Novel coating resins based on polycarbonates and poly(ester-co-carbonate)s made by catalytic chain growth polymerization of epoxides with CO2 and with anhydride/CO2

Abstract

In this work we describe a possibly new generation of (powder) coating resins of the polycarbonate or poly(ester-co-carbonate) type, synthesized from epoxides like cyclohexene oxide (CHO), anhydrides like phthalic anhydride (PA) and carbon dioxide (CO2) by chain growth polymerization, catalyzed by a chromium-Salophen complex and using dimethylaminopyridine (DMAP) as a co-catalyst. The molecular structures of the polymers produced were characterized and especially MALDI-ToF-MS yielded important information on the end-groups and other functional groups which are crucial for the curing chemistry of these resins. One special type of copolycarbonate in this study carried pendent vinyl groups, introduced by copolymerization of CHO and CO2 with 4-vinylcyclohexene oxide (VCHO). This copolycarbonate was first casted from solution, after which the polymer film was successfully cured with a trithiol compound by UV- or thermally induced radical curing chemistry. These cured coatings showed a good acetone resistance (≥75 double rubs) and reversed impact toughness. A powder coating evaluation of this CHO/VCHO-based copolycarbonate showed excellent processability, high pencil hardness (6-8H), value zero in a Gitterschnitt test on aluminum, reasonable appearance in a ‘PCI-smoothness test’ (value 2–3) and good acetone resistance (≥75 double rubs). Most probably due to a too high Tg (85–104°C) of the cured coating the reverse impact resistance was poor. A similar powder coating evaluation of a poly(ester-co-carbonate) based on CHO, PA and CO2 showed less promising results due to poor flow properties and foaming above 140°C.