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WO2021113576A1 - Composition aqueuse de revêtement de résine fluorée - Google Patents

Composition aqueuse de revêtement de résine fluorée Download PDF

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Publication number
WO2021113576A1
WO2021113576A1 PCT/US2020/063213 US2020063213W WO2021113576A1 WO 2021113576 A1 WO2021113576 A1 WO 2021113576A1 US 2020063213 W US2020063213 W US 2020063213W WO 2021113576 A1 WO2021113576 A1 WO 2021113576A1
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Prior art keywords
fluororesin
coating composition
aqueous
water
coating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
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PCT/US2020/063213
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English (en)
Inventor
Ryo Nakazawa
Kenji Suzuki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Chemours Mitsui Fluoroproducts Co Ltd
Chemours Co FC LLC
Original Assignee
Chemours Mitsui Fluoroproducts Co Ltd
Chemours Co FC LLC
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Publication date
Application filed by Chemours Mitsui Fluoroproducts Co Ltd, Chemours Co FC LLC filed Critical Chemours Mitsui Fluoroproducts Co Ltd
Priority to CN202080084414.0A priority Critical patent/CN114787295B/zh
Priority to KR1020227022584A priority patent/KR20220111306A/ko
Publication of WO2021113576A1 publication Critical patent/WO2021113576A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
    • C09D127/02—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
    • C09D127/12—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
    • C09D127/18—Homopolymers or copolymers of tetrafluoroethene
    • 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
    • C08G73/00—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups C08G12/00 - C08G71/00
    • C08G73/06—Polycondensates having nitrogen-containing heterocyclic rings in the main chain of the macromolecule
    • C08G73/10—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
    • C08G73/14—Polyamide-imides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
    • C08L27/02—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L27/12—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
    • C08L27/18—Homopolymers or copolymers or tetrafluoroethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
    • C08L71/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
    • C08L71/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
    • C08L71/12—Polyphenylene oxides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L79/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen or carbon only, not provided for in groups C08L61/00 - C08L77/00
    • C08L79/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
    • C08L79/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L81/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers
    • C08L81/06—Polysulfones; Polyethersulfones
    • 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
    • C09D179/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen, with or without oxygen, or carbon only, not provided for in groups C09D161/00 - C09D177/00
    • C09D179/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
    • C09D179/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/02—Emulsion paints including aerosols
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2202/00—Metallic substrate
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
    • C08L2205/035—Polymer mixtures characterised by other features containing three or more polymers in a blend containing four or more polymers in a blend

Definitions

  • the present invention relates to an aqueous fluororesin coating composition which strongly adheres to metal substrates, in particular stainless steel (SUS) substrates, and can form a coating film having excellent water vapor resistance and corrosion resistance, a coating film formed by applying the coating composition on a substrate, and an article having the coating film.
  • metal substrates in particular stainless steel (SUS) substrates
  • SUS stainless steel
  • Fluororesins have excellent heat resistance, chemical resistance, electrical properties, and mechanical properties in addition to having a very low coefficient of friction, non-tackiness, and water and oil repellency, leading to widespread use in all types of industrial fields such as chemical processin, mechanical devices, and electrical devices.
  • fluororesin coatings are used in the coating of cookware such as frying pans and rice cookers, fixing rolls/belts for fixing toners of office equipment, and various other fields, with the fields of applicability having further expanded in recent years to inkjet nozzles, chemical plant equipment, and the like.
  • a heat-resistant resin (so-called engineering plastic) having adhesiveness to substrates and capable of withstanding high temperatures greater than or equal to the melting point of the fluororesin is used as such a primer coating composition.
  • Patent Document 1 discloses precursors such as polyimide, polyamide-imide, and polyethersulfone and microparticles such as polyphenylene sulfide.
  • a heat-resistant resin is also called a binder.
  • aqueous coating is used as the medium of the fluororesin coating composition including the primer coating composition, with an aqueous (water-based) coating having been particularly preferably used in recent years from the perspective of environmental load and toxicity.
  • aqueous coating compositions since heat-resistant resins (binders) which impart adhesiveness to substrates are ordinarily water-insoluble, the particles thereof are dispersed in a liquid of the coating composition before use; however, a water-soluble polyamide-imide can also be used at this time (Patent Document 2).
  • a water-soluble polyamide-imide water-soluble PAI
  • a heat-resistant resin binder
  • a high adhesive force can be achieved with a small amount because the substance dissolves uniformly in the aqueous fluororesin coating composition. Therefore, the content of the fluororesin can be increased, not only making it possible to use the substance as a primer coating, but also enabling the use thereof as a one- coat coating capable of expressing effects with only one layer without a primer.
  • water-soluble polyamide-imides have high viscosity, thickeners can be reduced or not used at all, thereby enhancing the purity of the coating film and making it possible to achieve better performance.
  • using a water-soluble polyamide-imide is also advantageous in that a dispersion step or management of the degree of dispersion, which is necessary when a powder of various engineering plastics commonly used as a heat-resistant resin (binder) is used, becomes unnecessary, thereby yielding excellent productivity and also facilitating quality control. Accordingly, it is desirable to use a water-soluble polyamide-imide as a heat-resistant resin (binder) that imparts adhesiveness with a substrate in an aqueous coating composition.
  • Patent Document 4 proposes a fluororesin coating composition which improves the water vapor resistance or the like of a coating film that is formed using a water-soluble polyamide-imide containing 3,3’-dimethylbiphenyl-4,4’-diisocyanate and/or 3,3’- dimethylbiphenyl-4,4’-diamine as structural units.
  • this fluororesin coating composition does not achieve water vapor resistance and corrosion resistance sufficient for application to cookware.
  • NMP N-methyl-2-pyrrolidone
  • SUS stainless steel
  • Patent Document 1 JP H04-71951 B
  • Patent Document 2 JP 3491624 B
  • Patent Document 3 JP 4534916 B
  • Patent Document 4 WO2016/175099
  • Patent Document 5 JP 2016-89016 A
  • the object of the present invention is to provide an aqueous fluororesin coating composition which strongly adheres to metal substrates, in particular stainless steel (SUS) substrates, while combining excellent water vapor resistance and corrosion resistance so as to be suitably used in cookware such as fry pans or rice cookers, in addition to also being excellent from an environmental and safety hygienic standpoint.
  • the aqueous fluororesin coating composition of the present invention contains a water-soluble polyamide-imide resin, a polyether ether ketone, and a fluororesin, wherein the fluororesin is perfluororesin.
  • An aqueous fluororesin coating composition including: a water- soluble polyamide-imide resin, a polyether ether ketone, and a fluororesin, wherein the fluororesin is a perfluororesin.
  • aqueous fluororesin coating composition according to any one of (1) to (4), further including a polyether sulfone.
  • an aqueous fluororesin coating composition which has sufficient adhesiveness to metal substrates, in particular stainless steel (SUS) substrates, while combining excellent water vapor resistance and corrosion resistance so as to be suitably used in cookware.
  • metal substrates in particular stainless steel (SUS) substrates
  • SUS stainless steel
  • an aqueous fluororesin coating composition which uses water as a medium and is also excellent from an environmental and safety hygienic standpoint.
  • a coating film containing a large amount of a fluororesin can be provided, thereby enhancing the performance of a fluororesin coating.
  • aqueous fluororesin coating composition contains a water-soluble polyamide-imide resin, a polyether ether ketone, and a perfluororesin.
  • the “aqueous fluororesin coating composition” of the present invention is an aqueous (water-based) dispersion containing a water- soluble polyamide-imide resin, a polyether ether ketone, and a perfluororesin.
  • the aqueous fluororesin coating composition of the present invention is ordinarily suitably used as a primer coating (undercoat) for adhering a fluororesin layer to a substrate; however, the composition can also be used as a one-coat coating that does not use a primer coating.
  • PAI Water-soluble Polyamide-imide Resin
  • water-soluble polyamide-imide resin used in the present invention is a water-soluble resin having an amide bond and an imide bond in the main chain, preferably having repeating units represented by the following general formula:
  • the water-soluble PAI used in the present invention is obtained by copolymerizing a diisocyanate compound or a diamine compound as an amine component and a tribasic acid anhydride or a tribasic acid halide as an acid component in a polar solvent. While the synthesis conditions of the water-soluble PAI are varied and not particularly limited, synthesis is ordinarily performed at a temperature of from 80 to 180°C, and in order to reduce the effects of moisture in the air, synthesis is performed in an atmosphere of nitrogen or the like.
  • diisocyanate compound is not particularly limited, an example thereof is a diisocyanate compound represented by Formula (2) below.
  • X is a divalent organic group.
  • Examples of the divalent organic group represented by X include: alkylene groups having a carbon number of from 1 to 20; arylene groups such as phenylene groups or naphthylene groups which are unsubstituted or substituted with lower alkyl groups having a carbon number of from 1 to 5 such as methyl groups or lower alkoxy groups having a carbon number of from 1 to 5 such as methoxy groups; divalent organic groups formed by bonding two of the arylene groups described above via a single bond, a lower alkylene group having a carbon number of from 1 to 5, an oxy group (-0-), a carbonyl group (-CO-), or a sulfonyl group (-SO2-); and divalent organic groups formed by bonds of two lower alkylene groups having a carbon number of from 1 to 5 via the arylene groups described above.
  • the carbon number of the alkylene group is preferably from 1 to 18, more preferably from 1 to 12, even more preferably from 1 to 6, and particularly preferably from 1 to 4.
  • the divalent organic group represented by X is preferably a divalent organic group formed by bonding two of the arylene groups described above via a single bond, a lower alkylene group having a carbon number of from 1 to 5, an oxy group (-0-), a carbonyl group (-CO-), or a sulfonyl group (-SO2-).
  • a divalent organic group formed by bonding two of the arylene groups described above via a single bond or a lower alkylene group having a carbon number of from 1 to 5, and even more preferably a divalent organic group formed by bonding two phenylene groups via a single bond or a lower alkylene group having a carbon number of from 1 to 5 is used. Even when two or more types of diisocyanate compounds are used in combination, it is preferable to use two or more types selected from among these preferable modes.
  • the arylene group is preferably unsubstituted, while from the perspective of enhancing the adhesive strength of the coating film, the arylene group is preferably substituted with a lower alkyl group having a carbon number of from 1 to 5 such as a methyl group or a lower alkoxy group having a carbon number of from 1 to 5 such as a methoxy group.
  • diisocyanate compounds include xylylene diisocyanate, paraphenylene diisocyanate, tolylene diisocyanate, naphthalene diisocyanate, 3,3’-diphenylmethane diisocyanate, 4,4’- diphenylmethane diisocyanate, 3,3’-dimethylbiphenyl-4,4’-diisocyanate, 3,3’-dimethoxybiphenyl-4,4’-diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, and the like.
  • exemplary diamine compounds include a compound in which an isocyanate compound is substituted with an amino group in Formula (2) above.
  • diamine compounds include xylene diamine, phenylene diamine, 4,4’- diaminodiphenylmethane, 4,4’-diaminodiphenyl ether, 4,4’- diaminodiphenyl sulfone, 3,3’-diaminodiphenyl sulfone, 3,3’- dimethylbiphenyl-4,4’-diamine, isophorone diamine, and the like.
  • 3,3'-dimethylbiphenyl-4,4'-diisocyanate and/or 3,3'- dimethylbiphenyl-4,4'-diamine is preferable because the substrate adhesive strength and water vapor resistance of the coating film can be improved. Further, from the perspective of enhancing the working environment, 3, 3’-dimethylbiphenyl-4, 4’ -diisocyanate is preferably used (Patent Document 4).
  • a diisocyanate compound may be used alone, a diamine compound may be used alone, or a diisocyanate compound and a diamine compound may be used in combination. From the perspective of facilitating the reaction, a diisocyanate compound is preferably used.
  • a tribasic acid anhydride is a tricarboxylic anhydride.
  • the compound is preferably an aromatic tribasic acid anhydride, more preferably an aromatic tricarboxylic acid anhydride, and even more preferably a compound represented by Formula (3) or Formula (4) below. From the perspective of heat resistance, cost, and the like, a trimellitic acid anhydride is particularly preferable.
  • R is a hydrogen atom, an alkyl group having a carbon number of from 1 to 10, or a phenyl group, while Y is -CH2-, -CO-, -SO2-, or -0-.
  • a tribasic acid anhydride halide is preferably used as a tribasic acid halide, with an example thereof being a tricarboxylic acid anhydride halide.
  • the tribasic acid anhydride halide is preferably a tribasic acid anhydride chloride.
  • the compound is preferably an aromatic tribasic acid anhydride chloride, more preferably an aromatic tricarboxylic acid anhydride chloride, and even more preferably a compound in which the -COOR group in Formula (3) or Formula (4) above is replaced by a -COCI group.
  • a trimellitic acid anhydride chloride is particularly preferable.
  • a tricarboxylic acid anhydride is preferably used, with a trimellitic acid anhydride particularly preferable.
  • a polybasic acid or polybasic acid anhydride such as a dicarboxylic acid and tetracarboxylic acid dianhydride can be used as long as it does not impair the properties such as the heat resistance of the PAI.
  • the dicarboxylic acid is not particularly limited, but examples thereof may include terephthalic acid, isophthalic acid, adipic acid, sebacic acid, and the like.
  • the tetracarboxylic acid dianhydride is not particularly limited, but examples thereof may include pyromellitic dianhydride, benzophenone tetracarboxylic dianhydride, biphenyl tetracarboxylic dianhydride, and the like.
  • One type of each of a polybasic acid and a polybasic acid anhydride may be used alone, or two or more types may be used in combination.
  • the amount of the polybasic acid and polybasic acid anhydride (for example, dicarboxylic acid and tetracarboxylic dianhydride) other than tribasic acid anhydride and tribasic acid halide that are used is preferably from 0 to 50 mol%, more preferably from 0 to 30 mol%, and even more preferably from 0 to 15 mol% of all acid components.
  • the usage ratio of the diisocyanate compound and/or diamine compound to the acid component is preferably from 0.8 to 1.1 mols, more preferably from 0.95 to 1.08 mols, and even more preferably from 1.0 to 1.08 mols in terms of the total amount of the diisocyanate compound and/or diamine compound with respect to a total of 1.0 mol of the acid components.
  • a PAI obtained by reacting a diisocyanate compound and/or a diamine compound with an acid component can be used directly.
  • a terminal isocyanate group blocking agent may be optionally used for the purpose of stabilizing the PAI.
  • the PAI becomes a compound that has no isocyanate groups (-NCO groups) or has a reduced amount of isocyanate groups (-NCO groups) in comparison to a PAI obtained by reacting an isocyanate compound with an acid component.
  • Alcohol is an example of a blocking agent, with examples of alcohols including lower alcohols having a carbon number of from 1 to 6 such as methanol, ethanol, and propanol.
  • blocking agents include 2-butanone oxime, d-valerolactam, and e-caprolactam, and the like.
  • the blocking agent is not limited to these exemplary compounds.
  • One type of blocking agent may be used alone, or two or more types may be used in combination.
  • N-methyl-2-pyrrolidone NMP
  • N-ethylmoropholine N-formylmorpholine
  • N-acetylmorpholine N,N’-dimethylethylene urea
  • N,N-dimethylacetamide or N,N- dimethylformamide g-butyrolactone, and the like
  • NMP has preferably been used until now due to the availability and high boiling point thereof, it is preferable to use N-ethylmorpholine or N- formylmorpholine from the perspective of the effects on the human body, REACH regulations, legal regulations of the US FDA, or the like.
  • the amount of solvent used is not particularly limited, it is preferably from 50 to 500 parts by mass per 100 parts by mass of the total amount of the amine component and the acid component from the perspective of the solubility of the resin obtained.
  • the number average molecular weight of the PAI is preferably no lower than 5,000, more preferably no less than 10,000, even more preferably no lower than 13,000, and particularly preferably no lower than 15,000.
  • the number average molecular weight is preferably no greater than 50,000, more preferably no greater than 30,000, even more preferably no greater than 25,000, and particularly preferably no greater than 20,000.
  • the number average molecular weight of the PAI can be managed by sampling PAI at the time of synthesis, measuring the number average molecular weight, and continuing synthesis until the target number average molecular weight is obtained.
  • the number average molecular weight can be measured by gel permeation chromatography (GPC) using a standard polystyrene calibration curve.
  • the acid value of the PAI combining the carboxyl groups in the resin and carboxyl groups with ring-opened acid anhydride groups is preferably no less than 10 mgKOH/g.
  • the acid value is more preferably no less than 25 mgKOH/g and even more preferably no less than 35 mgKOH/g. These ranges are preferable ranges from the perspective of facilitating dissolution or dispersion of the PAI.
  • the amount of carboxyl groups reacting with the basic compound is sufficient, in addition to also being a preferable range in that water solubilization becomes easy.
  • the acid value of the fluororesin coating composition that is ultimately obtained is preferably no greater than 80 mgKOH/g.
  • the acid value is more preferably no greater than 60 mgKOH/g and even more preferably no greater than 50 mgKOH/g.
  • the acid value can be obtained using the following method. First,
  • PAI 0.5 g of PAI is collected and 0.15 g of 1 ,4-diazobicyclo[2,2,2]octane is added thereto.
  • 60 g of N-methyl-2-pyrrolidone and 1 mL of ion- exchanged water are added and stirred until the PAI is fully dissolved to prepare a solution for evaluation.
  • the solution for evaluation is titrated with a 0.05 mol/L potassium hydroxide ethanol solution by potentiometric titration to obtain an acid value.
  • the acid value is an acid value combining the carboxyl groups in the resin and carboxyl groups with ring-opened acid anhydride groups.
  • a basic compound may also be reacted to increase the solubility of the PAI in water.
  • the basic compound reacts with the carboxyl groups contained in the PAI to form a salt of the basic compound and the PAI.
  • the action of the basic compound can increase the solubility of the PAI in water.
  • examples of basic compounds include: alkylamines such as triethylamine, tributylamine, N,N- dimethylcyclohexylamine, N,N-dimethylbenzylamine, triethylene diamine, N-methylmorpholine, N,N,N’N’-tetramethylethylene diamine, N,N,N’N”,N”- pentamethyldiethylene triamine, N,N’,N’-trimethylaminoethylpiperadine, diethylamine, diisopropylamine, dibutylamine, ethylamine, isopropylamine, and butylamine; alkanolamines such as monoethanolamine, diethanolamine, triethanolamine, dipropanolamine, tripropanolamine, N- ethylethanolamine, N,N-dimethylethanolamine, N,N-diethylethanolamine, cyclohexanolamine, N-methylcyclohexanolamine, N-methyl
  • the basic compound is preferably used in an amount of no less than 2.5 equivalents, more preferably no less than 3.5 equivalents, and even more preferably no less than 4 equivalents with respect to the carboxyl groups and ring-opened acid anhydride groups contained in the resin.
  • the content of the basic compound is preferably no greater than 10 equivalents, more preferably no greater than 8 equivalents, and even more preferably no greater than 6 equivalents.
  • the water-soluble PAI used in the present invention is ordinarily used as a solution in the preparation of a fluororesin coating composition.
  • the water-soluble PAI solution can be easily obtained by dissolving the water-soluble PAI in water containing an organic solvent.
  • the organic solvent is not particularly limited as long as the solvent has high polarity and a high boiling point, with various polar agents capable of being used for the polymerization of PAI available.
  • NMP has been preferably used until now due to the availability and high boiling point thereof, it is preferable to use N-ethylmorpholine or N-formylmorpholine from the perspective of the effects on the human body, REACH regulations, legal regulations of the US FDA, or the like.
  • the organic solvent described above may be the same as a solvent that may be contained in the aqueous medium described below in the fluororesin coating composition of the present invention.
  • the water-soluble PAI preferably has a concentration of from 1 to 50 mass% and more preferably from 5 to 40 mass% of the water-soluble PAI solution in terms of viscosity.
  • Examples of commercially available products of such a water- soluble PAI solution include HPC-1000-28 and HPC-2100D-28 available from Hitachi Chemical Co., Ltd., with HPC-2100D-28 being preferable.
  • polyether ether ketone (PEEK) used in the present invention is a polymeric compound having at least the following repeating units as represented in Formula 5. Either a homopolymer or a copolymer thereof may be used.
  • Polyether ether ketone (PEEK) is typically manufactured by reacting 4,4-difluorobenzophenone with hydroquinone in diphenylsulfone in the presence of alkali metal carbonate (for example, potassium carbonate and/or sodium carbonate).
  • PEEK polyether ether ketone
  • the composition ratio of the water- soluble PAI is no less than 30 wt.% and preferably no less than 40 wt.%.
  • PAI is a thermosetting resin that is thought to have an effect of forming a film without flowing during the firing of the coating film, and in small amounts, a uniform film cannot be formed, with defects likely to occur.
  • PEEK is preferably contained in an amount of no less than 10 wt.% in the binder resin. It is thought that PEEK has an effect of enhancing the adhesive force to substrates, hydrolysis resistance performance, and film formability, in addition to having an effect of enhancing hydrolysis resistance performance and yielding a coating film having high adhesive force to a substrate, film formability for forming a uniform film, and excellent hydrolysis resistance performance.
  • the “perfluoro resin” refers to a fluororesin in which all of the hydrogen atoms in the molecular chain are substituted with fluorine, with specific examples thereof including polytetrafluoroethylene (PTFE), tetrafluoroethylene/hexafluoropropylene copolymer (FEP), tetrafluoroethylene/perfluoro(alkyl vinyl ether) copolymer (PFA), tetrafluoroethylene/hexafluoropropylene/perfluoro(alkyl vinyl ether) copolymer, etc.
  • PTFE polytetrafluoroethylene
  • FEP tetrafluoroethylene/hexafluoropropylene copolymer
  • PFA tetrafluoroethylene/perfluoro(alkyl vinyl ether) copolymer
  • a melt processable fluororesin is preferably used as the perfluororesin and exhibits melt fluidity at the melting point or higher because, when used as a coating film, the occurrence of pin holes can be suppressed and a uniform, smooth coating film can be obtained.
  • PFA is particularly preferable due to the excellent heat resistance thereof.
  • the perfluoro(alkyl vinyl ether) alkyl groups in the PFA preferably have a carbon number of from 1 to 5 and more preferably have a carbon number of from 1 to 3.
  • the amount of perfluoro(alkyl vinyl ether) in the PFA is preferably in a range of from 1 to 50 mass%.
  • a non-melt processable polytetrafluoroethylene (PTFE) is preferably used as the perfluoro resin.
  • the stress remaining in the coating film after heating can be reduced and the cost can also be reduced.
  • the simultaneous use of the melt processable perfluoro resin and the non-melt processable polytetrafluoroethylene (PTFE) yields the respective advantages described above and is more preferable.
  • other fluorine resins may be added as necessary.
  • Non-melt processable Polytetrafluoroethylene preferably used in the present invention is a high-molecular-weight polytetrafluoroethylene (PTFE) that does not exhibit melt fluidity at the melting point or higher, and may be either a homopolymer of tetrafluoroethylene (TFE) (homopolymer of TFE) or a TFE copolymer in which a monomer that is copolymerizable with TFE is contained in a range of no greater than 1 mass% (modified PTFE), or both may be used in combination.
  • TFE tetrafluoroethylene
  • modified PTFE modified PTFE
  • melt processable fluororesin examples include a low-molecular-weight melt processable polytetrafluoroethylene (melt processable PTFE), tetrafluoroethylene/perfluoro(alkyl vinyl ether) copolymers (PFA), tetrafluoroethylene/hexafluoropropylene copolymers (FEP), tetrafluoroethylene/hexafluoropropylene/perfluoro(alkyl vinyl ether) copolymers, tetrafluoroethylene/ethylene copolymers, polyvinylidene fluorides, polychlorotrifluoroethylenes, and chlorotrifluoroethylene/ethylene copolymers. These can be manufactured by conventionally known methods such as solution polymerization, emulsion polymerization, or suspension polymerization.
  • the fluororesin of the present invention can be used by dispersing a powder obtained by separating and drying a resin obtained by a known polymerization method, a powder obtained by further pulverizing the aforementioned powder, or a powder that has been refined and granulated by the method described in Japanese Examined Patent Application Publication No. S52-44576 or the like in the coating composition. Further, a fluororesin resin dispersion (dispersion) polymerized by emulsion polymerization can be used directly, or a fluororesin resin dispersion stabilized by adding a surfactant or adjusted to a high fluororesin resin concentration by concentrating with a known technique such as the method described in US Patent No. 3,037,953 can also be used. A stabilized fluororesin resin dispersion is preferable in that the dispersed state can be maintained over a long period of time without the coagulation or precipitation of the fluororesin.
  • the concentration of the fluororesin dispersion used in the coating composition of the present invention is preferably from 20 to 70 mass%, with the use of a composition adjusted to a 40 to 70 mass% by concentration preferable in that it becomes easy to adjust the fluororesin concentration in the coating composition.
  • concentration of the fluororesin dispersion used in the present invention include TeflonTM PTFE 31 -JR, PTFE 34-JR, PFA 334-JR, PFA 335-JR, and FEP 120-JR available from Chemours-Mitsui Fluoroproducts Co., Ltd.
  • the amount of the fluororesin is preferably from 35 to 90 mass% and particularly preferably from 45 to 80 mass% relative to the total amount of the binder resin and the fluororesin.
  • the amount of the fluororesin is less than 35 mass%, the water vapor resistance and corrosion resistance of the coating film, as well as the adhesion of the top coat, may decrease. In contrast, if the fluororesin exceeds 90 mass%, the corrosion resistance of the coating film may decrease, and furthermore, adhesion force to the substrate and strength of the coating film may decrease.
  • the amount of the fluororesin is preferably from 5 to 90 mass% and particularly preferably from 10 to 70 mass% relative to the total amount of the resin solid content. If the amount of the fluororesin is less than 5 mass%, the water vapor resistance and corrosion resistance of the coating film may decrease. Furthermore, the properties of the fluororesin coating such as releasability may not be sufficiently obtained. In contrast, if the fluororesin exceeds 90 mass%, corrosion resistance of the coating film may decrease along with the adhesion force to the substrate and the strength of the coating film, as in the case of the primer coating.
  • the “resin solid content” described above refers to the total mass of the binder resin (water-soluble PAI, PEEK, or other heat-resistant resin) and the fluororesin in a residue after the fluororesin coating composition of the present invention is applied to coated object, dried at a temperature of from 80 to 100°C, and then sintered for 45 minutes at approximately 380°C.
  • the fluororesin coating composition of the present invention the fluororesin is dispersed as particles in an aqueous medium.
  • the fluororesin described above preferably consists of particles having an average particle size of from 0.01 to 50 pm.
  • the average particle size is less than 0.01 pm, the dispersibility of the particles is poor and there is a risk that the resulting coating composition may have poor mechanical strength and storage stability.
  • the average particle size is greater than 50 pm, the particles lack uniform dispersibility and when applied using the obtained coating composition, a coating film with a smooth surface may not be obtained and the coating film physical properties may be poor.
  • a more preferable upper limit is 5 pm, with an even more preferable upper limit of 0.5 pm, while a more preferable lower limit is 0.05 pm.
  • the mechanical stability described above is a property such that a non-redispersible agglomerate is difficult to produce even when subjected to strong stirring or a shearing force with a homogenizer or the like at the time of feeding and redispersion.
  • the aqueous fluororesin coating composition of the present invention may also contain various additives used in ordinary coatings in accordance with the required properties such as dispersibility, conductivity, foaming prevention, and enhanced wear resistance, examples of which include: surfactants (for example, polyoxyethylene alkyl ether or polyoxyethylene alkyl phenyl ether-based non-ionic surfactants such as Liocol available from Lion, Inc., the TRITON and TERGITOL series available from the Dow Chemical Company, and Emalgen available from KAO, Inc.; sulfocuccinate-based, alkyl ether sulfonic acid sodium salt-based, or sulfate mono-long-chain alkyl-based anionic surfactants such as Repal available from Lion, Inc.
  • surfactants for example, polyoxyethylene alkyl ether or polyoxyethylene alkyl phenyl ether-based non-ionic surfactants such as Liocol available from Lion, Inc., the TRITON and TERGITOL series
  • polycarboxylate or acrylate-based polymer surfactants such as Leoal available from Lion, Inc. or OROTAN available from the Dow Chemical Company; and L-77 available from Momentive, and the Surfynol Series available from EVONIK (Surfynol 420, Surfynol 440, Surfynol 465, Surfynol 485, and the like); film forming agents (for example, polymeric film forming agents such as polyamides, polyamide-imides, acrylics, and acetates; higher alcohols or ethers; and polymeric surfactants having a film-forming effect); and thickeners (for example, water-soluble celluloses, solvent dispersion thickeners, sodium alginates, caseins, sodium caseinates, xanthan gums, polyacrylic acids, and acrylic esters), and the like.
  • film forming agents for example, polymeric film forming agents such as polyamides, polyamide-imides, acrylics, and acetates; higher alcohols or
  • organic and inorganic substances can be added to the aqueous fluororesin coating composition of the present invention as binders or fillers in accordance with the required properties.
  • organic substances include engineering plastics such as polyphenylene sulfides, polyether sulfones, polyphenyl sulfones, polyamides, polyimides, phenolic resins, urea resins, epoxy resins, urethane resins, melamine resins, polyester resins, polyether resins, acrylic resins, acrylic silicone resins, silicone resins, and silicone polyester resins.
  • inorganic substances include metal powders, metal oxides (aluminum oxide, zinc oxide, tin oxide, titanium oxide, and the like), glass, ceramics, silicon carbide, silicon oxide, calcium fluorides, carbon black, graphite, mica, and barium sulfate. Substances having a variety of shapes such as particle-shaped, fiber-shaped, and flake-shaped substances can be used as fillers.
  • the aqueous fluororesin coating composition of the present invention contains water as the main medium.
  • a polar solvent that is compatible with water or to disperse an organic solvent that is incompatible with water in order to appropriately adjust the rheology properties such as the liquid viscosity of the aqueous fluororesin coating composition or to enhance the dispersibility of the PEEK, the fillers, or the like.
  • the heat-resistant resin by adding a polar solvent, the heat-resistant resin (binder) is dissolved and becomes more uniform in the drying process after coating.
  • Stainless steel is an alloy produced by adding chromium, nickel, or the like to iron, and is broadly categorized into austenitic stainless steel, martensitic stainless steel, ferritic stainless steel, and austenitic/ferritic stainless steel.
  • austenitic stainless steel martensitic stainless steel
  • ferritic stainless steel ferritic stainless steel
  • austenitic/ferritic stainless steel There is a wide variety of stainless steel depending on the components of the alloy, with representative examples of stainless steels prescribed by the JIS standards including SUS304, SUS303, SUS316, SUS410, SUS430, SUS630, and the like.
  • the aqueous fluororesin coating composition of the present invention can be prepared by conventionally known methods or the like.
  • the composition can be obtained by appropriately mixing PEEK, a fluororesin, and other additives or fillers that are blended as necessary with the water-soluble PAI solution described above dissolved in water containing an organic solvent.
  • PEEK, a fluororesin, a pigment, or the like may be prepared by preparing a dispersion (dispersion solution) thereof in advance and mixing the obtained dispersion.
  • the aqueous fluororesin coating composition of the present invention preferably has a viscosity of from 0.1 to 50,000 mPa-s at 25°C.
  • a viscosity of from 0.1 to 50,000 mPa-s at 25°C.
  • the viscosity is less than 0.1 mPa-s, dripping or the like may easily occur when applied to a coated object, potentially making it difficult to obtain the target film thickness.
  • the viscosity exceeds 50,000 mPa- s, the coating workability may be diminished and the film thickness of the resulting coating film may not be uniform, potentially diminishing the surface smoothness or the like.
  • a more preferable lower limit is 1 mPa-s, and an even more preferable upper limit is 30,000 mPa-s.
  • the viscosity described above is the value obtained by taking a measurement using a BM-type single-cylinder rotary viscometer (available from Tokyo Keiki Co., Ltd.). 2.
  • the “coating film” of the present invention is a coating film obtained by applying the aqueous fluororesin coating composition of the present invention to a substrate.
  • a coating film is also included in which the coating composition of the present invention is used as a primer layer to be adhered to a substrate, with a plurality of layers coated and laminated thereon.
  • the “coating film” of the present invention can be formed by a typically used method such as spray coating, dip coating, or spin coating, for example, and is preferably heated to at least the melting point of the fluororesin in order to achieve melt-fluidity and obtain a uniform coating film.
  • the “coated article” of the present invention is an article obtained by applying the aqueous fluororesin coating composition of the present invention.
  • the “coated article” of the present invention include: cookware such as frying pans or rice cookers; heat-resistant release trays in factory lines or the like (such as a bread-baking process); office equipment-related articles such as fixing rollers/belts/inkjet nozzles; industrial equipment-related articles at chemical plants such as piping; and other articles requiring non-tackiness and water and oil repellency.
  • Cookware requiring high water vapor resistance and corrosion resistance is preferable.
  • HPC-2100D-28 available from Hitachi Chemical Co., Ltd. (Solution with a PAI concentration of approximately 28 mass%, a water concentration of from 22 to 32 mass%, and an N-formylmorpholine concentration of from 30 to 40 mass%)
  • PEEK powder VICOTETM Coatings 704 available from Victrex PLC Other binder resins Polyethersulfone (PES) resin PES Powder: SUMIKAEXCEL PES 4100MP available from Sumitomo Chemical Co., Ltd. polyetherimide (PEI) resin
  • PEI Powder Ultem 1000F3SP-1000 available from SABIC Fluororesin
  • PFA Aqueous dispersion (1) TeflonTM PFA 334-JR available from Chemours-Mitsui Fluoroproducts Co., Ltd. (PFA concentration: 60 mass%)
  • PFA Aqueous dispersion (2) TeflonTM PFA 335-JR available from Chemours-Mitsui Fluoroproducts Co., Ltd. (PFA concentration: 60 mass%)
  • PTFE Aqueous dispersion (1) TeflonTM PTFE 34-JR available from
  • Aqueous fluororesin coating compositions were obtained using the same procedure as in Example 1 while adjusting the amount of each component so as to obtain the coating compositions (composition ratio in the resin solid content (mass%)) shown in Table 1 below.
  • Comparative Examples 1 to 4 Fluororesin coating compositions were obtained using the same procedure as in Example 1 while adjusting the amount of each component so as to obtain the coating compositions (composition ratio in the resin solid content (mass%)) shown in Table 1 below.
  • the composition ratios (mass%) of the resin solid content in the coating compositions of the examples are shown in Table 1 below, with the composition ratios (mass%) of the resin solid content in the coating compositions of the comparative examples shown in Table 2 below.
  • a coating film for use in performance evaluation was produced using the following procedure.
  • a 170 mm square piece of aluminum (JIS A1050 compliant product, thickness: 2 mm) was used as a substrate, wiped with isopropyl alcohol, and then subjected to shot blasting with #60 alumina to obtain a surface roughness (Ra) of from 1 to 5 pm.
  • the fluororesin coating compositions of each of the examples and the comparative examples were spray-coated using a spray gun (W-101-101G, available from Anest Iwata Inc.) and dried for 20 minutes at 120°C and then for 20 minutes at 250°C to form a primer layer (fluororesin coating composition layer).
  • the substrate on which the primer layer was formed was subjected to electrostatic powder coating (coating weight: 3.0 to 3.5 g) with a PFA powder coating (TeflonTM coating MJ-102 available from Chemours-Mitsui Fluoroproducts Co., Ltd.) over the entire surface using a powder spray gun (GX355HW available from Parker Ionics) and this was sintered for 30 minutes at 400°C (substrate temperature) to form a top coat layer (PFA layer).
  • electrostatic powder coating coating weight: 3.0 to 3.5 g
  • PFA powder coating TeflonTM coating MJ-102 available from Chemours-Mitsui Fluoroproducts Co., Ltd.
  • GX355HW powder spray gun
  • test piece for adhesiveness evaluation was similarly produced using stainless steel (JIS SUS304, thickness: 1 mm) instead of aluminum and this was used in evaluation testing.
  • the test piece for evaluation (aluminum substrate) described above was left to stand for 100 hours in 0.8 megapascal steam at 170°C, then allowed to sit and cool to room temperature, after which the state of the coating film was then observed. Next, the substrate was heated to 200°C with a gas stove, then rapidly cooled with water, and the state of the coating film was confirmed. If any swelling or blistering occurred, testing was ended. If the state of the coating film was good, then this was repeated every 100 to 300 hours to perform three cycles of water vapor pressure processing. The adhesive strength of the coating film was then measured by the method described below.
  • test piece of the stainless-steel substrate was evaluated in the same manner as in the above method with the exception that the temperature of the water vapor was set to 150°C.
  • the coating film was cut with a cutter so as have a width of 1 cm at the center of the abovementioned test piece, after which the end of the coating film was peeled so as to serve as the gripping part for measuring the adhesive strength.
  • the peeled coating film described above was sandwiched between the chucks of the tester in accordance with the measurement method for the peel strength of an adhesive (90-degree peel test method) prescribed by JIS K 6854 and pulled at a rate of 50 mm/minute to measure the adhesive strength (peel strength).
  • the units were kgf (kilogram-force).

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Abstract

L'invention concerne : une composition aqueuse de revêtement de résine fluorée qui adhère fortement à des substrats métalliques, en particulier à de l'acier inoxydable (SUS), tout en combinant une excellente résistance à la vapeur d'eau et une excellente résistance à la corrosion de manière à pouvoir être utilisée de façon appropriée dans des ustensiles de cuisine tels que des poêles à frire ou des cuiseurs à riz, en plus d'être également excellente d'un point de vue hygiène, sécurité et environnement ; un film de revêtement formé par l'application de celle-ci en revêtement ; et un article portant le film de revêtement. La composition aqueuse de revêtement de résine fluorée comprend : une résine de polyamide-imide hydrosoluble ; une polyéther éther cétone ; et une résine perfluorée.
PCT/US2020/063213 2019-12-06 2020-12-04 Composition aqueuse de revêtement de résine fluorée Ceased WO2021113576A1 (fr)

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