WO2016208344A1 - 耐薬品性を有する塗膜 - Google Patents
耐薬品性を有する塗膜 Download PDFInfo
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- WO2016208344A1 WO2016208344A1 PCT/JP2016/066202 JP2016066202W WO2016208344A1 WO 2016208344 A1 WO2016208344 A1 WO 2016208344A1 JP 2016066202 W JP2016066202 W JP 2016066202W WO 2016208344 A1 WO2016208344 A1 WO 2016208344A1
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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
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/60—Additives non-macromolecular
- C09D7/63—Additives non-macromolecular organic
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/44—Amides
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
- C08G59/22—Di-epoxy compounds
- C08G59/28—Di-epoxy compounds containing acyclic nitrogen atoms
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/01—Hydrocarbons
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/05—Alcohols; Metal alcoholates
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/16—Nitrogen-containing compounds
- C08K5/20—Carboxylic acid amides
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
-
- 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
-
- 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
- C09D5/08—Anti-corrosive paints
-
- 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
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/20—Diluents or solvents
-
- 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
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2150/00—Compositions for coatings
- C08G2150/90—Compositions for anticorrosive coatings
Definitions
- the present invention relates to a coating film having chemical resistance.
- a paint obtained by adding an amine curing agent to an epoxy resin is used as an anticorrosion paint because it is excellent in anticorrosion and adhesiveness.
- a Mannich type curing agent formed by a Mannich condensation reaction of phenols, aldehydes, and an amine compound, or an adduct of this Mannich type curing agent and an epoxy resin has been used (see Patent Document 2).
- the tar epoxy paint as the anticorrosion paint is excellent in anticorrosion, water resistance, chemical resistance, etc., but since it contains tar, it is not only concerned about safety and health problems, but also black. It was difficult to maintain, and it was dark in an enclosed space, so there were problems such as the work being dangerous.
- the above-mentioned non-tar paint using a petroleum-based resin instead of tar has a problem in the compatibility between a cured resin composed of an epoxy resin and an amine curing agent and a petroleum-based resin, and particularly has a high degree of corrosion resistance and water resistance. It was insufficient to apply to the required use.
- the Mannich type curing agent is concerned with safety and health problems because phenols remain in the curing agent.
- the subject of this invention is providing the coating film which solves the said problem, has a favorable external appearance, and has high chemical resistance.
- the inventors of the present invention have a coating film containing a solvent at a specific ratio in a cured product formed from a specific epoxy resin composition, And it discovered having high chemical resistance, and came to this invention. That is, the present invention is as follows.
- R 1 and R 2 each independently represents a hydrogen atom, an alkyl group having 1 to 8 carbon atoms, an aralkyl group having 1 to 8 carbon atoms, or an aryl group.
- the coating film according to item 1 wherein (C) at least one selected from the group consisting of monovalent carboxylic acids represented by R 3 —COOH and derivatives thereof (R 3 is a C 1-7 alkyl optionally having a hydrogen atom or a hydroxyl group) Represents a group or an aryl group.)
- R 3 is a C 1-7 alkyl optionally having a hydrogen atom or a hydroxyl group
- Cyclic carbonate (E) Monoepoxy compound having 2 to 20 carbon atoms
- the solvent is at least one selected from the group consisting of an alcohol compound and a hydrocarbon compound having an aromatic ring.
- the coating film of 2nd term claim.
- the alcohol compound is at least one selected from the group consisting of methanol, ethanol, 2-propanol, 1-propanol, 2-methyl-1-propanol, 1-butanol and 2-butanol, The coating film according to item.
- the epoxy resin is derived from an epoxy resin having a glycidylamino group derived from metaxylylenediamine, an epoxy resin having a glycidylamino group derived from 1,3-bis (aminomethyl) cyclohexane, or a diaminodiphenylmethane.
- the epoxy resin has an epoxy resin having a glycidylamino group derived from metaxylylenediamine, an epoxy resin having a glycidyloxy group derived from bisphenol A, and an epoxy having a glycidyloxy group derived from bisphenol F 14.
- a method for improving chemical resistance of a coating film wherein the coating film is formed by curing an epoxy resin composition containing at least an epoxy resin, an epoxy resin curing agent and a solvent, and the epoxy resin curing agent is A method for improving the chemical resistance of a coating film, which is a reaction product of (A) and (B), and the solvent is contained in the coating film in an amount of 1% by mass to 20% by mass.
- B at least one selected from the group consisting of unsaturated carboxylic acids represented by the following formula (1) and derivatives thereof (In formula (1), R 1 and R 2 are the same as above.)
- the coating film of the present invention is suitably used for paint applications such as marine paints, heavy anticorrosion paints, tank paints, pipe interiors, exterior paints, and flooring paints.
- the present invention relates to a coating film containing a specific amount of solvent in a cured product formed from a specific epoxy resin composition. Specifically, it is a coating film formed by curing an epoxy resin composition containing at least an epoxy resin, an epoxy resin curing agent and a solvent, and the solvent is contained in the coating film in an amount of 1% by mass to 20% by mass. It contains and the coating film whose epoxy resin hardening
- curing agent is a reaction product of following (A) and (B).
- R 1 and R 2 each independently represents a hydrogen atom, an alkyl group having 1 to 8 carbon atoms, an aralkyl group having 1 to 8 carbon atoms, or an aryl group.
- the coating film of the present invention is formed by curing a specific epoxy resin composition, and exhibits a good appearance and high chemical resistance by containing a specific amount of a solvent in the coating film.
- Epoxy resin compositions are used in a wide range of fields, but it is generally assumed that no solvent remains in the cured product of the epoxy resin composition. Therefore, when an epoxy resin composition contains a solvent, the hardening is normally performed on heating conditions, and the solvent in hardened
- epoxy resin compositions that require gas barrier properties are used for food, beverages, pharmaceutical packaging materials, and the like, so that no solvent remains in the cured product.
- the present inventors have better chemical resistance compared to the case where the coating film formed by curing of the epoxy resin composition contains a specific amount of solvent as compared with the case where the solvent is not contained. It has been found to express. Below, the coating film of this embodiment is demonstrated.
- the epoxy resin used in the present embodiment may be any of a saturated or unsaturated aliphatic compound, alicyclic compound, aromatic compound, or heterocyclic compound having an epoxy group in the molecule, but is high. In consideration of expression of chemical resistance, an epoxy resin containing an aromatic ring or an alicyclic structure in the molecule is preferable.
- epoxy resin used in the present embodiment include an epoxy resin having a glycidylamino group derived from metaxylylenediamine, and an epoxy having a glycidylamino group derived from 1,3-bis (aminomethyl) cyclohexane.
- epoxy resin having glycidylamino group derived from diaminodiphenylmethane epoxy resin having glycidylamino group derived from paraaminophenol, epoxy resin having glycidyloxy group derived from paraaminophenol, derived from bisphenol A
- the above-mentioned various epoxy resins can be mixed and used at an appropriate ratio.
- the epoxy resin used in this embodiment includes an epoxy resin having a glycidylamino group derived from metaxylylenediamine, an epoxy resin having a glycidyloxy group derived from bisphenol A, and More preferably, the main component is at least one selected from the group consisting of epoxy resins having a glycidyloxy group derived from bisphenol F, and the main component is an epoxy resin having a glycidyloxy group derived from bisphenol A. More preferred.
- the “main component” means that other components can be included without departing from the gist of the present invention, preferably 50 to 100% by mass, more preferably 70 to 100% by mass. %, More preferably 90 to 100% by mass.
- the epoxy resin is obtained by reaction of various alcohols, phenols and amines with epihalohydrin.
- an epoxy resin having a glycidylamino group derived from metaxylylenediamine can be obtained by adding epichlorohydrin to metaxylylenediamine. Since metaxylylenediamine has four amino hydrogens, mono-, di-, tri- and tetraglycidyl compounds are formed.
- the number of glycidyl groups can be changed by changing the reaction ratio of metaxylylenediamine and epichlorohydrin.
- an epoxy resin having mainly four glycidyl groups can be obtained by addition reaction of about 4 times mole of epichlorohydrin to metaxylylenediamine.
- the epoxy resin contains excess epihalohydrin with respect to various alcohols, phenols and amines in the presence of an alkali such as sodium hydroxide at 20 to 140 ° C., preferably 50 to 120 ° C. for alcohols and phenols. In the case of a kind, it is synthesized by reacting at a temperature of 20 to 70 ° C. and separating the produced alkali halide.
- an alkali such as sodium hydroxide
- the number average molecular weight of the epoxy resin used in this embodiment varies depending on the molar ratio of epihalohydrin to various alcohols, phenols and amines, but is preferably 100 to 5,000, more preferably 150 to 3,000, Preferably, it is 200 to 1,000.
- the epoxy resin curing agent used in this embodiment is a reaction product of the following (A) and (B).
- (A) At least one selected from the group consisting of metaxylylenediamine and paraxylylenediamine
- (B) at least one selected from the group consisting of unsaturated carboxylic acids represented by the following formula (1) and derivatives thereof (In formula (1), R 1 and R 2 each independently represents a hydrogen atom, an alkyl group having 1 to 8 carbon atoms, an aralkyl group having 1 to 8 carbon atoms, or an aryl group.)
- the metaxylylenediamine or paraxylylenediamine as the component (A) is preferably metaxylylenediamine from the viewpoint of chemical resistance.
- a component may be used individually by 1 type and may be used in mixture of 2 types.
- component (B) examples include acrylic acid, methacrylic acid, 2-ethylacrylic acid, 2-propylacrylic acid, ⁇ -isopropylacrylic acid, 2-n-butylacrylic acid, 2-t-butylacrylic acid, 2- Pentylacrylic acid, ⁇ -phenylacrylic acid, ⁇ -benzylacrylic acid, crotonic acid, 2-pentenoic acid, 2-hexenoic acid, 4-methyl-2-pentenoic acid, 2-heptenoic acid, 4-methyl-2-hexene Acid, 5-methyl-2-hexenoic acid, 4,4-dimethyl-2-pentenoic acid, 4-phenyl-2-butenoic acid, cinnamic acid, o-methyl cinnamic acid, m-methyl cinnamic acid, p-methyl cinnamic Consists of unsaturated carboxylic acids such as acids, 2-octenoic acid, 2-nonenoic acid, 2-de
- acrylic acid or methacrylic acid derivatives examples include methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, and n-butyl (meth) acrylate.
- Alkyl esters of acrylic acid or methacrylic acid such as isobutyl (meth) acrylate, n-octyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, (meth) Hydroxyalkyl esters of acrylic acid or methacrylic acid, such as 2-hydroxybutyl acrylate, phenyl (meth) acrylate, benzyl (meth) acrylate, (meth) acrylamide, di (meth) acrylic anhydride, and chloride ( And (meth) acryl.
- Alkyl esters of acrylic acid or methacrylic acid such as isobutyl (meth) acrylate, n-octyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, (meth) Hydroxyalkyl esters of acrylic acid
- the component (B) is preferably at least one selected from the group consisting of acrylic acid, methacrylic acid, crotonic acid and derivatives thereof from the viewpoint of chemical resistance, and consists of acrylic acid, methacrylic acid and derivatives thereof. At least one selected from the group is more preferable, and at least one selected from the group consisting of acrylic acid, methacrylic acid, and alkyl esters having 1 to 3 carbon atoms thereof is more preferable, and includes methyl acrylate and methyl methacrylate. Even more preferred is at least one selected from the group.
- one type may be used alone, or two or more types may be used in combination.
- the reaction between the component (A) and the component (B) is carried out under conditions of 0 to 100 ° C., preferably 0 to 70 ° C., when carboxylic acid, ester or amide is used as the component (B). It is carried out by mixing (A) and (B) and performing an amide group formation reaction by dehydration, dealcoholization, and deamination under conditions of 100 to 300 ° C., preferably 130 to 250 ° C. In this case, during the amide group formation reaction, the inside of the reaction apparatus can be subjected to reduced pressure treatment at the final stage of the reaction, if necessary, in order to complete the reaction. Moreover, it can also dilute using a non-reactive solvent as needed. Furthermore, catalysts such as phosphites can be added as dehydrating agents and dealcoholizing agents.
- an acid anhydride or acid chloride is used as the component (B), it is carried out by carrying out an amide group formation reaction after mixing at 0 to 150 ° C., preferably 0 to 100 ° C.
- the inside of the reaction apparatus can be subjected to reduced pressure treatment at the final stage of the reaction, if necessary, in order to complete the reaction.
- it can also dilute using a non-reactive solvent as needed.
- tertiary amines such as pyridine, picoline, lutidine and trialkylamine can be added.
- the amide group site introduced by the above reaction has a high cohesive force, and the presence of the amide group site in a high proportion in the epoxy resin curing agent results in higher oxygen barrier properties and better resistance to various substrates. Adhesive strength is obtained.
- the reaction ratio of the component (A) to the component (B) is preferably such that the reaction molar ratio [(B) / (A)] is in the range of 0.3 to 1.0. If the reaction molar ratio [(B) / (A)] is 0.3 or more, a sufficient amount of amide groups are generated in the epoxy resin curing agent, and a high level of chemical resistance and adhesion tend to be exhibited. It is in. On the other hand, if the reaction molar ratio [(B) / (A)] is in the range of 1.0 or less, the amount of amino groups necessary for the reaction with the epoxy groups in the above-described epoxy resin is sufficient and excellent.
- the reaction molar ratio [(B) / (A)] of the component (A) and the component (B) is 0. More preferably, it is in the range of 0.5 to 1.0, and more preferably in the range of 0.6 to 1.0.
- the epoxy resin curing agent in the present embodiment is a reaction product of the above (A) and (B) and at least one compound selected from the following (C), (D) and (E): Also good.
- C at least one selected from the group consisting of monovalent carboxylic acids represented by R 3 —COOH and derivatives thereof (R 3 is a C 1-7 alkyl optionally having a hydrogen atom or a hydroxyl group) Represents a group or an aryl group.
- R 3 is a C 1-7 alkyl optionally having a hydrogen atom or a hydroxyl group
- D Cyclic carbonate
- E Monoepoxy compound having 2 to 20 carbon atoms
- R 3 represents a hydrogen atom, an alkyl group having 1 to 7 carbon atoms which may have a hydroxyl group or an aryl group, and R 3 is preferably an alkyl group having 1 to 3 carbon atoms or a phenyl group.
- the component (C) examples include monovalent carboxylic acids such as formic acid, acetic acid, propionic acid, butyric acid, lactic acid, glycolic acid, and benzoic acid or derivatives thereof such as esters, amides, acid anhydrides, acid chlorides, and the like. And at least one selected from the group consisting of formic acid, acetic acid, propionic acid, butyric acid, lactic acid, glycolic acid, benzoic acid and derivatives thereof is preferred. As the component (C), one type may be used alone, or two or more types may be used in combination.
- the cyclic carbonate as the component (D) is used from the viewpoint of reducing the reactivity between the epoxy resin curing agent and the epoxy resin as necessary, and improving workability. From the viewpoint of reactivity, a cyclic carbonate having a six-membered ring or less is preferable.
- ethylene carbonate, propylene carbonate, glycerin carbonate, 1,2-butylene carbonate, vinylene carbonate, 4-vinyl-1,3-dioxolan-2-one, 4-methoxymethyl-1,3-dioxolan-2-one, 1,3-dioxane-2-one and the like can be mentioned.
- At least one selected from the group consisting of ethylene carbonate, propylene carbonate, and glycerin carbonate is preferable, and ethylene carbonate is more preferable.
- the component (D) one type may be used alone, or two or more types may be used in combination.
- the monoepoxy compound as the component (E) is a monoepoxy compound having 2 to 20 carbon atoms, and reduces the reactivity between the epoxy resin curing agent and the epoxy resin as necessary to improve workability. Used. From the viewpoint of chemical resistance, a monoepoxy compound having 2 to 10 carbon atoms is preferable, and a compound represented by the following formula (2) is more preferable.
- R 4 represents a hydrogen atom, an alkyl group having 1 to 8 carbon atoms, an aryl group, or R 5 —O—CH 2 —
- R 5 represents a phenyl group or a benzyl group.
- Examples of the monoepoxy compound represented by the formula (2) include ethylene oxide, propylene oxide, 1,2-butylene oxide, styrene oxide, phenyl glycidyl ether, and benzyl glycidyl ether.
- the component (E) one type may be used alone, or two or more types may be used in combination.
- any one of (C), (D) and (E) is used alone. Or two or more types may be used in combination.
- the epoxy resin curing agent used in the present embodiment may be a reaction product obtained by further reacting with other components within the range that does not impair the effects of the present invention in addition to the above (A) to (E). Good.
- other components mentioned here include aromatic dicarboxylic acids or derivatives thereof.
- the amount of the “other components” used is preferably 30% by mass or less, more preferably 10% by mass or less, and more preferably 5% by mass with respect to the total amount of reaction components constituting the epoxy resin curing agent. More preferably, it is as follows.
- the reaction product of (A) and (B) with at least one compound selected from (C), (D) and (E) is the above (C), (D) and (E).
- At least one compound selected from the group consisting of (B) is used in combination with (A) which is a polyamine.
- the (B) to (E) may be added in any order and reacted with the (A).
- the (B) to (E) may be mixed and reacted with the (A). May be.
- the reaction between (A) and (C) can be carried out under the same conditions as the reaction between (A) and (B).
- the (B) and (C) may be mixed and reacted with the (A).
- the (A) and (B) are reacted with each other.
- (C) may be reacted.
- the (D) and / or (E) are first reacted, and then the (D) and / or (E) are reacted. preferable.
- the reaction between (A) and (D) and / or (E) is carried out by mixing (A) with (D) and / or (E) under the conditions of 25 to 200 ° C.
- urethane bond forming reaction It is carried out by carrying out a urethane bond forming reaction by addition reaction under the conditions of ° C, preferably 40 to 170 ° C. Further, if necessary, a catalyst such as sodium methoxide, sodium ethoxide, potassium t-butoxide can be used. In the urethane bond forming reaction, in order to accelerate the reaction, (D) and / or (E) can be melted or diluted with a non-reactive solvent as necessary.
- the epoxy resin curing agent in the present embodiment is a reaction product of (A) and (B) and at least one compound selected from (C), (D) and (E).
- the reaction molar ratio [(B) / (A)] between (A) and (B) is preferably in the range of 0.3 to 1.0 for the same reason as described above. A range of 1.0 is more preferable, and a range of 0.6 to 1.0 is more preferable.
- the reaction ratio of (A) to (C), (D) and (E) is such that the reaction molar ratio [ ⁇ (C) + (D) + (E) ⁇ / (A)] is 0.
- any ratio in the range of .05 to 3.1 is possible, preferably in the range of 0.07 to 2.5, and more preferably in the range of 0.1 to 2.0. Is more preferably in the range of 0.1 to 1.0, and still more preferably in the range of 0.1 to 0.7.
- the reaction molar ratio [ ⁇ (B) + (C) + (D) + (E) ⁇ between (A) and (B) to (E) above] / (A)] is preferably in the range of 0.35 to 2.5, more preferably in the range of 0.35 to 2.0, and in the range of 0.35 to 1.5. Is more preferable.
- the epoxy resin curing agent in this embodiment preferably has an active hydrogen equivalent as a resin solid content in the range of 30 to 400, more preferably 50 to 300, from the viewpoint of curability of the epoxy resin.
- the coating film of the present invention is a coating film formed by curing an epoxy resin composition containing at least the above-described epoxy resin, an epoxy resin curing agent, and a solvent.
- the solvent includes the epoxy resin and the solvent.
- the content of the solvent in the coating film is 1% by mass or more, it tends to be able to inhibit the appearance of the coating film from causing repellency and wrinkles, and the deterioration of chemical resistance against specific chemicals. It is in.
- the content of the solvent in the coating film is 20% by mass or less, a decrease in chemical resistance due to a decrease in the crosslinking density of the coating film tends to be suppressed.
- the epoxy resin curing agent is a skeleton containing a large amount of amine having active hydrogen in the curing agent
- a cured product obtained by reacting the curing agent with the epoxy resin usually has high hydrophilicity.
- moderate hydrophobicity is expressed. This is presumed to be related to the improvement of the chemical resistance (salt water spray resistance, water-containing methanol resistance, etc.) of the coating film.
- the solvent used in this embodiment is not particularly limited as long as it can dissolve the epoxy resin and the epoxy resin curing agent used in this embodiment, and is alcohol-based, ether-based, ester-based, glycol ether. , Ketone-based, cellosolve-based, halogen-containing hydrocarbon-based or hydrocarbon-based compounds.
- solvent used in this embodiment include methanol, ethanol, 2-propanol, 1-propanol, 2-methyl-1-propanol, 1-butanol, 2-butanol and other alcohol compounds, tetrahydrofuran, Ether compounds such as diethyl ether, ester compounds such as methyl acetate, ethyl acetate, propyl acetate, isobutyl acetate, butyl acetate, amyl acetate, 3-methoxy-3-methylbutanol, 3-methoxy-3-methylbutyl acetate, 1-methoxy-2-propanol, 1-methoxypropyl-2-acetate, 1-ethoxy-2-propanol, propylene glycol monopropyl ether, 3-methoxybutyl acetate, ethyl 3-ethoxypropionate, propylene glycol monomer Glycol ether compounds such as ruether propionate, diethylene glycol monobutyl ether, tri
- the above-mentioned various solvents can be mixed and used at an appropriate ratio.
- the epoxy resin and / or the epoxy resin curing agent is selected from the group consisting of alcohol compounds, glycol ether compounds and hydrocarbon compounds. At least one selected is preferable, at least one selected from the group consisting of alcohol compounds and hydrocarbon compounds is more preferable, at least one selected from the group consisting of alcohol compounds and hydrocarbon compounds having an aromatic ring Is more preferable.
- the alcohol compounds at least one selected from the group consisting of methanol, ethanol, 2-propanol, 1-propanol, 2-methyl-1-propanol, 1-butanol, and 2-butanol is preferable. At least one selected from the group consisting of -propanol, 1-propanol, 2-methyl-1-propanol, 1-butanol, and 2-butanol is more preferable, and 1-butanol is more preferable.
- the hydrocarbon compounds having an aromatic ring at least one selected from the group consisting of toluene, p-xylene, m-xylene, o-xylene, styrene, and ethylbenzene is preferable. Toluene, p-xylene, m More preferred is at least one selected from the group consisting of -xylene and o-xylene.
- the solvent is more preferably used in combination with an alcohol compound and a hydrocarbon compound having an aromatic ring.
- a hydrocarbon compound having an aromatic ring as the solvent, it is considered that the chemical resistance of the coating film is improved by the above-described estimation mechanism.
- an alcohol compound as a solvent, the epoxy resin and / or the epoxy resin curing agent can be uniformly dissolved, and the volatilization of the solvent can be suppressed to maintain the chemical resistance of the coating film for a long time. it is conceivable that.
- the ratio is not particularly limited, but is preferably 99/1 to 1/99, more preferably 99/1 to 10/90 in mass ratio. More preferably, it is in the range of 90/10 to 20/80, and still more preferably in the range of 90/10 to 40/60.
- the solvent evaporation rate is preferably such that a relative value (also referred to as “relative evaporation rate”) when butyl acetate is used as a reference value 1 is 0.10 or more and 4.5 or less. 0.20 or more, 4.2 or less, more preferably 0.30 or more and 4.0 or less, even more preferably 0.30 or more and 3.0 or less, and even more preferably 0.30. More preferably, it is 2.5 or less, more preferably 0.30 or more and 2.0 or less, and further preferably 0.30 or more and 1.5 or less.
- the evaporation rate When the evaporation rate is larger than 0.10, it tends to be able to suppress a decrease in the cross-linking density of the coating film and a decrease in chemical resistance due to a significant decrease in the volatilization amount of the solvent from the coating film. On the other hand, when the evaporation rate is lower than 4.5, there is a tendency that deterioration of the coating film appearance due to rapid volatilization of the solvent and deterioration of chemical resistance against specific chemicals can be suppressed.
- Examples of the solvent that satisfies the above conditions include the following.
- the numbers in parentheses indicate relative evaporation rates.
- Methanol (1.9), ethanol (1.54), 2-propanol (1.5), 1-butanol (0.47), 2-butanol (0.89), ethyl acetate (4.2), acetic acid Propyl (2.14), isobutyl acetate (1.45), butyl acetate (1.0), 1-methoxy-2-propanol (0.71), 1-methoxypropyl-2-acetate (0.44), 1-ethoxy-2-propanol (0.34), methyl ethyl ketone (3.7), methyl isobutyl ketone (1.6), cyclohexanone (0.32), ethylene glycol monomethyl ether (0.53), ethylene glycol monoethyl Ether (0.38), trichlorethylene (3.22), tetrachloroethylene (1.29), toluene (2.0), m-
- the solvent contained in the coating film of the present invention contains 50% by mass of the solvent having a relative evaporation rate of 0.60 or less, preferably 0.50 or less. It is preferably contained, more preferably 60% by mass or more, and even more preferably 70% by mass or more.
- the solvent may be contained in the epoxy resin and / or the epoxy resin curing agent, or may be added when the epoxy resin and / or the epoxy resin curing agent is blended.
- the epoxy resin composition used in the present embodiment contains at least the epoxy resin, the epoxy resin curing agent, and a solvent.
- the total mass of the epoxy resin and the epoxy resin curing agent in the epoxy resin composition is preferably 5 to 70% by mass, more preferably 10 to 65% by mass, still more preferably 15 to 60% by mass, More preferably, it is 25 to 60% by mass, and still more preferably 30 to 60% by mass.
- the solvent contained in the epoxy resin composition and preferred embodiments thereof are the same as described above. From the viewpoint of easily adjusting the amount of the solvent contained in the coating film of the present invention within a predetermined range, the solvent contained in the epoxy resin composition has a relative evaporation rate of 0.60 or less, preferably 0.50 or less. It is preferable to contain 30 mass% or more of a solvent on the basis of the total mass of the solvent in an epoxy resin composition, It is more preferable to contain 40 mass% or more, It is further more preferable to contain 50 mass% or more.
- the blending ratio of the epoxy resin and the epoxy resin curing agent in the epoxy resin composition is generally a standard blending range in the case of producing an epoxy resin reactant by reaction of the epoxy resin and the epoxy resin curing agent. Good.
- the ratio of the number of active amine hydrogens in the epoxy resin curing agent to the number of epoxy groups in the epoxy resin is 0.
- the range of 05 to 12.0 is preferable. More preferably, it is in the range of 0.05 to 10.0, more preferably in the range of 0.1 to 8.0, even more preferably in the range of 0.2 to 5.0, and even more preferably in the range of 0.3 to 4. It is in the range of 0, more preferably in the range of 0.4 to 3.0, still more preferably in the range of 0.5 to 2.0.
- the epoxy resin composition may include, as necessary, heat such as a polyurethane resin composition, a polyacrylic resin composition, and a polyurea resin composition as long as the effects of the present invention are not impaired.
- a curable resin composition may be mixed.
- the epoxy resin composition when the epoxy resin composition is applied to a general base material such as an iron plate or various plastics, in order to help wet the surface of the various base materials, the epoxy resin composition contains silicone or acrylic.
- Wetting agents such as compounds may be added. Suitable wetting agents include BYK331, BYK333, BYK340, BYK347, BYK348, BYK378, BYK380, BYK381, etc. available from BYK Chemie. When these are added, the range of 0.01 to 2.0% by mass based on the total mass of the epoxy resin composition is preferable.
- a tackifier such as a xylene resin, a terpene resin, a phenol resin, a rosin resin may be added as necessary. When these are added, the range of 0.01 to 2.0% by mass based on the total mass of the epoxy resin composition is preferable.
- a coupling agent such as a silane coupling agent or a titanium coupling agent may be added. When these are added, the range of 0.01 to 5.0% by mass based on the total mass of the epoxy resin composition is preferable.
- inorganic fillers such as silica, alumina, mica, talc, aluminum flakes and glass flakes may be added to the epoxy resin composition.
- inorganic fillers such as silica, alumina, mica, talc, aluminum flakes and glass flakes may be added to the epoxy resin composition.
- the range of 0.01 to 10.0% by mass is preferable based on the total mass of the epoxy resin composition.
- the epoxy resin composition in the present embodiment is included in the epoxy resin composition in the present embodiment in order to help disappearance of bubbles generated during stirring and mixing.
- An antifoaming agent made of a silicone acrylic compound may be added. Suitable antifoaming agents include BYK019, BYK052, BYK065, BYK066N, BYK067N, BYK070, BYK080, and the like, which are available from Big Chemie, with BYK065 being particularly preferred. When these are added, the range of 0.01 to 3.0% by mass is preferable based on the total mass of the epoxy resin composition.
- the epoxy resin composition in the present embodiment includes, for example, an amine complex of boron trifluoride such as boron trifluoride monoethylamine complex, boron trifluoride dimethyl ether, etc.
- boron trifluoride diethyl ether complexes boron trifluoride di-n-butyl ether complexes and other boron trifluoride ether complexes, 2-phenylimidazole and other imidazoles, benzoic acid, salicylic acid, N-ethylmorpholine, dibutyl Curing accelerating catalysts such as tin dilaurate, cobalt naphthenate and stannous chloride, anticorrosive additives such as zinc phosphate, iron phosphate, calcium molybdate, vanadium oxide, water-dispersed silica and fumed silica, phthalocyanine organic pigments , Organic pigments such as condensed polycyclic organic pigments, titanium
- the epoxy resin composition according to the present embodiment has a dilution of, for example, benzyl alcohol, furfuryl alcohol, tetrafurfuryl alcohol, etc. within a range that does not impair the effects of the present invention in order to adjust the viscosity as necessary.
- An amine such as an agent, metaxylylenediamine, 1,3-bis (aminomethyl) cyclohexane, or Jeffamine D230 may be added. When these are added, the range of 1.0 to 20.0% by mass is preferable based on the total mass of the epoxy resin composition, and the range of 5.0 to 10.0% by mass is more preferable.
- the thickness of the coating film of the present invention is not particularly limited and can be appropriately selected depending on the application.
- the thickness of the coating film can be set in the range of 10 to 2000 ⁇ m, preferably 50 to 1000 ⁇ m.
- the coating film of the present invention is formed by curing the epoxy resin composition.
- the content of the solvent in the coating film (cured product) in the present embodiment is 1% by mass or more and 20%. It is the range of the mass% or less.
- the concentration of the appropriate epoxy resin composition (coating solution), appropriate coating conditions, appropriate curing reaction conditions, and coating Appropriate adjustment conditions for the amount of solvent in the film are required. These conditions can be appropriately changed depending on the selected epoxy resin, epoxy resin curing agent, and solvent.
- the concentration of the epoxy resin composition varies depending on the type and molar ratio of the selected material and various states up to the case where the composition concentration is about 5% by mass using a certain type of appropriate organic solvent and / or water. Can take.
- the preferable concentration of the epoxy resin composition is as described above.
- the method for producing a coating film of the present invention includes, for example, coating the epoxy resin composition to form a coating film made of the epoxy resin composition (painting process), and then curing the coating film (curing process). Can be performed.
- a step of adjusting the amount of solvent may be further performed after the curing, if necessary.
- the coating temperature when producing a coating film from the epoxy resin composition is preferably 0 ° C. to 60 ° C., preferably 5 ° C. to 50 ° C., more preferably 10 ° C. to 45 ° C., and more preferably 10 ° C. to 30 ° C. Even more preferred is ° C.
- coating formats include roll coating, applicator coating, bar coater coating, Mayer bar coating, air knife coating, gravure coating, reverse gravure coating, micro gravure coating, micro reverse gravure coater coating, Any of the commonly used coating types such as die coater coating, slot die coater coating, vacuum die coater coating, dip coating, spin coating coating, spray coating, and brush coating can be used. Industrially, roll coating or spray coating is preferred.
- the thickness of a coating film can be suitably selected according to the use of the coating film obtained, and desired thickness.
- the curing temperature in this embodiment can be selected in the range from 0 ° C to 140 ° C.
- the curing temperature is preferably 0 ° C. to 120 ° C., more preferably 5 ° C. to 100 ° C., still more preferably 10 ° C. to 80 ° C., still more preferably 10 ° C. to 50 ° C., and even more preferably 10 ° C. to 30 ° C.
- the curing time is preferably 5 seconds to 7 days, more preferably 10 seconds to 2 days, and further preferably 30 seconds to 1.5 days.
- the curing time in the present specification means that the resin composition is applied onto a substrate using an applicator, and No. manufactured by Dazai Equipment Co., Ltd.
- the coating film produced on the substrate at a predetermined temperature is scratched with a steel needle, the trajectory is visually observed, and the time until the scratch is eliminated is taken. Note that the solvent remains in the coating film even when the scratches disappear.
- the curing temperature of the epoxy resin composition is 0 to 50 ° C.
- the curing time is 0.5 to 48 hours. More preferably, the curing temperature is 5 to 40 ° C., and the curing time is 1.5 to 36 hours.
- the temperature in the step of adjusting the amount of solvent in the coating film can be selected in the range from 5 ° C to 120 ° C.
- the temperature for adjusting the solvent amount may be a temperature different from the curing temperature.
- the temperature in the solvent amount adjusting step is preferably 5 to 100 ° C, more preferably 5 to 80 ° C, still more preferably 5 to 60 ° C, still more preferably 5 to 50 ° C, still more preferably 5 to 40 ° C. More preferably, -30 ° C is more preferable, and 10-30 ° C is further more preferable.
- the solvent amount adjustment time is preferably within 10 days, more preferably within 8 days, and even more preferably within 7 days.
- the content rate of the solvent in a coating film can be measured by the method as described in the following Example, for example.
- the method for producing a coating film of the present invention it is preferable to perform all the steps of the coating step, the curing step, and the solvent amount adjusting step at 50 ° C. or less. Thereby, it becomes easy to inhibit the amount of solvent in the coating from deviating from the specified range. More preferably, all the steps of the coating step, the curing step, and the solvent amount adjusting step are performed at 40 ° C. or lower, more preferably 30 ° C. or lower.
- the coating film When it is necessary to store after forming the coating film, it is preferable to store at 0 to 60 ° C from the viewpoint of preventing the amount of solvent in the coating from deviating from the specified range. More preferably, it is stored at 10 to 45 ° C, more preferably 10 to 30 ° C.
- the temperature when the coating film is used is preferably 0 to 50 ° C. If it is this range, it can suppress that the amount of solvents in a coating film deviates from a regulation range. More preferably, it is 5 to 45 ° C, more preferably 10 to 40 ° C, and still more preferably 10 to 30 ° C.
- the coating film of this embodiment is, for example, paint or adhesive for concrete, cement mortar, various metals, leather, glass, rubber, plastic, wood, cloth, paper, etc .; adhesive tape for packaging, adhesive label, frozen food label, Removable label, POS label, adhesive wallpaper, adhesive for adhesive flooring; art paper, lightweight coated paper, cast coated paper, coated paperboard, carbonless copier, impregnated paper, etc .; natural fiber, synthetic fiber, glass It can be used for a wide range of applications such as fibers, carbon fibers, metal fibers and other sizing agents, fraying prevention agents, processing agents, etc .; sealing materials, cement admixtures, building materials such as waterproofing materials, etc. Among these, it is suitable for coating applications.
- the epoxy resin composition forming the coating film of the present embodiment is a marine paint, heavy anticorrosion paint, tank paint, pipe interior paint, exterior paint, or flooring paint.
- This embodiment also provides a method for improving chemical resistance of a coating film (hereinafter also referred to as “method of the present invention”).
- the method of the present invention is a method for improving chemical resistance of a coating film, wherein the coating film is formed by curing an epoxy resin composition containing at least an epoxy resin, an epoxy resin curing agent and a solvent, and the epoxy resin curing agent Is a reaction product of the following (A) and (B), and is a method for improving the chemical resistance of a coating film, wherein the solvent is contained in an amount of 1% by mass or more and 20% by mass or less.
- a good appearance and high chemical resistance can be expressed by including a specific amount of a solvent in a coating film formed by curing a specific epoxy resin composition. .
- the content of the solvent in the coating film is in the range of 1% by mass to 20% by mass, preferably in the range of 1.5% by mass to 18% by mass, and preferably in the range of 2% by mass to 15% by mass.
- the range is more preferable, and the range of 3.0% by mass to 13.0% by mass is more preferable.
- the content of the solvent in the coating film is 1% by mass or more, it tends to be able to inhibit the appearance of the coating film from causing repellency and wrinkles, and the deterioration of chemical resistance against specific chemicals. It is in.
- the content of the solvent in the coating film is 20% by mass or less, a decrease in chemical resistance due to a decrease in the crosslinking density of the coating film tends to be suppressed.
- curing agent, a solvent, an epoxy resin composition, the manufacturing method of a coating film, and those preferable aspects are the same as the above.
- the method for evaluating the performance of the coating film is as follows. ⁇ Appearance> The coating films produced by the methods described in Examples and Comparative Examples were evaluated visually. C: With repelling B: With slight repelling A: Without repelling
- ⁇ Solvent content in coating film The solvent content in the coating films produced by the methods described in Examples and Comparative Examples was measured using gas chromatography. The ratio of each solvent was calculated based on a calibration curve.
- Pretreatment method A 500 mL flask whose volume was measured was charged with a coating film, covered with a silicon stopper, and heated at 100 ° C. for 30 minutes. The gas in the flask after heating was measured.
- Device GC-390B manufactured by GL Sciences Inc. Column: AQUATIQ2 manufactured by GL Sciences Co., Ltd.
- Epoxy resin curing agents A to E were prepared by the following method.
- (Epoxy resin curing agent A) A reaction vessel was charged with 1 mol of metaxylylenediamine (hereinafter sometimes referred to as MXDA). The temperature was raised to 60 ° C. under a nitrogen stream, and 0.93 mol of methyl acrylate (hereinafter sometimes referred to as MA) was added dropwise over 1 hour. While distilling off the methanol produced, the temperature was raised to 165 ° C. and maintained at 165 ° C. for 2.5 hours. A considerable amount of ethanol was added dropwise over 1.5 hours so that the solid content concentration was 50% by mass to obtain an epoxy resin curing agent A.
- MXDA metaxylylenediamine
- MA methyl acrylate
- Epoxy resin curing agent B A reaction vessel was charged with 1 mol of metaxylylenediamine. The temperature was raised to 60 ° C. under a nitrogen stream, and 0.93 mol of methyl acrylate was added dropwise over 1 hour. While distilling off the methanol produced, the temperature was raised to 165 ° C. and maintained at 165 ° C. for 2.5 hours. A considerable amount of 1-butanol was added dropwise over 1.5 hours so that the solid content concentration was 50% by mass to obtain an epoxy resin curing agent B.
- Epoxy resin curing agent D A reaction vessel was charged with 1 mol of metaxylylenediamine and 0.93 mol of methyl methacrylate (hereinafter sometimes referred to as MMA). It stirred at 100 degreeC under nitrogen stream for 5 hours. While distilling off the methanol produced, the temperature was raised to 165 ° C. and maintained at 165 ° C. for 2.5 hours. A considerable amount of 1-butanol was added dropwise over 1.5 hours so that the solid content concentration was 50% by mass to obtain an epoxy resin curing agent D.
- MMA methyl methacrylate
- Table 1 shows the blending ratio of each component in the epoxy resin curing agents A to E described above.
- the mixing ratio of MXDA, MA, MMA and EC in Table 1 indicates the molar ratio when the molar amount of MXDA is 100.
- the active hydrogen equivalents of the epoxy resin curing agents A to E were obtained by calculation.
- the “active hydrogen equivalent (solution)” is an active hydrogen equivalent relative to the total amount of the epoxy resin curing agent including the solvent, and the “active hydrogen equivalent (solid)” is a value relative to the resin solid content of the epoxy resin curing agent.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 3.5 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the conditions of 23 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 3.5 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the conditions of 23 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- Example 3 416 parts by mass of the epoxy resin curing agent A and 100 parts by mass of an epoxy resin having a glycidylamino group derived from metaxylylenediamine (Mitsubishi Gas Chemical Co., Ltd .; TETRAD-X, solid content concentration: 100% by mass)
- the solvent content in the obtained epoxy resin composition is shown in Table 2.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 3.0 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the conditions of 23 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 4.5 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the conditions of 23 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 4.0 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the conditions of 23 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 4.0 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under conditions of 23 ° C./2 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 4.0 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the adjustment process of the solvent amount in a coating film was abbreviate
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 4.0 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the condition of 5 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate as a base material (manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the base material at 5 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 5 ° C., curing time: 36.0 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the conditions of 23 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate as a base material (manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the base material at 5 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 5 ° C., curing time: 36.0 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the condition of 5 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the resin composition is applied onto a base material on a base material of zinc phosphate treated iron plate (manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) at 40 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 40 ° C., curing time: 1.5 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the adjustment process of the solvent amount in a coating film was abbreviate
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 8.0 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the conditions of 23 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 8.5 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the conditions of 23 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 3.5 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- a coating film was obtained after drying at 100 ° C./15 minutes after the curing step. Using the prepared coating film, the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 4.0 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the coating film was obtained after performing a drying process under the conditions of 100 ° C./15 minutes after the curing step. Using the prepared coating film, the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the zinc phosphate-treated iron plate (part: manufactured by Partec Co., Ltd .; SPCC-SD PB-N144 0.8 ⁇ 70 ⁇ 150 mm) is applied to the applicator on the substrate under the condition of 23 ° C. (Coating film thickness: 200 ⁇ m (immediately after coating)) and cured (curing temperature: 23 ° C., curing time: 16.0 hours).
- the solvent content was measured by the method described above. The results are shown in Table 3.
- the amount of solvent was adjusted under the conditions of 23 ° C./7 days to obtain a coating film.
- the appearance, salt spray resistance, hydrous methanol resistance, sulfuric acid resistance, and solvent content were evaluated by the methods described above. The results are shown in Table 4.
- the coating film of this embodiment can exhibit a good appearance and excellent chemical resistance at the same time, marine paint, heavy anticorrosion paint, tank paint, pipe interior paint, exterior paint, flooring It is suitably used for coating applications such as coatings.
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Abstract
Description
また、タールの代わりに石油系の樹脂を用いたノンタール塗料も開発されている(特許文献1参照)。
また、タールの代わりに石油系の樹脂を用いた上記ノンタール塗料では、エポキシ樹脂及びアミン硬化剤からなる硬化樹脂と石油系の樹脂との相溶性に問題があり、特に高度の防食性、耐水性などを要求される用途へ適用するには不十分であった。
さらに、上記マンニッヒ型硬化剤は、硬化剤中にフェノール類が残留することから、安全衛生上の問題が懸念される。
本発明の課題は、上記問題を解決し、良好な外観で、かつ高い耐薬品性を有する塗膜を提供することである。
(A)メタキシリレンジアミン及びパラキシリレンジアミンからなる群から選ばれる少なくとも1種
(B)下記式(1)で表される不飽和カルボン酸及びその誘導体からなる群から選ばれる少なくとも1種
(式(1)中、R1、R2はそれぞれ独立に、水素原子、炭素数1~8のアルキル基、炭素数1~8のアラルキル基、又はアリール基を表す。)
(C)R3-COOHで表される一価のカルボン酸及びその誘導体からなる群から選ばれる少なくとも1種(R3は水素原子、水酸基を有していてもよい炭素数1~7のアルキル基又はアリール基を表す。)
(D)環状カーボネート
(E)炭素数2~20のモノエポキシ化合物
[3]前記溶剤がアルコール系化合物及び芳香環を有する炭化水素系化合物からなる群から選ばれる少なくとも1種である、第1項又は第2項に記載の塗膜。
[4]前記溶剤の蒸発速度が、酢酸ブチルを基準値1としたときに0.10以上4.5以下である、第1項~第3項のいずれかに記載の塗膜。
[5]前記アルコール系化合物が、メタノール、エタノール、2-プロパノール、1-プロパノール、2-メチル-1-プロパノール、1-ブタノール及び2-ブタノールからなる群から選ばれる少なくとも1種である、第3項に記載の塗膜。
[6]前記芳香環を有する炭化水素系化合物が、トルエン、p-キシレン、m-キシレン、o-キシレン、スチレン及びエチルベンゼンからなる群から選ばれる少なくとも1種である、第3項に記載の塗膜。
[7]前記(A)成分が、メタキシリレンジアミンである第1項~第6項のいずれかに記載の塗膜。
[8]前記(B)成分が、アクリル酸、メタクリル酸、クロトン酸及びそれらの誘導体からなる群から選ばれる少なくとも1種である、第1項~第7項のいずれかに記載の塗膜。
[9]前記(B)成分における誘導体が、エステル、アミド、酸無水物及び酸塩化物からなる群から選ばれる少なくとも1種である、第1項~第8項のいずれかに記載の塗膜。
[10]前記(C)成分が、蟻酸、酢酸、プロピオン酸、酪酸、乳酸、グリコール酸、安息香酸及びそれらの誘導体からなる群から選ばれる少なくとも1種である、第2項~第9項のいずれかに記載の塗膜。
[11]前記(D)成分が、エチレンカーボネート、プロピレンカーボネート及びグリセリンカーボネートからなる群から選ばれる少なくとも1種である、第2項~第10項のいずれかに記載の塗膜。
[12]前記(E)成分が、下記式(2)で表される化合物である、第2項~第11項のいずれかに記載の塗膜。
(式(2)中、R4は水素原子、炭素数1~8のアルキル基、アリール基、又はR5-O-CH2-を表し、R5はフェニル基又はベンジル基を表す。)
[14]前記エポキシ樹脂が、メタキシリレンジアミンから誘導されたグリシジルアミノ基を有するエポキシ樹脂、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂及びビスフェノールFから誘導されたグリシジルオキシ基を有するエポキシ樹脂からなる群から選ばれる少なくとも1種である、第13項に記載の塗膜。
[15]前記エポキシ樹脂が、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂である、第14項に記載の塗膜。
[16]前記エポキシ樹脂組成物が船舶塗料、重防食塗料、タンク用塗料、パイプ内装用塗料、外装用塗料、又は床材用塗料である、第1項~第15項のいずれかに記載の塗膜。
[18]前記硬化後に、さらに溶剤量を調整する工程を行う、第17項に記載の塗膜の製造方法。
本発明は特定のエポキシ樹脂組成物から形成される硬化物中に特定量の溶剤を含有する塗膜に関する。具体的には、少なくともエポキシ樹脂、エポキシ樹脂硬化剤及び溶剤を含有するエポキシ樹脂組成物の硬化により形成される塗膜であって、該塗膜中に該溶剤を1質量%以上20質量%以下含有し、該エポキシ樹脂硬化剤が下記の(A)と(B)の反応生成物である塗膜に関する。
(A)メタキシリレンジアミン及びパラキシリレンジアミンからなる群から選ばれる少なくとも1種
(B)下記式(1)で表される不飽和カルボン酸及びその誘導体からなる群から選ばれる少なくとも1種
(式(1)中、R1、R2はそれぞれ独立に、水素原子、炭素数1~8のアルキル基、炭素数1~8のアラルキル基、又はアリール基を表す。)
これに対し本発明者らは、エポキシ樹脂組成物の硬化により形成される塗膜が特定量の溶剤を含有することにより、該溶剤を含有していない場合と比較して良好な耐薬品性を発現することを見出したものである。
以下に、本実施形態の塗膜について説明する。
本実施形態に用いられるエポキシ樹脂は、分子内にエポキシ基を有する、飽和又は不飽和の脂肪族化合物や脂環式化合物、芳香族化合物、あるいは複素環式化合物のいずれであってよいが、高い耐薬品性の発現を考慮した場合には、芳香環又は脂環式構造を分子内に含むエポキシ樹脂が好ましい。
なお、本実施形態において「主成分」とは、本発明の趣旨を逸脱しない範囲で他の成分を含みうることを意味し、好ましくは全体の50~100質量%、より好ましくは70~100質量%、さらに好ましくは90~100質量%を意味する。
本実施形態に用いられるエポキシ樹脂硬化剤は、下記の(A)と(B)の反応生成物である。
(A)メタキシリレンジアミン及びパラキシリレンジアミンからなる群から選ばれる少なくとも1種
(B)下記式(1)で表される不飽和カルボン酸及びその誘導体からなる群から選ばれる少なくとも1種
(式(1)中、R1、R2はそれぞれ独立に、水素原子、炭素数1~8のアルキル基、炭素数1~8のアラルキル基、又はアリール基を表す。)
アクリル酸又はメタクリル酸の誘導体としては、例えば、(メタ)アクリル酸メチル、(メタ)アクリル酸エチル、(メタ)アクリル酸n-プロピル、(メタ)アクリル酸イソプロピル、(メタ)アクリル酸n-ブチル、(メタ)アクリル酸イソブチル、(メタ)アクリル酸n-オクチル、(メタ)アクリル酸2-エチルヘキシル等の、アクリル酸又はメタクリル酸のアルキルエステル、(メタ)アクリル酸2-ヒドロキシエチル、(メタ)アクリル酸2-ヒドロキシブチル等の、アクリル酸又はメタクリル酸のヒドロキシアルキルエステル、(メタ)アクリル酸フェニル、(メタ)アクリル酸ベンジル、(メタ)アクリルアミド、ジ(メタ)アクリル酸無水物、及び塩化(メタ)アクリル等が挙げられる。
この場合、アミド基形成反応の際には、反応を完結させるために、必要に応じて反応の最終段階において反応装置内を減圧処理することもできる。また、必要に応じて非反応性の溶剤を使用して希釈することもできる。更に脱水剤、脱アルコール剤として、亜リン酸エステル類などの触媒を添加することもできる。
得られるエポキシ樹脂硬化物の高い耐薬品性や優れた塗膜性能を特に考慮する場合には、前記(A)成分と(B)成分の反応モル比[(B)/(A)]が0.5~1.0の範囲であることがより好ましく、0.6~1.0の範囲であることがさらに好ましい。
(C)R3-COOHで表される一価のカルボン酸及びその誘導体からなる群から選ばれる少なくとも1種(R3は水素原子、水酸基を有していてもよい炭素数1~7のアルキル基又はアリール基を表す。)
(D)環状カーボネート
(E)炭素数2~20のモノエポキシ化合物
前記(C)成分としては、蟻酸、酢酸、プロピオン酸、酪酸、乳酸、グリコール酸、安息香酸などの一価のカルボン酸又はその誘導体、例えばエステル、アミド、酸無水物、酸塩化物などが挙げられ、蟻酸、酢酸、プロピオン酸、酪酸、乳酸、グリコール酸、安息香酸及びそれらの誘導体からなる群から選ばれる少なくとも1種が好ましい。前記(C)成分は、1種類を単独で用いてもよく、2種類以上を組み合わせて用いてもよい。
例えば、エチレンカーボネート、プロピレンカーボネート、グリセリンカーボネート、1,2-ブチレンカーボネート、ビニレンカーボネート、4-ビニル-1,3-ジオキソラン-2-オン、4-メトキシメチル-1,3-ジオキソラン-2-オン、1,3-ジオキサン-2-オンなどが挙げられる。これらの中でも、耐薬品性の観点から、エチレンカーボネート、プロピレンカーボネート及びグリセリンカーボネートからなる群から選ばれる少なくとも1種が好ましく、エチレンカーボネートがより好ましい。前記(D)成分は、1種類を単独で用いてもよく、2種類以上を組み合わせて用いてもよい。
但し、該「他の成分」の使用量は、エポキシ樹脂硬化剤を構成する反応成分の合計量の30質量%以下であることが好ましく、10質量%以下であることがより好ましく、5質量%以下であることがさらに好ましい。
一方、前記(D)及び/又は(E)を用いる場合には、初めに前記(A)と(B)とを反応させてから、前記(D)及び/又は(E)と反応させることが好ましい。
前記(A)と前記(D)及び/又は(E)との反応は、25~200℃の条件下で(A)と、(D)及び/又は(E)とを混合し、30~180℃、好ましくは40~170℃の条件下で付加反応によるウレタン結合形成反応を行うことにより実施される。また、必要に応じてナトリウムメトキシド、ナトリウムエトキシド、カリウムt-ブトキシドなどの触媒を使用することができる。
ウレタン結合形成反応の際には、反応を促進するために、必要に応じて(D)及び/又は(E)を溶融させるか、もしくは非反応性の溶剤で希釈して使用することもできる。
但し、耐薬品性及び塗工性の観点から、前記(A)と、前記(B)~(E)との反応モル比[{(B)+(C)+(D)+(E)}/(A)]は、0.35~2.5の範囲であることが好ましく、0.35~2.0の範囲であることがより好ましく、0.35~1.5の範囲であることがさらに好ましい。
本発明の塗膜は、少なくとも前述したエポキシ樹脂、エポキシ樹脂硬化剤及び溶剤を含有するエポキシ樹脂組成物の硬化により形成される塗膜であり、本実施形態において前記溶剤が、前記エポキシ樹脂と前記エポキシ樹脂硬化剤とを硬化させて得られる硬化物(塗膜)中に特定量含まれることで、良好な外観と高い耐薬品性を発現する。
塗膜(硬化物)中の溶剤の含有量は、1質量%以上20質量%以下の範囲であり、1.5質量%以上18質量%以下の範囲であることが好ましく、2質量%以上15質量%以下の範囲であることがより好ましく、3.0質量%以上13.0質量%以下の範囲であることがさらに好ましい。
塗膜中の溶剤の含有量が、1質量%以上である場合、塗膜の外観にハジキやしわが発生し不良となることや、特定の薬品に対する耐薬品性が低下することを抑止できる傾向にある。一方、塗膜中の溶剤の含有量が20質量%以下である場合は、塗膜の架橋密度の低下による耐薬品性の低下を抑止できる傾向にある。
アルコール系化合物の中では、メタノール、エタノール、2-プロパノール、1-プロパノール、2-メチル-1-プロパノール、1-ブタノール、及び2-ブタノールからなる群から選ばれる少なくとも1種が好ましく、エタノール、2-プロパノール、1-プロパノール、2-メチル-1-プロパノール、1-ブタノール、及び2-ブタノールからなる群から選ばれる少なくとも1種がより好ましく、1-ブタノールがより好ましい。また、芳香環を有する炭化水素系化合物の中では、トルエン、p-キシレン、m-キシレン、o-キシレン、スチレン及びエチルベンゼンからなる群から選ばれる少なくとも1種が好ましく、トルエン、p-キシレン、m-キシレン、及びo-キシレンからなる群から選ばれる少なくとも1種がより好ましい。
アルコール系化合物及び芳香環を有する炭化水素系化合物を併用する場合、その比率には特に制限はないが、好ましくは質量比で99/1~1/99、より好ましくは99/1~10/90、さらに好ましくは90/10~20/80、よりさらに好ましくは90/10~40/60の範囲である。
蒸発速度が0.10より大きい場合、塗膜からの溶剤の揮発量が著しく少なくなることによる塗膜の架橋密度の低下や耐薬品性の低下を抑止できる傾向にある。一方、蒸発速度が4.5よりも小さい場合、急速に溶剤が揮発することによる塗膜外観の悪化や特定の薬品に対する耐薬品性の低下を抑止できる傾向にある。
メタノール(1.9)、エタノール(1.54)、2-プロパノール(1.5)、1-ブタノール(0.47)、2-ブタノール(0.89)、酢酸エチル(4.2)、酢酸プロピル(2.14)、酢酸イソブチル(1.45)、酢酸ブチル(1.0)、1-メトキシ-2-プロパノール(0.71)、1-メトキシプロピル-2-アセテート(0.44)、1-エトキシ-2-プロパノール(0.34)、メチルエチルケトン(3.7)、メチルイソブチルケトン(1.6)、シクロヘキサノン(0.32)、エチレングリコールモノメチルエーテル(0.53)、エチレングリコールモノエチルエーテル(0.38)、トリクロロエチレン(3.22)、テトラクロロエチレン(1.29)、トルエン(2.0)、m-キシレン(0.76)、シクロヘキサン(4.5)、メチルシクロヘキサン(3.2)、ノルマルヘプタン(3.62)、ベンゼン(4.12)。
なお、溶剤の相対蒸発速度は、塗料分野でよく用いられる指標であり、公知の文献等から調べることができる。また、溶剤の相対蒸発速度は、ASTM D3539-76に準じて求めてもよい。
本実施形態に用いられるエポキシ樹脂組成物は、少なくとも前記エポキシ樹脂、前記エポキシ樹脂硬化剤及び溶剤を含むものである。
本実施形態において、エポキシ樹脂組成物中のエポキシ樹脂とエポキシ樹脂硬化剤との総質量は、好ましくは5~70質量%、より好ましくは10~65質量%、さらに好ましくは15~60質量%、よりさらに好ましくは25~60質量%、よりさらに好ましくは30~60質量%である。
エポキシ樹脂組成物に含まれる溶剤及びその好ましい態様は、前記と同じである。本発明の塗膜に含まれる溶剤量を所定の範囲に調整しやすくする観点から、エポキシ樹脂組成物に含まれる溶剤は、前記相対蒸発速度が0.60以下、好ましくは0.50以下である溶剤を、エポキシ樹脂組成物中の溶剤の全質量を基準として30質量%以上含有することが好ましく、40質量%以上含有することがより好ましく、50質量%以上含有することがさらに好ましい。
本発明の塗膜は、前記エポキシ樹脂組成物の硬化により形成されるものであり、上述のように、本実施形態における塗膜(硬化物)中の溶剤の含有率は、1質量%以上20質量%以下の範囲である。塗膜中の溶剤含有率をこのような特定の範囲となるように制御するためには、適切なエポキシ樹脂組成物(塗布液)の濃度、適切な塗装条件、適切な硬化反応条件、及び塗膜中の溶剤量の適切な調整条件が必要である。これらの条件は選択したエポキシ樹脂、エポキシ樹脂硬化剤、溶剤により適宜変化し得る。さらに、エポキシ樹脂組成物の濃度は選択した材料の種類及びモル比などにより、ある種の適切な有機溶剤及び/又は水を用いて5質量%程度の組成物濃度にする場合までの様々な状態をとり得る。
エポキシ樹脂組成物の好ましい濃度については、前記のとおりである。
塗布膜の厚みは、得られる塗膜の用途、所望の厚みに応じて適宜選択できる。
エポキシ樹脂組成物の硬化条件として好ましい温度と時間の組み合わせとしては、例えば、前記エポキシ樹脂組成物の硬化温度が0~50℃であり、かつ、硬化時間が0.5~48時間であることが好ましく、硬化温度が5~40℃であり、かつ、硬化時間が1.5~36時間であることがより好ましい。
また、硬化反応工程内で所望の溶剤含有量とすることができる場合は、当該溶剤量調整工程を省略してもよい。
なお、塗膜中の溶剤の含有率は、例えば、下記実施例に記載の方法により測定することができる。
本実施形態の塗膜は、例えば、コンクリート、セメントモルタル、各種金属、皮革、ガラス、ゴム、プラスチック、木、布、紙等に対する塗料あるいは接着剤;包装用粘着テープ、粘着ラベル、冷凍食品ラベル、リムーバブルラベル、POSラベル、粘着壁紙、粘着床材の粘着剤;アート紙、軽量コート紙、キャストコート紙、塗工板紙、カーボンレス複写機、含浸紙等の加工紙;天然繊維、合成繊維、ガラス繊維、炭素繊維、金属繊維等の収束剤、ほつれ防止剤、加工剤等の繊維処理剤;シーリング材、セメント混和剤、防水材等の建築材料等の広範な用途に使用することができるが、これらの中でも塗料用途に好適である。特に、船舶塗料、重防食塗料、タンク用塗料、パイプ内装、外装用塗料、床材用塗料等の塗料用途として好適である。すなわち、本実施形態の塗膜を形成する前記エポキシ樹脂組成物が船舶塗料、重防食塗料、タンク用塗料、パイプ内装用塗料、外装用塗料、又は床材用塗料であることが好ましい。
本実施形態はまた、塗膜の耐薬品性向上方法(以下「本発明の方法」ともいう)を提供する。本発明の方法は、塗膜の耐薬品性向上方法であって、該塗膜は少なくともエポキシ樹脂、エポキシ樹脂硬化剤及び溶剤を含有するエポキシ樹脂組成物の硬化により形成され、該エポキシ樹脂硬化剤が下記の(A)と(B)の反応生成物であり、該塗膜中に該溶剤を1質量%以上20質量%以下含有させる、塗膜の耐薬品性向上方法である。
(A)メタキシリレンジアミン及びパラキシリレンジアミンからなる群から選ばれる少なくとも1種
(B)下記式(1)で表される不飽和カルボン酸及びその誘導体からなる群から選ばれる少なくとも1種
(式(1)中、R1、R2は前記と同じである。)
本発明の方法によれば、特定のエポキシ樹脂組成物の硬化により形成される塗膜中に溶剤を特定量含有させることにより、良好な外観と高い耐薬品性を発現させることができるものである。塗膜中の溶剤の含有量は、1質量%以上20質量%以下の範囲であり、1.5質量%以上18質量%以下の範囲であることが好ましく、2質量%以上15質量%以下の範囲であることがより好ましく、3.0質量%以上13.0質量%以下の範囲であることがさらに好ましい。塗膜中の溶剤の含有量が、1質量%以上である場合、塗膜の外観にハジキやしわが発生し不良となることや、特定の薬品に対する耐薬品性が低下することを抑止できる傾向にある。一方、塗膜中の溶剤の含有量が20質量%以下である場合は、塗膜の架橋密度の低下による耐薬品性の低下を抑止できる傾向にある。
なお、本発明の方法におけるエポキシ樹脂、エポキシ樹脂硬化剤、溶剤、エポキシ樹脂組成物、塗膜の製造方法、並びにそれらの好ましい態様は、前記と同じである。
<外観>
実施例及び比較例に記載の方法で作製した塗膜を目視により評価した。
C:ハジキ有り
B:若干ハジキ有り
A:ハジキ無し
実施例及び比較例に記載の方法で作製した塗膜の耐塩水噴霧性は、塩水噴霧試験機を用いて塗膜に塩水を噴霧した後の塗膜の外観を目視で評価した。
装置:スガ試験機株式会社 塩水噴霧試験機 STP-90
塩水濃度:5質量%
槽内設定温度:35℃
加湿器設定温度:47℃
試験時間:28日
C:錆有り
B:若干錆有り
A:錆無し
実施例及び比較例に記載の方法で作製した塗膜の耐含水メタノール性は、含水メタノール中に塗膜を浸漬した後の塗膜の外観を目視で評価した。
含水メタノール:メタノール/水=9/1(質量比)
保存温度:23℃
保存期間:28日
C:膨潤有り
B:若干膨潤有り
A:膨潤無し
実施例及び比較例に記載の方法で作製した塗膜の耐硫酸性は、10%硫酸中に塗膜を浸漬した後の塗膜の外観を目視で評価した。
保存温度:23℃
保存期間:7日
D:錆有り
C:若干錆有り
B:塗膜が膨潤するが錆無し
A:塗膜の膨潤、錆無し
実施例及び比較例に記載の方法で作製した塗膜中の溶剤含有量は、ガスクロマトグラフィーを用いて測定を行った。なお、各溶剤の割合は、検量線を基に算出した。
前処理方法:容量を測定した500mLフラスコに、塗膜を入れ、シリコン栓で蓋をし、100℃/30分加熱した。加熱後のフラスコ内の気体を測定した。
装置:ジーエルサイエンス(株)製 GC-390B
カラム:ジーエルサイエンス(株)製 AQUATIQ2 内径 0.53mm、長さ 30m、膜厚 3.00μm
インジェクション温度:150℃
ディテクション温度:150℃
カラム温度:40℃/8分→昇温(10℃/分)→80℃/8分
サンプル注入量:0.5mL
溶剤含有量算出方法:上記方法で塗膜1m2当たりの溶剤含有量を、検量線をもとに算出し、これら値をもとに塗膜の総質量に対する溶剤の割合を算出した。
(エポキシ樹脂硬化剤A)
反応容器に1molのメタキシリレンジアミン(以下、MXDAということがある)を仕込んだ。窒素気流下60℃に昇温し、0.93molのアクリル酸メチル(以下、MAということがある)を1時間かけて滴下した。生成するメタノールを留去しながら165℃に昇温し、165℃で2.5時間保持した。固形分濃度が50質量%になるように、相当量のエタノールを1.5時間かけて滴下し、エポキシ樹脂硬化剤Aを得た。
反応容器に1molのメタキシリレンジアミンを仕込んだ。窒素気流下60℃に昇温し、0.93molのアクリル酸メチルを1時間かけて滴下した。生成するメタノールを留去しながら165℃に昇温し、165℃で2.5時間保持した。固形分濃度が50質量%になるように、相当量の1-ブタノールを1.5時間かけて滴下し、エポキシ樹脂硬化剤Bを得た。
反応容器に1molのメタキシリレンジアミンを仕込んだ。窒素気流下60℃に昇温し、0.93molのアクリル酸メチルを1時間かけて滴下した。生成するメタノールを留去しながら165℃に昇温し、165℃で2.5時間保持した。固形分濃度が50質量%になるように、相当量の1-ブタノール/トルエン=55/45(質量比)で1.5時間かけて滴下し、エポキシ樹脂硬化剤Cを得た。
反応容器に1molのメタキシリレンジアミンと0.93molのメタクリル酸メチル(以下、MMAということがある)を仕込んだ。窒素気流下100℃で5時間攪拌した。生成するメタノールを留去しながら165℃に昇温し、165℃で2.5時間保持した。固形分濃度が50質量%になるように、相当量の1-ブタノールを1.5時間かけて滴下し、エポキシ樹脂硬化剤Dを得た。
反応容器に1molのメタキシリレンジアミンを仕込んだ。窒素気流下60℃に昇温し、0.88molのアクリル酸メチルを1時間かけて滴下した。生成するメタノールを留去しながら165℃まで昇温し、165℃で2.5時間保持した。100℃まで冷却し、固形分濃度が50質量%になるように所定量の1-ブタノールを加え、65℃に冷却した後、溶融したエチレンカーボネート(以下、ECということがある)0.27molを30分かけて滴下し、65℃で5時間保持し、エポキシ樹脂硬化剤Eを得た。
以上のエポキシ樹脂硬化剤A~Eにおける各成分の配合比を表1に記載する。表1におけるMXDA、MA、MMA及びECの配合比は、MXDAのモル量を100とした場合のモル比を示す。
エポキシ樹脂硬化剤A~Eの活性水素当量は計算によって求めた。なお「活性水素当量(solution)」は溶剤を含むエポキシ樹脂硬化剤全量に対する活性水素当量であり、「活性水素当量(solid)」はエポキシ樹脂硬化剤の樹脂固形分に対する値である。
実施例1
前記エポキシ樹脂硬化剤Aを222質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER828、固形分濃度:100質量%)を100質量部、溶剤として1-ブタノール111質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:3.5時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に23℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Aを65.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール57.9質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:3.5時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に23℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Aを416質量部、メタキシリレンジアミンから誘導されたグリシジルアミノ基を有するエポキシ樹脂(三菱ガス化学(株)製;TETRAD-X、固形分濃度:100質量%)を100質量部、溶剤として1-ブタノール208質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:3.0時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に23℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Bを65.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール57.9質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:4.5時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に23℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Cを65.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール57.9質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:4.0時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に23℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Cを65.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール57.9質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:4.0時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に23℃/2日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Cを65.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール57.9質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:4.0時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。塗膜中の溶剤量の調整工程は省略して塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Cを65.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール57.9質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:4.0時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に5℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Cを65.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール57.9質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、5℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:5℃、硬化時間:36.0時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に23℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Cを65.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール57.9質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、5℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:5℃、硬化時間:36.0時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に5℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Cを65.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール57.9質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、40℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:40℃、硬化時間:1.5時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。塗膜中の溶剤量の調整工程は省略して塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Dを70.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール60.4質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:8.0時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に23℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Eを92.8質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール71.4質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:8.5時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に23℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Aを222質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER828、固形分濃度:100質量%)を100質量部、溶剤として1-ブタノール111質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:3.5時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に100℃/15分間の条件にて乾燥処理をした後、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤Aを65.7質量部、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER1001X75、固形分濃度:75質量%)を100質量部、溶剤として1-ブタノール57.9質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.2)。得られたエポキシ樹脂組成物中の溶剤含有量を表2に示す。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:4.0時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に100℃/15分間の条件にて乾燥処理をした後塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
前記エポキシ樹脂硬化剤として、ダイマー酸により変性された汎用のポリアミド変性ポリアミン(富士化成(株)製、トーマイド225X、固形分濃度:100質量%)を103質量部、及びビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂(三菱化学(株)製;jER828、固形分濃度:100質量%)を100質量部、溶剤として1-ブタノール203質量部を調製し、よく攪拌することにより、エポキシ樹脂組成物を得た(エポキシ樹脂硬化剤中の活性アミン水素数/エポキシ樹脂中のエポキシ基の数=1.0)。
次に、基材であるリン酸亜鉛処理鉄板(パルテック(株)製;SPCC-SD PB-N144 0.8×70×150mm)に、23℃条件下、前記樹脂組成物を基材上にアプリケーターを用いて塗布し(塗布膜の厚さ:200μm(塗装直後))、硬化させた(硬化温度:23℃、硬化時間:16.0時間)。硬化工程終了直後に前述の方法で溶剤含有量を測定した。結果を表3に示す。さらに、硬化工程後に23℃/7日間の条件にて溶剤量を調整し、塗膜を得た。
作製した塗膜を用い、前述の方法で、外観、耐塩水噴霧性、耐含水メタノール性、耐硫酸性、及び溶剤含有量を評価した。結果を表4に示す。
一方、比較例1、2では、硬化工程後にさらに100℃で乾燥させることで塗膜中の溶剤を規定範囲の下限値(1質量%)未満まで揮発させた結果、耐塩水噴霧性、耐含水メタノール性、及び耐硫酸性が低下した。
さらに、比較例3のように、本実施形態におけるエポキシ硬化剤を使用しない場合、塗膜中の溶剤含有量が規定範囲内であっても、耐塩水噴霧性や耐含水メタノール性、及び耐硫酸性は発現しない。
Claims (19)
- 前記エポキシ樹脂硬化剤が前記の(A)及び(B)と、さらに下記の(C)、(D)及び(E)からなる群から選ばれる少なくとも1種の化合物との反応生成物である、請求項1に記載の塗膜。
(C)R3-COOHで表される一価のカルボン酸及びその誘導体からなる群から選ばれる少なくとも1種(R3は水素原子、水酸基を有していてもよい炭素数1~7のアルキル基又はアリール基を表す。)
(D)環状カーボネート
(E)炭素数2~20のモノエポキシ化合物 - 前記溶剤がアルコール系化合物及び芳香環を有する炭化水素系化合物からなる群から選ばれる少なくとも1種である、請求項1又は2に記載の塗膜。
- 前記溶剤の蒸発速度が、酢酸ブチルを基準値1としたときに0.10以上4.5以下である、請求項1~3のいずれかに記載の塗膜。
- 前記アルコール系化合物が、メタノール、エタノール、2-プロパノール、1-プロパノール、2-メチル-1-プロパノール、1-ブタノール及び2-ブタノールからなる群から選ばれる少なくとも1種である、請求項3に記載の塗膜。
- 前記芳香環を有する炭化水素系化合物が、トルエン、p-キシレン、m-キシレン、o-キシレン、スチレン及びエチルベンゼンからなる群から選ばれる少なくとも1種である、請求項3に記載の塗膜。
- 前記(A)成分が、メタキシリレンジアミンである請求項1~6のいずれかに記載の塗膜。
- 前記(B)成分が、アクリル酸、メタクリル酸、クロトン酸及びそれらの誘導体からなる群から選ばれる少なくとも1種である、請求項1~7のいずれかに記載の塗膜。
- 前記(B)成分における誘導体が、エステル、アミド、酸無水物及び酸塩化物からなる群から選ばれる少なくとも1種である、請求項1~8のいずれかに記載の塗膜。
- 前記(C)成分が、蟻酸、酢酸、プロピオン酸、酪酸、乳酸、グリコール酸、安息香酸及びそれらの誘導体からなる群から選ばれる少なくとも1種である、請求項2~9のいずれかに記載の塗膜。
- 前記(D)成分が、エチレンカーボネート、プロピレンカーボネート及びグリセリンカーボネートからなる群から選ばれる少なくとも1種である、請求項2~10のいずれかに記載の塗膜。
- 前記エポキシ樹脂が、メタキシリレンジアミンから誘導されたグリシジルアミノ基を有するエポキシ樹脂、1,3-ビス(アミノメチル)シクロヘキサンから誘導されたグリシジルアミノ基を有するエポキシ樹脂、ジアミノジフェニルメタンから誘導されたグリシジルアミノ基を有するエポキシ樹脂、パラアミノフェノールから誘導されたグリシジルアミノ基を有するエポキシ樹脂、パラアミノフェノールから誘導されたグリシジルオキシ基を有するエポキシ樹脂、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂、ビスフェノールFから誘導されたグリシジルオキシ基を有するエポキシ樹脂、フェノールノボラックから誘導されたグリシジルオキシ基を有するエポキシ樹脂及びレゾルシノールから誘導されたグリシジルオキシ基を有するエポキシ樹脂からなる群から選ばれる少なくとも1種である、請求項1~12のいずれかに記載の塗膜。
- 前記エポキシ樹脂が、メタキシリレンジアミンから誘導されたグリシジルアミノ基を有するエポキシ樹脂、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂及びビスフェノールFから誘導されたグリシジルオキシ基を有するエポキシ樹脂からなる群から選ばれる少なくとも1種である、請求項13に記載の塗膜。
- 前記エポキシ樹脂が、ビスフェノールAから誘導されたグリシジルオキシ基を有するエポキシ樹脂である、請求項14に記載の塗膜。
- 前記エポキシ樹脂組成物が船舶塗料、重防食塗料、タンク用塗料、パイプ内装用塗料、外装用塗料、又は床材用塗料である、請求項1~15のいずれかに記載の塗膜。
- 前記エポキシ樹脂組成物の硬化温度が0~50℃であり、かつ、硬化時間が0.5~48時間である、請求項1~16のいずれかに記載の塗膜の製造方法。
- 前記硬化後に、さらに溶剤量を調整する工程を行う、請求項17に記載の塗膜の製造方法。
- 塗膜の耐薬品性向上方法であって、該塗膜は少なくともエポキシ樹脂、エポキシ樹脂硬化剤及び溶剤を含有するエポキシ樹脂組成物の硬化により形成され、該エポキシ樹脂硬化剤が下記の(A)と(B)の反応生成物であり、該塗膜中に該溶剤を1質量%以上20質量%以下含有させる、塗膜の耐薬品性向上方法。
(A)メタキシリレンジアミン及びパラキシリレンジアミンからなる群から選ばれる少なくとも1種
(B)下記式(1)で表される不飽和カルボン酸及びその誘導体からなる群から選ばれる少なくとも1種
(式(1)中、R1、R2はそれぞれ独立に、水素原子、炭素数1~8のアルキル基、炭素数1~8のアラルキル基、又はアリール基を表す。)
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WO2019077523A1 (en) * | 2017-10-17 | 2019-04-25 | Aditya Birla Chemicals (Thailand) Limited | EPOXY RESINS OF GLYCIDYLAMINE TYPE BASED ON AMES NEGATIVE AMINES |
WO2021200028A1 (ja) * | 2020-04-01 | 2021-10-07 | 三菱瓦斯化学株式会社 | プリプレグ、繊維強化複合材、高圧ガス貯蔵タンク、プリプレグの製造方法及び高圧ガス貯蔵タンクの製造方法 |
WO2022030135A1 (ja) * | 2020-08-04 | 2022-02-10 | 三菱瓦斯化学株式会社 | 圧力容器用ライナー及び高圧ガス貯蔵タンク |
WO2022080048A1 (ja) * | 2020-10-15 | 2022-04-21 | 三菱瓦斯化学株式会社 | エポキシ樹脂硬化剤、エポキシ樹脂組成物、塗料及び接着剤 |
JP7463816B2 (ja) | 2020-04-01 | 2024-04-09 | 三菱瓦斯化学株式会社 | プリプレグの製造方法及び高圧ガス貯蔵タンクの製造方法 |
JP7463815B2 (ja) | 2020-04-01 | 2024-04-09 | 三菱瓦斯化学株式会社 | プリプレグ、繊維強化複合材、及び高圧ガス貯蔵タンク |
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EP4257339A4 (en) * | 2020-12-04 | 2024-05-15 | Mitsubishi Gas Chemical Company, Inc. | METHOD FOR PRODUCING A MOLDED ARTICLE, RESIN IMPREGNATION DEVICE AND 3D PRINTER |
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Publication number | Priority date | Publication date | Assignee | Title |
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WO2019077523A1 (en) * | 2017-10-17 | 2019-04-25 | Aditya Birla Chemicals (Thailand) Limited | EPOXY RESINS OF GLYCIDYLAMINE TYPE BASED ON AMES NEGATIVE AMINES |
US11548976B2 (en) | 2017-10-17 | 2023-01-10 | Aditya Birla Chemicals (Thailand) Limited | Glycidyl amine epoxy resins based on AMES negative amines |
WO2021200028A1 (ja) * | 2020-04-01 | 2021-10-07 | 三菱瓦斯化学株式会社 | プリプレグ、繊維強化複合材、高圧ガス貯蔵タンク、プリプレグの製造方法及び高圧ガス貯蔵タンクの製造方法 |
JP7463816B2 (ja) | 2020-04-01 | 2024-04-09 | 三菱瓦斯化学株式会社 | プリプレグの製造方法及び高圧ガス貯蔵タンクの製造方法 |
JP7463815B2 (ja) | 2020-04-01 | 2024-04-09 | 三菱瓦斯化学株式会社 | プリプレグ、繊維強化複合材、及び高圧ガス貯蔵タンク |
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EP3315570A4 (en) | 2019-02-20 |
TW201708429A (zh) | 2017-03-01 |
EP3315570B1 (en) | 2020-10-14 |
JP6705451B2 (ja) | 2020-06-03 |
US20180118877A1 (en) | 2018-05-03 |
CN107614632A (zh) | 2018-01-19 |
CN107614632B (zh) | 2021-05-07 |
TWI691564B (zh) | 2020-04-21 |
JPWO2016208344A1 (ja) | 2018-04-12 |
KR102560973B1 (ko) | 2023-07-28 |
EP3315570A1 (en) | 2018-05-02 |
US10752729B2 (en) | 2020-08-25 |
KR20180022679A (ko) | 2018-03-06 |
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