JP5225058B2 - Method for painting automobile body and automobile body having coating film - Google Patents

Description

  The present invention relates to a method for painting an automobile body and an automobile body having a coating film by the method.

For car body painting, there are undercoat paints, such as electrodeposition paints based on epoxy resins, intermediate paints based on polyester resins, and topcoat paints based on polyester paints. Three types of paints are used, and after the undercoat is applied, this is baked. After the intermediate coat is applied onto the cured undercoat, this is baked and cured, and then the topcoat is applied and baked. The painting method is completed.
Automotive body coatings have a role in terms of design, such as improving the appearance, and a role in terms of functionality, such as protection of the object to be coated. Particularly, intermediate coatings require excellent performance in terms of design and functionality. Therefore, it is necessary to form a coating film satisfying coating film performance such as concealment property of electrodeposition roughness (underground concealment property) and chipping resistance.
As a resin composition for an intermediate coating, a polyester resin is generally used as a main component (essential resin component) from the viewpoints of top coatability, pigment dispersibility, and sanding suitability (Patent Document 1, etc.). . However, a melamine curing system is generally used as a curing method for an intermediate coating material mainly composed of a polyester resin, and the finished appearance is not sufficiently satisfactory. Moreover, although the coating method which performs painting and baking of intermediate coating in two steps has been proposed (Patent Document 2), it is necessary to consider the entire coating process in order to form a high-performance multilayer coating film. .
On the other hand, the top coat has a role to prevent damage to the surface of the paint film due to dust and the like flying during car washing and traveling, and has excellent acid resistance as a technique for improving the scratch resistance of the paint film. Acrylic fat composition (Patent Document 3), a photocurable resin composition (Patent Document 4) that increases the hardness of the coating film by increasing the crosslink density, and a coating composition that exhibits elasticity by introducing polycaprolactone (Patent Document 5) and the like have been proposed. In addition, as a further improvement in the scratch resistance of the coating film, a top coating composition containing a hydroxyl group-containing acrylic resin and a polyisocyanate prepolymer as essential components and, if necessary, a polylactone polyol has been proposed (Patent Document 6). . However, in order to form a high performance laminated coating film, it is necessary to consider the entire coating process.

JP 2002-126737 A Japanese Patent Laying-Open No. 2005-177631 JP-A-8-9968 JP 2000-297112 A JP 2001-11376 A JP 2007-31690 A

  An object of the present invention is to use an intermediate coating and a clear coating that are specific compositions to form a coating film having a good finished appearance and to improve the base concealing property of the intermediate coating film, and to restore it. An object of the present invention is to provide a coating method capable of producing a laminated coating film having good strength and excellent scratch resistance.

The said subject is solved by the following this invention (1)-(6).
(1) On the steel sheet on which the electrodeposition coating film has been formed, a step of applying the first intermediate coating material and baking and curing to form the first intermediate coating layer; after this step, applying the second intermediate coating material and baking and curing Includes a step of forming a second intermediate coating film, a step of applying an aqueous base coating to form an uncured base coating after this step, and a step of applying a clear coating by wet-on-wet coating and baking and curing. A method of painting a car body,
Of the first intermediate coating and the second intermediate coating, at least the second intermediate coating is an acrylic resin containing a carboxyl group and a carboxylate ester group having an acid value of 50 to 300 mgKOH / g (solid content) (A ), An acid epoxy curable intermediate coating containing an epoxy group-containing acrylic resin (B) and a pigment (C) having an epoxy group equivalent of 50 to 700,
The clear paint is a two-component clear paint using a hydroxyl group-containing acrylic resin (L) having a hydroxyl value of 100 to 200 mg KOH / g (solid content) and a polyisocyanate prepolymer (M), and the polyisocyanate pre-polymer. The ratio of the isocyanate group equivalent of the polymer (M) to the hydroxyl equivalent of the hydroxyl group-containing acrylic resin (L) is [isocyanate group equivalent] / [hydroxyl group equivalent] = 1 / 0.5 to 1 / 1.5. A painting method characterized by

(2) The coating method according to (1), wherein the second intermediate coating further contains a carboxyl group-containing polyester resin (D) having an acid value of 50 to 350 mgKOH / g (solid content). .
(3) The coating method as described in (1) or (2) above, wherein the pigment concentration (PWC) of the second intermediate coating is 7 to 13% by mass.
(4) The clear paint further contains a polylactone polyol (N) within the range of (L) / (N) = 60/40 to 100/0 (solid content mass ratio), and the hydroxyl group-containing acrylic resin ( L) has a short side chain hydroxyl group (L1) and a long side chain hydroxyl group (L2) at (L1) / (L2) = 3/1 to 1/3 (molar ratio), and the hydroxyl equivalent LOH and Any of (1) to (3) above, wherein the ratio of the isocyanate group equivalent MI of the polyisocyanate prepolymer (M) is MI / LOH = 1 / 0.3 to 1 / 2.0 The coating method as described in 4.
(5) The coating method according to any one of (1) to (4), wherein the aqueous base paint contains a luster pigment.
(6) An automobile body having a laminated coating film formed by the coating method according to any one of (1) to (5).

  According to the method for coating an automobile body of the present invention, since the curing type of the intermediate coating film is an addition reaction of an acid epoxy curing system, the finished appearance is good, the base hiding property is excellent, and the clear coating film is restored. A laminated coating film having good strength and excellent scratch resistance can be obtained.

Hereinafter, the coating method of this invention is demonstrated in order of the formation process of a coating film.
In the coating method of the present invention, an electrodeposition coating film is first formed on a steel plate of an automobile body using an electrodeposition paint. The paint used for this electrodeposition coating is an electrodeposition coating on a steel sheet surface-treated with zinc phosphate or the like, and corresponds to a primer coating. In the present invention, either a cationic electrodeposition paint or an anion electrodeposition paint can be used, but it is preferable to use a cationic electrodeposition paint from the viewpoint of corrosion resistance and the like.

As the cationic electrodeposition coating, known ones can be used, and examples thereof include a coating composition containing a cationic base resin and a curing agent.
Although it does not specifically limit as a cationic base resin, For example, it describes in the amine-modified epoxy resin type | system | group described in Japanese Patent Publication No.54-4978, Japanese Patent Publication No.56-34186, etc., Japanese Patent Publication No.55-115476, etc. Amine-modified polyurethane polyol resin system, amine-modified polybutadiene resin system described in JP-B-62-61077, JP-A-63-86766, etc., JP-A-63-139909, JP-B-1-60516 Examples include amine-modified acrylic resin systems described in JP-A No. 6-128351, sulfonium group-containing resin systems described in JP-A-6-128351, and the like. In addition to those described in the above references, phosphonium group-containing resin systems and the like can also be used. Among the above cationic base resins, it is preferable to use an amine-modified epoxy resin system. Examples of the curing agent include, but are not limited to, amino resins and block polyisocyanate compounds.
This cationic electrodeposition coating is prepared by mixing and dispersing in water by a known method. For example, the component is dissolved in a water-miscible organic solvent and mixed with water and an acid (for example, a water-soluble organic acid or inorganic acid such as acetic acid, formic acid, lactic acid, phosphoric acid, sulfuric acid, etc.), neutralized, and charged. Examples thereof include a method of forming an electrodeposition coating bath, or a method in which the components are dispersed in an aqueous medium and neutralized with an acid to form an electrodeposition coating bath. In the cationic electrodeposition paint, a coloring pigment, an extender pigment, a rust preventive pigment, an anti-settling agent and the like can be blended as necessary.

The car body is painted as follows, for example.
The car body is moved from the car body assembly process to the painting process, and oil and dust adhering to the car body are first removed, and a rust-preventing chemical film is formed on the steel sheet surface constituting the car body as required. Next, the vehicle body (the object to be coated) is washed and immersed in an electrodeposition coating tank filled with an electrodeposition paint. In the electrodeposition coating tank, when a high voltage is applied to the electrodeposition paint, the electrodeposition paint undergoes electrophoresis, thereby forming an electrodeposition coating film (undercoating film) on the vehicle body. The vehicle body discharged from the electrodeposition coating tank is washed in the next electrodeposition water washing step, and excess electrodeposition paint adhering to the vehicle body is washed away. The vehicle body that has been subjected to the electrodeposition washing is then carried into an electrodeposition drying furnace, where the electrodeposition coating film is baked and cured, and then transferred to the intermediate coating process.

A first intermediate coating is first applied and baked and cured on the steel sheet on which the electrodeposition coating has been formed to form a first intermediate coating. After this step, a second intermediate coating is applied and baked and cured to form a second intermediate coating.
These intermediate coatings are liquid coatings containing a basic resin, a curing agent, and an organic solvent as main components, and appropriately blended with coloring pigments, anti-settling agents, extender pigments, and the like as necessary. As the organic solvent, ordinary organic solvents for paints can be used, such as aliphatic, alicyclic, and aromatic hydrocarbon solvents, alcohol solvents, ether solvents, ester solvents, ketone solvents, and the like. can give. These intermediate coatings are prepared by a known method.
Of the first intermediate coating and the second intermediate coating, at least the second intermediate coating is an acrylic resin (A) containing a carboxyl group and a carboxylate ester group having an acid value of 50 to 300 mgKOH / g (solid content) ( Hereinafter, an acid-epoxy curable intermediate coating material containing an epoxy group-containing acrylic resin (B) having an epoxy group equivalent of 50 to 700 and a pigment (C) is used. .

This acid group-containing acrylic resin (A) can be obtained, for example, by reacting an acrylic resin (a1) having an acid anhydride group with a monoalcohol (a2).
The acrylic resin (a1) having an acid anhydride group includes, for example, an acid anhydride group-containing ethylenically unsaturated monomer (a1-1) 15 to 40% by mass, preferably 15 to 35% by mass, and an acid anhydride group. It is obtained by copolymerizing 60 to 85% by mass, preferably 65 to 85% by mass of the ethylenically unsaturated monomer (a1-2) which is not present. If the amount of the acid anhydride group-containing ethylenically unsaturated monomer (a1-1) is less than 15% by mass, the curability is insufficient, and if it exceeds 40% by mass, the resulting coating film becomes too brittle and insufficient in weather resistance. Tend to. Examples of the acid anhydride group-containing ethylenically unsaturated monomer (a1-1) include itaconic anhydride, maleic anhydride, and citraconic anhydride.

  The ethylenically unsaturated monomer (a1-2) having no acid anhydride group is not particularly limited as long as it does not adversely affect the acid anhydride group, and has 3 to 15 carbon atoms having one ethylenically unsaturated bond. In particular, 3 to 12 monomers are preferable. Specific examples include styrene, α-methylstyrene, pt-butylstyrene, and methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, normal butyl (meth) acrylate, (meth) (Meth) acrylic esters such as isobutyl acrylate, tertiary butyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, lauryl (meth) acrylate, cyclohexyl (meth) acrylate, and isobornyl (meth) acrylate And VeoVa-9 and VeoVa-10 manufactured by Shell. Moreover, the monomer which has a carboxyl group like acrylic acid, methacrylic acid, itaconic acid and maleic acid is also mentioned. Among them, about 5 to 20 carbon atoms between an ethylenically unsaturated group and a carboxyl group such as ε-caprolactone 2 mol-modified acrylic acid (Toagosei Chemical Industry Co., Ltd., Aronix M-5300, molecular weight 300). Use of a long-chain carboxylic acid monomer having a minute spacer portion improves the scratch resistance of the coating film, which is particularly preferable.

For example, a hydroxyl group-containing ethylenically unsaturated monomer (a1-2-1) and an acid anhydride group-containing compound (a1-2-2) are mixed at a molar ratio of hydroxyl group to acid anhydride group of 1 / 0.5 to 1 /. A carboxyl group-containing ethylenically unsaturated monomer obtained by half-esterification in an amount of 1.0, preferably 1 / 0.8 to 1 / 1.0, is converted into an ethylenically unsaturated monomer (a1 having no acid anhydride group). -2). When this molar ratio exceeds 1 / 0.5, the polymer viscosity becomes high, resulting in poor workability. When the ratio is less than 1 / 1.0, an excessive acid anhydride group-containing compound (a1-2-2) remains, and the water resistance of the coating film decreases.
The hydroxyl group-containing ethylenically unsaturated monomer (a1-2-1) used here preferably has 5 to 23 carbon atoms, and more preferably 5 to 13 carbon atoms. This is because if the chain length is too short, the flexibility in the vicinity of the crosslinking point is lost and the chain becomes too hard, and if it is too long, the molecular weight between the crosslinking points becomes too large. In general, a monomer having a structure represented by the following formula is exemplified.

    [In the formula (1), R is a hydrogen atom or a methyl group, X is the following formula (2) (wherein Y is a linear or branched alkylene group having 2 to 8 carbon atoms, m Is an integer of 3 to 7, q is an integer of 0 to 4, or the following formula (3) (wherein R is a hydrogen atom or a methyl group, and n is 2). It is an integer of ˜50.) ]

Specifically, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 3-hydroxypropyl (meth) acrylate, 2-hydroxybutyl (meth) acrylate, (meth) acrylic acid Compounds such as 4-hydroxybutyl, 6-hydroxyhexyl (meth) acrylate and their reactants with ε-caprolactone and (meth) acrylic acid with a large excess of diols (e.g., 1,4 butanediol, 1, Examples thereof include compounds that can be prepared by esterifying 6 hexanediol, polyethylene glycol, polypropylene glycol).
Such compounds are commercially available, such as 4-hydroxybutyl acrylate “4HBA” and 4-hydroxybutyl methacrylate “4HBMA” manufactured by Mitsubishi Chemical Corporation, such as “Placcel” manufactured by Daicel Chemical Industries, Ltd. FM1 "and" Plexel FA1 ". Examples of the propylene oxide monomer include “Blenmer PP-1000” and “Blenmer PP-800” manufactured by NOF Corporation, and “Blenmer PE-90” as the ethylene oxide monomer.

Specific examples of the acid anhydride group-containing compound (a1-2-2) used herein include phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, 4-methylhexahydrophthalic anhydride, trimellitic anhydride, anhydrous And succinic acid.
The half-esterification reaction of the hydroxyl group-containing ethylenically unsaturated monomer (a1-2-1) and the acid anhydride group-containing compound (a1-2-2) is performed at a temperature of room temperature to 150 ° C. according to a usual method. .
The copolymerization of the acid anhydride group-containing ethylenically unsaturated monomer (a1-1) and the ethylenically unsaturated monomer (a1-2) having no acid anhydride group is known, for example, as solution polymerization such as radical polymerization. For example, the polymerization can be performed at normal pressure or under pressure at a polymerization temperature of 100 to 200 ° C. and a polymerization time of 3 to 8 hours. As the initiator, an azo-based or peroxide-based initiator is preferably used. Other additives such as chain transfer agents can also be used.

  The number average molecular weight of the obtained polymer is preferably 500 to 8000, more preferably 800 to 6000, and particularly preferably 1500 to 4000. When the number average molecular weight exceeds 8000, the compatibility between the resins decreases and the appearance deteriorates. When the number average molecular weight is less than 500, the curability of the resin composition becomes insufficient. The resulting polymer has an average of at least 2, preferably 2 to 15, acid anhydride groups in one molecule. When the number of acid anhydride groups contained in one molecule is less than 2, the resin composition Curability is insufficient. If it exceeds 15, it becomes too brittle and the weather resistance is insufficient. In addition, the said number average molecular weight can be obtained as a conversion value by a styrene polymer standard using a gel permeation chromatography (GPC).

Subsequently, the obtained acrylic resin (a1) having an acid anhydride group is in a molar ratio of the acid anhydride group to the hydroxyl group of 1/10 to 1/1, preferably 1/5 to 1/1, more preferably The acid group-containing acrylic resin (A) having a carboxyl group and a carboxylic ester group is prepared by reacting with the monoalcohol (a2) in an amount of 1 / 2.0 to 1/1. If this molar ratio is less than 1/10, there is too much excess alcohol, causing cracking during curing, and if it exceeds 1/1, unreacted anhydride groups remain, resulting in poor storage stability.
The monoalcohol (a2) used in the present invention preferably has 1 to 12, particularly 1 to 8 carbon atoms. When the acid group-containing acrylic resin (A) is heated, these alcohol components are easily detached and volatilized, so that the acid anhydride groups can be easily regenerated. Preferred monoalcohols include methanol, ethanol, n-propanol, i-propanol, n-butanol, i-butanol, t-butanol, n-hexyl alcohol, lauryl alcohol, methyl cellosolve, ethyl cellosolve, methoxypropanol, ethoxypropanol, Examples include furfuryl alcohol, dimethylaminoethanol, diethylaminoethanol, acetol, allyl alcohol, and propargyl alcohol. Particularly preferred are acetol, furfuryl alcohol, allyl alcohol, propargyl alcohol, ethanol and methanol.

The acid value of the resulting acid group-containing acrylic resin (A) is 50 to 300 mgKOH / g, preferably 50 to 250 mgKOH / g. When the acid value is less than 50 mgKOH / g, the curability of the coating film becomes insufficient, and when it exceeds 300 mgKOH / g, the storage stability of the intermediate coating becomes poor.
The acid group-containing acrylic resin (A) component is 10 to 70% by mass, preferably 15 to 50% by mass, more preferably 20 to 45% by mass, based on the total solid content in the intermediate coating. Is blended into. The blending amount is preferably large in consideration of the acid resistance of the coating film, and is preferably small in consideration of the brittleness of the coating film.

The epoxy group-containing acrylic resin (B) having an epoxy group equivalent of 50 to 700 used in the intermediate coating composition of the present invention has an average of 2 or more, preferably 2 to 10, more preferably 3 epoxy groups per molecule. It is a compound having ˜8.
Examples thereof include glycidyl ethers of polyhydric alcohols and glycidyl esters of polybasic acids. Examples of these include glycerin triglycidyl ether, trimethylolpropane triglycidyl ether, pentaerythritol tetraglycidyl ether, sorbitol hexaglycidyl ether, and hexahydrophthalic acid diglycidyl ester.

The number average molecular weight of this epoxy group-containing acrylic resin (B) is 200-10000, preferably 500-8000, more preferably 800-5000. A larger number average molecular weight is preferable in view of sufficient curability of the coating film, and a smaller number average molecular weight is preferable in order to increase the solid content of the resulting coating. The epoxy group equivalent is 50 to 700, preferably 80 to 600, more preferably 100 to 500. The epoxy group equivalent is preferably smaller in view of sufficient curability of the coating film, and is preferably larger in consideration of the brittleness of the coating film.
The epoxy group-containing acrylic resin (B) is an epoxy group-containing ethylenically unsaturated monomer of 10 to 60% by mass, preferably 15 to 50% by mass and an ethylenically unsaturated monomer having no epoxy group, preferably 40 to 90% by mass, preferably Is an acrylic polyepoxide obtained by copolymerizing 50 to 85% by mass. The amount of the epoxy group-containing ethylenically unsaturated monomer is preferably large in consideration of sufficient curability of the coating film, and is preferably small in consideration of the weather resistance of the coating film.

Examples of the epoxy group-containing ethylenically unsaturated monomer include glycidyl (meth) acrylate, β-methylglycidyl (meth) acrylate, 3,4-epoxycyclohexanyl (meth) acrylate, and the like. In order to prepare a paint exhibiting balanced curability and storage stability, it is preferable to use glycidyl (meth) acrylate.
Examples of the ethylenically unsaturated monomer having no epoxy group include the monomers listed above as the ethylenically unsaturated monomer having no acid anhydride group (a1-2). Copolymerization can also be carried out in the same manner as in the case of the acid group-containing acrylic resin (A).
In particular, when a hydroxyl group-containing ethylenically unsaturated monomer is used as an ethylenically unsaturated monomer having no epoxy group, the adhesion and recoatability of the resulting coating film are improved. In addition, the epoxy group-containing acrylic resin (B) obtained using the hydroxyl group-containing ethylenically unsaturated monomer reacts with the acid group acrylic resin (A) and functional groups of both the hydroxyl group and the epoxy group, as will be described later. Thus, a stronger coating film can be obtained.

The hydroxyl value of the epoxy group-containing acrylic resin (B) is 5 to 300 mgKOH / g, preferably 10 to 200 mgKOH / g, more preferably 15 to 150 mgKOH / g. When the hydroxyl value exceeds 300, the solid content of the paint is lowered or the water resistance of the cured coating film is insufficient, and when it is less than 5, the adhesion is inferior.
Particularly preferred epoxy group-containing acrylic resins (B) include (i) 5-70% by mass of a hydroxyl group-containing ethylenically unsaturated monomer having the structure of the above formula (1), and (ii) an epoxy group-containing ethylenically unsaturated monomer. It can be obtained by copolymerizing 10 to 60% by mass and, if necessary, (iii) 0 to 85% by mass of an ethylenically unsaturated monomer having neither a hydroxyl group nor an epoxy group.
In this case, the epoxy group-containing acrylic resin (B) preferably has an average of 2 to 12, more preferably 3 to 10 epoxy groups, and preferably an average of 0.5 to 10 hydroxyl groups in one molecule. Preferably 1-8.
The epoxy group-containing acrylic resin (B) is blended in an amount of 10 to 80% by mass, preferably 20 to 70% by mass, more preferably 30 to 65% by mass, based on the mass of the total solid content in the intermediate coating. . The amount of the epoxy group-containing acrylic resin (B) is preferably large in consideration of sufficient curability of the coating film, and is preferably small in consideration of yellowing resistance of the coating film.

  These intermediate coating materials contain pigments (C) such as colored pigments and extender pigments. By adding the pigment, it is possible to conceal fine irregularities on the surface of the electrodeposition coating film, which is the base of the intermediate coating film, and to improve the smoothness of the coating film. Color pigments include azo lake pigments, diketopyrrolopyrrole pigments, benzimidazolone pigments, phthalocyanine pigments, indigo pigments, perylene pigments, quinophthalone pigments, dioxazine pigments, quinacridone pigments, isoindolinone pigments Examples thereof include organic pigments such as pigments and metal complexes, and inorganic pigments such as yellow lead, yellow iron oxide, bengara, titanium dioxide, and carbon black. Examples of extender pigments include barium sulfate, barium carbonate, calcium carbonate, magnesium carbonate, silica, and talc. The pigment concentration (PWC) is preferably 7 to 13% by mass. In particular, when the pigment concentration (PWC) of the second intermediate coating material is in the range of 7 to 13% by mass, the coating film appearance of the composite coating film including the intermediate coating film and the base coating film is maintained while maintaining the undercoating property of the intermediate coating film. Is particularly good.

A carboxyl group-containing polyester resin (D) having an acid value of 50 to 350 mgKOH / g (solid content) is optionally added to the second intermediate coating material containing the component (A), the component (B), and the component (C). Can be contained.
The carboxyl group-containing polyester resin (D) can be obtained, for example, by half-esterifying a polyester polyol having 3 or more hydroxyl groups and an acid anhydride group-containing compound. The “polyester polyol” refers to a polyhydric alcohol having two or more ester bond chains. The polyhydric alcohol refers to an alcohol having two or more hydroxyl groups.
The polyester polyol used here reacts with an acid anhydride group-containing compound to provide a carboxyl group-containing polyester resin (D) having two or more acid functionalities per molecule and the following properties.
In general, such polyester polyols are prepared by condensing a low-molecular polyhydric alcohol having 3 to 16 carbon atoms having at least three hydroxyl groups and a linear aliphatic dicarboxylic acid. By introducing a linear aliphatic group into the low-molecular polyhydric alcohol, flexibility is imparted to the resulting coating film and impact resistance is improved.

Examples of the low molecular weight polyhydric alcohol include trimethylolpropane, trimethylolethane, 1,2,4-butanetriol, ditrimethylolpropane, pentaerythritol, dipentaerythritol, glycerin and a mixture thereof.
Dicarboxylic acids include dibasic acids such as phthalic acid, isophthalic acid, terephthalic acid, succinic acid, adipic acid, azelaic acid, sebacic acid, tetrahydrophthalic acid, hexahydrophthalic acid, maleic acid, fumaric acid and mixtures thereof. Is mentioned. Also, acid anhydrides such as succinic anhydride, phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, hymic anhydride, trimellitic anhydride, methylcyclohexricarboxylic anhydride, pyromellitic anhydride and mixtures thereof Group-containing compounds can also be used.

The polyester polyol is synthesized by a usual esterification reaction such as a dehydration condensation reaction between a polyhydric alcohol and a polybasic acid, or a reaction between the polyhydric alcohol and an acid anhydride group-containing compound. By such an operation, an oligomer of a relatively low molecular weight polyester polyol is obtained, and a high solid intermediate coating is provided.
Particularly preferred polyester polyols in the present invention are those obtained by adding a lactone compound such as ε-caprolactone to a low molecular weight polyhydric alcohol and extending the chain. This is because the molecular weight distribution becomes sharp, so that the intermediate coating can be made highly solid and a coating film excellent in weather resistance and water resistance can be obtained. Examples of the low molecular polyhydric alcohol that is particularly preferably used in this case include trimethylolpropane, ditrimethylolpropane, and pentaerythritol.

The “lactone compound” used in the present invention may be any cyclic compound that has an oxygen atom in the ring and thus reacts with a nucleating reagent to open a ring and generate a hydroxyl group at the terminal. A lactone compound having 4 to 7 carbon atoms is preferable because it easily causes a ring-opening addition reaction.
Specific examples include ε-caprolactone, γ-caprolactone, γ-valerolactone, δ-valerolactone, and γ-butyrolactone, and preferably ε-caprolactone, γ-valerolactone, and γ-butyrolactone are used.
Chain extension can be carried out under the same conditions as in ordinary ring-opening addition reactions. For example, a polyester polyol in which a low molecular weight polyhydric alcohol is chain-extended can be obtained by reacting at a temperature of 80 to 200 ° C. within 5 hours in a suitable solvent or without a solvent. A tin-based catalyst or the like may be used.
At that time, the molar amount of the lactone compound is 0.2 to 10 times, preferably 0.25 to 5 times, more preferably 0.3 to 3 times the molar amount of the OH group of the low molecular weight polyhydric alcohol. is there. The molar amount of the lactone compound relative to the molar amount of the OH group is preferably large in consideration of the impact resistance of the coating film, and is preferably small in order to ensure sufficient hardness of the coating film.

The carboxyl group-containing polyester resin (D) has an acid value of 50 to 350 mgKOH / g (solid content), preferably 100 to 300 mgKOH / g, more preferably 150 to 250 mgKOH / g, and a number average molecular weight of 400 to 3500, preferably Is a resin having a weight average molecular weight / number average molecular weight of 1.8 or less, preferably 1.5 or less, more preferably 1.35 or less.
The acid value is preferably smaller in order to ensure a sufficient solid content concentration of the intermediate coating, and larger in order to ensure sufficient curability of the coating film. The number average molecular weight is preferably small in order to ensure a sufficient solid content concentration of the intermediate coating material, and is preferably large in consideration of sufficient curability of the coating film and water resistance of the coating film. The ratio of weight average molecular weight / number average molecular weight is preferably as small as possible considering the water resistance and weather resistance of the coating film.

Half-esterification reaction between polyester polyol and acid anhydride group-containing compound is phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, 4-methylhexahydrophthalic anhydride, trimellitic anhydride, succinic anhydride, etc. Such an acid anhydride group-containing compound is used under normal reaction conditions such as room temperature to 150 ° C. and normal pressure. However, it is not necessary to modify all the hydroxyl groups of the polyester polyol to carboxyl groups, and the hydroxyl groups may remain.
Since the carboxyl group-containing polyester resin (D) having a hydroxyl group simultaneously provides a carboxyl group and a hydroxyl group on the surface of the coating film, for example, when recoated, it is superior to a polyester polycarboxylic acid having no hydroxyl group. Provides good adhesion.
In this case, the hydroxyl value of the carboxyl group-containing polyester resin (D) is 150 mgKOH / g (solid content) or less, preferably 5 to 100 mgKOH / g, more preferably 10 to 80 mgKOH / g. A smaller hydroxyl value is preferable considering the water resistance of the coating film.

Moreover, since the carboxyl group-containing polyester resin (D) having a hydroxyl group can react and bond with both the epoxy group-containing acrylic resin (B) and the acid group-containing acrylic resin (A) as described later, it is stronger. A coating film can be obtained. Those having an average of 0.1 or more hydroxyl groups in one molecule are preferred.
In general, the molar amount of the acid anhydride group of the acid anhydride group-containing compound relative to the molar amount of the OH group of the polyester polyol is desirably 0.2 to 1.0 times, particularly 0.5 to 0.9 times. A larger value is preferable in order to ensure sufficient curability of the coating film.
The carboxyl group-containing polyester resin (D) can be blended in an amount of 5 to 70% by weight, preferably 5 to 50% by weight, more preferably 10 to 40% by weight, based on the weight of the total solid content in the intermediate coating. . This amount is preferably as small as possible in order to ensure a sufficient solid content concentration of the intermediate coating material, and is preferably as large as possible considering the weather resistance of the coating film.

In the present invention, as the first intermediate coating, the acid epoxy curable intermediate coating or melamine curable intermediate coating mentioned as the second intermediate coating can be used, but from the viewpoint of smoothness of the obtained coating film. It is preferable to use the acid epoxy curable intermediate coating.
As the melamine-curing intermediate coating, an oil-free polyester resin having a number average molecular weight of 1000 to 4500, a hydroxyl value of 70 to 220 mgKOH / g (solid content), and an acid value of 5 to 20 mgKOH / g (solid content) and / or Or an alkyd resin (hereinafter collectively referred to as “polyester resin”), a melamine curing agent comprising at least one of methyl / butyl mixed alkyl etherified melamine and butyl etherified melamine resin, and a pigment. Is particularly preferred.
The above-mentioned polyester resin is a basic resin component that imparts chipping resistance, base concealment, surface smoothness, and the like, which are functions of the intermediate coating. The polyester resin preferably has a number average molecular weight of 1000 to 4500, a hydroxyl value of 70 to 220, and an acid value of 5 to 20. If the number average molecular weight is too small, sufficient curing cannot be obtained. If the number average molecular weight is too large, smoothness becomes insufficient and a good appearance cannot be obtained, and at the same time, the viscosity at the time of coating becomes too high. If the hydroxyl value is too small, the curability is poor, and if it is too large, the elasticity is lowered and the chipping resistance is poor. Similarly, if the acid value is too small, the curability becomes poor, and if it is too large, the water resistance is retreated. The polyester resin can be produced by polycondensation of polyvalent carboxylic acid and / or acid anhydride and polyhydric alcohol as essential components. As other reaction components other than the above essential components, monocarboxylic acid, hydroxycarboxylic acid, lactone and the like may be contained. Moreover, you may contain drying oil, anti-drying oil, and those fatty acids.
The polyester resin is preferably blended at a ratio of 20 to 70% by mass in the solid content. If the blending ratio is too small, the dispersion becomes poor and the glossiness is lowered. If the blending ratio is too large, the concealability of the base becomes insufficient. A more preferable blending amount is 30 to 50% by mass.

The curing agent is preferably a methyl / butyl mixed alkyl etherified melamine resin. When this curing agent is used, since the curing agent component has a low degree of condensation and the reaction initiation rate is slow, the degree of flow during heating is increased to increase the surface smoothness of the coating film and at the same time the reaction initiation rate is slow. Nevertheless, since the self-condensation rate is low, an excellent coating film performance can be obtained. However, if there is a possibility of baking at a low temperature, sufficient coating performance may not be obtained with the methyl / butyl mixed alkyl etherified melamine resin alone. In such a case, a butyl etherified melamine resin can be used in combination with a methyl / butyl mixed alkyl etherified melamine resin. The compounding ratio with respect to solid content of the said hardening | curing agent is 10-40 mass%, Preferably it is 15-35 mass%. If this ratio is too small, the curability becomes insufficient, and if it is too large, the formed coating film becomes hard and brittle.
As the pigment, a pigment (C) such as a colored pigment or an extender pigment can be blended as in the case of the second intermediate coating. The pigment is preferably 7 to 60% by mass in the solid content. If this ratio is too small, the base concealing property is not sufficiently secured, and if it is too large, the dispersibility is lowered and the gloss is retreated. More preferably, it is 10-50 mass% in solid content.
In the first intermediate coating, in addition to polyester resin, curing agent, pigment, cross-linked resin particles, organic bentonite, fatty acid polyamide, polyethylene wax, etc. as thickeners, aromatic hydrocarbons, aliphatic hydrocarbons as organic solvents -Based, ester-based, alcohol-based solvents, etc., using acid catalysts, UV absorbers, hindered amine light stabilizers, antioxidants, surface conditioners, leveling agents, pigment dispersants, plasticizers, antifoaming agents, etc. as additives be able to.

In the coating method of the present invention, the aqueous base paint is applied after the second intermediate coating film forming step. The water-based base paint is a liquid paint mainly composed of a basic resin, a curing agent, an organic solvent and water, and further appropriately blended with a color pigment, an anti-settling agent, an extender pigment, and the like, and is prepared by a known method. Is done.
Examples of the basic resin include acrylic resin, polyester resin, alkyd resin, epoxy resin, and urethane resin. It is preferable to use an acrylic emulsion and / or a water-soluble acrylic resin from the viewpoint of coating performance such as coating workability, weather resistance, water resistance, etc. Among them, an acrylic emulsion is more preferable.
As a hardening | curing agent, a melamine resin, an epoxy resin, etc. can be mentioned, for example, A melamine resin is preferable from the point of the various performance of a coating film, and cost. From the viewpoint of improving curability at low temperatures, it is also preferable to add a block isocyanate resin, a carbodiimide compound, or an oxazoline compound in combination.
In addition, a viscosity control agent and other additives may be appropriately blended in the water-based base coating material in order to prevent familiarity with the clear coating film and ensure coating workability.

The water-based base paint can be used as a metallic base paint by blending with a glitter pigment, and without blending the glitter pigment, a color pigment such as red, blue or black and, if necessary, a body pigment can be blended. It can also be used as a solid base paint.
The glitter pigment is not particularly limited. For example, a non-colored or colored metallic glitter material such as a metal or an alloy and a mixture thereof, interference mica powder, colored mica powder, white mica powder, graphite or a colorless colored flat pigment, etc. Can be mentioned. Since it is excellent in dispersibility and can form a highly transparent coating film, non-colored or colored metallic glitter materials such as metals or alloys and mixtures thereof are preferred. Specific examples of the metal include aluminum, aluminum oxide, copper, zinc, iron, nickel, tin and the like.

The shape of the glitter pigment is not particularly limited, and may be further colored. For example, a scaly pigment having an average particle diameter (D ₅₀ ) of 2 to ₅₀ μm and a thickness of 0.1 to 5 μm. Is preferred. The average particle diameter (D ₅₀ ) is a median diameter measured by a laser light scattering method. Those having an average particle size in the range of 10 to 35 μm are more preferable because of excellent glitter. The pigment concentration (PWC) in the aqueous base paint of the glitter pigment is generally 23% by mass or less. The pigment concentration is preferably as small as possible considering the appearance of the coating film. Preferably, it is 0.01-20 mass%, More preferably, it is 0.01-18 mass%. When an aqueous base paint containing a glitter pigment is used, the shading is noticeable.
As pigments other than the luster pigment, the color pigments and extender pigments described in the intermediate coating can be used. As a pigment, it can be used 1 type or in combination of 2 or more types among a luster pigment, a color pigment, and an extender pigment. The pigment concentration (PWC) in the aqueous base paint including the glitter pigment and all other pigments is generally 0.1 to 50% by mass, preferably 0.5 to 40% by mass, More preferably, it is 1-30 mass%. The pigment concentration is preferably as small as possible considering the appearance of the coating film. Examples of other additives include those exemplified in the intermediate coating.

In the coating method of the present invention, the clear coating is applied by wet-on-wet coating after the base coating film is formed. The clear paint is a liquid paint containing a basic resin, a curing agent and an organic solvent as main components, and further optionally containing a light stabilizer, an ultraviolet absorber and the like, and is prepared by a known method.
The clear paint is a two-component clear paint using a hydroxyl group-containing acrylic resin (L) having a hydroxyl value of 100 to 200 mg KOH / g (solid content) and a polyisocyanate prepolymer (M), and the polyisocyanate prepolymer The ratio of the isocyanate group equivalent of (M) to the hydroxyl equivalent of the hydroxyl group-containing acrylic resin (L) is [isocyanate group equivalent] / [hydroxyl group equivalent] = 1 / 0.5 to 1 / 1.5.
This two-component clear coating further contains polylactone polyol (N) within the range of (L) / (N) = 60/40 to 100/0 (solid content mass ratio), and contains a hydroxyl group-containing acrylic resin (L ) Has a short side chain hydroxyl group (L1) and a long side chain hydroxyl group (L2) at (L1) / (L2) = 3/1 to 1/3 (molar ratio), and a polyisocyanate prepolymer (M ) Is preferably MI / LOH = 1 / 0.3 to 1 / 2.0. The long side chain refers to a side chain having 6 or more carbon atoms, and the short side chain refers to a side chain having less than 6 carbon atoms. The carbon number of the long side chain is preferably 15 or more, and the carbon number of the short side chain is preferably 3 or less.

  Examples of the hydroxyl group-containing acrylic resin (L) include (1) hydroxymethyl (meth) acrylate, hydroxyethyl (meth) acrylate, hydroxypropyl (meth) acrylate, hydroxybutyl (meth) acrylate, and N-methylol. Ethylenic monomer having a hydroxy group such as acrylic amine, (2) ethylenic monomer having a carboxyl group such as (meth) acrylic acid, crotonic acid, itaconic acid, fumaric acid, maleic acid, (3) (meth) acrylic acid Methyl, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate, n-propyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, (meth Such as 2-ethylhexyl acrylate, n-octyl (meth) acrylate, n-dodecyl (meth) acrylate, etc. ) An ethylenic monomer copolymerizable with the monomers (1) and (2) such as alkyl acrylate, and a copolymer obtained by copolymerizing ε-caprolactone, (meth) acrylonitrile, styrene, etc. are preferable. Can be mentioned. The hydroxyl group-containing acrylic resin (L) may be only one type or two or more types.

In the hydroxyl group-containing acrylic resin (L), the short side chain hydroxyl group is a group derived from hydroxyethyl (meth) acrylate, and the long side chain hydroxyl group is an adduct of hydroxyethyl (meth) acrylate and ε-caprolactone. It is preferable that the group is derived from the viewpoint of achieving both scratch resistance and weather resistance. Such a hydroxyl group-containing acrylic resin (L) can be obtained by copolymerizing a monomer component containing hydroxyethyl (meth) acrylate and an adduct of hydroxyethyl (meth) acrylate and ε-caprolactone. This adduct is preferably formed by adding 2 to 5 mol of ε-caprolactone to 1 mol of hydroxyethyl (meth) acrylate, from the viewpoint of scratch resistance.
In the hydroxyl group-containing acrylic resin (L), the content ratio of the short side chain hydroxyl group (L1OH) and the long side chain hydroxyl group (L2OH) is (L1OH) / (L2OH) = 3/1 to 1/3 (molar ratio). It is preferable that the ratio is 2/1 to 1/2 (molar ratio). The content ratio of the long side chain hydroxyl group is preferably less in order to suppress deterioration of weather resistance due to hydrolysis of the coating film, and more preferably in order to ensure the restoring force and scratch resistance of the coating film. .

The hydroxyl group-containing acrylic resin (L) preferably has a total hydroxyl group equivalent of 100 to 200, more preferably 120 to 180. When the total hydroxyl group equivalent is less than 100, photodegradation is likely to occur when the coating film is formed, and weather resistance is lowered. On the other hand, when it exceeds 200, the restoring force is insufficient and a dent caused by impact is generated. The original coating film surface state cannot be restored, and the scratch resistance is lowered.
The hydroxyl group-containing acrylic resin (L) preferably has a glass transition temperature of 5 to 50 ° C, more preferably 10 to 40 ° C. The glass transition temperature is preferably low in order to ensure the restoring force and scratch resistance of the coating film, and is preferably high considering the weather resistance and stain resistance of the coating film.
The glass transition temperature is obtained by distilling off the solvent under reduced pressure from the resin varnish containing the hydroxyl group-containing acrylic resin (L) obtained when synthesizing the hydroxyl group-containing acrylic resin (L). It is a value measured at the time of temperature increase in the third step by performing the following temperature increase step, temperature decrease step and temperature increase step with a meter (DSC) (thermal analyzer SSC / 5200H, manufactured by Seiko Electronics Co., Ltd.).
First step: 20 ° C. → 100 ° C. (temperature increase rate 10 ° C./min)
Second step: 100 ° C. → −50 ° C. (temperature decrease rate 10 ° C./min)
Third step: −50 ° C. → 100 ° C. (temperature increase rate: 10 ° C./min)

The weight average molecular weight of the hydroxyl group-containing acrylic resin (L) is not particularly limited, but is preferably 6,000 to 20,000. In addition, the said weight average molecular weight can be obtained as a conversion value by a styrene polymer standard using a gel permeation chromatography (GPC).
The polylactone polyol (N) is not particularly limited, and examples thereof include bifunctional polycaprolactone diols such as a compound represented by the following general formula (1) and a compound represented by the following general formula (2). Such trifunctional polycaprolactone triols, other tetrafunctional polycaprolactone polyols and the like. The polylactone polyol (N) may be only one type or two or more types.

(In the formula (1), R is any one of C ₂ H ₄ , C ₂ H ₄ OC ₂ H ₄ , and C (CH ₂ ) ₂ (CH ₂ ) ₂ , and m and n are integers of 4 to 35. .)

(In the formula (2), R _{is, CH 2 CHCH 2, CH 3} C (CH 2) 2, CH 3 CH 2 C (CH 2) is ₃ either, l + m + n is an integer of 3 to 30. )
The polylactone polyol (N) preferably has 2 to 5 functional groups, more preferably 3 to 4. The number of functional groups is preferably small in order to ensure the restoring force and scratch resistance of the coating film, and more preferably in consideration of the weather resistance and stain resistance of the coating film.
In the clear paint, the solid content ratio of the hydroxyl group-containing acrylic resin (L) and the polylactone polyol (N) is preferably (L) / (N) = 60/40 to 100/0 (mass ratio). The polylactone polyol (N) may not be blended, but when blended, if the solid content ratio exceeds the ratio of (L) / (N) = 60/40, hydrolysis will occur. It is preferable not to exceed 40% by mass with respect to the total solid content of component (L) and component (N). More preferably, it is in the range of (L) / (N) = 80/20 to 100/0 (mass ratio).

Examples of the polyisocyanate prepolymer (M) include methylene diisocyanate, toluene diisocyanate, hexamethylene diisocyanate, and isophorone diisocyanate. The polyisocyanate prepolymer (M) may be only one type or two or more types.
In the clear coating, the polyisocyanate prepolymer (M) has a ratio of the isocyanate group equivalent (MI) to the total hydroxyl equivalent (LOH) of the hydroxyl group-containing acrylic resin (L) and the polylactone polyol (M) (MI) / (LOH) is preferably blended so as to be 1 / 0.3 to 1 / 2.0, more preferably blended so as to be 1 / 0.5 to 1 / 1.5. .
If the isocyanate group equivalent (MI) is less than the above range, photodegradation is likely to occur and the weather resistance is reduced. On the other hand, if the isocyanate group equivalent (MI) is more than the above range, the restoring force is insufficient. The dent produced by the impact cannot be returned to the original coating film surface state, and the scratch resistance is lowered.

The resin component in the clear paint also contains a structural unit-(CH2) n- that is generally called a soft segment in the molecular structure. If there are too many soft segments, the hardness, weather resistance, and chemical resistance of the coating film Therefore, the content ratio is preferably less than 25% by mass with respect to the total solid content of the hydroxyl group-containing acrylic resin (L) and the polyisocyanate prepolymer (M), and is 20% by mass or less. More preferably.
For clear paints, organic solvents, UV absorbers, light stabilizers, antioxidants, anti-yellowing agents, bluing agents, pigments, leveling agents, antifoaming agents, thickeners, anti-settling agents are used as necessary. Further, an antistatic agent, an antifogging agent and the like can be appropriately blended. As the organic solvent, ordinary organic solvents for paints can be used, and examples thereof include aliphatic, alicyclic, and aromatic hydrocarbon solvents, ether solvents, ester solvents, and ketone solvents.
In the coating method of the present invention, after the clear coating film is formed in this way, the base coating film and the clear coating film are baked and cured.

Examples of the coating conditions in each step of the coating method of the present invention include the following conditions.
The electrodeposition coating is not particularly limited, and a normal electrodeposition coating method can be applied.
In the present invention, the first intermediate coating is applied to the cured coating surface obtained by crosslinking and curing the electrodeposition coating. The first intermediate coating was applied to the ford cup no. 4 is diluted with thinner so that the viscosity when measured at 20 ° C. is 20 to 30 seconds, and it is applied by electrostatic coating, air spray, airless spray, or the like. The film thickness is preferably 20 to 50 μm, particularly preferably 30 to 40 μm, based on the cured coating film. Next, the coating film is held in an atmosphere of about 120 to 160 ° C. for 10 to 30 minutes to be crosslinked and cured to form a cured coating film surface, and a second intermediate coating is applied thereon.
The viscosity of the second intermediate coating is adjusted to 13 to 25 seconds, and it is applied by electrostatic coating, air spray, airless spray or the like. The film thickness is preferably 20 to 40 [mu] m, particularly 25 to 35 [mu] m, based on the cured coating film, and after standing at room temperature, it is kept in an atmosphere of about 120 to 160 [deg.] C. for 10 to 30 minutes for crosslinking and curing.

Next, a water-based base coating is applied to the coating surface of the cured second intermediate coating. The viscosity of the paint is adjusted to 50 to 60 seconds, and it is applied by electrostatic coating, air spray, airless spray or the like. The film thickness is preferably 5 to 40 μm, particularly 10 to 20 μm, based on the cured coating film, and is preheated after standing at room temperature. Preheating is a process of leaving or heating at a temperature of room temperature to less than 100 ° C. for 1 to 10 minutes under conditions where the applied intermediate coating film is not cured, and the solid content can be adjusted by preheating.
After preheating, a clear paint is applied on the coated surface by wet on wet. Specifically, a water-based base paint is applied and left at room temperature or a temperature near it for several minutes, and then a clear paint is applied. After standing at room temperature, it is heated to about 120 to 160 ° C. to be cured by crosslinking. The film thickness of the aqueous base coating is preferably 5 to 40 μm, particularly 10 to 30 μm based on the cured coating film, and the film thickness of the clear coating is 20 to 60 μm, particularly 30 to 50 μm based on the cured coating film. Preferably there is.

Hereinafter, the present invention will be described in detail with specific examples. “Part” means “part by mass”.
Production Example 1 Production of Polymer Containing Carboxyl Group and Carboxylic Anhydride Group In a 3 L reaction vessel equipped with a thermometer, stirrer, cooling pipe, nitrogen introduction pipe, and dropping funnel, 700 parts of xylene, mixed solvent Solvesso 100 ( 350 parts of Exxon Chemical Co., Ltd.) were charged, and the temperature was raised to 130 ° C. In this container, using a dropping funnel, 300 parts of styrene monomer, 109 parts of 2-ethylhexyl methacrylate, 325 parts of isobutyl acrylate, 25.7 parts of acrylic acid, 240 parts of maleic anhydride, 300 parts of propylene glycol monomethyl ether acetate, t-butyl par A solution consisting of 150 parts of oxy 2-ethylhexanoate and 150 parts of xylene was added dropwise over 3 hours. After maintaining at 130 ° C. for 30 minutes after the completion of dropping, a solution consisting of 20 parts of t-butylperoxy 2-ethylhexanoate and 20 parts of xylene was added dropwise over 30 minutes. After completion of the dropwise addition, the reaction was continued at 130 ° C. for another hour, and then 1100 parts of the solvent was distilled to obtain a polymer solution containing a carboxyl group and a carboxylic acid anhydride group having a nonvolatile content of 70% and a number average molecular weight of 2000 (a -1) was obtained.

Production Example 2 Production of Acid Group-Containing Acrylic Resin (A-1) Containing Carboxyl Group and Carboxylic Ester Group In 1590 parts of polymer solution (a-1) obtained in Production Example 1, 2 parts of triethylamine and 125 parts of methanol And reacted at 60 ° C. for 8 hours to obtain a polymer solution (A-1) containing a carboxyl group and a carboxylic ester group. With respect to this polymer solution (A-1), an infrared absorption spectrum was measured, and it was confirmed that absorption of acid anhydride (1785 cm-1) disappeared. The solid content acid value of the polymer solution (A-1) was 158 (mgKOH / g).

Production Example 3 Production of epoxy group-containing acrylic resin (B-1) having an epoxy group equivalent of 50 to 700 In a 3 L reaction vessel equipped with a thermometer, a stirrer, a cooling pipe, a nitrogen introduction pipe and a dropping funnel, 700 parts of xylene, 525 parts of propylene glycol monomethyl ether acetate was charged and the temperature was raised to 130 ° C. In the above container, using a dropping funnel, styrene monomer 200 parts, glycidyl methacrylate 229 parts, 4-hydroxybutyl acrylate 231 parts, cyclohexyl methacrylate 340 parts, t-butylperoxy-2-ethylhexanoate 120 Part and 200 parts of xylene were added dropwise over 3 hours. After maintaining at 130 ° C. for 30 minutes after the completion of dropping, a solution consisting of 10 parts of t-butylperoxy-2-ethylhexanoate and 50 parts of xylene was dropped for 30 minutes. After completion of the dropwise addition, the reaction was continued at 130 ° C. for another hour, and then 1200 parts of the solvent was distilled, and the hydroxyl group and epoxy having a non-volatile content of 77%, a number average molecular weight of 1800, an epoxy group equivalent of 625, and a hydroxyl group equivalent of 623 A polymer solution (B-1) containing a group was obtained.

Production Example 4 Production of carboxyl group-containing polyester resin (D-1) having an acid value of 50 to 350 mg KOH / g (solid content) A thermometer, a stirrer, a cooling pipe, a nitrogen introduction pipe, a water separator, and a rectifying tower are provided. The reaction vessel was charged with 183 parts of azelaic acid, 285 parts of isophthalic acid, 221 parts of trimethylolpropane, 110 parts of Cardura E (manufactured by Shell Chemical Co., Ltd.), and 290 parts of neopentyl glycol. After the raw materials are melted and can be stirred, 0.2 parts of dibutyltin oxide is added and stirring is started, and the reaction vessel temperature is raised from 180 ° C. to 220 ° C. over 3 hours while keeping the heating rate constant. did. The condensed water generated during this time was distilled out of the system. When the temperature reached 220 ° C., the reaction solution was kept at 220 ° C. for 1 hour. Thereafter, 30 parts of xylene as a refluxing solvent was gradually added to the reaction vessel, and the reaction was continued by switching to condensation in the presence of the solvent. When the resin acid value reached 1 or less, it was cooled to 150 ° C., 238 parts of hexahydrophthalic anhydride was added dropwise, and the infrared absorption spectrum was measured, and the temperature was kept until absorption of the acid anhydride group (1785 cm ⁻¹ ) disappeared. Then, it cooled to 100 degreeC. Further, 383 parts of xylene was added to obtain a polyester resin solution (D-1) having a nonvolatile content of 75%, a number average molecular weight of 1100, an acid value of 70 (mgKOH / g), and a hydroxyl value of 200 (mgKOH / g).

Production Example 5 Production of Acrylic Resin Containing Carboxyl Group (A′-2) Except that the monomer composition is 300 parts of styrene monomer, 125 parts of 2-ethylhexyl methacrylate, 373 parts of isobutyl acrylate, 202 parts of acrylic acid, In the same manner as in Production Example 1, an acrylic resin (A′-2) containing a carboxyl group was obtained. The acid value was 158 (mgKOH / g).

Production Example 6 Production of Hydroxyl-Containing Acrylic Resin (L-1) In a reaction vessel equipped with a stirrer, thermometer, reflux tube, dropping funnel, nitrogen introducing tube and thermostat-equipped heating device, butyl acetate and xylene were in a mass ratio of 1: 30 parts of the mixed solvent (S0) 3 was charged and the internal solvent temperature was raised to 120 ° C. while stirring. Subsequently, Plaxel FM3 (produced by Daicel Chemical Industries, Ltd.) 39.53 having 21.58 parts of 2-hydroxyethyl methacrylate (HEMA) as a short-chain hydroxyl group monomer and three ε-caprolactone groups as a long-chain hydroxyl group monomer. Part, isobornyl methacrylate (IBX) 24.5 parts, n-butyl methacrylate (nBMA) 12.85 parts, methacrylic acid (MAA) 1.53 parts mixed monomer solution, peroxide-based polymerization initiator “Kaya A polymerization initiator solution consisting of 6 parts of ester O (manufactured by Nippon Kayaku Co., Ltd.) and 32 parts of the mixed solvent (S0) was put in a separate dropping funnel, and the inside of the reaction vessel was stirred, The solution was added dropwise over 3 hours to conduct a polymerization reaction. During the reaction, the liquid temperature was kept at 120 ° C. while constantly stirring the internal solution. Next, a reaction vessel in which the polymerization temperature is maintained at 120 ° C. while stirring the polymerization initiator solution composed of 0.5 parts of the peroxide polymerization initiator “Kayaester O” and 9 parts of the mixed solvent (S0). It was added dropwise over 1 hour to produce a hydroxyl group-containing acrylic resin (L-1).
The hydroxyl group-containing acrylic resin (L-1) has the following characteristics: a short-chain hydroxyl group / long-chain hydroxyl group molar ratio of 2/1, a calculated OH number (OHV) of 140, a measured glass transition temperature (Tg) of 20 ° C., The weight average molecular weight measured by gel permeation chromatography (GPC) was 12,000, and the resin solid content (NV) was 60%.

Production Example 7 Production of Clear Coating In a stirring vessel, 125 parts of a hydroxyl group-containing acrylic resin (L-1), 25 parts of polycaprolactone “Placcel 308” (solid content 100%, functional group number 3, manufactured by Daicel Chemical Industries, Ltd.) Were sequentially added with stirring and mixed well. Next, 2 parts of “Tinuvin 900” (UV absorber; manufactured by Ciba Specialty Chemicals Co., Ltd.), 1 part of “Tinubin 292” (photoantioxidant; manufactured by Ciba Specialty Chemicals Co., Ltd.), “BYK306” (Surface conditioner; manufactured by Big Chemie Co., Ltd.) 1 part, 50 parts of an additive solution consisting of 96 parts of a mixed solvent of xylene / butyl acetate = 50/50 (S1), and after sufficient stirring, curing A clear coating composition used in Example 1 was produced using 70 parts of isocyanurate compound “Duranate THA100 (solid content 75%, manufactured by Asahi Kasei Co., Ltd.)” as an agent.
The value of [isocyanate group equivalent] / [hydroxyl group equivalent] of this coating composition was 1/1.

Example 1
(1) Preparation of paint The resin (D-1) obtained in Production Example 4, melamine resin (Mitsui Chemicals Co., Ltd., Euban 2ON-60) and the pigments shown in Table 1 were mixed in the proportions shown in Table 1. Diluted with a thinner (N175 / N150 = 5/5 manufactured by Nippon Paint Co., Ltd.) using a Ford Cup No. 4 so that the viscosity when measured at 20 ° C. is 25 seconds. An intermediate coating was prepared.
The resin (A-1) obtained in Production Example 2, the resin (B-1) obtained in Production Example 3, the resin (D-1) obtained in Production Example 4, and the pigment of Table 1 are shown in Table 1. The mixture was diluted with thinner (N175 / N150 = 5/5 manufactured by Nippon Paint Co., Ltd.) so that the viscosity was 18 seconds to prepare an intermediate coating for the second layer.
As the water-based base coating material, a water-based base coating material (AR-2200 silver manufactured by Nippon Paint Co., Ltd.) containing a luster pigment was diluted with deionized water so that the viscosity was 60 seconds.
As the clear paint, a solution prepared by diluting the clear paint composition obtained in Production Example 7 with a thinner (N1297 manufactured by Nippon Paint Co., Ltd.) so as to have a viscosity of 18 seconds was prepared.

(2) Coating formation and evaluation Pre-treatment of Dull steel plate using Surfdyne SD2000 (manufactured by Nippon Paint Co., Ltd.), followed by Powernicks PN1030 (cationic electrodeposition paint manufactured by Nippon Paint Co., Ltd.) The electrodeposition coating was performed so that the dry film thickness was 20 μm, and baked at 170 ° C. for 30 minutes.
Next, an intermediate coating for the first layer was applied with a film thickness of 35 μm by rotary atomization coating and baked at 140 ° C. for 20 minutes. Furthermore, the intermediate coating for the second layer was applied with a film thickness of 30 μm by rotary atomization and baked at 140 ° C. for 20 minutes.
Next, after applying a water-based base paint with a film thickness of 15 μm by air spray coating, preheating at 60 ° C. for 3 minutes, and applying a clear paint on the coated surface with a wet-on-wet film with a film thickness of 40 μm by air spray coating. And baked at 140 ° C. for 20 minutes.
The obtained multilayer coating film was subjected to the following measurements and tests, and the results shown in Table 1 were obtained. The sharpness of the appearance of the coating film was evaluated by using WAVE SCAN DOI manufactured by Big Chemie Co., Ltd., with the long wavelength (Lw) being smooth and the short wavelength (Sw) being glossy. Furthermore, visual evaluation was also performed about smoothness and glossiness. In Table 1, each symbol has the following meaning.
A: There is no distortion.
○: Almost no distortion.
Δ: Slightly distorted
X: There is considerable distortion.

Examples 2-5
The composition of the first intermediate coating material and / or the second intermediate coating material was changed to the values shown in Table 1, and the other conditions were the same as in Example 1 to form a multilayer coating film. The results shown in Table 1 were obtained.
Comparative Example 1
The second intermediate coating film formation step was not carried out, and the other conditions were the same as in Example 1, forming a multilayer coating film, and the results shown in Table 1 were obtained.
Comparative Example 2
The composition of the second intermediate coating was changed to the values shown in Table 1, and the other conditions were the same as in Example 1 to form a multilayer coating film. The results shown in Table 1 were obtained.
Comparative Example 3
The composition of the first intermediate coating was changed to the values shown in Table 1, the second intermediate coating film formation step was not performed, and the other conditions were the same as in Example 1 to form a multilayer coating film. The result was obtained.
Comparative Examples 4-6
The composition of the second intermediate coating was changed to the values shown in Table 1, and the other conditions were the same as in Example 1 to form a multilayer coating film. The results shown in Table 1 were obtained.

  According to the coating method of the present invention, it is possible to provide an automobile body having a laminated coating film that has a good finished appearance and has a sufficient foundation hiding property and scratch resistance.

Claims (6)

A step of applying a first intermediate coating onto a steel sheet on which an electrodeposition coating has been formed and baking and curing to form a first intermediate coating. After this step, a second intermediate coating is applied and baking cured to form a second intermediate coating. An automobile body comprising a step of forming a coating film, a step of applying an aqueous base coating to form an uncured base coating after this step, and a step of applying a clear coating by wet-on-wet coating and baking and curing. Painting method,
Of the first intermediate coating and the second intermediate coating, at least the second intermediate coating is an acrylic resin containing a carboxyl group and a carboxylate ester group having an acid value of 50 to 300 mgKOH / g (solid content) (A ), An acid epoxy curable intermediate coating containing an epoxy group-containing acrylic resin (B) and a pigment (C) having an epoxy group equivalent of 50 to 700,
The clear paint is a two-component clear paint using a hydroxyl group-containing acrylic resin (L) having a hydroxyl value of 100 to 200 mg KOH / g (solid content) and a polyisocyanate prepolymer (M), and the polyisocyanate pre-polymer. The ratio of the isocyanate group equivalent of the polymer (M) to the hydroxyl equivalent of the hydroxyl group-containing acrylic resin (L) is [isocyanate group equivalent] / [hydroxyl group equivalent] = 1 / 0.5 to 1 / 1.5. A painting method characterized by The coating method according to claim 1, wherein the second intermediate coating further contains a carboxyl group-containing polyester resin (D) having an acid value of 50 to 350 mgKOH / g (solid content). The coating method according to claim 1, wherein the second intermediate coating material has a pigment concentration (PWC) of 7 to 13% by mass. The clear coating further contains a polylactone polyol (N) within a range of (L) / (N) = 60/40 to 100/0 (solid content mass ratio), and the hydroxyl group-containing acrylic resin (L) Having a short side chain hydroxyl group (L1) and a long side chain hydroxyl group (L2) at (L1) / (L2) = 3/1 to 1/3 (molar ratio), the hydroxyl equivalent LOH and the polyisocyanate The coating method according to any one of claims 1 to 3, wherein the ratio of the prepolymer (M) to the isocyanate group equivalent MI is MI / LOH = 1 / 0.3 to 1 / 2.0. The coating method according to claim 1, wherein the water-based base paint contains a luster pigment. An automobile body having a laminated coating film formed by the coating method according to claim 1.