WO2006085839A1 - Revêtements durcissables par rayonnement sans solvant et non polluants - Google Patents

Revêtements durcissables par rayonnement sans solvant et non polluants Download PDF

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Publication number
WO2006085839A1
WO2006085839A1 PCT/US2005/002891 US2005002891W WO2006085839A1 WO 2006085839 A1 WO2006085839 A1 WO 2006085839A1 US 2005002891 W US2005002891 W US 2005002891W WO 2006085839 A1 WO2006085839 A1 WO 2006085839A1
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group
coating composition
weight
carrier medium
parts
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PCT/US2005/002891
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English (en)
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Ramkrishna Ghoshal
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Polyset Company, Inc.
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Priority to PCT/US2005/002891 priority Critical patent/WO2006085839A1/fr
Publication of WO2006085839A1 publication Critical patent/WO2006085839A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
    • 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
    • C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
    • C09D183/04—Polysiloxanes
    • C09D183/06—Polysiloxanes containing silicon bound to oxygen-containing groups

Definitions

  • the present invention relates to solventless siloxane epoxy compositions, and more particularly to solventless siloxane epoxy compositions that are curable by U. V. or electron beam radiation.
  • High performance metal, plastic, wood, and glass coatings are used in both indoor and outdoor applications, such as in building products, appliances, transports, inkjet recording, etc. Due to increasingly more stringent emission rules and increasing energy costs associated with coating conversion and pollution controls, it is preferable that such coatings contain 100% solids and no volatile organic compounds (zero VOCs). Unfortunately, however, most of the non- polluting coating systems currently being used last only about 30 years.
  • thermal curing coating chemistries are based on solution, emulsion, or dispersion of solid resins or very high viscosity resins (high molecular weight thermoplastic or thermostat resins), which involve very little or no curing (solidification). Conversion to the solid state, which provides tack-free, dry coatings can be completed quickly by simply evaporating the solvent from the solid resin solution. Thus, the present state-of-the-art thermal systems employ this technique.
  • one disadvantage associated with this type of solid/high viscosity resin is that the use of solvents or co-solvents is required, and thus, the materials contain VOCs.
  • low molecular weight, low viscosity monomers can also evaporate from the line, especially when heated at high temperatures and when present in thin films.
  • the coating line will still generate organic vapor emission of a different kind, i.e. from the monomers.
  • U. V. curable coatings which are 100% solids, zero VOC, are disadvantageous because they can be used only for non-pigmented coatings or thin film pigmented applications.
  • performance of such U. V. curable coatings is in general inferior to that of thermally cured coatings in the areas of adhesion, U.V. stability, corrosion resistance, and weatherability, which are very important properties for use in building products and in automotive applications.
  • Electron beam (E-beam or E.B.) curable coatings which contain 100% solids and zero VOC, can be used for pigmented coatings, but current E-beam coatings suffer from the same performance limitations as do U.V. curable coatings, when compared with thermal systems. This is largely because the same resin and curing chemistries (acrylates) are employed in existing E-beam curable coatings as in the U.V. materials. Additional costs incurred with radiation (both U.V. & E-beam) curable acrylate coatings include those associated with the use of nitrogen blanketing.
  • Alternate available cationic curing (U.V. & E.B.) epoxy chemistry coating compositions do not require nitrogen blanketing, but the cure rates of currently available epoxies are very slow when compared with acrylates.
  • a soft, tacky surface is left outside the area irradiated by the beam, which is unacceptable in a high speed, low dose line.
  • various processing and performance limitations have made them undesirable for use in Original Equipment Manufacture (OEM) markets, such as in appliances, building products, and automotives, etc.
  • OEM Original Equipment Manufacture
  • radiation curable (U.V. & E.B.) coatings have not been a good alternate technology for providing zero VOC, pollution-free coatings for coil coatings and printing inks.
  • current filled and pigmented coatings typically include the use of an environmentally unfavorable chromate filler in order to pass corrosion testing.
  • the viscosities of the monomers and oligomers should be low enough to formulate a highly filled and/or pigmented or dye-containing coating without the use of any solvents, and the coating should also be able to meet the application viscosity (less than 3000 cps) of a high speed reverse roll coating system, i.e. greater than 400 FPM.
  • the coatings should meet industry standards for each of the application areas in terms of adhesion, flexibility, gloss, weathering, corrosion, etc.
  • the coating chemistry should be suitable for high speed, low dose E-beam and U.V. cure lines, such that the materials can be immediately used or rolled into coils without any coating lift up problem, with or without nitrogen blanketing.
  • the present invention meets the aforementioned needs and avoids the problems associated with available metal, plastic, wood, or glass coatings.
  • the invention is predicated on the unexpected discovery of a new cationically curable resin chemistry based on novel siloxane epoxy resins. These novel resins can be cured by U.V. or E-beam radiation and can be cured in air without the need for nitrogen blanketing. This is advantageous because the cost of maintaining an inert atmosphere can contribute substantially to the overall cost of curing by radiation.
  • the compositions can be immediately rolled into coils without any coating lift up problem.
  • the coatings of the present invention are solventless and therefore, contain zero VOCs, making them desirable for use in industry because they do not present any health hazards before polymeric conversion.
  • the unique resins of the present invention are surprisingly superior to currently available coatings because they contain 100% solids, can be cured by high speed, low dose, E-beam or U.V. radiation and can be used as metal, plastic, wood, or glass coatings for both indoor and outdoor applications and for inkjet media.
  • Other advantages of the present compositions over currently available resins include excellent and improved cured film properties, such as exhibiting good adhesion, flexibility (tough without being brittle), weatherability, and unexpectedly good corrosion resistance even in the absence of a chromium-containing filler.
  • the coating compositions may be clear or may contain fillers, dyes, pigments, and/or other additives. Accordingly, in one aspect, the present invention is a clear coating composition comprising from about 90 to about 100 parts by weight of a base resin; from 0 to about 3 parts by weight of an adhesion promoter and from about 2 to about 10 parts by weight of a cationic polymerization initiator, based on the total weight of the composition.
  • the base resin comprises:
  • m is an integer having a value from 5 to 50;
  • the cationic polymerization initiator is selected from the group consisting of (i) at least one sulfonium salt catalyst in solution with a first carrier medium; (ii) a diaryliodonium salt catalyst in solution with a second carrier medium; and (iii) mixtures of (i) and (ii).
  • the present invention is a coating composition
  • a coating composition comprising from about 15 to about 75 parts by weight of the aforementioned base resin; from about 10 to about 85 parts by weight of one or more components selected from the group consisting of fillers, dyes, pigments, and additives; from 0 to about 1 part of an adhesion promoter and from about 1 to about 10 parts by weight of a cationic polymerization initiator, as previously described.
  • Formulations containing fillers, dyes and/or pigments, as well as any of the other aforementioned components, are useful on metal as primers or topcoats and on plastic as printing inks, for example.
  • the invention is a method for manufacturing a coated article.
  • the first step of the method involves applying either the aforementioned clear coating composition or the coating composition containing fillers, dyes or pigments, and/or additives diluents to an article made of wood, glass, plastic, or metal.
  • the composition deposited on the article is exposed to E-beam or U.V. radiation.
  • the coated article may be heated to a temperature ranging from about 80 0 C to about 125° C.
  • the invention is a coated article manufactured by the previously described method.
  • the present siloxane epoxy coating compositions include a base resin, an optional adhesion promoter and a cationic polymerization initiator.
  • the filled coatings also include fillers, pigments, and/or dyes, and may contain other additives, such as anti-setting agents, anti-foaming agents, flow- control agents, wetting agents, etc.
  • These epoxy resin coatings can be cured by E- beam or U.V. radiation (also referred to herein as "actinic radiation”) to give the desired processing parameters and excellent cured film properties described herein in terms of adhesion, flexibility, weatherability, corrosion resistance, etc.
  • the base resin includes a cycloaliphatic epoxy functional siloxane monomer having structure (IA), a cycloaliphatic epoxy functional siloxane oligomer having structure (IB), one or more non-silicon containing epoxy resins, and optional flexibilizers.
  • the clear, unfilled coating compositions contain from about 90 to about 100 parts by weight of the base resin based on the total weight of the formulation, and the dye-containing, pigmented, and/or filled compositions contain from about 15 to about 75 parts by weight of the base resin relative to the total weight of the formulation.
  • Cycloaliphatic epoxy functional siloxane monomer having structure (IA) has the chemical name l,l,3,3-tetramethyl-l,3-bis[2-(7-oxabicyclo[4.1.0]hept-3- yl)ethyl] disiloxane and has a molecular weight of 376 g/mole.
  • Siloxane (IA) is commercially available from Polyset Company Inc., Mechanicville, New York as PClOOO.
  • cycloaliphatic epoxy functional siloxane (IA) is incorporated into the base resin in amounts ranging from about 30 to about 55 parts by weight of the total base resin, and siloxane (IB), in amounts ranging from about 5 to about 30 parts by weight.
  • non-silicon-containing epoxy resins include epoxidized vegetable oils and epoxidized vegetable oil esters, such as VIKOFLEX® 9010, which is a methyl epoxy linseedate available from Atof ⁇ na Chemicals. Inc.
  • EECH 3,4- epoxycyclohexylmethyl-3',4'-epoxycyclohexane carboxylate
  • EECH 3,4- epoxycyclohexylmethyl-3',4'-epoxycyclohexane carboxylate
  • EECH has structure (HA) and is commercially available from Union Carbide as ERL 4221.
  • the base resin may include up to about 60 parts by weight of one or more flexibilizers, which provide flexibility to the compositions.
  • Suitable flexibilizers include epoxides based on a diglycidyl ether of bisphenol A, which are represented by structure (IIB):
  • n in structure (IIB) is 0 or about 0.07, 0.14, 2.3 or 4.8.
  • examples include ARALDITE® 6084 and ARALDITE® 6097, which are available from Ciba Geigy in solid form.
  • VIKOLOX® 14 which is a C- 14 epoxidized alpha olefin available from Elf Atochem, is another suitable flexibilizer.
  • Polyol flexibilizers such as caprolactan triol available from Solvay Interox, Inc. as C AP A® 4101 (previously sold as C AP A® 316) are also suitable.
  • C AP A® 4101 has the chemical name 2-oxepanone and is a polymer of 2-2-bis(hydroxymethyl)-l, 3-propanediol having the chemical formula (C 6 Hi 0 O 2 C 5 Hj 2 O 4 ).
  • Additional useful flexibilizers include thermoplastic acrylic resins, such as DEGALAN® 64/12 and DEGALAN® P24, which are available from Rohm; limonene oxides, such as limonene dioxide available from Elf Atochem; elastomers; and phenoxy resins.
  • Multifunctional hydroxyl-terminated epoxidized polybutadiene resins such as Poly bd® 600E and 605E available from Sartomer are also suitable.
  • Allyl ethers including, but not limited to, propenyl ethers available from International Specialty Products (ISP), BASF, etc., are also useful flexibilizers.
  • vinyl ethers such as Rapi-Cure CHVE (cyclohexane dimethanolvinylether), DDVE (n- dodecylvinylether), HBVE (4-hydroxybutylvinylether) and DVE-3 (triethyleneglycol divinylether) available from ISP may be used.
  • flexibilizers include carboxyl-terminated polybutadiene or carboxyl-terminated polybutadiene acrylonitrile of molecular weight 3000-5000 available as HYCARTM CTB-2000xl62 and CTBN 1300x31, respectively, from Noveon; and phenolic antioxidants, such as Ciba-Geigy's IrganoxTM 1035 (thiodiethylene bis (3,5-di-tert- butyl-4- hydroxyhydrocinnamate). Oxetane monomers available from Toagosei Co.
  • OXT 121 which is l,4-bis[(3-ethyl-3- oxetanylmethoxy)methyl]benzene
  • DOX OXT 221
  • Other suitable flexibilizers would be obvious to those of skill, and the invention is not limited to the flexibilizers described herein.
  • the present compositions may optionally include an adhesion promoter.
  • an adhesion promoter In clear formulations, up to about 3 parts by weight of the adhesion promoter may be added for improved adhesion to metal. However, in filled, pigmented or dye-containing compositions, up to about 1 part by weight is sufficient to provide good adhesion to the cured films.
  • adhesion promoters include, but are not limited to, epoxy alkoxysilanes, such as 2-(3,4- epoxycyclohexyl)-ethyl trimethoxysilane and 3-glycidyloxypropyltrimethoxysilane, both of which are available from Witco Corporation as A186 and A187, respectively.
  • the filled, dye-containing or pigmented coating formulations also contain from about 10 to about 85 parts by weight fillers, dyes, pigments, and/or other additives, such as anti-setting agents, flow control agents, antifoaming agents, wetting agents, etc.
  • additives such as anti-setting agents, flow control agents, antifoaming agents, wetting agents, etc.
  • examples of such ingredients include, but are not limited to, dyes, such as phthalo blue, carbon black, and the like; titanium dioxide pigments, such as TiO 2 2160, TiO 2 2310, TiO 2 2020, and the like available from Kronos, Inc.
  • talc magnesium silicate hydroxide
  • Nytal 300 which is available from R.T.Vanderbilt
  • ceramic microspheres such as ZeospheresTM microspheres, available from 3M as G-400 and G-200
  • antifoaming agents fluoride
  • BYK® 501 available from BYK Chemie USA, Inc.
  • wetting agents such as Silwet ® L-7604 available from OSI Specialities
  • grinding agents such as BYK® 307, available from BYK Chemie USA, Inc.
  • hydrophobic fumed silica such as Aerosil® R972, available from Degussa-Huls
  • barytes (BaSO 4 ) including synthetic barytes, such as CimbarTM EX and natural barytes, such as Mineral and Pigment Solutions' (MPSI) 4721 (particle size 1 ⁇ ).
  • inorganic particulate or flake fillers may be included.
  • conductive metallic fillers such as copper or silver particles and silver flakes, such as AAR-0595 from Chemet, may be included in the formulations for use as conductive inks.
  • Nonconductive inorganic metallic fillers, such zinc may also be included. Substitution with other similar fillers, pigments, dyes, and other additives will be obvious to those of skill in the coating arts.
  • One unexpected and surprising advantage of the present pigmented/filled compositions over currently available primer and topcoat resins is that excellent corrosion resistance is exhibited even in the absence of a chromate or phosphate additive.
  • current commercial coatings must include such anticorrosion ingredients, such as zinc chromate, strontium chromate, zinc phosphate, or strontium phosphate to pass corrosion testing. Because the use of these materials is an important environmental concern, elimination thereof in the compositions described herein makes the present coatings far more desirable than any coatings previously available.
  • the clear formulations contain from about 2 to about 10 parts by weight of the cationic polymerization initiator solution based on the total weight of the composition, and the filled/dye-containing/pigmented coatings include for curing from about 1 to about 10 parts by weight of the cationic polymerization initiator solution.
  • the cationic polymerization initiator includes one or more sulfonium salt catalysts in solution with a first carrier medium.
  • sulfonium salt catalysts may be used, such as the mixture of triarylsulfonium salts having the general structures (V) and (VI)
  • a ' is a non-nucleophilic anion, commonly [BF 4 ] “ , [PF 6 ] “ , [AsF 6 ] “ , [SbF 6 ] “ , [B(C 6 F 5 ) 4 ] ' , or [Ga(C 6 Fs) 4 ] “ .
  • a negatively charged moiety is conventionally indicated herein by a minus sign, either in a circle or without the circle. Each symbol is used interchangeably, and may be positioned as a superscript relative to the moiety.
  • a positively charged moiety is denoted by a plus symbol, with or without the circle.
  • An especially suitable mixture of triarylsulfonium salts for use in polymerizing the present compositions is the mixture of of S,S-diphenyl-4- thiophenoxyphenylsulfonium hexafluoroantimonate having structure (VA) and bis(diphenylsulfonio)-4,4'-diphenylsulfide bishexafluoroantimonate having structure (VIA).
  • This triarlysulfonium salt mixture is commercially available from Polyset Company as PC-2505 or from Dow Chemical as CyracureTM 6974.
  • a mixture of S,S-diphenyl-4-thiophenoxyphenylsulfonium hexafluorophosphate having structure (VB) and bis(diphenylsulfonio)-4,4'- diphenylsulf ⁇ de bishexafluorophosphate having structure (VIB) may be used to polymerize the present compositions.
  • This triarlysulfonium salt mixture is commercially available from Polyset Company as PC-2514.
  • Suitable sulfonium salt catalysts for use in the cationic polymerization initiator include dialkylphenylacylsulfonium salts having formula (IV)
  • R 1 is a Ci to C 30 monovalent organic radical
  • R 2 is a Ci to C 30 monovalent organic radical, or R 1 and R 2 taken together may form a 5 or 6-membered ring
  • R 3 is C 6 to C 2 o alkyl, aryl, C 6 to C 20 substituted alkyl or substituted aryl
  • R 4 is hydrogen or Ci to C 8 alkyl
  • a ' is a non-nucleophilic anion, such as one previously listed.
  • R 2 may also be a photosensitizing residue.
  • Preferred compounds of structure (IV) are those in which the non-nucleophilic anion A " is one of the ones previously listed; R 3 is aryl or substituted aryl; R 4 is hydrogen; R 1 is C H to C 30 alkyl, aryl, Ci 4 to C 30 substituted alkyl of substituted aryl; and R 2 is Ci to C 30 alkyl, aryl, Ci to C 30 substituted alkyl or substituted aryl.
  • R 3 groups are phenyl; indan-l-one-2-yl; ⁇ -tetralone-2-yl; biphenylyl; naphthyl; perylenyl, pyrenyl, anthracenyl, tetracenyl, coronenyl, benzoylphenyl, 9-oxothioxanthenyl; and phenyl substituted with halogen, nitro or alkoxy.
  • R 4 is hydrogen.
  • R 3 is phenyl
  • R 1 is C 8 to C 30 , preferably C 4 to C 30 , alkyl
  • R 2 is lower alkyl
  • R 4 is hydrogen.
  • dialkylphenacylsulfonium salts are fully described in U.S. Pat. No. 6,031,014 to Crivello issued Feb. 29, 2000.
  • Another suitable sulfonium salt catalyst is that of structure (VII), which is commercially produced by Asahi Denka
  • each sulfonium salt catalyst or mixture thereof is present in solution with a first carrier medium.
  • exemplary carriers include propylene carbonate and monomers such as 3,4-epoxycyclohexylmethyl-3',4'- epoxycyclohexane carboxylate (EECH)(structure (HA)) and bis(3,4- epoxycyclohexyl) adipate.
  • EECH 3,4-epoxycyclohexylmethyl-3',4'- epoxycyclohexane carboxylate
  • HA structure
  • bis(3,4- epoxycyclohexyl) adipate bis(3,4- epoxycyclohexyl) adipate.
  • An exemplary preferred cationic polymerization initiator comprises a catalyst solution containing about 50 wt. % of one of the mixtures of triarylsulfonium salts previously described, i.e. (i) S,S-diphenyl-4-thiophenoxyphenylsulfonium hexafluoroantimonate having structure (VA) and bis(diphenylsulfonio)-4,4'- diphenyl sulfide bishexafluoroantimonate having structure (VIA); or (ii) S, S- diphenyl-4-thiophenoxyphenylsulfonium hexafluorophosphate having structure (VB) and bis(diphenylsulfonio)-4,4'-diphenylsulfide bishexafluorophosphate having structure (VIB).
  • the catalyst solution is about 50 wt. % of one of the aforementioned carrier mediums.
  • the catalyst solution is about 50 wt.% of the mixture of salts having structures (VA) and (VIA) and about 50 wt. % propylene carbonate.
  • the cationic polymerization initiator is a diaryliodonium salt catalyst of structure (III) in solution with a second carrier medium.
  • This catalyst solution may be used alone to polymerize the formulations or in a blend with one of the aforementioned sulfonium salt catalyst solutions.
  • Structure (III) is represented as:
  • R is methyl or hydrogen
  • y is 0 or an integer from 1 to 25.
  • the methyl substituent may be located at any position of the aryl ring, i.e., at the 2, 3, or 4-carbon relative to the carbon attached to the iodine atom, which is identified as the 1 -carbon.
  • the 2-, 3-, and 4-carbon positions are also known as ortho-, meta-, and para-, as anyone of ordinary skill would know.
  • a ' is a non- nucleophilic anion, such as one of the ones previously listed.
  • diaryliodonium salt catalysts are: [4-(2 -hydroxy- 1- tetradecyloxy)-phenyl] phenyliodonium hexafluorophosphate having structure (IIIA); [4-(2 -hydroxy- 1 -tetradecyloxy)-phenyl] 4-methylphenyliodonium hexafluorophosphate having structure (UIB); [4-(2 -hydroxy- 1 -tetradecyloxy)- phenyl] phenyliodonium hexafluoroantimonate having structure (HIC); and [4-(2- hydroxy- 1 -tetradecyloxy)-phenyl] 4-methylphenyliodonium hexafluoroantimonate having structure (HID):
  • the fluorophosphate and fluoroantimonate diaryliodonium salt catalysts having structures (IIIA), (IIIB), (IIIC), and (HID) are commercially available from Polyset Company, respectively, as PC-2508, PCX-2519, PC-2506, and PCX-2509.
  • the most preferred fluorophosphate diaryliodonium salt is that of structure (HIA)
  • the most preferred fluoroantimonate diaryliodonium salt is that of structure (IIIC).
  • the diaryliodonium salt catalyst is separately dissolved in a second carrier medium, which may be the same as or different from the first carrier medium.
  • a second carrier medium such as 3,4-epoxycyclohexylmethyl-3',4'-epoxycyclohexane carboxylate (structure (HA), or bis(3,4-epoxycyclohexyl) adipate may be used.
  • An exemplary iodonium catalyst solution contains about 40 wt. % of the diaryliodonium salt and about 60 wt. % the corresponding carrier medium, which is typically 3,4- epoxycyclohexylmethyl-3',4'-epoxycyclohexane carboxylate (structure (HA).
  • the cationic polymerization initiator may be a blend or mixture of the sulfonium salt catalyst solution and the diaryliodonium salt catalyst solution.
  • One such exemplary initiator contains equal parts by weight of: (i) a first catalyst solution comprising about 50 wt. % of a mixture of S,S-diphenyl-4-thiophenoxyphenylsulfonium hexafluoroantimonate having structure (VA) and bis(diphenylsulfonio)-4,4'-diphenylsulfide bishexafluoroantimonate having structure (VIA) and about 50 wt.
  • a second catalyst solution comprising about 40 wt. % [4-(2 -hydroxy- 1 -tetradecyloxy)-phenyl] phenyliodonium hexafluoroantimonate having structure (IIIC) and about 60 wt. % 3,4-epoxycyclohexylmethyl- 3',4'-epoxycyclohexane carboxylate.
  • the invention is not limited to the use of this mixture, and many other blends of sulfonium salt catalyst solutions and diaryliodonium salt catalyst solutions using the catalysts and carrier mediums disclosed herein may be used, as one of ordinary skill in the coating arts would know.
  • the cationic polymerization initiator may contain an all sulfonium salt catalyst, an all diaryliodonium salt catalyst, or a mixture of sulfonium and iodonium salt catalysts.
  • the initiator is a mixture, equal parts by weight (50/50 wt. %) of the sulfonium salt catalyst solution and the diaryliodonium salt solution are generally employed.
  • the formulations of the present invention may be cured by U. V. or E-beam radiation. However, it should be noted that in some situations, the film may be slightly soft immediately after curing. The composition may then be baked in air at a temperature and time sufficient to obtain a film with desirable properties.
  • postbake refers to such a drying step. A typical postbake, which raises the substrate temperature to about 80 0 C-125 0 C for a period ranging from about 15 minutes to about an hour, is therefore often preferred for improving the properties of the cured films. Generally, an improvement in adhesion is observed regardless of the type and source of the substrate. However, it should be noted that the postbake is optional and is typically used simply to reduce the time after curing that improved film properties can be observed.
  • the amount and the identity of the cationic polymerization initiator can be adjusted accordingly.
  • an all sulfonium salt catalyst solution, an all diaryliodonium salt catalyst solution, or a blend thereof may be used for both U.V. curing and E-beam curing-with or without a postbake.
  • sulfonium salt catalysts are generally more efficient compared with diaryliodonium salts, even though diaryliodonium salt catalysts are less expensive.
  • diaryliodonium salts are more efficient as a curing catalyst.
  • compositions containing an all diaryliodonium salt catalyst can be cured by E-beam at a 2-3 Mrad dosage lower than that needed to cure compositions containing an all sulfonium salt catalyst.
  • sulfonium salts, diaryliodonium salts, or a combination thereof perform equally well in both U.V. and E-beam curing, with or without postbake.
  • E-beam curing with or without postbake is the preferred curing process.
  • Formulations containing dyes or low levels of pigmentation or containing semi-transparent fillers (fillers with very low hiding power), such as silicas, brytes, talcs, etc. may be cured by U.V. radiation with or without postbake using a U.V.
  • H-bulb basic mercury lamp
  • other mercury lamps such as a D-bulb or a V-bulb are suitable, as would be obvious to one of ordinary skill.
  • the following Table provides exemplary amounts (parts by weight) of the cationic polymerization initiator needed for curing the formulations by U.V. or E- beam radiation when the initiator contains either an all sulfonium salt catalyst or an all iodonium salt catalyst.
  • the Table is included for illustrative purposes only, and the invention is not limited to the listed amounts or to the particular catalysts, as one of skill would know.
  • “Sulfonium” refers to a 50/50 (wt. %) solution of PC-2505 in propylene carbonate
  • Diaryliodonium refers to a 40/60 (wt. %) solution of PC-2506 in 4221 (EECH).
  • sulfonium salt catalyst solution and of the diaryliodonium salt catalyst solution are typically employed such that the total parts by weight of the cationic polymerization initiator in the final formulation does not exceed 10 parts by weight, but preferably does not exceed the upper limits listed in the Table.
  • the resulting films after curing by E-beam or U.V. radiation using an all sulfonium salt catalyst, an all diaryliodonium salt catalyst or blend thereof exhibit good adhesion and are dry without being brittle.
  • the present invention also includes a method for manufacturing a coated article, as well as the coated article manufactured by the method.
  • article includes a wood, glass, plastic, or metal substrate.
  • Applications include, but are not limited to, decorative, insulating, and protective coatings on such materials, as well as coatings on plastic for use in inkjet printers and Radio Frequency Identification (RFID) Tags, to name a few.
  • RFID Radio Frequency Identification
  • a filled/pigmented/dye-containing or unfilled, clear formulation, as described herein, is first deposited onto the article by conventional techniques known in the art, such as spray or roll coating.
  • the composition applied to the article is cured by being exposed to E-beam radiation, typically ranging from about 3 to about 12 Mrad or to U. V. radiation, typically at a dose ranging from 500-2000 mJ/cm 2 and at a wavelength ranging from about 100 nm to about 400 nm.
  • the coated article may be subjected to a postbake step to improve the properties of the coating.
  • the composition is polymerized to > 90%.
  • the catalyst solutions and blends included in both the i ⁇ lled/pigmented and unfilled, clear formulations may be adjusted according to the type of curing desired. Exemplary embodiments are found in, but not limited to, the formulations provided in the examples provided herein.
  • lamps are medium or high pressure mercury arc lamps, such as H bulbs, D bulbs, or V bulbs.
  • Post-curing denoted in the examples as “postbake”, was done in an airflow convection oven (15 min. to 1 hour at 125 0 C PMT).
  • AL 36 refers to a Q-Panel of aluminum with a chromate pretreatment
  • R 36-1 refers to a Q-Panel of steel with Bondrite 1000 iron phosphate P60 chrome and deionized water rinse. No surface pre-treatment was done on the substrates other than cleaning the surface with methylene chloride or isopropanol or whatever was performed by metal panel suppliers.
  • the viscosity of some of the formulations was measured prior to curing.
  • the double rub test the number listed in the examples indicates how many cycles the material was rubbed from side to side in the presence of a solvent (methyl ethyl ketone-MEK) without any deterioration of the material. All formulations passed this test.
  • “pass” indicates that the material stayed adhered to the substrate and that there was no cracking. In contrast, "fail” would have indicated that the material cracked or delaminated from the panel.
  • the thickness of the films on the substrates ranged from about 0.5 to about 1.0 mm.
  • the formulations provide the desirable processing parameters and film properties described herein.
  • PC- 2505 (50%) refers to a 50/50 (wt. %) solution of PC-2505 in propylene carbonate
  • PC-2506 (49%) refers to a 40/60 wt. % solution of PC-2506 in 4221 (EECH).
  • EXAMPLE 3 E-beam Cure 8] Formulations containing the following components were prepared, cured, and tested:
  • Example 6 The formulations in Example 6 are curable by U. V. radiation (500- 1500 mJ/cm 2 , H-bulb) or by E-beam radiation (6-12 Mrad, 120 Kv) with or without a postbake (15 min. at 125 0 C) over metal, glass, or plastic substrates. Adhesions, solvent resistances, and pot life at 60-80 0 C were very good, meeting industry requirements.
  • Example 7 The formulations in Example 7 are curable by U. V. radiation (1000-2000 mJ/cm 2 , H-bulb) or by E-beam radiation (6-12 Mrad at 120 Kv) with or without a postbake (15 min. at 125 0 C) on various substrates, but particularly on plastics or films for RFID. tags.
  • a sulfonium salt catalyst e.g. PC-2505
  • PC-2506 is preferred for systems needing high temperature (60-80 0 C) stability, whereas for screen printing applications where no high temperature pot life is needed, a diaryliodonium salt catalyst, such as PC-2506 is preferred, particularly for E-beam cure with or without postbake or U.V. plus postbake cure.
  • Example 7 The formulations of Example 7 are altered by replacing part or all of the silver flakes with silver or silver-coated copper nanopowder of appropriate particle sizes ( ⁇ 100 nm), such as that available from Sigma- Aldrich. This avoids the problem of clogging the ink jet application head with silver flakes.
  • the formulations may be cured as described in Example 7.
  • Base resin (II) having the following composition was prepared:
  • Methyl ethyl ketone (MEK) (double rub) (ASTM D 5402-93)
  • Base resin (III) having the following composition was prepared:
  • Methyl ethyl ketone (MEK) (double rub) (ASTM D 5402-93)
  • Base resin (IV) having the following composition was prepared:
  • a "monovalent organic radical” refers to any residue that can be covalently attached to a sulfur and subsequently reacted with an .alpha.-haloketone to produce an acyl sulfonium salt.
  • Preferred Ci 4 to C 30 monovalent organic radicals and Ci to C 30 monovalent organic radicals of the claimed invention include alkyl, alkenyl, and alkynyl residues, aryl residues, arylalkyl residues, and oxygenated derivatives thereof.
  • Alkyl is intended to include linear, branched, or cyclic hydrocarbon structures and combinations thereof.
  • Lower alkyl refers to alkyl groups of from 1 to 4 carbon atoms. Examples of lower alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, s-and t-butyl and the like. Preferred alkyl groups are those of C 30 or below.
  • Cycloalkyl is a subset of alkyl and includes cyclic hydrocarbon groups of from 3 to 8 carbon atoms. Examples of cycloalkyl groups include c-propyl, c-butyl, c-pentyl, c-hexyl, norbornyl and the like.
  • Alkoxy or "alkoxyl” refers to groups of from 1 to 20 carbon atoms of a straight, branched, cyclic configuration and combinations thereof attached to the parent structure through an oxygen. Examples include methoxy, ethoxy, propoxy, isopropoxy, cyclopropyloxy, cyclohexyloxy and the like. “Lower-alkoxy” refers to groups containing one to four carbons.
  • Acyl refers to groups of from 1 to 8 carbon atoms of a straight, branched, cyclic configuration, saturated, unsaturated and aromatic and combinations thereof, attached to the parent structure through a carbonyl functionality. Examples include acetyl, benzoyl, propionyl, isobutyryl, t-butoxycarbonyl, benzyloxycarbonyl and the like. “Lower-acyl” refers to groups containing one to four carbons.
  • Aryl and “heteroaryl” mean a 5- or 6-membered aromatic or heteroaromatic ring containing 0-3 heteroatoms selected from O, N, or S; a bicyclic 9- or 10- membered, partially or fully aromatic or heteroaromatic ring system containing 0-3 heteroatoms selected from O, N, or S; or a tricyclic 13- or 14-membered partially or fully aromatic or heteroaromatic ring system containing 0-3 heteroatoms selected from O, N, or S.
  • the aromatic 6- to 14-membered carbocyclic rings include, e.g., benzene, naphthalene, indane, tetralin, and fluorene and the 5- to 1 0-membered aromatic heterocyclic rings include, e.g., imidazole, pyridine, indole, thiophene, benzopyranone, thiazole, furan, benzimidazole, quinoline, isoquinoline, quinoxaline, pyrimidine, pyrazine, tetrazole and pyrazole.
  • Arylalkyl means an alkyl residue attached to an aryl ring. Examples are benzyl, phenethyl and the like.
  • Substituted alkyl and “substituted aryl” refer to alkyl and aryl wherein up to three H atoms in each residue are replaced with halogen, hydroxy, loweralkoxy, carboxy, carboalkoxy, oxy, carboxamido, cyano, NO 2 , sulfoxide, sulfone, acylamino, amidino, phenyl, benzyl, heteroaryl, phenoxy, benzyloxy, or heteroaryloxy.

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  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Paints Or Removers (AREA)
  • Epoxy Resins (AREA)

Abstract

La présente invention décrit des compositions de revêtement à base de siloxane époxy sans solvant pour utilisation sur des métaux, des plastiques, du bois et du verre. Les compositions sont durcissables par voie cationique dans l’air par rayonnement ultraviolet ou de faisceau électronique. Les compositions de revêtement de siloxane époxy donnent, après durcissement, un film avec d’excellentes propriétés d'adhérence, de flexibilité et d’apparence. Les compositions de revêtement peuvent être transparentes ou peuvent contenir des charges et des colorants ou des pigments. La présente invention décrit également un procédé de fabrication d’un substrat de métal, de plastique, de bois ou de verre à l’aide des compositions de l'invention, ainsi que le matériau enduit fabriqué selon le procédé.
PCT/US2005/002891 2005-01-31 2005-01-31 Revêtements durcissables par rayonnement sans solvant et non polluants WO2006085839A1 (fr)

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Cited By (6)

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Publication number Priority date Publication date Assignee Title
WO2011134686A1 (fr) * 2010-04-29 2011-11-03 Huntsman Advanced Materials (Switzerland) Gmbh Composition durcissable
CN102603587A (zh) * 2011-01-03 2012-07-25 锦湖石油化学株式会社 锍化合物、光致产酸剂及其制备方法
WO2013103334A1 (fr) * 2012-01-03 2013-07-11 Essilor International (Compagnie Generale D'optique) Composition de revêtement durcissable
CN103298893A (zh) * 2011-01-04 2013-09-11 埃西勒国际通用光学公司 在光学制品上制备抗静电uv可固化硬涂层的方法
US10745503B2 (en) 2017-08-18 2020-08-18 Fina Technology, Inc. Epoxidized polyfarnesene and methods for producing the same
CN113845842A (zh) * 2021-10-26 2021-12-28 华南理工大学 一种超支化环氧低聚硅氧烷高耐磨重防腐涂料及其制备方法与应用

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Title
CRIVELLO J V ET AL: "THE SYNTHESIS, CHARACTERIZATION, AND PHOTOINITIATED CATIONIC POLYMERIZATION OF SILICON-CONTAINING EPOXY RESINS", JOURNAL OF POLYMER SCIENCE, POLYMER CHEMISTRY EDITION, INTERSCIENCE POUBLISHERS, NEW YORK, NY, US, vol. 28, no. 3, 1 February 1990 (1990-02-01), pages 479 - 503, XP000141356, ISSN: 0360-6376 *
CRIVELLO J V ET AL: "THE UV CURE OF EPOXY-SILICONE MONOMERS", POLYMERIC MATERIALS SCIENCE AND ENGINEERING, WASHINGTON, DC, US, vol. 60, 1989, pages 217 - 227, XP009035836, ISSN: 0743-0515 *

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011134686A1 (fr) * 2010-04-29 2011-11-03 Huntsman Advanced Materials (Switzerland) Gmbh Composition durcissable
CN102971382B (zh) * 2010-04-29 2015-07-08 亨斯迈先进材料（瑞士）有限公司 可固化组合物
CN102971382A (zh) * 2010-04-29 2013-03-13 亨斯迈先进材料（瑞士）有限公司 可固化组合物
JP2013525551A (ja) * 2010-04-29 2013-06-20 ハンツマン・アドヴァンスト・マテリアルズ・（スイッツランド）・ゲーエムベーハー 硬化性組成物
CN102603587B (zh) * 2011-01-03 2014-06-25 锦湖石油化学株式会社 锍化合物、光致产酸剂及其制备方法
CN102603587A (zh) * 2011-01-03 2012-07-25 锦湖石油化学株式会社 锍化合物、光致产酸剂及其制备方法
CN103298893A (zh) * 2011-01-04 2013-09-11 埃西勒国际通用光学公司 在光学制品上制备抗静电uv可固化硬涂层的方法
CN103298893B (zh) * 2011-01-04 2016-05-04 埃西勒国际通用光学公司 在光学制品上制备抗静电uv可固化硬涂层的方法
WO2013103334A1 (fr) * 2012-01-03 2013-07-11 Essilor International (Compagnie Generale D'optique) Composition de revêtement durcissable
CN104039901A (zh) * 2012-01-03 2014-09-10 埃西勒国际通用光学公司 可固化涂层组合物
US9557449B2 (en) 2012-01-03 2017-01-31 Essilor International (Compagnie Generale D'optique) Curable coating composition
US10745503B2 (en) 2017-08-18 2020-08-18 Fina Technology, Inc. Epoxidized polyfarnesene and methods for producing the same
CN113845842A (zh) * 2021-10-26 2021-12-28 华南理工大学 一种超支化环氧低聚硅氧烷高耐磨重防腐涂料及其制备方法与应用

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