Coating Composition and Cured Film Formed Therefrom

Abstract

A coating composition comprises a first copolymer and a second copolymer. The first copolymer has at least one linear polymer strand having a weight average molecular weight of at least 1,500 Daltons and functionality X with an equivalent weight of no more than 500. The second copolymer has at least one linear polymer strand having a weight average molecular weight of at least 1,500 Daltons and functionality X′ with an equivalent weight of no more than 1,500. The coating composition is free of gloss flattening agents, yet still produces a cured film having a low gloss of less than 70 gloss units at an angle of incidence of 60°, as measured according to ASTM D 2457.

1 . A coating composition which is free of gloss flattening agents yet still produces a cured film having a low gloss of less than 70 gloss units at an angle of incidence of 60°, as measured according to ASTM D 2457, said coating composition comprising:
 (A) a first copolymer having at least one linear polymer strand having a weight average molecular weight of at least 1,500 Daltons and functionality X with an equivalent weight of no more than 500; and   (B) a second copolymer having at least one linear polymer strand having a weight average molecular weight of at least 1,500 Daltons and functionality X′ with an equivalent weight of no more than 1,500;   wherein said functionality X of said first copolymer and said functionality X′ of said second copolymer are reactive with one another.   
   
   
       2 . A coating composition as set forth in  claim 1  wherein said functionality X of said first copolymer is further defined as epoxy functionality. 
   
   
       3 . A coating composition as set forth in  claim 2  wherein said functionality X′ of said second copolymer is further defined as carboxylic acid functionality. 
   
   
       4 . A coating composition as set forth in  claim 1  wherein said functionality X′ of said second copolymer is further defined as carboxylic acid functionality. 
   
   
       5 . A coating composition as set forth in  claim 1  wherein said first copolymer is the reaction product of at least one first ethylenically unsaturated monomer and at least one epoxy monomer. 
   
   
       6 . A coating composition as set forth in  claim 5  wherein said at least one epoxy monomer is reacted in an amount of at least 30% by weight based on the combined weight of said at least one first ethylenically unsaturated monomer and said at least one epoxy monomer. 
   
   
       7 . A coating composition as set forth in  claim 5  wherein said at least one epoxy monomer of said first copolymer is further defined as at least one of glycidyl methacrylate and glycidyl acrylate. 
   
   
       8 . A coating composition as set forth in  claim 5  wherein said at least one first ethylenically unsaturated monomer of said first copolymer is further defined as at least one first acrylic monomer. 
   
   
       9 . A coating composition as set forth in  claim 5  wherein said second copolymer is the reaction product of at least one second ethylenically unsaturated monomer and at least one carboxylic acid monomer. 
   
   
       10 . A coating composition as set forth in  claim 9  wherein said at least one carboxylic acid monomer is reacted in an amount of at least 6.5% by weight based on the combined weight of said at least one second ethylenically unsaturated monomer and said at least one carboxylic acid monomer. 
   
   
       11 . A coating composition as set forth in  claim 9  wherein said at least one carboxylic acid monomer of said second copolymer is selected from the group of methacrylic acid; acrylic acid; beta-carboxyethyl acrylate; acrylic acid dimer; methacrylic acid dimer; maleic acid; itaconic acid; the reaction product of cyclic anhydride and hydroxy functional acrylic monomer; the reaction product of alkyl substituted cyclic anhydride and hydroxy functional acrylic monomer; the reaction product of 2,3-epoxypropyl neodecanoate, (meth)acrylic acid, and cyclic anhydride; and combinations thereof. 
   
   
       12 . A coating composition as set forth in  claim 9  wherein said at least one second ethylenically unsaturated monomer of said second copolymer is further defined as at least one second acrylic monomer. 
   
   
       13 . A coating composition as set forth in  claim 9  wherein said at least one first acrylic monomer of said first copolymer and said at least one second acrylic monomer of said second copolymer are independently selected from the group of acrylic acid ester having between 1 and 20 carbon atoms, methacrylic acid ester having between 1 and 20 carbon atoms, 2-ethylhexyl acrylate, methyl methacrylate, isobutyl methacrylate, 2-ethylhexyl methacrylate, 2-hydroxyethyl methacrylate, isobornyl methacrylate, isodecyl methacrylate, cyclohexyl methacrylate, aromatic ester, aromatic ether, and combinations thereof. 
   
   
       14 . A coating composition as set forth in  claim 9  wherein said at least one first acrylic monomer of said first copolymer and said at least one second acrylic monomer of said second copolymer are independently selected from the group of hydroxy functional acrylic monomer; the reaction product of 2,3-epoxypropyl neodecanoate and at least one of (meth)acrylic acid, (meth)acrylic acid ester, maleic anhydride, isocyanato alkyl methacrylate, and dimethyl-m-isopropenylbenzyl isocyanate; and combinations thereof. 
   
   
       15 . A coating composition as set forth in  claim 9  wherein at least one of said at least one first ethylenically unsaturated monomer of said first copolymer and said at least one second ethylenically unsaturated monomer of said second copolymer further comprises styrene monomer. 
   
   
       16 . A coating composition as set forth in  claim 1  wherein at least one of said first copolymer and said second copolymer has functionality X″ different than said functionality X of said first copolymer and different than said functionality X′ of said second copolymer 
   
   
       17 . A coating composition as set forth in  claim 16  wherein said second copolymer has said functionality X″ different than said functionality X of said first copolymer and different than said functionality X′ of said second copolymer. 
   
   
       18 . A coating composition as set forth in  claim 16  wherein said functionality X″ has an equivalent weight of from 290 to 2,320. 
   
   
       19 . A coating composition as set forth in  claim 16  wherein said functionality X″ is further defined as hydroxy functionality. 
   
   
       20 . A coating composition as set forth in  claim 16  further comprising a cross-linking agent reactive with said functionality X″. 
   
   
       21 . A coating composition as set forth in  claim 20  wherein said cross-linking agent is selected from the group of melamine, isocyanurate, and combinations thereof. 
   
   
       22 . A coating composition as set forth in  claim 21  wherein at least one of said first ethylenically unsaturated monomer of said first copolymer and said second ethylenically unsaturated monomer of said second copolymer comprises a hydroxy-functional acrylic monomer to impart at least one of said first copolymer and said second copolymer, respectively, with said hydroxy functionality. 
   
   
       23 . A low gloss cured film comprising the reaction product of:
 (A) a first copolymer having at least one linear polymer strand having a weight average molecular weight of at least 1,500 Daltons and functionality X having an equivalent weight of no more than 500; and   (B) a second copolymer different than said first copolymer and having at least one linear polymer strand having a weight average molecular weight of at least 1,500 Daltons and functionality X′ having an equivalent weight of no more than 1,500;   wherein said low gloss cured film is free of gloss flattening agents and has a gloss of less than 70 gloss units at an angle of incidence of 60°, as measured according to ASTM D 2457.   
   
   
       24 . A low gloss cured film as set forth in  claim 23  wherein said gloss is less than 60 at an angle of incidence of 60°, as measured according to ASTM D 2457. 
   
   
       25 . A low gloss cured film as set forth in  claim 23  wherein said functionality X of said first copolymer is further defined as epoxy functionality. 
   
   
       26 . A low gloss cured film as set forth in  claim 25  wherein said functionality X′ of said second copolymer is further defined as carboxylic acid functionality. 
   
   
       27 . A low gloss cured film as set forth in  claim 23  wherein said functionality X′ of said second copolymer is further defined as carboxylic acid functionality. 
   
   
       28 . A low gloss cured film as set forth in  claim 23  wherein said first copolymer is the reaction product of at least one first ethylenically unsaturated monomer and at least one epoxy monomer. 
   
   
       29 . A low gloss cured film as set forth in  claim 28  wherein said at least one epoxy monomer is reacted in an amount of at least 30% by weight based on the combined weight of said at least one first ethylenically unsaturated monomer and said at least one epoxy monomer. 
   
   
       30 . A low gloss cured film as set forth in  claim 28  wherein said at least one epoxy monomer of said first copolymer is further defined as at least one of glycidyl methacrylate and glycidyl acrylate. 
   
   
       31 . A low gloss cured film as set forth in  claim 28  wherein said at least one first ethylenically unsaturated monomer of said first copolymer is further defined as at least one first acrylic monomer. 
   
   
       32 . A low gloss cured film as set forth in  claim 28  wherein said second copolymer is the reaction product of at least one second ethylenically unsaturated monomer and at least one carboxylic acid monomer. 
   
   
       33 . A low gloss cured film as set forth in  claim 32  wherein said at least one carboxylic acid monomer is reacted in an amount of at least 6.5% by weight based on the combined weight of said at least one second ethylenically unsaturated monomer and said at least one carboxylic acid monomer. 
   
   
       34 . A low gloss cured film as set forth in  claim 32  wherein said at least one carboxylic acid monomer of said second copolymer is selected from the group of methacrylic acid; acrylic acid; beta-carboxyethyl acrylate; acrylic acid dimer; methacrylic acid dimer; maleic acid; itaconic acid; the reaction product of cyclic anhydride and hydroxy functional acrylic monomer; the reaction product of alkyl substituted cyclic anhydride and hydroxy functional acrylic monomer; the reaction product of 2,3-epoxypropyl neodecanoate, (meth)acrylic acid, and cyclic anhydride; and combinations thereof. 
   
   
       35 . A low gloss cured film as set forth in  claim 32  wherein said second ethylenically unsaturated monomer of said second copolymer is further defined as at least one second acrylic monomer. 
   
   
       36 . A low gloss cured film as set forth in  claim 32  wherein said first acrylic monomer of said first copolymer and said second acrylic monomer of said second copolymer are independently selected from the group of acrylic acid ester having between 1 and 20 carbon atoms, methacrylic acid ester having between 1 and 20 carbon atoms, 2-ethylhexyl acrylate, methyl methacrylate, isobutyl methacrylate, 2-ethylhexyl methacrylate, 2-hydroxyethyl methacrylate, isobornyl methacrylate, isodecyl methacrylate, cyclohexyl methacrylate, aromatic ester, aromatic ether, and combinations thereof. 
   
   
       37 . A low gloss cured film as set forth in  claim 32  wherein said first acrylic monomer of said first copolymer and said second acrylic monomer of said second copolymer are independently selected from the group of hydroxy functional acrylic monomer; the reaction product of 2,3-epoxypropyl neodecanoate and at least one of (meth)acrylic acid, (meth)acrylic acid ester, maleic anhydride, isocyanato alkyl methacrylate, and dimethyl-m-isopropenylbenzyl isocyanate; and combinations thereof. 
   
   
       38 . A low gloss cured film as set forth in  claim 32  wherein at least one of said first ethylenically unsaturated monomer of said first copolymer and said second ethylenically unsaturated monomer of said second copolymer further comprises styrene monomer. 
   
   
       39 . A low gloss cured film as set forth in  claim 23  wherein at least one of said first copolymer and said second copolymer has functionality X″ different than said functionality X of said first copolymer and different than said functionality X′ of said second copolymer. 
   
   
       40 . A low gloss cured film as set forth in  claim 39  wherein said second copolymer has said functionality X″ different than said functionality X of said first copolymer and different than said functionality X′ of said second copolymer. 
   
   
       41 . A low gloss cured film as set forth in  claim 39  wherein said functionality X″ has an equivalent weight of from 290 to 2,320. 
   
   
       42 . A low gloss cured film as set forth in  claim 39  wherein said functionality X″ is further defined as hydroxy functionality. 
   
   
       43 . A low gloss cured film as set forth in  claim 39  further comprising the reaction product of a cross-linking agent and said functionality X″. 
   
   
       44 . A low gloss cured film as set forth in  claim 43  wherein said cross-linking agent is selected from the group of melamine, isocyanurate, and combinations thereof. 
   
   
       45 . A low gloss cured film as set forth in  claim 44  wherein at least one of said first ethylenically unsaturated monomer of said first copolymer and said second ethylenically unsaturated monomer of said second copolymer comprises a hydroxy-functional acrylic monomer to impart at least one of said first copolymer and said second copolymer, respectively, with said hydroxy functionality. 
   
   
       46 . A coating composition which is free of gloss flattening agents yet still produces a cured film having a low gloss of less than 70 gloss units at an angle of incidence of 60°, as measured according to ASTM D 2457, said coating composition comprising:
 (A) an epoxy acrylic copolymer which is substantially linear and is the reaction product of at least one acrylic ester monomer and at least one epoxy acrylic monomer, wherein said at least one epoxy acrylic monomer is reacted in an amount of at least 30% by weight based on the combined weight of said at least one acrylic ester monomer and said at least one epoxy acrylic monomer; and   (B) an acid acrylic copolymer which is substantially linear and is the reaction product of at least one second acrylic ester monomer and at least one carboxylic acid acrylic monomer, wherein said at least one carboxylic acid acrylic monomer is reacted in an amount of at least 6.5% by weight based on the combined weight of said second at least one acrylic ester monomer and said at least one carboxylic acid acrylic monomer.   wherein said epoxy acrylic copolymer and said acid acrylic copolymer are reactive with one another.   
   
   
       47 . A coating composition which is free of gloss flattening agents yet still produces a cured film having a low gloss of less than 70 gloss units at an angle of incidence of 60°, as measured according to ASTM D 2457, said coating composition comprising:
 (A) an epoxy acrylic copolymer which is substantially linear and is the reaction product of 2-ethylhexyl acrylate, methyl methacrylate, glycidyl methacrylate, and styrene, wherein said glycidyl methacrylate is reacted in an amount of 50% by weight based on the combined weight of said 2-ethylhexyl acrylate, methyl methacrylate, glycidyl methacrylate, and styrene; and   (B) an acid acrylic copolymer which is substantially linear and is the reaction product of isobutyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, acrylic acid, 2-hydroxyethyl methacrylate, wherein said acrylic acid is reacted in an amount of 20% by weight based on the combined weight of said isobutyl methacrylate, said 2-ethylhexyl acrylate, said 2-ethylhexyl methacrylate, said acrylic acid, and said 2-hydroxyethyl methacrylate;   wherein said epoxy acrylic copolymer and said acid acrylic copolymer are reactive with one another.