WO2021084802A1 - 水性塗料組成物 - Google Patents
水性塗料組成物 Download PDFInfo
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- WO2021084802A1 WO2021084802A1 PCT/JP2020/026283 JP2020026283W WO2021084802A1 WO 2021084802 A1 WO2021084802 A1 WO 2021084802A1 JP 2020026283 W JP2020026283 W JP 2020026283W WO 2021084802 A1 WO2021084802 A1 WO 2021084802A1
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- C08G18/755—Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic containing only one cycloaliphatic ring containing at least one isocyanate or isothiocyanate group linked to the cycloaliphatic ring by means of an aliphatic group containing one isocyanate or isothiocyanate group linked to the cycloaliphatic ring by means of an aliphatic group having a primary carbon atom next to the isocyanate or isothiocyanate group and at least one isocyanate or isothiocyanate group linked to a secondary carbon atom of the cycloaliphatic ring, e.g. isophorone diisocyanate
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- 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
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
- C08G18/72—Polyisocyanates or polyisothiocyanates
- C08G18/77—Polyisocyanates or polyisothiocyanates having heteroatoms in addition to the isocyanate or isothiocyanate nitrogen and oxygen or sulfur
- C08G18/78—Nitrogen
- C08G18/79—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates
- C08G18/791—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups
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- 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
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
- C08G18/72—Polyisocyanates or polyisothiocyanates
- C08G18/77—Polyisocyanates or polyisothiocyanates having heteroatoms in addition to the isocyanate or isothiocyanate nitrogen and oxygen or sulfur
- C08G18/78—Nitrogen
- C08G18/79—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates
- C08G18/791—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups
- C08G18/792—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups formed by oligomerisation of aliphatic and/or cycloaliphatic isocyanates or isothiocyanates
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- 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
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
- C08G18/72—Polyisocyanates or polyisothiocyanates
- C08G18/80—Masked polyisocyanates
- C08G18/8061—Masked polyisocyanates masked with compounds having only one group containing active hydrogen
- C08G18/8064—Masked polyisocyanates masked with compounds having only one group containing active hydrogen with monohydroxy compounds
- C08G18/8067—Masked polyisocyanates masked with compounds having only one group containing active hydrogen with monohydroxy compounds phenolic compounds
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- 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
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
- C08G18/72—Polyisocyanates or polyisothiocyanates
- C08G18/80—Masked polyisocyanates
- C08G18/8061—Masked polyisocyanates masked with compounds having only one group containing active hydrogen
- C08G18/8093—Compounds containing active methylene groups
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- 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
- C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
- C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
- C08G63/12—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from polycarboxylic acids and polyhydroxy compounds
- C08G63/40—Polyesters derived from ester-forming derivatives of polycarboxylic acids or of polyhydroxy compounds, other than from esters thereof
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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
- C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
- C09D167/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
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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
- C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
- C09D175/04—Polyurethanes
- C09D175/06—Polyurethanes from polyesters
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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
- C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
- C09D175/04—Polyurethanes
- C09D175/08—Polyurethanes from polyethers
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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
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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
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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
- C09D7/65—Additives macromolecular
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- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
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- B05D2202/00—Metallic substrate
- B05D2202/10—Metallic substrate based on Fe
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- B05D2401/20—Aqueous dispersion or solution
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- B05D2425/00—Indexing scheme corresponding to the position of each layer within a multilayer coating relative to the surface
- B05D2425/02—Indexing scheme corresponding to the position of each layer within a multilayer coating relative to the surface second layer from the top surface
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- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2425/00—Indexing scheme corresponding to the position of each layer within a multilayer coating relative to the surface
- B05D2425/03—Indexing scheme corresponding to the position of each layer within a multilayer coating relative to the surface third layer from the top surface
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- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2502/00—Acrylic polymers
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- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2503/00—Polyurethanes
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- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
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- B05D2504/00—Epoxy polymers
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- B05D2508/00—Polyesters
Definitions
- the present invention relates to a water-based coating composition.
- paint the intermediate coat paint ⁇ baking cure ⁇ paint the water-based base paint ⁇ preheat (preheat) ⁇ paint the clear paint ⁇ bake cure.
- the method of forming a multi-layer coating film by the bake (3C2B) method has been widely adopted, but in recent years, from the viewpoint of energy saving, the baking hardening step after coating the intermediate coating paint is omitted, and electrodeposition is applied to the object to be coated.
- the painted parts of the automobile body there are an "outer plate part” that can be seen from the outside of the finished car and an “inner plate part” that cannot be seen from the outside of the finished car. Is not required. Therefore, after the electrodeposition paint is applied to the object to be coated, the above-mentioned water-based intermediate coating paint, water-based base paint and clear paint are applied on the outer panel portion to form a multi-layer coating film having an excellent appearance, and the inside is formed. In the plate portion, studies are being conducted to reduce the number of coating steps and the type of paint on the inner plate portion by coating the water-based base coating on the electrodeposition coating to form the base coating.
- the uppermost coating film on the inner plate portion is a base coating film formed by the water-based base coating film
- the base coating film is required to have relatively high hardness and water resistance.
- the base coating film formed by the water-based base coating material may not have sufficient hardness and water resistance.
- Patent Document 1 describes (A) a pyrazole-blocked polyisocyanate compound containing two or more tertiary isocyanate groups blocked by a pyrazole compound in one molecule, and (B) a hydroxyl value of 10 to 250 mgKOH / g.
- a coating composition characterized by containing a hydroxyl group-containing resin having a weight average molecular weight of 1,000 to 200,000 as an essential component has excellent one-component storage stability and is baked under relatively low temperature of about 100 ° C. It is also described that sufficient curability and coating performance can be obtained, and that heat-resistant yellowing due to heating during baking is good.
- the coating composition is used as a base coating, if the clear coating is not applied on the base layer formed by the base coating, the coating film performance such as hardness and water resistance may not always be sufficient. there were.
- the present invention is intended to provide an aqueous coating composition which is excellent in storage stability and can exhibit high coating film performance even when cured at a relatively low temperature.
- PKa acid dissociation constant
- a water-based coating composition containing (A) a hydroxyl group and a carboxyl group-containing resin, (B) a blocked polyisocyanate compound, (C) a phosphoric acid group-containing compound, and (D) a basic compound, wherein the basic compound ( D) contains a basic compound having (D1) an acid dissociation constant (PKa) in the range of 7.0 to 8.5 and a boiling point in the range of 100 to 200 ° C., and the base.
- PKa acid dissociation constant
- the content ratio of the sex compound (D1) is in the range of 50 to 100% by mass based on the mass of the basic compound (D), and the pH of the aqueous coating composition is 7.0 to 8.
- a water-based coating composition within the range of 2. Item 2. Item 2. The aqueous coating composition according to Item 1, wherein at least a part of the blocking agent of the blocked polyisocyanate compound (B) is an active methylene-based blocking agent. Item 3. Item 2. The aqueous coating composition according to Item 1 or 2, wherein at least one of the phosphoric acid group-containing compound (C) is a phosphoric acid group-containing resin (C1). Item 4. Item 3.
- the water-based coating composition according to Item 3 wherein at least one of the phosphoric acid group-containing resin (C1) is a phosphoric acid group-containing acrylic resin (C1').
- Item 5 The basic compound (D1) having an acid dissociation constant (PKa) in the range of 7.0 to 8.5 and a boiling point in the range of 100 to 200 ° C. is N-methylmorpholine and / or N-ethyl.
- the water-based coating composition according to any one of Items 1 to 4 which is morpholine.
- the aqueous coating composition according to any one of Items 1 to 6 is applied onto an object to be coated to form an uncured colored coating film, and then the uncured colored coating film is applied to 60 to 60 to the uncured colored coating film.
- a method for forming a coating film which comprises heating and curing at a temperature within the range of 110 ° C.
- Item 8. A method for painting an automobile body, which includes a step of forming a first multi-layer coating film on an outer plate portion of an automobile body and a step of forming a second coating film on an inner plate portion of the automobile body.
- the step of forming the first multilayer coating film is (1a) An outer plate coloring base coat coating film forming step of coating the water-based coating composition (X) on the outer plate portion of the automobile body to form an uncured outer plate coloring base coat coating film (BCo). (1b) An outer plate clear coat coating film (CCo) is formed by coating a clear coat paint (Y) on the uncured outer plate coloring base coat coating film (BCo) to form an uncured outer plate clear coat coating film (CCo). The forming step, and (1c) the baking step of heating the uncured outer plate colored base coat coating film (BCo) and the uncured outer plate clear coat coating film (CCo) and simultaneously curing these coating films.
- An outer plate clear coat coating film (CCo) is formed by coating a clear coat paint (Y) on the uncured outer plate coloring base coat coating film (BC
- the step of forming the second coating film is (2a) An inner plate colored coating film forming step of coating the water-based coating composition (X) on the inner plate portion of the automobile body to form an uncured inner plate colored coating film (PCi), and (2a). 2b) A baking step of heating and curing the uncured inner plate colored coating film (PCi), Including A method for painting an automobile body, wherein the water-based paint composition (X) is the water-based paint composition according to any one of Items 1 to 6. Item 9. Item 8. The method for painting an automobile body according to Item 8, wherein the heating temperature in the baking step (1c) and the baking step (2b) is in the range of 60 to 110 ° C. Item 10. Item 8. The method for painting an automobile body according to Item 8 or 9, wherein the baking step (1c) and the baking step (2b) are performed at the same time.
- the water-based coating composition of the present invention is excellent in storage stability and can form a coating film exhibiting excellent coating film performance such as high hardness and water resistance even when cured at a relatively low temperature.
- the water-based coating composition of the present invention contains (A) a hydroxyl group and a carboxyl group-containing resin, (B) a blocked polyisocyanate compound, (C) a phosphate group-containing compound, and (D) a basic compound.
- the aqueous coating composition has a pH in the range of 7.0 to 8.2, and the basic compound (D) has an acid dissociation constant (PKa) in the range of 7.0 to 8.5.
- PKa acid dissociation constant
- a basic compound (D1) that is within and has a boiling point in the range of 100 to 200 ° C., and the proportion of the basic compound (D1) is 50, based on the mass of the basic compound (D). It is in the range of ⁇ 100% by mass.
- the water-based paint is a term to be contrasted with the organic solvent-type paint, and generally, water or a medium containing water as a main component (water-based medium), a coating film-forming resin, a pigment, etc. Means a paint in which is dispersed and / or dissolved.
- the organic solvent type paint is a paint that does not substantially contain water as a solvent or that all or most of the solvent is an organic solvent.
- the water-based coating composition of the present invention has a pH in the range of 7.0 to 8.2.
- a pH in the range of 7.0 to 8.2.
- the pH is preferably in the range of 7.1 to 8.0, and more preferably in the range of 7.2 to 7.8.
- the hydroxyl group- and carboxyl group-containing resin (A) is not particularly limited as long as it is a resin containing a hydroxyl group and a carboxyl group, and the type of resin is specifically, for example, an acrylic resin or a polyester resin. Examples thereof include a polyether resin, a polycarbonate resin, and a polyurethane resin.
- the hydroxyl group and carboxyl group-containing resin (A) an acrylic resin, a polyester resin, and a polyurethane resin containing a hydroxyl group and a carboxyl group can be preferably used.
- Acrylic resin containing hydroxyl groups and carboxyl groups (A1)
- the hydroxyl group- and carboxyl group-containing acrylic resin (A1) includes a hydroxyl group-containing polymerizable unsaturated monomer (M-1), a carboxyl group-containing polymerizable unsaturated monomer (M-2), and other copolymerizable polymerizable unsaturated monomers. It can be synthesized by copolymerizing the monomer (M-3) by a conventional method.
- the hydroxyl group-containing polymerizable unsaturated monomer (M-1) is a compound having one hydroxyl group and one polymerizable unsaturated bond in one molecule, and this hydroxyl group mainly acts as a functional group that reacts with a cross-linking agent. It is a thing.
- the monomer a monoesterified product of acrylic acid or methacrylic acid and a dihydric alcohol having 2 to 10 carbon atoms is preferable, and for example, 2-hydroxyethyl (meth) acrylate or 2-hydroxypropyl. Examples thereof include (meth) acrylate and 4-hydroxybutyl (meth) acrylate.
- a monoesterified product such as 2-hydroxyethyl (meth) acrylate is further ring-opened by ⁇ -caprolactone or the like.
- the carboxyl group-containing polymerizable unsaturated monomer (M-2) is a compound having one or more carboxyl groups and one polymerizable unsaturated bond in one molecule, and is, for example, acrylic acid, methacrylic acid, or crotonic acid. , Itaconic acid, maleic acid, maleic anhydride and the like. These can be used alone or in combination of two or more.
- the other copolymerizable polymerizable unsaturated monomer (M-3) is a compound having one polymerizable unsaturated bond in one molecule other than the above-mentioned monomers (M-1) and (M-2). , Specific examples are listed below.
- Alkyl or cycloalkyl (meth) acrylate For example, methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl ( Meta) acrylate, tert-butyl (meth) acrylate, n-hexyl (meth) acrylate, n-octyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, nonyl (meth) acrylate, tridecyl (meth) acrylate, lauryl (meth) Meta) acrylate, stearyl (meth) acrylate, isostearyl (meth) acrylate, cyclohexyl (meth) acrylate, methylcyclohexyl (meth) acrylate
- (Vii) Polymerizable unsaturated monomer having an alkyl fluorinated group: perfluoroalkyl (meth) acrylate such as perfluorobutylethyl (meth) acrylate and perfluorooctylethyl (meth) acrylate; fluoroolefin and the like.
- a polymerizable unsaturated monomer having a photopolymerizable functional group such as a maleimide group.
- (Ix) Vinyl compound N-vinylpyrrolidone, ethylene, butadiene, chloroprene, vinyl propionate, vinyl acetate and the like.
- (Xi) Polymerizable unsaturated monomer having two or more polymerizable unsaturated groups in one molecule: allyl (meth) acrylate, ethylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, neo Pentyl glycol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate and the like.
- Epoxide group-containing polymerizable unsaturated monomer glycidyl (meth) acrylate, ⁇ -methylglycidyl (meth) acrylate, 3,4-epoxycyclohexylmethyl (meth) acrylate, 3,4-epoxycyclohexylethyl (meth) acrylate , 3,4-Epoxide cyclohexylpropyl (meth) acrylate, allyl glycidyl ether, etc.
- (Xiii) A (meth) acrylate having a polyoxyethylene chain whose molecular end is an alkoxy group.
- (Xiv) Polymerizable unsaturated monomer having a sulfonic acid group: 2-acrylamide-2-methylpropanesulfonic acid, 2-sulfoethyl (meth) acrylate, allylsulfonic acid, 4-styrenesulfonic acid, etc .; sodium salts of these sulfonic acids And ammonium salts, etc.
- (Xv) Polymerizable unsaturated monomer having a phosphoric acid group: acid phosphooxyethyl (meth) acrylate, acid phosphooxypropyl (meth) acrylate, acid phosphooxypoly (oxyethylene) glycol (meth) acrylate, acid phosphooxypoly (Oxypropylene) glycol (meth) acrylate, etc.
- (Xviii) Polymerically unsaturated monomer having a carbonyl group: acrolein, diacetoneacrylamide, diacetonemethacrylamide, acetoacetoxyethyl methacrylate, formylstyrene, vinyl alkyl ketone having 4 to 7 carbon atoms (eg, vinyl methyl ketone) , Vinyl ethyl ketone, vinyl butyl ketone), etc.
- (Xix) Polymerizable unsaturated monomer having an acid anhydride group: maleic anhydride, itaconic anhydride, citraconic anhydride and the like.
- the polymerizable unsaturated group means an unsaturated group capable of radical polymerization.
- examples of such polymerizable unsaturated groups include vinyl groups, (meth) acryloyl groups and the like.
- (meth) acrylate means acrylate or methacrylate.
- (Meta) acrylic acid means acrylic acid or methacrylic acid.
- (meth) acryloyl means acryloyl or methacryloyl.
- (meth) acrylamide means acrylamide or methacrylamide.
- the ratio of the hydroxyl group-containing polymerizable unsaturated monomer (M-1) used in producing the hydroxyl group- and carboxyl group-containing acrylic resin (A1) is preferably 1 to 50% by mass based on the total amount of the monomer components. 2 to 40% by mass is more preferable, and 3 to 30% by mass is further preferable.
- the hydroxyl group and carboxyl group-containing acrylic resin (A1) may have a hydroxyl value of 1 to 150 mgKOH / g from the viewpoints of curability, chipping resistance, adhesion, hardness, finished appearance, etc. of the obtained coating film. It is preferably 2 to 120 mgKOH / g, more preferably 5 to 100 mgKOH / g.
- the proportion of the carboxyl group-containing polymerizable unsaturated monomer (M-2) used in producing the hydroxyl group- and carboxyl group-containing acrylic resin (A1) is 1 to 50% by mass based on the total amount of the monomer components.
- the acid value of the hydroxyl group- and carboxyl group-containing acrylic resin (A1) is preferably 1 to 150 mgKOH / g from the viewpoint of storage stability of the paint, water resistance of the obtained coating film, and the like. It is more preferably 100 mgKOH / g, and even more preferably 5 to 80 mgKOH / g.
- the content of the hydroxyl group and the carboxyl group-containing acrylic resin (A1) is the amount of the resin solid content in the aqueous coating composition.
- 2 to 70% by mass is preferable, 5 to 50% by mass is more preferable, and 10 to 40% by mass is further preferable.
- hydroxyl group and carboxyl group-containing acrylic resin (A1) is preferably hydroxyl group and carboxyl group-containing acrylic resin particles (A1') having a core-shell structure.
- Acrylic resin particles containing hydroxyl groups and carboxyl groups having a core-shell structure (A1')
- the "shell portion" of the "hydroxyl group- and carboxyl group-containing acrylic resin particles (A1') having a core-shell structure” means the polymer layer existing in the outermost layer of the resin particles, and the "core portion” is the shell. It means a polymer layer of the inner layer of the resin particles excluding the portion, and "having a core-shell structure” means a structure having the core portion and the shell portion.
- hydroxyl group- and carboxyl group-containing acrylic resin particles (A1') having a core-shell structure may be simply referred to as "hydroxyl group and carboxyl group-containing acrylic resin particles (A1')".
- the core-shell type structure usually has a layered structure in which the core portion is completely covered with the shell portion, but the amount of monomers in the shell portion forms a layered structure depending on the mass ratio of the core portion and the shell portion or the like. It may not be enough to squeeze. In such a case, it is not necessary to have a complete layer structure as described above, and a structure in which a part of the core portion is covered with a shell portion may be used.
- the hydroxyl group and carboxyl group-containing acrylic resin particles (A1') usually have a core portion, which is a copolymer (I) having a polymerizable unsaturated monomer as a copolymerization component, and a copolymer having a polymerizable unsaturated monomer as a copolymerization component.
- the polymerizable unsaturated monomer the polymerizable unsaturated monomers (M-1) to (M-3) can be appropriately combined and used.
- a copolymer crosslinked structure can be imparted by using the above-mentioned polymerizable unsaturated monomer having two or more polymerizable unsaturated groups in one molecule as the above-mentioned polymerizable unsaturated monomer.
- the ratio of its use can be appropriately determined depending on the degree of cross-linking of the copolymer, but usually, the above-mentioned polymerization. In the range of about 0.1 to 30% by mass, particularly about 0.5 to 10% by mass, and more particularly about 1 to 7% by mass, based on the total amount of the sex unsaturated monomers (M-1) to (M-3). It is preferably inside.
- the hydroxyl group and carboxyl group-containing acrylic resin particles (A1') are emulsion-polymerized with a polymerizable unsaturated monomer mixture to obtain an emulsion of the core copolymer (I), and then the polymerizable unsaturated monomer is contained in the emulsion. It can be obtained by adding a mixture and further emulsion polymerization to prepare a shell copolymer (II).
- the emulsion polymerization for preparing the emulsion of the core copolymer (I) can be carried out by a conventionally known method.
- emulsion polymerization of a polymerizable unsaturated monomer mixture using a polymerization initiator in the presence of an emulsifier.
- an emulsifier an anionic emulsifier and a nonionic emulsifier can be preferably used.
- anionic emulsifier examples include sodium salts and ammonium salts such as alkyl sulfonic acid, alkyl benzene sulfonic acid, and alkyl phosphoric acid.
- nonionic emulsifier examples include polyoxyethylene oleyl ether, polyoxyethylene stearyl ether, polyoxyethylene lauryl ether, polyoxyethylene tridecyl ether, polyoxyethylene phenyl ether, polyoxyethylene nonylphenyl ether, and polyoxy.
- Ethylene octylphenyl ether, polyoxyethylene monolaurate, polyoxyethylene monostearate, polyoxyethylene monooleate, sorbitan monolaurate, sorbitan monostearate, sorbitan trioleate, polyoxyethylene sorbitan monolaurate, etc. be able to.
- a polyoxyalkylene group-containing anionic emulsifier having an anionic group and a polyoxyalkylene group such as a polyoxyethylene group or a polyoxypropylene group in one molecule; an anionic group and a radically polymerizable unsaturated substance in one molecule.
- a reactive anionic emulsifier having a group or the like can also be used.
- Examples of the reactive anionic emulsifier include a sodium salt of a sulfonic acid compound having a radically polymerizable unsaturated group such as an allyl group, a metalyl group, a (meth) acryloyl group, a propenyl group, and a butenyl group, and an ammonium salt of the sulfonic acid compound. And so on.
- the amount of the emulsifier used is preferably about 0.1 to 15% by mass, particularly preferably about 0.5 to 10% by mass, and more particularly about 1 to 5% by mass with respect to the total amount of all the monomers used. Within the range is preferred.
- polymerization initiator examples include benzoyl peroxide, octanoyl peroxide, lauroyl peroxide, stearoyl peroxide, cumene hydroperoxide, tert-butyl peroxide, tert-butylperoxylaurate, and tert-butylperoxy.
- Organic peroxides such as isopropyl carbonate, tert-butylperoxyacetate, diisopropylbenzenehydroperoxide; azobisisobutyronitrile, azobis (2,4-dimethylvaleronitrile), azobis (2-methylpropionnitrile), azobis (2-Methylbutyronitrile), 4,4'-azobis (4-cyanobutanoic acid), dimethylazobis (2-methylpropionate), azobis [2-methyl-N- (2-hydroxyethyl) -propion Azo], azo compounds such as azobis ⁇ 2-methyl-N- [2- (1-hydroxybutyl)] -propionamide ⁇ ; persulfates such as potassium persulfate, ammonium persulfate, sodium persulfate and the like.
- persulfates such as potassium persulfate, ammonium persulfate, sodium persulfate and the like.
- polymerization initiators can be used alone or in combination of two or more. Further, if necessary, a reducing agent such as sugar, sodium formaldehyde sulfoxylate, or an iron complex can be used in combination with the above-mentioned polymerization initiator to prepare a redox initiator.
- a reducing agent such as sugar, sodium formaldehyde sulfoxylate, or an iron complex can be used in combination with the above-mentioned polymerization initiator to prepare a redox initiator.
- the amount of the polymerization initiator used is generally preferably about 0.1 to 5% by mass, particularly preferably about 0.2 to 3% by mass, based on the total amount of all the monomers used.
- the method of adding the polymerization initiator is not particularly limited, and can be appropriately selected depending on the type and amount thereof. For example, it can be contained in a monomer mixture or an aqueous medium in advance, or it can be added all at once at the time of polymerization, or it can be added dropwise.
- the hydroxyl group and carboxyl group-containing acrylic resin particles (A1') are obtained by adding a polymerizable unsaturated monomer mixture to the emulsion of the core copolymer (I) obtained above and further polymerizing the shell copolymer (shell copolymer). It can be obtained by forming II).
- the monomer mixture forming the shell copolymer (II) can appropriately contain components such as the polymerization initiator, chain transfer agent, reducing agent, and emulsifier, if necessary.
- the monomer mixture can be dropped as it is, but it is preferable to drop the monomer mixture as a monomer emulsion obtained by dispersing it in an aqueous medium.
- the particle size of the monomer emulsion in this case is not particularly limited.
- a method for polymerizing the monomer mixture forming the shell part copolymer (II) for example, the monomer mixture or its emulsion is added dropwise in a lump or gradually to form an emulsion of the core part copolymer (I).
- a method of adding and heating to an appropriate temperature while stirring can be mentioned.
- the hydroxyl group- and carboxyl group-containing acrylic resin particles (A1') thus obtained have a multi-layer structure in which the copolymer (I) is a core portion and the copolymer (II) is a shell portion.
- the aqueous coating composition of the present invention contains the hydroxyl group and carboxyl group-containing acrylic resin particles (A1'), the content of the hydroxyl group and carboxyl group-containing acrylic resin particles (A1') is determined in the aqueous coating composition. Based on the amount of solid resin, 2 to 70% by mass is preferable, 5 to 50% by mass is more preferable, and 10 to 40% by mass is further preferable.
- the hydroxyl group- and carboxyl group-containing acrylic resin particles (A1') form another resin layer between the step of obtaining the core part copolymer (I) and the step of obtaining the shell part copolymer (II). It is possible to add a step of supplying a polymerizable unsaturated monomer (one type or a mixture of two or more types) to carry out emulsion polymerization. Among them, as an additional layer, it is preferable to form a gradient polymer layer and use the hydroxyl group- and carboxyl group-containing acrylic resin particles (A1 ′′) having a core-shell structure containing the gradient polymer layer.
- the gradient polymer layer of "hydroxyl group- and carboxyl group-containing acrylic resin particles (A1 ′′) having a core-shell structure including a gradient polymer layer” has a layer structure in which the composition continuously changes (has a composition gradient). It means a polymer layer having. More specifically, it means a polymer layer having a composition gradient in which the composition of the monomer (monomer mixture) is continuously changed from, for example, monomer A (monomer mixture A) to monomer B (monomer mixture B).
- hydroxyl group- and carboxyl group-containing acrylic resin particles (A1 ′′) having a core-shell structure including a gradient polymer layer may be simply referred to as “hydroxyl group and carboxyl group-containing acrylic resin particles (A1 ′′)”.
- the gradient polymer layer can generally be obtained by a known polymerization method called power feed polymerization. Specifically, for example, when two types of monomer A (monomer mixture A) and monomer B (monomer mixture B) are polymerized, the monomer B (monomer mixture B) and the monomer A (monomer mixture A) are used.
- a gradient polymer layer can be obtained by introducing the monomer A (monomer mixture A) into the reaction vessel and carrying out the polymerization reaction while dropping it into the container to be accommodated.
- the synthesis conditions (the timing of starting mixing of the monomer A (monomer mixture A) and the monomer B (monomer mixture B), the monomer B (monomer mixture B), and the monomer A (monomer mixture A) are contained.
- a gradient polymer layer having a desired composition gradient can be obtained by setting the rate of dropping into the container and the rate of introducing the monomer A (monomer mixture A) into the reaction vessel).
- the ratio of the gradient polymer layer in the hydroxyl group and carboxyl group-containing acrylic resin particles (A1 ′′) is the total copolymerization of the hydroxyl group and carboxyl group-containing acrylic resin particles (A1 ′′) from the viewpoint of water resistance of the obtained coating film. It is preferably about 20 to 80% by mass, particularly preferably about 25 to 75% by mass, and further preferably about 30 to 70% by mass with respect to the total amount of the components.
- the hydroxyl group and carboxyl group-containing acrylic resin particles (A1 ′′) have a hydroxyl value of 1 to 150 mgKOH / g from the viewpoints of curability, chipping resistance, adhesion, finished appearance, etc. of the obtained coating film. It is preferably 2 to 120 mgKOH / g, more preferably 5 to 100 mgKOH / g.
- the core portion of the hydroxyl group- and carboxyl group-containing acrylic resin particles (A1 ′′) preferably has a hydroxyl value of 0 to 150 mgKOH / g from the viewpoint of water resistance and chipping resistance of the obtained coating film, from 5 to 5. It is more preferably 120 mgKOH / g, and even more preferably 10 to 100 mgKOH / g.
- the shell portion of the hydroxyl group- and carboxyl group-containing acrylic resin particles (A1 ′′) preferably has a hydroxyl value of 0 to 150 mgKOH / g from the viewpoint of water resistance and chipping resistance of the obtained coating film, and 2 to 2 to It is more preferably 120 mgKOH / g, and even more preferably 5 to 100 mgKOH / g.
- the hydroxyl group and carboxyl group-containing acrylic resin particles (A1 ′′) preferably have an acid value of 1 to 80 mgKOH / g from the viewpoint of storage stability of the paint, water resistance of the obtained coating film, and the like. It is more preferably 50 mgKOH / g, and even more preferably 5 to 30 mgKOH / g.
- the core portion of the hydroxyl group- and carboxyl group-containing acrylic resin particles (A1 ′′) preferably has an acid value of 0 to 50 mgKOH / g, preferably 0 to 30 mgKOH / g, from the viewpoint of production stability and storage stability of the paint. It is more preferably g, and even more preferably 0 to 10 mgKOH / g.
- the shell portion of the hydroxyl group- and carboxyl group-containing acrylic resin particles (A1 ′′) preferably has an acid value of 1 to 100 mgKOH / g from the viewpoint of storage stability of the paint and water resistance of the obtained coating film. It is more preferably 5 to 80 mgKOH / g, and even more preferably 10 to 50 mgKOH / g.
- the hydroxyl group and carboxyl group-containing acrylic resin particles (A1 ′′) preferably have a glass transition temperature of ⁇ 20 to 100 ° C., preferably 0 to 100, from the viewpoint of water resistance, chipping resistance, and the like of the obtained coating film. The temperature is more preferably 20 to 100 ° C.
- the core portion of the hydroxyl group- and carboxyl group-containing acrylic resin particles (A1 ′′) preferably has a glass transition temperature of ⁇ 50 to 50 ° C. from the viewpoint of water resistance and chipping resistance of the obtained coating film.
- the temperature is more preferably 30 to 50 ° C, and even more preferably 0 to 50 ° C.
- the shell portion of the hydroxyl group- and carboxyl group-containing acrylic resin particles (A1 ′′) preferably has a glass transition temperature of 0 to 120 ° C., preferably 20 to 100 ° C., from the viewpoint of water resistance of the obtained coating film. More preferably, it is more preferably 30 to 100 ° C.
- the content of the hydroxyl group and carboxyl group-containing acrylic resin particles (A1 ′′) is the water-based coating composition. Based on the amount of solid resin in the resin, 2 to 70% by mass is preferable, 5 to 50% by mass is more preferable, and 10 to 40% by mass is further preferable.
- Polyester resin containing hydroxyl groups and carboxyl groups (A2)
- the hydroxyl group- and carboxyl group-containing polyester resin (A2) can be synthesized by an esterification reaction of a polybasic acid and a polyvalent alcohol according to a conventional method by a known method.
- Polybasic acid is a compound having two or more carboxyl groups in one molecule, for example, phthalic acid, isophthalic acid, terephthalic acid, succinic acid, adipic acid, azelaic acid, sebacic acid, tetrahydrophthalic acid, hexahydro. Examples thereof include phthalic acid, maleic acid, fumaric acid, itaconic acid, trimellitic acid, pyromellitic acid and anhydrides thereof.
- the polyvalent alcohol is a compound having two or more hydroxyl groups in one molecule, and is, for example, ethylene glycol, propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5.
- -Pentanediol 1,6-hexanediol, 2,2-diethyl-1,3-propanediol, neopentyl glycol, 1,9-nonanediol, 1,4-cyclohexanediol, hydroxypivalate neopentyl glycol ester, Diols such as 2-butyl-2-ethyl-1,3-propanediol, 3-methyl-1,5-pentanediol, 2,2,4-trimethylpentanediol, hydride bisphenol A, and trimethyl propane, Trivalent or higher polyol components such as trimethylolethane, glycerin, pentaerythritol, and 2,2-dimethylolpropionic acid, 2,2-dimethylolbutanoic acid, 2,2-dimethylolpentanoic acid, 2,2- Examples thereof include hydroxycarboxylic acids such as dimethylol
- ⁇ -olefin epoxides such as propylene oxide and butylene oxide
- monoepoxy compounds such as Cardura E10 (manufactured by HEXION Specialty Chemicals, trade name, glycidyl ester of synthetic highly branched saturated fatty acid) are reacted with an acid to react these.
- the compound may be introduced into the polyester resin.
- the introduction of the carboxyl group into the polyester resin is, for example, a method in which after the esterification reaction of the polybasic acid and the polyhydric alcohol, a polybasic acid such as trimellitic acid or trimellitic anhydride and their anhydrides are further reacted. Alternatively, it can also be carried out by a method of adding anhydrous acid to a hydroxyl group-containing polyester to half-esterify it.
- the hydroxyl group- and carboxyl group-containing polyester resin (A2) includes linseed oil fatty acid, coconut oil fatty acid, safflower oil fatty acid, soybean oil fatty acid, sesame oil fatty acid, eno oil fatty acid, hemp oil fatty acid, tall oil fatty acid, and dehydrated castor oil. It may be a fatty acid-modified polyester resin modified with a (semi) dry oil fatty acid such as a fatty acid. Generally, the amount of denaturation of these fatty acids is preferably 30% by mass or less in terms of oil length. Further, the hydroxyl group- and carboxyl group-containing polyester resin (A2) may be partially reacted with a monobasic acid such as benzoic acid.
- a monobasic acid such as benzoic acid.
- hydroxyl group- and carboxyl group-containing polyester resin (A2) can be modified with a fatty acid, a monoepoxy compound, a polyisocyanate compound, an acrylic resin, or the like during or after the preparation of the resin.
- fatty acids examples include palm oil fatty acid, cotton seed oil fatty acid, hemp seed oil fatty acid, rice bran oil fatty acid, fish oil fatty acid, tall oil fatty acid, soybean oil fatty acid, flaxseed oil fatty acid, tung oil fatty acid, rapeseed oil fatty acid, castor oil fatty acid, and dehydrated castor bean paste.
- oil fatty acids and safflower fatty acids examples include oil fatty acids and safflower fatty acids.
- monoepoxy compound for example, "Cadura E10P" (trade name, manufactured by HEXION, glycidyl ester of synthetic highly branched saturated fatty acid) can be preferably used.
- polyisocyanate compound examples include aliphatic diisocyanate compounds such as lysine diisocyanate, hexamethylene diisocyanate, and trimethylhexane diisocyanate; hydrogenated xylylene diisocyanate, isophorone diisocyanate, methylcyclohexane-2,4-diisocyanate, and methylcyclohexane-2.
- 6-Diisocyanate 4,4'-methylenebis (cyclohexylisocyanate), 1,3- (isocyanatomethyl) cyclohexane and other alicyclic diisocyanates; aromatic diisocyanates such as tolylene diisocyanate, xylylene diisocyanate and diphenylmethane diisocyanate
- Aroma diisocyanates such as tolylene diisocyanate, xylylene diisocyanate and diphenylmethane diisocyanate
- Organic polyisocyanate such as trivalent or higher valent polyisocyanate such as lysine triisocyanate itself; Additives of each of these organic polyisocyanates and polyhydric alcohol, low molecular weight polyester resin, water, etc .; (For example, isocyanurate), biuret-type adduct and the like.
- These polyisocyanate compounds can be used alone or in admixture of two or more.
- a known method can be used, for example, with a polymerizable unsaturated group-containing polyester resin and a polymerizable unsaturated monomer. Examples thereof include a method of polymerizing a mixture, a method of reacting a polyester resin containing a hydroxyl group and a carboxyl group with an acrylic resin, and the like.
- the hydroxyl group- and carboxyl group-containing polyester resin (A2) preferably has a hydroxyl value of 1 to 250 mgKOH / g, more preferably 2 to 200 mgKOH / g, and even more preferably 5 to 200 mgKOH / g.
- the acid value of the hydroxyl group- and carboxyl group-containing polyester resin (A2) is preferably 1 to 150 mgKOH / g, more preferably 2 to 100 mgKOH / g, and 2 to 50 mgKOH / g. More preferred.
- the weight average molecular weight of the hydroxyl group- and carboxyl group-containing polyester resin (A2) is preferably 3,000 to 100,000, more preferably 4,000 to 50,000, and 5,000 to 30. It is more preferably 000.
- the average molecular weight is a value calculated from a chromatogram measured by a gel permeation chromatograph based on the molecular weight of standard polystyrene.
- the gel permeation chromatograph "HLC8120GPC” (manufactured by Tosoh Corporation) was used.
- TKgel G-4000HXL “TSKgel G-3000HXL”
- TKgel G-2500HXL and "TSKgel G-2000HXL” (all manufactured by Tosoh Corporation, trade name) are used.
- Mobile phase tetrahydrofuran, measurement temperature; 40 ° C., flow rate; 1 mL / min, detector; RI conditions.
- the content of the hydroxyl group and the carboxyl group-containing polyester resin (A2) is the amount of the resin solid content in the aqueous coating composition.
- 2 to 70% by mass is preferable, 5 to 50% by mass is more preferable, and 5 to 40% by mass is further preferable.
- the hydroxyl group- and carboxyl group-containing polyurethane resin (A3) can be obtained by a conventional method, for example, by reacting a polyol with a polyisocyanate compound. Further, after the reaction, the chain can be extended in the presence of a chain extender which is a low molecular weight compound having at least two active hydrogens in one molecule such as diol and diamine. Further, it can be modified with an acrylic resin or the like during or after the preparation of the resin.
- carboxyl group-free polyol examples include dihydric alcohols such as ethylene glycol, diethylene glycol, propylene glycol, butylene glycol, and hexamethylene glycol, and trivalent alcohols such as trimethylolpropane, glycerin, and pentaerythritol, as low molecular weight polyols. Alcohol and the like can be mentioned.
- Examples of the high molecular weight ones include polyether polyols, polyester polyols, acrylic polyols, epoxy polyols and the like.
- polyether polyol examples include polyethylene glycol, polypropylene glycol, polytetramethylene glycol and the like.
- the polyester polyol includes the above-mentioned dihydric alcohol, dipropylene glycol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol and other alcohols, and dibasic acids such as adipic acid, azelaic acid and sebatic acid. Examples thereof include polycondensates of the above, lactone-based ring-opening polymer polyols such as polycaprolactone, and polycarbonate polyols.
- carboxyl group-containing polyol examples include 2,2-dimethylolpropionic acid and 2,2-dimethylolbutanoic acid, with 2,2-dimethylolpropionic acid being particularly preferable.
- a small amount of a solvent such as N-methylpyrrolidone can also be used in order to allow the reaction to proceed rapidly.
- polyisocyanate compound to be reacted with the above polyol examples include aliphatic polyisocyanates such as hexamethylene diisocyanate, trimethylhexamethylene diisocyanate, dimerate diisocyanate, and lysine diisocyanate; and burette type of these polyisocyanates.
- isocyanurate ring adducts isophorone diisocyanates, 4,4'-methylenebis (cyclohexylisocyanate), methylcyclohexane-2,4- (or -2,6-) diisocyanates, 1,3-(or 1,4-) ) Di (isocyanatomethyl) cyclohexane, 1,4-cyclohexanediisocyanate, 1,3-cyclopentanediisocyanate, 1,2-cyclohexanediisocyanate and other alicyclic diisocyanates; and burette-type adducts of these polyisocyanates, Isocyanurate ring adduct; xylylene diisocyanate, metaxylylene diisocyanate, tetramethylxylylene diisocyanate, tolylene diisocyanate, 4,4'-diphenylmethane diisocyanate, 1,5-na
- Examples of the diol as the chain extender include ethylene glycol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, cyclohexanediol, and the like, and examples of the diamine include diamine.
- examples of the diamine include diamine.
- ethylenediamine, propylenediamine, xylylenediamine, N- (2-hydroxyethyl) ethylenediamine and the like can be mentioned.
- the hydroxyl group and carboxyl group-containing polyurethane resin (A3) preferably has a hydroxyl value of 1 to 250 mgKOH / g, more preferably 2 to 200 mgKOH / g, and even more preferably 5 to 200 mgKOH / g.
- the acid value of the hydroxyl group- and carboxyl group-containing polyurethane resin (A3) is preferably 1 to 100 mgKOH / g, preferably 2 to 50 mgKOH / g, from the viewpoint of production stability and water resistance of the obtained coating film. It is more preferably present, and further preferably 2 to 30 mgKOH / g.
- the weight average molecular weight of the hydroxyl group- and carboxyl group-containing polyurethane resin (A3) is preferably 3,000 or more, more preferably 5,000 or more, and further preferably 10,000 or more.
- the content of the hydroxyl group and carboxyl group-containing polyurethane resin (A3) is the amount of resin solid content in the aqueous coating composition.
- 2 to 70% by mass is preferable, 5 to 50% by mass is more preferable, and 10 to 40% by mass is further preferable.
- the blocked polyisocyanate compound (B) is a compound in which the isocyanate group of the polyisocyanate compound (b1) is blocked with a blocking agent (b2).
- Polyisocyanate compound (b1) is a compound having at least two isocyanate groups in one molecule, and is, for example, an aliphatic polyisocyanate, an alicyclic polyisocyanate, an aromatic aliphatic polyisocyanate, an aromatic polyisocyanate, and Derivatives thereof, etc., as well as any combination thereof can be mentioned.
- aliphatic polyisocyanate examples include trimethylene diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, pentamethylene diisocyanate, 1,2-propylene diisocyanate, 1,2-butylene diisocyanate, 2,3-butylene diisocyanate, and 1,3.
- An aliphatic diisocyanate such as butylene diisocyanate, 2,4,4- or 2,2,4-trimethylhexamethylene diisocyanate, diisocyanate dimerate, methyl 2,6-diisocyanatohexanate (common name: lysine diisocyanate); 2 , 6-Diisocyanatohexanoic acid 2-isocyanatoethyl, 1,6-diisocyanato-3-isocyanatomethylhexane, 1,4,8-triisocyanatooctane, 1,6,11-triisocyanatoundecane, 1, , 8-Diisocyanato-4-isocyanatomethyloctane, 1,3,6-triisocyanatohexane, 2,5,7-trimethyl-1,8-diisocyanato-5-isocyanatomethyloctane and other aliphatic triisocyanates, etc. Can be mentioned.
- alicyclic polyisocyanate examples include 1,3-cyclopentenediisocyanate, 1,4-cyclohexanediisocyanate, 1,3-cyclohexanediisocyanate, and 3-isocyanatomethyl-3,5,5-trimethylcyclohexylisocyanate (common name).
- Isophorone diisocyanate 4-methyl-1,3-cyclohexylene diisocyanate (common name: hydrogenated TDI), 2-methyl-1,3-cyclohexylene diisocyanate, 1,3- or 1,4-bis (isocyanato) Alicyclic diisocyanates such as methyl) cyclohexane (common name: hydrogenated xylylene diisocyanate) or a mixture thereof, methylenebis (4,1-cyclohexanediyl) diisocyanate (common name: hydrogenated MDI), norbornan diisocyanate; 1,3,5 -Triisocyanatocyclohexane, 1,3,5-trimethylisocyanatocyclohexane, 2- (3-isocyanatopropyl) -2,5-di (isocyanatomethyl) -bicyclo (2.2.1) heptane, 2- (3-Isocyanatopropyl) -2,
- aromatic aliphatic polyisocyanate examples include methylenebis (4,5-phenylene) diisocyanate (common name: MDI), 1,3- or 1,4-xylylene diisocyanate or a mixture thereof, ⁇ , ⁇ '-diisocyanato-.
- Arophilic aliphatic diisocyanates such as 1,4-diethylbenzene, 1,3- or 1,4-bis (1-isocyanato-1-methylethyl) benzene (common name: tetramethylxylylene diisocyanate) or a mixture thereof; 1,3 , 5-Arophilic aliphatic triisocyanates such as triisocyanatomethylbenzene and the like can be mentioned.
- aromatic polyisocyanate examples include m-phenylene diisocyanate, p-phenylenedi isocyanate, 4,4'-diphenyldiisocyanate, 1,5-naphthalenediisocyanate, and 2,4-tolylene diisocyanate (common name: 2,4-).
- aromatic diisocyanates such as 4,4'-toluene diisocyanate, 4,4'-diphenyl ether diisocyanate; triphenylmethane-4 , 4', 4''-triisocyanate, 1,3,5-triisocyanatobenzene, 2,4,6-triisocyanatotoluene and other aromatic triisocyanates; 4,4'-diphenylmethane-2,2' , 5,5'-Tetraisocyanate and other aromatic tetraisocyanates and the like.
- Examples of the above-mentioned derivatives include the above-mentioned polyisocyanate dimer, trimmer, biuret, allophanate, uretdione, uretoimine, isocyanurate, oxadiazine trione and the like, and polymethylene polyphenyl polyisocyanate (crude MDI, polypeptide MDI). Crude TDI and the like can be mentioned.
- polyisocyanate compound (b1) aliphatic diisocyanates, alicyclic diisocyanates and derivatives thereof are preferable because the obtained blocked polyisocyanate compound (B) does not easily turn yellow when heated, and among them, they are formed. Aliphatic diisocyanates and derivatives thereof are more preferable from the viewpoint of improving the flexibility of the coating film.
- the polyisocyanate compound (b1) includes an aliphatic polyisocyanate, an alicyclic polyisocyanate, an aromatic aliphatic polyisocyanate, an aromatic polyisocyanate, derivatives thereof, and any combination thereof, and any combination thereof. Includes compounds that can react with and prepolymers produced by reacting isocyanate groups under excessive conditions.
- Examples of the compound capable of reacting with the polyisocyanate include compounds having an active hydrogen group such as a hydroxyl group and an amino group, and specific examples thereof include polyhydric alcohols, low molecular weight polyester resins, amines and water. Can be mentioned.
- the polyisocyanate compound (b1) is a polymer of an isocyanate group-containing polymerizable unsaturated monomer, or a polymerizable unsaturated monomer other than the above-mentioned isocyanate group-containing polymerizable unsaturated monomer and the above-mentioned isocyanate group-containing polymerizable unsaturated monomer. Contains a copolymer with.
- the polyisocyanate compound (b1) is preferably 300 to 20, from the viewpoint of the reactivity of the obtained blocked polyisocyanate compound (B) and the compatibility between the blocked polyisocyanate compound (B) and other coating components. It is preferable to have a number average molecular weight in the range of 000, more preferably 400 to 8,000, and even more preferably 500 to 2,000.
- the polyisocyanate compound (b1) is contained in one molecule from the viewpoint of the reactivity of the obtained blocked polyisocyanate compound (B) and the compatibility between the blocked polyisocyanate compound (B) and other coating components.
- the average number of isocyanate functional groups is preferably in the range of 2 to 100.
- the average number of isocyanate functional groups is more preferably 3 or more from the viewpoint of enhancing the reactivity of the obtained blocked polyisocyanate compound (B).
- the average number of isocyanate functional groups is more preferably 20 or less from the viewpoint of preventing gelation during the production of the blocked polyisocyanate compound (B).
- Blocking agent (b2) examples of the blocking agent (b2) for blocking the isocyanate group in the polyisocyanate compound (b1) include active methylene-based, alcohol-based, phenol-based, oxime-based, amine-based, acid amide-based, imidazole-based, and pyridine-based. Examples thereof include mercaptan-based blocking agents, and the blocking agents can be used alone or in combination of two or more.
- the blocking agent (b2) preferably has at least a part of the blocking agent being an active methylene-based blocking agent, and more preferably the blocking agent being an active methylene-based blocking agent. ..
- Examples of the active methylene-based blocking agent include dimethyl malonate, diethyl malonate, di-propyl malonate, diisopropyl malonate, di-butyl malonate, diisobutyl malonate, disec-butyl malonate, and malon.
- the active methylene-based blocking agent includes dimethyl malonate, diethyl malonate, diisopropyl malonate, methyl acetoacetate, from the viewpoint of smoothness and vividness of the coating film formed by the aqueous coating composition of the present invention. It is preferably at least one compound selected from the group consisting of ethyl acetoacetate, methyl isobutyryl acetate and ethyl isobutyryl acetate.
- the isocyanate group blocking reaction in the polyisocyanate compound (b1) can optionally include a reaction catalyst.
- the reaction catalyst include metal hydroxide, metal alkoxide, metal carboxylate, metal acetylacetylate, hydroxide of onium salt, onium carboxylate, metal salt of active methylene compound, onium salt of active methylene compound, and aminosilane. Types, amines, phosphines and other basic compounds can be mentioned.
- the blocked polyisocyanate compound (B) is used as a spacer (b3) having at least two isocyanate-reactive functional groups from the viewpoint of low-temperature curability of the aqueous coating composition of the present invention and water resistance of the coating film to be formed. It preferably contains the derived structure.
- the spacer (b3) is a compound having at least two isocyanate-reactive functional groups.
- the functional group is not particularly limited as long as it is a functional group having reactivity with an isocyanate group.
- the isocyanate-reactive functional group include a hydroxyl group, an amino group, a carboxyl group, a thiol group and the like. Among them, a hydroxyl group and an amino group are preferable, and a hydroxyl group is particularly preferable. Therefore, the spacer (b3) is preferably a compound having at least two hydroxyl groups, or preferably a compound having at least two amino groups, and among them, a compound having at least two hydroxyl groups. preferable.
- Examples of the compound having at least two hydroxyl groups include dihydric alcohols such as ethylene glycol, diethylene glycol, propylene glycol, butylene glycol, and hexamethylene glycol, trimethylolpropane, glycerin, and pentaerythritol as low molecular weight compounds.
- Examples of the trihydric alcohol of the above, and examples of the high molecular weight ones include polyether polyols, polyester polyols, acrylic polyols, and epoxy polyols. Of these, a polyether polyol is preferable from the viewpoint of water resistance and chipping resistance of the obtained coating film.
- polyether polyol a commercially available product can also be used.
- examples of the commercially available product include "PEG # 200", “PEG # 300", “PEG # 400”, “PEG # 600”, “PEG # 1000", “PEG # 1500”, and "PEG # 1540".
- a polyether amine can be mentioned.
- a commercially available product can also be used. Examples of the commercially available products include “JEFFAMINE D-400”, “JEFFAMINE D-2000", “JEFFAMINE D-4000”, “JEFFAMINE ED-600”, “JEFFAMINE ED-900”, and “JEFFAMINE ED” manufactured by HUNTSMAN. -2003, "ELASTAMINE RT-1000", “JEFFAMINE T-403", “JEFFAMINE T-3000”, “JEFFAMINE T-5000” and the like can be mentioned.
- the molecular weight of the spacer (b3) is in the range of 500 to 6,000 from the viewpoint of low temperature curability of the aqueous coating composition of the present invention and the hardness, chipping resistance and water resistance of the coating film to be formed. It is preferably in the range of 800 to 5,000, more preferably in the range of 1,000 to 4,000.
- the number of functional groups of the spacer (b3) is preferably 2 to 3 and more preferably 2 from the viewpoint of storage stability of the aqueous coating composition of the present invention.
- the polyisocyanate compound (b1) containing the structure derived from the spacer (b3) can be formed.
- the polyisocyanate compound (b1) and the spacer are used from the viewpoints of storage stability of the aqueous coating composition of the present invention, hardness of the formed coating film, water resistance, and production stability of the blocked polyisocyanate compound (B).
- the ratio to (b3) is such that the number of moles of active hydrogen in the spacer (b3) is in the range of 0.03 to 0.6 mol based on 1 mol of the isocyanate group in the polyisocyanate compound (b1). Is preferable.
- the blocked polyisocyanate compound (B) contains a structure derived from a hydrophilic group-containing compound (b4) having one isocyanate-reactive functional group from the viewpoint of storage stability of the aqueous coating composition of the present invention. It can be a waste.
- the hydrophilic group-containing compound (b4) has one isocyanate-reactive functional group.
- Examples of the hydrophilic group-containing compound (b4) include a nonionic hydrophilic group-containing compound, an anionic hydrophilic group-containing compound, a cationic hydrophilic group-containing compound, and any combination thereof.
- the hydrophilic group-containing compound (b4) is a nonionic hydrophilic group-containing compound because the reaction of blocking the isocyanate group in the polyisocyanate compound (b1) with the above-mentioned blocking agent (b2) is not easily inhibited. Is preferable.
- nonionic hydrophilic group-containing compound examples include compounds having a polyoxyalkylene group.
- examples of the polyoxyalkylene group include a polyoxyethylene group, a polyoxypropylene group, a polyoxyethylene oxypropylene group and the like.
- the nonionic hydrophilic group-containing compound preferably has a polyoxyethylene group from the viewpoint of storage stability of the aqueous coating composition of the present invention.
- the number of the compounds having a polyoxyethylene group is 3 or more, preferably 5 to 100, and more preferably 8 to. It preferably has 45 contiguous polyoxyethylene groups, i.e., a polyoxyethylene block.
- the compound having a polyoxyethylene group may contain an oxyalkylene group other than the oxyethylene group in addition to the polyoxyethylene block.
- the oxyalkylene group other than the oxyethylene group include an oxypropylene group, an oxybutylene group, and an oxystyrene group.
- the molar ratio of the oxyethylene group in the oxyalkylene group in the compound having a polyoxyethylene group may be in the range of 20 to 100 mol% from the viewpoint of storage stability of the aqueous coating composition of the present invention. It is preferable, and more preferably in the range of 50 to 100 mol%. When the molar ratio of the oxyethylene group in the oxyalkylene group is 20 mol% or more, the hydrophilicity is sufficiently imparted, and the storage stability of the aqueous coating composition of the present invention becomes good.
- the nonionic hydrophilic group-containing compound has a number average molecular weight in the range of 200 to 2,000 from the viewpoint of storage stability of the aqueous coating composition of the present invention and water resistance of the formed coating film. Is preferable. From the viewpoint of storage stability of the aqueous coating composition of the present invention, the number average molecular weight is more preferably 300 or more, and further preferably 400 or more. The number average molecular weight is more preferably 1,500 or less, and even more preferably 1,200 or less, from the viewpoint of water resistance of the coating film formed by the water-based coating composition of the present invention.
- nonionic hydrophilic group-containing compound examples include polyethylene glycol monoalkyl ether (also known as ⁇ -alkoxypolyoxyethylene) such as polyethylene glycol monomethyl ether and polyethylene glycol monoethyl ether; polypropylene glycol monomethyl ether and polypropylene glycol monoethyl.
- polyethylene glycol monoalkyl ether also known as ⁇ -alkoxypolyoxyethylene
- polyethylene glycol monomethyl ether and polyethylene glycol monoethyl ether examples include polypropylene glycol monomethyl ether and polypropylene glycol monoethyl.
- Polyethylene glycol monoalkyl ether such as ether (also known as ⁇ -alkoxypolyoxypropylene); ⁇ -alkoxypolyoxyethylene (oxypropylene) such as ⁇ -methoxypolyoxyethylene (oxypropylene) and ⁇ -ethoxypolyoxyethylene (oxypropylene) Propylene); polyethylene glycol (propylene glycol) monomethyl ether, polyethylene glycol (propylene glycol) monoalkyl ether such as polyethylene glycol (propylene glycol) monoethyl ether, and any combination thereof can be mentioned.
- ether also known as ⁇ -alkoxypolyoxypropylene
- ⁇ -alkoxypolyoxyethylene (oxypropylene) such as ⁇ -methoxypolyoxyethylene (oxypropylene) and ⁇ -ethoxypolyoxyethylene (oxypropylene) Propylene
- polyethylene glycol (propylene glycol) monomethyl ether polyethylene glycol (propylene glycol) monoalky
- nonionic hydrophilic group-containing compound polyethylene glycol monomethyl ether and polyethylene glycol monoethyl ether are preferable, and polyethylene glycol monomethyl ether is more preferable.
- polyethylene glycol (propylene glycol) means a copolymer of ethylene glycol and propylene glycol, and includes a block copolymer and a random copolymer.
- polyethylene glycol monomethyl ethers examples include "UNIOX M-400”, “UNIOX M-550”, “UNIOX M-1000”, and “UNIOX M-” manufactured by NOF CORPORATION. 2000 ”and the like.
- a polyisocyanate compound (b1) containing a structure derived from the hydrophilic group-containing compound (b4) is formed. can do.
- the polyisocyanate compound (b1) and the hydrophilic group are selected from the viewpoints of storage stability of the aqueous coating composition of the present invention and adhesion, smoothness, brightness, water resistance and chipping resistance of the formed coating film.
- the ratio with the containing compound (b4) is based on 1 mol of the isocyanate group in the polyisocyanate compound (b1), and the number of moles of active hydrogen in the hydrophilic group-containing compound (b4) is 0.03 to 0.6 mol. It is preferably within the range.
- the isocyanate group and the blocking agent (b2) in the polyisocyanate compound (b1) are reacted with the spacer (b3) and / or the hydrophilic group-containing compound (b4).
- the order of the reactions is not particularly limited. Specifically, after reacting a part of the isocyanate groups in the polyisocyanate compound (b1) with the spacer (b3) and / or the hydrophilic group-containing compound (b4), the remaining isocyanate groups are blocked by the blocking agent (b2).
- Method of blocking after blocking a part of the isocyanate groups in the polyisocyanate compound (b1) with a blocking agent (b2), the spacer (b3) and / or the hydrophilic group-containing compound (b4) is reacted with the remaining isocyanate groups.
- a blocking agent (b2), a spacer (b3) and / or a hydrophilic group-containing compound (b4) are simultaneously reacted with an isocyanate group in the polyisocyanate compound (b1).
- the weight average molecular weight of the blocked polyisocyanate compound (B) is preferably in the range of 20,000 to 200,000 from the viewpoints of production stability, water resistance of the formed coating film, hardness, and the like. It is more preferably in the range of 000 to 150,000, and even more preferably in the range of 30,000 to 120,000.
- the content of the blocked polyisocyanate compound (B) is preferably 2 to 70% by mass, more preferably 5 to 50% by mass, further preferably 10 to 40% by mass, based on the amount of resin solids in the aqueous coating composition. preferable.
- Phosphate group-containing compound (C) examples include phosphoric acid; mono-n-propyl phosphoric acid, monoisopropyl phosphoric acid, mono-n-butyl phosphoric acid, monoisobutyl phosphoric acid, mono-tert-butyl phosphoric acid, and monooctyl.
- Monoalkyl phosphoric acid such as phosphoric acid and monodecyl phosphoric acid; di-n-propyl phosphoric acid, diisopropyl phosphoric acid, di-n-butyl phosphoric acid, diisobutyl phosphoric acid, di-tert-butyl phosphoric acid, dioctyl phosphoric acid, didecyl phosphoric acid and the like.
- a phosphoric acid group-containing resin (C1) is preferable from the viewpoint of storage stability of the aqueous coating composition of the present invention.
- the phosphoric acid group-containing resin (C1) include a phosphoric acid group-containing acrylic resin (C1'), a phosphoric acid group-containing polyester resin, a phosphoric acid group-containing polyether resin, a phosphoric acid group-containing polycarbonate resin, and a phosphoric acid group-containing polyurethane. Examples thereof include resins and phosphoric acid group-containing epoxy resins.
- phosphoric acid groups are contained from the viewpoint of storage stability of the aqueous coating composition of the present invention, water resistance of the formed coating film, and chipping resistance.
- Acrylic resin (C1') is preferable.
- the phosphoric acid group-containing acrylic resin (C1') can be synthesized by copolymerizing a polymerizable unsaturated monomer having a phosphoric acid group and other polymerizable unsaturated monomers by a conventional method.
- Examples of the polymerizable unsaturated monomer having a phosphoric acid group include the compounds exemplified by the above-mentioned hydroxyl group and carboxyl group-containing acrylic resin (A1).
- Examples of other polymerizable unsaturated monomers include the hydroxyl group-containing polymerizable unsaturated monomer (M-1) and the carboxyl group-containing polymerizable unsaturated monomer (M) exemplified in the hydroxyl group and carboxyl group-containing acrylic resin (A1). -2), and other copolymerizable polymerizable unsaturated monomers (M-3) other than the above-mentioned polymerizable unsaturated monomers having a phosphoric acid group can be mentioned.
- the polymerizable unsaturated monomer having a phosphoric acid group is 1 to 50% by mass, particularly 5 by mass, based on the total amount of each monomer component constituting the phosphoric acid group-containing acrylic resin. It is preferably about 40% by mass.
- the weight average molecular weight of the phosphoric acid group-containing acrylic resin (C1') is preferably 3000 to 30000, particularly preferably 5000 to 25000, and further particularly in the range of 10000 to 20000 from the viewpoint of finished appearance and coating film performance. It is preferable to have.
- the content of the phosphoric acid group-containing compound (C) is preferably 0.1 to 20% by mass, more preferably 0.5 to 15% by mass, and 1 to 10 based on the amount of the resin solid content in the aqueous coating composition. Mass% is more preferred.
- the basic compound (D) is a compound used for neutralizing the carboxyl group of the hydroxyl group and the carboxyl group-containing resin (A) and adjusting the pH of the aqueous coating composition. Therefore, compounds that chemically react with other functional groups, such as the chain extender diamine described in the explanation column of the hydroxyl group- and carboxyl group-containing polyurethane resin (A3), are excluded.
- the content of the basic compound (D) can be such that the pH of the aqueous coating composition of the present invention is in the range of 7.0 to 8.2.
- the content of the basic compound (D) is preferably 0.1 to 15% by mass, more preferably 0.5 to 10% by mass, and 1 to 8% by mass, based on the amount of resin solids in the aqueous coating composition. % Is more preferable.
- the basic compound (D) is a basic compound having an (D1) acid dissociation constant (PKa) in the range of 7.0 to 8.5 and a boiling point in the range of 100 to 200 ° C.
- the content of the basic compound (D1) is in the range of 50 to 100% by mass based on the mass of the basic compound (D).
- the basic compound (D1) has an acid dissociation constant (PKa) in the range of 7.0 to 8.5 and a boiling point in the range of 100 to 200 ° C.
- PKa acid dissociation constant
- the acid dissociation constant (PKa) of the basic compound (D1) is preferably in the range of 7.2 to 8.2, and more preferably in the range of 7.3 to 7.8. ..
- the boiling point is 100 ° C.
- the boiling point of the basic compound (D1) is preferably in the range of 105 to 180 ° C, and more preferably in the range of 110 to 160 ° C.
- Examples of the basic compound (D1) include morpholine (PKa8.4, boiling point 129 ° C.), allylmorpholine (PKa7.1, boiling point 158 ° C.), N-methylmorpholine (PKa7.4, boiling point 116 ° C.), N. -Ethylmorpholine (PKa7.7, boiling point 139 ° C.), triallylamine (PKa8.3, boiling point 156 ° C.) and the like can be mentioned. These can be used alone or in combination of two or more.
- the basic compound (D1) may be N-methylmorpholine (PKa 7.4, boiling point 116 ° C.) or N-methylmorpholine (PKa 7.4, boiling point 116 ° C.) from the viewpoint of storage stability of the aqueous coating composition of the present invention, hardness of the coating film formed, and water resistance. It is preferable to use N-ethylmorpholine (PKa7.7, boiling point 139 ° C.).
- the content of the basic compound (D1) in the aqueous coating composition of the present invention is in the range of 50 to 100% by mass based on the mass of the basic compound (D).
- the content of the basic compound (D1) in the water-based coating composition of the present invention is 50% by mass or more, a water-based coating composition having excellent storage stability, hardness of the formed coating film, and water resistance can be obtained. Can be done.
- the content of the basic compound (D1) in the aqueous coating composition of the present invention is preferably in the range of 70 to 100% by mass, preferably 90 to 100% by mass, based on the mass of the basic compound (D). It is more preferably in the range of 100% by mass.
- Examples of the basic compound (D) other than the basic compound (D1) include ammonia, triethylamine, triethanolamine, 2- (dimethylamino) ethanol, diethylethanolamine and the like.
- the water-based coating composition of the present invention is excellent in storage stability and can form a coating film exhibiting excellent coating performance such as high hardness and water resistance even when cured at a relatively low temperature.
- the acid dissociation constant (PKa) of the basic compound (D1) is 7.0 or more, the carboxyl groups of the hydroxyl group and the carboxyl group-containing resin (A) can be neutralized, and the storage is stable. Since the properties are good and the acid dissociation constant (PKa) of the basic compound (D1) is 8.5 or less, the reaction between the hydroxyl group and carboxyl group-containing resin (A) and the blocked polyisocyanate compound (B).
- the amount of volatilization of the basic compound (D1) increases during heat curing, and the hydroxyl group and carboxyl group-containing resin (A) and the blocked polyisocyanate compound (B) It is presumed that a coating film exhibiting excellent coating film performance can be formed without inhibiting the catalytic effect of the phosphate group-containing compound (C) on the reaction with.
- the water-based coating composition of the present invention can further contain a melamine resin (E).
- a melamine resin (E) a partially methylolated melamine resin or a completely methylolated melamine resin obtained by the reaction of the melamine component and the aldehyde component can be used.
- the aldehyde component include formaldehyde, paraformaldehyde, acetaldehyde, benzaldehyde and the like.
- methylol group of the above-mentioned methylolated melamine resin which is partially or completely etherified with an appropriate alcohol
- examples of the alcohol used for etherification include methyl alcohol, ethyl alcohol, n-propyl alcohol, i-propyl alcohol, n-butyl alcohol, i-butyl alcohol, 2-ethyl-1-butanol, and 2-ethyl-1.
- -Hexanol and the like can be mentioned.
- a methyl-butyl mixed etherified melamine resin is more preferred.
- the melamine resin (B) preferably has a weight average molecular weight of 400 to 6,000, more preferably 500 to 4,000, and even more preferably 600 to 3,000.
- a commercially available product can be used as the melamine resin (E).
- Commercially available product names include, for example, “Symel 202", “Symel 203", “Symel 204", “Symel 211", “Symel 212", “Symel 238", “Symel 251", “Symel 253", “Symel 254", “Symel 303", “Symel 323", “Symel 324", “Symel 325", “Symel 327”, “Symel 350”, “Symel 370", “Symel 380", “Symel 385", “Symel 1156", “Symel 1158", “Symel 1116", “Symel 1130” (all manufactured by Ornex Japan Co., Ltd.); “Regimin 735", “Regimin 740", “Regimin 741”, “Regimin 745", “Regimin 746”, “Regimin 747” (above, manufactured by Monsanto); “Uban
- the content of the melamine resin (E) is preferably 2 to 40% by mass based on the amount of resin solids in the water-based coating composition. 3 to 30% by mass is more preferable, and 5 to 20% by mass is further preferable.
- the aqueous coating composition of the present invention further comprises a resin other than the above, a pigment, an organic solvent, a curing catalyst other than the phosphate group-containing compound (C), a dispersant, an anti-settling agent, and a defoaming agent, if necessary. It can contain an agent, a thickener, an ultraviolet absorber, a light stabilizer, a surface conditioner and the like.
- resins other than the above include acrylic resins that do not contain hydroxyl groups and / or carboxyl groups, polyester resins that do not contain hydroxyl groups and / or carboxyl groups, polyurethane resins that do not contain hydroxyl groups and / or carboxyl groups, hydroxyl groups and / or carboxyls.
- examples include a group-free polyether resin, a hydroxyl group and / or a carboxyl group-free polycarbonate resin, a hydroxyl group and / or a carboxyl group-free epoxy resin, and among them, a hydroxyl group-free carboxyl group-containing polyurethane resin is used. Is preferable.
- the above-mentioned carboxyl group-containing polyurethane resin containing no hydroxyl group can be obtained by a conventional method, for example, by reacting a polyol with a polyisocyanate. Further, after the reaction, the chain can be extended in the presence of a chain extender which is a low molecular weight compound having at least two active hydrogens in one molecule such as diol and diamine. Further, it can be modified with an acrylic resin or the like during or after the preparation of the resin.
- a chain extender which is a low molecular weight compound having at least two active hydrogens in one molecule such as diol and diamine. Further, it can be modified with an acrylic resin or the like during or after the preparation of the resin.
- the polyol, polyisocyanate and chain extender the compounds described in the explanation column of the hydroxyl group and carboxyl group-containing polyurethane resin (A3) can be used.
- the pigment examples include coloring pigments, extender pigments, and brilliant pigments.
- the pigment can be used alone or in combination of two or more.
- the blending amount of the pigment is 1 to 200 parts by mass, preferably 1 to 200 parts by mass, based on 100 parts by mass of the resin solid content in the water-based coating composition of the present invention. It is preferably in the range of 5 to 160 parts by mass, more preferably 15 to 140 parts by mass.
- the coloring pigment examples include titanium oxide, zinc oxide, carbon black, molybdenum red, Prussian blue, cobalt blue, azo pigment, phthalocyanine pigment, quinacridone pigment, isoindolin pigment, slene pigment, and perylene pigment. , Dioxazine pigments, diketopyrrolopyrrole pigments and the like.
- the blending amount of the coloring pigment is preferably 1 to 180 parts by mass, based on 100 parts by mass of the resin solid content in the water-based coating composition of the present invention. Is preferably in the range of 5 to 150 parts by mass, more preferably 15 to 130 parts by mass.
- the extender pigment examples include barium sulfate, talc, clay, kaolin, barium carbonate, calcium carbonate, silica, alumina white and the like.
- the extender pigment barium sulfate can be preferably used from the viewpoint of improving designability and the like.
- the blending amount of the extender pigment is preferably 1 to 180 parts by mass, based on 100 parts by mass of the resin solid content in the aqueous coating composition of the present invention. Is preferably in the range of 5 to 140 parts by mass, more preferably 10 to 120 parts by mass.
- the glitter pigment examples include aluminum (including vapor-deposited aluminum), copper, zinc, brass, nickel, glass flakes, aluminum oxide, mica, titanium oxide and / or iron oxide-coated aluminum oxide, titanium oxide and the like. / Or an iron oxide-coated mica or the like.
- aluminum pigments include non-leaving type aluminum pigments and leaving type aluminum pigments, both of which can be used.
- the bright pigment is preferably scaly.
- the brilliant pigment those having a longitudinal dimension in the range of 1 to 100 ⁇ m, particularly 5 to 40 ⁇ m, and a thickness of 0.001 to 5 ⁇ m, particularly 0.01 to 2 ⁇ m are suitable.
- the blending amount of the brilliant pigment is 0.1 to 0.1 to 100 parts by mass based on 100 parts by mass of the resin solid content in the water-based coating composition of the present invention. It is preferably in the range of 100 parts by mass, preferably 1 to 50 parts by mass, and more preferably 3 to 25 parts by mass.
- organic solvent examples include ketone solvents such as acetone, methyl ethyl ketone and methyl isobutyl ketone; ester solvents such as ethyl acetate, butyl acetate, methyl benzoate, ethyl ethoxypropionate, ethyl propionate and methyl propionate; isopropanol.
- ketone solvents such as acetone, methyl ethyl ketone and methyl isobutyl ketone
- ester solvents such as ethyl acetate, butyl acetate, methyl benzoate, ethyl ethoxypropionate, ethyl propionate and methyl propionate
- isopropanol examples of the organic solvent.
- Alcohol-based solvents such as n-butanol, isobutanol, 2-ethylhexanol; ether solvents such as tetrahydrofuran, dioxane and dimethoxyethane; ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, diethylene glycol monomethyl ether, propylene glycol monomethyl ether acetate. , 3-Methyl butyl acetate and other glycol ether-based solvents; aromatic hydrocarbon-based solvents, aliphatic hydrocarbon-based solvents and the like can be mentioned.
- the aqueous coating composition of the present invention When used, it can be used for coating by adding water and / or an organic solvent or the like as necessary to dilute it and adjusting the viscosity to an appropriate level.
- the appropriate viscosity varies depending on the coating composition, but for example, Ford Cup Viscometer No. When adjusted using No. 4, the viscosity can be adjusted to about 20 to 100 seconds, preferably about 25 to 70 seconds at 20 ° C.
- the coating solid content concentration of the water-based coating composition is usually about 5 to 70% by mass, preferably about 10 to 55% by mass.
- the water-based coating composition of the present invention may be either a one-component coating material or a multi-component coating material, but from the viewpoints of excellent productivity without a coating mixing process and simplification of maintenance of the coating machine. Therefore, it is preferable to use a one-component paint.
- the water-based coating composition of the present invention can be applied to an object to be coated by a method known per se, for example, air spray coating, airless spray coating, rotary atomization coating, curtain coat coating, etc. Electricity may be applied. Of these, air spray coating and rotary atomization coating are preferable. Further, such a coating method can be carried out once or several times until a desired film thickness is obtained.
- the amount of the aqueous coating composition of the present invention applied is usually preferably 5 to 40 ⁇ m, preferably 7 to 35 ⁇ m, and more preferably 10 to 30 ⁇ m as the cured film thickness.
- the water-based coating composition of the present invention can form a coating film exhibiting excellent coating film performance such as high hardness and water resistance even when cured at a relatively low temperature, and therefore is to be coated.
- a coating film of the present invention is applied onto an object to form an uncured colored coating film, and then the uncured colored coating film is heated at a temperature in the range of 60 to 110 ° C. to be cured. It can be suitably used in a film forming method.
- Step (A1) A step of coating the aqueous coating composition of the present invention on an object to be coated to form an uncured colored coating film, and a step (A2): an uncured film formed in the step (A1).
- a method for forming a coating film which comprises a step of heating and curing the colored coating film of No. 1 at a temperature in the range of 60 to 110 ° C.
- Step (B1) A step of coating the aqueous coating composition of the present invention on an object to be coated to form an uncured colored coating film.
- Step (B2) A step of coating a clear coating composition on the uncured colored coating film to form an uncured clear coating film, and a step (B3): formed in the step (B1).
- a coating film forming method comprising a step of simultaneously heating and curing an uncured colored coating film and a clear coating film formed in the step (B2) at a temperature in the range of 60 to 110 ° C.
- Step (C1) A step of applying an intermediate coating composition on an object to be coated to form an uncured intermediate coating film.
- Step (C2) A step of coating the aqueous coating composition of the present invention on the uncured intermediate coating film to form an uncured colored coating film.
- Step (C3) A step of coating a clear coating composition on the uncured colored coating film to form an uncured clear coating film, and a step (C4): formed in the step (C1).
- the uncured intermediate coating film, the uncured colored coating film formed in the step (C2), and the clear coating film formed in the step (C3) are coated at a temperature in the range of 60 to 110 ° C.
- a coating film forming method including a step of simultaneously heating and curing.
- Step (D1) A step of coating the aqueous coating composition of the present invention on an object to be coated to form an uncured intermediate coating film.
- Step (D2) A step of coating a colored coating composition on the uncured intermediate coating film to form an uncured colored coating film.
- Step (D3) A step of coating a clear coating composition on the uncured colored coating film to form an uncured clear coating film.
- Step (D4) The uncured intermediate coating film formed in the step (D1), the uncured colored coating film formed in the step (D2), and the clear formed in the step (D3).
- a coating film forming method comprising a step of simultaneously heating and curing a coating film at a temperature in the range of 60 to 110 ° C.
- Examples of the object to be coated include outer and inner panels of automobile bodies such as passenger cars, trucks, motorcycles, and buses; automobile parts; outer panels of home electric appliances such as mobile phones and audio equipment. it can. Of these, the outer plate portion, the inner plate portion, and the automobile parts of the automobile body are preferable.
- the material of these objects to be coated is not particularly limited.
- metal materials such as iron, aluminum, brass, copper, tin, stainless steel, zinc-plated steel, zinc alloy (Zn-Al, Zn-Ni, Zn-Fe, etc.) plated steel; polyethylene resin, polypropylene resin, acrylonitrile- Resins such as butadiene-styrene (ABS) resin, polyamide resin, acrylic resin, vinylidene chloride resin, polycarbonate resin, polyurethane resin and epoxy resin, various plastic materials such as FRP; inorganic materials such as glass, cement and concrete; wood ; Textile materials such as paper and cloth can be mentioned. Of these, metal materials and plastic materials are preferable.
- phosphoric acid is applied to a metal surface such as an automobile body outer plate portion and an inner plate portion, an automobile part, a household electric product, and a metal base material such as a steel plate constituting these. It may be subjected to surface treatment such as salt treatment, chromate treatment, or composite oxide treatment.
- a coating film may be further formed on the object which may or may not be surface-treated.
- an object to be coated which is a base material, may be subjected to a surface treatment, if necessary, and an undercoat coating film may be formed on the surface treatment.
- the undercoat coating film can be formed, for example, when the object to be coated is an automobile body, using a paint for an undercoat that is known per se, which is usually used in painting an automobile body.
- an electrodeposition paint preferably a cationic electrodeposition paint can be used.
- the intermediate coating composition includes a base resin such as an acrylic resin having a crosslinkable functional group such as a carboxyl group and a hydroxyl group, a polyester resin, an alkyd resin, a urethane resin, and an epoxy resin, and an amino resin such as a melamine resin and a urea resin.
- a cross-linking agent such as a polyisocyanate compound which may be blocked, and a paint made together with a pigment, a thickener, and other components of the option can be used.
- the colored coating composition examples include base resins such as acrylic resins having crosslinkable functional groups such as carboxyl groups and hydroxyl groups, polyester resins, alkyd resins, urethane resins and epoxy resins, and amino resins such as melamine resins and urea resins.
- base resins such as acrylic resins having crosslinkable functional groups such as carboxyl groups and hydroxyl groups
- polyester resins such as acrylic resins having crosslinkable functional groups such as carboxyl groups and hydroxyl groups
- alkyd resins such as urethane resins and epoxy resins
- amino resins such as melamine resins and urea resins.
- a cross-linking agent such as a polyisocyanate compound which may be blocked can be used as a paint together with a pigment, a thickener, and other components of the option.
- thermosetting clear paint composition any thermosetting clear paint composition known for painting automobile bodies and the like can be used.
- thermosetting clear coating composition include an organic solvent-type thermosetting coating composition containing a base resin having a crosslinkable functional group and a curing agent, an aqueous thermosetting coating composition, and powder thermosetting.
- a paint composition and the like can be mentioned.
- Examples of the crosslinkable functional group contained in the substrate resin include a carboxyl group, a hydroxyl group, an epoxy group, and a silanol group.
- Examples of the type of the base resin include acrylic resin, polyester resin, alkyd resin, urethane resin, epoxy resin, and fluororesin.
- Examples of the curing agent include polyisocyanate compounds, blocked polyisocyanate compounds, melamine resins, urea resins, carboxyl group-containing compounds, carboxyl group-containing resins, epoxy group-containing resins, and epoxy group-containing compounds.
- Examples of the base resin / curing agent combination of the clear coating composition include a hydroxyl group-containing resin / polyisocyanate compound, a carboxyl group-containing resin / epoxy group-containing resin, a hydroxyl group-containing resin / blocked polyisocyanate compound, and a hydroxyl group-containing resin / melamine resin. Etc. are preferable, and a hydroxyl group-containing resin / polyisocyanate compound is more preferable.
- the clear coating composition may be a one-component coating material or a multi-component coating material such as a two-component urethane resin coating material.
- the clear coating composition can contain a coloring pigment, a brilliant pigment, a dye, etc. to the extent that the transparency is not impaired, if necessary, and further, an extender pigment, an ultraviolet absorber, a light stabilizer, etc.
- An antifoaming agent, a thickener, a rust preventive agent, a surface conditioner and the like can be appropriately contained.
- the coating method of the clear coating composition is not particularly limited, but a wet coating film can be formed by, for example, an air spray coating, an airless spray coating, a rotary atomization coating, a curtain coat coating, or the like. In these coating methods, electrostatic application may be performed if necessary. Of these, air spray coating or rotary atomization coating is particularly preferable.
- the coating amount of the clear coating composition is usually preferably an amount of 10 to 70 ⁇ m, preferably 20 to 50 ⁇ m as the cured film thickness.
- the viscosity of the clear coating composition is set to a viscosity range suitable for the coating, usually Ford Cup No. 4 It is preferable to appropriately adjust the viscometer using a solvent such as an organic solvent so that the viscosity range is about 15 to 60 seconds at 20 ° C., particularly about 20 to 50 seconds.
- the heating can be performed by a known means, and for example, a drying furnace such as a hot air furnace, an electric furnace, or an infrared induction heating furnace can be applied.
- the heating temperature is in the range of 60 to 110 ° C, preferably 70 to 90 ° C.
- the heating time is not particularly limited, but is preferably in the range of 10 to 40 minutes, more preferably 20 to 40 minutes.
- a step of forming a first multi-layer coating film on an outer plate portion of the automobile body and a step of forming a second coating film on an inner plate portion of the automobile body are performed.
- the step of forming the first multi-layer coating film is (1a) not yet applied the water-based coating composition (X) on the outer plate portion of the automobile body.
- the step of forming the second coating film which includes a baking step of heating the clear coating coating film (CCo) and simultaneously curing these coating films, is (2a) the water-based coating on the inner plate portion of the automobile body.
- the outer plate portion of the automobile body (hereinafter, may be simply referred to as "outer plate portion”) is a portion that can be visually recognized from the outside of the completed vehicle that has completed the mounting process.
- the inner plate portion of the automobile body (hereinafter, may be simply referred to as “inner plate portion”) is a portion that cannot be seen from the outside of the completed vehicle that has completed the mounting process.
- the outer plate portion and the inner plate portion are usually formed of a coated steel plate obtained by coating a steel plate such as a cold-rolled steel plate, a galvanized steel plate, a galvanized steel plate, a stainless steel plate, or a tin-plated steel plate with an electrodeposition paint.
- the steel sheet may be subjected to chemical conversion treatment before being coated with the electrodeposition paint.
- chemical conversion treatment include phosphate treatment such as zinc phosphate treatment and iron phosphate treatment, composite oxide film treatment, chromium phosphate treatment, chromate treatment and the like.
- the coated steel sheet may be coated with an intermediate coating composition after coating with an electrodeposition coating to form an intermediate coating film, and the intermediate coating film may be uncured.
- the intermediate coating composition the intermediate coating composition described in the column of the coating film forming method can be used.
- Step of Forming First Multilayer Coating Film includes the steps (1a) to (1c) described below.
- Step (1a) the water-based coating composition (X) is coated on the outer plate portion of the automobile body to form an uncured outer plate colored base coat coating film (BCo).
- the water-based paint composition (X) the water-based paint composition of the present invention is used.
- the method for coating the water-based coating composition (X) include an air spray method, an airless spray method, and an electrostatic coating method.
- the film thickness of the outer plate colored base coat coating film (BCo) is usually 5 to 40 ⁇ m, preferably 7 to 35 ⁇ m, and more preferably 10 to 30 ⁇ m as the cured film thickness.
- the outer panel colored base coat coating film (BCo) can be preheated, air blown, or the like under heating conditions in which the coating film is not substantially cured before the clear coat coating film (Y) is applied.
- the preheat temperature is preferably 40 to 100 ° C, more preferably 50 to 90 ° C, and even more preferably 60 to 80 ° C.
- the preheating time is preferably 30 seconds to 15 minutes, more preferably 1 to 10 minutes, and even more preferably 2 to 5 minutes.
- the air blow can be performed, for example, by blowing air heated to room temperature or a temperature of 25 to 80 ° C. on the coated surface of the object to be coated for 30 seconds to 15 minutes.
- the colored coating composition (Z) is applied onto the uncured outer plate colored base coating coating film (BCo) before the clear coating coating film (Y) is applied.
- a cured outer plate second colored base coat coating film (BCo2) may be formed.
- the colored coating composition (Z) the colored coating composition described in the column of the coating film forming method can be used.
- Step (1b) the clear coat paint (Y) is coated on the uncured outer plate colored base coat coating film (BCo) to form the uncured outer plate clear coat coating film (CCo).
- the clear coat paint (Y) the clear paint composition described in the column of the coating film forming method can be used.
- the method for applying the clear coat paint (Y) include an air spray method, an airless spray method, and an electrostatic coating method.
- the film thickness of the outer panel clear coat coating film (CCo) is usually 10 to 70 ⁇ m, preferably 20 to 50 ⁇ m as a cured film thickness.
- Step (1c) In the step (1c) of the present invention, the uncured outer plate colored base coat coating film (BCo) and the uncured outer plate clear coat coating film (CCo) are heated to cure these coating films at the same time.
- the above heating can be performed by a known means, and for example, a drying furnace such as a hot air furnace, an electric furnace, or an infrared induction heating furnace can be applied.
- the heating temperature is preferably 60 to 110 ° C, more preferably 70 to 90 ° C.
- the heating time is not particularly limited, but is preferably in the range of 10 to 40 minutes, more preferably 20 to 40 minutes.
- Step of Forming Second Coating Film includes (2a) and (2b) described below.
- Step (2a) the water-based coating composition (X) is coated on the inner plate portion of the automobile body to form an uncured inner plate colored coating film (PCi).
- the water-based paint composition (X) the water-based paint composition of the present invention is used.
- the method for coating the water-based coating composition (X) include an air spray method, an airless spray method, and an electrostatic coating method.
- the film thickness of the inner plate colored coating film (PCi) may be usually 5 to 40 ⁇ m, preferably 7 to 35 ⁇ m, and more preferably 10 to 30 ⁇ m as the cured film thickness.
- a method of omitting the coating of the clear paint is adopted.
- Step (2b) the uncured inner plate colored coating film (PCi) is heated and cured.
- the baking step in the step (2b) is preferably performed at the same time as the baking step in the step (1c) from the viewpoint of energy saving and the like.
- the above heating can be performed by a known means, and for example, a drying furnace such as a hot air furnace, an electric furnace, or an infrared induction heating furnace can be applied.
- the heating temperature may be 60 to 110 ° C, preferably in the range of 70 to 90 ° C.
- the heating time is not particularly limited, but is preferably in the range of 10 to 40 minutes, more preferably 20 to 40 minutes.
- the method for painting an automobile body of the present invention includes a step of forming a first coating film on an outer plate portion of an automobile body and a step of forming a second coating film on an inner plate portion of the automobile body.
- the step of forming the first coating film is (1a')
- the water-based coating composition (X) is coated on the outer panel portion of the automobile body
- the uncured outer panel is colored.
- a step of forming the second coating film which comprises a step of forming an outer panel colored coating film (PCo) for forming a film (PCo), and (1b') a baking step of heating and curing the uncured outer panel colored coating film (PCo).
- (2b') include a baking step of heating and curing the uncured inner plate colored coating film (PCi), and the aqueous coating composition (X) is the aqueous coating composition of the present invention. Including the painting method of.
- Step of Forming First Coating Film includes the steps (1a') and (1b') described below.
- the water-based coating composition (X) is coated on the outer plate portion of the automobile body to form an uncured outer plate colored coating film (PCo).
- the water-based paint composition (X) the water-based paint composition of the present invention is used.
- the method for coating the water-based coating composition (X) include an air spray method, an airless spray method, and an electrostatic coating method.
- the film thickness of the outer panel colored coating film (PCo) is usually 5 to 40 ⁇ m, preferably 7 to 35 ⁇ m, and more preferably 10 to 30 ⁇ m as the cured film thickness.
- the uncured outer panel colored coating film (PCo) is heated and cured.
- the above heating can be performed by a known means, and for example, a drying furnace such as a hot air furnace, an electric furnace, or an infrared induction heating furnace can be applied.
- the heating temperature is in the range of 60 to 110 ° C, preferably 70 to 90 ° C.
- the heating time is not particularly limited, but is preferably in the range of 10 to 40 minutes, more preferably 20 to 40 minutes.
- a method of omitting the coating of the clear paint is adopted. By adopting this method, the cost of the outer panel coating process can be reduced.
- Step of Forming Second Coating Film includes (2a') and (2b') described below.
- the water-based coating composition (X) is coated on the inner plate portion of the automobile body to form an uncured inner plate colored coating film (PCi).
- the water-based paint composition (X) the water-based paint composition of the present invention is used.
- the method for coating the water-based coating composition (X) include an air spray method, an airless spray method, and an electrostatic coating method.
- the film thickness of the inner plate colored coating film (PCi) may be usually 5 to 40 ⁇ m, preferably 7 to 35 ⁇ m, and more preferably 10 to 30 ⁇ m as the cured film thickness.
- the present invention when forming the second coating film on the inner plate portion, a method of omitting the coating of the clear paint is adopted. By adopting this method, the cost of the inner plate coating process can be reduced. Further, by using the same water-based paint composition (X) as that used for the outer plate portion for the inner plate portion, it is possible to reduce the types of paints used and reduce the cost of the inner plate portion coating process.
- the uncured inner plate colored coating film (PCi) is heated and cured.
- the baking step in the step (2b') is preferably performed at the same time as the baking step in the step (1c) from the viewpoint of energy saving and the like.
- the above heating can be performed by a known means, and for example, a drying furnace such as a hot air furnace, an electric furnace, or an infrared induction heating furnace can be applied.
- the heating temperature may be 60 to 110 ° C, preferably in the range of 70 to 90 ° C.
- the heating time is not particularly limited, but is preferably in the range of 10 to 40 minutes, more preferably 20 to 40 minutes.
- the particles were discharged while being filtered through a nylon cloth to obtain acrylic resin particles (A1'-1) containing a hydroxyl group and a carboxyl group having a solid content concentration of 30%.
- the obtained hydroxyl group- and carboxyl group-containing acrylic resin particles (A1'-1) had an acid value of 16 mgKOH / g, a hydroxyl value of 66 mgKOH / g, and a glass transition temperature of 21 ° C.
- Monomer emulsion (1) 42 parts of deionized water, 0.72 parts of "Aqualon KH-10", 2 parts of methylenebisacrylamide, 5 parts of styrene, 15 parts of methylmethacrylate, 5 parts of 2-hydroxyethylmethacrylate and n-butyl 23 parts of acrylate was mixed and stirred to obtain a monomer emulsion (1).
- Monomer emulsion (2) 42 parts of deionized water, 0.72 parts of "Aqualon KH-10", 0.05 parts of ammonium persulfate, 2.5 parts of methacrylic acid, 10 parts of 2-hydroxyethyl methacrylate, 5 parts of styrene, 12.5 parts of methyl methacrylate, 10 parts of n-butyl acrylate and 10 parts of n-butyl methacrylate were mixed and stirred to obtain a monomer emulsion (2).
- Manufacturing example 2 130 parts of deionized water, "Aqualon KH-10" (trade name, manufactured by Dai-ichi Kogyo Seiyaku Co., Ltd., emulsifier, effective) in a reaction vessel equipped with a thermometer, thermostat, stirrer, reflux condenser, nitrogen introduction tube and dropping device. 0.52 parts (component 97%) was charged, stirred and mixed in a nitrogen stream, and the temperature was raised to 80 ° C. Next, 1.72 parts of the following monomer emulsion (1) and 5.3 parts of a 6% ammonium persulfate aqueous solution were introduced into the reaction vessel and held at 80 ° C. for 15 minutes.
- the remaining monomer emulsion (1) was added dropwise to the reaction vessel kept at the same temperature over 3 hours, and aging was carried out for 1 hour after the completion of the addition.
- the following monomer emulsion (2) was added dropwise over 1 hour, and after aging for 1 hour, 20 parts of a 5% 2- (dimethylamino) ethanol aqueous solution was gradually added to the reaction vessel and cooled to 30 ° C.
- the particles were discharged while being filtered through a 100-mesh nylon cloth to obtain hydroxyl group- and carboxyl group-containing acrylic resin particles (A1'-2) having a solid content concentration of 30%.
- the obtained hydroxyl group- and carboxyl group-containing acrylic resin particles (A1'-2) had an acid value of 16 mgKOH / g, a hydroxyl value of 66 mgKOH / g, and a glass transition temperature of 21 ° C.
- Monomer emulsion (1) 42 parts of deionized water, 0.72 parts of "Aqualon KH-10", 2 parts of methylenebisacrylamide, 5 parts of styrene, 15 parts of methylmethacrylate, 5 parts of 2-hydroxyethylmethacrylate and n-butyl 23 parts of acrylate was mixed and stirred to obtain a monomer emulsion (1).
- Monomer emulsion (2) 42 parts of deionized water, 0.72 parts of "Aqualon KH-10", 0.05 parts of ammonium persulfate, 2.5 parts of methacrylic acid, 10 parts of 2-hydroxyethyl methacrylate, 5 parts of styrene, 12.5 parts of methyl methacrylate, 10 parts of n-butyl acrylate and 10 parts of n-butyl methacrylate were mixed and stirred to obtain a monomer emulsion (2).
- the obtained hydroxyl group- and carboxyl group-containing acrylic resin particles (A1''-1) had an acid value of 16 mgKOH / g, a hydroxyl value of 66 mgKOH / g, and a glass transition temperature of 21 ° C.
- Monomer emulsion (1) 42 parts of deionized water, 0.72 parts of "Aqualon KH-10", 2 parts of methylenebisacrylamide, 5 parts of styrene, 15 parts of methylmethacrylate, 5 parts of 2-hydroxyethylmethacrylate and n-butyl 23 parts of acrylate was mixed and stirred to obtain a monomer emulsion (1).
- Monomer emulsion (2) 42 parts of deionized water, 0.72 parts of "Aqualon KH-10", 0.05 parts of ammonium persulfate, 2.5 parts of methacrylic acid, 10 parts of 2-hydroxyethyl methacrylate, 5 parts of styrene, 12.5 parts of methyl methacrylate, 10 parts of n-butyl acrylate and 10 parts of n-butyl methacrylate were mixed and stirred to obtain a monomer emulsion (2).
- Production Example 4 of Production of Polyester Resin (A2) Containing Hydroxyl Group and Carboxyl Group In a reaction vessel equipped with a thermometer, thermostat, stirrer, reflux cooler and water separator, 174 parts of trimethylol propane, 327 parts of neopentyl glycol, 352 parts of adipic acid, 109 parts of isophthalic acid and 1,2-cyclohexanedicarboxylic acid. After charging 101 parts of acid anhydride and raising the temperature from 160 ° C. to 230 ° C. over 3 hours, the generated condensed water was kept at 230 ° C. while being distilled off by a water separator, and the acid value was 3 mgKOH / g or less. It was reacted until it became.
- Production example 5 In a reaction vessel equipped with a thermometer, thermostat, stirrer, reflux cooler and water separator, 174 parts of trimethylol propane, 327 parts of neopentyl glycol, 352 parts of adipic acid, 109 parts of isophthalic acid and 1,2-cyclohexanedicarboxylic acid. After charging 101 parts of acid anhydride and raising the temperature from 160 ° C. to 230 ° C. over 3 hours, the generated condensed water was kept at 230 ° C. while being distilled off by a water separator, and the acid value was 3 mgKOH / g or less. It was reacted until it became.
- methyl ethyl ketone solution was cooled to 40 ° C., 493.2 g of deionized water containing 9.8 parts of N-ethylmorpholine was added and emulsified, and then a 5% N- (2-hydroxyethyl) ethylenediamine aqueous solution 275.9 was added thereto. After adding the portion and stirring for 60 minutes, methyl ethyl ketone was distilled off under reduced pressure heating, and the concentration was adjusted with deionized water to obtain a solid content of 35%, an acid value of 14 mgKOH / g, a hydroxyl value of 12 mgKOH / g, and an average particle size of 120 nm. (A3-1), a polyurethane resin dispersion containing a hydroxyl group and a carboxyl group, was obtained.
- Production example 7 211.9 parts of polytetramethylene glycol (number average molecular weight 1000), 11.5 parts of 2,2-dimethylolpropionic acid, 6.9 parts of trimethylolpropane in a reaction vessel equipped with a thermometer, a stirrer and a reflux condenser. , 112.2 parts of isophorone diisocyanate and 298.5 parts of methyl ethyl ketone were charged, the reaction system was replaced with nitrogen gas, and then reacted at 80 ° C. with stirring to obtain an NCO-terminated urethane prepolymer having a free isocyanate group content of 3.2%.
- methyl ethyl ketone solution was cooled to 40 ° C., 493.2 g of deionized water containing 8.6 parts of triethylamine was added for emulsification, and then 275.9 parts of a 5% N- (2-hydroxyethyl) ethylenediamine aqueous solution was added thereto. Is added, and after stirring for 60 minutes, methyl ethyl ketone is distilled off under reduced pressure heating, and the concentration is adjusted with deionized water to have a solid content of 35%, an acid value of 14 mgKOH / g, a hydroxyl value of 12 mgKOH / g, and an average particle size of 120 nm. A hydroxyl group- and carboxyl group-containing polyurethane resin dispersion (A3-2) was obtained.
- Production Example 8 of Production of Carboxyl Group-Containing Polyurethane Resin (U-1) Not Containing Hydroxyl Groups 211.9 parts of polytetramethylene glycol (number average molecular weight 1000), 11.5 parts of 2,2-dimethylolpropionic acid, 6.9 parts of trimethylolpropane in a reaction vessel equipped with a thermometer, a stirrer and a reflux condenser. , 112.2 parts of isophorone diisocyanate and 298.5 parts of methyl ethyl ketone were charged, the reaction system was replaced with nitrogen gas, and then reacted at 80 ° C.
- Liquid (U-1) was obtained.
- a blocked polyisocyanate compound (B-1) having an average molecular weight of 4,000 was obtained.
- Production Example 11 of production of phosphoric acid group-containing acrylic resin (C1') A mixed solvent of 27.5 parts of methoxypropanol and 27.5 parts of isobutanol was placed in a reaction vessel equipped with a thermometer, a thermostat, a stirrer, a reflux condenser and a dropping device, and heated to 110 ° C. Next, 25 parts of styrene, 27.5 parts of n-butyl methacrylate, 20 parts of "isostearyl acrylate” (trade name, manufactured by Osaka Organic Chemical Industry Co., Ltd., branched higher alkyl acrylate), 7.5 parts of 4-hydroxybutyl acrylate, below.
- Phosphoric acid group-containing polymerizable monomer 57.5 parts of monobutyl phosphate and 41 parts of isobutanol are placed in a reaction vessel equipped with a thermometer, a thermostat, a stirrer, a reflux condenser and a dropping device, and the temperature is raised to 90 ° C. After dropping 42.5 parts of glycidyl methacrylate over 2 hours, the mixture was further stirred and aged for 1 hour. Then, 59 parts of isopropanol was added to obtain a phosphoric acid group-containing polymerizable monomer solution having a solid content concentration of 50%. The acid value of the obtained monomer due to the phosphoric acid group was 285 mgKOH / g.
- the obtained mixed solution was placed in a wide-mouthed glass bottle, glass beads having a diameter of about 1.3 mm ⁇ were added as dispersion media, sealed, and dispersed with a paint shaker for 4 hours to obtain a pigment dispersion (P-1). Obtained.
- Production Example 13 In a container equipped with a stirrer, 44.4 parts (20 parts of solid content) of the hydroxyl group and carboxyl group-containing polyester resin solution (A2-2) obtained in Production Example 5, "Mitsubishi Carbon Black MA-100" (trade name, Mitsubishi) 10 parts of carbon black manufactured by Chemical Corporation and 50 parts of deionized water were added, mixed uniformly, and 0.3 part of 2- (dimethylamino) ethanol was added to the mixed solution to adjust the pH to 7.5. Next, the obtained mixed solution was placed in a wide-mouthed glass bottle, glass beads having a diameter of about 1.3 mm ⁇ were added as dispersion media, sealed, and dispersed with a paint shaker for 4 hours to obtain a pigment dispersion (P-2). Obtained.
- Production Example 1 of water-based coating composition 104.9 parts of pigment dispersion liquid (P-1) obtained in Production Example 12, 100 parts (solid content 30 parts) of hydroxyl group and carboxyl group-containing acrylic resin particles (A1'-1) obtained in Production Example 1, Production Example 57.1 parts (20 parts solid content) of the hydroxyl group- and carboxyl group-containing polyurethane resin dispersion obtained in No. 6 and 42.9 parts (B-1) of the blocked polyisocyanate compound (B-1) obtained in Production Example 9. 30 parts of solid content) and 4 parts (2 parts of solid content) of the phosphoric acid group-containing acrylic resin solution (C1'-1) obtained in Production Example 11 were uniformly mixed.
- the results of storage stability are also shown in Tables 1-1 to 1-3.
- Example 21 (First multi-layer coating film forming step) "WP-505T" (trade name, manufactured by Kansai Paint Co., Ltd., polyester melamine resin-based water-based intermediate coating paint) is applied to the test plate obtained above using a rotary atomization type electrostatic coating machine to cure the film thickness. It was electrostatically coated to a thickness of 30 ⁇ m and left for 5 minutes to form an uncured intermediate coating film. Next, on the uncured intermediate coating film, the water-based coating composition NO. 1 was electrostatically coated using a rotary atomization type electrostatic coating machine so that the dry film thickness was 15 ⁇ m, left for 5 minutes, and then preheated at 80 ° C. for 3 minutes to obtain an uncured colored coating film. Was formed.
- WP-505T trade name, manufactured by Kansai Paint Co., Ltd., polyester melamine resin-based water-based intermediate coating paint
- a dry film of "Soflex # 520 Clear” (manufactured by Kansai Paint Co., Ltd., a two-component acrylic urethane-based organic solvent-based clear paint containing a hydroxyl group-containing acrylic resin and a polyisocyanate compound) is applied onto the colored coating film. It was electrostatically coated to a thickness of 35 ⁇ m and left for 7 minutes to form a clear coating film.
- the test plate (A-1) was prepared by heating at 80 ° C. for 30 minutes to heat-cure the intermediate coating film, the colored coating film, and the clear coating film.
- Example 22 to 42, Comparative Examples 10 to 18 In Example 21, a test plate was prepared in the same manner as in Example 21 except that the type and heating temperature of the aqueous coating composition were changed as shown in Table 2 below. Each test plate obtained above was evaluated by the following test method. The evaluation results are shown in Table 2 below.
- Hardness after water resistance The test plates obtained in the above Examples and Comparative Examples were immersed in warm water at 40 ° C. for 240 hours, dried at 20 ° C. for 12 hours, and then JIS K 5600-5-4 (1999) "Scratch hardness (pencil)". The pencil hardness of the coated surface of each test plate was measured according to the method). If the pencil hardness is B or higher, it passes. The evaluation results are shown in Table 2.
- Chipping resistance The test plates obtained in the above Examples and Comparative Examples are installed on the sample holding table of the stepping stone tester "JA-400" (trade name, manufactured by Suga Test Instruments Co., Ltd., chipping resistance tester). At 0 ° C., 50 g of granite crushed stone having a particle size of No.
- the present invention is not limited to the above-described embodiments, and various modifications based on the technical idea of the present invention are possible.
- the configurations, methods, processes, shapes, materials, numerical values, etc. given in the above-described embodiments and examples are merely examples, and if necessary, different configurations, methods, processes, shapes, materials, numerical values, etc. May be used.
- the configurations, methods, processes, shapes, materials, numerical values and the like of the above-described embodiments can be combined with each other as long as they do not deviate from the gist of the present invention.
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Abstract
Description
さらに最近では、使用されるエネルギーをさらに削減するため、上記焼き付け硬化工程における加熱温度をより低くすることが求められている。
しかし、加熱温度が比較的低い場合においても高い硬化性を有する塗料組成物は、一般に反応性が高く、貯蔵安定性が不十分な場合があった。
しかし、特に前記のように焼き付け硬化工程における加熱温度が比較的低い場合においては、上記水性ベース塗料によって形成されるベース塗膜は十分な硬度及び耐水性を得られない場合があった。
項1.(A)水酸基及びカルボキシル基含有樹脂、(B)ブロック化ポリイソシアネート化合物、(C)リン酸基含有化合物及び(D)塩基性化合物を含有する水性塗料組成物であって、前記塩基性化合物(D)が、(D1)酸解離定数(PKa)が7.0~8.5の範囲内であり、かつ、沸点が100~200℃の範囲内である塩基性化合物を含有し、かつ前記塩基性化合物(D1)の含有割合が、該塩基性化合物(D)の質量を基準として、50~100質量%の範囲内であり、そして、前記水性塗料組成物のpHが7.0~8.2の範囲内である、水性塗料組成物。
項2.前記ブロック化ポリイソシアネート化合物(B)のブロック剤の少なくとも一部が、活性メチレン系のブロック剤である、項1に記載の水性塗料組成物。
項3.前記リン酸基含有化合物(C)の少なくとも1種が、リン酸基含有樹脂(C1)である、項1又は2に記載の水性塗料組成物。
項4.前記リン酸基含有樹脂(C1)の少なくとも1種が、リン酸基含有アクリル樹脂(C1’)である、項3に記載の水性塗料組成物。
項5.前記酸解離定数(PKa)が7.0~8.5の範囲内でありかつ沸点が100~200℃の範囲内である塩基性化合物(D1)が、N-メチルモルホリン及び/又はN-エチルモルホリンである、項1~4のいずれか1項に記載の水性塗料組成物。
項6.さらに、メラミン樹脂(E)を含有する、項1~5のいずれか1項に記載の水性塗料組成物。
項7.被塗物上に項1~6のいずれか1項に記載の水性塗料組成物を塗装して、未硬化の着色塗膜を形成することと、次いで、前記未硬化の着色塗膜を60~110℃の範囲内の温度で加熱して硬化させることとを含む、塗膜形成方法。
項8.自動車車体の外板部に第1複層塗膜を形成する工程、及び
自動車車体の内板部に第2塗膜を形成する工程
を含む、自動車車体の塗装方法であって、
前記第1複層塗膜を形成する工程が、
(1a)前記自動車車体の外板部上に、水性塗料組成物(X)を塗装して、未硬化の外板着色ベースコート塗膜(BCo)を形成する外板着色ベースコート塗膜形成工程、
(1b)前記未硬化の外板着色ベースコート塗膜(BCo)上に、クリヤーコート塗料(Y)を塗装して未硬化の外板クリヤーコート塗膜(CCo)を形成する外板クリヤーコート塗膜形成工程、及び
(1c)前記未硬化の外板着色ベースコート塗膜(BCo)及び前記未硬化の外板クリヤーコート塗膜(CCo)を加熱し、これらの塗膜を同時に硬化させる焼付工程、
を含み、
前記第2塗膜を形成する工程が、
(2a)前記自動車車体の内板部上に、前記水性塗料組成物(X)を塗装して、未硬化の内板着色塗膜(PCi)を形成する内板着色塗膜形成工程、及び
(2b)上記未硬化の内板着色塗膜(PCi)を加熱し硬化させる焼付工程、
を含み、
かつ、前記水性塗料組成物(X)が項1~6のいずれか1項に記載の水性塗料組成物である、自動車車体の塗装方法。
項9.前記焼付工程(1c)及び前記焼付工程(2b)における加熱温度が60~110℃の範囲内である、項8に記載の自動車車体の塗装方法。
項10.前記焼付工程(1c)及び前記焼付工程(2b)が同時に行なわれる、項8又は9に記載の自動車車体の塗装方法。
本発明の水性塗料組成物は、(A)水酸基及びカルボキシル基含有樹脂、(B)ブロック化ポリイソシアネート化合物、(C)リン酸基含有化合物及び(D)塩基性化合物を含有し、かつ、pHが7.0~8.2の範囲内である水性塗料組成物であって、該塩基性化合物(D)は、酸解離定数(PKa)が7.0~8.5の範囲内でありかつ沸点が100~200℃の範囲内である塩基性化合物(D1)を含有し、該塩基性化合物(D1)の割合が、該塩基性化合物(D)の質量を基準として、50~100質量%の範囲内である。
上記pHが7.0以上であると、貯蔵安定性に優れた水性塗料組成物を得ることが出来、8.2以下であると、形成される塗膜の硬度及び耐水性に優れた水性塗料組成物を得ることが出来る。
なかでも、上記pHは、7.1~8.0の範囲内であることが好ましく、7.2~7.8の範囲内であることがより好ましい。
水酸基及びカルボキシル基含有樹脂(A)は、水酸基及びカルボキシル基を含有する樹脂であれば、特に限定されるものではなく、樹脂の種類としては、具体的には、例えば、アクリル樹脂、ポリエステル樹脂、ポリエーテル樹脂、ポリカーボネート樹脂、ポリウレタン樹脂などを挙げることができる。特に、水酸基及びカルボキシル基含有樹脂(A)として、水酸基及びカルボキシル基を含有するアクリル樹脂、ポリエステル樹脂、及びポリウレタン樹脂を好適に使用することができる。
水酸基及びカルボキシル基含有アクリル樹脂(A1)は、水酸基含有重合性不飽和モノマー(M-1)、カルボキシル基含有重合性不飽和モノマー(M-2)、及びその他の共重合可能な重合性不飽和モノマー(M-3)を常法により共重合せしめることによって合成することができる。
(iii) アダマンチル基を有する重合性不飽和モノマー:アダマンチル(メタ)アクリレート等。
(iv) トリシクロデセニル基を有する重合性不飽和モノマー:トリシクロデセニル(メタ)アクリレート等。
(v) 芳香環含有重合性不飽和モノマー:ベンジル(メタ)アクリレート、スチレン、α-メチルスチレン、ビニルトルエン等。
(vi) アルコキシシリル基を有する重合性不飽和モノマー:ビニルトリメトキシシラン、ビニルトリエトキシシラン、ビニルトリス(2-メトキシエトキシ)シラン、γ-(メタ)アクリロイルオキシプロピルトリメトキシシラン、γ-(メタ)アクリロイルオキシプロピルトリエトキシシラン等。
(vii) フッ素化アルキル基を有する重合性不飽和モノマー:パーフルオロブチルエチル(メタ)アクリレート、パーフルオロオクチルエチル(メタ)アクリレート等のパーフルオロアルキル(メタ)アクリレート;フルオロオレフィン等。
(viii) マレイミド基等の光重合性官能基を有する重合性不飽和モノマー。
(x) 含窒素重合性不飽和モノマー:(メタ)アクリロニトリル、(メタ)アクリルアミド、N,N-ジメチルアミノエチル(メタ)アクリレート、N,N-ジエチルアミノエチル(メタ)アクリレート、N,N-ジメチルアミノプロピル(メタ)アクリルアミド、メチレンビス(メタ)アクリルアミド、エチレンビス(メタ)アクリルアミド、グリシジル(メタ)アクリレートとアミン化合物との付加物等。
(xi) 重合性不飽和基を1分子中に2個以上有する重合性不飽和モノマー:アリル(メタ)アクリレート、エチレングリコールジ(メタ)アクリレート、1,4-ブタンジオールジ(メタ)アクリレート、ネオペンチルグリコールジ(メタ)アクリレート、1,6-ヘキサンジオールジ(メタ)アクリレート等。
(xii) エポキシ基含有重合性不飽和モノマー:グリシジル(メタ)アクリレート、β-メチルグリシジル(メタ)アクリレート、3,4-エポキシシクロヘキシルメチル(メタ)アクリレート、3,4-エポキシシクロヘキシルエチル(メタ)アクリレート、3,4-エポキシシクロヘキシルプロピル(メタ)アクリレート、アリルグリシジルエーテル等。
(xiv) スルホン酸基を有する重合性不飽和モノマー:2-アクリルアミド-2-メチルプロパンスルホン酸、2-スルホエチル(メタ)アクリレート、アリルスルホン酸、4-スチレンスルホン酸等;これらスルホン酸のナトリウム塩及びアンモニウム塩等。
(xv) リン酸基を有する重合性不飽和モノマー:アシッドホスホオキシエチル(メタ)アクリレート、アシッドホスホオキシプロピル(メタ)アクリレート、アシッドホスホオキシポリ(オキシエチレン)グリコール(メタ)アクリレート、アシッドホスホオキシポリ(オキシプロピレン)グリコール(メタ)アクリレート等。
(xvii) 光安定性重合性不飽和モノマー:4-(メタ)アクリロイルオキシ1,2,2,6,6-ペンタメチルピペリジン、4-(メタ)アクリロイルオキシ-2,2,6,6-テトラメチルピペリジン、4-シアノ-4-(メタ)アクリロイルアミノ-2,2,6,6-テトラメチルピペリジン、1-(メタ)アクリロイル-4-(メタ)アクリロイルアミノ-2,2,6,6-テトラメチルピペリジン、1-(メタ)アクリロイル-4-シアノ-4-(メタ)アクリロイルアミノ-2,2,6,6-テトラメチルピペリジン、4-クロトノイルオキシ-2,2,6,6-テトラメチルピペリジン、4-クロトノイルアミノ-2,2,6,6-テトラメチルピペリジン、1-クロトノイル-4-クロトノイルオキシ-2,2,6,6-テトラメチルピペリジン等。
(xix) 酸無水物基を有する重合性不飽和モノマー:無水マレイン酸、無水イタコン酸、無水シトラコン酸等。
また、本明細書において、「(メタ)アクリレート」はアクリレート又はメタクリレートを意味する。「(メタ)アクリル酸」は、アクリル酸又はメタクリル酸を意味する。また、「(メタ)アクリロイル」は、アクリロイル又はメタクリロイルを意味する。また、「(メタ)アクリルアミド」は、アクリルアミド又はメタクリルアミドを意味する。
本発明において、「コアシェル構造を有する水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’)」の「シェル部」は樹脂粒子の最外層に存在する重合体層を意味し、「コア部」は上記シェル部を除く樹脂粒子内層の重合体層を意味し、「コアシェル構造を有する」は上記コア部とシェル部を有する構造を意味するものである。
なお、以下では「コアシェル構造を有する水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’)」を単に「水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’)」ということがある。
上記コアシェル型構造は、通常、コア部がシェル部に完全に被覆された層構造が一般的であるが、コア部とシェル部の質量比率等によっては、シェル部のモノマー量が層構造を形成せしめるのに不十分な場合もあり得る。そのような場合は、上記のような完全な層構造である必要はなく、コア部の一部をシェル部が被覆した構造であってもよい。
コア部共重合体(I)のエマルションを調製する乳化重合は、従来公知の方法により行うことができる。例えば、乳化剤の存在下で、重合開始剤を使用して重合性不飽和モノマー混合物を乳化重合することにより行うことができる。
上記乳化剤としてはアニオン性乳化剤及びノニオン性乳化剤を好適に使用することができる。
上記反応性アニオン性乳化剤としては、アリル基、メタリル基、(メタ)アクリロイル基、プロペニル基、ブテニル基等のラジカル重合性不飽和基を有するスルホン酸化合物のナトリウム塩、該スルホン酸化合物のアンモニウム塩等を挙げることができる。
上記シェル部共重合体(II)を形成するモノマー混合物は、必要に応じて、前記重合開始剤、連鎖移動剤、還元剤、乳化剤等の成分を適宜含有することができる。また、当該モノマー混合物は、そのまま滴下することもできるが、該モノマー混合物を水性媒体に分散して得られるモノマー乳化物として滴下することが好ましい。この場合におけるモノマー乳化物の粒子径は特に制限されるものではない。
シェル部共重合体(II)を形成するモノマー混合物の重合方法としては、例えば、該モノマー混合物又はその乳化物を、一括で又は徐々に滴下して、上記コア部共重合体(I)のエマルションに、添加し、攪拌しながら適当な温度に加熱する方法を挙げることができる。
本発明において、「グラジエントポリマー層を含むコアシェル構造を有する水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)」のグラジエントポリマー層とは、組成が連続的に変化する(組成勾配を有する)層構造を有するポリマー層を意味するものである。
より具体的には、例えばモノマーA(モノマー混合物A)からモノマーB(モノマー混合物B)へとモノマー(モノマー混合物)組成が連続的に変化した、組成勾配を有するポリマー層を意味するものである。
なお、以下では「グラジエントポリマー層を含むコアシェル構造を有する水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)」を単に「水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)」ということがある。
上記パワーフィード重合において、合成条件(モノマーA(モノマー混合物A)とモノマーB(モノマー混合物B)との混合開始のタイミング、モノマーB(モノマー混合物B)を、モノマーA(モノマー混合物A)を収容する容器内に滴下する速度と、モノマーA(モノマー混合物A)を反応容器に導入する速度の設定等)により、所望の組成勾配を有するグラジエントポリマー層を得ることができる。
水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)中のグラジエントポリマー層の比率は、得られる塗膜の耐水性の観点から、水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)の全共重合成分の総量に対して、20~80質量%程度が好ましく、特に25~75質量%程度が好ましく、さらに特に30~70質量%程度であることが好ましい。
水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)のコア部は、得られる塗膜の耐水性、耐チッピング性の観点から、水酸基価が、0~150mgKOH/gであることが好ましく、5~120mgKOH/gであることがより好ましく、10~100mgKOH/gであることがさらに好ましい。
水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)のシェル部は、得られる塗膜の耐水性、耐チッピング性の観点から、水酸基価が、0~150mgKOH/gであることが好ましく、2~120mgKOH/gであることがより好ましく、5~100mgKOH/gであることがさらに好ましい。
水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)のコア部は、製造安定性、塗料の貯蔵安定性の観点から、酸価が、0~50mgKOH/gであることが好ましく、0~30mgKOH/gであることがより好ましく、0~10mgKOH/gであることがさらに好ましい。
水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)のシェル部は、塗料の貯蔵安定性、得られる塗膜の耐水性の観点から、酸価が、1~100mgKOH/gであることが好ましく、5~80mgKOH/gであることがより好ましく、10~50mgKOH/gであることがさらに好ましい。
水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)は、得られる塗膜の耐水性、耐チッピング性等の観点から、ガラス転移温度が、-20~100℃であることが好ましく、0~100℃であることがより好ましく、20~100℃であることがさらに好ましい。
水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)のコア部は、得られる塗膜の耐水性、耐チッピング性の観点から、ガラス転移温度が、-50~50℃であることが好ましく、-30~50℃であることがより好ましく、0~50℃であることがさらに好ましい。
水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’)のシェル部は、得られる塗膜の耐水性の観点から、ガラス転移温度が、0~120℃であることが好ましく、20~100℃であることがより好ましく、30~100℃であることがさらに好ましい。
水酸基及びカルボキシル基含有ポリエステル樹脂(A2)は、既知の方法で、常法に従い、多塩基酸と多価アルコ-ルとをエステル化反応させることによって合成することができる。
水酸基及びカルボキシル基含有ポリウレタン樹脂(A3)は、常法により、例えば、ポリオールとポリイソシアネート化合物とを反応させることにより得ることができる。また、該反応後、ジオール、ジアミン等の、1分子中に少なくとも2個の活性水素をもつ低分子量化合物である鎖伸長剤の存在下で、鎖伸長することができる。また、該樹脂の調製中又は調製後に、アクリル樹脂等で変性することができる。
ブロック化ポリイソシアネート化合物(B)は、ポリイソシアネート化合物(b1)のイソシアネート基をブロック剤(b2)でブロック化した化合物である。
ポリイソシアネート化合物(b1)は、1分子中に少なくとも2個のイソシアネート基を有する化合物であって、例えば、脂肪族ポリイソシアネート、脂環族ポリイソシアネート、芳香脂肪族ポリイソシアネート、芳香族ポリイソシアネート、及びそれらの誘導体等、並びにそれらの任意の組み合わせを挙げることができる。
また、ポリイソシアネート化合物(b1)には、イソシアネート基含有重合性不飽和モノマーの重合体、又は上記イソシアネート基含有重合性不飽和モノマーと上記イソシアネート基含有重合性不飽和モノマー以外の重合性不飽和モノマーとの共重合体が含まれる。
ポリイソシアネート化合物(b1)中のイソシアネート基をブロック化するブロック剤(b2)としては、例えば、活性メチレン系、アルコール系、フェノール系、オキシム系、アミン系、酸アミド系、イミダゾール系、ピリジン系、メルカプタン系等のブロック剤を挙げることができ、該ブロック剤は、それぞれ単独で、又は2種以上組み合わせて使用することができる。
スペーサー(b3)は、少なくとも2個のイソシアネート反応性官能基を有する化合物である。
上記官能基は、イソシアネート基に対して反応性を有している官能基であれば特に制限されない。該イソシアネート反応性官能基としては、例えば、水酸基、アミノ基、カルボキシル基、チオール基等が挙げられ、なかでも水酸基、アミノ基が好ましく、特に、水酸基が好ましい。
したがって、スペーサー(b3)は、少なくとも2個の水酸基を有する化合物であるか、又は少なくとも2個のアミノ基を有する化合物であることが好ましく、なかでも少なくとも2個の水酸基を有する化合物であることが好ましい。
上記ポリエーテルアミンは、市販品を使用することもできる。該市販品としては、例えば、HUNTSMAN社製の「JEFFAMINE D-400」、「JEFFAMINE D-2000」、「JEFFAMINE D-4000」、「JEFFAMINE ED-600」、「JEFFAMINE ED-900」、「JEFFAMINE ED-2003」、「ELASTAMINE RT-1000」、「JEFFAMINE T-403」、「JEFFAMINE T-3000」、「JEFFAMINE T-5000」などを挙げることができる。
上記スペーサー(b3)の官能基数としては、本発明の水性塗料組成物の貯蔵安定性の観点から、2~3個であることが好ましく、2個であることがさらに好ましい。
親水基含有化合物(b4)は、1個のイソシアネート反応性官能基を有する。該親水基含有化合物(b4)としては、ノニオン性の親水基含有化合物、アニオン性の親水基含有化合物、及びカチオン性の親水基含有化合物、並びにそれらの任意の組み合わせが挙げられる。親水基含有化合物(b4)としては、ポリイソシアネート化合物(b1)中のイソシアネート基を前述のブロック剤(b2)によってブロック化する反応が阻害されにくいという理由から、ノニオン性の親水基含有化合物であることが好ましい。
反応の順序は、特に限定されない。
具体的には、ポリイソシアネート化合物(b1)中のイソシアネート基の一部にスペーサー(b3)及び/又は親水基含有化合物(b4)を反応させた後、残りのイソシアネート基をブロック剤(b2)でブロックする方法、ポリイソシアネート化合物(b1)中のイソシアネート基の一部をブロック剤(b2)でブロックした後、残りのイソシアネート基にスペーサー(b3)及び/又は親水基含有化合物(b4)を反応させる方法、並びに、ポリイソシアネート化合物(b1)中のイソシアネート基にブロック剤(b2)、スペーサー(b3)及び/又は親水基含有化合物(b4)を同時に反応させる方法等が挙げられる。
リン酸基含有化合物(C)としては、例えば、リン酸;モノ-n-プロピルリン酸、モノイソプロピルリン酸、モノ-n-ブチルリン酸、モノイソブチルリン酸、モノ-tert-ブチルリン酸、モノオクチルリン酸、モノデシルリン酸等のモノアルキルリン酸;ジ-n-プロピルリン酸、ジイソプロピルリン酸、ジ-n-ブチルリン酸、ジイソブチルリン酸、ジ-tert-ブチルリン酸、ジオクチルリン酸、ジデシルリン酸等のジアルキルリン酸;モノ-n-プロピル亜リン酸、モノイソプロピル亜リン酸、モノ-n-ブチル亜リン酸、モノイソブチル亜リン酸、モノ-tert-ブチル亜リン酸、モノオクチル亜リン酸、モノデシル亜リン酸等のモノアルキル亜リン酸;ジ-n-プロピル亜リン酸、ジイソプロピル亜リン酸、ジ-n-ブチル亜リン酸、ジイソブチル亜リン酸、ジ-tert-ブチル亜リン酸、ジオクチル亜リン酸、ジデシル亜リン酸等のジアルキル亜リン酸;アルキルエーテルリン酸、ポリオキシエチレンアルキルエーテルリン酸、リン酸基含有樹脂(C1)等を挙げることができる。これらは1種単独で、又は2種以上組み合わせて使用することができる。
上記リン酸基含有樹脂(C1)としては、リン酸基含有アクリル樹脂(C1’)、リン酸基含有ポリエステル樹脂、リン酸基含有ポリエーテル樹脂、リン酸基含有ポリカーボネート樹脂、リン酸基含有ポリウレタン樹脂、リン酸基含有エポキシ樹脂などを挙げることができ、なかでも、本発明の水性塗料組成物の貯蔵安定性及び形成される塗膜の耐水性並びに耐チッピング性の観点から、リン酸基含有アクリル樹脂(C1’)であることが好ましい。
リン酸基含有アクリル樹脂(C1’)は、リン酸基を有する重合性不飽和モノマー及びその他の重合性不飽和モノマーを、常法により共重合せしめることによって合成することができる。
塩基性化合物(D)は、水酸基及びカルボキシル基含有樹脂(A)の有するカルボキシル基の中和、及び、水性塗料組成物のpH調整のために使用される化合物である。そのため、水酸基及びカルボキシル基含有ポリウレタン樹脂(A3)の説明欄で記載した鎖伸長剤のジアミンのように、他の官能基と化学反応をする化合物は除かれる。
塩基性化合物(D1)は、酸解離定数(PKa)が7.0~8.5の範囲内であり、かつ、沸点が100~200℃の範囲内である。
上記酸解離定数(PKa)が7.0以上であると、貯蔵安定性に優れた水性塗料組成物を得ることができ、8.5以下であると、形成される塗膜の硬度及び耐水性に優れた水性塗料組成物を得ることが出来る。
なかでも、塩基性化合物(D1)の酸解離定数(PKa)は、7.2~8.2の範囲内であることが好ましく、7.3~7.8の範囲内であることがさらに好ましい。
上記沸点が100℃以上であると、貯蔵安定性に優れた水性塗料組成物を得ることができ、200℃以下であると、形成される塗膜の硬度及び耐水性に優れた水性塗料組成物を得ることが出来る。
なかでも、塩基性化合物(D1)の沸点は、105~180℃の範囲内であることが好ましく、110~160℃の範囲内であることがさらに好ましい。
上記塩基性化合物(D1)としては、本発明の水性塗料組成物の貯蔵安定性、形成される塗膜の硬度及び耐水性の観点から、N-メチルモルホリン(PKa7.4、沸点116℃)又はN-エチルモルホリン(PKa7.7、沸点139℃)を使用することが好ましい。
本発明の水性塗料組成物における塩基性化合物(D1)の含有量が50質量%以上であると、貯蔵安定性、形成される塗膜の硬度並びに耐水性に優れた水性塗料組成物を得ることができる。
なかでも、本発明の水性塗料組成物における塩基性化合物(D1)の含有量は、塩基性化合物(D)の質量を基準として、70~100質量%の範囲内であることが好ましく、90~100質量%の範囲内であることがさらに好ましい。
本発明の水性塗料組成物は、さらに、メラミン樹脂(E)を含有することができる。
メラミン樹脂(E)としては、メラミン成分とアルデヒド成分との反応によって得られる部分メチロール化メラミン樹脂又は完全メチロール化メラミン樹脂を使用することができる。アルデヒド成分としては、ホルムアルデヒド、パラホルムアルデヒド、アセトアルデヒド、ベンズアルデヒド等を挙げることができる。
本発明の水性塗料組成物は、さらに必要に応じて、上記以外の樹脂、顔料、有機溶剤、リン酸基含有化合物(C)以外の硬化触媒、分散剤、沈降防止剤、消泡剤、増粘剤、紫外線吸収剤、光安定剤、表面調整剤等を含有することができる。
上記水酸基を含有しないカルボキシル基含有ポリウレタン樹脂は、常法により、例えば、ポリオールとポリイソシアネートとを反応させることにより得ることができる。また、該反応後、ジオール、ジアミン等の、1分子中に少なくとも2個の活性水素をもつ低分子量化合物である鎖伸長剤の存在下で、鎖伸長することができる。また、該樹脂の調製中又は調製後に、アクリル樹脂等で変性することができる。
上記ポリオール、ポリイソシアネート及び鎖伸長剤は、上記水酸基及びカルボキシル基含有ポリウレタン樹脂(A3)の説明欄にて記載した化合物を使用することができる。
本発明の水性塗料組成物が、上記顔料を含有する場合、該顔料の配合量は、本発明の水性塗料組成物中の樹脂固形分100質量部を基準として、1~200質量部、好ましくは5~160質量部、さらに好ましくは15~140質量部の範囲内であることが好適である。
本発明の水性塗料組成物が、上記着色顔料を含有する場合、該着色顔料の配合量は本発明の水性塗料組成物中の樹脂固形分100質量部を基準として、1~180質量部、好ましくは5~150質量部、さらに好ましくは15~130質量部の範囲内であることが好適である。
本発明の水性塗料組成物が、上記体質顔料を含有する場合、該体質顔料の配合量は本発明の水性塗料組成物中の樹脂固形分100質量部を基準として、1~180質量部、好ましくは5~140質量部、さらに好ましくは10~120質量部の範囲内であることが好適である。
上記光輝性顔料は鱗片状であることが好ましい。また、該光輝性顔料としては、長手方向寸法が1~100μm、特に5~40μm、厚さが0.001~5μm、特に0.01~2μmの範囲内にあるものが適している。
本発明の水性塗料組成物が、上記光輝性顔料を含有する場合、該光輝性顔料の配合量は、本発明の水性塗料組成物中の樹脂固形分100質量部を基準として、0.1~100質量部、好ましくは1~50質量部、さらに好ましくは3~25質量部の範囲内であることが好適である。
適正粘度は、塗料組成により異なるが、例えば、フォードカップ粘度計No.4を用いて調整した場合、20℃において、通常、20~100秒程度、好ましくは25~70秒程度の粘度とすることができる。
本発明の水性塗料組成物は、比較的低温で硬化させた場合においても、高い硬度や耐水性等の優れた塗膜性能を示す塗膜を形成することができるため、被塗物上に、本発明の水性塗料組成物を塗装して未硬化の着色塗膜を形成した後、該未硬化の着色塗膜を60~110℃の範囲内の温度で加熱して硬化させる塗膜形成方法において好適に用いることができる。
工程(A1):被塗物上に本発明の水性塗料組成物を塗装して、未硬化の着色塗膜を形成する工程、及び
工程(A2):前記工程(A1)で形成された未硬化の着色塗膜を60~110℃の範囲内の温度で加熱して硬化させる工程、を含む塗膜形成方法。
工程(B1):被塗物上に本発明の水性塗料組成物を塗装して、未硬化の着色塗膜を形成する工程、
工程(B2):前記未硬化の着色塗膜上に、クリヤー塗料組成物を塗装して、未硬化のクリヤー塗膜を形成する工程、並びに
工程(B3):前記工程(B1)で形成された未硬化の着色塗膜、及び、前記工程(B2)で形成されたクリヤー塗膜を、60~110℃の範囲内の温度で同時に加熱して硬化させる工程、を含む塗膜形成方法。
工程(C1):被塗物上に中塗り塗料組成物を塗装して、未硬化の中塗り塗膜を形成する工程、
工程(C2):前記未硬化の中塗り塗膜上に、本発明の水性塗料組成物を塗装して、未硬化の着色塗膜を形成する工程、
工程(C3):前記未硬化の着色塗膜上に、クリヤー塗料組成物を塗装して、未硬化のクリヤー塗膜を形成する工程、並びに
工程(C4):前記工程(C1)で形成された未硬化の中塗り塗膜、前記工程(C2)で形成された未硬化の着色塗膜、及び、前記工程(C3)で形成されたクリヤー塗膜を、60~110℃の範囲内の温度で同時に加熱して硬化させる工程、を含む塗膜形成方法。
工程(D1):被塗物上に本発明の水性塗料組成物を塗装して、未硬化の中塗り塗膜を形成する工程、
工程(D2):前記未硬化の中塗り塗膜上に、着色塗料組成物を塗装して、未硬化の着色塗膜を形成する工程、
工程(D3):前記未硬化の着色塗膜上に、クリヤー塗料組成物を塗装して、未硬化のクリヤー塗膜を形成する工程、
工程(D4):前記工程(D1)で形成された未硬化の中塗り塗膜、前記工程(D2)で形成された未硬化の着色塗膜、及び、前記工程(D3)で形成されたクリヤー塗膜を、60~110℃の範囲内の温度で同時に加熱して硬化させる工程、を含む塗膜形成方法。
下塗り塗膜を形成するための下塗り塗料としては、例えば、電着塗料、好ましくはカチオン電着塗料を使用することができる。
また、上記クリヤー塗料組成物は、一液型塗料であってもよいし、二液型ウレタン樹脂塗料等の多液型塗料であってもよい。
本発明の自動車車体の塗装方法は、自動車車体の外板部に第1複層塗膜を形成する工程、及び自動車車体の内板部に第2塗膜を形成する工程を含む、自動車車体の塗装方法であって、前記第1複層塗膜を形成する工程が、(1a)前記自動車車体の外板部上に、水性塗料組成物(X)を塗装して、未硬化の外板着色ベースコート塗膜(BCo)を形成する外板着色ベースコート塗膜形成工程、(1b)前記未硬化の外板着色ベースコート塗膜(BCo)上に、クリヤーコート塗料(Y)を塗装して未硬化の外板クリヤーコート塗膜(CCo)を形成する外板クリヤーコート塗膜形成工程、及び(1c)前記未硬化の外板着色ベースコート塗膜(BCo)及び前記未硬化の外板クリヤーコート塗膜(CCo)を加熱し、これらの塗膜を同時に硬化させる焼付工程を含み、前記第2塗膜を形成する工程が、(2a)前記自動車車体の内板部上に、前記水性塗料組成物(X)を塗装して、未硬化の内板着色塗膜(PCi)を形成する内板着色塗膜形成工程、及び(2b)上記未硬化の内板着色塗膜(PCi)を加熱し硬化させる焼付工程を含み、かつ、前記水性塗料組成物(X)が本発明の水性塗料組成物である自動車車体の塗装方法を含む。
自動車車体の内板部(以下、単に「内板部」と称することがある。)とは、艤装工程を終了した完成車の外側から視認できない部分である。
外板部及び内板部は、通常、冷延鋼板、亜鉛メッキ鋼板、亜鉛合金メッキ鋼板、ステンレス鋼板、錫メッキ鋼板等の鋼板に、電着塗料を塗装した塗装鋼板から形成される。
第1複層塗膜を形成する工程は、以下に記す工程(1a)~(1c)を含む。
本発明の工程(1a)においては、自動車車体の外板部上に、水性塗料組成物(X)を塗装して、未硬化の外板着色ベースコート塗膜(BCo)を形成する。
上記水性塗料組成物(X)としては、本発明の水性塗料組成物が使用される。
水性塗料組成物(X)を塗装する方法としては、例えば、エアスプレー法、エアレススプレー法、静電塗装法等が挙げられる。
外板着色ベースコート塗膜(BCo)の膜厚は硬化膜厚として、通常、5~40μm、好ましくは7~35μm、さらに好ましくは10~30μmである。
外板着色ベースコート塗膜(BCo)は、クリヤーコート塗料(Y)を塗装する前に、塗膜が実質的に硬化しない加熱条件でプレヒート、エアブロー等を行うことができる。プレヒートの温度は、40~100℃が好ましく、50~90℃がより好ましく、60~80℃が更に好ましい。プレヒートの時間は、30秒間~15分間が好ましく、1~10分間がより好ましく、2~5分間が更に好ましい。また、上記エアブローは、例えば、被塗物の塗装面に、常温又は25~80℃の温度に加熱された空気を、30秒間~15分間吹き付けることにより行うことができる。
本発明の第1複層塗膜では、未硬化の外板着色ベースコート塗膜(BCo)上に、クリヤーコート塗料(Y)を塗装する前に、着色塗料組成物(Z)を塗装し、未硬化の外板第2着色ベースコート塗膜(BCo2)を形成しても良い。着色塗料組成物(Z)としては、前記塗膜形成方法の欄にて説明した着色塗料組成物を使用することができる。
本発明の工程(1b)においては、前記未硬化の外板着色ベースコート塗膜(BCo)上に、クリヤーコート塗料(Y)を塗装して未硬化の外板クリヤーコート塗膜(CCo)を形成する。
上記クリヤーコート塗料(Y)としては、前記塗膜形成方法の欄にて説明したクリヤ塗料組成物を使用することができる。
上記クリヤーコート塗料(Y)を塗装する方法としては、例えば、エアスプレー法、エアレススプレー法、静電塗装法等が挙げられる。
前記外板クリヤーコート塗膜(CCo)の膜厚は硬化膜厚として、通常、10~70μm、好ましくは20~50μmである。
本発明の工程(1c)においては、前記未硬化の外板着色ベースコート塗膜(BCo)及び前記未硬化の外板クリヤーコート塗膜(CCo)を加熱し、これらの塗膜を同時に硬化させる。
上記加熱は公知の手段により行うことができ、例えば、熱風炉、電気炉、赤外線誘導加熱炉などの乾燥炉を適用できる。加熱温度は60~110℃が好ましく、より好ましくは70~90℃の範囲内である。加熱時間は、特に制限されないが、好ましくは10~40分間、より好ましくは20~40分間の範囲内である。
第2塗膜を形成する工程は、以下に記す(2a)及び(2b)を含む。
本発明の工程(2a)においては、自動車車体の内板部上に、前記水性塗料組成物(X)を塗装して、未硬化の内板着色塗膜(PCi)を形成する。
上記水性塗料組成物(X)としては、本発明の水性塗料組成物が使用される。
水性塗料組成物(X)を塗装する方法としては、例えば、エアスプレー法、エアレススプレー法、静電塗装法等が挙げられる。
内板着色塗膜(PCi)の膜厚は、硬化膜厚として、通常、5~40μmであってよく、好ましくは7~35μm、さらに好ましくは10~30μmである。
本塗装方法において、内板部に第2塗膜を形成するにあたっては、クリヤー塗料の塗装を省略する方式が採用される。
この方式を採用することによって、内板部塗装工程のコストを削減することができる。
また、内板部に、外板部で用いるものと同一の水性塗料組成物(X)を用いることによって、使用する塗料の品種を減らし、内板部塗装工程のコストを削減することができる。
本発明の工程(2b)においては、上記未硬化の内板着色塗膜(PCi)を加熱し硬化させる。該工程(2b)における焼付工程は、省エネルギー等の観点から、前記工程(1c)の焼付工程と同時に行うことが好ましい。
上記加熱は公知の手段により行うことができ、例えば、熱風炉、電気炉、赤外線誘導加熱炉などの乾燥炉を適用できる。加熱温度は60~110℃であってよく、好ましくは70~90℃の範囲内である。加熱時間は、特に制限されないが、好ましくは10~40分間、より好ましくは20~40分間の範囲内である。
第1塗膜を形成する工程は、以下に記す工程(1a’)及び(1b’)を含む。
本発明の工程(1a’)においては、自動車車体の外板部上に、水性塗料組成物(X)を塗装して、未硬化の外板着色塗膜(PCo)を形成する。
上記水性塗料組成物(X)としては、本発明の水性塗料組成物が使用される。
水性塗料組成物(X)を塗装する方法としては、例えば、エアスプレー法、エアレススプレー法、静電塗装法等が挙げられる。
外板着色塗膜(PCo)の膜厚は硬化膜厚として、通常、5~40μm、好ましくは7~35μm、さらに好ましくは10~30μmである。
本発明の工程(1b’)においては、上記未硬化の外板着色塗膜(PCo)を加熱し硬化させる。
上記加熱は公知の手段により行うことができ、例えば、熱風炉、電気炉、赤外線誘導加熱炉などの乾燥炉を適用できる。加熱温度は60~110℃、好ましくは70~90℃の範囲内である。加熱時間は、特に制限されないが、好ましくは10~40分間、より好ましくは20~40分間の範囲内である。
本塗装方法において、外板部に第1塗膜を形成するにあたっては、クリヤー塗料の塗装を省略する方式が採用される。
この方式を採用することによって、外板部塗装工程のコストを削減することができる。
第2塗膜を形成する工程は、以下に記す(2a’)及び(2b’)を含む。
本発明の工程(2a’)においては、自動車車体の内板部上に、前記水性塗料組成物(X)を塗装して、未硬化の内板着色塗膜(PCi)を形成する。
上記水性塗料組成物(X)としては、本発明の水性塗料組成物が使用される。
水性塗料組成物(X)を塗装する方法としては、例えば、エアスプレー法、エアレススプレー法、静電塗装法等が挙げられる。
内板着色塗膜(PCi)の膜厚は硬化膜厚として、通常、5~40μmであってよく、好ましくは7~35μm、さらに好ましくは10~30μmである。
本発明において、内板部に第2塗膜を形成するにあたっては、クリヤー塗料の塗装を省略する方式が採用される。
この方式を採用することによって、内板部塗装工程のコストを削減することができる。
また、内板部に、外板部で用いるものと同一の水性塗料組成物(X)を用いることによって、使用する塗料の品種を減らし、内板部塗装工程のコストを削減することができる。
本発明の工程(2b’)においては、上記未硬化の内板着色塗膜(PCi)を加熱し硬化させる。該工程(2b’)における焼付工程は、省エネルギー等の観点から、前記工程(1c)の焼付工程と同時に行うことが好ましい。
上記加熱は公知の手段により行うことができ、例えば、熱風炉、電気炉、赤外線誘導加熱炉などの乾燥炉を適用できる。加熱温度は60~110℃であってよく、好ましくは70~90℃の範囲内である。加熱時間は、特に制限されないが、好ましくは10~40分間、より好ましくは20~40分間の範囲内である。
コアシェル構造を有する水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’)の製造
製造例1
温度計、サーモスタット、撹拌器、還流冷却器、窒素導入管及び滴下装置を備えた反応容器に脱イオン水130部、「アクアロンKH-10」(商品名、第一工業製薬社製、乳化剤、有効成分97%)0.52部を仕込み、窒素気流中で撹拌混合し、80℃に昇温した。
次いで下記のモノマー乳化物(1)1.72部及び6%過硫酸アンモニウム水溶液5.3部を反応容器内に導入し、80℃で15分間保持した。その後、残りのモノマー乳化物(1)を3時間かけて、同温度に保持した反応容器内に滴下し、滴下終了後1時間熟成を行なった。その後、下記のモノマー乳化物(2)を1時間かけて滴下し、1時間熟成した後、5%N-エチルモルホリン水溶液20部を反応容器に徐々に加えながら30℃まで冷却し、100メッシュのナイロンクロスで濾過しながら排出し、固形分濃度30%の水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’-1)を得た。得られた水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’-1)は、酸価が16mgKOH/g、水酸基価が66mgKOH/g、ガラス転移温度が21℃であった。
温度計、サーモスタット、撹拌器、還流冷却器、窒素導入管及び滴下装置を備えた反応容器に脱イオン水130部、「アクアロンKH-10」(商品名、第一工業製薬社製、乳化剤、有効成分97%)0.52部を仕込み、窒素気流中で撹拌混合し、80℃に昇温した。
次いで下記のモノマー乳化物(1)1.72部及び6%過硫酸アンモニウム水溶液5.3部を反応容器内に導入し、80℃で15分間保持した。その後、残りのモノマー乳化物(1)を3時間かけて、同温度に保持した反応容器内に滴下し、滴下終了後1時間熟成を行なった。その後、下記のモノマー乳化物(2)を1時間かけて滴下し、1時間熟成した後、5%2-(ジメチルアミノ)エタノール水溶液20部を反応容器に徐々に加えながら30℃まで冷却し、100メッシュのナイロンクロスで濾過しながら排出し、固形分濃度30%の水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’-2)を得た。得られた水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’-2)は、酸価が16mgKOH/g、水酸基価が66mgKOH/g、ガラス転移温度が21℃であった。
製造例3
温度計、サーモスタット、撹拌器、還流冷却器、窒素導入管及び滴下装置を備えた反応容器に、脱イオン水130部及び「アクアロンKH-10」(商品名、第一工業製薬社製、乳化剤、有効成分97%)0.52部を仕込み、窒素気流中で撹拌混合し、80℃に昇温した。
次いで下記のモノマー乳化物(1)1.72部及び6%過硫酸アンモニウム水溶液5.3部を反応容器内に導入し、80℃で15分間保持した。その後、モノマー乳化物(1)35.4部を1時間かけて、同温度に保持した反応容器内に滴下し、滴下終了後すぐに残りのモノマー乳化物(1)55.6部を反応容器内に滴下し始めた。それと同時に、モノマー乳化物(2)55.6部を、モノマー乳化物(1)に対して滴下を行い、2時間かけて、モノマー乳化物(1)及びモノマー乳化物(2)の滴下を終了した。その後、残りのモノマー乳化物(2)37.17部を反応容器内に1時間かけて滴下し、1時間熟成した後、5%N-エチルモルホリン水溶液20部を反応容器に徐々に加えながら30℃まで冷却し、次いで100メッシュのナイロンクロスで濾過しながら排出して、固形分濃度30%の水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’-1)を得た。得られた水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’’-1)は、酸価が16mgKOH/g、水酸基価が66mgKOH/g、ガラス転移温度が21℃であった。
製造例4
温度計、サーモスタット、攪拌装置、還流冷却器及び水分離器を備えた反応容器に、トリメチロールプロパン174部、ネオペンチルグリコール327部、アジピン酸352部、イソフタル酸109部及び1,2-シクロヘキサンジカルボン酸無水物101部を仕込み、160℃から230℃まで3時間かけて昇温させた後、生成した縮合水を水分離器により留去させながら230℃で保持し、酸価が3mgKOH/g以下となるまで反応させた。この反応生成物に、無水トリメリット酸59部を添加し、170℃で30分間付加反応を行った後、50℃以下に冷却し、N-エチルモルホリンを75.8部添加し中和してから、脱イオン水を徐々に添加することにより、固形分濃度45%の水酸基及びカルボキシル基含有ポリエステル樹脂溶液(A2-1)を得た。得られた水酸基及びカルボキシル基含有ポリエステル樹脂は、水酸基価が128mgKOH/g、酸価が35mgKOH/g、重量平均分子量が13,000であった。
温度計、サーモスタット、攪拌装置、還流冷却器及び水分離器を備えた反応容器に、トリメチロールプロパン174部、ネオペンチルグリコール327部、アジピン酸352部、イソフタル酸109部及び1,2-シクロヘキサンジカルボン酸無水物101部を仕込み、160℃から230℃まで3時間かけて昇温させた後、生成した縮合水を水分離器により留去させながら230℃で保持し、酸価が3mgKOH/g以下となるまで反応させた。この反応生成物に、無水トリメリット酸59部を添加し、170℃で30分間付加反応を行った後、50℃以下に冷却し、2-(ジメチルアミノ)エタノールを58.7部添加し中和してから、脱イオン水を徐々に添加することにより、固形分濃度45%の水酸基及びカルボキシル基含有ポリエステル樹脂溶液(A2-2)を得た。得られた水酸基及びカルボキシル基含有ポリエステル樹脂は、水酸基価が128mgKOH/g、酸価が35mgKOH/g、重量平均分子量が13,000であった。
製造例6
温度計、撹拌機及び還流コンデンサーを備えた反応槽に、ポリテトラメチレングリコール(数平均分子量1000)211.9部、2,2-ジメチロールプロピオン酸11.5部、トリメチロールプロパン6.9部、イソホロンジイソシアネート112.2部及びメチルエチルケトン298.5部を仕込み、反応系を窒素ガスで置換した後、撹拌下80℃で反応させ遊離イソシアネート基含有量3.2%のNCO末端ウレタンプレポリマーを得た。得られた該メチルエチルケトン溶液を40℃に冷却しN-エチルモルホリン9.8部を含む脱イオン水493.2gを加え乳化後、これに5%N-(2-ヒドロキシエチル)エチレンジアミン水溶液275.9部を添加し、60分間撹拌後、メチルエチルケトンを減圧加熱下に留去し、脱イオン水で濃度調整して、固形分35%、酸価14mgKOH/g、水酸基価12mgKOH/g、平均粒子径120nmの水酸基及びカルボキシル基含有ポリウレタン樹脂分散液(A3-1)を得た。
温度計、撹拌機及び還流コンデンサーを備えた反応槽に、ポリテトラメチレングリコール(数平均分子量1000)211.9部、2,2-ジメチロールプロピオン酸11.5部、トリメチロールプロパン6.9部、イソホロンジイソシアネート112.2部及びメチルエチルケトン298.5部を仕込み、反応系を窒素ガスで置換した後、撹拌下80℃で反応させて、遊離イソシアネート基含有量3.2%のNCO末端ウレタンプレポリマーを得た。得られた該メチルエチルケトン溶液を40℃に冷却しトリエチルアミン8.6部を含む脱イオン水493.2gを加えて乳化した後、これに5%N-(2-ヒドロキシエチル)エチレンジアミン水溶液275.9部を添加し、60分間撹拌後、メチルエチルケトンを減圧加熱下に留去し、脱イオン水で濃度調整して、固形分35%、酸価14mgKOH/g、水酸基価12mgKOH/g、平均粒子径120nmの水酸基及びカルボキシル基含有ポリウレタン樹脂分散液(A3-2)を得た。
製造例8
温度計、撹拌機及び還流コンデンサーを備えた反応槽に、ポリテトラメチレングリコール(数平均分子量1000)211.9部、2,2-ジメチロールプロピオン酸11.5部、トリメチロールプロパン6.9部、イソホロンジイソシアネート112.2部及びメチルエチルケトン298.5部を仕込み、反応系を窒素ガスで置換した後、撹拌下80℃で反応させ遊離イソシアネート基含有量3.2%のNCO末端ウレタンプレポリマーを得た。得られた該メチルエチルケトン溶液を40℃に冷却し、N-エチルモルホリン9.8部を含む脱イオン水493.2gを加えて乳化した後、これに5%エチレンジアミン水溶液159.2部を添加し、60分間撹拌後、メチルエチルケトンを減圧加熱下に留去し、脱イオン水で濃度調整して、固形分35%、酸価14mgKOH/g、平均粒子径120nmの水酸基を含有しないカルボキシル基含有ポリウレタン樹脂分散液(U-1)を得た。
製造例9
温度計、サーモスタット、攪拌装置、還流冷却器、窒素導入管、滴下装置及び除去溶媒簡易トラップを備えた反応容器に、「スミジュールN-3300」(商品名、住化バイエルウレタン社製、ヘキサメチレンジイソシアネート由来のイソシアヌレート構造含有ポリイソシアネート、固形分100%、イソシアネート基含有率21.8%)1500部及び2,6-ジ-t-ブチル-4-メチルフェノール0.9部を仕込み、よく混合して、窒素気流下で、130℃で3時間加熱した。次いで、酢酸エチル1200部及びマロン酸ジイソプロピル1300部を仕込み、窒素気流下で攪拌しながら、ナトリウムメトキシドの28%メタノール溶液14部を加え、65℃で8時間攪拌し、固形分70%、重量平均分子量4,000のブロック化ポリイソシアネート化合物(B-1)を得た。
温度計、サーモスタット、攪拌装置、還流冷却器、窒素導入管、滴下装置を備えた反応容器に、「スミジュールN-3300」(商品名、住化バイエルウレタン社製、ヘキサメチレンジイソシアネート由来のイソシアヌレート構造含有ポリイソシアネート、固形分100%、イソシアネート基含有率21.8%)1610部、「PTMG2000」(商品名、三菱ケミカル社製、ポリテトラメチレンエーテルグリコール、平均分子量2,000、固形分100%)1200部及び2,6-ジ-t-ブチル-4-メチルフェノール0.9部を仕込み、よく混合して、窒素気流下で、130℃で3時間加熱した。次いで、酢酸エチル1200部及びマロン酸ジイソプロピル1250部を仕込み、窒素気流下で攪拌しながら、ナトリウムメトキシドの28%メタノール溶液14部を加え、65℃で8時間攪拌し、最終固形分が70%となるよう酢酸エチルで希釈して、固形分70%、重量平均分子量50,000のブロック化ポリイソシアネート化合物(B-2)を得た。
製造例11
温度計、サーモスタット、撹拌器、還流冷却器及び滴下装置を備えた反応容器に、メトキシプロパノール27.5部及びイソブタノール27.5部の混合溶剤を入れ、110℃に加熱した。次いで、スチレン25部、n-ブチルメタクリレート27.5部、「イソステアリルアクリレート」(商品名、大阪有機化学工業社製、分岐高級アルキルアクリレート)20部、4-ヒドロキシブチルアクリレート7.5部、下記リン酸基含有重合性モノマー15部、2-メタクリロイルオキシエチルアシッドホスフェート12.5部、イソブタノール10部及びt-ブチルパーオキシオクタノエート4部からなる混合物121.5部を、4時間かけて上記混合溶剤に加え、さらにt-ブチルパーオキシオクタノエート0.5部とイソプロパノール20部からなる混合物を1時間滴下した。その後、1時間攪拌熟成して固形分濃度50%のリン酸基含有アクリル樹脂溶液(C1’-1)を得た。本樹脂のリン酸基による酸価は83mgKOH/g、水酸基価は29mgKOH/g、重量平均分子量は10,000であった。
製造例12
撹拌装置を備える容器に、製造例4で得た水酸基及びカルボキシル基含有ポリエステル樹脂溶液(A2-1)44.4部(固形分20部)、「三菱カーボンブラックMA-100」(商品名、三菱ケミカル社製、カーボンブラック)10部及び脱イオン水50部を入れ、均一に混合し、混合溶液にN-エチルモルホリンを0.5部添加して、pH7.5に調整した。次いで、得られた混合溶液を広口ガラスビン中に入れ、分散メジアとして直径約1.3mmφのガラスビーズを加えて密封し、ペイントシェイカーにて4時間分散して、顔料分散液(P-1)を得た。
撹拌装置を備える容器に、製造例5で得た水酸基及びカルボキシル基含有ポリエステル樹脂溶液(A2-2)44.4部(固形分20部)、「三菱カーボンブラックMA-100」(商品名、三菱ケミカル社製、カーボンブラック)10部及び脱イオン水50部を入れ、均一に混合し、混合溶液に2-(ジメチルアミノ)エタノールを0.3部添加して、pH7.5に調整した。次いで、得られた混合溶液を広口ガラスビン中に入れ、分散メジアとして直径約1.3mmφのガラスビーズを加えて密封し、ペイントシェイカーにて4時間分散して、顔料分散液(P-2)を得た。
実施例1
製造例12で得た顔料分散液(P-1)104.9部、製造例1で得た水酸基及びカルボキシル基含有アクリル樹脂粒子(A1’-1)100部(固形分30部)、製造例6で得た水酸基及びカルボキシル基含有ポリウレタン樹脂分散液(A3-1)57.1部(固形分20部)、製造例9で得たブロック化ポリイソシアネート化合物(B-1)42.9部(固形分30部)及び製造例11で得たリン酸基含有アクリル樹脂溶液(C1’-1)4部(固形分2部)を均一に混合した。次いで、pH調整用の塩基性化合物(D)として、N-エチルモルホリン0.6部を添加し、pH7.7とした。次いで、「UH-752」(商品名、ADEKA社製、増粘剤)及び脱イオン水を添加し、pH7.7、塗料固形分48%、20℃におけるフォードカップNO.4による粘度が30秒の水性塗料組成物NO.1を得た。
配合組成を下記表1-1~表1-3に示すものとする以外は、実施例1と同様にして、20℃におけるフォードカップNO.4による粘度が30秒の各水性塗料組成物NO.2~29を得た。
水性塗料組成物NO.1~29の貯蔵安定性について、pH変動値及び粘度変化率によって評価した。
pH変動値=|40℃で10日間静置した後のpH値-製造直後のpH値|
◎及び○が合格である。
◎:pH変動値が0.1未満、
〇:pH変動値が0.1以上、0.3未満、
×:pH変動値が0.3以上。
粘度変化率(%)=|(40℃で10日間静置した後の粘度/製造直後の粘度)-1|×100
◎及び○が合格である。
◎:粘度変化率が20%未満、
○:粘度変化率が20%以上、50%未満、
×:粘度変化率が50%以上。
貯蔵安定性の結果を併せて表1-1~表1-3に示す。
(*2)「NACURE 5523」:商品名、KING INDUSTRIES社製、ドデシルベンゼンスルホン酸のアミン塩、有効成分35%。
(試験用被塗物の作製)
リン酸亜鉛処理された鋼板(450mm×300mm×0.8mm)に「エレクロンGT-10」(商品名、関西ペイント社製、カチオン電着塗料)を乾燥膜厚20μmとなるように電着塗装し、170℃で30分間加熱して硬化させた。
かくして、電着塗装後の外板部及び内板部を想定した試験板を得た。
(第1複層塗膜形成工程)
上記で得られた試験板に、「WP-505T」(商品名、関西ペイント社製、ポリエステルメラミン樹脂系水性中塗り塗料)を、回転霧化型の静電塗装機を用いて、硬化膜厚30μmとなるように静電塗装し、5分間放置して、未硬化の中塗り塗膜を形成した。
次いで、該未硬化の中塗り塗膜上に、水性塗料組成物NO.1を、回転霧化型の静電塗装機を用いて、乾燥膜厚で15μmとなるように静電塗装し、5分間放置後、80℃で3分間プレヒートを行ない、未硬化の着色塗膜を形成した。
次いで、該着色塗膜上に「ソフレックス#520クリヤー」(関西ペイント社製、商品名、水酸基含有アクリル樹脂及びポリイソシアネート化合物を含有する2液型アクリルウレタン系有機溶剤型クリヤー塗料)を乾燥膜厚で35μmとなるように静電塗装し、7分間放置し、クリヤー塗膜を形成した。
次いで、80℃で30分間加熱して、中塗り塗膜、着色塗膜及びクリヤー塗膜を加熱硬化させることにより、試験板(A-1)を作製した。
上記で得られた試験板に、水性塗料組成物NO.1を、回転霧化型の静電塗装機を用いて、乾燥膜厚で15μmとなるように静電塗装し、5分間放置後、80℃で30分間加熱して、試験板(B-1)を作製した。
実施例21において、水性塗料組成物の種類及び加熱温度を下記表2の通りに変更すること以外は、実施例21と同様にして試験板を作製した。
上記で得られた各試験板について、下記の試験方法により評価を行った。評価結果を下
記表2に示す。
低温硬化性:JIS K 5600-5-4(1999)「引っかき硬度(鉛筆法)」に準拠して、上記実施例及び比較例で得られた試験板の鉛筆硬度を測定した。鉛筆硬度は6B×<6B<5B<4B<3B<2B<B<HB<F<H<2Hの順であり、鉛筆硬度がHB以上であれば合格である。評価結果を表2に示す。
耐水付着性:上記実施例及び比較例で得られた試験板を40℃の温水に240時間浸漬し、引き上げて表面の水分をふき取り後すぐ、塗面にJIS K 5600-5-6(1990)に準じて塗膜に2mm×2mmのゴバン目100個を作り、その面に粘着テープを貼着し、急激に剥がした後に、塗面に残ったゴバン目塗膜の数を評価した。◎及び○が合格である。評価結果を表2に示す。
◎:残存個数/全体個数=100個/100個で縁欠けなし
○:残存個数/全体個数=100個/100個で縁欠けあり
△:残存個数/全体個数=99個~90個/100個
×:残存個数/全体個数=89個以下/100個。
耐水後硬度:上記実施例及び比較例で得られ試験板を40℃の温水に240時間浸漬し、20℃で12時間乾燥した後、JIS K 5600-5-4(1999)「引っかき硬度(鉛筆法)」に準拠して、各試験板の塗面の鉛筆硬度を測定した。鉛筆硬度がB以上であれば合格である。評価結果を表2に示す。
耐チッピング性:飛石試験機「JA-400型」(商品名、スガ試験機社製、耐チッピング性試験装置)の試片保持台に上記実施例及び比較例で得られた試験板を設置し、0℃において、該試験板から30cm離れた所から0.39MPa(4kgf/cm2)の圧縮空気により、粒度7号の花崗岩砕石50gを試験板に45度の角度で衝突させた。その後、得られた該試験板を水洗して、乾燥し、塗面に布粘着テープ(ニチバン社製)を貼着して、それを剥離した後、塗膜のキズの発生程度等を目視で観察し、下記基準により評価した。◎及び○が合格である。評価結果を表2に示す。
◎:キズの大きさが極めて小さく、電着面や素地の鋼板が露出していない。
○:キズの大きさが小さく、電着面や素地の鋼板が露出していない。
△:キズの大きさは小さいが、電着面や素地の鋼板が露出している。
×:キズの大きさはかなり大きく、素地の鋼板も大きく露出している。
例えば、上述の実施形態及び実施例において挙げた構成、方法、工程、形状、材料及び数値などはあくまでも例に過ぎず、必要に応じてこれと異なる構成、方法、工程、形状、材料及び数値などを用いてもよい。
また、上述の実施形態の構成、方法、工程、形状、材料及び数値などは、本発明の主旨を逸脱しない限り、互いに組み合わせることが可能である。
Claims (10)
- (A)水酸基及びカルボキシル基含有樹脂、(B)ブロック化ポリイソシアネート化合物、(C)リン酸基含有化合物及び(D)塩基性化合物を含有する水性塗料組成物であって、前記塩基性化合物(D)が、
(D1)酸解離定数(PKa)が7.0~8.5の範囲内であり、かつ、沸点が100~200℃の範囲内である塩基性化合物
を含有し、かつ前記塩基性化合物(D1)の含有割合が、前記塩基性化合物(D)の質量を基準として、50~100質量%の範囲内であり、そして、前記水性塗料組成物のpHが7.0~8.2の範囲内である、水性塗料組成物。 - 前記ブロック化ポリイソシアネート化合物(B)のブロック剤の少なくとも一部が、活性メチレン系のブロック剤である、請求項1に記載の水性塗料組成物。
- 前記リン酸基含有化合物(C)の少なくとも1種が、リン酸基含有樹脂(C1)である、請求項1又は2に記載の水性塗料組成物。
- 前記リン酸基含有樹脂(C1)の少なくとも1種が、リン酸基含有アクリル樹脂(C1’)である、請求項3に記載の水性塗料組成物。
- 前記酸解離定数(PKa)が7.0~8.5の範囲内でありかつ沸点が100~200℃の範囲内である塩基性化合物(D1)が、N-メチルモルホリン及び/又はN-エチルモルホリンである、請求項1~4のいずれか1項に記載の水性塗料組成物。
- さらに、メラミン樹脂(E)を含有する、請求項1~5のいずれか1項に記載の水性塗料組成物。
- 被塗物上に請求項1~6のいずれか1項に記載の水性塗料組成物を塗装して、未硬化の着色塗膜を形成することと、次いで、前記未硬化の着色塗膜を60~110℃の範囲内の温度で加熱して硬化させることとを含む、塗膜形成方法。
- 自動車車体の外板部に第1複層塗膜を形成する工程、及び
自動車車体の内板部に第2塗膜を形成する工程
を含む、自動車車体の塗装方法であって、
前記第1複層塗膜を形成する工程が、
(1a)前記自動車車体の外板部上に、水性塗料組成物(X)を塗装して、未硬化の外板着色ベースコート塗膜(BCo)を形成する外板着色ベースコート塗膜形成工程、
(1b)前記未硬化の外板着色ベースコート塗膜(BCo)上に、クリヤーコート塗料(Y)を塗装して未硬化の外板クリヤーコート塗膜(CCo)を形成する外板クリヤーコート塗膜形成工程、及び
(1c)前記未硬化の外板着色ベースコート塗膜(BCo)及び前記未硬化の外板クリヤーコート塗膜(CCo)を加熱し、これらの塗膜を同時に硬化させる焼付工程、
を含み、
前記第2塗膜を形成する工程が、
(2a)前記自動車車体の内板部上に、前記水性塗料組成物(X)を塗装して、未硬化の内板着色塗膜(PCi)を形成する内板着色塗膜形成工程、及び
(2b)上記未硬化の内板着色塗膜(PCi)を加熱し硬化させる焼付工程、
を含み、
かつ、前記水性塗料組成物(X)が請求項1~6のいずれか1項に記載の水性塗料組成物である、自動車車体の塗装方法。 - 前記焼付工程(1c)及び前記焼付工程(2b)における加熱温度が60~110℃の範囲内である、請求項8に記載の自動車車体の塗装方法。
- 前記焼付工程(1c)及び前記焼付工程(2b)が同時に行なわれる、請求項8又は9に記載の自動車車体の塗装方法。
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