JPS5829816B2 - Funmu Kanou Namizu Bunsan Acrylic Kiyoji Yugotai - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Applying various coating compositions to substrates can be accomplished in a variety of ways.

The substrate may be coated by dip coating, roll coating, electrocoating, spraying, etc.

Similarly, the coating composition itself can be applied in many forms, such as, for example, as a solvent solution, a solvent dispersion, or an aqueous dispersion.

This form of coating composition has been commonly used throughout the years because so many compositions can be easily applied in a solvent solution.

However, in the past, ecological trends and recent air pollution legislation have stimulated an increased demand for water-based coating compositions that contain little solvent.

Due to mass productivity such as in the automobile industry, an application method that is becoming very important in various coating methods is the spray method.

Coatings made of acrylic polymers have recently been used in the automotive industry due to their aesthetic appearance and protective properties.

Thus, spray coatings consisting of water-dispersed acrylic polymer compositions with high solids content are highly desirable not only in the automotive industry but also in other industries.

The only problem with spraying substrates such as automobile bodies and equipment is that the coating efficiency is currently very low.

That is, due to overspray and paint splashing off the substrate, only about half of the solids of the paint passing through the spray gun is accurately deposited onto the substrate.

Good appearance and at least about 0.5 mm (2 mils) thick
Due to the need to obtain a total topcoat film coverage of , the capabilities of currently available spray guns, and the problems discussed above, it is difficult to achieve adequate automotive topcoating in less than two paint coats with conventional techniques. It is known that.

That is, the entire substrate to be topcoated must be passed through the spray equipment at least three times.

One coat of paint is generally defined in paint manufacturing terms as one hour of spraying for two flash times (solvent evaporation time).

A three-coat system requires a large amount of time and process expense, so a two-coat system is recommended that allows the same coverage obtained using a three-coat system to be obtained with only two coats of paint. Significant efforts are being made in the coating industry to obtain

According to one embodiment of the present invention, spraying an acrylic polymer composition that is dispersed in water and has a high solids content provides high film formation and coating efficiency, and that the acrylic copolymer composition used Adjust the degree of sum to pH 7.2~
The film obtained by preparing the sprayable composition with a value of 8.0 was
It has been found that resistance to ing) is improved.

Using this method, a two-coat system can produce a film of at least the same thickness and appearance as films previously formed with three-coat systems.

Not only is it possible to obtain a film former in two coats, but it is also more effective than when used in prior art systems consisting of completely or substantially neutralized compositions with a pH value of 8.0 or higher. It has also been found that an unexpectedly small amount of paint is used.

The use of this composition significantly reduces the cost of coating automobiles and other substrates.

The major problems in achieving high solids content aqueous coating compositions for spray application have remained unsolved to date.

That is, about 15-20% when using prior art methods of preparing aqueous thermosetting acrylic compositions.
Only compositions containing a solids content of .

This is because the viscosity of high solids content spray compositions makes their coating unsuitable for spray application.

However, by using the system of the present invention, it is possible to spray even solids contents of 30% and much higher if the sprayable composition is maintained at a pH of 7.2 to 8.0. Is possible.

Being able to do so not only results in a more economical system, but also higher film formation and uniform coverage.

The prior art also provides methods for forming an acrylic copolymer, neutralizing the copolymer, adding water, then adding aminoplast resin, spraying and baking to cure the coating.

Although this process generally achieves its objectives, it does produce some crater and requires curing at 350'F or higher.

Baking at such high temperatures can create stability problems for the coating and can cause damage to some components of the final coating and substrate.

In accordance with another embodiment of the present invention, certain acrylic copolymers can be sprayed at high solids contents when then premixed directly with aminoplast resins after neutralization and before adding water. It has also been found that the compositions can be cured at temperature to form water-dispersible compositions.

The composition of the present invention is an aqueous dispersion in which various components are combined.

All or some of these components may be completely or partially soluble in water, or they may be in the form of discrete particles dispersed in water.

The neutralized acrylic copolymers described below are typically water soluble, at least sufficiently water soluble to form what is commonly known as a "soap solution" in water. be.

The acrylic copolymer that is premixed with the aminoplast resin generally contains from about 1% to about 20% by weight of hydroxyalkyl esters of acrylic acid, methacrylic acid, or other alpha-beta ethylenically unsaturated carboxylic acids. It is something to do.

These esters can be formed from alkylene glycols esterified with acids or can also be prepared by reaction of acids and alkylene oxides.

From about 4% to about 15% by weight of an unsaturated carboxylic acid and at least one other ethylenically unsaturated carboxylic acid copolymerizable with the acid and the ester described above is copolymerized with the hydroquine alkyl ester.

Preferred hydroxyalkyl esters in acrylic copolymers are esters of acrylic and methacrylic acids in which the hydroxyalkyl group has up to about 5 carbon atoms.

These esters include, for example, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, 3-hydroxypropyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 3-hydroxypropyl methacrylate, 4-hydroxybutyl methacrylate, and the like. It is a mixture of esters of

Corresponding esters of other unsaturated acids such as ethacrylic acid, crotonic acid and similar acids having up to about 6 carbon atoms can also be used.

In addition to unsaturated monocarboxylic acids, mono- or diesters of unsaturated dicarboxylic acids such as maleic acid, fumaric acid and itaconic acid, at least one of the esterifying groups thereof
Those containing a hydroxyl group may also be used.

Esters of such unsaturated dicarboxylic acids provide special characteristics in certain compositions.

Examples of such esters include eva, mono(2-hydroxyethyl)malate, mono(2-hydroxyethyl)fumarate, bis(2-hydroxyethyl)malate, mono(2-hydroxypropyl)malate, bis(2-hydroxyethyl)malate, Mention may be made of propyl) maleate, mono(2-hydroxyethyl) itaconate), bis(2-hydroxyethyl) itaconate and 2-hydroxyethylbutyl maleate.

The unsaturated acid monomer of the copolymer is acrylic acid or methacrylic acid; other acids having up to about 6 carbon atoms;
Acids such as the unsaturated monocarboxylic and dicarboxylic acids mentioned above in conjunction with esters may also be utilized.

When monoesters of dicarboxylic acids are utilized as hydroxyalkyl monomers, they can also be considered as all or part of the acid-type monomer.

The remainder of the acrylic copolymer is comprised of one or more other ethylenically unsaturated monomers copolymerizable with the ester or acid described above.

Any of the following monomers can be used.

That is, commonly used monomers include various alkyl esters of α/β-ethylenically unsaturated carboxylic acids such as alkyl acrylates and alkyl methacrylates, such as ethyl, methyl, propyl, butyl, hexyl, and ethylhexyl. and lauryl acrylate and methacrylate, and other alkyl groups with approximately 20 carbon atoms
Similar esters up to.

Vinyl aromatic hydrocarbons may also be used to form copolymers, typical examples of which are styrene, alpha-alkylstyrene, and vinyltoluene.

Furthermore, other unsaturated monomers can be used, such as monoolefinic and diolefinic hydrocarbons, other unsaturated esters of organic and inorganic acids, unsaturated nitriles, unsaturated amides,
other unsaturated acids, etc.

Some specific monomers that may be mentioned are ethylene, l
・3-Butadiene, acrylonitrile, acrylamide, vinyl acetate, α-chlorostyrene, vinyl chloride, methyl crotonate, allyl chloride,
and similar compounds.

These copolymers are made using conditions and catalysts commonly used in making acrylic polymers.

For example, a free radical catalyst is usually present and the polymerization temperature is generally about 65°C to 140°C.

This copolymer is partially or completely neutralized by the base.

This is accomplished by reacting all or some of the acidic carboxyl groups in the copolymer with a base.

Various organic bases and ammonia can be used for this neutralization.

Preferred organic bases are primary, secondary and tertiary amines.

These amines that can be used are alkylamines such as ethylamine, flobylamine, dimethylamine, dibutylamine, cyclohexylamine, diisoamylamine:
Unsaturated amines such as allylamine: Aromatic amines such as aniline: Aralkylamines such as benzylamine: m
-) alkarylamines such as luidine; cyclic amines such as dimorpholine and piperidine; diamines such as hydrazine, ethylenediamine and piperazine; and substituted amines such as triethanolamine.

In some cases, part of the intermediate phase is carried out with diamines and part with other bases.

Alternatively, part of the neutralization can be performed with an amine such as an amino-alkyl-alkanediol, for example 2-methyl-2-amino-1°3 furopanediol.

The most preferred amines are tertiary amines such as triethylamine, tripropylamine and tributylamine.

Ammonia is sometimes used, but it is more unstable than amines, and therefore the preferred neutralizing agent is an amine.

The neutralization reaction is generally accomplished by mixing a neutralizing base with the copolymer resin.

The partially neutralized or fully neutralized acrylic copolymer is premixed with the aminoplast resin.

The aminoplast resin is an aldehyde condensation product of melamine, urea, acetoguanamine or similar compounds.

They can be water-soluble or insoluble in organic solvents.

Generally, the aldehyde used is formaldehyde, while other aldehydes such as acetaldehyde, crotonaldehyde, acrolein, benzaldehyde,
Useful products can also be made from furfural and other aldehydes.

Although condensation products of melamine or urea are the most common and preferred, products from other amines or amides can be used where at least one amino group is present.

For example, further condensation products include triazinediazine,
Triazoles can be prepared from guanidine, guanamine and alkyl or aryl substituted derivatives of these compounds, such as alkyl substituted ureas, aryl substituted ureas and cyclic ureas, and alkyl substituted melamines and aryl substituted melamines.

Some examples of such compounds are N-N/-dimethylurea, benzylurea, N-N'-ethyleneurea, diazinediamine, formoguanamine, benzoguanamine, arrneline, 2-rioro4 -6-diamituto 3,5-triazine, 3,5-diaminotriazole, 4,6-diamitupyrimidine, 24,6-dolinoenyltriamino 1,3,5-triazine, and the like.

These aldehyde condensation products contain methylol or similar alkylol groups depending on the particular aldehyde used.

If necessary, these methylol groups can be etherified by reaction with alcohols.

A variety of alcohols may be used for this purpose, essentially any monohydric alcohol, but the preferred alcohols are methanol, butanol and similar lower alcohols.

The amine-aldehyde condensation products are prepared by methods well known in the art, using acidic or basic catalysts and varying time and temperature conditions.

The aldehydes are used as aqueous or alcoholic solutions, as appropriate, and the condensation, polymerization and etherification reactions can be carried out successively or simultaneously.

The aminoplast resin is about 5% to about 50% by weight of the composition.
should account for

The aminoplast resin and partially neutralized copolymer may be mixed cold or if necessary
0"F) or higher.

Preferably they are mixed at a temperature of about 75°C to 120°C.

In formulating coating compositions to be sprayed, the premixed portion or fully neutralized composition is heated at room temperature or 50°C to about 1
It is added to water at an elevated temperature of about 00°C.

Regular tap water can usually be used in formulating the coating composition.

It has been found that compositions for spraying can contain up to 60% solids or more.

Usually it will contain at least 30% solids.

The above composition can be sprayed onto the substrate using any spray gun available on the market.

With this composition it is possible to coat any substrate such as wood, paper, metal, etc.

The most preferred application is automotive coatings.

The above composition has a temperature of about 3°C to about 427°C (200) to 80°C.
0'F) for about 1 minute to about 30 minutes.

As noted above, the method of the present invention provides faster curing at lower temperatures, reducing time, expense, and potential damage to the performance of the composition and substrate.

Although curing catalysts such as p-toluenesulfonic acid, butyl phosphoric acid, etc. may be used in amounts up to about 2% by weight of the composition, this method allows the composition to be cured without the use of catalysts. It is possible.

According to one embodiment of the invention, the degree of neutralization of the copolymer can be from about 20% to about 80% as long as the pH value of the final composition is between 7.2 and 8-0.

At pH values below 7.2, this composition is milky and unstable.

At pH values above 8.0, this composition is stable but has a very low solids content.

The essential method of determining the best degree of neutralization is to partially neutralize a small sample, add water to form the desired composition and measure its pH.

If the pH is higher or lower than 7.2-8.0, then add another small sample until the pH is 7.2-8.0.
．． It is further complete or incomplete neutralization until it reaches 0.

The aminoplast resin is added either after the neutralization step or after the introduction of water.

The pH at which the composition is to be sprayed is critical to the invention.

Partial neutralization is when the composition to be sprayed has a pH of 7.2-8.
．． It must be controlled to have 0.

Compositions that fall at pH values below 7.2 have a significant tendency to "kickout" or to form sediments which cause uneven coating compositions and uneven spraying.

At pH values above 8.0, the solids content of the composition is only as high as 20% and the film formation per spray pass is less than 0.1 mm (0.4 mil).

Typical automotive spray equipment is set at certain fluid delivery rates, and at these delivery rates, prior art compositions deposit only about 0.18 m/coat on a substrate.
Films only 0.7 mils thick can be formed.

At least 0.51 as a requirement for automotive use
Because 2 mil (mm) thick film formation is required, the substrate generally must be coated three times.

If one attempts to solve the above film formation problem by increasing the fluid delivery rate so that a 2 mil thick film can be achieved with only two coats, the results are as follows: The resulting film has an unacceptable appearance due to sagging of the paint.

Since mass production of automobiles requires a limited amount of time to coat each unit, and the process cannot be delayed for economic reasons, it is desirable to simply coat the substrate for a longer time per coat. This problem cannot be alleviated by continuing to run the spray gun.

However, using the method of this embodiment of the invention, film formation of 0.51 mm (2 mils) or thicker in two coats can be achieved using standard fluid delivery rates and applying each substrate for the same amount of time. This can be achieved by spraying.

The use of paint can therefore be made more efficient than in prior art methods.

Paint efficiency is measured by spraying a fixed volume of paint solids in solution with a spray gun and measuring the volume of paint deposited on the resulting substrate.

Thus, the efficiency of the compositions of the present invention was compared to prior art solutions by spraying similar amounts of each solution of the same volume of solids at the same feed rate and measuring film deposition.

It has been found that the spray coating efficiency of the compositions of the invention is unexpectedly superior to that of the prior art.

Thus, using the method of this embodiment of the invention,
Substrates such as automotive materials can be coated with less paint to achieve the same or better film formation, resulting in appreciable savings.

The coating compositions described above can be used as coatings for all types of substrates.

Preferably, the composition is sprayed onto either primed or unprimed metals such as aluminum and steel.

The following examples disclose specific illustrations of this embodiment of the invention.

However, this embodiment G''! of the invention should not be construed as being limited to these examples; there are, of course, various possible variations and modifications.

Example 1 An aqueous coating composition was prepared by charging a container with 2791 ethyl cellosolve and heating to 260'F.

Over the next 3 hours, 52S' 2-hydroquine ethyl acrylate, 200.42 acrylic acid, 447z
Styrene 280.22 2-ethylhexyl acrylate, 244.82 methyl methacrylate, 266
．． A mixture of 4P butyl methacrylate and 17P tertiary dodecyl mercaptan was added at reflux and held for 2 hours.

At that point an additional 13.8 S' of ethyl cellosolve and 1
Added 1.58 ft of azobisisobutyronitrile.

The mixture was then refluxed for a further 2 hours.

118.8P of N.N-dimethylethanolamine was added to the polymer-solvent mixture to achieve 50% neutralization of the copolymer.

Next, add the above partially neutralized copolymer to 529.8? of melamine formaldehyde [Cymel 303 (Cymel 303)] and then
81' of deionized water to form a coating composition having a solids content of 34.8%.

The pH of this water-based composition was 7.5.

The composition was easily handled and sprayed easily even at high solids contents.

The above compositions were compared to compositions prepared with identical components in monomer makeup.

The copolymer was mixed with N・N-dimethylethanolamine.
00% neutralization and the resulting composition had a pH value of 8.5.

The composition was then divided into several separate portions and different amounts of water were added to each portion to determine at what solids content the spray application could be easily achieved.

The results revealed that compositions with as little as 20% solids content could be formulated for use in this method.

When the solid content was 20% or more, the viscosity was too high to be applied by conventional methods.

Next, the above two compositions (a composition with pH 7.5 and a composition with pH 8,
163'C (composition of 32
51') to form a baked film.

A composition with a pH of 8.5 is only 0.4 mm (1,
A composition with a pH of 7.5 requires 3 to 4 coats to obtain a film thickness of 6 mils) and has a pH of 7.5.
One coat was found to form a 0.46 mm (1.8 mil) thick film.

The above composition was also compared to the same composition having a pH of 7.0 with only 40% neutralization.

This composition was milky and non-uniform and the films formed therefrom were completely unsatisfactory.

Compositions falling within the pH value range of 7.2 to 8.0 can be sprayed even at higher solids contents and result in better films compared to compositions with higher or lower pH values. It turns out.

Examples 2 to 6 363-6y of ethyl cellosolve was charged to the reactor and 11
An aqueous coating composition was prepared by heating to 5°C.

Over the next 3 hours 90.3S' hydroxyethyl acrylate, 119.7f acrylic acid, 267.1
′? styrene 167.31 2-ethylhexyl acrylate, 146.3S' methyl methacrylate,
A composition consisting of 159z butyl methacrylate, 10.3f tertiary dodecyl mercaptan and 3.9i azobisisobutyronitrile was added at 120°C.

During the next 2 hours at 125°C a composition consisting of 68.2P ethyl cellosolve and 3z azobisinobutyronitrile was added.

The reaction was continued for 2 hours at 120°C, then 9.01 dimethylethanolamine was added to partially neutralize the resin, 16355' deionized water was added, and the melamine formaldehyde resin was mixed with them. A coating composition was formed having a pH of .5.

This coating composition has a viscosity of only 120 cps,
It was possible to spray even at high solid content.

The effect of pH on the viscosity and stability of the compositions of the invention
Partially neutralized with various amounts of dimethylethanolamine, p
H and the resulting viscosity were measured and shown.

The results are as follows.

In accordance with another embodiment of the invention, a substantial portion of the acidic groups of the copolymer, such as about 40% or more, is neutralized and the aminoplast is added before adding water.

It should be noted that the aminoplast must be premixed with the copolymer before addition of water in order to obtain a reduced curing temperature.

Thus, using the method of the present invention, curing temperatures are 28°C (50'F) below those required for normally prepared compositions.
) or more.

Additionally, the final composition has a similar avatar (cra) when sprayed.
ters) and fewer scars.

Example 1 above and Example 7 below are examples of water-dispersible coating compositions of this embodiment of the invention.

These examples are illustrative and the invention should not be construed as limited to these embodiments.

All parts and percentages are by weight unless otherwise specified.

Example 7 100 CI of ethyl cellosolve was added to the reactor at 128°C and over the next 3 hours 541.8P hydroxyethyl acrylate, 718.2P acrylic acid, 1602? (
7) Snfvn, 1003.8 P-2-f-hexyl acrylate, 877.8f methyl acrylate,
An aqueous coating composition was prepared by adding a composition consisting of 9541 butyl methacrylate, 93P tertiary dodecyl mercaptan, and 23.42 azobisisobutyronitrile.

When the above additions were complete, a composition of 308z ethyl cellosolve and 18f azobisisobutyronitrile was added over 2 hours at 145°C.

The reaction was continued for an additional 1.5 hours at 140°C and the resin was partially neutralized by adding 4251 dimethylethanolamine over the next 15 minutes.

The partially neutralized resin was heated to 1899.
2z melamine formaldehyde resin [Cy Mel
mel) 303], the reaction materials were added, and the premixed resin was then added to 9992P deionized water at 75°C.

The coating composition had a total solids content of 38.47% and a pH of 7.3.

The above coating composition was then compared to a composition prepared by forming the same resin, partially neutralized with the same amount of diethylethanolamine, then dissolved in deionized water, and then mixed with the same amount of melamine formaldehyde. did.

The above premix composition was heated at 135°C (275'F) for 3 hours.
When baked for 0 minutes, it had good moisture resistance and cured to a much higher degree than conventionally prepared compositions.

It is particularly preferred that both embodiments of the invention are utilized simultaneously.

Example 1 is illustrative of this particularly preferred embodiment.

Embodiments of the invention are as follows.

(1) The copolymer is about 1% to about 20% by weight of α/β-
Patent (2) characterized in that the composition comprises a hydroxyalkyl ester of an ethylenically unsaturated carboxylic acid and about 4% to about 15% by weight of the unsaturated carboxylic acid, wherein the composition is based on the copolymer and aminoplast. , about 95% to about 5 by weight
0% of said copolymer as well as about 5% to about 50% by weight of aminoplast resin based on said copolymer and aminoplast. .

(3) The method of claim 1, wherein the copolymer is neutralized by about 20% to about 80%.

(4) A method according to the preceding claims, characterized in that the aminoplast resin is mixed with the copolymer after addition of water.

(5Xa) partially neutralizing a copolymer of a hydroxyalkyl ester of an α/β monoethylenically unsaturated carboxylic acid, an unsaturated carboxylic acid, and at least one other copolymerizable ethylenically unsaturated monomer; (b) adding an aminoplast resin to the composition; (C) adding enough water to the composition to provide a composition with a solids content of at least 30%, such that the final composition has a solids content of about 7.2%; pH of ~8.0
(d) spraying the high solids content composition onto a substrate; and (e) spraying the coated substrate. A method for coating a substrate, characterized in that it bakes a coating to obtain a coating.

(6) The copolymer is characterized by comprising about 1% to about 20% hydroquine alkyl ester of α/β monoethylenically unsaturated carboxylic acid and about 4% to about 15% unsaturated carboxylic acid. The method according to item 5 above.

(7) The composition is based on the copolymer and aminoplast, and is based on about 95% to about 50% by weight of the copolymer and about 50% by weight of the copolymer and aminoplast. 7. The method of claim 6, wherein the aminoplast resin comprises 50% to about 50% aminoplast resin.

(8) The method according to item 5, wherein the copolymer is neutralized by about 20% to about 80%.

(9) The method according to item 5, characterized in that the aminoplast resin is mixed with a copolymer after adding water.

(1 sail a) A copolymer consisting of a hydroxyalkyl ester of α/β-ethylenically unsaturated carboxylic acid, an unsaturated carboxylic acid and at least one other copolymer ethylenically unsaturated monomer, at least partially (b) premixing the at least partially neutralized copolymer with an aminoplast resin; and (C) diluting the composition with water. A method of forming a solids content aqueous dispersion composition.

(11) The method according to item 10, characterized in that the copolymer is at least partially neutralized with an amine.

(12+ The mixture of aminoplast resin and copolymer is comprised of about 95% to 50% copolymer by weight and about 5% to about 50% aminoplast resin by weight, based on the total amount of aminoplast resin and copolymer. The first material is made of plastic.
The method described in item 0.

α3) The copolymer is about 1% to about 20% by weight of α/β-
11. The method of claim 10, comprising a hydroxyalkyl ester of an ethylenically unsaturated carboxylic acid and about 4% to about 15% by weight of the unsaturated carboxylic acid.

(14) The method according to item 11 above, characterized in that the copolymer is neutralized with dimethylethanolamine.

(1) adding sufficient water to the at least partially neutralized copolymer-aminoplast mixture to form a sprayable solution with a solids content of at least 25%; The method according to item 10.

(LGXa) A copolymer consisting of a hydroxyalkyl ester of an α/β-ethylenically unsaturated carboxylic acid, an unsaturated carboxylic acid, and at least one other copolymerizable ethylenically unsaturated monomer. (b) premixing said at least partially neutralized copolymer with an aminoplast resin; (e) adding sufficient water to form a solution with a solids content of at least 25%; d) spraying the composition onto a substrate; and (e
) A method of coating a substrate with a highly water-dispersible solids content composition, characterized in that the coating is thermally cured.

(17) The method according to item 16, characterized in that the copolymer is at least partially neutralized with an amine.

08) The method of claim 16, wherein the coating is cured at a temperature of at least about 93°C (200'F).

α9) The mixture of the aminoplast resin and copolymer is
Based on the total amount of aminoplast resin and copolymer, approximately 95
% to about 50% by weight of the copolymer and about 5% to about 50% by weight of the aminoplast.
The method described in Section 6.

(20) The copolymer is about 1% to about 20% by weight of α and β
- an ethylenically unsaturated carboxylic acid and about 4% to about 15% by weight of the unsaturated carboxylic acid;
The method described in Section 6.

(2υ) The method according to item 17, characterized in that the copolymer is neutralized with dimethylethanolamine.

Claims (1)

[Scope of Claims] 1(a) From hydroxyalkyl esters of acrylic acid in which the hydroxyalkyl group contains 1 to 5 carbon atoms and hydroxyalkyl esters of methacrylic acid in which the hydroxyalkyl group contains 1 to 5 carbon atoms. hydroxyalkyl esters of α/β-ethylenically unsaturated carboxylic acids selected from the group consisting of; unsaturated carboxylic acids selected from the group consisting of acrylic acid and methacrylic acid; and alkyl acrylates in which the alkyl group contains 1 to 20 carbon atoms. and alkyl methacrylates, styrene/α-alkylstyrenes, vinyltoluenes, monoolefinic and diolefinic hydrocarbons, halogenated monoolefinic hydrocarbons and halogenated diolefinic hydrocarbons, unsaturated esters of organic and inorganic acids. (b) a formaldehyde condensate of melamine; and (e) adding to said composition sufficient water to bring the composition to a solids content of at least 30%, thereby forming a final composition. A method of forming a sprayable, high solids content aqueous dispersion composition comprising adjusting the degree of neutralization such that the product has a pH value of about 7.2>about 8.0.