Coating processes – Direct application of electrical – magnetic – wave – or... – Polymerization of coating utilizing direct application of...
Reissue Patent
2000-07-10
2002-05-14
Cameron, Erma (Department: 1762)
Coating processes
Direct application of electrical, magnetic, wave, or...
Polymerization of coating utilizing direct application of...
C427S536000, C427S539000, C427S337000, C427S407200, C427S409000, C427S412100, C427S419700
Reissue Patent
active
RE037698
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to a method of manufacturing a fluorocarbon-based polymer coating film used on an apparatus or the like requiring a heat-resistant, weather-resistant and wear-resistant coating. The coating can be used on electric apparatuses, such as hot plates and rice cooking machines; vehicles; and industrial apparatus.
BACKGROUND OF THE INVENTION
Fluorocarbon-based polymer coating films have been used extensively and are manufactured by making the surface of an Al substrate rough by means of a brush or chemical etching; coating the rough surface with a primer or the like; coating with a paint suspending fine particles of a fluorocarbon-based material, such as polytetrafluoroethylene in ethanol or the like; and then drying and baking at about 400° C. for about one hour to fix the fluorocarbon-based polymer to the substrate surface of the material.
This method of manufacture is simple. However, since the polymer and substrate are bonded together merely by an anchor effect, there is a limit to the adhesion of the polymer to the substrate. The method is insufficient in view of adhesion and mechanical strength as a method of manufacturing fluorocarbon-based coating films used for apparatus or the like requiring a heat-resistant, weather-resistant and wear-resistant coating. Such electric apparatus include hot plates and rice cooking apparatus; vehicles; and industrial apparatus.
SUMMARY OF THE INVENTION
In view of the above drawbacks in the prior art method, it is an object of the present invention to form a fluorocarbon-based coating layer or film having satisfactory adhesion to a substrate that is pinhole-free, thereby improving the performance of an apparatus or the like requiring a heat-resistant, weather-resistant and wear-resistant coating. Such electric apparatuses include hot plates and rice cooking apparatus; vehicles; and industrial apparatus.
The primary objective of this invention is to provide a fluorocarbon-based polymer coating film comprising at least an siloxane film formed as a inner layer and a fluorocarbon-based polymer film formed as an outer layer on the surface of a substrate. The substrate surface and the inner layer are bonded with covalent bonds, and the inner layer and the outer layer are bonded with covalent bonds.
Another objective or this invention is to provide a method of manufacturing a fluorocarbon-based polymer coating film comprising the steps of contacting a substrate having hydroxyl groups on a surface with a non-aqueous solvent containing a material with a chlorosilyl group; coating said substrate surface with either a non-aqueous solvent containing a compound having a fluorocarbon group and a chlorosilyl group or a solvent containing a compound having a fluorocarbon group and alkoxysilane group or a compound represented by the following formula
CF
3
—(CF
2
)
n
—(R)
m
—SiY
q
(OA)
3-q
where n represents 0 or an integer; R represents an
alkyl
alkylene
group or a hydrocarbon substituted group containing C═C, C≡C, a silicon atom or an oxygen atom; m represents 0 or 1; Y represents a hydrogen atom, an alkyl group, an alkoxy group, a fluorine-containing alkoxy group or a fluorine-containing alkyl group; A represents a hydrogen atom; and q represents 0, 1 or 2; and,
and
baking the substrate after the contacting and coating steps.
Another objective of this invention is to provide a method of manufacturing a fluorocarbon-based polymer coating film comprising the steps of contacting a substrate having a surface containing hydroxyl groups with a non-aqueous solvent containing a material having a chlorosilyl group; washing the substrate with a non-aqueous solvent to remove the material without reaction; coating the substrate with either a non-aqueous solvent containing a compound having a fluorocarbon group and a chlorosilyl group or a solvent containing a compound having a fluorocarbon group and alkoxysilyl group.
It is preferable in this invention that both sets of the covalent bonds connecting the substrate surface and the inner layer, and the inner layer and the outer layer are siloxane bonds.
It is preferable in this invention that the inner layer is formed with a siloxane-based monomolecular film.
It is preferable in this invention that the substrate is made from a member of a group consisting of metals, ceramics and plastics.
It is preferable in this invention that the substrate is made of a plastic material treated in a plasma atmosphere containing oxygen.
It is preferable in this method invention that the material having a chlorosilyl group contains a member
of a
selected from the
group consisting of SiCl
4
, SiHCl
3
, SiH
2
Cl
2
and Cl—(SiCl
2
O)
n
—SiCl
3
(n being an integer, preferably 1 to 3).
It is preferable in this
method
invention that the compound having a fluorocarbon group and chlorosilyl group is represented by a formula: CF
3
—(CF
2
)
n
—(R)
m
—SiX
p
Cl
3-p
where n represents 0 or an integer; R represents an
alkyl
alkylene
group or a hydrocarbon substituted group containing C═C, C≡C, a silicon atom or a hydrogen atom; m represents 0 or 1; X represents a hydrogen atom, an alkyl group, an alkoxy group, a fluorine-containing alkoxy group or a fluorine-containing alkyl group; p represents 0, 1 or 2.
It is preferable in this
method
invention that the compound having a fluorocarbon group and an alkoxysilane group is represented by a formula:
CF
3
—(CF
2
)
n
—(R)
m
—SiY
q
(OA′)
3-q
where n represents 0 or an integer, R represents an
alkyl
alkylene
group or a hydrocarbon substituted group containing C═C, C≡C, a silicon atom or an oxygen atom; m represents 0 or 1; Y represents a hydrogen atom, an alkyl group, an alkoxy group, a fluorine-containing alkoxy group or a fluorine-containing alkyl group; OA′ represents an alkoxy group; and q represents 0, 1 or 2.
It is preferable in this
method
invention that the material represented by a formula: SiX
s
Cl
4-s
where X represents a hydrogen atom or an alkyl group, and s represents 0, 1 or 2; is added to a non-aqueous solvent containing a compound having a fluorocarbon group and a chlorosilyl group.
It is preferable in this
method
invention that the material represented by a formula: SiY
1
(OA″)
4-t
where Y represents an alkyl group; A″ represents a hydrogen atom or an alkyl group; and t represents 0, 1 and 2; is added to solvent containing a compound having a fluorocarbon group and an alkoxysilane group.
It is preferable in this method invention that fine particles of a fluorocarbon-based polymer are dispersed in advance in either the non-aqueous solvent containing a compound having a fluorocarbon group and a chlorosilyl group or the solvent containing a compound having a fluorocarbon group and an alkoxysilane group.
REFERENCES:
patent: 4368476 (1983-01-01), Uehara et al.
patent: 4539061 (1985-09-01), Sagiv
patent: 4673474 (1987-06-01), Ogawa
patent: 4810564 (1989-03-01), Takahashi et al.
patent: 4863794 (1989-09-01), Fujii et al.
patent: 4961996 (1990-10-01), Carre et al.
patent: 5328768 (1994-07-01), Goodwin
patent: 5580605 (1996-12-01), Ogawa et al.
patent: 363924 (1989-11-01), None
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patent: 60-40254 (1985-03-01), None
patent: 61-016910 (1986-01-01), None
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patent: 0 166 363 (1991-08-01), None
EPO Search Report to EP 0 545 201 (equivalent to Goodwin '768 patent), Jun. 1993.
Abstract of JP 61-016910, Jan. 1986.*
World Patents Index Latest, Derwent Publications Ltd., London, GB; AN 86-065417 & JP-A-61 016 910 (Hitachi Cable KK), Jan. 24, 1986 (abstract).
Ogawa Kazufumi
Soga Mamoru
Cameron Erma
Matsushita Electric Industrial Co.
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