DESCRIPTIC»T
AQUEOUS COATING COMPOSITION AND RUST PREVENTION METHOD USING THE
AQUEOUS COATING COMPOSITION
5 Technical Field
[0001]
The present invention relates to aqueous coating composition,
andmoreparticularlyto an aqueous coating composition (aqueous binder
composition), that is a binder composition, or an aqueous coating
10 composition (aqueous rust-preventive coating composition), that is
a rust-preventive coating composition,
[0002]
Further, the present invention relates to a rust prevention
coating method for a base such as a steel material, using the aqueous
15 coating composition such as an aqueous rust-preventive coating
composition.
BackgroTUid Art
[0003]
20 Conventional solvent-based coating compositions include
various volatile organic solvents (organic solvents) in order to
improve dispersibility of a binder such as a polymer or in order to
control viscosities of the compositions. In the preparation of a
polymer-based component of a binder, an organic solvent is sometimes
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used as a solvent. On that account, the organic solvent is sometimes
included together with the polymer-based component that is a binder
in the coating compositions.
Also in coating compositions including a hydrolysis condensate
5 (polyorganosiloxane) of a silane compound or a metal oxide as a binder,
solvent-based compositions are the mainstream coating compositions.
For example, a solvent-based rust-preventive coating composition
including tetraethyl silicate (binder), zinc dust (rust-preventive
pigment) and a large amount of an organic solvent is known,
10 In such a solvent-based coating composition, the organic solvent
can dissolve the binder homogeneously, and therefore, excessive
thickening or occurrence of a non-dissolved substance (gel) can be
reduced. That is to say, it is thought that the organic solvent
contributes to inhibiting local deterioration reaction or
15 decomposition reaction of the coating composition, said reactionbeing
liable to take place in the excessively thickened portion or the
non-dissolved substance (gel). Thus, the organic solvent can
chemically stabilize the coating composition. Moreover, the organic
solvent has a function of maintaining the low viscosity of the
20 composition by virtue of dilution effect, and hence, application of
the composition can be easily carried out by using publicly known
various methods. Further, when the solvent-based coating composition
is applied to a base, the organic solvent vaporizes efficiently from
the composition applied, and hence, the coating composition is cured
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in a relatively short time to form a coating film.
[0004]
The solvent-based coating compositions including a hydrolysis
condensate of a silane compound as a binder are favorably used as
5 solvent-based binder compositions or solvent-based rust-preventive
coating compositions. Uses of these compositions extend over many
divergencies.
[0005]
Examples of main uses of the solvent-based binder compositions
10 include uses as coating agents used for surfaces of bases, such as
mica plate, glass laminated sheet, glass sleeve, rubber, plastic and
leather, binders for asbestos, anti-scattering curing agents or
surface reinforcing agents for asbestos-containing spray materials,
anti-scattering primary curing agents used in removal of
15 asbestos-containing spray materials, metal-based rust-preventive
pigments or pollution inhibitors or surface protective agents, stone
material-based antifouling treatment agents or water repellants,
heat-resistant coating materials, additives therefor, and binders
and additives for various coating materials.
20 [0006]
Examples of main uses of the solvent-based rust-preventive
coating compositions including a binder include uses as coating
compositions for primary rust prevention and thick-coating type
inorganic zinc coating compositions (dry film thickness: e.g., 50
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to 200 pm).
[0007]
The primary rust-preventive coating compositions are used for
the purpose of temporarily preventing rusting on the surface of steel
5 used for automobiles, domestic electrical appliances, large steel
structures (ships, bridges, plants, etc.)A containers for
transportation, land tanks, etc., during manufacturing or
construction. Examples of the primary rust-preventive coating
compositions include organic primary rust-preventive coating
10 compositions, such as wash primer, non-zinc epoxy primer and epoxy
zinc-rich primer, and inorganic zinc primary rust-preventive coating
compositions. Of these, inorganic zinc primary rust-preventive
coating compositions having excellent weldability are widely used.
[0008]
15 The thick-coating type inorganic zinc coating compositions are
used for cargo tanks and ballast tanks of ships such as chemical tankers
and ships for exclusive use of methanol. These cargo tanks and ballast
tanks are required to have resistance to cargos such as petroleum
refining products and chemical products, resistance to corrosion by
20 tank wash water (fresh water, seawater), mechanical properties that
can sufficiently cope with strain of a steel plate caused by water
pressure during pouring of ballast water or expansion and contraction
of a steel material caused by temperature change, etc., and the
thick-coating type inorganic zinc coating compositions exert these
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excellent properties. The thick-coating type inorganic zinc coating
compositions are favorably used particularly for ballast tanks that
are required to have long-teim resistance to corrosion by seawater.
The solvent-based thick-coating type inorganic zinc coating
5 compositions including polyorganosiloxane are inferior to epoxy
resin-based coating compositions in workability, properties such as
coating film strength and flexibility, and characteristics such as
long-term corrosion resistance. On that account, the epoxy
resin-based coating compositions are widely used as the thick-coating
10 type inorganic zinc coating compositions at present.
The solvent-based coating compositions including a metal oxide
as a binder are also used as various coating agents though they are
not used so much as the coating compositions including
polyorganosiloxane as a binder
15 [0009]
On the other hand, VOC countermeasures (reduction of
environmental burden) have been recently required in many countries.
On that account, non-solvent or low-solvent coating compositions have
been desired.
20 As a means to obtain the non-solvent or low-solvent coating
compositions, for example, technique to obtain high solid coating
compositions, such as increase in solids content of a binder such
as a polymer or use of a reactive monomer as a diluent, has been proposed.
Further, technique to obtain aqueous coating compositions
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utilizing a method of using, as a diluent, water or a surface active
agent instead of an organic solvent (water dispersion method, such
as emulsifying method or suspending method) has been studied. In
this method, the surface active agent has functions of facilitating
5 dispersing of a binder in water and favorably maintaining the dispersed
state for a certain period of time. The coating composition obtained
by dispersing the binder in water by a compulsive method such as a
method of using mechanical pressure in the presence of a surface active
agent as above has good stability in the points that the degree of
10 sedimentation of components such as a binder in the coating composition
is low and the degree of thickening of the coating composition is
low, but when a coating film is formed from the composition, a surface
active agent remains in the film, and hence, topcoating adhesion
properties are sometimes deteriorated. Accordingly, the binder is
15 desired to be water-soluble so that no surface active agent shall
need to be used.
On the other hand, such a coating composition is required to
have, in addition to the water solubility, properties such as good
curability and drying properties when the composition is formed into
20 a film, but compatibility of these properties is extremely difficult.
Further, a coating film formed from the composition is also required
to have not only good water resistance, corrosion resistance and
topcoating adhesion properties but also good weldability and cutting
properties, but compatibility of them is also difficult.
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In the existing circumstances, the coating compositions having
aqueous system (aqueous coating compositions) cannot exhibit
properties equal to those of the solvent-based coating compositions.
Such aqueous coating compositions have been disclosed in patent
5 literatures 1 to 9.
The coating compositions of the patent literatures enumerated
below can be broadly divided into compositions in which the binder
is a hydrolysis condensate (polyorganosiloxane) of a silane compound
(patent literatures 1 to 6) and compositions in which the binder is
10 a metal oxide sol (patent literatures 7 to 9). In the patent
literatures 1 to 5, the binder included in the coating compositions
is a hydrolysis condensate prepared from an alkoxysilane, and in the
patent literature 6, the binder included in the coating composition
is a hydrolysis condensate prepared from an amino group-containing
15 silane coupling agent (amino group-containing silane compound).
In the patent literature 1 (JP-A-2002-121485), an aqueous
composition for anticorrosive coating, which comprises organic
functional silane including an alkoxy group and capable of being
diluted with water and a wetting agent and which is used as a rust
20 preventive for a metal substrate such as a steel fastener, has been
disclosed.
In the patent literature 2 ( JP-A-2000-144020), a
rust-preventive coating agent in which phosphoric acid, phosphorous
acid or hypophosphorous acid ion, and a sulfur-containing compound
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comprising a thiocarbonyl compound, a thiol compound, a sulfide or
persulfuric acid ion are included in an aqueous solution including
a silane coupling agent (e.g., specifically, various alkoxysilanes)
and its hydrolysis condensate has been disclosed.
5 In the patent literature 3 (JP-A-2002-105401), an aqueous
two-component type protective coating agent for steel materials, which
includes a first component of water dispersibility including a binder
obtained by reacting an amino group-containing alkoxysilane with an
epoxy group-containing alkoxysilane in the presence of a relatively
10 strong acid, and a pigment, and a second component comprising finely
pulverized zinc dust, has been disclosed.
In the patent literature 4 (JP-A-2008-528741), a siloxane
polymer (binder composition) having N-formyl group or the like, which
is obtained by the reaction of an amino group-containing alkoxysilane
15 with a formic acid ester, and a rust-preventive coating composition
including the binder composition and an anticorrosive pigment such
as zinc have been disclosed.
In the patent literature 5 (WO2008/003695), a two-component
type coating composition including, in an aqueous solution, (a) an
20 aqueous binder (first component) including a polymer or oligomer
compound formed from a tetra-substituted alkoxysilane compound, a
functional tri-substituted alkoxysilane compound, and if necessary,
a colloidal silica water dispersing agent, and (b) a reactive filler
(second component) such as zinc dust has been disclosed.
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In the patent literature 6 (JP-A-2008-150537), a coating
composition including, as a binder, a hydrolysis condensate prepared
by the reaction of an amino group-containing silane coupling agent
(amino group-containing silane compound) has been described, and
5 specifically, an aqueous rust-preventive coating material including
a water-soluble or hydrolyzable amino group-containing silane
coupling agent as a binder and a metal pigment comprising at least
one of tin and tin-containing alloys having white rust prevention
properties and zinc has been disclosed.
10 Next, examples using a metal oxide sol as a binder are described.
In the patent literature 7 (JP-B-1981-29904), an inorganic
film-forming composition comprising water- dispersible colloidal
silica, urea or thiourea, water-soluble lithiumpolysilicate and zinc
dust has been disclosed.
15 In the patent literature 8 (WO2008/128932), a coating
composition including i) zinc dust and/or zinc alloy and ii) colloidal
silica having been surface-treated with a silane compound under the
specific conditions has been disclosed.
In the patent literature 9 (JP-B-2005-510584) , an aqueous shop
20 primer composition including an aqueous silica sol as a binder, and
zinc dust or zinc alloy has been disclosed.
Citation List
Patent Literature
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[0010]
Patent literature 1: JP-A-2002-121485
Patent literature 2: JP-A-2000-144020
Patent literature 3: JP-A-2002-105401
5 Patent literature 4: JP-A-2008-528741
Patent literature 5: WO2008/003695
Patent literature 6: JP-A-2008-150537
Patent literature 7: JP-B-1981-29904
Patent literature 8: WO2008/128932
10 Patent literature 9: JP-A-2005-510584
Smmnaxy of Invention
Technical Problem
[0011]
15 In any of the aqueous coating compositions of these patent
literatures, however, there are problems of various properties, for
example, a problem of drying properties such that long time curing
or heating is necessary, as described below, and the range of use
applications is limited.
20 First, when the binder is a hydrolysis condensate of an
alkoxysilane compound, a by-product formed after the hydrolysis is
an alcohol, and the by-product has low corrosion properties and
irritation properties and has high volatility, so that it can be easily
removed by distillation or the like, and the hydrolysis condensate
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can be easily purified, as described in the patent literatures 1 to
5. Further, there is an advantage that the hydrolysis condensate
can be prepared by a reaction container or a reaction device in which
storage or hydrolysis reaction is simply carried out, but in obtaining
5 a hydrolysis condensate of a high molecular weight, the degree of
freedom in the design of a product is not so high because the reactivity
of the silane compound is low. That is to say, in the case of hydrolysis
reaction of an alkoxysilane compound only, the number of alkoxysilyl
groups undergoing reaction in one molecule is small, and therefore,
10 there are problems in the molecular design such that increase of a
molecular weight is difficult (number-average molecular weight: about
several hundred) and even if a co-hydrolyzate having a narrow molecular
weight distribution is intended to be prepared from several kinds
of alkoxysilanes as starting substances, the molecular weight
15 distribution is widened and the ratio of constituent units of the
co-hydrolyzate largely differs from the blending ratio of the staring
substances. Hence, it is difficult to obtain a co-hydrolyzate having
a desired molecular structure. Further, because of such problems,
any of the resulting aqueous coating compositions cannot acquire
20 well-balanced excellent properties of drying properties (curing
properties), water resistance, corrosion resistance, coating film
strength, etc. Furthermore, the aqueous rust-preventive coating
compositions (aqueous coating compositions for primary rust
prevention, aqueous thick-coating type inorganic zinc coating
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compositions) including such a binder can exhibit only insufficient
properties in not only the above properties but also rust prevention
properties, properties of topcoating film (topcoating properties)
and weldability.
5 When the binder is a hydrolysis condensate of an amino
group-containing alkoxysilane, the amino group actions as a reaction
catalyst to thereby excessively promote hydrolysis
condensate-forming reaction in the preparation of the binder
(hydrolysis condensate), as disclosed in the patent literature 3.
10 On that account, there is a possibility of occurrence of troubles
such as gelation during the reaction or storage. Thus, it is difficult
to control a molecular weight of the hydrolysis condensate obtained
by the use of the amino group-containing alkoxysilane. Moreover,
when the molecular weight is too high, it is difficult to disperse
15 the resulting hydrolysis condensate in water. On the other hand,
when the molecular weight is low, or when the concentration of a binder
component, which is obtained by promoting the hydrolysis reaction
in a low concentration of raw material silane in order to reduce
occurrence of the gelation, is low, there occurs a problem such that
20 the resulting hydrolysis condensate cannot exhibit satisfactory
curing properties/drying properties and water resistance of a coating
film.
When the binder is not a hydrolysis condensate of an alkoxysilane
compoundbut a hydrolysis condensate of amino group-containing silane.
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the interaction between an amino group, which is derived from the
amino group-containing silane and is present in the binder, and a
rust-preventive pigment such as zinc becomes strong, as described
in the patent literature 6. It is said that when the coating object
5 is a steel material or the like, an iron atom is ionized to form rust,
but zinc is ionized by an acid, and the zinc ion formed inhibits
ionization of the iron atom to thereby exhibit rust prevention action.
The amino group derived from the amino group-containing silane and
included in the binder undergoes interaction with zinc (it is thought
10 that zinc that is an amphoteric metal probably forms a complex or
a substance analogous to it together with the amino group) to thereby
inhibit efficient ionization of zinc, and as a result, the possibility
of impairing the rust prevention action of zinc becomes high. That
is to say, the hydrolysis condensate that is obtained from the amino
15 group-containing alkoxysilane in order to impart water solubility
has an advantage of good water solubility, but because of use of the
amino group-containing alkoxysilane, the rust prevention effect that
is the original object is lowered, far from being improved. Hence,
it cannot be necessarily said that such composition is effective.
20 It is thought that when the binder is an inorganic oxide sol,
there is room for improvement in properties, such as drying properties,
curing properties, water resistance, anticorrosion properties and
coating film strength, as disclosed in the patent literatures 6 to
9.
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Particularly when a surface of a coating film (coating layer)
formed from such an aqueous coating composition including an alkali
metal silicate (mixture of silicon oxide and alkali metal oxide) as
disclosed in the patent literature 7 is further coated with a topcoating
5 material to form a topcoating film, various problems attributable
to the action (alkalinity) of an alkali metal remaining on the coating
layer surface occur. For example, a blister of the topcoating film
occurs, or when zinc is included in the aqueous coating composition,
white rust due to corrosion of zinc occurs. Because of such problems,
10 removal work to remove the coating film of the aqueous coating
composition from base is separately needed prior to coating with the
topcoating material. Presence of this removal work is very
disadvantageous because one step surely increases in the topcoating
process. Moreover, for customers who generally use a method in which
15 a coating material that is a high-performance coating composition
and can inhibit occurrence of white rust is preferentially adopted
and the removal work is not adopted, the above composition cannot
be said to be a composition sufficiently satisfying the customers'
requirements.
20 Also in the case where the binder is water glass or an aqueous
silica sol such as a colloidal silica water dispersing agent (e.g.,
patent literatures 8 and 9) and pH of the binder is on the alkaline
side because an excess ammonium compound or a large amount of an alkali
metal oxide is included in the binder, the same problems as above
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occur.
In order to cope with such conventional problems, the present
inventors have earnestly studied, and as a result, they have found
that the conventional problems can be solved by using, as a binder
5 in a coating composition, a hydrolysis condensate obtained by
subjecting a specific silane compound (as raw material silane), such
as acetoxysilane, ketoxime silane or chlorosilane which is rather
avoided because it generates irritant and corrosive hydrogen chloride
gas during the reaction though its reactivity is extremely high, to
10 hydrolysis reaction and condensation reaction under the specific pH
conditions. Thus, the present invention has been accomplished.
That is to say, it is an object of the present invention to
provide an aqueous coating composition capable of exerting an effect
that the composition, while using water as a diluting solvent, can
15 form a coating film having well-balanced excellent drying properties,
curing properties and coating film properties (coating film strength)
nearly equal to those of a coating film formed from a conventional
solvent-based coating composition using an organic solvent as a diluent,
and said effect being unable to be achieved by conventional aqueous
20 coating compositions.
In particular, there can be provided a binder composition and
a rust-preventive coating composition each of which can be expected
to exhibit interaction between a residual functional group of a
hydrolysis condensate and a metal oxide sol when the composition
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includes the hydrolysis condensate obtained by subjecting a specific
silane compound such as chlorosilane to hydrolysis reaction and
condensation reaction in the presence of a metal oxide sol, and each
of which is capable of forming a coating film having higher strength.
5
Solution to Problem
[0012]
The aqueous coating composition of the present invention
comprises a binder (A) and water (B), wherein the binder (A) comprises
10 a hydrolysis condensate obtained by subjecting a silane raw material
(a) including a silane compound (al) represented by the following
formula (I) to hydrolysis reaction and condensation reaction under
the conditions of pH of 0.4 to 8.0;
[0013]
15 R^^SiR^^R^^- (Ym-SiR^^R^^) p-R^^ (I)
[0014]
wherein R'"'^ to R^^ are each independently a hydrogen atom, a halogen
atom, an alkyl group of 1 to 10 carbon atoms, an alkenyl group of
2 to 5 carbon atoms, an aryl group of 6 to 12 carbon atoms, Z-R^^-
20 (Z is a halogen atom, a hydroxyl group, an epoxy group, an acryloxy
group, a methacryloxy group or a polyoxyalkylene group represented
by R^O-(R^O)c- (R^ is a hydrogen atom or an alkyl group of 1 to 10
carbon atoms, R^ is an alkylene group of 2 to 4 carbon atoms, and
c is an integer of 1 to 15), and R^^ is an alkylene group of 1 to
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10 carbon atoms), or -OR (R is a hydrogen atom, an alkyl group
of 1 to 10 carbon atoms or an alkenyl group of 1 to 10 carbon atoms),
at least one of R"^^ to R^^ is a halogen atom,
[0015]
5 Y is an oxygen atom or an alkylene group of 1 to 10 carbon atoms,
[0016]
m is 0 or 1, and p is an integer of not less than 0.
In the aqueous coating composition of the present invention,
the silane raw material (a) preferably comprises a silane compound
10 (a2) represented by the following general formula (II) in addition
to the silane compound (al);
[0017]
R^'^SiR^'^R^''- (Y'n>--SiR''V^)p'-R* (II)
[0018]
15 wherein R''''^ to R^ are each independently a hydrogen atom, an
alkyl group of 1 to 10 carbon atoms, an alkenyl group of 2 to 5 carbon
atoms, an aryl group of 6 to 12 carbon atoms, Z-R^'^- (Z is a hydroxyl
group, an epoxy group, an acryloxy group, a methacryloxy group or
a polyoxyalkylene group represented by R^'o- (R^'O) c'- (R^' is a hydrogen
20 atom or an alkyl group of 1 to 10 carbon atoms, R'^' is an alkylene
group of 2 to 4 carbon atoms, and c' is an integer of 1 to 15), and
R^"^ is an alkylene group of 1 to 10 carbon atoms), -OR®'' (R^*^ is an
alkyl group of 1 to 10 carbon atoms or an alkenyl group of 1 to 10
carbon atoms), a hydroxyl group or an acyl group.
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at least one of R to R is a hydroxyl group, a -OR group
(R^'^ is an alkyl group of 1 to 10 carbon atoms), Z-R^''- (Z is an epoxy
group, and R''^ is an alkylene group of 1 to 10 carbon atoms), or an
acyl group,
5 [0019]
Y' is an oxygen atom or an alkylene group of 1 to 10 carbon
atoms,
[0020]
m' is 0 or 1, and p' is an integer of not less than 0.
10 In the aqueous coating composition of the present invention,
the binder (A) preferably comprises a hydrolysis condensate and a
metal oxide represented by the following chemical fonnula (III),
wherein the hydrolysis condensate is obtained by sub j ecting the silane
raw material (a) to hydrolysis reaction and condensation reaction
15 in the presence of a metal oxide sol (C) comprising the metal oxide;
[0021]
MpOr (III)
wherein M is Si, Al or Ti, and p and r are each independently an integer
of 1 to 3.
20 In the aqueous coating composition of the present invention,
at least one of R'^^ to R^^ in the formula (I) is preferably a chlorine
atom from the viewpoints that it is excellent in hydrolysis reactivity
and dehydrocondensation reactivity and an aqueous coating composition
having desired effects is finally obtained.
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[0022]
In the aqueous coating composition of the present invention,
at least one of R^'" to R^*" in the general formula (II) is preferably
a glycidoxy group from the viewpoints of vyater solubility and storage
5 stability.
[0023]
In the aqueous coating composition of the present invention,
Y in the formula (I) is preferably an alkylene group of 1 to 10 carbon
atoms.
10 [0024]
In the aqueous coating composition of the present invention,
the metal oxide sol (C) is preferably a silicic anhydride sol.
[0025]
In the aqueous coating composition of the present invention,
15 the silicic anhydride sol is preferably a fumed silica sol.
[0026]
In the aqueous coating composition of the present invention,
it is preferable that the metal oxide sol (C) is a colloidal silica
water dispersing agent, and the colloidal silica water dispersing
20 agent has pH of not more than 7 and a Na20 content of not more than
400 ppm.
[0027]
In the aqueous coating composition of the present invention,
the metal oxide sol (C) is preferably a sol comprising fumed alumina
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or fumed titania.
[0028]
It is preferable that the aqueous coating composition o£ the
present invention further comprises a pigment and a ratio
5 ((PVC) / (CPVC)) of a pigment volume concentration (PVC) to a critical
pigment volume concentration (CPVC) in the aqueous coating composition
is preferably higher than 1.
[0029]
The aqueous coating composition of the present invention
10 preferably further comprises a rust-preventive pigment (D).
[0030]
In the aqueous coating composition of the present invention,
the rust-preventive pigment (D) preferably includes zinc powder and/or
zinc alloy powder having a mean particle diameter of 2 to 20 yiia.
15 [0031]
The aqueous coating composition of the present invention
preferably further comprises metallic molybdenum and/or a molybdenum
compound as a white rust inhibiter (E).
[0032]
20 The aqueous coating composition of the present invention is
preferably used as a binder composition,
[0033]
The aqueous coating composition of the present invention is
preferably used as a rust-preventive coating composition.
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[0034]
The aqueous coating composition of the present invention is
preferably a coating composition for primary rust prevention.
[0035]
5 The aqueous coating composition of the present invention is
preferably a thick-coating type inorganic zinc coating composition.
[0036]
The primary rust prevention coating method for a steel material
of the present invention comprises applying the coating composition
10 for primary rust prevention to a surface of a steel material and then
curing the applied coating composition to form a primary
rust-preventive coating film.
[0037]
The rust prevention coating method for a steel material of the
15 present invention comprises applying the thick-coating type inorganic
zinc coating composition to a surface of a steel material and then
curing the applied coating composition to form a thick-coating type
inorganic zinc rust-preventive coating film.
[0038]
20 The steel structure of the present invention has, on a surface
of a steel material, a primary rust-preventive coating film formed
from the coating composition for primary rust prevention.
[0039]
The steel structure of the present invention has, on a surface
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of a steel material, a thick-coating type inorganic zinc
rust-preventive coating film formed from the thick-coating type
inorganic zinc coating composition.
5 Advantageous Effects of Invention
[0040]
The aqueous coating composition of the present invention can
exhibit an effect that the composition, while using water as a diluting
solvent, can form a coating film having well-balanced excellent drying
10 properties, curing properties and coating film properties (coating
film strength) nearly equal to those of a coating film formed from
a conventional solvent-based coating composition using an organic
solvent as a diluent, and said effect being unable to be achieved
by conventional aqueous coating compositions.
15 [0041]
When the aqueous coating composition of the present invention
is used as a rust-preventive coating composition, the rust-preventive
coating composition can exhibit an effect that the composition, while
using water as a diluting solvent, provides a rust-preventive coating
20 film which has both of excellent weldability and excellent cutting
properties nearly equal to those of a coating film formed from a
conventional solvent-based rust-preventive coating composition,
while maintaining rust prevention properties inherent in a
rust-preventive pigment such as zinc, and said effect being unable
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to be achieved by coating films formed from conventional aqueous
coating compositions.
[0042]
The rust prevention method of the present invention can form,
5 on a surface of a base such as a steel material, a rust-preventive
coating film which has both of excellent weldability and excellent
cutting properties nearly equal to those of a rust-preventive coating
film formed from a solvent-based rust-preventive coating composition,
while maintaining rust prevention properties inherent in a
10 rust-preventive pigment such as zinc.
Brief Description of Drawings
[0043]
Fig. 1 is a view showing an IR chart (after dehydration) of
15 a binder composition of Example 1,
Fig. 2 is a view showing a GPC chart (after dehydration) of
a binder composition of Example 1.
Fig. 3 is a view showing a Si^^NMR chart of a binder composition
of Example 1.
20 Fig. 4 is a view showing an IR chart (after dehydration) of
a binder composition of Example 2.
Fig. 5 is a view showing a GPC chart (after dehydration) of
a binder composition of Example 2.
Fig. 6 is a view showing an IR chart (after dehydration) of
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a binder composition of Example 3.
Fig. 7 is a view showing a GPC chart (after dehydration) of
a binder composition of Example 3.
Fig. 8 (a) is a group of views showing sandblasted plates (upper
5 plate and lower plate) (steel plates for welding test and coated
portions) used in a weldability test of a topcoating film formed from
a primary rust-preventive coating composition of an example or a
comparative example, and Fig. 8(b) is a group of views showing an
embodiment of welding (outline of welding method) carried out in a
10 weldability test of a topcoating film.
Description of Embodiments
[0044]
The agueous coating composition of the present invention
15 comprises a binder (A) and water (B), wherein the binder (A) comprises
a hydrolysis condensate obtained by subjecting a silane raw material
(a) comprising the below-described specific silane compound (al) to
hydrolysis reaction and condensation reaction under the conditions
of pH of 0.4 to 8.0.
20 [0045]
Binder (A)
The binder (A) comprises a hydrolysis condensate obtained by
subjecting a silane raw material (a) comprising a silane compound
(al) represented by the following general formula (I) to hydrolysis
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reaction and condensation reaction under the conditions of pH of 0.4
to 8.0. Here, the binder (A) may comprise, in addition to the
hydrolysis condensate, arbitrary components except water, when needed,
or may be a binder composed of the hydrolysis condensate only.
5 [0046]
The silane raw material (a) may comprise, in addition to the
silane compound (al), such silane compounds other than the silane
compound (al) as described later (silane compound (a2), silane compound
(a3), etc.), when needed.
10 [0047]
R^^SiR^^R^^- (yn,-SiR^^R^^)p-R^^ (I)
[0048]
In the formula (I), R'^^ to R^^ are each independently a hydrogen
atom, a halogen atom, an alkyl group of 1 to 10 carbon atoms, an alkenyl
15 group of 2 to 5 carbon atoms, an aryl group of 6 to 12 carbon atoms,
Z-R^^- (Z is a halogen atom, a hydroxyl group, an epoxy group (e.g.,
glycidoxy group, 3, 4-epoxycyclohexyl group or the like), an acryloxy
group, a methacryloxy group or a polyoxyalkylene group represented
by R^O-(R''0)C- (R^ is a hydrogen atom or an alkyl group of 1 to 10
20 carbon atoms, R'^ is an alkylene group of 2 to 4 carbon atoms, and
c is an integer of 1 to 15) , and R^^ is an alkylene group of 1 to
10 carbon atoms), or -OR^^ (R^^ is a hydrogen atom, an alkyl group
of 1 to 10 carbon atoms or an alkenyl group of 1 to 10 carbon atoms),
and
SF-2426
26
at least one of R'^^ to R^^ is a halogen atom.
[0049]
Y is an oxygen atom or an alkylene group of 1 to 10 carbon atoms.
[0050]
5 m is 0 or 1, and p is an integer of not less than 0.
[0051]
The silane raw material (a) may be one composed of a silane
compound (al) only (that is, in 100 parts by weight of the silane
raw material (a), the silane compound (al) maybe included in an amount
10 of 100 parts by weight) , as described above. However, in order that
(1) rapid progress of hydrolysis condensation reaction caused by
excessively high reactivity between the silane compound (al) and water
and formation of water-insoluble products such as a gel-like substance
may be prevented, or in order that (2) appropriate reactivity may
15 be obtained and introduction of an appropriate functional group may
be achieved, or from the viewpoint that (3) a compound having
appropriate molecular weight and structure can be obtained and an
aqueous coating composition capable of forming a coating film that
can finally exhibit desired effects (e.g., improvement in adhesion
20 to base and coating film strength) is obtained, the silane raw material
preferably comprises the later-described silane compound (a2) in
addition to the silane compound (al).
[0052]
From the viewpoints of improvement in dispersibility of the
SF-2426
27
binder (A) and a pigment in each other, reinforcement of a coating
film formed from the coating composition and cost reduction by
decreasing the amount of a relatively expensive silane compound used,
the binder (A) preferably comprises a hydrolysis condensate and the
5 metal oxide, wherein the hydrolysis condensate obtained by subjecting
the silane raw material (a) to hydrolysis reaction and condensation
reaction in the presence of the later-described metal oxide sol (C).
[0053]
When the silane raw material (a) includes the silane compound
10 (al) only, the resulting hydrolysis condensate is a single hydrolysis
condensate having constituent units derived from the silane compound
(al) . When the silane raw material (a) includes the silane compound
(a2), etc., in addition to the silane compound (al), the resulting
hydrolysis condensate is a co-hydrolysis condensate having
15 constituent units derived from the silane compounds (al) and (a2),
etc. When the hydrolysis condensate is prepared by subjecting the
silane raw material (a) to hydrolysis/condensation reaction in the
presence of the later-described metal oxide sol (C), the binder (A)
is a composite substance comprising the resulting hydrolysis
20 condensate and a metal oxide that is included in the metal oxide sol
(C).
[0054]
The preparation product comprising the hydrolysis condensate
prepared is usually a transparent aqueous solution (in the case where
SF-2426
28
the hydrolysis condensate is water-soluble) or a white opaque water
dispersion (in the case where the hydrolysis condensate is slightly
water-soluble and water-dispersible).
[0055]
5 In the hydrolysis reaction and the condensation reaction of
the silane raw material (a), pH of the system is 0.4 to 8.0, and from
the viewpoint that drying properties and curability of the coating
film and coating film properties (coating film strength) of the dry
coating film are further improved, pH is preferably 0.7 to 6.0, more
10 preferably 0.9 to 5.0. Here, these pH conditions indicate that the
silane raw material (a) undergoes hydrolysis/condensation reaction
at pH of the above specific range constantly through the reaction,
and mean that the pH does not deviate from the above range from the
beginning to the end of the reaction.
15 [0056]
In the case where the binder (A) comprises a metal oxide and
a hydrolysis condensate obtained by subjecting the silane raw material
(a) to hydrolysis reaction and condensation reaction in the presence
of the later-described metal oxide sol (C), and in the case where
20 the pH in the hydrolysis reaction and the condensation reaction of
the silane raw material (a) deviates from the above range and is lower
than the lower limit, aggregation of colloidal particles of the metal
oxide tends to take place. Also in the case where the pH deviates
from the above range and is higher than the upper limit, aggregation
SF-2426
29
of colloidal particles of the metal oxide tends to take place. If
the pH in the hydrolysis reaction and the condensation reaction of
the silane raw material (a) deviates from the above range, aggregation
of colloidal particles of the metal oxide tends to take place, as
5 described above, and this phenomenon is attributed to lowering of
stability (i.e., storage stability) of colloidal particles of the
metal oxide, and as a result, stability (i.e., storage stability)
of the binder is sometimes deteriorated.
[0057]
10 The present invention is described below by taking, as an example,
a process in which the silane raw material (a) comprising methyl
trichlorosilane as the silane compound (al) and comprising
y-glycidoxypropyltrimethoxysilane as the later-described silane
compound (a2) is subjected to hydrolysis reaction and condensation
15 reaction to form a binder (A) that is a hydrolysis condensate. The
reactions indicated by the following chemical reaction formulas (i)
to (iii) correspond to reactions in the later-described Example 2.
[0058]
As indicated by the following chemical reaction formulas (i)
20 and (ii), methyltrichlorosilane and
y-glycidoxypropyltrimethoxysilane are each hydrolyzed to form a
silanol group (Si-OH group). It is thought that these hydrolysis
reactions do not proceed at once but proceed stepwise generally.
[0059]
SF-2426
30
CI + H2O OH
C I — S i - C H g - ^ - ^ HO-Si-CHs+3HCI (i)
CI OH
9*^2 CH2
? o
(
")) is usually 140 to 500,000, preferably 200 to 100,000,
more preferably 300 to 30,000. When the molecular weight is in such
20 a range, the hydrolysis condensate can exhibit, as a binder,
satisfactory level of drying properties and curability of a coating
film while maintaining solubility in water.
[0072]
When the reaction product comprising the hydrolysis condensate
SF-2426
36
comprises a metal oxide derived from the metal oxide sol (C), the
mean particle diameter of a composite substance comprising the metal
oxide and the hydrolysis condensate (measurement by dynamic light
scattering method (specifically, see'M4) Measurement of mean particle
5 diameter" of the later-described "")) is usually 1 to 500 nm, preferably 4 to 300 nm, more
preferably 5 to 200 nm. When the mean particle diameter is in such
a range, the composite substance stably exists as colloidal particles,
and there is no fear of gelation of the hydrolysis condensate and
10 sedimentation of the components, so that the composite substance
exhibits good dispersibility as a binder. Moreover, drying
properties and curability of a coating film formed from the coating
composition are good. The composite substances comprise not only
a substance (mixture) in which the metal oxide and the hydrolysis
15 condensate are simply mixed but also a substance in which the metal
oxide andthe hydrolysis condensate are chemically bondedor physically
bonded.
[0073]
(Silane compound (al), silane compound (a2) and metal oxide sol (C) )
20 The silane compounds (al) to (a4) and the metal oxide sol (C)
are described below.
[0074]
(Silane compound (al))
The silane compound (al) included in the silane raw material
SF-2426
37
(a) is representeci t»y the following general formula (I) (structural
formula: the following structural formula (I'))-
[0075]
RlasjR2apj3a.^Y^.5Jp,4ap5aj^.R6a (|)
R"-si4-Y„-si-4-R=" (r)
5 [0076]
In the general formula (I) and the structural formula {I'),
R-^^ to R^^ are each independently a hydrogen atom, a halogen atom,
an alkyl group of 1 to 10 carbon atoms, an alkenyl group of 2 to 5
carbon atoms, an aryl group of 6 to 12 carbon atoms, Z-R''^- (Z is
10 a halogen atom, a hydroxyl group, an epoxy group (e.g., glycidoxy
group, 3,4-epoxycyclohexyl group or the like), an acryloxy group,
a methacryloxy group or a polyoxyalkylene group represented by
R^O-(R''0)C- (R^ is a hydrogen atom or an alkyl group of 1 to 10 carbon
atoms, R^ is an alkylene group of 2 to 4 carbon atoms, and c is an
15 integer of 1 to 15) , and R^^ is an alkylene group of 1 to 10 carbon
atoms) , or -OR®^ (R®^ is a hydrogen atom, an alkyl group of 1 to 10
carbon atoms or an alkenyl group of 1 to 10 carbon atoms), and
at least one of R-^^ to R^^ is a halogen atom.
[0077]
20 Y is an oxygen atom or an alkylene group of 1 to 10 carbon atoms,
SF-2426
38
[0078]
m is 0 or 1, and p is an integer of not less than 0.
At least one of functional groups (R-^^ to R^^ in the general
formula (I) and the structural formula (I')) directly bonded to Si
5 atoms is a halogen atom that is a hydrolyzable group, so that the
silane compound (al) has good reactivity and is easily available.
[0079]
Y is an oxygen atom or an alkylene group of 1 to 10 carbon atoms,
and from the viewpoints of easy availability and good reactivity,
10 Y is preferably an alkylene group of 1 to 10 carbon atoms, more preferably
an alkylene group of 2 to 5 carbon atoms.
[0080]
From the viewpoints of excellent hydrolysis reactivity and
dehydrocondensation reactivity, it is preferable that in the silane
15 compound (al), the functional groups (R""-^ to R^^ in the general foimula
(I) and the structural formula (I') ) directly bonded to Si atoms are
each independently a halogen atom (preferably chlorine atom), an alkyl
group of 1 to 10 carbon atoms or -OR®^ (R®^ is an alkyl group of 1
to 10 carbon atoms), at least 3 of the functional groups (R'^^ to R^^
20 in the general formula (I) and the structural fo3:mula (I') ) directly
bonded to Si atoms are each a halogen atom (preferably chlorine atom),
andp is an integer of 0 to 4 (preferably 0 or 1, particularly preferably
p=0) . When p is an integer of 1 or 2, it is preferable that m is
1 and Y is an alkylene group of 1 to 10 carbon atoms (preferably an
SF-2426
39
alkylene group of 2 to 5 carbon atoms).
[0081]
Examples of the silane compounds (al) represented by the
following general formula (I) (structural formula: the following
5 Structural formula (I')) are given below.
[0082]
Examples of Chlorosilanes include tetrachlorosilane,
trichlorosilane, methyltrichlorosilane, ethyltrichlorosilane,
vinyltrichlorosilane, n-propyltrichlorosilane,
10 i-propyltrichlorosilane, n-butyltrichlorosilane,
sec-butyltrichlorosilane, t-butyltrichlorosilane,
n-pentyltrichlorosilane, n-hexyltrichlorosilane,
n-octyltrichlorosilane, methyldichlorosilane,
dimethyldichlorosilane, methylethyldichlorosilane,
15 methylvinyldichlorosilane, dimethylchlorosilane,
diethylchlorosilane, trimethylchlorosilane,
vinyldimethylchlorosilane, vinyldiethylchlorosilane,
allyltrichlorosilane, methylallyldichlorosilane,
Y-acryloxypropyltrichlorosilane and
20 y-methacryloxypropyltrichlorosilane.
[0083]
The silane compounds (al) may be silane compounds wherein a
chlorine atom in the above chlorosilanes is replaced with fluorine,
bromine or iodine, that is, fluorosilanes, bromosilanesor iodosilanes.
SF-2426
40
such as trimethylfluorosilane, trimethylbromosilane or
trimethyliodosilane. The silane compounds wherein a chlorine atom
in the above chlorosilanes is replaced with a fluorine atom, a bromine
atom or an iodine atom are on the market.
5 [0084]
A silane compound (al) having an alkoxy group aS a functional
group directly bonded to a Si atom together with the halogen atom
is also useful, and examples of such silane compounds (al) include
methyldichloromethoxysilane, methylchlorodiethoxysilane,
10 methyldimethoxychlorosilane, methyldi-i-propoxychlorosilane,
ethyl-n-butoxydibromosilane, dimethoxychlorosilane,
Y-chloropropyltrimethoxysilane, ychloropropyltriethoxysilane,
y-chloropropyltripropoxysilane,
y-chloropropylmethyldimethoxysilane,
15 y-chloropropylmethyldiethoxysilane,
y-chloropropyldimethylethoxysilane,
y-chloropropylethyldimethoxysilane and
y-chloropropylethyldiethoxysilane.
[0085]
20 As the silane compounds (al), polysilanes such as disilanes
(in the general formula (I) and the structural formula (I'), m is
0 and p is an integer of not less than 1) are also useful. Examples
of such polysilanes include alkylene group-containing disilyl
compounds, e.g., disilanes, such as trimethyltrichlorodisilane.
SF-2426
41
dimethyltetrachlorodisilane, trimethyltrimethoxydisilane and
dimethyltetramethoxydisilane.
Further, disilylethanes and disilylpropanes, which ai^^
produced by the addition reaction of disilane compounds with silane
5 compounds such as vinylchlorosilane, allylchlorosllane and hydrogen
atom-containing chlorosilane using platinum or a platinum compound
as a catalyst, as indicated by the following formulas, are also useful
compounds as the silane compounds (al). In the following chemical
formulas, description of functional groups directly bonded to Si atoms
10 other than -CH=CH2, -CH2-CH=CH2, -CH2-CH2- and -CH2-CH2-CH2- is omitted.
[0086]
sSi-CH=CH2+H-Si= - =Si-CH2-CH2-Si=
(Platinum catalyst)
HSi-CH2-CH=CH2+H-Si= -* =Si-CH2-CH2-CH2-Si=
15 (Platinum catalyst)
[0087]
Examples of the disilane compounds as the silane compounds (al)
include disilylalkyls (e.g., disilylethanes, disilylpropanes and
disilylbutanes).
20 [0088]
Examples of the disilylethanes include compounds, such as
Cl3SiCH2CH2SiCl3, (CH30)2ClSiCH2CH2SiCl3, (CH3O) 3SiCH2CH2SiCl3,
CI (CH3O) 2SiCH2CH2Si (CH3O) CI2, CI (C2H5O) 2SiCH2CH2Si (C2H5O) CI2,
(CH3O) 3SiCH2CH2Si (C2H5O) 3, CI2 (CH3) SiCH2CH2SiCl3,
SF-2426
42
(CH3O) zClSiCHzCHsSi (CH3) CI2, (CH3O) 2 (CH3) SiCH2CH2Si (CH3) CI2,
Cl2(C6H5)SiCH2CH2SiCl3, (CH30)2(C6H5) SiCH2CH2Si (CH30)Cl2 and
CI2 (CgHs) SiCH2CH2Si (C2H5O) 3.
[0089]
5 Examples of t h e d i s i l y l p r o p a n e s i n c l u d e compounds, such as
(CgHs) (CH3) ClSiCH2CH2CH2Si (CH3) CI2, (C2H5O) 2 (CH3) SiCH2CH2CH2Si {CH3) CI2,
(C2H5O) 3SiCH2CH2CH2Si (CH3) CI2, (CH3O) 3SiCH2CH2CH2Si (C2H5O) 3,
(C2H50)3SiCH2CH2CH2Si(C2H50)Cl2, (C2H50)3SiCH2CH2CH2SiCl3,
Cl3SiCH2CH2CH2SiCl3, (CH3O) 3SiCH2CH2CH2SiCl3,
10 CI (CH3O) 2SiCH2CH2CH2Si (CH3O) CI2, CI (C2H5O) 2SiCH2CH2CH2Si (C2H5O) CI2,
(CH3O) 3SiCH2CH2CH2Si (C2H5O) 3, CI2 (CH3) SiCH2CH2CH2SiCl3,
(CH3O) 2ClSiCH2CH2CH2Si (CH3) CI2, (CH3O) 2 (CH3) SiCH2CH2CH2Si (CH3) CI2,
CI2 (CeHs) SiCH2CH2CH2SiCl3, (CH3O) 2 (CeHs) SiCH2CH2CH2Si (CH3O) CI2 and
CI2 (CeHs) SiCHzCHzCHzSi (C2H5O) 3.
15 [0090]
Examples of t h e d i s i l y l b u t a n e s i n c l u d e compounds, such as
(CH3O) 2ClSiCH2CH2CH2CH2SiCl3, {C2H5O) 3SiCH2CH2CH2CH2SiCl3,
CI (CH3O) 2SiCH2CH2CH2CH2Si (CH3O) CI2, (C2H5O) 3SiCH2CH2CH2CH2Si (C2H5O) CI2,
(CH3O) 3SiCH2CH2CH2CH2Si (C2H5O) 3/ (C2H5O) 3SiCH2CH2CH2CH2Si (CH3) CI2,
20 (C2H50)2(CH3)SiCH2CH2CH2CH2Si(CH3)Cl2 and
(CgHs) (CH3) ClSiCH2CH2CH2CH2Si (CH3) CI2.
[0091]
By t h e p r e p a r a t i o n u s i n g a s i l a n e compound h a v i n g a l o n g er
a l k y l e n e group t h a n t h a t of t h e a f o r e s a i d u n s a t u r a t e d g r o u p - c o n t a i n i ng
SF-2426
43
silane, a disilyl compound including an alkylene group of a longer
chain is obtained.
[0092]
Examples of the silane compounds (al) have been enumerated above,
5 and of these, chlorosilanes (that is, at least ong of R^^ to R^^ in
the general formula (I) and the structural formula (I') is a chlorine
atom) are preferable when it is taken into consideration that drying
properties and curing properties of a coating film of the resulting
coating composition and coating film strength and rust prevention
10 properties of a dry coating film formed from the composition are good,
that they are easily available and that handling thereof is also
relatively easy. Of the chlorosilanes, more preferable are
tetrachlorosilane and methyltrichlorosilane.
[0093]
15 (Silane compound (a2))
The silane raw material (a) may comprise a silane compound (a2)
representedby the following general fojnnula (II) (structural formula:
the following structural formula (II')) in addition to the silane
compound (al),
20 [0094]
SF-2426
44
plb5Jp2bp3b_(Y'^.-SiR4^R^^)p.-R^^ (II)
[0095]
In the above formulas (the general formula (II) and the
structural formula (II') ), R^'' to R^ are each independently a hydrogen
5 atom, an alkyl group of 1 to 10 carbon atoms, an alkenyl group of
2 to 5 carbon atoms, an aryl group of 6 to 12 carbon atoms, Z-R^''-
(Z is a hydroxyl group, an epoxy group (e.g., glycidoxy group,
3,4-epoxycyclohexyl group or the like), an acryloxy group, a
methacryloxy group or a polyoxyalkylene group represented by
10 R^'o- (R^'O) c'- (R^' is a hydrogen atom or an alkyl group of 1 to 10 carbon
atoms, R^' is an alkylene group of 2 to 4 carbon atoms, and c' is
an integer of 1 to 15), and R^*^ is an alkylene group of 1 to 10 carbon
atoms), -OR^'^ (R^'' is an alkyl group of 1 to 10 carbon atoms or an
alkenyl group of 1 to 10 carbon atoms), a hydroxyl group or an acyl
15 group,
at least one of R"'''' to R^^ is a hydroxyl group, a -OR^"^ group
{R^^ is a alkyl group of 1 to 10 carbon atoms) , Z-R'''^- (Z is an epoxy
group, and R^'^ is an alkylene group of 1 to 10 carbon atoms), or an
acyl group.
20 [0096]
SF-2426
45
Y' is an oxygen atom or an alkylene group of 1 to 10 carbon
atoms.
[0097]
m' isOorl, andp' is an integer of not less than 0 (for example,
5 m' is 1, and p' is an integer of 0 to 10 (preferably 0 to 5)).
[0098]
As examples of such silane compounds (a2), various silane
compounds are enumerated below, and of these, silane compounds (a2)
having an epoxy group (in the general formula (II) and the structural
10 formula (II') , at least one of R^'^ to R* is Z-R^"^- (Z is an epoxy group,
and R^'^ is an alkylene group of 1 to 10 carbon atoms) ) are preferable
as the silane compounds (a2) because they have good water solubility
and storage stability. The epoxy group is more preferably a glycidoxy
group (that is, silane compounds (a2) having a glycidoxy group is
15 more preferable).
[0099]
When coating film strength of a dry coating film formed from
a coating composition comprising the resulting binder (A) and drying
properties (curing properties) of a coating film formed from the
20 coating composition are taken into consideration,
y-glycidoxypropyltrimethoxysilane is more preferable.
[0100]
Examples of the silane compounds (a2) having a hydroxyl group
(-0H) include trimethylsilanol, triethylsilanol,
SF-2426
46
triisopropylsilanol and tri-n-butylsilanol.
[0101]
Examples of the silane compounds (a2) having an alkoxy group
(-OR, R: alkyl group of about 1 to 5 carbon atoms) include
5 trimethoxysilane, triethoxysilane, tri-n-propoxysilane,
tri-i-propoxysilane, n-butoxysilane, methyltrimethoxysilane,
methyltriethoxysilane, methyltriisopropoxysilane,
methyltributoxysilane, ethyltrimethoxysilane,
ethyltriethoxysilane, ethyltriisopropoxysilane,
10 vinyltrimethoxysilane, vinyltriethoxysilane,
vinyltriisopropoxysilane, dimethyldimethoxysilane,
dimethyldiethoxysilane, dimethyldiisopropoxysilane,
dimethylmethoxyethoxysilane, dimethylmethoxyisopropoxysilane,
methylethyldimethoxysilane, methylethyldiethoxysilane,
15 trimethylmethoxysilane, triethyltriethoxysilane,
triisopropylmethoxysilane, vinyldimethylmethoxysilane,
allyltrimethoxysilane and allylmethyldiethoxysilane.
[0102]
Examples of the silane compounds {a2) having an epoxy group
20 (e.g., glycidoxy group, 3, 4-epoxycyclohexylgrouporthelike) include
Y-glycidoxypropyltrimethoxysilane,
y-glycidoxypropyltriethoxysilane,
y-glycidoxypropyltri-i-propoxysilane,
y-glycidoxypropylmethyldimethoxysilane.
SF-2426
47
Y-glycidoxypropylmethyldiethoxysilane,
Y-giycidoxypropyldimethylethoxysilane,
Y-glycidoxypropylethyldimethoxysilane,
y-glycidoxypropylethyldiethoxysilane,
5 p-(3,4-epoxyGyclohexyl)ethyltrimethoxysilane,
P-(3,4-epoxycyclohexyl)ethyltriethoxysilane,
(i- (3,4-epoxycyclohexyl) ethyltri-i-propoxysilane,
(3- (3, 4-epoxycyclohexyl) ethylmethyldimethoxysilane,
(3- (3, 4-epoxycyclohexyl) ethylmethyldiethoxysilane and
10 (3- (3, 4-epoxycyclohexyl) ethylmethyldi-i-propoxysilane.
[0103]
Examples of the silane compounds (a2) having an acyl group
include methyltriacetoxysilane, ethyltriacetoxysilane,
vinyltriacetoxysilane, dimethyldiacetoxysilane,
15 triethylmethoxysilane and tetraacetoxysilane.
[0104]
The silane compound (a2) may be not such a monomer type compound
(in the general formula (II) and the structural formula (II'), p'=0)
as above but an oligomer or polymer type compound (in the general
20 formula (II) and the structural formula (II'), p'^0).
[0105]
Examples of the silane compounds (a2) of oligomer type include
tetramethoxydisiloxane, tetraethoxydisiloxane,
dimethyltetramethoxydisiloxane, methylethyltetramethoxydisiloxane.
SF-242'6
48
trimethylpentamethoxytrisiloxane and
tetramethyltetramethoxycyclotetrasiloxane,
[0106]
Examples of the silane compounds (a2) of polymer type include
5 hydrolysis condensates (alkyl silicates) of orthoethoxysilane,
Orthoniethoxysilane, orthoisopropoxysilane, methyltrimethoxysilane,
methyltriethoxysilane, etc.
[0107]
Examples of commercial products of the above silane compounds
10 include Ethyl Silicate 40, Ethyl Silicate 45, Methyl Silicate 51 and
Methyl Silicate 56 (all manufactured by Tama Chemicals, Ltd.). Of
these, a hydrolysis condensate of methyltrimethoxysilane or
methyltriethoxysilane is preferable from the viewpoints of ease of
obtaining, reactivity, etc.
15 [0108]
The content of the silane compound (a2) based on 100 parts by
weight of the silane compound (al) is preferably 10 to 5000 parts
by weight, more preferably 30 to 3000 parts by weight, still more
preferably 50 to 2000 parts by weight. If the content of the silane
20 compound (a2) is less than the lower limit of the above range, the
number of the polymerization reaction sites (OH groups formed by
hydrolysis) derived from the silane compound (a2) to the number of
the polymerization reaction sites (OH groups formed by hydrolysis)
derived from the silane compound (al) is too small. Therefore, the
SF-2426
49
proportion of constituent units derived from the silane compound (a2)
to the constituent units in the resulting hydrolysis condensate is
lowered, and it sometimes becomes difficult to obtain appropriate
molecular weight and structure. I£ the content exceeds the upper
5 limit of the above range, the number of the polymerization reaction
sites (OH groups formed by hydrolysis) derived from the silane compound
(al) to the number of the polymerization reaction sites (OH groups
formed by hydrolysis) derived from the silane compound (a2) is too
small. Therefore, the proportion of constituent units derived from
10 the silane compound (al) to the constituent units in the resulting
hydrolysis condensate is lowered, and appropriate molecular designing
becomes impossible.
[0109]
In the silane compounds (a2) , the amount of the tetrafunctional
15 silane compound based on 100 parts by weight of the trifunctional
silane compound is preferably 0.1 to 200 parts by weight, more
preferably 1 to 100 parts by weight, still more preferably 5 to 80
parts by weight. If the content of the tetraf unctinal silane compound
is less than the lower limit of the above range, the number of the
20 polymerization reaction sites (OHgroups formedbyhydrolysis) derived
from the tetrafunctional silane compound to the number of the
polymerization reaction sites (OH groups formedby hydrolysis) derived
from the trifunctional silane compound is too small, and therefore,
it is difficult to obtain appropriate molecular weight and structure.
SF-2426
50
If the content is more than the upper limit of the above range, the
molecular weight becomes too high, and as a result, solubility is
deteriorated to cause sedimentation or gelation.
[0110]
5 The trifunctional silane compound and the tetrafunctional
silane compound indicate a silane compound having, as R'^'^ to R^'' in
the general formula (II) and the structural formula (II'), afunctional
groups selected from the group consisting of a hydroxyl group, a -OR^'^
group (R®^ is an alkyl group of 1 to 10 carbon atoms) and an acyl
10 group, and a silane compound having 4 functional groups selected from
them, respectively.
[0111]
By appropriately designing molecular structure (number of
crosslinkages, molecular weight distribution, type of end group,
15 presence or absence of end group having hydrolysis reactivity and
condensation reactivity, molecular weight) of a hydrolysis condensate
prepared, water solubility and storage stability of the hydrolysis
condensate can be improved, or curability of a coating film formed
from the coating composition can be controlled.
20 [0112]
In the present invention, the silane raw material (a) comprises
the silane compound (al), preferably the silane compound (al) and
the silane compound (a2), but if necessary, it may comprise a silane
compound which is different from the silane compound (al) and the
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silane compound (a2) and is hydrolyzable and condensable (silane
compound which undergoes hydrolysis reaction and condensation
reactiontogetherwiththe silane compound (al) andbecomes constituent
units of a hydrolysis condensate (silane compound (a3)). As the silane
5 compound (a3), a silane coinpound Wherein at least one Icetoxime group
(e.g., the following functional group) is bonded to a Si atom
(oxime-based silane compound) can be mentioned, and the oxime-based
silane compound is, for example,
methyltris(methylethylketoxime)silane.
CLAIMS
1. Aqueous coating composition comprising a binder (A) and water
(B);
the said binder (A) comprising a hydrolysis condensate obtained
5 by subjecting a silane raw material (a) comprising a silane compound
(al) represented by the following general formula (I) to hydrolysis
reaction and condensation reaction under the conditions of pH of 0.4
to 8.0;
R^^SiR^^R^^- (Ym-SiR''^R^^)p-R^^ (I)
10 wherein R'"'^ to R^^ are each independently a hydrogen atom, a
halogen atom, an alkyl group of 1 to 10 carbon atoms, an alkenyl group
of 2 to 5 carbon atoms, an aryl group of 6 to 12 carbon atoms, Z-R^^-
(Z is a halogen atom, a hydroxyl group, an epoxy group, an acryloxy
group, a methacryloxy group or a polyoxyalkylene group represented
15 by R^O-(R'^0)C- (R^ is a hydrogen atom or an alkyl group of 1 to 10
carbon atoms, R"^ is an alkylene group of 2 to 4 carbon atoms, and
c is an integer of 1 to 15), and R^^ is an alkylene group of 1 to
10 carbon atoms) , or -OR®^ (R®^ is a hydrogen atom, an alkyl group
of 1 to 10 carbon atoms or an alkenyl group of 1 to 10 carbon atoms) ,
20 at least one of R'^^ to R^^ is a halogen atom,
Y is an oxygen atom or an alkylene group of 1 to 10 carbon atoms,
m is 0 or 1, and
p is an integer of not less than 0.
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148
2. The aqueous coating composition as claimed in claim 1, wherein
the said silane raw material (a) comprises a silane compound (a2)
represented by the following general formula (II) in addition to the
silane compound (al);
5 R^^SiR^^R^^- (Y^--SiR^^R^^)p-R^ (11)
wherein R''''' to R^^ are each independently a hydrogen atom, an
alkyl group of 1 to 10 carbon atoms, an alkenyl group of 2 to 5 carbon
atoms, an aryl group of 6 to 12 carbon atoms, Z-R^'^- (Z is a hydroxyl
group, an epoxy group, an acryloxy group, a methacryloxy group or
10 a polyoxyalkylene group represented by R^'O-(R'''0)C'- (R^' is a hydrogen
atom or an alkyl group of 1 to 10 carbon atoms, R'^' is an alkylene
group of 2 to 4 carbon atoms, and c' is an integer of 1 to 15), and
R^"^ is an alkylene group of 1 to 10 carbon atoms), -GR^"^ (R^'' is an
alkyl group of 1 to 10 carbon atoms or an alkenyl group of 1 to 10
15 carbon atoms), a hydroxyl group or an acyl group,
at least one of R''"'^ to R^*^ is a hydroxyl group, a -OR^'^ group
(R^'' is a alkyl group of 1 to 10 carbon atoms), Z-R^"^- (Z is an epoxy
group, and R^^ is an alkylene group of 1 to 10 carbon atoms) , or an
acyl group,
20 Y' is an oxygen atom or an alkylene group of 1 to 10 carbon
atoms,
m' is 0 or 1, and
p' is an integer of not less than 0.
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3. The aqueous coating composition as claimed in claim 1 or 2,
wherein the said binder (A) comprises a hydrolysis condensate and
a metal oxide represented by the following chemical formula (III),
the said hydrolysis condensate obtained by subjecting the silane raw
5 material (a) to hydrolysis reaction and condensation reaction in the
presence of a metal oxide sol (C) comprising the metal oxide;
MpOr (III)
wherein M is Si, Al or Ti, and p and r are each independently
an integer of 1 to 3.
10
4. The aqueous coating composition as claimed in any one of claims
1 to 3, wherein at least one of R-^^ to R^^ in the formula (I) is a
chlorine atom.
15 5. The aqueous coating composition as claimed in claim 2 or 3,
wherein at least one of R'"'^ to R^'^ in the general foimula (11) is a
glycidoxy group.
6. The aqueous coating composition as claimed in any one of claims
20 1 to 5, wherein Y in the formula (I) is an alkylene group of 1 to
10 carbon atoms.
7. The aqueous coating composition as claimed in any one of claims
3 to 6, wherein the said metal oxide sol (C) is a silicic anhydride
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150
sol.
8. The aqueous coating composition as claimed in claim 1, wherein
the said silicic anhydride sol is a fumed silica sol.
5
9. The aqueous coating composition as claimed in any one of claims
3 to 6, wherein the said metal oxide sol (C) is a colloidal silica
water dispersing agent, and the said colloidal silica water dispersing
agent has pH of not more than 7 and a Na20 content of not more than
10 400 ppm.
10. The aqueous coating composition as claimed in any one of claims
3 to 6, wherein the said metal oxide sol (C) is a sol comprising fumed
alumina or fumed titania.
15
11. The aqueous coating composition as claimed in any one of claims
1 to 10, which further comprises a pigment, and a ratio ( (PVC) / (CPVC) )
of a pigment volume concentration (PVC) to a critical pigment volume
concentration (CPVC) in the aqueous coating composition is higher
20 than 1.
12. The aqueous coating composition as claimed in any one of claims
1 to 11, which further comprises a rust-preventive pigment (D).
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13. The aqueous coating composition as claimed in claim 12, wherein
the said rust-prgventivQ pipont (D) comprisQS 2inc powdor and/or
zinc alloy powder having a mean particle diameter of 2 to 20 pm.
5 14. The aqueous coating composition as claimed in any one of claims
1 to 13, which further comprises metallic molybdenum and/or a
molybdenum compound as a white rust inhibiter (E).
15. The aqueous coating composition as claimed in any one of claims
10 1 to 11, which is used as a binder composition.
16. The aqueous coating composition as claimed in any one of claims
12 to 14, which is used as a rust-preventive coating composition.
15 17. The aqueous coating composition as claimed in claim 16, which
is a coating composition for primary rust prevention.
18. The aqueous coating composition as claimed in claim 16, which
is a thick-coating type inorganic zinc coating composition.
20
19. A primary rust prevention coating method for a steel material,
comprising applying the coating composition for primary rust
prevention as claimed in claim 17 to a surface of a steel material
and then curing the applied coating composition to form a primary
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,, rust-preventive coating film.
'20. A rust prevention coating method for a steel material,
comprising applying the thick-coating type inorganic zinc coating
5 composition as claimed in claim 18 to a surface of a steel material
and then curing the applied coating composition to form a thick-coating
type inorganic zinc rust-preventive coating film.
21. A steel structure having, on a surface of a steel material,
10 a primary rust-preventive coating film formed from the coating
composition for primary rust prevention as claimed in claim 17.
22. A steel structure having, on a surface of a steel material,
a thick-coating type inorganic zinc rust-preventive coating film
15 formed from the thick-coating type inorganic zinc coating composition
as claimed in claim 18.