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Aqueous dispersions and coatingsRelated Patent Categories: Synthetic Resins Or Natural Rubbers -- Part Of The Class 520 Series, Natural Rubber Compositions Having Nonreactive Materials (dnrm) Other Than: Carbon, Silicon Dioxide, Glass Titanium Dioxide, Water, Hydrocarbon, Halohydrocarbon, Ethylenically Unsaturated Reactant Admixed With A Preformed Reaction Product Derived From: (a) At Least One Polycarboxylic Acid, Ester, Or Anhydride; (b) At Least One Polyhydroxy Compound; And (c) At Least One Fatty Acid Glycerol Ester, Or A Fatty Acid Or Salt Derived From A Naturally Occurring Glyceride, Tall Oil, Or A Tall Oil Fatty Acid, At Least One Solid Polymer Derived From Ethylenic Reactants Only, Polymer Mixture Of Two Or More Solid Polymers Derived From Ethylenically Unsaturated Reactants Only; Or Mixtures Of Said Polymer Mixture With A Chemical Treating Agent; Or Products Or Processes Of Preparing Any Of The Above Mixtures, Treating Polymer Or Polymer Mixture With A Chemical Treating Agent Other Than Solid Polymer, Agent Is An Organic MaterialAqueous dispersions and coatings description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070117928, Aqueous dispersions and coatings. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This is a division of U.S. patent application Ser. No. 10/817,651 filed Apr. 2, 2004, which claims priority to U.S. Provisional Patent Application Ser. No. 60/459,728, filed Apr. 2, 2003. Both of these applications are incorporated herein by reference in their entirety. BACKGROUND [0002] A wide variety of coatings have been used to coat the surfaces of packaging articles (e.g., food and beverage cans). For example, metal cans are sometimes coated using "coil coating" operations, i.e., a planar sheet of a suitable substrate (e.g., steel or aluminum metal) is coated with a suitable composition and cured. The coated substrate then is formed into the can end or body. Alternatively, liquid coating compositions may be applied (e.g., by spraying, dipping, rolling, etc.) to the substrate and then cured. [0003] Packaging coatings should preferably be capable of high-speed application to the substrate and provide the necessary properties when cured to perform in this demanding end use. For example, the coating should be safe for food contact, have excellent adhesion to the substrate, and resist degradation over long periods of time, even when exposed to harsh environments. [0004] Many current packaging coatings contain mobile or bound bisphenol A ("BPA") or aromatic glycidyl ether compounds or PVC compounds. Although the balance of scientific evidence available to date indicates that the small trace amounts of these compounds that might be released from existing coatings does not pose any health risks to humans, these compounds are nevertheless perceived by some people as being potentially harmful to human health. Consequently, there is a strong desire to eliminate these compounds from food contact coatings. [0005] From the foregoing, it will be appreciated that what is needed in the art is a packaging container (e.g., a food or beverage can) that is coated with a composition that does not contain extractible quantities of such compounds. Such packages, compositions and methods for preparing the same are disclosed and claimed herein. SUMMARY [0006] The present invention relates to novel aqueous dispersions that are suitable for use as coating compositions and methods of coating substrates using these dispersions. [0007] A dispersion of the present invention preferably includes the reaction product of (i) an oxirane-functional vinyl addition polymer; (ii) an acid-functional polymer (e.g., an acid-functional vinyl addition polymer or an acid-functional polyester resin); and (iii) a tertiary amine. The reaction product is preferably dispersed in a carrier (e.g., water) with optional crosslinkers and other optional adjuvants. Preferred compositions and dispersions are substantially free of mobile BPA and aromatic glycidyl ether compounds (e.g., BADGE, BFDGE and epoxy novalacs). [0008] In one embodiment, the method includes: providing an oxirane-functional vinyl addition polymer having an oxirane functionality of 0.5 to 5; providing an acid-functional polymer having an acid number of 30 to 500; reacting the oxirane-functional vinyl addition polymer and the acid-functional polymer together in the presence of a tertiary amine to form a water-dispersible polymer; and dispersing the water-dispersible polymer in a carrier that includes water. [0009] In one presently preferred embodiment: (i) the oxirane-functional vinyl polymer is the reaction product of 1 to 10 wt. % oxirane-functional monomer, 0 to 60 wt. % hydroxy-functional monomer, and the balance other monomer (e.g., non-functional monomer); and the polymer has an oxirane functionality of 0.5 to 5 and a number average molecular weight of 2,500 to 20,000; (ii) the acid-functional polymer is a vinyl polymer formed as the reaction product of an acid-functional monomer (more preferably at least 15 wt. % acid-functional monomer), and the balance other monomer (e.g., non-functional monomer); and the polymer has an acid number of 30 to 500 (more preferably 100 to 500) and a number average molecular weight of 2,000 to 15,000; (iii) the tertiary amine is dimethyl ethanol amine or the like; (iv) wherein the aforementioned polymers are reacted together in the presence of the tertiary amine to form at least some quaternary ammonium salt, with a weight ratio of (i):(ii) of 90:10 to 50:50, and with a ratio of amine:oxirane groups of 0.8:1 to 5:1; and (v) the reacted polymers are dispersed in water. [0010] In another embodiment, the present invention provides a method, that includes: providing an oxirane-functional vinyl addition polymer having an oxirane functionality of 0.5 to 5; providing an acid-functional polymer having an acid number of 30 to 500; providing a tertiary amine; combining the acid-functional polymer with the tertiary amine to form a mixture and at least partially neutralize the acid-functional polymer; and combining the oxirane-functional vinyl addition polymer and the mixture to form a water-dispersible polymer; and dispersing the water-dispersible polymer in a carrier that includes water. In certain embodiments, the mixture is added over a period of time to the oxirane-functional vinyl addition polymer. [0011] In another embodiment, the present invention provides a method, that includes: providing a first set of monomers for making an oxirane-functional vinyl addition polymer having an oxirane functionality of 0.5 to 5; providing a second set of monomers for making an acid-functional polymer having an acid number of 30 to 500; providing a tertiary amine; polymerizing at least one set of the monomers to form a first polymer; polymerizing the other set of monomers in the presence of the first polymer; adding tertiary amine to form a water-dispersible polymer; and dispersing the water-dispersible polymer in a carrier that includes water. In certain embodiments, polymerizing at least one of the sets of monomers occurs in the presence of the other set of monomers. Alternatively, in certain embodiments, polymerizing at least one of the sets of monomers occurs prior to addition of the other set of monomers. [0012] The present invention also provides a composition that includes an aqueous dispersion of a quaternary ammonium salt, wherein the salt includes the reaction product of an oxirane-functional vinyl addition polymer having an oxirane functionality of 0.5 to 5; an acid-functional polymer having an acid number of 30 to 500; and a tertiary amine. [0013] In another embodiment, the present invention includes a coating composition that includes: an aqueous dispersion of a quaternary ammonium salt, wherein the salt includes the reaction product of an oxirane-functional vinyl addition polymer having an oxirane functionality of 0.5 to 5; an acid-functional polymer having an acid number of 30 to 500; and a tertiary amine; and a crosslinker. [0014] The present invention provides methods of coating an article. Such methods include applying a composition of the present invention to a substrate surface and hardening the composition. [0015] The present invention also provides articles. In one embodiment, the article includes a substrate having an uncured film thereon, wherein the film includes an aqueous dispersion of a quaternary ammonium salt, wherein the salt includes the reaction product of an oxirane-functional vinyl addition polymer having an oxirane functionality of 0.5 to 5; an acid-functional polymer having an acid number of 30 to 500; and a tertiary amine. In certain embodiments, the uncured film further includes a crosslinker. [0016] In another embodiment, the article includes a substrate having a cured film thereon, wherein the cured film is preparable from a coating composition that includes an aqueous dispersion of a quaternary ammonium salt, wherein the salt includes the reaction product of an oxirane-functional vinyl addition polymer having an oxirane functionality of 0.5 to 5; an acid-functional polymer having an acid number of 30 to 500; a tertiary amine; and an optional crosslinker. [0017] In yet another embodiment, the article includes a substrate having a cured film thereon, wherein the cured film includes a crosslinked polymer having a crosslink segment of the general formula: --Y--C(R.sub.2)--C(R)(OH)--C(R.sub.2)--O--(O)C--X.sub.r--, wherein: Y is a divalent organic group, more preferably a divalent organic group that includes a C(O)O moiety; X is a divalent organic group; R is H, or a C1 to C6 organic group, preferably H; and r is 0 or 1, preferably 0. DEFINITIONS [0018] The term "substantially free" of a particular mobile compound means that the compositions of the present invention contain less than 1000 parts per million (ppm) of the recited mobile compound. The term "essentially free" of a particular mobile compound means that the compositions of the present invention contain less than 100 parts per million (ppm) of the recited mobile compound. The term "essentially completely free" of a particular mobile compound means that the compositions of the present invention contain less than 5 parts per million (ppm) of the recited mobile compound. The term "completely free" of a particular mobile compound means that the compositions of the present invention contain less than 20 parts per billion (ppb) of the recited mobile compound. [0019] The term "mobile" means that the compound can be extracted from the cured coating when a coating (typically approximately 1 mg/cm.sup.2 thick) is exposed to a 10 weight percent ethanol solution for two hours at 121.degree. C. followed by exposure for 10 days in the solution at 49.degree. C. [0020] If the aforementioned phrases are used without the term "mobile" (e.g., "substantially free of XYZ compound") then the compositions of the present invention contain less than the aforementioned amount of the compound whether the compound is mobile in the coating or bound to a constituent of the coating. Continue reading about Aqueous dispersions and coatings... Full patent description for Aqueous dispersions and coatings Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Aqueous dispersions and coatings patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Aqueous dispersions and coatings or other areas of interest. ### Previous Patent Application: Adhesive composition Next Patent Application: Fluoropolymer blending process Industry Class: Synthetic resins or natural rubbers -- part of the class 520 series ### FreshPatents.com Support Thank you for viewing the Aqueous dispersions and coatings patent info. 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