# US 4,399,241 A · Base for a graft polymer, novel graft polymer compositions, solvents and water-reducible coatings incorporating the novel graft polymers, and processes for making them > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 4,399,241 A - Document ID: US4399241A - Status: Granted - Kind: A - Application number: 06/132,507 - Filed: 1980-03-21 - Granted: 1983-08-16 - Earliest claimed: 1980-03-21 - Assignees: SCM Corporation - Inventors: Vincent W. Ting; James T. K. Woo; Richard M. Marcinko - Web page: https://patentgrep.com/patent/US4399241A ## CPC - C08F 283/10: on to polymers containing more than one epoxy radical per molecule {(C08F283/004 takes precedence)} - C09D 151/00: Coating compositions based on graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds (based on ABS polymers C09D155/02); Coating compositions based on derivatives of such polymers - C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS - 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 (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D) ## Abstract Provides new and improved water-reducible coating compositions and methods of making them. Three preferred processes are disclosed. These differ in the manner of incorporating and chemical nature of an extender polymer. Broadly, the process of the invention is one for forming an aqueous dispersion of a fluent resinous composition of a. a mixture in an organic solvent of (i) an ionizable graft polymer of an epoxy resin and an addition polymerized resin, the addition polymerized resin being bonded to aliphatic backbone carbon atoms of the epoxy resin by carbon-to-carbon bonds, and (ii) an extender resin; b. an aqueous vehicle, and c. an ionizing agent; the ionization present from said combined components being sufficient to establish the components as a dispersion in the aqueous vehicle, and then addition polymerizing a quantity of addition polymerizable monomer, under addition polymerizing conditions, in said aqueous dispersion, the aqueous dispersion serving as a vehicle therefor. In another aspect of the invention, a grafting base is produced by advancing an aromatic epoxy resin in the presence of at least one extender resin and a sufficient amount of an organic solvent to render the initial mixture and grafting base product fluent. ## Claims ### Claim 1 A process for making a fluent blend of an advanced epoxy resin and an extender polymer, said epoxy resin and said extender polymer each having aliphatic backbone carbon atoms that have either one or two carbon atoms bonded thereto, which comprises: mixing an aromatic 1,2-epoxy resin, having an epoxy equivalent weight below about 2,000, with at least one extender polymer and with a sufficient amount of an organic solvent to render the mixture fluent, and then advancing the epoxy resin in the presence of said extender polymer and said solvent, by reacting the epoxy resin with a polyfunctional compound that adds to the epoxy resin at its epoxide groups, to increase the molecular weight of the resin, which polyfunctional compound is either a polycarboxylic compound or a polyhydroxy compound, maintaining sufficient solvent in the mixture that the blend of advanced epoxy resin and extender polymer remains fluent, and polymerizing addition polymerizable monomer in the presence of said mixture by addition polymerization under addition polymerizing conditions. ### Claim 2 (depends on 1) The process of claim 1 wherein the epoxy resin is an adduct of a diglycidyl ether of a bisphenol that has an epoxy equivalent weight in the range from about 180 up to about 2,000, and the resin is advanced by reacting it at a temperature in the range from about 130.degree. C. to about 250.degree. C. with a bisphenol, to the point that it has an epoxy equivalent weight above about 2,000. ### Claim 3 (depends on 2) The process of claim 2 wherein the extender polymer is a hydrocarbon polymer. ### Claim 4 (depends on 2) The process of claim 2 wherein the extender polymer is selected from the group consisting of a low molecular weight polyethylene, polystyrene, a styrene acrylate copolymer, an ethylene-vinyl acetate copolymer, a hydroxyl-terminated polyester or polyurethane, a styrene-acrylonitrile copolymer, a hydrocarbon resin, an epoxy resin, and mixtures of two or more of these. ### Claim 5 (depends on 2) The process of claim 2 wherein the extender polymer is ethylenically unsaturated and addition polymerizable. ### Claim 6 (depends on 5) The process of claim 5 wherein the extender polymer is a polybutadiene. ### Claim 7 (depends on 2) The process of claim 2 wherein the extender polymer is a different epoxy resin than said first-named, aromatic, 1,2-epoxy resin. ### Claim 8 (depends on 7) The process of claim 7 wherein the extender polymer is epoxidized polybutadiene. ### Claim 9 (depends on 1) The process of claim 1 wherein the polyfunctional compound is one that reacts with the epoxy resin to extend the resin and to increase the number of aliphatic backbone carbon atoms that have either one or two carbons bonded thereto. ### Claim 10 (depends on 9) The process of claim 9 wherein the polyfunctional compound is an aromatic polyhydric alcohol. ### Claim 11 (depends on 10) The process of claim 10 wherein the polyfunctional compound is a diphenol. ### Claim 12 (depends on 11) The process of claim 11 wherein the polyfunctional compound is bisphenol A. ### Claim 13 (depends on 1, 2) The process of claim 1 or 2 wherein the polyfunctional compound is a polynuclear polyhydroxy phenol. ### Claim 14 (depends on 2) The process of claim 2 wherein the bisphenol is bisphenol A and the extender polymer is polystyrene. ### Claim 15 (depends on 1) A process according to claim 1 wherein the polyfunctional compound is a polycarboxylic acid or a polycarboxylic acid anhydride. ### Claim 16 (depends on 15) The process of claim 15 wherein the polyfunctional compound is a saturated aliphatic polycarboxylic acid or polycarboxylic acid anhydride. ### Claim 17 (depends on 15) The process of claim 15 wherein the polyfunctional compound is adipic acid. ### Claim 18 (depends on 15) The process of claim 15 wherein the acid is azelaic acid. ### Claim 19 (depends on 15) The process of claim 15 wherein the polyfunctional compound is a cyclic polycarboxylic acid or a cyclic polycarboxylic acid anhydride. ### Claim 20 (depends on 19) The process of claim 19 wherein the polyfunctional compound is a tetrahydrophthalic acid or anhydride. ### Claim 21 (depends on 19) The process of claim 19 wherein the polyfunctional compound is a phthalic acid or anhydride. ### Claim 22 (depends on 2) The process of claim 2 wherein the solvent employed is one that dissolves the blend. ### Claim 23 (depends on 2) The process of claim 2 wherein the solvent employed comprises 2-butoxyethanol-1. ### Claim 24 (depends on 23) The process of claim 23 wherein the solvent also comprises n-butanol. ### Claim 25 (depends on 2, 3, 11) The process of claim 2, 3, 11, or 22, wherein the epoxy resin has a molecular weight, following advancement, of not substantially less than 4,000, and forms at least 50% by weight of the blend following advancement. ### Claim 26 (depends on 1, 2, 3, 11, 22, 23, 24) A tractable blend produced by the process of claim 1, 2, 3, 11, 22, 23 or 24. ### Claim 27 A process for producing a fluent resinous composition which comprises: forming a tractable blend substantially free from particulate resinous matter, said blend consisting essentially of polyepoxy resin, extender polymer and organic solvent; advancing at a temperature between about 130.degree. C. and 250.degree. C. said polyepoxy resin in said blend to greater molecular weight by reacting said polyepoxy resin with epoxy resin advancing agent, said extender polymer and said solvent being inert towards said polyepoxy resin and said advancing agent under the blend forming and advancing conditions used and, effecting termination of the advancement while the resulting mass remains tractable, polymerizing addition polymerizable monomer in the presence of said resulting mass by addition polymerization under addition polymerizing conditions. ### Claim 28 (depends on 27) The process of claim 27 wherein the advanced epoxy resin retains some oxirane functionality. ### Claim 29 (depends on 28) The process of claim 28 wherein at least part of the remaining oxirane functionality is modified by reaction with oxirane modifying agent that is monofunctional with respect to reacting with oxirane groups, thereby forming a modified mass. ### Claim 30 (depends on 29) The process of claim 29 wherein said reaction with said modifying agent provides the modified mass with ionizable functionality.