Two modified types of hyperbranched polymer were successfully prepared using hyperbranched polyether (HBPE) as a matrix, cis-5-norbornene-endo-2,3-dicarboxylic anhydride (CDA) or o-phthalic anhydride (PA) as a modifier and by grafting an NCO-terminated compound (IPDI-HEA). The modified hyperbranched polymers were incorporated into a typical water-soluble polyacrylate (WPA) as crosslinkers to develop high-performance waterborne UV-curable coatings via electrophoretic deposition (EPD). Although the particle size of the electrophoretic dispersion increased from 43.8 nm to 164 nm, no microphase separation occurred, and the smooth SEM images of the coatings confirmed their uniformity. The rate of photopolymerization (R p) and percentage conversion of the double bonds increased with increasing active unsaturated double bond content, and were partially affected by steric effects. Thermal gravity analysis and tensile tests indicated that the UV-curable EPD coating films exhibited better thermal stability due to their hyperbranched structure, soft and hard segment content and crosslinking density. The coated tin plate could resist chemical corrosion after immersion in NaCl solution. The coatings demonstrated strong adhesion to extremely bent tin plates and outstanding tolerance to knife-scratches and impact. This is a promising method for the design of desirable coatings in the EPD industry.
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