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.

Zinc and iron substrates were coated with polyester acrylate films. The samples were cured by an exposure to different doses of ultraviolet (UV) radiation energy at different radiant fluxes of the UV light source. Infrared spectroscopy was used to estimate the resulting degree of macromolecular cross-linking. Its effect on the barrier properties of the coating was investigated by Electrochemical Impedance Spectroscopy (EIS). A reduced water uptake and a reduced swelling of the coating as well as a decelerated diffusion of water through the polymer bulk were detected on polyester acrylate coated zinc samples that were exposed to increasing UV energy doses at low UV light intensity. With the Scanning Kelvin Probe (SKP), a similar tendency was detected for the resistance of polyester acrylate/iron oxide/iron interfaces against cathodic delamination. In contrast, curing with large energy doses at high UV intensity led to decelerated ion transport kinetics along the interface, but did not further improve the barrier properties of the coating. This indicated that SKP data gained on Fe substrates and EIS data recorded on Zn substrates can be correlated if UV curing does not result in strong tension within the polyester acrylate films.

No abstract