CN114502674A - 低光泽度聚氨酯涂料组合物 - Google Patents
低光泽度聚氨酯涂料组合物 Download PDFInfo
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- CN114502674A CN114502674A CN202080070139.7A CN202080070139A CN114502674A CN 114502674 A CN114502674 A CN 114502674A CN 202080070139 A CN202080070139 A CN 202080070139A CN 114502674 A CN114502674 A CN 114502674A
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- curing agent
- coating composition
- powder coating
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- isocyanate
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Abstract
本公开描述了一种低光泽度聚氨酯单组分粉末涂料组合物，该组合物包含90‑100重量％包含热固性树脂、用于与热固性树脂反应的异氰酸酯固化剂和聚碳酸酯二醇的树脂体系，其中热固性树脂包含羟基值为200‑250mgKOH/g的第一羟基官能聚酯树脂(i)和羟基值为20‑40mgKOH/g的第二羟基官能聚酯树脂(ii)，(i):(ii)的重量比为15:85‑35:65，异氰酸酯固化剂包括至少一种非封端的脲二酮固化剂，异氰酸酯固化剂的异氰酸酯基团与热固性树脂的羟基的比值为0.8‑1.2，且基于粉末涂料组合物的总重量，粉末涂料组合物中的聚碳酸酯二醇的总重量％为1‑10重量％。
Description
本专利申请涉及低光泽度聚氨酯粉末涂料组合物，该组合物可用于其中透明度、低光泽度和耐久性重要的多种工业粉末涂料市场。
粉末涂料组合物是固体组合物，通常包含固体成膜树脂或不同树脂的混合物，以及通常一种或多种颜料和添加剂如增塑剂、稳定剂、流动助剂和增量剂。树脂可以是热固性树脂，这意指其与交联剂(其本身可为另一树脂)呈反应性。通常树脂的玻璃化转变温度(Tg)在30℃以上。粉末涂料组合物已变得日益重要，因为它们在固化时向环境排放的挥发性物质非常少或没有。通常任何该类排放物限于固化反应的副产物如封端剂或挥发性缩合产物。
已将粉末涂料用于为各种制品提供纹理或消光表面涂层。消光饰面(mattefinish)是指在涂层固化后，涂层的光泽度低。光泽度的概念是由通过光泽计测量的表面评价产生的视觉印象。光泽计的测量结果与来自具有限定折射率的黑色玻璃标准的反射光量有关。平滑和高度抛光的表面会清晰地反射出图像。在粗糙表面上，光线会向各个方向漫散射。光泽度可用60°和85°的光泽头(gloss head)来测量。
工业中存在数种方法来实现消光饰面。常见的是加入消光剂，该消光剂可为一种反应性组分或可为一种惰性组分如白垩或长石。已知颜料有助于消光效果。因此，制备不含颜料的透明涂料本身是困难的。
粉料涂层中的消光饰面可通过用固化剂如多羧酸的单盐或双盐和环状脒交联两种环氧树脂来实现。一种环氧树脂与固化剂的固化比另一种环氧树脂固化更快。在固化过程中，反应性的差异导致成膜中的分离区，这导致在涂层表面中的微纹理，其使线散射，提供低光泽表面。这些基于环氧基树脂的涂层通常不为紫外线耐受性或稳定性的，且因此，当暴露在紫外光时，涂料的各组分降解。
一些商业非着色消光粉末涂料产品基于聚酯-丙烯酸类混合技术。聚酯-丙烯酸类混合技术是指与丙烯酸类固化剂交联的羧基聚酯树脂。它们还包含羟烷基酰胺(HAA)或异氰脲酸三缩水甘油基酯(TGIC)交联剂。虽然这些非着色产品在粘合性、耐揉搓性、耐化学性和耐腐蚀性方面实现了令人满意的性能，但仍需要改善其外观(平滑度、透明度、泛黄度)并进一步降低其光泽度。
其他商业消光粉末涂料采用使用聚酯树脂与作为交联剂的异氰脲酸三缩水甘油基酯(TGIC)。降低光泽度的一种方法是分别挤出和研磨两种不同的聚酯树脂和相应的固化剂，然后将它们干混在一起。聚酯树脂和固化剂是不同的，具有不同的反应性，这在固化过程中会导致成膜中的分离区，降低光泽度。然而，这些双组分聚酯TGIC粉料涂层的光泽度范围仅限于在60°角下低至30个光泽度单位。期望获得透明的(非着色的)消光粉末涂料体系，其产生较低的光泽度范围。
本申请提供了一种粉末涂料组合物，其可形成消光且透明的涂层，其耐久性与市场上领先的商业消光非着色的粉末涂料一样好，不同的是具有改善的外观和甚至较低的光泽度值。
透明涂层是指按照标准方法ASTM D1003在玻璃板上以3.0密耳的干膜厚度测量时，涂层的雾度值小于60％。该方法测量通过经涂覆的玻璃板的透光率。
本公开提供的涂料组合物可形成具有低光泽度粉末的涂层、消光和平光(flatmatt)饰面。低光泽度涂料组合物是指其可形成具有小于90的光泽度值的涂层，消光涂层是指其具有小于40且大于20的光泽度值，而平光涂层是指它具有小于20的光泽度值(当根据标准方法ASTM D-523在铝板(AL-Q)上在60度下测量时)。
根据本公开的涂料组合物是一种单组分组合物。尽管不含颜料，但其可形成耐久性、透明、消光和平光的饰面。
在第一方面，本公开提供了一种单组分粉末涂料组合物，该组合物包含90-100重量％包含热固性树脂和用于与热固性树脂反应的固化剂以及聚碳酸酯二醇的树脂体系，其中
-热固性树脂包含羟基值为200-250mgKOH/g的第一羟基官能聚酯树脂(i)和羟基值为20-40mgKOH/g的第二羟基官能聚酯树脂(ii)，并且(i):(ii)的重量比为15:85-35:65，
-固化剂包括至少一种非封端的脲二酮固化剂，和
-异氰酸酯固化剂的异氰酸酯基团与热固性树脂的羟基的比值为0.8-1.2，
-基于粉末涂料组合物的总重量，粉末涂料组合物中的聚碳酸酯二醇的总重量％为1-10重量％。
单组分粉末涂料组合物是指将树脂和固化剂共挤出并形成粉末涂料组合物中相同粉末颗粒的一部分。这与双组分粉末涂料组合物不同，后者是两种单独挤出的树脂和相应的固化剂的物理混合物。
第一羟基官能聚酯树脂和第二羟基官能聚酯树脂能够独立地与固化剂反应。聚酯树脂必须以15:85-35:65的(i):(ii)的相对重量比存在，以提供低光泽度、消光或平光的饰面。令人惊讶地，涂料组合物中两种聚酯树脂的比值控制经固化的膜的技术性能和外观。
合适聚酯包括例如且不限于通过多元醇和多羧酸的缩合而制备的那些，因此具有至少一个羟基官能团和至少一个羧基官能团。
聚酯是通过本领域中已知的缩合聚合反应技术制备的那些。代表性的缩合聚合反应包括通过醇和羧酸或酸酐的缩合制备的聚酯，其中包括或不包括干性油、半干性油或非干性油脂肪酸。通过调整醇和酸的化学计量比，同时维持过量的羟基，可容易地产生羟基官能聚酯，以提供宽范围的所需分子量、不饱和含量和性能特征。
聚酯衍生自一种或多种芳族和/或脂族和/或环脂族羧酸和/或其酸酐，以及一种或多种脂族和/或芳族多元醇。羧酸包括饱和和不饱和多羧酸及其衍生物，如马来酸、富马酸、琥珀酸、己二酸、壬二酸、二环戊二烯二羧酸、六氢邻苯二甲酸酐、甲基六氢邻苯二甲酸酐、芳族多羧酸，如邻苯二甲酸、间苯二甲酸、对苯二甲酸等。羧酸可包括单羧酸，单羧酸还可用于制备羟基官能聚酯，以控制分子量、官能度和其他特性性能。单羧酸可含有6-18个碳原子，最优选7-14个碳原子，如辛酸、2-乙基己酸、异壬酸、癸酸、十二酸、苯甲酸、六氢苯甲酸及其混合物。合适的酸酐可包括马来酸酐、邻苯二甲酸酐、偏苯三酸酐、衣康酸酐、柠康酸酐、乌头酸酐、丙烯酸酐、马来酸酐、柠康酸酐、环己基马来酸酐、烷基马来酸酐、苄基马来酸酐、苯基马来酸酐、丙基马来酸酐和1,2-二乙基马来酸酐(单独或其组合)。
代表性脂族和/或芳族多元醇(其可为饱和或不饱和的多元醇，其可与羧酸以化学计量比过量反应而产生羟基官能聚酯)包括二醇，如乙二醇。二丙二醇、2,2,4-三甲基1,3-戊二醇、新戊二醇、1,2-丙二醇、1,4-丁二醇、1,3-丁二醇、2,3-丁二醇、1,5-戊二醇、1,6-己二醇、2,2-二甲基-1,3-丙二醇、1,4-环己烷二甲醇、1,2-环己烷二甲醇、1,3-环己烷二甲醇、1,4-双(2-羟基乙氧基)环己烷、亚丙基二醇、亚丁基二醇、亚戊基二醇、亚己基二醇、亚癸基二醇、二甘醇、三甘醇、四甘醇、亚降冰片烷二醇、1,4-苯二甲醇、1,4-苯二乙醇、2,4-二甲基-2-亚乙基己烷-1,3-二醇、2-丁烯-1,4-二醇，以及多元醇，如三羟甲基乙烷、三羟甲基丙烷、三羟甲基己烷、三羟乙基丙烷、1,2,4-丁三醇、甘油、季戊四醇、双季戊四醇等。
第一羟基官能聚酯(i)具有200和250mgKOH/g的羟基值且第二羟基官能聚酯树脂(ii)具有20-40mgKOH/g的羟基值。羟基值(OHV或OH值)为相当于1g羟基官能聚酯中羟基含量的氢氧化钾的毫克数。羟基值(OH值)可根据ASTM方法E222(修订版10)，测试方法A通过实验方式测定。
(i):(ii)的重量比为15:85-35:65。在一些实施方案中，(i):(ii)的重量比可为20:80-30:70。
第一羟基官能聚酯树脂可例如具有50-55℃的玻璃化转变温度(Tg)。第二羟基官能聚酯树脂可例如具有55-60℃的Tg。聚酯树脂的玻璃化转变温度可根据ASTM E 1356使用差示扫描比色计(MDSC Q200TA)测定。
第一羟基官能聚酯树脂可包括例如可由Allnex以名称Crylcoat E 04362市购的聚酯。
第二种羟基官能聚酯树脂可包括例如可由Allnex以名称Crylcoat E 04375市购的聚酯。
单组分粉末涂料组合物的树脂体系至少包含本文所述和要求保护的热固性树脂和固化剂。树脂体系中的组分在固化时形成附着涂膜。该树脂体系还可任选地包含热塑性树脂。
该树脂体系还包含聚碳酸酯二醇组分。令人惊讶地，加入聚碳酸酯二醇提供固化膜表面的独特的丝绸般柔软触感，与市场上经固化的液体消光聚氨酯产品的表面相似。
基于粉末涂料组合物的总重量，聚碳酸酯二醇在粉末涂料组合物中的总重量％为1-10重量％。
聚碳酸酯二醇优选具有20-50mgKOH/g的羟基值。其可具有1500-4000g/mol，例如2000-4000g/mol的数均分子量。聚合物的数均分子量为通过用聚苯乙烯标准校准的凝胶渗透色谱法(GPC)测得的数均分子量。
聚碳酸酯二醇可具有下式，HO—[—R2—OCO]n-O-R2—OH，其中R2是具有2-12个碳原子，优选4-7个碳原子，例如5-6个碳原子的脂族烃链。脂族烃链优选为线性烃链。n为树脂，优选为3-30，例如4-20或5-15。
聚碳酸酯二醇可作为与第二羟基官能聚酯的物理混合物加入粉末涂料组合物中。聚碳酸酯二醇和第二羟基官能聚酯的混合物可通过将聚碳酸酯二醇和第二羟基官能聚酯在高温下(例如150-250℃)混合在一起而产生，在该温度下，聚碳酸酯二醇和第二羟基官能聚酯均为液体，然后使其冷却而形成固体。例如，一种方法可为将液体聚碳酸酯二醇在其聚合后直接混入第二羟基官能聚酯中，并且仍为液体(在约180-220℃下)，然后使该混合物冷却。
聚碳酸酯二醇组分的实例包括以下化合物：通过烷烃二醇与碳酸二甲酯、碳酸二乙酯或碳酸二苯酯的酯交换反应制备的聚碳酸酯二醇；以及由烷烃二醇和光气通过表面缩聚反应制备的聚碳酸酯二醇。烷烃二醇的实例包括乙二醇、丙二醇、1,4-丁二醇、1,5-戊二醇、3-甲基-1,5-戊二醇、1,6-己二醇、1,7-庚二醇、1,8-辛二醇、1,9-壬二醇、1,10-癸二醇、1,11-十一烷二醇、1,12-十二烷二醇和环己烷1，4-二甲醇。例如，聚碳酸酯二醇可通过使1，5-戊二醇、1,6-己二醇和碳酸二甲酯(DMC)反应而制备。该方法描述于RSC Adv.,2017,7,12550-12560中。结果为无规共聚物。如果使用两种二醇来制备聚碳酸酯二醇(如1,5-戊二醇、1,6-己二醇)，则二醇可以以1:2-2:1的摩尔比使用。
合适的聚碳酸酯二醇组分可由UBE Industries以Eternacoll商品名市购。
本公开的涂料组合物需要异氰酸酯固化剂，其中固化剂的异氰酸酯基团与热固性树脂的羟基的比值为0.8-1.2。
第一和第二羟基官能聚酯中的羟基能够与异氰酸酯固化剂中的异氰酸酯基团反应。异氰酸酯基团和羟基之间的反应在本领域中作为由羟基官能聚合物和异氰酸酯固化剂形成聚氨酯的一种固化过程是已知的。
异氰酸酯固化剂通常具有200-400g/eq的异氰酸酯当量重量。异氰酸酯当量重量是指要具有一当量异氰酸酯基团(NCO)的异氰酸酯的克数。一当量NCO基团＝42.02g。
本公开的异氰酸酯固化剂包括非封端的脲二酮固化剂。
优选地，至少20重量％的异氰酸酯固化剂包括非封端的脲二酮固化剂，或至少30重量％的异氰酸酯固化剂包括非封端的脲二酮固化剂。
脲二酮固化剂在本领域中是已知的。它们可通过使异氰酸酯二聚获得。原则上，脲二酮固化剂可基于所有已知的有机异氰酸酯。然而，优选使用脂族、环脂族、芳族或芳脂族二异氰酸酯或NCO官能度为≧2的多异氰酸酯。可提及的实例为甲苯二异氰酸酯(TDI)、双(异氰酸酯基苯基)甲烷和由苯胺和甲醛缩合和随后的光气化(MDI)制备的多苯基多亚甲基多异氰酸酯，2,2′-二环己基甲烷二异氰酸酯/2,4′-二环己基甲烷二异氰酸酯/4,4′-二环己基甲烷二异氰酸酯(H12MDI)、降冰片烷二异氰酸酯(NBDI)、六亚甲基二异氰酸酯(HDI)、异佛尔酮二异氰酸酯(IPDI)和双(异氰酸基环己基)甲烷。美国专利No.8,134,014公开了一种制备具有高含量的脲二酮基团的多异氰酸酯的方法。
异氰酸酯固化剂额外可包含封端的脲二酮固化剂。封端的脲二酮固化剂为当用本领域技术人员已知的方法封端尚未转化为脲二酮的游离NCO基团时。例如，当期望异氰酸酯在室温下不与其他聚合物组分反应时，使用封端的异氰酸酯。本发明人发现，通过改变涂料组合物中封端与非封端的脲二酮固化剂的比值，可以控制地改变涂料组合物的光泽度。非封端的脲二酮的比例越大，则涂层就越消光(光泽度单位越低)。因此，改变封端与非封端的脲二酮的比例是一种光泽度在20-10或甚至更低之间变化的可控制方式。
在一个实施方案中，异氰酸酯固化剂包括100％的非封端的脲二酮固化剂。替换地，非封端的脲二酮固化剂与封端的脲二酮固化剂的重量比可为100:0-20:80。在一些实施方案中，至少20重量％、至少30重量％、至少40重量％、至少50重量％、至少60重量％、至少70重量％、至少80重量％、至少90重量％或100重量％的异氰酸酯固化剂是非封端的脲二酮固化剂，其中重量％基于涂料组合物中的异氰酸酯固化剂总重量。如果固化剂不包括100％的非封端的脲二酮固化剂，则异氰酸酯固化剂的其余部分可包括封端的脲二酮固化剂。
异氰酸酯封端剂包括但不限于：醇类、酚类(如苯酚、壬基苯酚甲酚)、肟类(如丁酮肟、环己酮肟)、丙二酸酯类、内酰胺类(如ε-己内酰胺)、吡唑类(如二甲基吡唑)、咪唑类、三唑类、丙二酸酯和乙酸酯以及羟胺类。在室温下，封端的异氰酸酯不会以显著的速度与多元醇反应。在高温下，封端的多异氰酸酯会释放出封端剂，而异氰酸酯会与多元醇反应。
合适的市售非封端脲二酮是环脂族脲二酮，可以以名称
EF403可由Bayer AG获得。非封端的脲二酮固化剂的量(以重量计)可为粉末涂料组合物的约1重量％至35重量％，例如3-30重量％。
合适的市售封端脲二酮是环脂族脲二酮，可以以名称
BF1540获得，其为异佛尔酮二异氰酸酯的聚脲二酮，可由Evonik Degussa获得。
粉末涂料可额外包含能够与热固性树脂的羧基官能团反应的非异氰酸酯固化剂。羧基的固化剂优选是具有活性氢的化合物，例如β-羟烷基酰胺。
非异氰酸酯固化剂可包括β-羟烷基酰胺固化剂。β-羟烷基酰胺提供的交联聚合物网络是硬、耐用、耐腐蚀和耐溶剂的。据信β-羟烷基酰胺通过与含羧基化合物的酯化反应而形成多个酯交联来固化涂层。为了获得最佳固化，羟烷基酰胺的羟基官能度平均应为至少2，优选大于2，更优选大于2，直至并包括4。β-羟烷基酰胺固化剂的量(以重量计)优选为粉末涂料组合物的约0.5重量％至10重量％，更优选为约1重量％至7重量％。
β-羟烷基酰胺可例如通过取决于反应物的选择和催化剂的存在或不存在在环境温度至约200℃的温度下使羧酸的低级烷基酯或酯的混合物与β-羟烷基胺反应而制备。合适的催化剂是碱性催化剂，包括例如甲醇钠、甲醇钾、丁醇钠、丁醇钾、氢氧化钠和氢氧化钾，其存在量基于烷基酯的重量优选为约0.1重量％至约1重量％。特别合适的市售β-羟烷基酰胺是
QM-1260，可由瑞士EMS-Primid获得。
例如，粉末涂料组合物可包含
-40-70重量％的热固性树脂，
-15-40重量％的异氰酸酯固化剂，和
-0.5-7重量％的非异氰酸酯固化剂，
其中重量％基于粉末涂料组合物的总重量。
可使用固化促进剂(催化剂)来加快固化过程。催化剂组分可包括叔胺，铋、锡、铁、锑、钴、钍、铝、锌、镍、铈、钼、钒、铜、锰和锆的有机金属衍生物或盐，金属氢氧化物和金属羧酸盐。叔胺可包括但不限于三乙胺、三亚乙基二胺、N,N,N′,N′-四甲基乙二胺、N,N,N′,N′-四乙基乙二胺、N-甲基吗啉、N-乙基吗啉、N,N,N′,N′-四甲基胍、N,N,N′,N′-四甲基-1,3-丁二胺、N,N-二甲基乙醇胺、N,N-二乙基乙醇胺。合适的有机金属衍生物包括二正丁基锡双(巯基乙酸异辛基酯)、二月桂酸二甲锡、二月桂酸二丁锡、硫化二丁锡、辛酸亚锡、辛酸铅和乙酰丙酮铁。在一个方面，催化剂为辛酸亚锡，称为Octaflow ST-70，可由Estron Chemical市购。
粉末涂料组合物可包含至多最多10重量％的至少一种或多种其他添加剂，例如至多最多8重量％，至多最多5重量％或至多最多3重量％。添加剂可选自由例如颜料、抗氧化剂、紫外线吸收剂、流动添加剂、脱气剂和蜡组成的组。
由于粉末涂料组合物是透明的，因此该涂料组合物包含非常少的(如果有的话)颜料如TiO2。优选地，涂料组合物包含0重量％一种或多种颜料。令人惊讶地，本发明的透明涂层可以提供非常消光的饰面。
抗氧化剂是减少由热引起的聚合物降解的化合物。聚合物的热降解可导致变色(通常是泛黄)并降低涂层的耐久性和机械性能。抗氧化剂的实例包括受阻酚抗氧化剂、芳族胺和有机亚磷酸盐和亚膦酸盐。
流动添加剂的功能是在粉末颗粒在涂层/基材和涂层/空气表面熔化、流动和聚结时降低其表面张力。合适的流动添加剂包括经酰胺改性的聚合物酯，可由Troy ChemicalCompany以名称
486CFL市购。
粉末涂料组合物可含有脱气剂。脱气剂允许在粉料涂覆工艺的熔融和固化阶段过程中将挥发性气体由基材排出且由此可以防止针孔和对涂层的其他损坏。脱气剂包括经酰胺改性的酚化脲表面活性剂。
紫外线吸收剂的作用是吸收有害的紫外线辐射并在其可能导致聚合物降解之前将能量以热量无害地释放。保护程度是吸收剂浓度、涂层厚度和吸收剂的消光或“效率”的函数。合适的紫外线吸收剂包括醌类、位阻酚类化合物、亚膦酸盐、亚磷酸盐、硫醚、邻羟基三芳基s-三嗪化合物和HALS(受阻胺光稳定剂)。
粉末涂料中的大多数添加剂在挤出前与树脂和固化剂预混料混合且因此并入树脂/固化剂粉末制品中。然而，有时将非常细小颗粒尺寸的添加剂(平均颗粒尺寸为约10-40nm)如胶体二氧化硅(热解法二氧化硅或火成二氧化硅)或氧化铝或氢氧化铝在其挤出后与粉末混合。当在制造中的该阶段加入时，它们被称为后共混或干共混添加剂。
根据本公开的涂料组合物可施加于不同类型的基材。
在另一方面，本公开提供了一种经涂覆的基材，包括用上述单组分粉末涂料组合物涂覆的基材。该基材可为金属基材，如钢(包括轻轨钢框架和钢梁和钢柱)、铝、铝合金。基材还可为非金属基材如塑料或可以承受固化粉末涂料施加条件的任何其他材料。
涂料组合物可用于各种粉末涂料市场，包括汽车、施工、硬件、建筑物或其他工业市场。
本文公开的组合物为经固化的膜表面提供独特的柔软丝滑触感，与经固化的液体消光聚氨酯产品的表面相似，以及消光至平光饰面，并改善柔性。
本文所用“例如”、“如”或“包括”是为了引入进一步澄清更一般主题的实例。除非另有明确指出，该类实例仅作为理解本公开中说明的实施方案的辅助手段提供，并不意指以任何方式限制。这些短语也不表示任何种类的所公开的实施方案的优选情形。
除非另有说明，组分的重量％基于粉末涂料组合物中所有组分的总重量。
对本领域普通技术人员来说，本文说明的实施方案的许多变化是显而易见的并且仍然在本公开及其等效物的范围内。本领域技术人员将认识到在本公开的精神和任何当前或未来权利要求的范围内的许多变化。本文所用单数形式“一种”、“一个”和“该”包括复数指称，除非上下文另有明确说明。例如，“取代基”的指称包括单个取代基以及两个或更多个取代基等。
实施例
下面的实施例以解释和说明的方式提供且不意欲限制本公开的范围。
测试方法
A.外观/平滑度–该参数通过比较涂膜和可由美国粉末涂料协会(PCI)获得的标准板来评定。PCI是位于美国肯塔基州的非盈利组织，其提供粉末涂料目测平滑度标准。粉末涂料目测平滑度标准是一套黑色光亮的10块板，显示了可使用粉末涂料实现的正常平滑度。最佳平滑度为评级为10的表面且不良平滑度为评级为1的表面，评估通过目测进行。
B.经固化的膜的膜厚度使用Positector 6000FN1(一种来自DeFleskoCorporation的涂层测厚仪)测量。膜厚度以在板的上半部和下半部测量的两个读数中的最高值报告(以密耳计)。
C.光泽度使用具有校准瓦盘(tile tray)Cat#4522/4527的BYK micro-TRI-光泽计或同等产品测量。铝板(AL-Q)上的经固化的膜的光泽度根据ASTM D-523测量。在所有情况下均报告了60度的光泽度。光泽度以光泽度单位报告。光泽度单位越低，光泽度就越低(越消光)。
D.根据ASTM D3359划格法胶带测试方法B测试实验室样品与铝基材的初始划格法附着力测试。该方法规定以指定间距的交叉线图案切透膜并用Permacell#99胶带粘贴切割区域，然后迅速移除胶带。检查具有切口的区域，以确定漆是否松动或移除，并对该区域评级。根据测试方法由0B至5B报告测试结果。5B是完美评级且它意指没有移除漆。所测试的板是经预处理的Al。
E.Delta b值在Leneta板上以3.0密耳测定。Delta b使用Datacolor 600分光光度计在CIE实验室，日光D65/10°下使用喷涂有3.0密耳的粉末样品并在375°F下固化20分钟的Leneta 4x12英寸的板(一半是黑色的且一半是白色的)测量。Leneta板的白色侧的b值是标准值。Delta b是CIELAB色标的黄蓝轴上与标准值的变化的量度。正的delta b表示颜色较黄，负的delta b表示颜色较蓝。较好的结果是当delta b值接近于零时(表示颜色变化较小)。
F.耐甲基乙基酮(MEK)揉搓性。将棉球辊(cotton tip applicator)用MEK饱和且使用约2.6cm动程在测试涂层的表面上以总共50对来回擦拭而擦拭。显现出MEK耐受性等级为4-5的涂层具有可接受的固化、物理性能和耐溶剂性。板的评级如下。
评级＝5＝优异耐化学性-未擦除涂料或着色-涂层表面没有软化或发暗。
评级＝4＝非常好的耐化学性-轻微擦除涂料或着色。
评级＝3＝一般至良好的耐化学性-适中轻微擦除涂料或着色。
评级＝2＝差至一般耐化学性-重度擦除涂料或着色。
评级＝1＝极差或没有耐化学性-严重擦除涂料或着色或完全摩擦至基材。
G.样品透明度的评估基于雾度值的测量。该测试基于玻璃板上以3.0密耳的厚度喷涂的样品膜的透光率。测量使用用于雾度测量的OnColor分光光度计装置进行，事先根据标准方法ASTM D1003使用黑白校准片校准。较透明的涂层具有较低雾度值(％)。
H.根据ASTM B368-09的铜加速乙酸盐喷雾(CASS)。该测试方法用于确定粉末样品对由CASS溶液可能产生的腐蚀环境的耐腐蚀性。将以标准膜厚(3密耳)喷涂有粉末样品并在标准固化下固化的三块测试板(经Al处理)，按照双方同意的方式用经批准的切割装置垂直划线，然后将板以垂直位置置于测试室，在测试室中对于每升盐溶液，将由5％的氯化钠在DI水中的溶液组成的测试溶液用氯化铜处理。溶液的pH值应为3.0-3.1。然后用冰乙酸处理该溶液以将pH值调整至3.1-3.3，然后与空气混合，且用雾化喷嘴喷出至测试室。测试持续时间为168小时。然后将测试板洗涤，用压缩空气干燥并检查沿划线的腐蚀、起泡和边缘处的腐蚀。对于各样品，测试三块板。内部实验室测试的板根据OEM规范FCA MS PA 6-7评估，该规范规定了可接受的性能标准，即从线划线的最大蠕变为3.0mm。
I.在分析实验室中使用扫描电子显微镜SEM和激光扫描共焦显微镜(LSCM)对喷涂于底漆和液体底涂层的样品的暴露于和未暴露于氙气灯下的表面的形貌进行了详细分析。用Hitachi S-3400N SEM使用15kV加速电压和50Pa气氛进行成像。将样品以45°角安装以成像。使用Keyence VK-8700激光扫描共焦显微镜以使样品的表面轮廓成像。使用20x/0.46物镜与红色激光和白色光源二者。使用VK分析器软件进行图像后处理，包括一阶倾斜校正和粗糙度分析。将分析器软件中的正常高度截止滤波器施用于所有图像。一个区域的平均表面粗糙度(Sa)是用于量化样品表面形貌的粗糙度分析参数。Sa值表示与通过表面的算术平均平面相比，每个点的高度的绝对差。Sa值对样品的粗糙度从最高至最低以B>A>C的顺序进行评级，这与目测观察非常吻合。样品A＝未暴露的3涂层板，样品B＝暴露2250小时的3涂层板，而样品C＝暴露3750小时的3涂层板。
实施例涂料组合物的施用
除非另有说明，将涂料组合物用Nordson Versa静电喷枪(Nordson Corporation，Amherst，Ohio，USA)喷涂至来自Q-panel Corporation USA的尺寸为3英寸x6英寸或4英寸x12英寸的铝板(AL-Q板)上。一些测试板经预处理且其他不经预处理，这取决于要进行的测试。将涂料固化20分钟至金属基材表面温度为375°F(191℃)。干膜厚度为3密耳。
涂料组合物样品1和2-与领先商业粉末产品的比较
根据本公开的涂料组合物样品1和2与由AkzoNobel提供的市场上领先的消光非着色聚酯-丙烯酸类混合粉末涂料产品(组合物A*)进行比较。组合物A*是一种采用羧基聚酯树脂和作为固化剂的缩水甘油基官能丙烯酸类聚合物以及羟烷基酰胺和其他添加剂的单组分聚酯/丙烯酸类混合消光非着色粉末涂料组合物。
涂料组合物样品1和2通过将表1中除干流动添加剂以外的所有组分用Prism混合器以2000rpm共混30秒，用长筒挤出机WP-30双螺杆挤出机(Werner Pfleiderer,Ramsey,New Jersey,USA)以400rpm的挤出速度和15-30％的扭矩以及最高93°F的挤出温度挤出而制备。将熔融的挤出材料通过冷却的冷冻辊供入以形成固体片材，将其破碎成不同小尺寸的碎片。手动加入干流动添加剂，并通过袋摇动30秒与碎片混合。用Brinkman研磨机以0.5mm筛网尺寸将碎片磨成细粉，然后通过来自Vorti Sieve,Salem,Ohio,USA的USA 200目(75微米)筛分。
按照上述测试方法A至H测试了样品1和2以及标准商业产品的涂层性能。测试结果提供在表2中。测试结果表明，与领先的商业聚酯-丙烯酸类混合粉末涂料相比，本公开的涂层具有优异外观(平滑度、透明度、雾度、泛黄度)并且具有类似的耐久性能。
表1
1.CRYLCOAT E 04375(OHV 30mg KOH/g),Allnex Inc.USA(聚合物树脂)
2. 10重量％ETERNACOLL PH 300UBE Spain和90重量％CRYLCOAT E04375 AllnexUSA(聚合物树脂)
3.CRYLCOAT E 04362(OHV 220mg KOH/g),Allnex USA(聚合物树脂)
4.POWDERMATE 486CFL,Troy Chemical Corporation(流动添加剂)
5.POWDERMATE 542DG,Troy Chemical Corporation(脱气蜡)
6.CRELAN EF 403(LS 2147),Bayer AG USA(交联剂)
7.VESTAGON B1540,Evonik(交联剂)
8.OCTAFLOW ST-70,Estron Chemicals USA(催化剂)
9.HALS STABILIZER TINUVIN 622LD,Basf·USA(UV吸收剂)
10.ADDITIVE TINUVIN 405,Basf USA(UV吸收剂)
11.ANTIOXIDANT IRGAFOS 1076,Basf USA(抗氧化剂)
12.ANTIOXIDANT IRGAFOS 168,Basf·USA(抗氧化剂)
13.Primid QM1260,EMS Chemie NA(交联剂)
14.Evonik Corporation(流动添加剂)
表2
*对比商业产品
涂料组合物样品2-10-第一羟基官能聚酯树脂与第二羟基官能聚酯树脂的比值如何影响涂层的光泽度
涂料组合物样品2-10通过将表3中除干流动添加剂以外的所有组分用Prism混合器以2000rpm共混30秒，用长筒挤出机WP-30双螺杆挤出机(Werner Pfleiderer,Ramsey,New Jersey,USA)以400rpm的挤出速度和15-30％的扭矩以及最高200°F的挤出温度挤出而制备。将熔融的挤出材料通过冷却的冷冻辊供入以形成固体片材，将其破碎成不同小尺寸的碎片。手动加入干流动添加剂，并通过袋摇动30秒与碎片混合。用Brinkman研磨机以0.5mm筛网尺寸将碎片磨成细粉，然后通过来自Vorti Sieve,Salem,Ohio,USA的USA 200目(75微米)筛分。
除了第一羟基官能聚酯树脂(CRYLCOAT E 04362)与第二羟基官能聚酯树脂(CRYLCOAT E04375)的比值在0:100至100:0之间变化外，样品2-10的配制剂是相同的。
将涂料组合物施加于涂覆有黑色底涂层的AL-Q板(厚度为3.0密耳)。根据上文提及的光泽度测试方法使用BYK micro-TRI-光泽计以光泽度单位测量所有涂层的光泽度。结果显示在表4和图1中。
表3
组分1至14与样品1和2中使用的相同。
*对比样品
表4
*对比样品
结果表明，当树脂包含羟基值为200-250mgKOH/g的第一羟基官能聚酯树脂(i)和羟基值为20-40mgKOH/g的第二羟基官能聚酯树脂(ii)，并且(i):(ii)的重量比为15:85-35:65时，涂层的光泽度明显较低。
涂料组合物样品11-17-非封端的脲二酮与封端的脲二酮的比值如何影响涂层的光泽度
涂料组合物样品11-17通过将表5中除干流动添加剂以外的所有组分用Prism混合器以2000rpm共混30秒，用长筒挤出机WP-30双螺杆挤出机(Werner Pfleiderer，Ramsey，New Jersey，USA)以400rpm的挤出速度和15-30％的扭矩以及最高200°F的挤出温度挤出而制备。将熔融的挤出材料通过冷却的冷冻辊供入以形成固体片材，将其破碎成不同小尺寸的碎片。手动加入干流动添加剂，并通过袋摇动30秒与碎片混合。用Brinkman研磨机以0.5mm筛网尺寸将碎片磨成细粉，然后通过来自Vorti Sieve,Salem,Ohio,USA的USA 200目(75微米)筛分。
除了非封端的脲二酮与封端的脲二酮的比值在0:100至100:0之间变化外，样品11-17的配制剂是相同的。异氰酸酯固化剂的总重量在所有实施例中是相同的。第一羟基官能聚酯与第二羟基官能聚酯的重量比在所有情况下均是相同的(27:73)。
将涂料组合物施加于涂覆有黑色底涂层的AL-Q板(厚度为3.0密耳)。根据上文提及的光泽度测试方法使用BYK micro-TRI-光泽计以光泽度单位测量所有涂层的光泽度。结果显示在表6和图2中。
表5
组分1至14与组合物样品1和2中使用的相同。
*对比样品
表6
*对比例
结果显示，当大于20重量％的异氰酸酯固化剂包括非封端的脲二酮异氰酸酯固化剂时，光泽度会下降。具有非封端的脲二酮异氰酸酯固化剂的配制剂可以实现消光和平光的透明饰面。
涂料组合物样品18-聚碳酸酯二醇如何影响涂层的美观
涂料组合物样品18通过将表7中除干流动添加剂以外的所有组分用Prism混合器以2000rpm共混30秒，用长筒挤出机WP-30双螺杆挤出机(Werner Pfleiderer,Ramsey,NewJersey,USA)以400rpm的挤出速度和15-30％的扭矩以及最高93°F的挤出温度挤出而制备。将熔融的挤出材料通过冷却的冷冻辊供入以形成固体片材，将其破碎成不同小尺寸的碎片。手动加入干流动添加剂，并通过袋摇动30秒与碎片混合。用Brinkman研磨机以0.5mm筛网尺寸将碎片磨成细粉，然后通过来自Vorti Sieve,Salem,Ohio,USA的USA 200目(75微米)筛分。
除了样品18的树脂体系包括聚碳酸酯二醇外，样品1和18的配制剂实际上是相同的。
表7
组分1-14与上表1所列相同。
在不同暴露水平下，观测到样品1和样品18之间具有明显的表面形貌差异。形貌的目测差异对应于所计算出的平均粗糙度参数(Sa)。Sa越低，表面就越丝滑越平滑。
如下表8所示，在每组样品中测得Sa具有相同的趋势。2250小时暴露的样品的Sa最大，然后是0小时暴露的样品，且在3750小时Xe暴露后，样品最平滑。当比较相同暴露时间时，用样品1制得的涂层总是比用样品18(含有聚碳酸酯二醇)制得的涂层粗糙。
表8
Claims (13)
1.一种单组分粉末涂料组合物，包含90-100重量％包含热固性树脂、用于与热固性树脂反应的异氰酸酯固化剂和聚碳酸酯二醇的树脂体系，其中
(a)热固性树脂包含羟基值为200-250mgKOH/g的第一羟基官能聚酯树脂(i)和羟基值为20-40mgKOH/g的第二羟基官能聚酯树脂(ii)，并且(i):(ii)的重量比为15:85-35:65，
(b)异氰酸酯固化剂包括至少一种非封端的脲二酮固化剂，
(c)固化剂的异氰酸酯基团与热固性树脂的羟基的比值为0.8-1.2，和
(d)基于粉末涂料组合物的总重量，粉末涂料组合物中的聚碳酸酯二醇的总重量％为1-10重量％。
2.根据权利要求1所述的单组分粉末涂料组合物，其包含最多10重量％的一种或多种其他添加剂。
3.根据前述权利要求中任一项所述的单组分粉末涂料组合物，其包含0重量％的颜料。
4.根据前述权利要求中任一项所述的单组分粉末涂料组合物，其中异氰酸酯固化剂具有200-400g/eq的异氰酸酯当量重量。
5.根据前述权利要求中任一项所述的单组分粉末涂料组合物，其中聚碳酸酯二醇具有20-50mgKOH/g的羟基值。
6.根据前述权利要求中任一项所述的单组分粉末涂料组合物，其中聚碳酸酯二醇具有1500-4000g/mol的数均分子量。
7.根据前述权利要求中任一项所述的单组分粉末涂料组合物，其中异氰酸酯固化剂额外包含封端的脲二酮固化剂。
8.根据前述权利要求中任一项所述的单组分粉末涂料组合物，其中至少20重量％的异氰酸酯固化剂包括非封端的脲二酮固化剂。
9.根据前述权利要求中任一项所述的单组分粉末涂料，其中所述涂料组合物额外包含能够与热固性树脂的羧基官能团反应的非异氰酸酯固化剂。
10.根据权利要求9所述的单组分粉末涂料组合物，其中非异氰酸酯固化剂包括一种β-羟烷基酰胺固化剂。
11.根据权利要求9或权利要求10所述的单组分粉末涂料组合物，其包含：
(a)40-70重量％的热固性树脂，
(b)15-40重量％的异氰酸酯固化剂，和
(c)0.5-7重量％的非异氰酸酯固化剂
其中重量％基于粉末涂料组合物的总重量。
12.一种经涂覆的基材，包含用根据前述权利要求中任一项所述的单组分粉末涂料组合物涂覆的基材。
13.根据权利要求12所述的经涂覆的基材，其中所述基材为金属基材。
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Also Published As
| Publication number | Publication date |
|---|---|
| KR20220066129A (ko) | 2022-05-23 |
| US20230279260A1 (en) | 2023-09-07 |
| EP4045551A1 (en) | 2022-08-24 |
| MX2022004301A (es) | 2022-05-10 |
| CN114502674B (zh) | 2024-03-19 |
| WO2021074342A1 (en) | 2021-04-22 |
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