JPWO2019131636A1 - 粉体塗料の製造方法 - Google Patents
粉体塗料の製造方法 Download PDFInfo
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- fluororesin
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- C08F214/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
- C08F214/18—Monomers containing fluorine
- C08F214/24—Trifluorochloroethene
- C08F214/245—Trifluorochloroethene with non-fluorinated comonomers
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Abstract
Description
N値を30%以上とすることで、原料中でのフッ素樹脂及び非フッ素樹脂の分散を良好にすることができる。また、K値が21.0〜50.0%且つN値が30%以上であると、フッ素樹脂の増粘を制御しつつ、溶融混練におけるフッ素樹脂及び非フッ素樹脂の分散を良好にすることができる。
オートクレーブ内に、キシレン(503g)、エタノール(142g)、CTFE(387g)、CHVE(326g)、HBVE(84.9g)、炭酸カリウム(12.3g)、及びtert−ブチルペルオキシピバレートの50質量%キシレン溶液(20mL)を導入して昇温し、65℃で11時間重合した。次いで、オートクレーブ内溶液をろ過し、含フッ素重合体からなるフッ素樹脂を含む溶液を得た。得られた溶液を、65℃で24時間真空乾燥することによって溶媒を除去し、さらに130℃で20分間真空乾燥した。得られたブロック状のフッ素樹脂を粉砕して、粉末状のフッ素樹脂を得た。
粉体塗料組成物の製造に使用した各成分の詳細、及び組成物全量に対する各成分の質量%を以下に示す。
・フッ素樹脂:製造例1で製造したフッ素樹脂 16質量%
・非フッ素樹脂:ポリエステル(ALLNEX社製、商品名「CRYLCOAT(登録商標)4890−0」、Mn:2,500、軟化温度:120℃、SP値:22.8(J/cm3)1/2) 36.7質量%
・硬化剤:ブロック化イソシアネート系硬化剤(デグサ社製、商品名「ベスタゴン(登録商標)B1530」) 9質量%
・顔料:デュポン社製、商品名「タイピュア(登録商標)R960」、酸化チタン含有量89% 33質量%
・硬化触媒:ジブチルスズジラウレートの100倍希釈キシレン溶液 0.2質量%
・脱ガス剤:ベンゾイン 0.4質量%
・表面調整剤1:ビックケミー社製、商品名「BYK(登録商標)−360P」 1.9質量%
・表面調整剤2:EASTMAN社製、商品名「Benzoflex(商標)352」 2.8質量%
上述の成分を、高速ミキサー(凌宇社製)を用いて10秒間混合し、粉末状の混合物を得た。得られた混合物を原料として、2軸押出機(凌宇社製、25mm径スクリュー押出機)を用いて以下の混練条件にて溶融混練を行い、混練物を得た。用いられた2軸押出機は図1に示したものと同様の構成を有する押出機である。また、スクリュー2の構成、ニュートラル型混練セグメント、非ニュートラル型混練セグメントの各セグメントの構成もそれぞれ、図2〜4に示したものと同様である。
・K値(LK/LS×100):37.9%
・N値(LN/LK×100):60.6%
・ニュートラル型混練セグメントの個数:4個
・LS/DS:17.4
・バレル設定温度:120℃
・スクリュー回転数:100rpm
例1において、混練条件のうち、K値(%)、N値(%)、ニュートラル型の混練セグメントの個数、スクリュー回転数を表1のように変更した以外は同様にして、各例においてそれぞれ粉体塗料を得た。
<試験片の作成>
クロメート処理を行ったアルミ板の一面に、静電塗装機(GEMA社製、商品名:Classic Standard)を用いて、各例で得られた粉体塗料を静電塗装した。次いで、200℃雰囲気中で20分間保持して硬化させ、23℃まで冷却して、厚さ55〜65μmの硬化膜が形成されたアルミ板を得た。得られた硬化膜付きアルミ板(75mm×150mm)を試験片として、後述の評価に供した。結果を表1に示す。
試験片を切断し、硬化膜の断面を、下記2種類の走査電子顕微鏡(装置1及び装置2)により観察した。断面観察は、以下の条件にて行った。
装置1:日本電子社製「JSM−5900LV」
・加速電圧:20kV
・倍率:10,000倍
・測定前処理:JEOL社製オートファインコーター「JFC−1300」による、20mA、45秒の白金コート
装置2:日本電子社製「JCM−6000」
・加速電圧:15kV
・倍率:10,000倍
・測定前処理:日本電子社製オートファインコーター「Smart Coater」による、20mA、60秒の白金コート
A:断面写真において、フッ素樹脂層と非フッ素樹脂層との明確な界面が視認され、且つフッ素樹脂層が連続していることが確認された。
B:断面写真において、フッ素樹脂層と非フッ素樹脂層との界面が視認されなかった、又はフッ素樹脂層に不連続な部分があった。
上記の両装置によって得られた断面写真において、硬化膜の表面の全表面面積に対して、最上層であるフッ素樹脂層の表面面積が何%存在するかを目視で算出した。
得られた試験片における硬化膜表面の入射角60度鏡面光沢度(%)を、JIS K 5600−4−7に準拠して測定した。測定は、試験機器(日本電色工業社製、商品名「PG−1M」)を用い、試験片の上部・中部・下部の三か所に対して行い、得られた測定値の平均値を算出した。
試験片における硬化膜表面の平滑性を、PCI(パウダーコーティングインスティチュート)により平滑性目視判定用標準板を用いて、以下の基準に従って判定した。標準板の数値(PCI値)は1〜10であり、このPCI値が大きくなるほど平滑性に優れる。
A:PCI値が3以上であり、はじきや濡れ性の不良等が確認されなかった。
B:PCI値が3未満であり、はじきや濡れ性の不良等が確認された。
JIS K5600−5−4に準拠して、試験片における硬化膜の鉛筆硬度を測定した。
JIS K 5600−5−3に準拠して、500gのおもりの落下高5〜100cmに対する硬化膜の抵抗性について、硬化膜の剥離が生じない落下高の最大値(cm)で評価した。落下高の最大値が大きいほど、耐衝撃性に優れる。
JIS K 5600−5−1に準拠して、規定された直径の円筒形マンドレルに試験片の硬化膜を巻き付けたときの硬化膜の抵抗性について、硬化膜の割れが生じない円筒形マンドレルの直径の最低値(mm)で評価した。円筒形マンドレルの直径の最低値が小さいほど、耐屈曲性に優れる。
2 スクリュー
3 供給部
5 ダイ
6 モータ部
10 混練押出機
21 搬送ゾーン
22 混練ゾーン
23 計量化ゾーン
24 ニュートラルゾーン
25 非ニュートラルゾーン
41 搬送セグメント
42 混練セグメント
44 ニュートラル型の混練セグメント
45、45A、45B 非ニュートラル型の混練セグメント
441〜444 ニュートラルセグメントのニーディングディスク(混練ディスク)
451〜454 非ニュートラルセグメントのニーディングディスク(混練ディスク)
DM1 非ニュートラルセグメントの長径
DM2 非ニュートラルセグメントの短径
DN1 ニュートラルセグメントの長径
DN2 ニュートラルセグメントの短径
DS スクリュー直径(外径)
LK 混練ゾーンの長さ
LN ニュートラルゾーンの長さ
LR 非ニュートラルゾーンの長さ
LS スクリューの有効長さ
PM 非ニュートラルセグメントの軸方向の長さ(ピッチ)
PN ニュートラルセグメントの軸方向の長さ(ピッチ)
WM 非ニュートラルセグメントのディスク幅
WN ニュートラルセグメントのディスク幅
Claims (15)
- フッ素樹脂と非フッ素樹脂とを含む粉体塗料の製造方法であって、
混練ゾーンを有するスクリューを備えた混練押出機を用いて、前記フッ素樹脂と前記非フッ素樹脂とを含む原料を混練する工程を含み、
前記スクリューの有効長さLSに対する前記混練ゾーンの長さLKの割合(LK/LS×100)が21.0〜50.0%である、粉体塗料の製造方法。 - 前記混練ゾーンが、ニュートラル型の混練セグメントを備えたニュートラルゾーンを含み、
前記混練ゾーンの長さLKに対する前記ニュートラルゾーンの長さLNの割合(LN/LK×100)が30%以上である、請求項1に記載の製造方法。 - 前記スクリューが直径DSを有し、前記直径DSに対する前記スクリューの有効長さLSの比の値(LS/DS)が10以上である、請求項1又は2に記載の製造方法。
- 前記スクリューの回転数が、10〜1,000rpmである、請求項1又は2に記載の製造方法。
- 前記ニュートラル型の混練セグメントが、複数のニーディングディスクを備えたニュートラル型の混練セグメントである、請求項2に記載の製造方法。
- 前記混練押出機が、2軸以上の複数軸を有する、請求項1又は2に記載の製造方法。
- 前記フッ素樹脂のガラス転移温度及び前記非フッ素樹脂のガラス転移温度のうち高い方の温度以上、且つ、前記原料の硬化開始温度以下で混練する、請求項1又は2に記載の製造方法。
- 100℃以上、300℃以下の温度で混練する、請求項1又は2に記載の製造方法。
- 前記非フッ素樹脂が、ポリエステル樹脂、アクリル樹脂、エポキシ樹脂、ポリエチレン樹脂からなる群から選ばれる一種以上である、請求項1又は2に記載の製造方法。
- 前記フッ素樹脂が、フルオロオレフィンに基づく単位及びフッ素原子を含まない単量体に基づく単位を含む含フッ素重合体を含む、請求項1又は2に記載の製造方法。
- 前記フッ素樹脂が、フルオロオレフィンに基づく単位及びフッ素原子を含まない単量体に基づく単位を含む含フッ素重合体を含み、
前記フッ素原子を含まない単量体に基づく単位が、架橋性基を有する単量体に基づく単位を含む、請求項1又は2に記載の製造方法。 - 前記フッ素樹脂及び非フッ素樹脂が、水酸基価及び酸価の一方又は両方を有する、請求項1又は2に記載の製造方法。
- 前記原料における、前記フッ素樹脂の含有量が、5〜95質量%である、請求項1又は2に記載の製造方法。
- 前記原料における、フッ素樹脂と非フッ素樹脂との質量比が、70/30〜10/90である。請求項1又は2に記載の製造方法。
- 前記原料は、硬化剤を含む、請求項1又は2に記載の製造方法。
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