CA1329856C - Thermosetting epoxy resin based powder coating - Google Patents

Thermosetting epoxy resin based powder coating

Info

Publication number
CA1329856C
CA1329856C CA000568485A CA568485A CA1329856C CA 1329856 C CA1329856 C CA 1329856C CA 000568485 A CA000568485 A CA 000568485A CA 568485 A CA568485 A CA 568485A CA 1329856 C CA1329856 C CA 1329856C
Authority
CA
Canada
Prior art keywords
epoxy resin
based powder
acid anhydride
powder composition
resin based
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA000568485A
Other languages
French (fr)
Inventor
Katugi Kitagawa
Akira Shinozuka
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Somar Corp
Original Assignee
Somar Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to JP61290161A priority Critical patent/JPH0781098B2/en
Application filed by Somar Corp filed Critical Somar Corp
Priority to CA000568485A priority patent/CA1329856C/en
Priority to KR1019880006710A priority patent/KR960008473B1/en
Priority to US08/240,040 priority patent/US5455290A/en
Application granted granted Critical
Publication of CA1329856C publication Critical patent/CA1329856C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING 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
    • C09D5/00Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/03Powdery paints
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/34Silicon-containing compounds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/04Oxygen-containing compounds
    • C08K5/09Carboxylic acids; Metal salts thereof; Anhydrides thereof
    • C08K5/092Polycarboxylic acids

Landscapes

  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Paints Or Removers (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Epoxy Resins (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE
A thermosetting epoxy resin based powder composition composed of an epoxy resin, a high-melting point polycarboxylic acid anhydride and a filler, the high-melting point polycarboxylic acid anhydride comprising fine particles of no more than 149 µm in average size that have reacted with the epoxy resin in the molten state on their surfaces.

Description

13298~

THERMOSETTING EPOXY RESIN BASED
POWDER COATING
-: . :- -FIELD OF T~E INVENTION
The present invention relates to a thermosetting epoxy resin based powder coating (which is hereinafter referred to simply as a powder coating).
BACKGROUND OF THE INVENTION ~.
Various powder coatings have been known that consist ba~ically of a uniform mixture of an epoxy resin, a carboxylic acid anhydride in powder form, and a filler.
These powder coatings are ap~lied by the ~luidized-bed coating process, the electro~tatic fluidized-bed coating process or some other ~uitable methods to form insulation films on electrical and electronic devices.
Powder coatings are either melt-mixed or dry-blended. In the first process, dry ingredients including an epoxy resin ba~e and additives such as a curing agent and a ~iller are mixed; the premix is then melt-compounded, cooled to ~olidify, finely ground, and clas~fied. In the second proce~, the premix of dry lngrédient~ ifi pre~ure-compounded, finely ground and 20 cla8~i~ied. I~ a high-melting point polycarboxylic acid ;
-anhydride used as the curing agent poorly mixe~ and di8per~e~ in the re~in, a product having desired coating ;:

13298~i performance cannot be attained. If a low-melting point monocarboxylic acid anhydride is additionally used in an attempt to improve the dispersive ~iscibility of the polycarboxylic acid anhydride with the resin, the anti-blocking property and storage stability of the final productwill be impaired. If the polycarboxylic acid anhydride is mixed and dispersed in the resin at elevated temperatures, the storage stability of the final product i8 impaired.

SUMMARY OF THE INVENTION

An ob~ect, therefore, of the present invention is to provide a thermosetting epoxy resin based powder coating that i8 ~ree ~rom the aforementioned defects of the prior art.
The thermosetting epoxy resin based powder coating o~ the present invention that attains this object i8 a powder composition compo~ed o~ an epoxy resin, a high-melting point polycarboxylic acid anhydride and a ~iller, and the high-melting point polycarboxylic acid anhydride compri~e~ ~ine particles o~ not more than 149 ~m in average ~ize that have reacted with the epoxy re~in in the molt~n ;; ~tate on thelr ~ur~ace~.
Accordlngly, in one aspect, the invention resides in a thermosetting epoxy resin based powder compo~ition - oompo~-d o~ an epoxy re~in, a high-melting point .
~ 25 polycarboxylic acid anhydride and a filler, ~aid high--- melting polnt poly¢arboxylic acid anhydride having a higher ~ C ~ - 2 ~
~ ' ~

-- 1 3 2 ~

melting temperature than the epoxy resin and comprising fine paxticles of no more that 149 ~m in average size that have : .
reacted with the epoxy resin in the molten state on their surfaces -DETAILED DESCRIPTION OF THE INVENTION
. ._ :.. ;.

The epoxy resin for use in the present invention . :
may be seleoted from ~mong known epoxy re~ins that are ~ ~

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commonly used in powder coatings,-such as bisphenol A type epoxy resins, novolac type epoxy resins, and alicyclic epoxy resins. Epoxy resins that are solid at ordinary temperatures are preferably used in the present invention S and they may, if desired, be combined with epoxy resins that are liquid at ordinary temperatures in a low proportion.
The high-melting point polycarboxylic acid anhydride used as a curing agent in the present invention 10 i8 such that it melts at a higher temperature than the epoxy resin used (if two or more epoxy resins are used, the one having the highe~t melting point is meant).
Examples of such high-melting point polycarboxylic acid anhydride include: phthalic anhydride (m.p. 128 - 130C), benzophenone tetracarboxylic acid anhydride (m.p. 218 -225C), 5-(2,5-dioxotetrahydrofuryl)-3-methyl-3-cyclohexene-1,2-dicarboxylic acid anhydride ~m.p. 167C), tetrahydrophthalic anhydride (m.p. 100C), trimellitic anhydride (m.p. 145C), and pyromellitic anhydride ~m.p.
265C).
In the present invention, the polycarboxylic acid anhydrlde 1~ used in the form of fine particles of not more than 149 ~m, preferably between 5 and 44 ~m, in average ~ize. According to the ~tudies conducted by the 2S pra~ent inventors, when ~uch fine particulate poly-1 329~6 :'.',,' - .

carboxylic acid anhydride was compounded into a molten epoxy resin, with the compounding temperature and time being appropriately controlled (preferably the compounding temperature being 50 to 150 C and time being 1 to 5 minutes), the most part ~preferably at least 70 wt%) of the polycarboxylic acid anhydride used reacted with the epoxy resin on the surfaces of the particles of the anhydride and dispersed and mixed uniformly with the resin so as to provide a powder coating that had good storage stability and appearance (i.e., anti-blocking property).
If the polycarboxylic acid anhydride has an average particle size exceeding 149 ~m, its particles will disperse and mix in the epoxy resin only poorly during high-temperature coatins operations even if the anhydride particle~ have been reacted with the molten epoxy resin on their ~urfaces. This will result in failure to produce a coating film havlng good appearance. In mixing the fine particulate polycarboxylic acid anhydride with the molten epoxy re~in, selection of an appropriate heating temperature is also important. If the temperature for di~persing and mixing in the molten reain i8 excessive, most of the ~ine particles of the anhydride will dissolve by reacting with the redin and the storage stability of the latter wlll be impaired. Therefore, it is important for the purpo8e8 of the pre8ent invention that the 13~93~ 6 polycarboxylic acid anhydride used as a curing agent be in fine particulate form and that the fine particles react with the resin on their surfaces without losing their shape as fine particles. Needless to say, some part of the fine particles of the polycarboxylic acid anhydride may dissolve away as a result of reaction with the molten epoxy resin. The polycarboxylic acid anhydride is incorporated in the powder coating of the present invention in an amount generally ranging from 0.45 to 1.55 equivaients, preferably from 0.65 to 1.25 equivalents, per epoxy equivalent weight of the epoxy resin.
The filler used in the present invention can be selected from among those which are commonly employed with the powder coating of the type contemplated by the present invention, such as the powders of zircon, talc, quartz glass, calcium carbonate, magnesia, calcium silicate and silica. ~hese fillers have particle sizes of not more than 149 ~m (not coar~er than 100 mesh), preferably in the range of 2 ~m to 44 ~m. ~he filler i9 to be incorporated in an amount that generally ranges rom 5 to 300 parts by weight, preferably from 30 to 150 part~ by weight, per 100 ~arts by weight o the epoxy re~in.
Be~ides the ingredients de~cribed above, the powder coating of the present invention may also incorporate some other common additives ~uch a~ a cure : 13?~98~6 ~

accelerator (e.y., imidazole, dicyandiamide and tertiary amine), a pigment (e.g., chromium oxide and red iron oxide) and a flow-control agent (e.g., acrylic ester oligomer).
The following example is provided for the purpose of further illustrating the present invention but is in no way to be taken as limiting.
EX~MPLE
A hundred parts by weight of Epikote 1002 (the trade name of Yuka-Shell Epoxy Co., Ltd. for a bisphenol A
type epoxy resin that i5 solid at ordinary temperature and which has a melting point of 83C) was provided. To this epoxy re~in, 100 parts by weight of fine particulate calcium sil~cate (wollastonite with an average particle ~ize of about 3 ~m) and one of the polycarboxylic acid anhydride~ shown in Table 1 a~ curing agents were added.
The ingredients were melt-mixed under heating, cooled to ~olidify, and finely ground.
~he resulting coatlng powders were visually checked for their appearance ~anti-blocking property). At the ~ame tlme, the ~torage stabllity of theae powders was evaluated by the followlng method. The results are shown in Table 1.

~ ~rade ~ rk 1329 ~ 6 (Test for Storage Stability) The gel time (at 150C) of each powder was measured at immediately a~ter preparation (initial) and 7 days after its preparation and the change that occurred was measured in accordance with JIS C-2104.
The symbols appearing in the column of "Curing Agent" in Table 1 have the following meanings: -~
BTDA, benzophenone tetracarboxylic acid :::
anhydride; -MCTC, 5-~2,5-dioxotetrahydrofuryl)-3-methyl-3-cyclohexene-1,2-dicarboxylic acid anhydride; ::
THPA, tetrahydrophthalic anhydride.
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1~ ~ ~I N ~ ~ U~ ~0 ~3298~

As will be understood the data shown in Table 1, the coating powder samples prepared in accordance with the present invention have the high melting point polycarboxylic acids (curing agent) dispersed and mixed sufficiently uniformly in an epoxy resin to provide good appearance (anti-blocking property). When these powders are coated on electrical or electronic devices, they~: :
produce insulation films having few pinholes or voids,:; .
thereby increasing the reliability of the electrical or electronic devices. As a further advantage, the powder coating of the present invention has excellent storage stability.
While the invention has been described in detail and w~ th reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departlng from the spirit and scope thereof. ..

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Claims (8)

1. A thermosetting epoxy resin based powder composition composed of an epoxy resin, a high-melting point polycarboxylic acid anhydride and a filler, said high-melting point polycarboxylic acid anhydride having a higher melting temperature than the epoxy resin and comprising fine particles of no more that 149 µ m in average size that have reacted with the epoxy resin in the molten state on their surfaces.
2. A thermosetting epoxy resin based powder composition as in claim 1, wherein said eposy resin is selected from bisphenol A type epoxy resins, novolac type epoxy resins and alicyclic epoxy resins.
3. A thermosetting epoxy resin based powder composition as in claim 1, wherein said high-melting point polycarboxylic acid anhydride is selcted from phthalic anhydride, benzophenone tetracarboxylic acid anhydride, 5-(2,5-dioxotetrahydrofuryl)-3-methyl-3-cyclohexene-1,2-dicarboxylic acid anhydride, tetrahydrophthalic anhydride, trimellitic anhydride, and pyromellitic anhydride.
4. A thermosetting epoxy resin based powder composition as in claim 1, wherein the particle size of said high-melting point polycarboxylic acid anhydride is 5 - 44 µm.
5. A thermosetting epoxy resin based powder composition as in claim 1, wherein the amount of said polycarboxylic acid anhydride is from 0.45 to 1.55 equivalents per epoxy equivalent weight of said epoxy resin.
6. A thermosetting epoxy resin based powder composition as in claim 1, wherein said filler is selected from the powders of zircon, talc, quartz glass, calcium carbonate, magnesia, calcium silicate and silica.
7. A thermosetting epoxy resin based powder composition as in claim 6, wherein said filler has a particle size of 2 - 44 µm.
8. A thermosetting epoxy resin based powder composition as in claim 6, wherein the amount of said filler ranges from 5 to 300 parts by weight per 100 parts by weight of said epoxy resin.
CA000568485A 1986-12-05 1988-06-02 Thermosetting epoxy resin based powder coating Expired - Fee Related CA1329856C (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
JP61290161A JPH0781098B2 (en) 1986-12-05 1986-12-05 Thermosetting epoxy resin powder coating
CA000568485A CA1329856C (en) 1986-12-05 1988-06-02 Thermosetting epoxy resin based powder coating
KR1019880006710A KR960008473B1 (en) 1986-12-05 1988-06-04 Thermosetting epoxy resin based powder coating
US08/240,040 US5455290A (en) 1986-12-05 1994-05-09 Powder composition of epoxy resin, high melting acid anhydride and calcium silicate

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP61290161A JPH0781098B2 (en) 1986-12-05 1986-12-05 Thermosetting epoxy resin powder coating
CA000568485A CA1329856C (en) 1986-12-05 1988-06-02 Thermosetting epoxy resin based powder coating
KR1019880006710A KR960008473B1 (en) 1986-12-05 1988-06-04 Thermosetting epoxy resin based powder coating
US08/240,040 US5455290A (en) 1986-12-05 1994-05-09 Powder composition of epoxy resin, high melting acid anhydride and calcium silicate

Publications (1)

Publication Number Publication Date
CA1329856C true CA1329856C (en) 1994-05-24

Family

ID=27426548

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000568485A Expired - Fee Related CA1329856C (en) 1986-12-05 1988-06-02 Thermosetting epoxy resin based powder coating

Country Status (4)

Country Link
US (1) US5455290A (en)
JP (1) JPH0781098B2 (en)
KR (1) KR960008473B1 (en)
CA (1) CA1329856C (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19813286A1 (en) * 1998-03-26 1999-09-30 Metallgesellschaft Ag Process for separating vaporous phthalic anhydride from a gas stream
US6677484B1 (en) * 2000-07-31 2004-01-13 E. I. Du Pont De Nemours And Company Melt-sprayed curing agent powder and powder coating compositions made therefrom

Family Cites Families (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3269974A (en) * 1963-06-25 1966-08-30 Hysol Corp Powdered epoxy resin compositions
US3484398A (en) * 1965-03-18 1969-12-16 Dexter Corp Powdered epoxy resin compositions
US3374193A (en) * 1965-07-19 1968-03-19 Shell Oil Co Polyepoxide fluidized bed coating compositions
US3624032A (en) * 1969-04-24 1971-11-30 Morton Int Inc Epoxy compositions cured with carboxylic acid anhydrides and metallic salt of acetylacetone
BE789216A (en) * 1971-10-01 1973-03-26 Shell Int Research OMPOSITIES WERKWIJZE TER BEREIDING VAN POEDERVORMIGE DEKLAAGC
US3989573A (en) * 1973-12-11 1976-11-02 Westinghouse Electric Corporation Glass-epoxy laminates for high temperature use
US4009223A (en) * 1974-05-08 1977-02-22 Westinghouse Electric Corporation Thin film electrostatic epoxy coating powder
GB1498542A (en) * 1975-12-30 1978-01-18 Ciba Geigy Ag Compositions for curing epoxide resins
US4271061A (en) * 1979-03-06 1981-06-02 Nitto Electric Industrial Co., Ltd. Epoxy resin compositions for sealing semiconductors
CA1154895A (en) * 1980-02-21 1983-10-04 Dieter Skudelny Flowable mixture and use of synthetic calcium silicate
CA1164124A (en) * 1980-07-15 1984-03-20 Kurt Munk Pourable solid mixture
US4358552A (en) * 1981-09-10 1982-11-09 Morton-Norwich Products, Inc. Epoxy resinous molding compositions having low coefficient of thermal expansion and high thermal conductivity
US4560739A (en) * 1983-12-02 1985-12-24 Ciba-Geigy Corporation Triglycidyl compounds of aminophenols
JPS6189271A (en) * 1984-10-08 1986-05-07 Sumitomo Deyurezu Kk Epoxy resin composition for powder coating
JPS61151274A (en) * 1984-12-25 1986-07-09 Sumitomo Bakelite Co Ltd Powder coating
US4734468A (en) * 1986-02-28 1988-03-29 Shell Oil Company Epoxy resin composition
DE3622610A1 (en) * 1986-07-05 1988-01-14 Bayer Ag LIQUID CRYSTALLINE DIGLYCIDYL COMPOUNDS, THEIR PRODUCTION AND USE IN HARDENABLE EPOXY BLENDS
JPH0618985B2 (en) * 1987-06-03 1994-03-16 信越化学工業株式会社 Epoxy resin composition

Also Published As

Publication number Publication date
KR900000419A (en) 1990-01-30
JPH0781098B2 (en) 1995-08-30
KR960008473B1 (en) 1996-06-26
JPS63142070A (en) 1988-06-14
US5455290A (en) 1995-10-03

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