Hyperbranched aliphatic polyesters and reactive diluents in thermally cured coil coatings

Two hydroxy-functional hyperbranched aliphatic polyesters based on 2,2-dimethylolpropionic acid (bis-MPA) and a partially aromatic conventional polyester have been studied as thermoset resins for solvent-borne thermally cured polyester cross-linked with melamine coatings for precoated sheet metal, i.e., coil coatings. The hyperbranched polyesters differ with respect to the ratio of the end groups, being either hydroxyls or alkyl esters. The rheological properties of formulations with different polyester resin composition and reactive diluent, i.e., rape seed methyl ester, content have been evaluated with viscosity measurements. Films cured either under industrial cure conditions to obtain a peak metal temperature of 232-241 degrees C or at a lower temperature, i.e., 130 degrees C, on untreated or organic primer-coated hot-dipped-galvanized steel substrates have been prepared. The film properties have been evaluated with differential scanning calorimetry and conventional film characterization techniques, i.e., adhesion, impact, Erichsen cupping, pencil hardness, microhardness, and scratch and chemical resistance tests. Formulations possessing high drying ability with maintained suitable film application viscosity were obtained using a hyperbranched polyester resin and a reactive diluent. It is proposed that a solvent-free polyester/melamine formulation with sufficient film properties to withstand the rough forming procedures associated with coil coatings can be obtained by further modification of the resin and greater amounts of reactive diluent.