High-solids thermoset binders formed using hyperbranched polyols as reactive intermediates, coating compositions formed therewith, and methods of making and using same

A method of making a coating composition comprising:

• a. providing a principal resin polyol as a first reactant, the principal resin polyol comprises at least one of a polyester polyol, a polyether polyol, and a polyacrylate;
• b. providing an effective amount of a second reactant to the principal resin polyol to form a polyol reaction mixture, wherein the second reactant is a hyperbranched polyol comprises both external and partially embedded hydroxyl groups in its structure;
• c. providing an effective amount of a polymerization catalyst;
• d. providing a crosslinker;
• and
• e. adding a solvent,
• wherein the hyperbranched polyol comprises
• I. a central nucleus comprising a hydrocarbon structure with a plurality of oxygen
• II. a first chain extension attached to the central nucleus, the first chain extension being formed from a compound comprising a carboxyl group and a plurality of hydroxyl groups;
• III. an intermediate substituent attached to the first chain extension, the intermediate substituent being formed from a compound comprising at least one of polyfunctional carboxylic acids and anhydrides and corresponding polyacids thereof;
• and
• IV. a second chain extension attached to the intermediate substituent, the second chain extension being formed from a compound comprising at least one of cis 2,3-epoxybutane, 1-2-epoxybutane, 1-2-epoxyhexane, 1-2-epoxydecane, cis-7,8-epoxy-2methyloctadecane, and hexafluropropylene oxide.

A method of making a binder comprising:

• a. providing a principal resin polyol as a first reactant, the principal resin polyol comprises at least one of a polyester polyol, a polyether polyol, and a polyacrylates;
• b. providing an effective amount of a second reactant to the principal resin polyol to form a polyol reaction mixture, wherein the second reactant is a hyperbranched polyol comprising both external and partially embedded hydroxyl groups in the structure thereof;
• and
• c. providing a crosslinker to the reaction mixtures
• wherein the hyperbranched polyol comprises
• I. a central nucleus comprising a hydrocarbon structure with a plurality of oxygen atoms;
• II. a first chain extension attached to the central nucleus, the first chain extension being formed from a compound comprising a carboxyl group and a plurality of hydroxyl groups:
• III. an intermediate substituent attached to the first chain extension, the intermediate substituent being formed from a compound comprising at least one of polyfunctional carboxylic acids and anhydrides and corresponding polyacids thereof;
• and
• IV. a second chain extension attached to the intermediate substituent, the second chain extension being formed from a compound comprising at least one of cis 2,3-epoxybutane, 1-2-epoxybutane, 1-2-epoxyhexane, 1-2-epoxydecane, cis-7,8-epoxy-2methyloctadecane and hexafluropropylene oxide.

A coating composition comprising a solvent and a mixture of:

• a. a principal resin polyol comprising at least one of a polyester polyol, a polyether polyol, and a polyacrylate;
• b. a hyperbranched polyol having both external and partially embedded hydroxyl groups in the structure thereof;
• c. a crosslinker;
• and
• d. an effective amount of a polymerization catalyst,
• wherein the hyperbranched polyol comprises
• I. a central nucleus comprising a hydrocarbon structure with a plurality of oxygen atoms;
• II. a first chain extension attached to the central nucleus, the first chain extension being formed from a compound comprising a carboxyl group and a plurality of hydroxyl groups;
• III. an intermediate substituent attached to the first chain extension, the intermediate substituent being formed from a compound comprising at least one of polyfunctional carboxylic acids and anhydrides and corresponding polyacids thereof;
• and
• IV. a second chain extension attached to the intermediate substituent, the second chain extension being formed from a compound comprising at least one of cis 2,3-epoxybutane, 1-2-epoxybutane, 1-2-epoxyhexane, 1-2-epoxydecane, cis-7,8-epoxy-2methyloctadecane, and hexafluropropylene oxide.