, with increasing preference in the order given, 5, 4.8, 4.5, 4.2, 4, 3.8, 3.5, 3.2, 3.0, 2.8, 2.5, 2.2, 2.0, 1.9 or 1.8 %.

[0038.] Essentially any type of free radical generator can be used to initiate polymerization of the monomers. For example, free radical generating chemical compounds, ultraviolet light or radiation can be used. A radical initiator may be added to facilitate the polymerization of the ethylenically unsaturated monomer within the epoxy containing micelle of the dispersion.

Relative degrees of grafting, if any, between epoxy pre-polymer and polymerized monomer can be achieved to provide for specific molecular weights and specific performance ends by careful selection of initiator type. Initiators may be added at various points in the process of forming the dispersion. In one embodiment, the initiator is organic soluble and is introduced in the organic phase prior to dispersion of the epoxy pre-polymer, ethylenically unsaturated monomer, and curing agent in water. In another embodiment, the initiator is water-soluble and is introduced after dispersion of the epoxy pre-polymer/ethylenically unsaturated monomer/curing agent mixture in water. In another embodiment both organic soluble initiators and water-soluble initiators are added. In another embodiment an organic soluble initiator is introduced after the aqueous dispersion is formed. In this embodiment, the organic soluble initiator is added directly or dissolved in a co-solvent and dripped into the dispersion.

[0039.] Non-exclusive examples of suitable organic soluble initiators, e.g. oxidants, include peroxides, peroxy esters as well as organic soluble azo compounds. Benzoyl peroxide is one preferred example. Non-exclusive examples of suitable water-soluble initiators include hydrogen peroxide, tert-butyl peroxide, t-butyl peroxtoate, hydroperoxides such as t-butyl hydroperoxide, alkali metal (sodium, potassium or lithium) or ammonium persulfate; azo initiators such as azobisisobutyronitrile or 2,2'-azobis(2-amidinopropane)dihydrochloride; or mixtures thereof. Ammonium persulfate and Vazo 68 WSP (Available from E.I. DuPont de Nemours) are two preferred examples. In one embodiment such initiators may also be combined with reducing agents, e.g. reductant solutions, to form a redox system. Non-exclusive examples of reducing agents include sulfites such as alkali metal meta bisulfite, or hyposulfite, sodium thiosulfate, or isoascorbic acid, or sodium formaldehyde sulfoxylate. The free radical precursor and reducing agent together, referred to as a redox system herein, may be used at a level of from about 0.01% to 5%, based on the weight of monomers used. Non-exclusive examples of redox systems include: t-butyl hydroperoxide/sodium formaldehyde sulfoxylate/Fe(III); t-butyl

hydroperoxide/isoascorbic acid/Fe(III); and ammonium persulfate/sodium bisulfite/sodium hydrosulfite/Fe(III). In another embodiment, sodium formaldehyde sulfoxylate is used to initiate polymerization in conjunction with at least one anionic surfactant, such as sulfates and sulfonates in the absence of peroxides. Incorporation of anionic endgroups resulting from this method provides an increased level of stability for the emulsion as well as the corresponding

autodeposition bath. Nonylphenol ethoxylate sulfate ammonium salt and sodium lauryl sulfate are two suitable non-exclusive examples.

[0040.] In one embodiment, the polymerization of the ethyl enically unsaturated monomer is carried out with applied heat. A wide variety of temperatures can be employed and the specific optimum temperature varies with each initiator. Alternatively, redox initiation methods are widely known in the art by which polymerization can be conducted at ambient or near ambient conditions.

[0041.] Coalescing agents may be incorporated into the dispersion. Coalescing agents will be apparent to those skilled in the art. Non-exclusive examples of coalescing agents include monoethers and monoesters of glycols, preferably glycols with at least one terminal hydroxy group. Monoethers of ethylene glycol are readily available. Monoethers of propylene glycol, particularly the methyl, t-butyl, n-butyl, and phenol monoethers of propylene glycol, dipropylene glycol and tripropylene glycol are preferred from this class.

[0042.] A dispersion or coating bath composition of the present invention may also contain a number of additional ingredients that are added before, during, or after the formation of the dispersion. Such additional ingredients include fillers, biocides, foam control agents, pigments and soluble colorants, and flow control or leveling agents. The compositions of these various components may be selected in accordance with the concentrations of corresponding components used in conventional epoxy resin-based autodeposition compositions, such as those described in U.S. Pat. Nos. 5,500,460, and 6,096,806 and U.S. Ser. No. 09/578,935, the teachings of which are hereby incorporated by reference. Pigments and soluble colorants may generally be selected for compositions according to this invention from materials established as satisfactory for similar uses. Examples of suitable materials include carbon black, titania, phthalocyanine blue, phthalocyanine green, quinacridone red, hansa yellow, and/or benzidine yellow pigment, and the like provided that they are sufficiently stable in the autodeposition coating bath.

[0043.] To prepare a coating bath composition suitable for coating a metallic substrate by autodeposition, the epoxy dispersion is combined with at least one autodeposition accelerator component, which is capable of causing the dissolution of active metals (e.g., iron) from the surface of the metallic substrate in contact with the bath composition. Preferably, the amount of accelerator present is sufficient to dissolve at least about 0.020 gram equivalent weight of metal ions per hour per square decimeter of contacted surface at a temperature of 20. degree. C.

Preferably, the accelerator(s) are utilized in a concentration effective to impart to the bath composition an oxidation-reduction potential that is at least 100 millivolts more oxidizing than a standard hydrogen electrode. Such accelerators are well-known in the autodeposition coating field and include, for example, substances such as an acid, oxidizing agent, and/or complexing agent capable of causing the dissolution of active metals from active metal surfaces in contact with an autodeposition composition. The autodeposition accelerator component may be chosen from the group consisting of hydrofluoric acid and its salts, fluosilicic acid and its salts, fluotitanic acid and its salts, ferric ions, acetic acid, phosphoric acid, sulfuric acid, nitric acid, hydrogen peroxide, peroxy acids, citric acid and its salts, and tartaric acid and its salts. More preferably, the accelerator comprises: (a) a total amount of fluoride ions of at least 0.4 g/L, (b) an amount of dissolved trivalent iron atoms that is at least 0.003 g/L, (c) a source of hydrogen ions in an amount sufficient to impart to the autodeposition composition a pH that is at least 1.6 and not more than about 5, and, optionally, (d) hydrogen peroxide. Hydrofluoric acid is preferred as a source for both the fluoride ions as well as the proper pH. Ferric fluoride can supply both fluoride ions as well as dissolved trivalent iron. Accelerators comprised of HF and FeF3 are especially preferred for use in the present invention. [0044.] In one embodiment, ferric cations, hydrofluoric acid, and hydrogen peroxide are all used to constitute the autodeposition accelerator component. In a working composition according to the invention, independently for each constituent: the concentration of ferric cations preferably is at least, with increasing preference in the order given, 0.5, 0.8 or 1.0 g/1 and independently preferably is not more than, with increasing preference in the order given, 2.95, 2.90, 2.85, or 2.75 g/1; the concentration of fluorine in anions preferably is at least, with increasing preference in the order given, 0.5, 0.8, 1.0, 1.2, 1.4, 1.5, 1.55, or 1.60 g/1 and independently is not more than, with increasing preference in the order given, 10, 7, 5, 4, or 3 g/1; and the amount of hydrogen peroxide added to the freshly prepared working composition is at least, with increasing preference in the order given, 0.05, 0.1, 0.2, 0.3, or 0.4 g/1 and independently preferably is not more than, with increasing preference in the order given, 2.1, 1.8, 1.5, 1.2, 1.0, 0.9, or 0.8 g/1.

[0045.] In one embodiment the invention relates to autodeposition coating baths comprising autodeposition compositions as disclosed herein and further comprising at least one additive selected from zinc fluoride hydrate, sodium acetylacetonate hydrate and combinations thereof.

[0046.] The coating can be formulated by either a single emulsion containing both the aqueous epoxy dispersion and the crosslinker or two distinct emulsions that separate the aqueous epoxy dispersion from the crosslinker until the two emulsions are combined to form the autodepositing coating bath. Being able to provide a two-pack of aqueous epoxy dispersion and crosslinker allows formulation flexibility and product customization based on customer requirements.

[0047.] In one embodiment, autodeposition compositions in a single package comprising emulsions containing aqueous epoxy dispersion and crosslinker are provided as described above.

[0048.] In another embodiment, autodeposition compositions can be formulated in a two- package product comprising two component emulsions, for example: Component A comprising a crosslinker for said aqueous epoxy dispersion and optional stabilizer; and Component B comprising a aqueous epoxy dispersion, solvent and any hydroxyfunctional monomer.

Alternatively, Component A may comprise all components of the single package latex, in the absence of epoxy resin, solvent and hydroxy functional monomer; while Component B may comprise all components of the single package latex, in the absence of curing agent and stabilizer, with amounts of other components adjusted to be comparable to the single package latex. Ratios between two resin packages A/ B: 0/100 - 40/60. The two components may generally be kept separate until combined with water and other components to formulate an autodepositing coating bath.

[0049.] The current state-of-the-art commercial autodeposition products, such as Bonderite MPP 900 series, contain both curing agents (or crosslinkers) and the chemical groups that react with them in a single resin package. The same also holds true for the current electro-deposition resin technology and or some other major commercial metal primer packages. As it is still the industry norm that the formulations are baked at high temperatures, such as 350 F/ 177 C or above to become fully cured, the blocked isocyanates used in these products are mostly alcohol or lactam based products which are usually stable enough in a single package. However, when the autodeposition coating is designed to be baked at lower temperatures such as below 270 F/132°C, different curing agents that can deblock at these temperatures are usually needed and these curing agents generally also have poor in-can or shelf stability during transportation or shelf stability. Thus it is beneficial, at least for shelf stability, to put curing agents and the chemical groups that can react with them in different packages, therefore, they don't crosslink prematurely during storage and transportation in certain regions or seasons.

[0050.] In this embodiment, the blocked isocyanates are incorporated in a resin package that does not have any chemical groups that can react with them, and all the epoxy resins and hydroxyl containing components are incorporated in another package. These two resins can be blended in a designed ratio at a later stage or before charging into the autodeposition paint bath, therefore, the sufficient in-can stability can be maintained. A second advantage of the two package system can allow customers to customize the paint bath by changing the ratio of the resin packages to maximize certain properties or attributes of the autodeposition technologies. This allows a greater flexibility compared with the current state-of-the-art technologies.

[0051.] An autodepositing liquid bath composition according to the present invention comprises, preferably consists essentially of, or more preferably consists of, water and:

(A) a concentration of at least 1.0%, based on the whole composition, of dispersed or both dispersed and dissolved film forming polymer molecules, i.e. epoxy resin, acrylic monomer reaction products; (B) a surfactant component in sufficient quantity to emulsify all dispersed constituent molecules of component (A) so that, in the autodepositing liquid composition, no separation or segregation of bulk phases that is perceptible with normal unaided human vision occurs during storage at 25° C. for at least 24 hours after preparation of the autodepositing liquid composition, in the absence of contact of the autodepositing liquid composition with any metal, particularly any metal that dissolves in the autodepositing composition to produce therein metal cations with a charge of at least two, or other material that reacts with the autodepositing liquid composition;

(C) a curing component comprising at least one latent cross-linking agent chemically

reactive with constituents of component (A) at a temperature of 130° C or less; and

(D) a dissolved accelerator component, selected from the group consisting of acids, oxidizing agents, and complexing agents, sufficient in strength and amount to impart to the total autodepositing liquid composition an oxidation-reduction potential that is at least 100 millivolts hereinafter usually denoted "mV") more oxidizing than a standard hydrogen electrode (hereinafter usually abbreviated "SHE"); and,

optionally, one or more of the following:

(E) a component of pigment, filler, or other dispersed solid phase materials other than the materials that constitute any part of any of the preceding components;

(F) a component of solvent in which constituents of component (A) that are insoluble in water were dissolved during some step in the preparation of the autodepositing liquid composition, other than materials that constitute any part of any of the preceding components;

(G) a component of organic acid stabilizer for component (C) , other than materials that form any part of any of the preceding components;;

(H) a component of coalescing agent, other than materials that form any part of any of the preceding components;

(I) a plasticizer component, other than materials that constitute part of any of the preceding components.

Autodeposition compositions according to the invention have a pH that is at least 1.6, or preferably is, with increasing preference in the order given, at least 1.7, 1.8, 1.9, 2.0, or 2.1 and independently preferably is, with increasing preference in the order given, not more than 5, 4.5, 3.8, 3.6, 3.4, 3.2, 3.0. 2.8, 2.6, 2.4, or 2.3;

[0052.] A process for making an autodepositing aqueous dispersion, the process comprising the steps of: (a) dissolving and/or dispersing an epoxy resin or pre-polymer with at least one ethylenically unsaturated monomer to form a mixture; (b) dispersing the mixture of step (a) in water with at least one surfactant to form a fine particle dispersion; and (c) polymerizing the at least one ethylenically unsaturated monomer contained in the fine particle dispersion to form an aqueous dispersion, wherein at least one water soluble initiator and/or at least one organic soluble initiator, e.g. promoter, reductant solution and/or oxidant solution is added prior to or during step (c); at least one latent curing agent having a deblocking temperature of no more than 135°C, and optionally one or more of a solvent and a stabilizer, is incorporated into the mixture before the at least one ethylenically unsaturated monomer is polymerized.

[0053.] A coating process according to this invention will preferably comprise the steps of: (a) contacting an article with an active metal surface with the aforedescribed autodeposition bath composition for a sufficient time to cause formation of a film of uncured coating (which film may also contain certain other components of the autodeposition bath composition, particularly the curing agent) having a predetermined thickness on the metal surface, (b) separating the coated metal surface from contact with the autodeposition bath composition, (c) rinsing the coated metal surface to remove at least some of the absorbed but otherwise unadhered components of the bath composition from the more adherent portion of the coating, and (d) heating the rinsed surface to form a final cured coating. Without wishing to be bound by theory, it is believed that when the wet adherent coating is heated, the epoxy resin and crosslinker present in the epoxy dispersion react to form a thermoset polymeric matrix. Optionally, rinsing step (c) may include rinsing with water followed by one or more of a post-treatment step and a post-catalysis step, as described herein.

[0054.] Ordinarily, a metal surface is degreased and rinsed with water before applying an autodeposition composition. Conventional techniques for cleaning and degreasing the metal surface to be treated according to the invention can be used for the present invention. The rinsing with water can be performed by exposure to running water, but will ordinarily by performed by immersion for from 10 to 120 seconds, or preferably from 20 to 60 seconds, in water at ordinary ambient temperature.

[0055.] Any method can be used for contacting a metal surface with the autodeposition composition of the present invention. Examples include immersion (e.g., dipping), spraying or roll coating, and the like. Immersion is usually preferred. Preferably, contact between an active metal surface and the autodeposition bath compositions of this invention is for a time between about 0.5 and about 10 minutes, more preferably between about 1 and about 3 minutes. Contact preferably is long enough to produce a final film thickness of from about 10 to about 50 microns (preferably about 18 to about 25 microns).

[0056.] Optionally, a post-treatment reagent capable of causing modifications of the coated film may be included in the rinse used after cessation of contact between the wet coated surface and the bulk of the autodeposition bath composition. Such a post-treatment reagent may also be brought into contact with the wet coated film after rinsing with water alone. Contact time may be at least 1 second and preferably is not more than 5 minutes. Although the autodeposition bath compositions of the invention generally produce wet coated films that can be heated after simple rinsing with tap or deionized water to give good quality final films, the corrosion resistance of the cured coating may be further improved by rinsing with an aqueous post-treatment solution comprising soluble zirconium or titanium compounds, such as fluorometallate or carbonate compounds of these metals, e.g. ammonium zirconium carbonate; or an alkaline earth metal compound such as calcium nitrate, as described in co-owned U.S. Pat. No. 6,613,387 and which is incorporated herein by reference in its entirety. The concentration of the total of the post- treatment reagent present in the aqueous liquid rinse composition used according to the invention preferably is, with increasing preference in the order given, at least 0.001, 0.002, 0.004, 0.008, 0.016, 0.023, 0.033, 0.040, 0.047, 0.054, or 0.060 grams per liter and independently preferably is, with increasing preference in the order given, not more than 10.0, 9.0, 8.0, 7.0, 6.0, 5.0, 4.0, 2.0, 1.5, 1.3, 1.0, 0.7, 0.4, 0.20, 0.15, 0.100, 0.090, 0.080, 0.075, or 0.070 grams per liter.

[0057.] In some embodiments, a post-catalysis step where an aqueous catalyst solution is applied may be used after cessation of contact between the wet coated surface and the bulk of the autodeposition bath composition and any water rinsing or post-treatment rinsing steps, and before the curing step. Although the autodeposition bath compositions of the invention generally produce wet coated films that can be heated after simple rinsing with tap or deionized water to give good quality final films, the corrosion resistance and chemical resistance of the

autodeposition coatings that cure at low temperature, as described herein, may be further improved by rinsing with an aqueous catalyst solution comprising a catalyst for isocyanate reactions with active hydrogens, in particular catalysts for the blocked or inhibited isocyanates of the autodeposition coating composition in the wet coated films.

[0058.] Suitable catalysts for use in the aqueous catalyst solution may include organic metallic compounds, nitrogen containing catalysts, as well as phosphorus-based compounds. The catalysts used in this invention are those that can be incorporated and stable in an aqueous formulation and can act as a catalyst for a urethane -type reaction of isocyanate with an active hydrogen. Amine based catalysts are preferred in this invention. By way of non-limiting example, suitable amine based catalysts include cyclic amidines, such as DBU, DBN and 1,2- dimethyl-l,4,5,6-tetrahydropyrimidine and the like; tertiary amines such as N-(3- dimethylaminopropyl)-N,N-diisopropanolamine; Diazabicyclo[2.2.2]octane; quinuclidine-based catalysts; and triazine-based catalysts, such as l,3,5-tris(3-(dimethylamino)propyl)-hexahydro-s- triazine. Some primary or secondary amine containing compounds, such as imidazole, DMI and dicyandiamide and the like, can work both as catalyst and curing agents, therefore, are also suitable in this application. The concentration of the total of the catalyst present in the aqueous catalyst solution used according to the invention preferably is, with increasing preference in the order given, at least 0.1, 0.2, 0.4, 0.8, 0.016, 0.023, 0.033, 0.040, 0.047, 0.054, 0.061, or 0.068 grams per liter and independently preferably is, with increasing preference in the order given, not more than 10.0, 9.0, 8.0, 7.0, 6.0, 5.0, 4.0, 2.0, 1.5, 1.3, 1.0, 0.7, 0.4, 0.20, 0.15, 0.100, 0.090, 0.080, 0.075, or 0.072 grams per liter. Contact time with the aqueous catalyst solution may be at least 1 second and preferably is not more than 10 minutes.

[0059.] Final heating of the rinsed wet coated and optionally post-treated autodeposited film is preferably at a temperature (PMT) of no more than 135° C. The curing temperature must be sufficiently high so as to effect reaction of the latent crosslinker with the epoxy-and hydroxyl- reactive functional groups of the epoxy dispersion present in the autodeposited film. As discussed above, the latent crosslinker is selected such that deblocking of the curing agent does not take place to any significant extent during transportation or storage, preferably no deblocking takes place during these times. The deblocking temperature of the latent crosslinker, i.e. the curing agent, is at least in increasing order of preference about 55, 56, 58, 60, 62, 64, 66, 68, 70, 71, 72, 74, 76, 78, 80, 82, 84, 86, 88, 90, 92, 94, 96, 98, 100, 102, 104, 106, 108, 110, 112, 114, 116, 118, 120, 122 or 124 °C and not more than in increasing order of preference about 140, 139, 138, 137, 136, 135, 134, 133, 132, 131, 130, 129, 128, 127, 126, 125 or 124°C. Generally, the final heating temperature is selected to dry and cure the coating at a temperature within the range from at least about 60° C. to about 132° C, more preferably between about 100° C. and 125° C, for a time of about 3 to about 60 minutes, more preferably for about 10 to about 30 minutes.

[0060.] The heating can be performed in multiple stages, if desired, by adjusting temperature of the stages and selection of curing agent deblocking temperature. For example, in one embodiment, in a first stage lasting from about 5 to about 15 minutes, the coated substrate is heated to a peak temperature of about 55° C. to about 65° C. to flash off most of the residual water in the coating and in a second stage lasting from about 30 to about 50 minutes, the coated substrate is heated to a peak temperature of about 100° C. to about 130° C, thereby unblocking the curing agent. The peak temperature preferably is attained in preferably, no more than about 10 minutes after the first heating stage has been completed.

[0061.] Metal substrates coated according to the invention having a cured autodeposition coating deposited thereon are found to have corrosion resistance comparable to conventional autodeposition coatings that require a higher cure temperature in the neutral salt spray ("NSS") test, such as ASTM B-l 17 and in chemical resistance tests, e.g. methylethyl ketone double rub testing (ASTM D4752).

[0062.] Coatings according to the invention are also compatible with co-cure processes wherein a paint is applied to a dewatered uncured autodeposited coating and the two layers are cured together, see for example WO 2009088993. The lower curing temperature of

autodeposition coatings according to the invention enables use of a wider variety of paints in a process in which the uncured autodeposition coating is dewatered, paint is applied to the uncured autodeposition coating and then the paint and the autodeposition coating are cured in the same curing step by heating to temperatures of less than about 135°C, as disclosed herein.

[0063.] Autodeposition compositions employed in the present invention can be used for treating surfaces of iron, zinc, iron alloy and zinc alloy, and particularly steel portions of various components such as automobile sheet components and automobile components such as shock absorbers, jacks, leaf springs, suspension components and brackets, and the like, and components of furniture such as drawer rails, and the like. Autodeposition coatings are particularly well suited for indoor metal furniture that is subjected to wear and surface impacts, e.g., filing cabinets, filing shelves, desks, etc.

EXAMPLES

Autodepositing Epoxy-Acrylic Dispersion (Dispersion) Preparation Process

[0064.] In a reactor, a monomer solution was made by dissolving epoxy and/or phenoxy resin, with other components, such as curing agent, solvent, or stabilizer, in monomer mixture as specified in the tables below, under agitation. Surfactant Solution was added under agitation to form a crude dispersion. The crude dispersion was then passed through an M-l 10Y

Microfluidizer at 10,000 PSI, or as otherwise specified, one to three times to form a fine mini- emulsion with a particle size of below 300 nm. Then the mini-emulsion was loaded into a reactor and heated to 53 °C under nitrogen atmosphere. Promoter and Reductant Solution I were then added to the reactor. Reductant Solution II was metered into the reactor over a period of 3 hours. One hour into the Reductant Solution II addition, Oxidant Solution was metered in over a period of 3 hours. After the completion of the Oxidant Solution addition, the reactor was held for another 1 hour at 53 °C, and then was cooled to room temperature, about 22°C.

Autodeposition Bath Preparation

[0065.] Latex and aqueous carbon black pigment slurry with non- volatile solids of approximately 38.0% were added to a container and mixed until a homogeneous Make-up was obtained (Table I). An autodeposition paint bath was made by adding the reagents listed in the Table I sequentially under agitation in a 1L container. The bath parameters were then adjusted to within the ranges listed in Table II before processing panels through the autodeposition paint bath.

Table I

Bath DI water 700

ACC Starter 300* 25

Make-up 111.3

DI water 163.7

ACC Activator 35* 3.5 - 5

*ACC Starter 300 and ACC Activator 35 are conventional autodeposition paint bath components commercially available from Henkel Corporation.

Table II

Coating process

[0066.] Commercially available cold rolled steel (CRS) panels (supplied by ACT

Laboratories, Inc.) were coated in an autodeposition bath using one of the following processes (Table III), and then tested for chemical resistance and corrosion resistance.

Table III

E2 is a commercially available Zr-containing post-treatment.

*See Examples Testing

[0067.] Chemical resistance: "MEK DR" is methylethyl ketone double rub (ASTM D4752).

[0068.] Corrosion resistance: "504 NSS (mm)" is neutral salt spray, 504 hours (ASTM B 1 17).

Example la: Latex preparation with DMP Blocked HDI Trimer, 70% and phenoxy resin

[0069.] A latex was made with the components listed in Table la. The final latex was obtained with a solid content of 35.0% and a particle size of approximately 230 nm.

Table la

Example lb: Latex preparation with DMP Blocked HDI Trimer, 70% and BPA epoxy resin

[0070.] A latex was made with the components listed in Table la, except the phenoxy resin was replaced with BPA epoxy resin, EEW: 2500-4000 g/eq. The final latex was obtained with a solid content of 35.8% and a particle size of approximately 220 nm.

Example 2a: Bath preparation and testing results of Latex Example la [0071.] Autodeposition make-up and bath of Latex Example la were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 2a

Example 2b-d: Bath preparation and testing results of Latex Example la with different additives in baths

[0072.] Autodeposition make-ups and baths of Latex Example 1 a were made according to Table I except zinc fluoride hydrate (ZnF₂-4H₂0) and sodium acetylacetonate hydrate

(NaAcAc-H₂0) were added in the baths (Table 2b-d) as additives and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 2b-d

Example 2e: Bath preparation and testing results of Latex Example la with additives in the bath and using DBU rinse of different concentrations

[0073.] Autodeposition make-up and bath of Latex Example la were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. In the bath, 0.27 grams of zinc fluoride hydrate (ZnF₂-4H₂0) and 0.48 grams of sodium acetylacetonate hydrate (NaAcAc-H₂0) were added. CRS panels were coated and tested, and the results are listed below.

Table 2e

Example 2f: Bath preparation and testing results of Latex Example lb

[0074.] Autodeposition make-up and bath of Latex Example lb were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 2f

Example 3: Bath preparation and testing results of commercially available Epoxy Acrylic Autodeposition Coating Composition baked at low temperatures

[0075.] Autodeposition make-up and bath of a commercial epoxy acrylic autodeposition coating product were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 3b

Example 4a: Latex preparation with BPA epoxy and MEKO blocked HDI trimer

[0076.] A latex was made with the components listed in Table 4a. The final latex was obtained with a solid content of 35.8% and a particle size of 230 nm. All the components and amounts are listed in Table 4a.

Table 4a

Component Reagent Amount in wt%

Epoxy resin BPA epoxy, EEW 860- TA5

930g/eq

BPA epoxy, EEW: 2500- 6.63

4000 g/eq

Curing Agent MEKO blocked HDI trimer 2.37

Monomer mixture Styrene/ Acrylic 17.94

2-hydroxyethyl 0.69

methacrylate Solvent Butylene carbonate 1.51

Surfactant Solution Sodium lauryl sulfate 1.57

DI Water 51.74

Promoter 1% FeS04 solution 0.02

Reductant Solution I SFS 0.01

DI water 0.41

Reductant Solution II SFS 0.10

DI water 3.00

Oxidant Solution 70% tBHP solution 0.16

DI water 2.95

Example 4b: Latex preparation with BPA epoxy and MEKO blocked IPDI trimer

[0077.] A latex was made with the components listed in Table 4a except the Curing agent MEKO blocked HDI trimer was replaced with the MEKO blocked IPDI trimer. The final latex was obtained with a solid content of 36.1%> and a particle size of approximately 230 nm.

Example 4c: Latex preparation with BPA epoxy and DMP/ DEM blocked HDI trimer

[0078.] A latex was made with the components listed in Table 4a except that BPA epoxy, EEW 860-930g/eq was replaced with BPA epoxy, EEW: 525-550 g/eq and Curing agent MEKO blocked HDI trimer of 2.37% in total formulation was replaced with DMP/ DEM blocked HDI trimer of 5.48% in total formulation. The final latex was obtained with a solid content of 34.9% and a particle size of 220 nm.

Example 4d: Latex preparation with BPA epoxy and DEM blocked IPDI trimer

[0079.] A latex was made with the components listed in Example 4c except that curing agent DMP/ DEM blocked HDI trimer of 5.48% in total formulation was replaced with DEM blocked IPDI trimer of 7.3% in total formulation. The final latex was obtained with a solid content of 35.3%) and a particle size of approximately 240 nm. Example 4e: Latex preparation with BPA epoxy, only and MDI Uretdione

[0080.] A latex was made with the components listed in Table 4e. The final latex was obtained with a solid content of 34.2% and a particle size of 240 nm. All the components and amounts are listed in Table 4e.

Table 4e

Component Reagent Amount in wt%

Epoxy resin BPA epoxy, EEW 860- 17.28

930g/eq

Curing Agent MDI Uretdione 2.20

Monomer mixture Styrene/Acrylic 16.62

2-hydroxyethyl 0.65

methacrylate

Solvent 2,2,4-trimethyl-l,3- 1.47

pentanediol mono(2- methylpropanoate)

Surfactant Solution Ammonium lauryl sulfate 1.56

DI Water 52.38

Promoter l% FeS0₄ solution 0.02

Reductant Solution I SFS 0.01

DI water 0.48

Reductant Solution II SFS 0.12

DI water 3.51

Oxidant Solution 70% tBHP solution 0.18

DI water 3.45

Example 5a: Bath preparation and testing results of Latex Example 4a

[0081.] Autodeposition make-up and bath of Latex Example 4a were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below. The bath was not stable and crashed after a few weeks. Table 5a

Example 5b: Bath preparation and testing results of Latex Example 4b

[0082.] Autodeposition make-up and bath of Latex Example 4b were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated, however, all coatings had mud cracking across the panels as indicated in Table 5b.

Table 5b

Example 5c: Bath preparation and testing results of Latex Example 4c

[0083.] Autodeposition make-up and bath of Latex Example 4c were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below. The bath was not stable and crashed after a few months.

Table 5 c

MEK DR (DR) 80 >200 140

504 NSS (mm) -45 -25 -50

Example 5d: Bath preparation and testing results of Latex Example 4d

[0084.] Autodeposition make-up and bath of Latex Example 4d were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 5d

Example 5e: Bath preparation and testing results of Latex Example 4e

[0085.] Autodeposition make-up and bath of Latex Example 4a were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 5e

Example 6a: Latex preparation with 2,2,4-trimethyl-l,3-pentanediol mono(2- methylpropanoate)

[0086.] A latex was made with the same components listed in Table 4a except that Curing agent MEKO blocked HDI trimer was replaced with DMP blocked HDI trimer and Solvent Butyl ene carbonate was replaced with 2,2,4-trimethyl-l,3-pentanediol mono(2- methylpropanoate). The final latex was obtained with a solid content of 36.4% and a particle size of approximately 220 nm.

Example 6b: Latex preparation with 2,2,4-trimethyl-l,3-pentanediol mono(2- methylpropanoate) and Dinonylnaphthalene disulfonic acid 55% in isobutanol

[0087.] A latex was made with the same components for Example 6a except that Stabilizer Dinonylnaphthalene disulfonic acid 55%o in isobutanol was added. The final latex was obtained with a solid content of 36.8% and a particle size of approximately 230 nm.

Example 6c: Latex preparation with Propylene carbonate and Dinonylnaphthalene disulfonic acid 55% in isobutanol

[0088.] A latex was made with the same components for Example 6b except that Solvent 2,2,4-trimethyl-l ,3-pentanediol mono(2-methylpropanoate) was replaced with propylene carbonate. The final latex was obtained with a solid content of 36.1% and a particle size of approximately 230 nm.

Example 6d: Latex preparation of Propylene carbonate and Organic sulfonic acid, proprietary

[0089.] A latex was made with the same components for Example 6c except that Stabilizer Dinonylnaphthalene disulfonic acid 55% in isobutanol was replaced with a proprietary organic sulfonic acid. The final latex was obtained with a solid content of 35.9% and a particle size of approximately 240 nm.

Example 6e: Latex preparation with Propylene carbonate and Dinonylnaphthalene monosulfonic acid 50% in heptane

[0090.] A latex was made with the same components for Example 6c except that Stabilizer Dinonylnaphthalene disulfonic acid 55% in isobutanol was replaced with Dinonylnaphthalene monosulfonic acid 50% in heptane. The final latex was obtained with a solid content of 35.8% and a particle size of approximately 230 nm. Example 7a: Bath preparation and testing results of Latex Example 6a

[0091.] Autodeposition make-up and bath of Latex Example 6a were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 7a

Example 7b: Bath preparation and testing results of Latex Example 6b

[0092.] Autodeposition make-up and bath of Latex Example 6b were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 7b

Example 7c: Bath preparation and testing results of Latex Example 6c

[0093.] Autodeposition make-up and bath of Latex Example 6c were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 7c

Example 7d: Bath preparation and testing results of Latex Example 6d

[0094.] Autodeposition make-up and bath of Latex Example 6d were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 7d

Example 7e: Bath preparation and testing results of Latex Example 6d

[0095.] Autodeposition make-up and bath of Latex Example 6d were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and the results are listed below.

Table 7e

Example 8: Storage stability comparison between Latex Examples 6a and 6b at 50 °C.

[0096.] The Latex Examples 6a and 6b were stored in 50 °C oven for three weeks to test storage stability. The polymers were analyzed using Gel Permeation Chromatography (GPC) before and after the storage period. The test results indicated that the Latex Example 6b had less polymer loss due to pre-mature crosslinking after the storage period at elevated temperature than Latex Example 6a.

Example 9a: Resin preparation of single resin package

[0097.] A latex was made with the components listed in Table 9a. The final latex was obtained with a solid content of 35.7% and a particle size of approximately 200 nm.

Table 9a

Component Reagent Amount in wt%

Epoxy resin BPA epoxy, EEW: 860- 7.65

930 g/eq

BPA epoxy, EEW: 2500- 6.34

4000 g/eq

Curing Agent DMP blocked HDI trimer; 3.10 70%

Monomer mixture Styrene/acrylic 18.41

2-hydroxyethyl 0.71

methacrylate

Solvent Butoxyethanol acetate 1.55

Stabilizer Dinonylnaphthalene 0.71

monosulfonic acid 50% in

heptane

Surfactant Solution Sodium lauryl sulfate 1.61

DI Water 53.11

Promoter l% FeS0 solution 0.02

Reductant Solution I SFS 0.01

DI water 0.43

Reductant Solution II SFS 0.11

DI water 3.08

Oxidant Solution 70% tBHP solution 0.16

DI water 3.03

Example 9b: Resin preparation of package A of two resin package system

[0098.] A latex was made with the same components as listed in Table 9a except that Epoxy resins, 2-hydroxyethylmethacrylate and Solvent were not added. The final latex was obtained with a solid content of 32.2% and a particle size of approximately 90 nm.

Example 9c: Resin preparation of package B of two resin package system

[0099.] A latex was made with the same components as listed in Table 9a except that Curing agent and Stabilizer were not added. The final latex was obtained with a solid content of 37.0% and a particle size of approximately 220 nm.

Example 10: Bath preparation and testing results of single package Example 9a vs two package 9b&9c blend

[00100.] Autodeposition make-ups and baths of Latex Example 9a as well as a blend of 9b and 9c (9b/ 9c: 35.7/ 140.9) were made according to Table I and the bath parameters were adjusted within ranges as listed in Table II. CRS panels were coated and tested, and Latex Example 9a and the blend of 9b and 9c had similar performance in both MEK and NSS testing.

Example 11: Storage stability comparison between single package Latex Example 9a and Latex Example 9b of the two part package 9b & 9c at 50 °C

[00101.] The Latex Examples 9b and 9a were stored in 50 °C oven for three weeks to test storage stability. The polymers were analyzed using Gel Permeation Chromatography (GPC) before and after the storage period. The test results indicated that the Latex Example 9b had less polymer loss due to pre-mature crosslinking after the storage period at elevated temperature than Latex Example 9a.

Claims

CLAIMS We claim:

1. An autodepo siting liquid bath composition comprising water and:

(A) dispersed or both dispersed and dissolved film forming polymer present in a concentration of at least 1.0% of the composition;

(B) a surfactant component present in sufficient quantity to emulsify component (A);

(C) a curing component comprising at least one latent cross-linking agent chemically reactive with constituents of component (A) at temperatures of 140° C or less and stable at pH ranges of 1.5 to about 6; and

(D) a dissolved accelerator component;

wherein the autodepositing liquid bath composition is capable of depositing on an active metal surface and curing upon heating by cross-linking at temperatures of 140° C or less.

2. The autodepositing liquid bath composition of claim 1, (E) a component of pigment, filler, or other dispersed solid phase materials other than the materials that constitute any part of any of the preceding components.

3. The autodepositing liquid bath composition according to any of claims 1 to 2, (F) a component of solvent, other than materials that constitute any part of any of the preceding components;

4. The autodepositing liquid bath composition according to any of claims 1 to 3, (G) a component of organic acid stabilizer for component (C), other than materials that form any part of any of the preceding components;

5. The autodepositing liquid bath composition according to any of claims 1 to 4, further comprising (H) a component of coalescing agent, other than materials that form any part of any of the preceding components;

6. The autodepositing liquid bath composition according to any of claims 1 to 5, further comprising (I) a plasticizer component, other than materials that constitute part of any of the preceding components.

7. The autodepositing liquid bath composition according to any of claims 1 to 6, wherein (F) comprises propylene carbonate, butyl benzoate, butylene carbonate, butoxyethanol acetate, 2,2,4- trimethyl-l,3-pentanediol mono(2-methylpropanoate) or a combination thereof.

8. An autodeposition coating process comprising steps of:

(a) contacting an article having an active metal surface with the autodeposition bath composition according to any of claims 1 to 7 for a sufficient time to form an uncured autodeposited coating on the metal surface,

(b) removing the object from the autodeposition bath composition,

(c) rinsing the uncured autodeposited coating, and

(d) heating the uncured autodeposited coating to a temperature of at least 55°C and no more than 140°C for a time sufficient to thereby form a cured autodeposited coating.

9. The autodeposition coating process according to claim 8, wherein the rinsing step (c) comprises rinsing with water followed by one or more of a post-treatment step and a post- catalysis step.

10. The autodeposition coating process according to claim 9, wherein the post-treatment step comprises rinsing the uncured autodeposited coating with an aqueous post-treatment solution comprising at least one water-soluble compound of zirconium or titanium present in a range of 0.001 g/1 to about 10.0 g/1.

11. The autodeposition coating process according to claim 9, wherein the post-catalysis step comprises applying an aqueous catalyst solution to the uncured autodeposited coating.

12. The autodeposition coating process according to claim 11, wherein the aqueous catalyst solution comprises a catalyst for a urethane -type reaction of isocyanate with an active hydrogen, wherein concentration of a total of the catalyst present is about 0.1 g/1 to about 10.0 g/1.

13. The autodeposition coating process according to any of claims 8 to 12, wherein the heating step (d) has a final heating temperature in a range of at least 60° C to about 132° C, for a time of about 3 to about 60 minutes.

14. An article of manufacture comprising at least one metallic surface and deposited on the metallic surface a cured autodeposited coating made according to the method according to any of claims 8 to 14.

15. An article of manufacture comprising at least one metallic surface and deposited on the metallic surface an autodeposited, cross-linked coating cured at a temperature of no more than 140°C; said coating being resistant to delamination at temperatures of up to about 220°C.

16. A process for making an aqueous epoxy dispersion, comprising steps of:

(a) dissolving and/or dispersing an epoxy pre-polymer with at least one ethylenically unsaturated monomer to form a mixture;

(b) dispersing the mixture of step (a) in water with at least one surfactant to form a fine particle dispersion; and

(c) polymerizing the at least one ethylenically unsaturated monomer contained in the fine particle dispersion to form an aqueous epoxy dispersion;

wherein at least one initiator is added prior to or during step (c); and wherein at least one latent curing agent having a deblocking temperature of no more than 140°C, and optionally one or more of a solvent and a stabilizer, is incorporated into the mixture before the at least one ethylenically unsaturated monomer is polymerized.

17. The process of claim 16, wherein as the stabilizer, an organic acid selected from sulfonic and phosphonic acid is present in the mixture prior to polymerization in a concentration ranging from 0.5% to 5%, measured as a percentage of total monomer present.

18. An autodeposition coating concentrate comprising: an aqueous epoxy dispersion, at least one latent curing agent having a deblocking temperature of no more than 140°C and stable at pH ranges of 1.5 to about 6, and one or more solvents and/or stabilizers.

19. The autodeposition coating concentrate of claim 18, wherein the one or more solvents is present in the autodeposition coating concentrate and comprises propylene carbonate, butyl benzoate, butylene carbonate, butoxyethanol acetate, 2,2,4-trimethyl-l,3-pentanediol mono(2- methylpropanoate) or a combination thereof.

20. A two-package system of autodeposition coating composition comprising:

A) a first emulsion component comprising a crosslinker for an aqueous epoxy dispersion and optionally a stabilizer and/or surfactant; and

B) a second emulsion component comprising the aqueous epoxy dispersion, solvent and optionally hydroxyfunctional monomer and/or surfactant.