WO2013146078A1 - 複合粒子、粉体塗料、塗膜、積層体、及び、複合粒子の製造方法 - Google Patents
複合粒子、粉体塗料、塗膜、積層体、及び、複合粒子の製造方法 Download PDFInfo
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- WO2013146078A1 WO2013146078A1 PCT/JP2013/055454 JP2013055454W WO2013146078A1 WO 2013146078 A1 WO2013146078 A1 WO 2013146078A1 JP 2013055454 W JP2013055454 W JP 2013055454W WO 2013146078 A1 WO2013146078 A1 WO 2013146078A1
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/12—Powdering or granulating
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- 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
- C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
- C09D127/02—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
- C09D127/12—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
- C09D127/18—Homopolymers or copolymers of tetrafluoroethene
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- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/005—Processes for mixing polymers
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/12—Powdering or granulating
- C08J3/126—Polymer particles coated by polymer, e.g. core shell structures
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- 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
- C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
- C09D127/02—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
- C09D127/12—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
- C09D127/20—Homopolymers or copolymers of hexafluoropropene
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- 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
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/03—Powdery paints
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- 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
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/03—Powdery paints
- C09D5/031—Powdery paints characterised by particle size or shape
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- 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
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/03—Powdery paints
- C09D5/033—Powdery paints characterised by the additives
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2327/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
- C08J2327/02—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment
- C08J2327/12—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2327/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
- C08J2327/02—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment
- C08J2327/12—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
- C08J2327/18—Homopolymers or copolymers of tetrafluoroethylene
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2479/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen, or carbon only, not provided for in groups C08J2461/00 - C08J2477/00
- C08J2479/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
- C08J2479/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08J2481/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen, or carbon only; Polysulfones; Derivatives of such polymers
- C08J2481/04—Polysulfides
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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
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
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- 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]
- Y10T428/3154—Of fluorinated addition polymer from unsaturated monomers
Definitions
- the present invention relates to composite particles that can be used in powder coatings, powder coatings composed of the composite particles, coating films formed from the powder coatings, laminates comprising the coating films, and methods for producing composite particles .
- Fluorine resin is prepared in paint compositions and applied to base materials that require corrosion resistance, non-adhesiveness, heat resistance, etc. for bread molds, rice cookers, etc. There are uses. However, since the fluororesin has poor adhesion to a base material made of metal, ceramic, etc. due to its non-adhesiveness, a primer having an affinity for both the fluororesin and the base material is applied to the base material in advance. I came.
- the fluororesin layer needs to be thickened for corrosion-resistant applications. To make it thicker, it is necessary to apply a powder coating made of fluororesin and baked at a temperature above the melting point of the fluororesin. Need to be overcoated.
- the primer is required to have heat-resistant adhesion that can withstand the firing at a high temperature for a long time and can maintain the adhesion to a substrate or the like.
- chromium phosphate primers that have excellent resistance to long-term high-temperature firing have been widely used as primers with excellent heat-resistant adhesion.
- awareness of environmental problems has increased, and there has been a strong demand for many years to develop a chromium-free primer that does not contain hexavalent chromium and has strong heat-resistant adhesion comparable to that of a chromium phosphate primer.
- Patent Document 1 discloses a polymer compound (A) having an amide group and / or an imide group, an antioxidant substance (B), and fluorine.
- a powder coating material containing a resin (C), wherein the polymer compound (A) has an average particle size of less than 50 ⁇ m is described.
- Patent Document 2 discloses a composition that can be used as a primer for a multi-layer coating system.
- the composition includes a plurality of multi-component particles, and each component of the particles is a melt-processable fluoropolymer.
- a composition is described wherein each separate component of the particles is a heat resistant non-dispersed polymer binder. It is also described that the composition described in Patent Document 2 is in the form of a free-flowing powder that hardly separates during transportation or processing.
- Patent Document 3 includes a step (I) of obtaining a heat-meltable fluororesin powder mixed composition by mixing a heat-meltable fluororesin fine powder and a layered compound.
- a method for producing a heat-meltable fluororesin composite composition comprising the step (II) of melt-mixing the powder mixture composition by applying a shear stress using a melt-mixing extruder is described.
- the powder coating material does not contain substances that have a high environmental impact, and it not only has high adhesion to the base material, but is also required to be able to form a coating film that adheres uniformly to the base material.
- it is necessary to blend a large amount of the adhesive component in order to form a coating film that adheres uniformly to the substrate.
- the present invention does not include a fluorine-containing surfactant having a high environmental load, and even if the amount of the adhesive component is small, a coating film having excellent adhesion to the substrate and being uniformly adhered to the substrate.
- a fluorine-containing surfactant having a high environmental load, and even if the amount of the adhesive component is small, a coating film having excellent adhesion to the substrate and being uniformly adhered to the substrate.
- composite particles that can be formed.
- the present invention is a composite particle comprising a fluoropolymer and an adhesive polymer, wherein the content of the fluorosurfactant is less than 0.1 ppm.
- the composite particles are preferably obtained by bonding particles made of a fluorine-containing polymer and particles made of an adhesive polymer.
- the composite particles are preferably obtained by bonding particles made of a fluorine-containing polymer and particles made of an adhesive polymer using an apparatus having centrifugal diffusion and eddy current action.
- the composite particles are preferably those in which, when the particles are allowed to stand for a sufficient time after being dispersed in water, the particles are suspended in water without being suspended.
- the composite particles preferably have an average particle diameter of 1 to 1000 ⁇ m.
- the composite particles preferably have a mass ratio of the fluoropolymer and the adhesive polymer of 5/50 to 99/1.
- the adhesive polymer is at least one compound selected from the group consisting of polyimide, polyamideimide, polyamide, polyamic acid (polyamic acid), epoxy resin, polysulfide, polyarylene sulfide, and polyethersulfone. Is preferred.
- the fluorine-containing polymer is at least one selected from the group consisting of a tetrafluoroethylene-perfluoro (alkyl vinyl ether) copolymer, a tetrafluoroethylene-hexafluoropropylene copolymer, and a tetrafluoroethylene-ethylene copolymer.
- a fluororesin is preferred.
- the present invention is also a powder coating comprising the composite particles.
- the present invention is also a coating film formed from the powder coating material.
- the present invention is also a laminate comprising the above-mentioned coating film on a metal substrate, wherein the adhesion strength between the coating film and the metal substrate is 50 to 300 N / cm.
- the standard deviation of the adhesive strength between the coating film and the metal substrate is preferably less than 10.
- the present invention also provides a method for producing the above composite particle, the step of introducing a fluoropolymer and an adhesive polymer into a surface modifier, and the surface modification of the fluoropolymer and the adhesive polymer. It is also a method for producing composite particles, which includes a step of obtaining composite particles by mixing in a texture machine and a step of recovering composite particles from the surface modifier.
- the surface reformer is preferably a high-speed fluid mixer, a high-speed rotary impact pulverizer, or a friction mill.
- the surface reformer is more preferably a friction mill.
- the composite particles of the present invention have the above-described configuration, the load on the environment is small, and when used as a powder paint without impairing the original characteristics of the fluoropolymer, the amount of the adhesive component is small. However, it is possible to form a coating film that is excellent in adhesion to the substrate and that is uniformly adhered to the substrate.
- the composite particle of the present invention comprises a fluorine-containing polymer and an adhesive polymer, and the content of the fluorine-containing surfactant is less than 0.1 ppm.
- the composite particles of the present invention are designed so that the particles of the fluorine-containing polymer and the particles of the adhesive polymer are united, and the variation between the fluorine-containing polymer and the adhesive polymer during coating is eliminated. be able to.
- the composite particles of the present invention have a fluorine-containing surfactant content of less than 0.1 ppm.
- a fluorine-containing surfactant content of less than 0.1 ppm.
- a fluorine-containing surfactant is not used, and therefore a composite particle having a fluorine-containing surfactant content of less than 0.1 ppm is obtained by using a fluorine-containing polymer obtained by suspension polymerization. Can do.
- the said fluorine-containing surfactant is a well-known fluorine-containing surfactant used in emulsion polymerization for obtaining a fluorine-containing polymer.
- the fluorine-containing surfactant may be any compound having a fluorine atom and having surface activity, and examples thereof include ammonium perfluorooctanoate (PFOA).
- the concentration of the fluorine-containing surfactant can be measured by extracting the fluorine-containing surfactant contained in the composite particles into acetone by Soxhlet extraction, and measuring the concentration with a mass spectrometer Quattro micro GC manufactured by Japan Waters. . Since the detection limit in this measurement method is 0.1 ppm, the content of the fluorine-containing surfactant being less than 0.1 ppm means that the fluorine-containing surfactant contained in the composite particles cannot be detected.
- the composite particles of the present invention can be suitably used as a powder coating material.
- a powder coating composed of the composite particles of the present invention is applied to a substrate, a coating film that is excellent in adhesion to the substrate and adheres uniformly to the substrate can be obtained.
- the composite particles of the present invention are formed so that the fluorine-containing polymer and the adhesive polymer are gathered together, the charge amount can be controlled. Therefore, it is particularly suitable as a powder coating material used for electrostatic coating.
- the composite particles of the present invention are preferably obtained by bonding particles made of a fluorine-containing polymer and particles made of an adhesive polymer.
- a method for coalescing the particles made of the fluoropolymer and the particles made of the adhesive polymer the particles made of the fluoropolymer and the particles made of the adhesive polymer are introduced into a surface modifier described later. The method of processing is mentioned.
- “cohesion” means fluorine-containing so that when particles are dispersed in water and allowed to stand for a sufficient time, water does not suspend and particles float in water. It means that the particles made of the polymer and the particles made of the adhesive polymer are integrally formed.
- FIG. 12 is a schematic view showing a form in which the fluoropolymer particles and the adhesive polymer particles are bonded together.
- the composite particles 120 are those in which the adhesive polymer particles 122 and 123 are bonded to the fluorine-containing polymer particles 121, the adhesive polymer particles are uniformly distributed during coating. As a result of obtaining a distributed coating film, the obtained coating film and the base material are uniformly adhered.
- the adhesive polymer particles act efficiently, in the powder coating using the composite particles of the present invention, the blending amount of the adhesive polymer particles can be reduced as compared with the conventional case.
- the fluorinated polymer particles 131 and the adhesive polymer particles 132 and Since 133 is in a separated state there is a possibility that a coating film with unevenness in the distribution of the adhesive polymer particles may be obtained.
- the adhesion between the obtained coating film and the substrate may be non-uniform, and in order to firmly bond the entire surface of the substrate, it is necessary to add a large amount of an adhesive polymer.
- the composite particles of the present invention are more preferably obtained by bonding particles made of a fluorine-containing polymer and particles made of an adhesive polymer using an apparatus having centrifugal diffusion and eddy current action.
- an apparatus having centrifugal diffusion and eddy current action include a friction mill described later.
- the particles of the present invention are allowed to stand for a sufficient time after the particles are dispersed in water, the particles are preferably suspended without water being suspended.
- the composite particles of the present invention preferably have an average particle diameter of 1 to 1000 ⁇ m.
- the average particle size of the composite particles is more preferably 20 to 500 ⁇ m. If the average particle size is too large, a coating film having a smooth surface may not be obtained. If the average particle size is too small, the coating efficiency may be reduced.
- the average particle size of the composite particles can be measured with a laser diffraction / scattering particle size analyzer MT3300EX II manufactured by Nikkiso Co., Ltd.
- the average particle size is preferably 1 ⁇ m or more and less than 100 ⁇ m, and more preferably 20 ⁇ m or more and less than 100 ⁇ m. Moreover, when used for the powder coating material used for rotational coating or rotational molding, it is preferable that an average particle diameter is 100 to 1000 micrometer, and 100 to 500 micrometer is more preferable.
- the composite particles of the present invention preferably have a mass ratio [fluorinated polymer / adhesive polymer] of 50/50 to 99/1 between the fluoropolymer and the adhesive polymer. More preferably, it is 70/30 to 98/2, and still more preferably 80/20 to 98/2.
- the mass ratio of the fluoropolymer and the adhesive polymer is in the above range, the adhesion between the coating film obtained using the composite particles of the present invention and the substrate is further increased, It becomes what adhered to the base material more uniformly.
- the fluoropolymer and the adhesive polymer are separated.
- the adhesion of the adhesive becomes uneven, and it is necessary to blend a large amount of the adhesive polymer in order to firmly bond the entire surface of the substrate.
- the composite particles of the present invention are used, even when the amount of the adhesive polymer is small as described above, the adhesion with the substrate is strong, and a coating film that is uniformly adhered to the substrate is obtained. Can do.
- the fluoropolymer is not particularly limited as long as it can be melt-molded.
- the fluoropolymer preferably has a clear melting point, and is preferably a fluororesin.
- the fluorinated polymer preferably has a melting point of 100 to 347 ° C., more preferably 150 to 322 ° C.
- the fluorine-containing polymer is preferably a homopolymer or copolymer having a repeating unit derived from at least one fluorine-containing ethylenic monomer.
- the fluorine-containing polymer may be obtained by polymerizing only a fluorine-containing ethylenic monomer, or by polymerizing a fluorine-containing ethylenic monomer and an ethylenic monomer having no fluorine atom. It may be.
- a perfluoroalkyl group having 1 to 5 carbon atoms from the group consisting of alkyl perfluorovinyl ether derivative represented by the It is preferred to have at least one repeating unit derived from the fluorine-containing ethylenic monomer is-option.
- the fluoropolymer may have a repeating unit derived from an ethylenic monomer having no fluorine atom, and is ethylenic having 5 or less carbon atoms from the viewpoint of maintaining heat resistance and chemical resistance. Having a repeating unit derived from a monomer is also one preferred form.
- the fluororesin may have at least one fluorine-free ethylenic monomer selected from the group consisting of ethylene, propylene, 1-butene, 2-butene, vinyl chloride, vinylidene chloride and unsaturated carboxylic acid. preferable.
- fluoropolymer examples include tetrafluoroethylene-perfluoro (alkyl vinyl ether) copolymer, tetrafluoroethylene-hexafluoropropylene copolymer, tetrafluoroethylene-ethylene copolymer, tetrafluoroethylene-hexafluoro.
- Propylene-ethylene copolymer tetrafluoroethylene-hexafluoropropylene-vinylidene fluoride copolymer, tetrafluoroethylene-perfluoroalkyl vinyl ether-chlorotrifluoroethylene copolymer, chlorotrifluoroethylene-ethylene copolymer, poly Examples include chlorotrifluoroethylene, polyvinylidene fluoride, and polyvinyl fluoride. These fluoropolymers may be used alone or in combination of two or more.
- fluoropolymer examples include polytetrafluoroethylene [PTFE], polychlorotrifluoroethylene [PCTFE], TFE-ethylene [Et] copolymer [ETFE], and Et-chlorotrifluoroethylene [CTFE] copolymer.
- PTFE polytetrafluoroethylene
- PCTFE polychlorotrifluoroethylene
- Et copolymer
- CTFE Et-chlorotrifluoroethylene
- CTFE-TFE copolymer examples include polytetrafluoroethylene [PTFE], polychlorotrifluoroethylene [PCTFE], TFE-ethylene [Et] copolymer [ETFE], and Et-chlorotrifluoroethylene [CTFE] copolymer.
- CTFE-TFE copolymer TFE-HFP copolymer [FEP]
- TFE-PAVE copolymer [PFA] TFE-PAVE copolymer
- PVdF polyvinylidene flu
- PAVE perfluoro (methyl vinyl ether) [PMVE], perfluoro (ethyl vinyl ether) [PEVE], perfluoro (propyl vinyl ether) [PPVE], perfluoro (butyl vinyl ether), among others, PMVE. PEVE or PPVE is more preferable.
- alkyl perfluorovinyl ether derivative those in which Rf 2 is a perfluoroalkyl group having 1 to 3 carbon atoms are preferable, and CF 2 ⁇ CF—O—CH 2 —CF 2 CF 3 is more preferable.
- the fluoropolymer is more preferably a melt-processable fluororesin, and more preferably at least one fluororesin selected from the group consisting of PFA, FEP, and ETFE.
- the PFA is not particularly limited, but a copolymer having a molar ratio of TFE units to PAVE units (TFE units / PAVE units) of 70 to 99/30 to 1 is preferable. A more preferred molar ratio is 80 to 98.5 / 20 to 1.5.
- TFE units / PAVE units a copolymer having a molar ratio of TFE units to PAVE units (TFE units / PAVE units) of 70 to 99/30 to 1 is preferable.
- a more preferred molar ratio is 80 to 98.5 / 20 to 1.5.
- TFE units / PAVE units When there are too few TFE units, there exists a tendency for a mechanical physical property to fall, and when too much, melting
- monomer units derived from monomers copolymerizable with TFE and PAVE are 0.1 to 10 mol%, and TFE units and PAVE units are 90 to 99.9 mol% in
- FEP is not particularly limited, but a copolymer having a molar ratio of TFE units to HFP units (TFE units / HFP units) of 70 to 99/30 to 1 is preferable. A more preferred molar ratio is 80 to 97/20 to 3.
- TFE units / HFP units a monomer unit derived from a monomer copolymerizable with TFE and HFP in an amount of 0.1 to 10 mol%, and a total of 90 to 99.9 mol% of TFE units and HFP units.
- a polymer is also preferred. Examples of the monomer copolymerizable with TFE and HFP include PAVE and alkyl perfluorovinyl ether derivatives.
- ETFE is preferably a copolymer having a molar ratio of TFE units to ethylene units (TFE units / ethylene units) of 20 to 90/80 to 10. A more preferred molar ratio is 37 to 85/63 to 15, and a still more preferred molar ratio is 38 to 80/62 to 20.
- ETFE may be a copolymer composed of TFE, ethylene, and a monomer copolymerizable with TFE and ethylene.
- the monomer copolymerizable with TFE and ethylene may be an aliphatic unsaturated carboxylic acid such as itaconic acid or itaconic anhydride.
- the monomer copolymerizable with TFE and ethylene is preferably from 0.1 to 10 mol%, more preferably from 0.1 to 5 mol%, particularly preferably from 0.2 to 4 mol%, based on the fluoropolymer. preferable.
- the content of each monomer in the copolymer described above can be calculated by appropriately combining NMR, FT-IR, elemental analysis, and fluorescent X-ray analysis depending on the type of monomer.
- the fluorine-containing polymer preferably has an average particle size of 1 ⁇ m or more, more preferably 20 ⁇ m or more. Moreover, it is preferable that it is 1000 micrometers or less, and it is more preferable that it is 500 micrometers or less. If the average particle size is too large, a smooth coating film may not be obtained. If the average particle size is too small, the coating efficiency may be reduced.
- the apparent density of the fluoropolymer is preferably 0.40 or more, more preferably 0.50 or more, and further preferably 0.60 or more. Moreover, it is preferable that it is 1.40 or less, and it is more preferable that it is 1.30 or less. When the apparent density is in the above range, a smooth coating film can be obtained.
- the apparent density can be measured according to JIS K 6891.
- the fluoropolymer As the method for producing the fluoropolymer, emulsion polymerization and suspension polymerization are mainly commercialized.
- the fluoropolymer When obtaining a fluoropolymer from emulsion polymerization, the fluoropolymer is provided in the form of a dispersion that exists as fine particles in water.
- the powder particles obtained from this dispersion by spray-drying or coagulation are concerned about the ecological accumulation of fluorosurfactants used during polymerization, and the coating film formed from the powder also contains fluorine. Since the surfactant remains, the original characteristics of the fluororesin-containing coating film may be impaired.
- the composite particle of the present invention it is preferable to use a fluoropolymer obtained from a suspension polymerized product.
- the fluoropolymer can be produced without using the fluorosurfactant, the coating film formed from the composite particles of the present invention does not contain the fluorosurfactant, and the environmental load is reduced. It becomes small and it becomes possible to express the original characteristic of a fluororesin coating film. Further, the adhesion between the coating film and the substrate due to the volatile decomposition of the fluorine-containing surfactant does not occur.
- a fluoropolymer obtained by suspension polymerization it is preferable to use a fluoropolymer obtained by suspension polymerization.
- a fluorine-containing surfactant is not used, and therefore a composite particle having a fluorine-containing surfactant content of less than 0.1 ppm is obtained by using a fluorine-containing polymer obtained by suspension polymerization. Can do.
- the composite particle of the present invention comprises a fluorine-containing polymer and an adhesive polymer.
- an adhesive polymer includes polyimide [PI], polyamideimide [PAI], polyamide [PA], polyamic acid (polyamic acid), epoxy resin, polysulfide, polyarylene sulfide [PAS], and polyethersulfone [PES]. It is preferably at least one compound selected from the group consisting of
- the PAI, PA and polyamic acid are usually polymers having an amide group (—NH—C ( ⁇ O) —) in the main chain or side chain and an aromatic ring in the main chain.
- the PAI is a polycondensate having an amide group, an aromatic ring, and an imide group.
- the PAI is not particularly limited, and for example, in addition to the conventionally known PAI, those in which an amide group is introduced by oxidizing polyimide [PI] can be used.
- the polyamide is a polycondensate having an amide bond (—NH—C ( ⁇ O) —) in the main chain.
- the polyamide is not particularly limited, and examples thereof include aliphatic polyamides such as nylon 6, nylon 66, nylon 11, and nylon 12; aromatic polyamides such as polyparaphenylene terephthalamide and polymetaphenylene isophthalamide. .
- the polyamic acid is a polycondensate having an amide group and a carboxyl group or a derivative of a carboxyl group (for example, a derivative of an alkyl esterified carboxyl group).
- the polyamic acid is not particularly limited, and examples thereof include a polyamic acid having a molecular weight of thousands to tens of thousands.
- the polyimide is changed to PAI or polyamic acid by oxidation.
- the polyimide When the composite particles of the present invention are used in a powder coating, the polyimide is oxidized when the powder coating is applied and baked at a high temperature for a long time to introduce an amide group into the main chain and change to PAI or polyamic acid. Can be made. PAI is not required if all of the imide groups in the main chain of PI are converted to amide groups, and polyamic acid is the one in which all of the imide groups in the main chain of PI are converted into amide groups and carboxyl groups. is there.
- the method for introducing an amide group into the PI is not particularly limited.
- a method of opening the imide group (imide ring) of PI by oxidation, or hydrolysis by causing an alkali to act on the imide group (imide ring) of PI Methods and the like.
- an epoxy resin having a bisphenol A unit is preferable.
- the PAS is not particularly limited, and examples thereof include polyphenylene sulfide ketone, polyphenylene sulfide sulfone, polybiphenylene sulfide, and polyphenylene sulfide [PPS]. Among them, PPS is preferably used. PAS is preferably used when the use of amine or elution of metal ions is disliked as in the semiconductor manufacturing process. When heat-resistant adhesion is required, PAS is also a heat-resistant binder, so PAS is suitably used not only for antioxidant properties but also for imparting heat-resistant adhesion.
- the said adhesive polymer may be used independently and may be used in combination of 2 or more type.
- the adhesive polymer preferably has an average particle size of 1 to 50%, more preferably 2 to 20%, with respect to the average particle size of the fluoropolymer. Since the average particle diameter of the adhesive polymer is sufficiently smaller than the average particle diameter of the fluoropolymer, it is assumed that the fluoropolymer particles are included in the adhesive polymer, and the ratio of the fluoropolymer is large. Sufficient adhesiveness can be realized.
- the adhesive polymer a commercially available powder may be used, or a fine powder obtained by pulverization and pulverization may be used. Moreover, the powder which grind
- the pulverization method is not particularly limited, but it can be pulverized by ordinary paraperizer pulverization, atomizer pulverization, or the like.
- the adhesive polymer at least one polymer compound selected from the group consisting of polyimide [PI], polyamideimide [PAI], polyamide [PA], polyamic acid (polyamic acid), and epoxy resin ( A) and at least one sulfur-containing compound (B) selected from the group consisting of polysulfide, polyarylene sulfide [PAS], and polyethersulfone [PES] are preferably used in combination.
- a preferable upper limit is 200 ⁇ m, and a more preferable upper limit is 150 ⁇ m. If the average particle diameter of the said high molecular compound (A) is in the said range, a preferable minimum can be 0.01 micrometer and a more preferable minimum can be 0.1 micrometer. Further, the average particle diameter of the polymer compound (A) is preferably relatively smaller than the average particle diameter of the fluoropolymer, more preferably less than 100 ⁇ m, and further preferably 50 ⁇ m or less. preferable.
- a preferable upper limit is 200 ⁇ m, and a more preferable upper limit is 150 ⁇ m. If the average particle diameter of the said sulfur containing compound (B) is in the said range, a preferable minimum can be 0.01 micrometer and a more preferable minimum can be 0.1 micrometer.
- the average particle size of the sulfur-containing compound (B) is preferably relatively smaller than the average particle size of the fluoropolymer, and more preferably 20 ⁇ m or less.
- the method for producing composite particles of the present invention is a method for producing the above composite particles, comprising the steps of introducing a fluoropolymer and an adhesive polymer into a surface modifier, the fluoropolymer and the adhesive weight.
- the process includes a step of mixing the coalescence in a surface reformer to obtain composite particles, and a step of recovering the composite particles from the surface reformer.
- a surface reformer that can be used to produce the composite particles of the present invention will be described.
- the surface reformer for example, a high-speed fluid mixer, a high-speed rotary impact pulverizer, or a friction mill is preferable.
- the surface reformer it is possible to obtain composite particles capable of forming a coating film that adheres to the base material and adheres uniformly to the base material with high efficiency.
- the composite particles of the present invention are not wet, but use the surface reformer which is dry production as described above, so that the production workability can be simplified, and the fluoropolymer particles and the adhesive polymer particles Can be obtained.
- composite particles that are suspended in water without being suspended can be produced.
- a fluorine-containing polymer and an adhesive polymer are mixed by an ordinary dry blend, the fluorine-containing polymer and the adhesive polymer do not coalesce, and the fluorine-containing polymer and the adhesive polymer are not bonded at the time of coating.
- the blending ratio varies and unevenness occurs in the adhesion of the resulting coating film. In such a case, it is necessary to add an adhesive polymer in excess.
- the mixed powder of the fluoropolymer and the adhesive resin obtained by co-coagulation is isolated from the aqueous dispersion of the fluoropolymer and the adhesive resin by water treatment, the obtained mixture is obtained. Even when a coating film is produced using powder, the adhesion to the substrate is not sufficient, and the adhesion to the substrate also varies. Further, since the compounding is performed in the liquid, a huge facility such as a drying facility is necessary for commercial implementation, and aggregation during the drying is inevitable, and the productivity is not necessarily high.
- a device in which a vertical rotation shaft and a guide plate are provided inside a high-speed fluid mixer drum, and two blades are arranged at the bottom of the rotation shaft. By rotating the rotating shaft at a high speed, the powder flows upward by the lower blade, and a strong mechanical stress is applied by the upper blade. Furthermore, a large impact force is given by the powder colliding with the guide plate and the inner wall of the apparatus at high speed. It is preferable to treat the fluoropolymer powder temperature in the range of 100 to 200 ° C.
- High-speed rotary impact pulverizer A device composed of a rotating disk that rotates at high speed inside the drum, and a circulation circuit that connects the center and inner wall of the drum.
- the powder supplied by the air current receives an impact force caused by a collision with an impact pin disposed on the rotating disk and an inner wall of the apparatus. Since these powders are once discharged from the inside of the drum through the circulation circuit and then returned to the drum, mechanical stress is repeatedly applied. It is preferable to treat the fluoropolymer powder temperature in the range of 50 to 200 ° C.
- a device in which a plurality of blades are arranged on the outer peripheral portion of a rotating shaft inside a friction mill drum, and by rotating the blades, centrifugal diffusion and eddy current action are caused to flow the powder in the drum.
- the powder is mechanically stressed by being pressed against the inner wall of the apparatus.
- a stirring member having a function of feeding and returning powder in the direction of the rotation axis may be operated. It is preferable to treat the fluoropolymer powder temperature in the range of 50 to 200 ° C.
- a friction mill is more preferable as the surface reformer because a coating film in which the adhesion between the substrate and the coating film is higher and the substrate and the coating film are more uniformly adhered is obtained.
- the rotary body has a rotating body having a plurality of blades on the outer periphery, and a casing having a cylindrical inner peripheral surface close to the radial tip of the blade, and the shaft of the rotating body
- the blades adjacent to each other along the central direction extend from the shaft center in different directions, and at least one pair of the blades adjacent to each other along the axial center is opposite to the previous shaft center.
- the specification which inclines in direction is preferable.
- an apparatus described in Japanese Patent Application Laid-Open No. 2010-18999 can be used.
- Examples of such an apparatus include Nobilta manufactured by Hosokawa Micron Corporation.
- These devices may be supplied directly with powder after polymerization obtained by suspension polymerization, or may be supplied after pulverization after high density using a roll or the like.
- different types of fluoropolymers may be mixed before being supplied to the processing apparatus.
- additives other than the fluorinated polymer can be mixed before being supplied to the processing apparatus.
- 1% by weight or less of PTFE can be mixed with PFA.
- a metal compound containing 1% by weight or less of copper, zinc, cobalt and the like can be mixed with PFA or ETFE.
- the method for producing composite particles of the present invention preferably includes a step of polymerizing a fluorine-containing ethylenic monomer by suspension polymerization to obtain a fluorine-containing polymer.
- the method for producing composite particles of the present invention may include a pulverization step for pulverizing the fluoropolymer, if desired.
- the particle size distribution may be narrowed by performing a classification treatment in order to improve the handleability of the fluoropolymer powder.
- the powder coating material of this invention consists of the said composite particle. Since the powder coating material of the present invention is composed of the above composite particles, the adhesion between the coating film formed from the powder coating material and the substrate is high, and the coating film and the substrate are uniformly adhered. A coated film can be formed.
- the powder coating material of the present invention may further contain usual additives added to the powder coating material.
- the additive include a leveling agent, a solid lubricant, a pigment, a bright material, a filler, a pigment dispersant, an anti-settling agent, a moisture absorbent, a surface conditioner, a thixotropic agent, a viscosity conditioner, and a gelling agent.
- the coating film of this invention is also formed from the said powder coating material. Since the coating film of this invention is formed from the powder coating material which consists of the said composite particle, its adhesiveness with a base material is high, and it adheres to a base material uniformly. In addition, since it does not contain a fluorine-containing surfactant, it has a low environmental impact and has the original characteristics of a fluorine-containing polymer such as non-adhesiveness.
- the coating film of the present invention can be formed by coating a powder coating composed of the composite particles on a substrate.
- the coating method include an electrostatic coating method, a rotation coating method, and a rotation molding method.
- the preferable average particle diameter of the fluoropolymer used for the composite particles is 1 ⁇ m or more and less than 100 ⁇ m, more preferably 20 ⁇ m or more and less than 100 ⁇ m.
- the preferable average particle diameter of the fluoropolymer used for the composite particles is 100 ⁇ m or more and 1000 ⁇ m or less, and more preferably 100 ⁇ m or more and 500 ⁇ m or less.
- the thickness of the coating film of the present invention is not particularly limited and may be appropriately determined depending on the application, but may be, for example, 20 to 1000 ⁇ m.
- the laminated body of this invention is a laminated body provided with the said coating film on a metal base material. Since the laminated body of this invention is provided with the said coating film, it has high adhesiveness with a metal base material, and adheres
- Examples of the metal base material include metals such as iron, stainless steel, and aluminum.
- the shape of the metal substrate is appropriately selected depending on the use of the laminate.
- the laminate of the present invention has an adhesive strength of 50 to 300 N / cm with the metal substrate.
- the adhesive strength with the metal substrate is preferably 60 to 300 N / cm, more preferably 70 to 300 N / cm, still more preferably 80 to 300 N / cm, and particularly preferably 90 to 300 N / cm.
- the adhesive strength is determined by coating the powder coating composed of the composite particles on a metal substrate by electrostatic coating, and cutting the resulting coating film until reaching the metal surface at intervals of 10 mm. The sample was pulled in a 90 ° direction with respect to the test piece at a pulling speed of 50 mm / min in accordance with JIS K 6854-1 (1999), and the peel adhesive strength was measured. Iron can be used as the metal substrate.
- the standard deviation of the adhesive strength between the coating film and the metal substrate is preferably less than 10. It can be said that the smaller the standard deviation of the adhesive strength, the more uniformly the coating film and the metal substrate are in close contact with each other.
- the standard deviation of the adhesive strength is calculated from the following formula.
- S 1 to S i are adhesive strengths for each sample (test piece), and i is the number of samples.
- the composite particles, powder paints, coating films and laminates of the present invention are used for belts and rolls used in kitchen appliances such as frying pans, household appliances such as rice cookers, office automation equipment such as printers and copiers, and various plants. It can be used in various applications such as corrosion-resistant linings for pipes and tanks used in
- Average particle size (particle size distribution) Evaluation was performed using a laser diffraction / scattering particle size analyzer MT3300EX II manufactured by Nikkiso Co., Ltd.
- Fluorine-containing surfactant concentration The fluorine-containing surfactant contained in the composite particles was extracted into acetone by Soxhlet extraction, and this concentration was evaluated by a mass spectrometer Quattro micro GC manufactured by Nippon Waters.
- the film thickness provided by electrostatic coating was evaluated with an electromagnetic film thickness meter SWT-8100 manufactured by Sanko Electronics.
- Standard deviation of adhesive strength between coating film and substrate was calculated from the following formula.
- S 1 to S i are adhesive strengths for each sample (test piece), and i is the number of samples.
- Theta composer (processing equipment (I)) manufactured by Tokuju Kogakusha Co., Ltd. Hybridization system (processing equipment (II)) manufactured by Nara Machinery Co., Ltd. Nobilta manufactured by Hosokawa Micron (Treatment equipment (III))
- Example 1 Tetrafluoroethylene-perfluoro (alkyl vinyl ether) copolymer [PFA] (true specific gravity 2.15, melting point 304 ° C., TFE / PAVE molar ratio 98/2) obtained by suspension polymerization, manufactured by Shinto Kogyo Co., Ltd. Was used so as to obtain a sheet having a width of 60 mm and a thickness of 5 mm.
- PFA Tetrafluoroethylene-perfluoro (alkyl vinyl ether) copolymer
- PFA average particle size 23 ⁇ m obtained by pulverization
- polyamideimide resin trade name: Torlon 4000TF, manufactured by Solvay Advanced Polymers, average particle size: 2 ⁇ m
- polyphenylene sulfide resin trade name: Ryton V-1, Philips
- a powder made of composite particles of PFA, polyamide-imide resin, and polyphenylene sulfide resin was obtained by treating a product manufactured by Kogyo Co., Ltd. (average particle size: 5 ⁇ m) with a Theta composer manufactured by Tokuju Corporation. The fluorine-containing surfactant concentration in the obtained powder was calculated. Further, an underwater separation test was performed using the obtained composite particles.
- Example 2 A powder composed of composite particles was obtained in the same manner as in Example 1 except that the Theta Composer manufactured by Tokuju Kogakusho Co. was changed to a hybridization system manufactured by Nara Machinery Co., Ltd. Moreover, the coating film was formed similarly to Example 1 and various evaluation was performed. The evaluation results were as shown in Table 1.
- Example 3 A powder composed of composite particles was obtained through the same procedure as in Example 1 except that the Theta Composer manufactured by Tokuju Kogakusho Co., Ltd. in Example 1 was changed to Nobilta manufactured by Hosokawa Micron Corporation. Moreover, the coating film was formed similarly to Example 1 and various evaluation was performed. The evaluation results were as shown in Table 1.
- Example 4 A powder composed of composite particles was obtained through the same procedure as in Example 1 except that the blending ratio of PFA, polyamideimide resin and polyphenylene sulfide resin was changed as shown in Table 1. Moreover, the coating film was formed similarly to Example 1 and various evaluation was performed. The evaluation results were as shown in Table 1. A photograph obtained by observing the obtained composite particles with a scanning electron microscope (SEM) is shown in FIG.
- SEM scanning electron microscope
- Example 5 A powder composed of composite particles was obtained through the same procedure as in Example 2 except that the blending ratio of PFA, polyamideimide resin and polyphenylene sulfide resin was changed as shown in Table 1. Moreover, the coating film was formed similarly to Example 2 and various evaluation was performed. The evaluation results were as shown in Table 1. A photograph obtained by observing the obtained composite particles with a scanning electron microscope (SEM) is shown in FIG. A photograph after the underwater separation test is shown in FIG.
- SEM scanning electron microscope
- Example 6 A powder composed of composite particles was obtained through the same procedure as in Example 3 except that the blending ratio of PFA, polyamideimide resin and polyphenylene sulfide resin was changed as shown in Table 1. Moreover, the coating film was formed similarly to Example 3 and various evaluation was performed. The evaluation results were as shown in Table 1. A photograph obtained by observing the obtained composite particles with a scanning electron microscope (SEM) is shown in FIG. The charge amount at the time of observation was ⁇ 7.00 ⁇ c / g. A photograph after the underwater separation test is shown in FIG.
- SEM scanning electron microscope
- Example 7 The composite particles were subjected to the same procedure as in Example 3 except that the average particle size of PFA after pulverization was changed to 132 ⁇ m and the blending ratio of PFA, polyamideimide resin and polyphenylene sulfide resin was changed as shown in Table 1. A powder consisting of Moreover, the coating film was formed similarly to Example 3 and various evaluation was performed. The evaluation results were as shown in Table 1.
- Example 8 Tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer [PFA] is converted to tetrafluoroethylene-hexafluoropropylene copolymer [FEP] (true specific gravity 2.15, melting point 269 ° C., TFE / HFP molar ratio 90/10)
- FEP tetrafluoroethylene-hexafluoropropylene copolymer
- a powder composed of composite particles was obtained through the same procedure as in Example 7 except for changing to.
- the average particle size of the FEP after pulverization is 35 ⁇ m.
- the coating film was formed similarly to Example 7 and various evaluation was performed. The evaluation results were as shown in Table 1.
- Example 9 Tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer [PFA] is converted to tetrafluoroethylene-ethylene copolymer [ETFE] (true specific gravity 1.85, melting point 254 ° C., TFE / ethylene / (perfluorobutyl) ethylene molar ratio. Except for the point that was replaced with 56/42/2), a powder composed of composite particles was obtained through the same procedure as in Example 1. The average particle diameter of ETFE after pulverization is 43 ⁇ m. Moreover, the coating film was formed similarly to Example 1 and various evaluation was performed. The evaluation results were as shown in Table 1.
- Example 10 A powder composed of composite particles was obtained through the same procedure as in Example 9 except that the Theta composer manufactured by Tokuju Kogakusho Co. was changed to a hybridization system manufactured by Nara Machinery Co., Ltd. Moreover, the coating film was formed similarly to Example 9, and various evaluation was performed. The evaluation results were as shown in Table 1.
- Example 11 A powder composed of composite particles was obtained through the same procedure as in Example 9 except that the Theta Composer manufactured by Deoksugaku Kosakusho was changed to Nobilta manufactured by Hosokawa Micron. Moreover, the coating film was formed similarly to Example 9, and various evaluation was performed. The evaluation results were as shown in Table 1.
- Example 12 A powder composed of composite particles was obtained through the same procedure as in Example 9 except that the blending ratio of ETFE, polyamideimide resin and polyphenylene sulfide resin was changed as shown in Table 1. Moreover, the coating film was formed similarly to Example 9, and various evaluation was performed. The evaluation results were as shown in Table 1.
- Example 13 A powder composed of composite particles was obtained through the same procedure as in Example 10 except that the blending ratio of ETFE, polyamideimide resin and polyphenylene sulfide resin was changed as shown in Table 1. Moreover, the coating film was formed similarly to Example 10 and various evaluation was performed. The evaluation results were as shown in Table 1.
- Example 14 A powder composed of composite particles was obtained through the same procedure as in Example 11 except that the blending ratio of ETFE, polyamideimide resin and polyphenylene sulfide resin was changed as shown in Table 1. Moreover, the coating film was formed similarly to Example 11, and various evaluation was performed. The evaluation results were as shown in Table 1. A photograph obtained by observing the obtained composite particles with a scanning electron microscope (SEM) is shown in FIG. The charge amount at the time of observation was ⁇ 5.82 ⁇ c / g. Further, a photograph after the underwater separation test is shown in FIG.
- SEM scanning electron microscope
- Example 15 The composite particles were subjected to the same procedure as in Example 11 except that the average particle diameter of ETFE after pulverization was changed to 254 ⁇ m and the blending ratio of ETFE, polyamideimide resin and polyphenylene sulfide resin was changed as shown in Table 1. A powder consisting of Moreover, the coating film was formed similarly to Example 11, and various evaluation was performed. The evaluation results were as shown in Table 1.
- Comparative Example 1 (Dry blend) Tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (true specific gravity 2.15, melting point 304 ° C., TFE / PAVE molar ratio 98/2, average particle size 23 ⁇ m) obtained by suspension polymerization and resin (trade name: Torlon 4000TF (manufactured by Solvay Advanced Polymers) and polyphenylene sulfide resin (trade name: Ryton V-1, Phillips) are uniformly dispersed in a mixer (V-type blender, Dalton), and the mixing ratios shown in Table 1 Of mixed powder was obtained. The fluorine-containing surfactant concentration in the obtained powder was calculated. Moreover, the water separation test was done using the obtained powder.
- a coating film is formed on the iron substrate by electrostatic coating using the obtained powder, and the film thickness of the coating film, the adhesion between the coating film and the substrate, and the adhesive strength between the coating film and the substrate. Standard deviation was determined. The evaluation results were as shown in Table 1.
- Comparative Example 2 Tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (true specific gravity 2.15, melting point 304 ° C., TFE / PAVE molar ratio 98/2) obtained by emulsion polymerization and liquid polyamideimide resin (trade name: HI-680) And a polyphenylene sulfide resin (trade name: Ryton V-1, manufactured by Philips) were processed with a mini spray dryer B-290 manufactured by Nihon Büch Co., Ltd. A mixed powder was obtained. The fluorine-containing surfactant concentration in the obtained powder was calculated. Moreover, the water separation test was done using the obtained powder.
- a coating film is formed on the iron substrate by electrostatic coating using the obtained powder, and the film thickness of the coating film, the adhesion between the coating film and the substrate, and the adhesive strength between the coating film and the substrate. Standard deviation was determined. The evaluation results were as shown in Table 1.
- Comparative Example 3 (Dry blend) A mixed powder having the blending ratio shown in Table 1 was obtained through the same procedure as in Comparative Example 1 except that the blending ratio of PFA, polyamideimide resin and polyphenylene sulfide resin was changed as shown in Table 1. Moreover, the coating film was formed similarly to the comparative example 1, and various evaluation was performed. The evaluation results were as shown in Table 1. A photograph obtained by observing the obtained mixed powder with a scanning electron microscope (SEM) is shown in FIG. The amount of charge at the time of observation was -9.10 ⁇ c / g. Further, a photograph after the underwater separation test is shown in FIG.
- SEM scanning electron microscope
- Comparative Example 4 Tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (true specific gravity 2.15, melting point 304 ° C., TFE / PAVE molar ratio 98/2) obtained by emulsion polymerization and liquid polyamideimide resin (trade name: HI-680) Hitachi Chemical Co., Ltd.) and polyphenylene sulfide resin (trade name: Ryton V-1, manufactured by Philips) are co-coagulated, dried and separated and pulverized with a cooking mixer, and mixed at the mixing ratio shown in Table 1. A powder was obtained. The fluorine-containing surfactant concentration in the obtained powder was calculated. Moreover, the water separation test was done using the obtained powder. Moreover, the coating film was formed similarly to the comparative example 1, and various evaluation was performed. The evaluation results were as shown in Table 1.
- Comparative Example 5 Tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer [PFA] is converted to tetrafluoroethylene-ethylene copolymer [ETFE] (true specific gravity 1.85, melting point 254 ° C., TFE / ethylene / (perfluorobutyl) ethylene molar ratio.
- the mixed powder of the compounding ratio of Table 1 was obtained through the same procedure as the comparative example 1 except having replaced with 56/42/2).
- the average particle diameter of ETFE is 43 ⁇ m.
- the coating film was formed similarly to the comparative example 1, and various evaluation was performed. The evaluation results were as shown in Table 1.
- a photograph obtained by observing the obtained powder with a scanning electron microscope (SEM) is shown in FIG.
- the amount of charge at the time of observation was -17.82 ⁇ c / g.
- a photograph after the underwater separation test is shown in FIG.
- Processing apparatus in Table 1 is as shown below.
- Processing device (I) Theta composer processing device manufactured by Tokusu Kosakusho Co., Ltd.
- III Hybridization system processing device manufactured by Nara Machinery Co., Ltd.
- III Nobilta manufactured by Hosokawa Micron
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Abstract
Description
本発明の複合粒子は、含フッ素重合体の粒子と接着性重合体の粒子がひとまとまりになるよう設計されたものであり、塗装時の含フッ素重合体と接着性重合体とのばらつきをなくすことができる。このような複合粒子を用いることにより、従来より少ない接着性成分の配合量であっても、基材との密着性が優れ、基材との密着のムラの少ない塗膜を得ることができる。
更に、フッ素樹脂の割合を多くすることができるので、プライマーとして使用した場合にトップコート層との接着性をより向上させることもできる。
上記含フッ素界面活性剤の含有量は、懸濁重合により得られる含フッ素重合体を使用することで達成することができる。懸濁重合では、含フッ素界面活性剤を使用しないため、懸濁重合により得られる含フッ素重合体を使用することで、含フッ素界面活性剤の含有量が0.1ppm未満の複合粒子を得ることができる。
また、本発明の複合粒子は、含フッ素重合体と接着性重合体とが、ひとまとまりになるように形成されているため、帯電量をコントロールすることもできる。従って、特に静電塗装に使用する粉体塗料の材料として好適である。
本明細書中で「合着」とは、粒子を水に分散させた後に充分な時間で静置した場合に、水が懸濁することがなく、水に粒子が浮遊するように、含フッ素重合体からなる粒子と接着性重合体からなる粒子とが一体的に形成されていることを意味する。
一方で、含フッ素重合体粒子と接着性重合体粒子とを通常のドライブレンド等により得られた混合粉末では、図13に示すように、含フッ素重合体粒子131と接着性重合体粒子132及び133とが分離した状態にあるため、接着性重合体粒子の分布にムラが生じた塗膜が得られるおそれがある。その結果、得られる塗膜と基材との密着が不均一になるおそれがあり、基材の全面で強固に接着させるには、接着性重合体を多量に配合する必要がある。
平均粒子径が大きすぎると、平滑な表面の塗膜が得られないおそれがある。平均粒子径が小さすぎると、塗装効率が低下するおそれがある。
複合粒子の平均粒子径は、日機装社製のレーザー回折・散乱式粒度分析計 MT3300EX IIにより測定することができる。
また、回転塗装又は回転成形に使用する粉体塗料に用いられる場合、平均粒子径が100μm以上1000μm以下であることが好ましく、100μm以上500μm以下がより好ましい。
含フッ素重合体と接着性重合体との質量比が上記範囲であることにより、本発明の複合粒子を用いて得られる塗膜と基材との密着性がより高くなり、また、塗膜と基材とがより均一に密着したものとなる。
ドライブレンド等の従来の方法で得られる含フッ素重合体と接着性重合体との混合粉末では、含フッ素重合体と接着性重合体とが分離しているため、得られる塗膜と基材との密着が不均一になるおそれがあり、基材の全面で強固に接着させるには、接着性重合体を多量に配合する必要があった。本発明の複合粒子を用いた場合、接着性重合体の配合量が上記のように少なくても、基材との密着が強固であり、また、基材と均一に密着した塗膜を得ることができる。
上記含フッ素重合体は、溶融成形可能なものであれば特に限定されない。上記含フッ素重合体は、明確な融点を有するものであることが好ましく、フッ素樹脂であることが好ましい。
CH2=CX5Rf3、CF2=CFRf3、CF2=CFORf3、CH2=C(Rf3)2
(式中、X5は水素原子又はフッ素原子、Rf3はエーテル結合性酸素原子を含んでいてもよいフルオロアルキル基を表す。)で表される単量体が挙げられ、なかでも、CF2=CFRf3、CF2=CFORf3及びCH2=CX5Rf3で表される含フッ素ビニルモノマーが好ましく、HFP、CF2=CF-ORf4(式中、Rf4は炭素数1~5のパーフルオロアルキル基を表す。)で表されるパーフルオロ(アルキルビニルエーテル)〔PAVE〕及びRf3が炭素数1~8のフルオロアルキル基であるCH2=CX5Rf3で表される含フッ素ビニルモノマーがより好ましい。また、TFE及びエチレンと共重合可能な単量体としては、イタコン酸、無水イタコン酸等の脂肪族不飽和カルボン酸であってもよい。TFE及びエチレンと共重合可能な単量体は、含フッ素重合体に対して0.1~10モル%が好ましく、0.1~5モル%がより好ましく、0.2~4モル%が特に好ましい。
上記見掛密度は、JIS K 6891にしたがって測定することができる。
そのため、本発明の複合粒子では、懸濁重合品から得た含フッ素重合体を使用することが好ましい。この場合、含フッ素界面活性剤を使用せずに含フッ素重合体を製造することができるため、本発明の複合粒子から形成される塗膜にも含フッ素界面活性剤が含まれず、環境負荷が小さく、フッ素樹脂塗膜の本来の特徴を発現することが可能となる。また、含フッ素界面活性剤が揮発分解することによる塗膜と基材との密着性の阻害も生じない。
本発明の複合粒子は、含フッ素重合体と接着性重合体とからなる。本発明の複合粒子が接着性重合体からなるものであることにより、基材との密着性が優れた塗膜を形成することができる。
上記接着性重合体は、ポリイミド〔PI〕、ポリアミドイミド〔PAI〕、ポリアミド〔PA〕、ポリアミド酸(ポリアミック酸)、エポキシ樹脂、ポリサルファイド、ポリアリーレンサルファイド〔PAS〕、及び、ポリエーテルサルフォン〔PES〕からなる群より選択される少なくとも1種の化合物であることが好ましい。
上記接着性重合体としては、市販されている粉末を用いてもよいし、更に、粉砕を行い微粉化した微粉末を用いてもよい。また、市販されているペレットタイプのものを粉砕した粉末であってもよい。粉砕方法は特に限定されないが、通常のパラペライザー粉砕、アトマイザー粉砕等により粉砕することができる。
本発明の複合粒子は、湿式ではなく、上記のような乾式生産である表面改質機を用いることで、生産作業性を簡便にでき、含フッ素重合体の粒子と、接着性重合体の粒子とが合着された複合粒子を得ることができる。また、水に分散させた後に充分な時間で静置した場合に、水が懸濁することなく水に浮遊する複合粒子を製造することができる。
例えば、通常のドライブレンドにより含フッ素重合体と接着性重合体とを混合した場合、含フッ素重合体と接着性重合体とが合着せず、塗装時に含フッ素重合体と接着性重合体との配合比にばらつきが生じ、得られる塗膜の密着性にムラが生じるおそれがある。そのような場合、接着性重合体を過剰に配合する必要が生じる。
また、含フッ素重合体と接着性樹脂との水性分散液中から、共凝析により得られた含フッ素重合体と接着性樹脂との混合粉末を水処理によって単離する場合、得られた混合粉末を用いて塗膜を製造しても基材との密着性が充分でなく、基材との密着性にもばらつきが生じる。また、液中で複合化を行うため、商業的に実施するには乾燥設備などの巨大な設備が必要となったり、乾燥中の凝集も避けられず、その生産性は必ずしも高いものではない。
ドラム内部に垂直方向の回転軸と案内板が設けられ、回転軸の底部には二枚の羽根が配される装置。回転軸を高速回転させることで粉末は下羽根によって上方に流動し、上羽根によって強力な機械的応力が付与される。さらに粉末が案内板や装置内壁に高速で衝突することによって大きな衝撃力が与えられる。含フッ素重合体粉末温度が100~200℃の範囲で処理することが好ましい。
ドラム内部で高速回転する回転盤、及び、ドラムの中心部と内壁部を結ぶ循環回路から構成される装置。気流により供給される粉末は回転盤に配された衝撃ピン及び装置内壁との衝突による衝撃力を受ける。これらの粉末は循環回路を経て一度ドラム内部から排出された後に再びドラム内へ戻されるため、機械的応力が繰り返し付与される。含フッ素重合体粉末温度が50~200℃の範囲で処理することが好ましい。
ドラム内部にある回転軸の外周部に複数の羽根を配し、これを回転させることで遠心拡散及び渦流作用を生じさせてドラム内で粉末を流動させる装置。粉末は装置内壁に押し付けられることで機械的応力が付与される。粉末を回転軸方向に送りと戻しの機能を有する攪拌部材が稼動してもよい。含フッ素重合体粉末温度が50~200℃の範囲で処理することが好ましい。
上記接着強度は、上記複合粒子からなる粉体塗料を、静電塗装により金属基材上に塗装し、得られた塗膜に10mm間隔で金属面に達するまで切り目を入れ、テンシロン万能試験機を用い、JIS K 6854-1(1999年)に準拠して引っ張り速度50mm/分で試験片に対して90°方向に引張り、その剥離接着強度を測定した。金属基材としては、鉄を用いることができる。
接着強度の標準偏差は、下記式より算出する。
mは接着強度の平均であり、mは下記式で算出される。
m=(S1+S2+S3+・・・+Si)/i
日機装社製のレーザー回折・散乱式粒度分析計 MT3300EX IIにより評価した。
ソックスレー抽出により複合粒子に含まれる含フッ素界面活性剤をアセトン中に抽出し、この濃度を日本ウォーターズ社製の質量分析計 Quattro micro GCにより評価した。
静電塗装により設けた塗膜を、サンコウ電子社製の電磁式膜厚計SWT-8100型により評価した。
実施例及び比較例で得られた塗膜に、10mm間隔で金属面に達するまで切り目を入れ、テンシロン万能試験機を用い、JIS K 6854-1(1999年)に準拠して引っ張り速度50mm/分で試験片に対して90°方向に引張り、その剥離接着強度を測定した。
接着強度の標準偏差は、下記式より算出した。
mは接着強度の平均であり、mは下記式で算出される。
m=(S1+S2+S3+・・・+Si)/i
純水5gに複合粉体0.5gを入れ、振り混ぜ、しばらく静置したあと、水の濁り具合を確認した。
○:分離しない。
×:分離する。
徳寿工作所社製 シータコンポーザ(処理装置(I))
奈良機械製作所社製 ハイブリダイゼーションシステム(処理装置(II))
ホソカワミクロン社製 ノビルタ(処理装置(III))
懸濁重合により得たテトラフルオロエチレン-パーフルオロ(アルキルビニルエーテル)共重合体[PFA](真比重2.15、融点304℃、TFE/PAVEのモル比が98/2)を新東工業社製のローラーコンパクターBSC-25型を用い、得られるシートが真比重の90%以上となるように圧縮し、幅60mm、厚さ5mmのシートを得た。次に、上記ローラーコンパクター付属の解砕機で約10mm径に解砕したものを、奈良機械製作所製の粉砕機コスモマイザーN-1型を用いて粉砕した。粉砕して得られたPFA(平均粒子径23μm)とポリアミドイミド樹脂(商品名:トーロン4000TF、ソルベイアドバンストポリマーズ社製、平均粒子径:2μm)とポリフェニレンサルファイド樹脂(商品名:ライトンV-1、フィリップス社製、平均粒子径:5μm)を徳寿工作所社製 シータコンポーザで処理することにより、PFAとポリアミドイミド樹脂とポリフェニレンサルファイド樹脂との複合粒子からなる粉末を得た。得られた粉末中の含フッ素界面活性剤濃度を算出した。また、得られた複合粒子を用いて、水中分離試験を行った。
更に、得られた粉末を用いて、下記条件の静電塗装により鉄基材上に塗膜を形成し、塗膜の膜厚、塗膜と基材との密着性、塗膜と基材との接着強度の標準偏差を求めた。評価結果は、表1に示す通りであった。
徳寿工作所社製 シータコンポーザを、奈良機械製作所社製 ハイブリダイゼーションシステムに変更した以外は実施例1と同じ方法で複合粒子からなる粉末を得た。また、実施例1と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
実施例1の徳寿工作所社製 シータコンポーザを、ホソカワミクロン社製 ノビルタに変更した以外は実施例1と同様の手順を経て複合粒子からなる粉末を得た。また、実施例1と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
PFAとポリアミドイミド樹脂とポリフェニレンサルファイド樹脂との配合比を表1に示すように変更した以外は、実施例1と同様の手順を経て複合粒子からなる粉末を得た。また、実施例1と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
得られた複合粒子を走査型電子顕微鏡(SEM)により観察して得られた写真を図1に示す。
PFAとポリアミドイミド樹脂とポリフェニレンサルファイド樹脂との配合比を表1に示すように変更した以外は、実施例2と同様の手順を経て複合粒子からなる粉末を得た。また、実施例2と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
得られた複合粒子を走査型電子顕微鏡(SEM)により観察して得られた写真を図2に示す。また、水中分離試験を行った後の写真を図7に示す。
PFAとポリアミドイミド樹脂とポリフェニレンサルファイド樹脂との配合比を表1に示すように変更した以外は、実施例3と同様の手順を経て複合粒子からなる粉末を得た。また、実施例3と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
得られた複合粒子を走査型電子顕微鏡(SEM)により観察して得られた写真を図3に示す。観察時の帯電量は、-7.00μc/gであった。また、水中分離試験を行った後の写真を図8に示す。
粉砕後のPFAの平均粒子径を132μmに変更し、PFAとポリアミドイミド樹脂とポリフェニレンサルファイド樹脂との配合比を表1に示すように変更した以外は、実施例3と同様の手順を経て複合粒子からなる粉末を得た。また、実施例3と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
テトラフルオロエチレン-パーフルオロアルキルビニルエーテル共重合体[PFA]をテトラフルオロエチレン-ヘキサフルオロプロピレン共重合体〔FEP〕(真比重2.15、融点269℃、TFE/HFPのモル比が90/10)に変更したこと以外は実施例7と同様の手順を経て、複合粒子からなる粉末を得た。なお、粉砕後のFEPの平均粒子径は35μmである。
また、実施例7と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
テトラフルオロエチレン-パーフルオロアルキルビニルエーテル共重合体[PFA]をテトラフルオロエチレン-エチレン共重合体〔ETFE〕(真比重1.85、融点254℃、TFE/エチレン/(パーフルオロブチル)エチレンのモル比が56/42/2)に代えた点以外は実施例1と同様の手順を経て、複合粒子からなる粉末を得た。なお、粉砕後のETFEの平均粒子径は43μmである。
また、実施例1と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
徳寿工作所社製 シータコンポーザを奈良機械製作所社製 ハイブリダイゼーションシステムに変更した以外は実施例9と同様の手順を経て、複合粒子からなる粉末を得た。また、実施例9と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
徳寿工作所社製 シータコンポーザをホソカワミクロン社製 ノビルタに変更した以外は実施例9と同様の手順を経て、複合粒子からなる粉末を得た。また、実施例9と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
ETFEとポリアミドイミド樹脂とポリフェニレンサルファイド樹脂との配合比を表1に示すように変更した以外は、実施例9と同様の手順を経て複合粒子からなる粉末を得た。また、実施例9と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
ETFEとポリアミドイミド樹脂とポリフェニレンサルファイド樹脂との配合比を表1に示すように変更した以外は、実施例10と同様の手順を経て複合粒子からなる粉末を得た。また、実施例10と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
ETFEとポリアミドイミド樹脂とポリフェニレンサルファイド樹脂との配合比を表1に示すように変更した以外は、実施例11と同様の手順を経て複合粒子からなる粉末を得た。また、実施例11と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
得られた複合粒子を走査型電子顕微鏡(SEM)により観察して得られた写真を図4に示す。観察時の帯電量は、-5.82μc/gであった。また、水中分離試験を行った後の写真を図9に示す。
粉砕後のETFEの平均粒子径を254μmに変更し、ETFEとポリアミドイミド樹脂とポリフェニレンサルファイド樹脂との配合比を表1に示すように変更した以外は、実施例11と同様の手順を経て複合粒子からなる粉末を得た。また、実施例11と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
懸濁重合により得たテトラフルオロエチレン-パーフルオロアルキルビニルエーテル共重合体(真比重2.15、融点304℃、TFE/PAVEのモル比が98/2、平均粒子径23μm)と樹脂(商品名:トーロン4000TF、ソルベイアドバンストポリマーズ社製)とポリフェニレンサルファイド樹脂(商品名:ライトンV-1、フィリップス社製)を混合機(V型ブレンダー、ダルトン社製)で均一分散し、表1に記載の配合比の混合粉末を得た。得られた粉末中の含フッ素界面活性剤濃度を算出した。また、得られた粉末を用いて、水中分離試験を行った。
更に、得られた粉末を用いて静電塗装により鉄基材上に塗膜を形成し、塗膜の膜厚、塗膜と基材との密着性、塗膜と基材との接着強度の標準偏差を求めた。評価結果は、表1に示す通りであった。
乳化重合により得たテトラフルオロエチレン-パーフルオロアルキルビニルエーテル共重合体(真比重2.15、融点304℃、TFE/PAVEのモル比が98/2)と液状ポリアミドイミド樹脂(商品名:HI-680、日立化成工業社製)とポリフェニレンサルファイド樹脂(商品名:ライトンV-1、フィリップス社製)を日本ビュッヒ社製のミニスプレードライヤーB-290で処理することにより、表1に記載の配合比の混合粉末を得た。得られた粉末中の含フッ素界面活性剤濃度を算出した。また、得られた粉末を用いて、水中分離試験を行った。
更に、得られた粉末を用いて静電塗装により鉄基材上に塗膜を形成し、塗膜の膜厚、塗膜と基材との密着性、塗膜と基材との接着強度の標準偏差を求めた。評価結果は、表1に示す通りであった。
PFAとポリアミドイミド樹脂とポリフェニレンサルファイド樹脂との配合比を表1に示すように変更した以外は、比較例1と同様の手順を経て表1に記載の配合比の混合粉末を得た。また、比較例1と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
得られた混合粉末を走査型電子顕微鏡(SEM)により観察して得られた写真を図5に示す。観察時の帯電量は、-9.10 μc/gであった。また、水中分離試験を行った後の写真を図10に示す。
乳化重合により得たテトラフルオロエチレン-パーフルオロアルキルビニルエーテル共重合体(真比重2.15、融点304℃、TFE/PAVEのモル比が98/2)と液状ポリアミドイミド樹脂(商品名:HI-680、日立化成工業社製)とポリフェニレンサルファイド樹脂(商品名:ライトンV-1、フィリップス社製)を共凝析させ、乾燥後にクッキングミキサーで分離解砕することにより表1に記載の配合比の混合粉末を得た。得られた粉末中の含フッ素界面活性剤濃度を算出した。また、得られた粉末を用いて、水中分離試験を行った。
また、比較例1と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
テトラフルオロエチレン-パーフルオロアルキルビニルエーテル共重合体[PFA]をテトラフルオロエチレン-エチレン共重合体〔ETFE〕(真比重1.85、融点254℃、TFE/エチレン/(パーフルオロブチル)エチレンのモル比が56/42/2)に代えた点以外は比較例1と同様の手順を経て、表1に記載の配合比の混合粉末を得た。なお、ETFEの平均粒子径は43μmである。また、比較例1と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
得られた粉末を走査型電子顕微鏡(SEM)により観察して得られた写真を図6に示す。観察時の帯電量は、-17.82μc/gであった。また、水中分離試験を行った後の写真を図11に示す。
テトラフルオロエチレン-パーフルオロアルキルビニルエーテル共重合体[PFA]をテトラフルオロエチレン-ヘキサフルオロプロピレン共重合体〔FEP〕(真比重2.15、融点269℃、TFE/HFPのモル比が90/10)に代えた点以外は比較例1と同様の手順を経て表1に記載の配合比の混合粉末を得た。なお、FEPの平均粒子径は35μmである。また、比較例1と同様に、塗膜を形成し、各種評価を行った。評価結果は、表1に示す通りであった。
処理装置(I) :徳寿工作所社製 シータコンポーザ
処理装置(II) :奈良機械製作所社製 ハイブリダイゼーションシステム
処理装置(III):ホソカワミクロン社製 ノビルタ
32:PFA粒子
42:ETFE粒子
120:複合粒子
121、131:含フッ素重合体粒子
122、123、132,133:接着性重合体粒子
Claims (15)
- 含フッ素重合体と接着性重合体とからなる複合粒子であって、
含フッ素界面活性剤の含有量が0.1ppm未満であることを特徴とする複合粒子。 - 含フッ素重合体からなる粒子と接着性重合体からなる粒子とを合着させることにより得られる請求項1記載の複合粒子。
- 遠心拡散及び渦流作用を有する装置を使用して、含フッ素重合体からなる粒子と接着性重合体からなる粒子とを合着させることにより得られる請求項1又は2記載の複合粒子。
- 粒子を水に分散させた後に充分な時間で静置した場合に、水が懸濁することがなく、水に粒子が浮遊する請求項1、2又は3記載の複合粒子。
- 平均粒子径が1~1000μmである請求項1、2、3又は4記載の複合粒子。
- 含フッ素重合体と接着性重合体との質量比が5/50~99/1である請求項1、2、3、4又は5記載の複合粒子。
- 接着性重合体は、ポリイミド、ポリアミドイミド、ポリアミド、ポリアミド酸、エポキシ樹脂、ポリサルファイド、ポリアリーレンサルファイド、及び、ポリエーテルサルフォンからなる群より選択される少なくとも1種の化合物である請求項1、2、3、4、5又は6記載の複合粒子。
- 含フッ素重合体は、テトラフルオロエチレン-パーフルオロ(アルキルビニルエーテル)共重合体、テトラフルオロエチレン-ヘキサフルオロプロピレン共重合体及びテトラフルオロエチレン-エチレン共重合体からなる群より選択される少なくとも1種のフッ素樹脂である請求項1、2、3、4、5、6又は7記載の複合粒子。
- 請求項1、2、3、4、5、6、7又は8記載の複合粒子からなる粉体塗料。
- 請求項9に記載の粉体塗料から形成される塗膜。
- 金属基材上に、請求項10記載の塗膜を備える積層体であって、
塗膜と金属基材との接着強度が50~300N/cmである積層体。 - 塗膜と金属基材との接着強度の標準偏差が、10未満である請求項11記載の積層体。
- 請求項1、2、3、4、5、6、7又は8記載の複合粒子を製造する方法であって、
含フッ素重合体と接着性重合体とを表面改質機に投入する工程、
前記含フッ素重合体と接着性重合体とを表面改質機中で混合して複合粒子を得る工程、及び、
前記表面改質機から複合粒子を回収する工程
を含むことを特徴とする複合粒子の製造方法。 - 表面改質機は、高速流動混合機、高速回転式衝撃粉砕機、又は、摩擦式ミルである請求項13記載の複合粒子の製造方法。
- 表面改質機は、摩擦式ミルである請求項13又は14記載の複合粒子の製造方法。
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US9944817B2 (en) | 2018-04-17 |
US20150030857A1 (en) | 2015-01-29 |
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