Classifications

• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07D—HETEROCYCLIC COMPOUNDS
  • C07D407/00—Heterocyclic compounds containing two or more hetero rings, at least one ring having oxygen atoms as the only ring hetero atoms, not provided for by group C07D405/00
  • C07D407/02—Heterocyclic compounds containing two or more hetero rings, at least one ring having oxygen atoms as the only ring hetero atoms, not provided for by group C07D405/00 containing two hetero rings
  • C07D407/12—Heterocyclic compounds containing two or more hetero rings, at least one ring having oxygen atoms as the only ring hetero atoms, not provided for by group C07D405/00 containing two hetero rings linked by a chain containing hetero atoms as chain links
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07D—HETEROCYCLIC COMPOUNDS
  • C07D303/00—Compounds containing three-membered rings having one oxygen atom as the only ring hetero atom
  • C07D303/02—Compounds containing oxirane rings
  • C07D303/12—Compounds containing oxirane rings with hydrocarbon radicals, substituted by singly or doubly bound oxygen atoms
  • C07D303/18—Compounds containing oxirane rings with hydrocarbon radicals, substituted by singly or doubly bound oxygen atoms by etherified hydroxyl radicals
  • C07D303/20—Ethers with hydroxy compounds containing no oxirane rings
  • C07D303/22—Ethers with hydroxy compounds containing no oxirane rings with monohydroxy compounds
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07D—HETEROCYCLIC COMPOUNDS
  • C07D301/00—Preparation of oxiranes
  • C07D301/02—Synthesis of the oxirane ring
  • C07D301/03—Synthesis of the oxirane ring by oxidation of unsaturated compounds, or of mixtures of unsaturated and saturated compounds
  • C07D301/14—Synthesis of the oxirane ring by oxidation of unsaturated compounds, or of mixtures of unsaturated and saturated compounds with organic peracids, or salts, anhydrides or esters thereof
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07D—HETEROCYCLIC COMPOUNDS
  • C07D303/00—Compounds containing three-membered rings having one oxygen atom as the only ring hetero atom
  • C07D303/02—Compounds containing oxirane rings
  • C07D303/12—Compounds containing oxirane rings with hydrocarbon radicals, substituted by singly or doubly bound oxygen atoms
  • C07D303/16—Compounds containing oxirane rings with hydrocarbon radicals, substituted by singly or doubly bound oxygen atoms by esterified hydroxyl radicals
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
  • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
  • C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
  • C08G59/22—Di-epoxy compounds
  • C08G59/226—Mixtures of di-epoxy compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
  • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
  • C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
  • C08G59/22—Di-epoxy compounds
  • C08G59/24—Di-epoxy compounds carbocyclic
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
  • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
  • C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
  • C08G59/32—Epoxy compounds containing three or more epoxy groups
  • C08G59/38—Epoxy compounds containing three or more epoxy groups together with di-epoxy compounds
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
  • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • G03F7/004—Photosensitive materials
  • G03F7/038—Macromolecular compounds which are rendered insoluble or differentially wettable
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31511—Of epoxy ether

Definitions

• Invention I relates to a method of producing an epoxy resin compound. More particularly, it relates to a method of producing an alicyclic epoxy compound having a specific structure by oxidizing an alicyclic olefin compound with an aliphatic percarboxylic acid having low,water content.
• the alicyclic epoxy compound is useful for use in coatings, inks, adhesives, sealants, encapsulants, stabilizers or the like.
• Invention II relates to an epoxy resin composition containing an alicyclic epoxy compound as a main component and applications thereof. More particularly, it relates to an epoxy resin composition which can be cured by heating, thereby obtaining a cured product having good moisture and heat resistance and transparency, and applications thereof for photosemiconductor encapsulation.
• Invention III relates to an ultraviolet rays-curable can-coating composition containing an alicyclic epoxy compound as a main component, which can be cured by ultraviolet irradiation, thereby forming a coating film having excellent film performances such as processability, adhesion, hardness and scratch resistance, particularly excellent outer appearance and retort resistance of films, and to a process of producing a coated metal can using this composition.
• Celloxide 3000 has methyl group on carbon constituting epoxy group, so that reactivity of epoxy group is low as compared with a compound having no methyl group. For this reason, an alicyclic epoxy resin has mainly been used in the case of, for example, preferentially achieving low viscosity or high Tg.
• Celloxide 2021 and Celloxide 2081 each has an ester group in the molecule thereof, and therefor has hydrolyzability. Those also have poor moisture and heat resistance as compared with bisphenol type epoxy compounds.
• JP-09255764 A describes an epoxy resin for photosemiconductor encapsulation, containing a diglycidyl ether of a hydrogenated bisphenol A.
• This epoxy resin however, has the problems on discoloration, weatherability, heat resistance and the like of a cured product.
• JP-10156952 A describes a resin composition for optical three-dimensional shapes using the same alicyclic epoxy compound as in the present invention, but it does not contain any description regarding utilization of the resin composition for encapsulation of photosemiconductor.
• JP-2000063485A describes a build-up curable composition using a composition comprising a specific alicyclic epoxy compound and a multivalent epoxy compound having a polyhydric phenol skeleton, but its main feature does not reside in heat resistance and transparency.
• JP-48029899 A describes that a compound wherein X in an alicyclic epoxy compound (A) represented by the formula (I) described later is —CH 2 — is synthesized, and curing reaction with an acid anhydride is conducted using this compound, to thereby improve physical properties of the resulting cured product as compared with conventional alicyclic epoxy compounds.
• synthesis of the epoxy compound uses perbenzoic acid, and therefore this makes it difficult to utilize the synthesis industrially.
• JP-58172387 A a percarboxylic acid is synthesized from hydrogen peroxide, an acidic catalyst and an organic acid, the resulting percarboxylic acid is extracted with an organic solvent, and epoxidation is conducted using the extracted percarboxylic acid.
• the solvent to be used will be, for example, benzene, but use of such the solvent is not preferable from the viewpoint of toxicity. In view of the above circumstances, it has been demanded to develop an epoxy resin having an alicyclic skeleton which does not have an ester group in the molecule thereof, and its efficient production method.
• an object of the invention I is to provide a method of conducting epoxidation of an alicyclic olefin compound efficiently and economically, and also by using a solvent having low toxicity.
• An object of the invention II is to provide an epoxy resin composition for photosemiconductor encapsulation, which provides a cured product having excellent moisture and heat resistance and transparency.
• examples of ultraviolet rays-curable coating compositions include: cationic polymerization type coating materials containing a cation-polymerizable compound having an epoxy group or a vinyl group and a cationic polymerization initiator that generates a cation by ultraviolet irradiation; and radical polymerization type coating materials containing a radical polymerizable compound having a radically polymerizable unsaturated group and a radical polymerization initiator that generates radical by ultraviolet irradiation.
• the radical polymerization type coating material has a characteristic that curing rate is relatively fast. However, it has problems that adhesion to a raw material and processability are insufficient, surface curability is poor due to inhibition of curing by oxygen, and in particular, in the case of using the coating material in the form of a thin film (2 to 8 ⁇ m), facilities for nitrogen sealing or the like are necessary.
• the cationic polymerization type coating material has the advantages that adhesion to a raw material and processability are good as compared with the radical polymerization type coating material, and that facilities for nitrogen sealing or the like are not necessary. However, it has problems that because curing rate is slow, film performances, in particular film appearance and retort resistance, are insufficient.
• both of the radical polymerization type coating material and cationic polymerization type coating material have the problem that curability is insufficient in low irradiation dose (less than 100 mj/cm 2 ).
• the reason for this is considered to be that, for example, although many of alicyclic epoxy compounds suitable for cationic curing have an ester linkage in the molecule, the ester linkage reacts with cation species, thereby inhibiting polymerization of epoxy.
• JP-10158581 A describes an ultraviolet rays-curable can-coating composition containing a compound having an alicyclic epoxy group in the molecule, a compound having an oxetane ring in the molecule, a specific copolymer and a cationic polymerization initiator.
• this coating composition has problems on hardness in hot water pertaining to retort resistance, film appearance, impact resistance, and the like, due to the above reasons.
• an object of the invention III is to provide an ultraviolet rays-curable can-coating composition and a process for producing a coated metal can.
• a coating film can be formed, which is a thin coating film that does not require facilities for, for example, nitrogen sealing, can be cured by ultraviolet irradiation in small irradiation dose, and is excellent in film performances required as a can coating material, such as processability, adhesive properties, hardness and scratch resistance, particularly film appearance and retort resistance, and also a coating film exhibiting excellent hardness in hot water can be formed by performing heating after ultraviolet irradiation.
• the invention III has been completed based on these findings.
• a first aspect of the present invention relates to a method of producing an alicyclic epoxy compound (A) represented by the following formula (I):
• X represents a divalent group selected from oxygen atom, sulfur atom, —SO—, —SO 2 —, —CH 2 —, —C(CH 3 ) 2 —, —CBr 2 —, —C(CBr 3 ) 2 13 , —C(CF 3 ) 2 —, —C(CCl 3 ) 2 — and —CH(C 6 H 5 )—, or a single bond linking two alicyclic rings; and R 1 to R 18 are the same or different and each represents hydrogen atom, halogen atom, a hydrocarbon group which may contain oxygen atom or halogen atom, or an alkoxyl group which may have substituent groups), the method characterized by comprising epoxidizing an alicyclic olefin compound represented by the above formula (II) using an aliphatic percarboxylic acid having water content of 2% by weight or less.
• a second aspect of the present invention relates to a method of producing an alicyclic epoxy compound (A) according to the first aspect, characterized in that the aliphatic percarboxylic acid is obtained by oxidation of the corresponding aldehyde with oxygen.
• a third aspect of the present invention relates to a method of producing an alicyclic epoxy compound (A) according to the first or second aspect, characterized in that the water content in the aliphatic percarboxylic acid is 0.8% by weight or less.
• a fourth aspect of the present invention relates to a method of producing an alicyclic epoxy compound (A) according to any one of the first to third aspects, characterized in that the aliphatic percarboxylic acid is peracetic acid.
• a fifth aspect of the present invention relates to a liquid epoxy resin composition
• a liquid epoxy resin composition comprising an epoxy resin, and a curing agent and/or a curing accelerator, characterized in that the epoxy resin comprises in an amount of 100 to 20% by weight an alicyclic epoxy compound (A) represented by the following formula (I):
• X represents a divalent group selected from oxygen atom, sulfur atom, —SO—, —SO 2 —, —CH 2 —, —C(CH 3 ) 2 —, —CBr 2 —, —C(CBr 3 ) 2 —, —C(CF 3 ) 2 —, —C(CCl 3 ) 2 — and —CH(C 6 H 5 )—, or a single bond linking two alicyclic rings; and R 1 to R 18 are the same or different and each represents hydrogen atom, halogen atom, a hydrocarbon group which may contain oxygen atom or halogen atom, or an alkoxyl group which may have substituent groups).
• a sixth aspect of the present invention relates to a liquid epoxy resin composition according to the fifth aspect, characterized in that the alicyclic epoxy compound (A) represented by the formula (I) is an epoxy compound produced by using percarboxylic acid having water content of 1% by weight or less.
• a seventh aspect of the present invention relates to a liquid epoxy resin composition according to the fifth or sixth aspect, characterized in that the curing agent is an initiator which releases a substance initiating cationic polymerization by heating.
• An eighth aspect of the present invention relates to a liquid epoxy resin composition according to any one of the fifth to seventh aspects, characterized in that the curing agent is a liquid acid anhydride.
• a ninth aspect of the present invention relates to a liquid epoxy resin composition which is obtained by adding 110 to 160 parts by weight of a curing agent (C) which is a liquid acid anhydride and 3 to 7 parts by weight of a curing accelerator, to 100 parts by weight of the alicyclic epoxy compound (A) represented by the formula (I) of the fifth aspect, or by further adding 0.1 to 20 parts by weight of an initiator (E) that releases cation species upon heating, to 100 parts by weight of the alicyclic epoxy compound (A).
• a curing agent (C) which is a liquid acid anhydride and 3 to 7 parts by weight of a curing accelerator
• a tenth aspect of the present invention relates to a liquid epoxy resin composition according to any one of the fifth to ninth aspects, which is used for photosemiconductor encapsulation.
• An eleventh aspect of the present invention relates to a photosemiconductor device, comprising a photosemiconductor element encapsulated with the epoxy resin composition for photosemiconductor encapsulation according to the tenth aspect.
• a twelfth aspect of the present invention relates to an ultraviolet rays-curable can-coating composition comprising: 10 to 100 parts by weight of an alicyclic epoxy compound (A) represented by the following formula (I):
• X represents a divalent group selected from oxygen atom, sulfur atom, —SO—, —SO 2 —, —CH 2 —, —C(CH 3 ) 2 —, —CBr 2 —, —C(CBr 3 ) 2 —, —C(CF 3 ) 2 —, —C(CCl 3 ) 2 — and —CH(C 6 H 5 )—, or a single bond linking two alicyclic rings; and R 1 to R 18 are the same or different and each represents hydrogen atom, halogen atom, a hydrocarbon group which may contain oxygen atom or halogen atom, and an alkoxyl group which may have substituent groups); 0 to 90 parts by weight of a compound having an alicyclic epoxy group in the molecule and also having an ester linkage and/or an epoxy compound (B) having a glycidyl group; 1 to 50 parts by weight of a copolymer (F) having at least
• a thirteenth aspect of the present invention relates to an ultraviolet rays-curable can-coating composition according to the twelfth aspect, characterized in that the copolymer (F) is a copolymer of glycidyl group-containing polymerizable unsaturated monomer and/or alicyclic epoxy group-containing polymerizable unsaturated monomer, and other polymerizable monomer.
• the copolymer (F) is a copolymer of glycidyl group-containing polymerizable unsaturated monomer and/or alicyclic epoxy group-containing polymerizable unsaturated monomer, and other polymerizable monomer.
• a fourteenth aspect of the present invention relates to an ultraviolet-curing can coating composition according to any one of the twelfth to thirteenth aspects, which further contains a lubricity-imparting agent in an amount of 0.01 to 10 parts by weight based on 100 parts by weight of the total amount of the alicyclic epoxy compound (A) and the epoxy compound (B) represented by the above formula (I).
• a fifteenth aspect of the present invention relates to an ultraviolet rays-curable can-coating composition according to any one of the twelfth to fourteenth aspects, which further contains fine particles of resins in an amount of 0.1 to 50 parts by weight per 100 parts by weight of the total amount of the alicyclic epoxy compound (A) represented by the above formula (I) and the epoxy compound (B).
• a sixteenth aspect of the present invention relates to an ultraviolet rays-curable can-coating composition according to any one of the twelfth to fifteenth aspects, characterized in that the alicyclic epoxy compound (A) represented by the formula (I) is an epoxy compound produced by using an aliphatic percarboxylic acid having water content of 2% by weight or less.
• a seventeenth aspect of the present invention relates to a process of producing a coated metal can, which comprises applying the ultraviolet rays-curable can-coating composition according to any one of the twelfth to sixteenth aspects to a metal plate, a resin film-laminated metal plate or a metal can molded from those metal plates, and irradiating the coated product with ultraviolet rays to cure the resulting coating film.
• the alicyclic epoxy compound (A) represented by the above-mentioned formula (I) in the invention I is produced by oxidizing an alicyclic olefin compound represented by the formula (II) with an aliphatic percarboxylic acid having a water content of 2% by weight or less.
• the alicyclic olefin compound used as a raw material is generally synthesized by dehydration reaction of a compound having the corresponding hydroxyl group.
• the alicyclic olefin compound represented by the formula (II) can be synthesized from, for example, a compound having a cyclohexanol structure, as described in JP-48029899 A, 58172387 A and 2000169399 A.
• the alicyclic olefin compound obtained preferably has double bonds at 3- and 4-positions to substituent X
• the compound having hydroxyl group which is a raw material of the alicyclic olefin compound preferably has hydroxyl group at 4-position to substituent X.
• the examples of those compounds include a compound containing at least two cyclohexane rings having hydroxyl group bonded thereto in the molecule, and the present invention is particularly effective to dehydration reaction thereof.
• Examples of the compound containing at least two cyclohexane rings having hydroxyl group bonded thereto in the molecule include hydrogenated biphenol, dicyclohexanol methane, bis(dimethylcyclohexanol)methane, 1,2-bis(cyclohexanol)ethane, 1,3-bis(cyclohexanol)propane, 1,4-bis(cyclohexanol)butane, 1,5-bis(cyclohexanol)pentane, 1,6-bis(cyclohexanol)hexane, 2,2-bis(cyclohexanol)propane, bis(cyclohexanol)phenylmethane, ⁇ , ⁇ (-bis(4-hydroxycyclohexyl)-4-(4-hydroxy- ⁇ , ⁇ -dimethylcyclohex yl)-ethylbenzene, 3,3-bis(cyclohexanol)pentane, 5,
• the aliphatic percarboxylic acid having low water content is preferably used as an epoxidizing agent that can be used for epoxidation of double bond in the alicyclic olefin compound.
• the reason for this is that if epoxidation is conducted in the presence of moisture, ring-opening reaction of epoxy group proceeds, and thus yield of an epoxy compound decreases.
• the aliphatic percarboxylic acid it is essential for the aliphatic percarboxylic acid to have a water content of 2% by weight or less, preferably 1% by weight or less, more preferably 0.8% by weight or less and most preferably 0.6% by weight or less.
• the aliphatic percarboxylic acid having a water content of 2% by weight or less as described in the present invention generally means peracetic acid or the like produced by air oxidation of acetaldehyde or the like.
• peracetic acid is produced by a method described in German Patent Laid-Open No. 1418465 or JP-54003006 A.
• the aliphatic percarboxylic acid having a water content of 2% by weight or less may also be produced by synthesizing an aliphatic percarboxylic acid from an aliphatic carboxylic acid using hydrogen peroxide, and then extracting it through distillation or by using a solvent.
• the method using air oxidation of acetaldehyde or the like enables a large amount of high concentration aliphatic percarboxylic acid to be synthesized continuously. As a result, the aliphatic percarboxylic acid can substantially be obtained inexpensively.
• aliphatic percarboxylic acids performic acid, peracetic acid, perisobutyric acid, pertrifluroacetic acid or the like can be used. Of those, peracetic acid is particularly preferable because it is industrially available at low cost and has high stability.
• Amount of the aliphatic percarboxylic acid as an epoxidizing agent is not strictly limited, and the optimum amount thereof in each case can be determined in accordance with variable factors such as individual epoxidizing agent used, desired degree of epoxidation, or individual material to be epoxidized.
• the epoxidizing agent is preferably added in an equimolar amount or more to olefin group.
• the amount of the epoxidizing agent exceeding 2 times by mole is generally disadvantageous.
• the amount is preferably 1 to 1.5 times by mole.
• Epoxidation reaction is conducted using or not using an inert solvent, or by controlling reaction temperature, depending on an apparatus or physical properties of a raw material.
• the inert solvent can be used to decrease viscosity of a raw material or to stabilize an epoxidizing agent by means of dilution.
• peracetic acid aromatic compounds, esters or the like can be used.
• Particularly preferable solvents are hexane, cyclohexane, toluene, ethyl acetate and methyl acetate.
• a reaction temperature range that can be used is determined by reactivity of the epoxidizing agent to be used.
• the reaction temperature is 0° C. or higher and 100° C. or lower.
• the reaction temperature is preferably 20 to 70° C. If the reaction temperature is lower than 20° C., reaction proceeds slowly, and if it is higher than 70° C., decomposition of peracetic acid occurs.
• Charging molar ratio of the epoxidizing agent to unsaturated bond can be varied according to the purpose, such as, how much of unsaturated bond should be remained.
• reaction mixture may be simply stirred for 1 to 5 hours.
• the epoxidized product obtained can be isolated by an appropriate method such as a method of precipitating it in a poor solvent, a method of introducing the epoxidized product in hot water while stirring it and removing a solvent by distillation, and a direct desolvation method.
• the alicyclic epoxy compound (A) represented by the above formula (I) produced by the production method of the invention I can produce intermediates for use in various coatings, inks, adhesives, sealants, moldings or other articles using those, by homopolymerization, copolymerization or reacting with other compound.
• Examples of the end uses of the alicyclic epoxy compound (A) produced by the production method of the invention I include acid scavengers, coatings for furniture, coatings for decoration, cans for beverages or other can coatings, adhesives, automobile undercoats, sealers, finish coatings, inks for character information or image information, sealants for electronic parts, printing plates or photoresists suitable for development of printed circuit boards, cast printing rolls, glasses mainly containing unsaturated polyester and styrene, molded blends reinforced with carbon, graphite or other fibers or molded articles made by sheet forming blend, solvents, flame retardants, intermediates for producing other compounds useful for various end uses including medicines and medical goods.
• the alicyclic epoxy compound (A) produced by the production method of the invention I can also possess heat resistance, transparency and good dielectric properties, which are the characteristics of a cured resin using a compound having an alicyclic skeleton.
• the invention II relates to a liquid epoxy resin composition using the alicyclic epoxy compound (A) represented by the above formula (I) as a preferable alicyclic epoxy resin, and a photosemiconductor device in which a photosemiconductor element is encapsulated with the liquid epoxy resin composition.
• alicyclic epoxy compound (A) represented by the above formula (I) as a preferable alicyclic epoxy resin
• photosemiconductor device in which a photosemiconductor element is encapsulated with the liquid epoxy resin composition.
• the alicyclic epoxy compound (A) used in the invention II is the compound as described in detail in the invention I, and is generally a liquid at ordinary temperature (25° C.).
• the liquid epoxy resin composition in the invention II contains the alicyclic epoxy compound (A) in an amount of 100 to 20% by weight.
• alicyclic epoxy compound (A) compounds produced by the production method as described in the invention I in detail are preferably used, but compounds produced by other production method can also be used. Further, commercially available products can be also used.
• the following reactive diluent may be used together with the above epoxy compounds.
• low-viscosity cycloalkylene glycol diglycidyl ether for example, low-viscosity cycloalkylene glycol diglycidyl ether having a viscosity of 100 cps or lower at 25° C. is used.
• the cycloalkyleneglycol diglycidyl ether include cyclohexanedimethanol diglycidyl ether and cyclohexanediol diglycidyl ether.
• Glycidyl type epoxy resins such as liquid bisphenol A or F, hydrogenated bisphenol A type epoxy resins, glycidyl amine type epoxy resins and the like may also be used.
• a solid epoxy resin can be used so long as an epoxy resin having such a solid epoxy resin blended therewith has a viscosity of 40,000 cp or lower at 45° C.
• the solid epoxy resin that can be used include solid bisphenol epoxy resins, novolak type epoxy resins, glycidyl esters, triglycidyl isocyanurates and EHPE-3150 (a product of Daicel Chemical Industries, Ltd.)
• Those epoxy resins can be used alone or as mixtures of two or more thereof.
• any compound can be selected from compounds generally used as a curing agent for an epoxy resin.
• the acid anhydride for use in the invention II is preferably liquid at ordinary temperature.
• Specific examples of the acid anhydride include methyltetrahydrophthalic anhydride, methylhexahydrophthalic anhydride, dodecenylsuccinic anhydride and methylendomethylenetetrahydrophthalic anhydride.
• Acid anhydrides that are solid at ordinary temperature such as phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride and methylcyclohexenedicarboxylic anhydride, can be used in an amount such that it does not adversely affect impregnation property of the liquid epoxy resin composition of the invention II.
• an acid anhydride that is solid at ordinary temperature it is preferable that the solid acid anhydride is dissolved in an acid anhydride that is liquid at ordinary temperature, and is used as a mixture that is liquid at ordinary temperature.
• an amount of the acid anhydride added is an amount effective for exhibiting the effects as the curing agent (C).
• the amount of acid anhydride is not particularly limited, the acid anhydride is preferably used in a proportion such that the amount thereof is 0.5 to 1.5 acid anhydride equivalent based on one equivalent of epoxy group in the epoxy resin component.
• the curing accelerator (D) in the invention II mainly comprises diazabicycloundecene-based curing accelerator, and it is necessary that the diazabicycloundecene-based curing accelerator comprises at least 50% by weight of the entire curing accelerator (C). If the proportion of the diazabicycloundecene-based curing accelerator is less than 50% by weight, pot life cannot sufficiently be prolonged. In order to obtain a sufficient pot life, it is preferable that the proportion of the diazabicycloundecene-based curing accelerator is 70% by weight or more.
• Examples of the diazabicycloundecene-based curing accelerator include 1,8-diazabicyclo[5.4.0]undecene-7 and a salt thereof.
• octylate of 1,8-diazabicyclo[5.4.0]undecene-7 is preferable.
• the curing accelerator (D) may be composed of the diazabicycloundecene-based curing accelerator alone or may be a mixture of the diazabicycloundecene-based curing accelerator and up to 50% by weight of a curing accelerator for other epoxy resins such as tertiary amine hardening accelerators and phosphorus-based curing accelerators (e.g., triphenylphosphine) that are commonly used.
• a curing accelerator for other epoxy resins such as tertiary amine hardening accelerators and phosphorus-based curing accelerators (e.g., triphenylphosphine) that are commonly used.
• the curing accelerator (D) is used in an amount of 0.3 to 10 parts by weight based on 100 parts by weight of the epoxy resin. If the amount of the curing accelerator (D) is less than 0.3 part by weight, curing acceleration effect is insufficient, and on the other hand, if the amount thereof exceeds 10 parts by weight, pot life is shortened disadvantageously. Therefore, from the viewpoints of curing acceleration and pot life, the particularly preferable amount of the curing accelerator (D) is 1 to 5 parts by weight based on 100 parts by weight of the epoxy resin component.
• the curing accelerator (D) is a compound having a function of promoting a curing reaction when the epoxy resin is hardened by an acid anhydride.
• curing accelerator (D) used in the invention II include: tertiary amines such as benzyldimethyl amine and 2,4,6-tris(dimethylaminomethyl)phenol; imidazoles such as 2-ethyl-4-methylimidazole and 1-cyanoethyl-2-ethyl-4-methylimidazole; organic phosphine compounds such as triphenylphosphine; tertiary amine salts; quaternary ammonium salts; phosphonium salts; and metal salts such as tin octylate, that are known compounds.
• tertiary amines such as benzyldimethyl amine and 2,4,6-tris(dimethylaminomethyl)phenol
• imidazoles such as 2-ethyl-4-methylimidazole and 1-cyanoethyl-2-ethyl-4-methylimidazole
• organic phosphine compounds such as triphenylphosphine
• the amount of the curing accelerator (D) added is preferably 1 to 10 parts by weight based on 100 parts by weight of the epoxy resin.
• Cationic polymerization initiator (E) may be used as a curing agent in the invention III.
• the cationic polymerization initiator (E) is a compound which releases a substance initiating a polymerization by heating.
• the initiator is added in an amount of 0.05 to 5 parts by weight, preferably 0.1 to 3 parts by weight, based on 100 parts by weight of the epoxy resin. When the initiator is added within the above range, a cured product having excellent heat resistance, transparency, weatherability and the like can be obtained.
• Examples of the cationic polymerization initiator (E) include aryl diazonium salts such as PP-33 from Asahi Denka Industry Co.; aryl iodonium salts; aryl sulfonium salts such as FC-509 from 3M, UVE 1014 from G.E., VI-6974, VI-6970, VI-6990 and VI-6950 from Union Carbide, SP-170 and SP-150 from Asahi Denka Industry Co., SI060L, SI-80L and SI-100L from Sanshin Chemical Industry Co., and allene-ion complexes such as CG-24-61 from Ciba Geigy AG.
• aryl diazonium salts such as PP-33 from Asahi Denka Industry Co.
• aryl iodonium salts such as FC-509 from 3M
• UVE 1014 from G.E.
• VI-6974, VI-6970, VI-6990 and VI-6950 from Union Carbide
• cationic polymerization initiator (E) examples include chelate compounds of metal (such as aluminum or titanium) and acetates or diketones; and chelate compounds including system with silanol or phenols.
• metal such as aluminum or titanium
• chelate compounds including system with silanol or phenols examples include triphenyl silanol and bisphenol S.
• liquid epoxy resin composition of the invention II can be added to the liquid epoxy resin composition of the invention II in an amount not adversely affecting viscosity of the liquid epoxy resin composition.
• additives examples include silicone or fluorine-based defoamers and silane coupling agents such as ⁇ -glycidoxypropyl trimethoxysilane.
• the liquid epoxy resin composition of the invention II provides a cured product having high glass transition temperature and high transparency, and low water absorption, and therefore is suitable for use as a resin composition for photosemiconductor encapsulation.
• the liquid epoxy resin composition of the invention II can further contain, optionally, various additives such as fillers, flame retardants, defoamers, coloring materials and silane coupling agents, which are hitherto commonly used in the epoxy resin compositions for photosemiconductor encapsulation.
• the invention III relates to an ultraviolet rays-curable can-coating composition containing an alicyclic epoxy resin compound (A) represented by the formula (I) as an essential component, and to a process of producing a coated metal can using the composition.
• the alicyclic epoxy compound (A) used in the invention III is preferably a compound produced by the method as described in detail in the invention I.
• the alicyclic epoxy compound (A) is generally liquid at ordinary temperature (25°).
• an alicyclic epoxy compound other than the alicyclic epoxy compound (A) for example, a compound having an alicyclic epoxy group in the molecule and having an ester linkage and/or an epoxy compound (B) having a glycidyl group can be used together in an amount of 0 to 80% by weight.
• any compound can be used without particular limitation if it is a compound having at least one piece, preferably 1 to 2 pieces, of alicyclic epoxy groups in the molecule.
• Such a compound include di(3,4-epoxycyclohexyl)adipate, (3,4-epoxycyclohexyl)methyl-3,4-epoxycyclohexane carboxylate, (3,4-epoxy-6-methylcyclohexyl)methyl-3,4-epoxy-6-methylcyclohe xyane carboxylate, and ethylene-1,2-di(3,4-epoxycyclohexane carboxylic acid) ester.
• Those compounds can be used alone or as a mixture of two or more thereof.
• particularly preferable compounds are 3,4-epoxycyclohexylmethy-3,4-epoxycyclohexane carboxylate, 3,4-epoxycyclohexylmethyl alcohol, 3,4-epoxycyclohexylethyl trimethoxysilane and compounds represented by the following formula:
• the compound having an oxetane ring in the molecule for use in the coating composition of the invention III is a compound having at least one piece, preferably 1 to 15 pieces, more preferably 1 to 4 pieces, of oxetane rings represented as below,
• OXE oxetane compound
• Examples of such OXE include a compound represented by the following formula (4) , and compounds represented by the formulae (10), (11) and (12) shown hereinafter.
• R 6 represents a hydrogen atom, a fluorine atom, a straight-chain, branched-chain or cyclic alkyl group having 1 to 6 carbon atoms (such as methyl, ethyl, n- or i-propyl, n-, i- or t-butyl, pentyl, hexyl or cyclohexyl group), a straight-chain or branched-chain fluoroalkyl group having 1 to 6 carbon atoms (such as monofluoromethyl, difluoromethyl, trifluoromethyl, 2,2,2-trifluoroethyl, perfluoromethyl, perfluoropropyl, perfluorobutyl or perfluorohexyl), allyl group, aryl group (such as phenyl, naphthyl, tolyl or xylyl group), aralkyl group (such as benzyl or phenethy
• Examples of the mono- to tetravalent organic group that may be represented by R 7 include straight-chain, branched-chain or cyclic mono- to tetravalent hydrocarbon groups having 1 to 30 carbon atoms, which may contain at least one hetero atom selected from O, S, N and F and/or a siloxane linkage.
• examples of the monovalent group that may be represented by R 7 include: a straight-chain, branched-chain or cyclic alkyl group having 1 to 6 carbon atoms (such as methyl, ethyl, n- or i-propyl, n-, i or t-butyl, pentyl, hexyl or cyclohexyl group); a straight-chain or branched-chain alkoxyalkyl group having 1 to 6 carbon atoms (such as methoxyethyl, ethoxyethyl, butoxyethyl or ethoxymethyl group); a straight-chain or branched chain fluoroalkyl group having 1 to 6 carbon atoms (such as monofluoromethyl, difluoromethyl, trifluoromethyl, 2,2,2-trifluoroethyl, perfluoromethyl, perfluoropropyl, perfluorobutyl or perfluorohexyl group
• Examples of the divalent group that may be represented by R 7 include: a straight-chain, branched chain or cyclic alkylene group (in particular, an alkylene group having 1 to 15 carbon atoms such as methylene, ethylene, 1,2- or 1,3-propylene, butylene or cyclohexylene group); a (polylalkyleneoxy) group having 4 to 30, preferably 4 to 8, carbon atoms (such as poly(oxyethylene) or poly (propyleneoxy) group); phenylene group; xylilene group; groups represented by the following formulae (5) and (6):
• R 8 represents O, S, CH 2 , NH, SO, SO 2 , C(CF 3 ) 2 or C(CH 3 ) 2 )
• R 9 represents an alkylene group having 1 to 6 carbon atoms, an arylene group or a direct linkage); and a group having 2 to 30, preferably 2 to 6, carbon atoms, in which alkylene group and alkylene group are linked with (poly)siloxane chain (such as a group wherein the alkylene group is ethylene or propylene group, and the (poly)siloxane chain has a molecular weight of 130 to 15,000, preferably 130 to 500, which is preferably a group represented by the following formula (7)):
• Examples of tri- or tetravalent group which R 7 may represent include groups represented by the following formulae (8) to (11):
• R 10 represents an alkyl group having 1 to 6 carbon atoms, such as ethyl group
• R 11 are the same or different, and each represents an alkylene group having 1 to 6 carbon atoms, such as ethylene;
• R 12 are the same or different, and each represents a hydrogen atom, a fluorine atom, an alkyl group having 1 to 6 carbon atoms, a fluoroalkyl group having 1 to 6 carbon atoms, allyl group, aryl group, furyl group or thienyl group.
• the mono- to tetravalent organic groups which R 7 may represents is preferably mono- or divalent group (that is, p is preferably 1 or 2). Of those groups, preferred are an alkyl group having 1 to 6 carbon atoms such as methyl, ethyl, propyl, butyl or hexyl; allyl group; glycidyl group; vinyl group; analkoxyalkyl group having 1 to 6 carbon atoms such as ethoxyethyl and methoxyethyl; benzyl group; an alkylene group having 1 to 6 carbon atoms such as methylene, ethylene, propylene, butylene and hexylene; p-xylylene group; and a group represented by the following formula:
• R 6 is preferably hydrogen atom; an alkyl group having 1 to 6 carbon atoms such as methyl, ethyl, propyl, butyl or hexyl; or allyl group. Of those, hydrogen atom, methyl or ethyl is more preferable.
• the compound (OXE) having at least one oxetane ring in the molecule is preferably a compound having at least one oxetane ring and hydroxyl group, respectively, in the molecule (OXE-1) and a compound having at least two oxetane rings, or having oxetane ring and epoxy group, in the molecule.
• Examples of the oxetane compound (OXE-1) include a compound of the formula (4) wherein p is 1 and R 7 is hydrogen atom, particularly a compound represented by the following formula (4-1):
• R 61 represents a hydrogen atom, a fluorine atom, a straight-chain or branched-chain alkyl group having 1 to 6 carbon atoms, a straight-chain or branched-chain fluoroalkyl group having 1 to 6 carbon atoms or allyl group.
• a representative example of the compound represented by the formula (4-1) is a compound of the formula (4-1) wherein R is ethyl group.
• polyoxetane compound an example of the compound having at least two oxetane rings in the molecule (hereinafter this compound is referred to as “polyoxetane compound”) is a compound of the formula (4) wherein p is an integer of 2 to 4. Of those, a compound represented by the following formula (4-2) is particularly preferable.
• R 61 is the same as defined above
• R 71 represents di- to tetravalent organic groups as defined for R 7 in the formula (4)
• q is an integer of 2 to 4.
• a representative example of the compound represented by the formula (4-2) is a compound of the formula (4-2) wherein R 61 is ethyl group, and R 71 is 1,4-tetramethylene group, dodecamethylene group, o-, m- or p-xylylene group, a group of the formula (6) wherein R 9 is ethylene group, and a group of the formula (7).
• examples of the polyoxetane compound further include compounds represented by the following formula (12), (13) and (14):
• R 61 are the same or different, and are the same as defined above and are preferably ethyl group
• oxetane compound a compound having oxetane ring and epoxy group in the molecule (hereinafter, this compound is referred to as “epoxy group-containing oxetane compound”) includes a compound having one oxetane ring and one epoxy group in the molecule and preferably having a molecular weight of less than 1,000.
• epoxy group-containing oxetane compound includes a compound having one oxetane ring and one epoxy group in the molecule and preferably having a molecular weight of less than 1,000.
• a specific example of such a compound is a compound represented by the following formula (15):
• R 13 represents epoxy group-containing group
• R 61 is the same as defined above.
• a representative example of the epoxy group-containing oxetane compound is a compound represented by the formula (15) wherein R 61 is ethyl group and R 13 is glycidyl group or 3,4-epoxycyclohexylmethyl group.
• the oxetane compound (OXE) can be used alone or as a mixture of two or more thereof. Use of a combination of the compound (OXE-1) and the compound (OXE-2) is particularly preferable. Amounts of the compound (OXE-1) and the compound (OXE-2) when used in combination are such that the amount of the compound (OXE-1) used is 1 to 75 parts by weight, preferably 3 to 50 parts by weight, and the amount of the compound (OXE-2) used is 1 to 75 parts by weight, preferably 3 to 50 parts by weight, per 100 parts by weight of the total amount of the epoxy compound (A) and the epoxy compound (B).
• Copolymer (F) Containing at Least One Glycidyl Group and/or Alicyclic Epoxy Group in the Molecule
• Copolymer (F) for use in the coating composition of the invention III is a copolymer having at least one glycidyl group and/or alicyclic epoxy group in the molecule.
• Examples of alicyclic epoxy group-containing monomer which is a raw material of the copolymer include Cyclomer A200 and M100, products of Daicel Chemical Industries, Ltd.
• Other monomers copolymerizable with the epoxy group-containing monomer are monomers that are appropriately used, optionally, according to intended performances of the copolymer (F) obtained.
• the other monomers include C 1 -C 24 aklyl or cycloalkyl esters of acrylic acid or methacrylic acid, such as methyl methacrylate, ethyl methacrylate, methyl acrylate, ethyl acrylate, n-, i-or t-butyl acrylate, n-, i-or t-butylmethacrylate, hexyl acrylate, hexyl methacrylate, octyl acrylate, octyl methacrylate, lauryl acrylate, lauryl methacrylate, stearyl acrylate, stearyl methacrylate, cyclohexyl acrylate or cyclohexyl methacrylate; C 1 -C 8
• the copolymer (F) can be obtained by polymerizing monomer components comprising the epoxy group-containing monomer and optionally other monomers in the presence or absence of a radical polymerization initiator by a known polymerization method, such as solution polymerization, bulk polymerization, emulsion polymerization and suspension polymerization.
• the copolymer (F) has a number average molecular weight of 1,000 to 100,000, preferably 2,000 to 50,000.
• the amount of each monomer component in polymerization of the copolymer (F) is preferably within the following ranges based on 100 parts by weight of the sum of the monomer components.
• Epoxy group-containing monomer 10 to 95 parts by weight, preferably 20 to 80 parts by weight.
• Concentration of epoxy group in the copolymer (F) is 0.1 to 7.0 equivalents/kg, preferably 0.2 to 5.0 equivalents/kg.
• Cationic polymerization initiator (G) used in the invention III is a compound that generates cation by ultraviolet irradiation, thereby initiating polymerization.
• Examples of the cationic polymerization initiator include hexafluoroantimonates, pentafluorohydroxyantimonates, hexafluorophosphates, hexafluoroarsenates and other cationic polymerization initiators, represented by the following formulae (I) to (XV):
• Ar represents aryl group such as phenyl group
• X ⁇ represents PF 6 ⁇ , SbF 6 ⁇ or AsF 6 ⁇ ;
• R 20 represents an alkyl group having 1 to 12 carbon atoms or an alkoxy group having 1 to 12 carbon atoms, r is an integer of 0 to 3, and X ⁇ is the same as defined above;
• Y ⁇ represents PF 6 ⁇ , SbF 6 ⁇ , AsF 6 ⁇ or SbF 5 (OH) ⁇ ;
• R 21 represents an aralkyl group having 7 to 15 carbon atoms or an alkenyl group having 3 to 9 carbon atoms
• R 22 represents a hydrocarbon group having 1 to 7 carbon atoms or hydroxyphenyl group
• R 23 represents an alkyl group having 1 to 5 carbon atoms, which may contain oxygen atom or sulfur atom
• X ⁇ is the same as defined above;
• R 24 and R 25 each independently represents an alkyl group having 1 to 12 carbon atoms or an alkoxy group having 1 to 12 carbon atoms;
• cationic polymerization initiator commercially available products can also be used, and examples thereof include UVACURE1591 (a product of UCB, U.S.A.), CD-1010, CD-1011 and CD-1012 (products of Sartomer Co., U.S.A.), IRGACURE 264 (a product of Ciba Geigy AG) and CIT-1682 (a product of Nippon Soda Co.).
• the coating composition of the invention III can optionally contain lubricity-imparting agents; sensitizers; pigments or dyes, such as coloring pigment or extender pigment, added in an amount not substantially inhibiting the curing; modifying resins such as polyol resins, phenolic resins, acrylic resins, polyester resins, polyolefin resins, epoxy resins and epoxidized polybutadiene resins; organic resin fine particles; solvents; or the like, in addition to the components (A), (B), (F) and (G) that are essential components.
• lubricity-imparting agents such as polyol resins, phenolic resins, acrylic resins, polyester resins, polyolefin resins, epoxy resins and epoxidized polybutadiene resins
• modifying resins such as polyol resins, phenolic resins, acrylic resins, polyester resins, polyolefin resins, epoxy resins and epoxidized polybutadiene resins
• organic resin fine particles
• the lubricity-imparting agent is added for the purpose of improving lubricating property of a coating film obtained, and examples thereof include waxes such as fatty acid ester waxes that are an esterified product of polyol compound and fatty acid, silicone waxes, fluorine waxes, polyolefin waxes, animal waxes or vegetable waxes.
• waxes such as fatty acid ester waxes that are an esterified product of polyol compound and fatty acid, silicone waxes, fluorine waxes, polyolefin waxes, animal waxes or vegetable waxes.
• Examples of the polyol compound that is a raw material of the fatty acid ester waxes include ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3- or 1,4-butanediol, neopentyl glycol, 1,6 -hexanediol, glycerin, di- or more polyglycerin, trimethylpropane, pentaerythritol and dipentaerythritol.
• polyol compound having at least three hydroxyl groups in the molecule, and of the polyglycerin, trimethylol propane and pentaerythritol are more preferable.
• the fatty acid that is another raw material of the fatty acid ester waxes includes saturated or unsaturated fatty acids, and is preferably a fatty acid having 6 to 32 carbon atoms.
• Preferred specific examples of the suitable fatty acid include saturated fatty acids such as caprylic acid, pelargonic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachic acid, behenic acid, cerotic acid, montanic acid and melissic acid; and unsaturated fatty acids such as caproleic acid, undecylenic acid, palmitoleic acid, oleic acid, linoleic acid, linolenic acid, eleostearic acid, cetoleic acid, erucic acid, licanic acid ricinoleic acid and arachidonic acid.
• the fatty acid ester wax is preferably one in which at least 1 ⁇ 3 of the number of hydroxyl groups in the polyol compound is esterified with fatty acid.
• Examples of the silicon wax include BYK-300, BYK-320 and BYK-330 (products of BYK Chemie Co.); Silhouette L-77, Silhouette L-720 and Silhouette L-7602 (products of Nippon Unicar, Ltd.), Paintadd 29, Paintadd 32 and Paintadd M (products of Dow Corning Co.); and Shin-Etsu Silicone KF-96 (a product of Shin-Etsu Chemical Co.).
• Examples of the fluorine wax include Shamrock Wax SST-1MG, Shamrock Wax SST-3 and shamrock Wax Fluoroslip 231 (products of Shamrock Chemicals CO.), and POLYFLUO 120, 150 and 400 (products of Micropowders CO.).
• Examples of the polyolefin wax include Shamrock Wax S-394 and Shamrock Wax S-395(products of Shamrock Chemicals Co.); Hoechst Wax PE-520 and Hoechst Wax PE-521 (products of Hoechst AG); and Mitsui Hi-Wax (a product of Mitsui Chemical Industry Co.).
• Examples of the animal wax include lanolin and beeswax.
• Examples of the vegetable wax include carnauba wax and beeswax.
• the lubricity-imparting agents can be used alone or as a mixture of two or more thereof.
• the amount of the lubricity-imparting agent added is generally 10 parts by weight or less, preferably 0.1 to 5 parts by weight, more preferably 0.5 to 3 parts by weight, based on 100 parts by weight of the total amount of the compound (A) having alicyclic epoxy group and not having ester linkage in the molecule and the compound (B) having alicyclic epoxy group and ester linkage in the molecule.
• the silicon wax is excellent in a lubricity-imparting property before retort treatment after coating and curing are performed, and the fatty acid ester wax is excellent in lubricity-imparting property after retort treatment after coating and curing are performed. Therefore, it is preferable to add at least one kind of wax selected from the silicon wax and fatty acid ester wax.
• the sensitizer is added for the purpose of further improving curability by ultraviolet ray, and examples thereof include pyrene, perylene, acridine orange, thioxanthone, 2-chlorothioxanthone and benzoflavin.
• the sensitizer is used in an amount of generally 10 parts by weight or less, preferably 3 parts by weight or less, based on 100 parts by weight of the total amount of the epoxy compound (A) and the epoxy compound (B).
• the modifying resin is preferably used in an amount of generally 0.1 to 50 parts by weight, preferably 5 to 20 parts by weight, based on 100 parts by weight of the sum of the compound (A) having alicyclic epoxy group and not having ester linkage in the molecule, and the compound having alicyclic epoxy group and ester linkage in the molecule and/or epoxy compound (B) having glycidyl group.
• the modifying resins epoxidized polybutadiene resin is particularly effective for improving processability and adhesion of a coating film and the like.
• the organic resin fine particles preferably have a particle size of 50 to 500 nm, and are, for example, acrylic resin fine particles the inside of which is three-dimensionally crosslinked.
• the organic resin fine particles include fine particles obtained by pulverizing an organic polymer; fine particles obtained by drying and pulverizing polymer fine particles which are obtained by emulsion polymerizing in water in the presence of an emulsifier; and fine particles obtained by drying and pulverizing of polymer fine particles which are obtained by dispersion polymerization in an organic solvent in the presence of a polymeric stabilizer.
• Addition of the organic resin fine particles to the coating composition of the invention III can improve adhesion and processability of a coating film.
• the amount thereof is generally 0.1 to 50 parts by weight, preferably 1 to 10 parts by weight, based on 100 parts by weight of the total amount of the epoxy compound (A) and the epoxy compound (B).
• the coating composition of the invention III can be prepared by mixing each component described above, and stirring the resulting mixture so as to obtain a uniform coating composition.
• the coating composition can be prepared as follows. Each component is mixed, followed by optionally heating (e.g., at about 50° C.), and the resulting mixture is stirred with a dissolver or the like until a uniform coating composition is obtained, for example, by stirring it for about 10 minutes.
• the compound (A) having an alicyclic epoxy group and not having an ester linkage in the molecule the compound having alicyclic epoxy group and ester linkage in the molecule and/or epoxy compound (B) having glycidyl group, the copolymer (F) and the cationic polymerization initiator (G) are used in the amounts as described below.
• the alicyclic epoxy compound (A) can be used in an amount of 10 to 90 parts by weight, preferably 20 to 70 parts by weight, more preferably 30 to 60 parts by weight, and the compound (B) can be used in an amount of 10 to 90 parts by weight, preferably 30 to 80 parts by weight, more preferably 40 to 70 parts by weight, provided that the total amount of the compound (A) having alicyclic epoxy group and not having ester linkage in the molecule, and the compound having alicyclic epoxy group and ester linkage in the molecule and/or epoxy compound (B) having glycidyl group is 100 parts by weight.
• the sum of the compounds (A) and (B) is 100 parts by weight, if the amount of the alicyclic epoxy compound (A) is less than 10 parts by weight, a coating composition obtained has poor hardness and poor adhesion. On the other hand, if the amount of the alicyclic epoxy compound (A) exceeds 90 parts by weight, curability and retort resistance of a coating film by ultraviolet irradiation in low irradiation dose deteriorate.
• the amount of the copolymer (F) used is generally 1 to 50 parts by weight, preferably 3 to 30 parts by weight, more preferably 5 to 20 parts by weight, based on 100 parts by weight of the total amount of the alicyclic epoxy compound (A) having alicyclic epoxy group and not having ester linkage in the molecule, and the compound having alicyclic epoxy group and ester linkage in the molecule and/or epoxy compound (B) having glycidyl group.
• the amount of the copolymer (F) is less than 1 part by weight, hardness of the resulting coating film in hot water after post-heating is poor in the ultraviolet irradiation in low irradiation dose, and adhesiveness of the coating film, hardness of the coating film, and the like deteriorate.
• the amount of the copolymer (F) exceeds 50 parts by weight, curability by ultraviolet irradiation in low irradiation dose is particularly poor, and hardness of the resulting coating film and retort resistance decrease.
• the amount of the cationic polymerization initiator (G) used is generally 0.01 to 20 parts by weight, preferably 0.1 to 10 parts by weight, more preferably 1 to 5 parts by weight, based on 100 parts by weight of the total amount of the alicyclic epoxy compound (A) having alicyclic epoxy group and not having ester linkage in the molecule, and the compound having alicyclic epoxy group and ester linkage in the molecule and/or epoxy compound (B) having glycidyl group.
• the ultraviolet rays-curable can-coating composition of the present invention III has an ultraviolet rays curability.
• the coating composition can be applied to metal plates that are molded and processed into metal cans made of tinplate, aluminum, tin-free steel, iron, zinc, copper, zinc-plated steel plate, steel plate plated with an alloy comprising zinc and other metal, or the like (chemical treatment such as zinc phosphate treatment and chromate treatment may be applied to these metal plates); resin film-laminated metal plates obtained by laminating on the metal plates mentioned above a resin film such as a polyester resin (such as polyethylene terephthalate), a polyolefin resin (such as polyethylene and polypropylene), a polyamide resin, an epoxy resin, and a polyvinyl chloride resin; or metal cans formed from those metal plates, followed by irradiation with ultraviolet ray, thereby forming a cured coating film. Thickness of the coating film can appropriately be selected depending on the purposes of use, but the dry thickness thereof is
• the ultraviolet rays-curable can-coating composition of the invention III can be applied by a coating method such as roll coating, spray coating, brush coating, bar coat coating, roller coating and silk screen printing.
• a solvent is removed by heating or the like from the coating film after the coating process, and the coating film is then cured with ultraviolet irradiation.
• Irradiation conditions can appropriately be varied depending on the kind of the coating composition applied, thickness of the coating film formed, or the like. Wavelength of ultraviolet ray irradiated is generally within a range of 200 to 600 nm.
• Irradiation source having wavelength of high sensitivity can appropriately be selected and used in accordance with the kind or the like of the cationic polymerization initiator used.
• Examples of irradiation source of ultraviolet ray include high-pressure mercury lamp, ultrahigh pressure mercury lamp, xenon lamp, carbon-arc, metal halide lamp and sunlight.
• Irradiation conditions to the coating film are generally such that the amount of radiation is 10 to 1,000 mJ/cm 2 , preferably 50 to 500 mJ/cm 2 .
• the coating film may be optionally heated after ultraviolet irradiation.
• This heating makes it possible to reduce unreacted products in the coating film and to relax curability of the coating film by ultraviolet irradiation or strain of the coating film generated by molding and processing. In some cases, hardness or adhesion of the coating film can be improved by the heating.
• the heating can be conducted under the conditions of atmospheric temperature of 150 to 250° C. for 1 to 30 minutes.
• the ultraviolet rays-curable can-coating composition of the invention III contains the alicyclic epoxy compound (A) having alicyclic epoxy group and not having ester linkage in the molecule, the compound having alicyclic epoxy group and ester linkage in the molecule and/or epoxy compound (B) having glycidyl group, and the copolymer (F) as film-forming resin components, and can efficiently be cured by cationic polymerization even by ultraviolet irradiation in low irradiation dose in the presence of the cationic polymerization initiator (G), without requiring facilities such as nitrogen sealing.
• the coating film obtained from the composition are excellent in film performances, such as processability, adhesiveness, hardness and scratch resistance, which are required even for a thin film as a can coating material. Further, the coating composition can also form a coating film having excellent film appearance and retort resistance.
• the coating composition of the invention III is particularly suitable for use as a coating material for outer surface of a can.
• reaction was completed at the time when water was no longer distilled off.
• di(3,4-cyclohexenyl)methane was formed in a yield of 96%.
• the reaction solution obtained was washed with 500 ml of ion-exchanged water using a separatory funnel. An organic layer was then distilled under reduced pressure to obtain 269 g of colorless, transparent liquid di(3-4-cyclohexenyl)methane.
• Example I-1 100 g of 2,2-bis(cyclohexenyl)propane synthesized in Example I-1 was charged in the 1 liter flask with a jacket used in Example I-1. Then, 578.8 g of the aforementioned benzene solution of perpropionic acid was added dropwise for about 1 hour so that temperature in the reaction system becomes 30° C. After completion of the dropwise addition, the resulting mixture was aged at 30° C. for 4 hours. Further, the crude solution was washed with water at 40° C. and low boiling components were removed under 70° C./20 mmHg to obtain 81.8 g of an epoxy compound. Purity of 2,2-(3′,4′-epoxycyclohexyl)propane in the epoxy compound was 52%.
• epoxidation of the alicyclic olefin compound can be conducted efficiently and economically using a less toxic solvent.
• a heat-resistant sample composition was thermally cured at 120° C. for 1 hour and then at 160° C. for 3 hours (in Examples II-7 to II-8 and Comparative Example II-2, at 100° C. for 1 hour and then at 160° C. for 3 hours) to obtain a test piece*(length: 10 mm, width: 5 mm, thickness; 5 mm). Glass transition temperature of the test piece obtained was measured with thermomechanical measuring apparatus (TMA) (manufactured by Seiko Instruments Co.). The results obtained were evaluated by the following criteria.
• TMA thermomechanical measuring apparatus
• ⁇ 130° C. or higher and lower than 140° C.
• compositions having a glass transition temperature of 140° C. or higher have good heat resistance.
• a moisture resistant sample composition was thermally cured under the same conditions as in the sample for the heat resistance test above to obtain a test piece (length: 50 mm, width: 50 mm, thickness: 3 mm).
• This test piece was moistened with a pressure cooker (manufactured by Sabai Espec Corp.) under the conditions of 120° C., 2 atm: and 50 hours. Weight increase ratio of the test piece after moistening was obtained by the following equation.
• Weight increase ratio (%) (W ⁇ W 0 )/W 0 ⁇ 100
• W o is the weight of the test piece before moistening
• W is the weight of the test piece after moistening.
• Test pieces having weight increase ratio of less than 1.5% have good moisture resistance.
• An epoxy resin composition was thermally cured at 120° C. for 1 hour and then at 160° C. for 3 hours (in Examples II-7 to II-8 and Comparative Example II-2, at 100° C. for 1 hour and then at 160° C. for 3 hours) and molded to obtain a cured product having a thickness of 1 mm.
• Each component constituting an epoxy resin composition for photosemiconductor encapsulation of the invention II was blended in the respective proportion (parts by weight) shown in Table II-1, and uniformly mixed.
• each composition was cured in the same manner as in the Examples, and heat resistance, moisture resistance and light transmittance of the resulting cured product were measured in the same manners as in the Examples. The results obtained are shown in Table II-2.
• Celloxide 2021P (trade name) (CEL-2021P): a product of Daicel Chemical Industries, Ltd., 3,4-epoxycyclohexyl-3,4-epoxycyclohexane carboxylate, epoxy equivalent: 134
• EHPE-3150 a product of Daicel Chemical Industries,Ltd., an alicyclic epoxy resin, epoxy equivalent: 168
• TEPIC Triglycidyl isocyanurate
• Epikote 828 (trade name): a product of Yuka Shell Epoxy Co., a bisphenol A type epoxy resin, liquid at 25° C., epoxy equivalent: 187
• DBU 1,8-diazabicyclo[5.4.0]undecene-7
• the epoxy resin composition for photosemiconductor encapsulation of the invention II can provide a cured product having excellent heat and moisture resistance and transparency.
• the copolymer (F) obtained had a number average molecular weight of about 2,500 and an oxirane oxygen concentration of 1.4%.
• UVACURE-1591 sulfonium salt type cationic catalyst (a product of Daicel-UCB Co.)
• each of the coating compositions obtained in Examples III-1 to III-7 and Comparative Examples III-1 to III-2 was applied to a tin-free steel plate (TFS) having a thickness of 0.20 mm, and a PET steel plate composed of a tin-free steel plate having a thickness of 0.20 mm having thermo-compression bonded thereto a homo PET (polyethylene terephthalate) having a film thickness of 12 ⁇ m, in a dry thickness of 5 ⁇ m, and the coated plate was irradiated with ultraviolet ray by using a high pressure mercury vapor lamp (160 W/cm) placed at a distance of 15 cm from the coated plate so that energy dose becomes 80 mJ/cm 2 to thereby cure the coating film, thereby obtaining a coated test plate.
• TFS tin-free steel plate
• PET steel plate composed of a tin-free steel plate having a thickness of 0.20 mm having thermo-compression bonded thereto a homo PET (polyethylene terephthalate) having
• Pencil hardness Coating film of the coated test plate was subjected to pencil scratch test as defined in JIS K-5400, 8.4.2 (1990). Evaluation was made by a tear method.
• Impact resistance Falling weight having a diameter on point of impact of 3 ⁇ 8 inch and a weight of 500 g was fallen on a surface on the coated test plate opposite to the coated film from a height of 30 cm using a Du Pon't type impact tester according to JIS K-5400, 8.3.2 (1990) to conduct impact processing. The processed portion was observed with a microscope, and evaluated by the following criteria.
• Adhesion 100 squares of 1.5 mm ⁇ 1.5 mm are formed on a coated surface of a coated test plate according to a cross-cut tape method as defined by JIS K-5400, 8.5.2 (1990). An adhesive cellophane tape is adhered on the coated surface having 100 squares. After rapidly peeling off the tape from the coated surface, the state of the squares is evaluated by the following criteria.
• Hardness in hot water A coated test plate was heated at 200° C. for 1 minutes, and then dipped in a 80° C. hot water for 10 minutes. Pencil hardness of the coated test plate was measured in the 80° C. hot water.
• Leveling property Each coating composition was applied onto a PET steel plate with a roll coat method (natural coating) in a dry film thickness of 5 ⁇ m. Ultraviolet irradiation is conducted under the condition such that the process of from the coating to the ultraviolet irradiation takes 0.5 second, to thereby cure the coating film, and the coated surface at that time is visually evaluated. Evaluation was conducted by the following criteria.
• ⁇ Excellent smoothness, with no roll traces being observed on a coated surface.
• ⁇ Good smoothness, with only slight roll traces being observed on a coated surface.
• ⁇ Considerably poor smoothness, with considerable roll traces being observed on a coated surface.
• the ultraviolet rays-curable can-coating composition of the invention III can be cured by ultraviolet irradiation in low irradiation dose, and the resulting cured product has excellent film performances such as processability, adhesion, hardness, scratch resistance and the like, and in particular has excellent film appearance and retort resistance.

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