Stock material or miscellaneous articles – Composite – Of silicon containing
Reexamination Certificate
2000-11-08
2002-08-20
Dawson, Robert (Department: 1712)
Stock material or miscellaneous articles
Composite
Of silicon containing
C428S323000, C428S332000, C427S387000, C427S377000, C524S858000, C524S863000, C106S287160, C106S287170, C106S287180, C106S287190
Reexamination Certificate
active
06436543
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a novel high-gloss, heat-resistant paint composition that can form a paint film that can be applied in one spray coating and one baking and shows a high gloss and a heat resistance up to 800° C. when applied to austenitic stainless steel, a method for manufacturing the high-gloss, heat-resistant paint, a method for applying the high-gloss, heat-resistant paint, and a high-gloss, heat-resistant paint film.
BACKGROUND OF THE INVENTION
Numerous inorganic heat-resistant paints suited for various applications have heretofore been developed and marketed. Major types of such inorganic heat-resistant paints include an inorganic paint using an aqueous solution of aluminum phosphate as a binder solution, an inorganic paint using an aqueous solution of alkaline silicate as a binder solution, an inorganic paint using an alcoholic solution of polysilicon alkoxide as a binder solution (also referred to as so-gel binder), and an inorganic paint using an organic solvent solution of polysilazane as a binder solution.
The paint using an aqueous solution of aluminum phosphate is a corrosion-resistant paint containing a pigment of fine aluminum metal powder, as disclosed in U.S. Pat. No. 3,248,249 and U.S. Pat. No. 5,278,650, for example, which has excellent corrosion-resistant properties based on the sacrificial corrosion preventing effects of aluminum which is oxidized in preference to iron as the base metal. Its heat resistance, however, normally does not exceed 600° C. that is close to the melting point of aluminum. Furthermore, commercially available paints of this type often contain carcinogenic sexivalent chrome, posing environmental concerns.
Although the heat-resistant paint using an aqueous solution of alkaline silicate as a binder solution is inexpensive, high heat resistance cannot be expected from it due to such alkali content as Na
+
ion having an effect of lowering melting point. The heat-resistant paint using an organic solvent solution of polysilazane as a binder solution, as disclosed in Japanese Published Unexamined Patent Application Hei-6(1994)-122852, is adapted so that the binder solution of this system that would normally be cured only at high temperatures can be cured at low temperatures, but its applications are limited at present due to its high price.
The heat-resistant paint using an alcoholic solution of polysilicon alkoxide as a binder, on the other hand, can be commercially available at relatively low prices, and a highly heat-resistant paint can be obtained by combining heat-resistant pigments. Japanese Published Unexamined Patent Application No. Hei-6(1994)-9928 discloses a high-gloss, heat-resistant paint having a beat resistance of 500° C., but has no mention of an embodiment of a colored paint having hiding power. Binders comprising an alcoholic solution of polysilicon alkoxide as disclosed in Japanese Published Examined Patent Application No. Hei-5(1993)-33275 and Japanese Published Examined Patent Application No. Hei-8(1996)19352 introduce an Al
2
O
3
content by adding aluminum alkoxide or alumina sol, both of which are relatively inexpensive, to the binder solution comprising the alcoholic solution of polysilicon alkoxide to improve the adhesion and heat resistance of the paint film.
Commercially available polysilicon alkoxide heat-resistant paints manufactured based on these technologies have a heat resistance exceeding 600° C., and their varnish-like coating film has a gloss. Heat-resistant paints manufactured by combining inorganic pigments having hiding power have no heat resistance exceeding 600° C. (those paints whose coating films tend to peel are defined in this Specification as having no heat resistance despite the fact that their paint film materials are beat resistant), or even if they are heat resistant, their paint films have only a semi-gloss unless their varnish is top coated. Those glossy paint films formed by top coating varnish onto a film containing pigments are thick by the thickness of the top coated film, and tend to peel in a temperature cycle exceeding 600° C. due to the difference in thermal expansion coefficient between the paint film and the base material.
On the other hand, exhaust pipes of motorcycles have heretofore normally been made of carbon steel, to which a corrosion-preventive paint is applied. More recently, however, an increasing number of them are made of stainless steel due to the reduced cost of stainless steel, and as a result, the need for corrosion-prevent coating has been reduced, and there is a growing trend among motor cyclists toward such aesthetically attractive exhaust pipes as coated with glossy paints.
SUMMARY OF THE INVENTION
The present invention is intended to overcome these problems inherent in the prior art. It is therefore an object of the present invention to provide a new high-gloss, heat-resistant paint composition that can be applied to austenitic stainless steel and other materials in one spray coating and one baking to form a paint film having a heat resistance exceeding 600° C. and good adhesion, a method for manufacturing the same, a method for applying the high-gloss, heat resistant paint, and a high-gloss, heat-resistant paint film.
The invention of a high-gloss, heat-resistant paint composition as the first invention employs technical means in which the composition embodying the invention is a heat-resistant paint composition preparedby combining inorganic pigment powder having hiding power with a binder solution chiefly consisting of an alcoholic solution of polysilicon alkoxide; the binder solution containing an effective amount of an aluminum ingredient; the composition containing 8~50 wt. % of hydrophilic organic solvent having a boiling point of not less than 100° C. and not more than 220° C.; the average grain size of primary particles of the inorganic pigment powder dispersed in the binder solution being not more than 0.3 &mgr;m; and the solidified paint film produced after the composition has been dried and baked contains not less than 60 vol. % of the vitreous matrix formed as the result of solidification of binder content.
In the present invention, when the average thickness of a paint film that can be obtained by applying the composition to an object being painted is 10 &mgr;m, it is easy to add inorganic pigment powder of an amount enough to form a paint film having hiding power.
In another preferred high-gloss, heat-resistant paint according to the present invention, the vitreous matrix produced after the binder solution has been solidified contains 10~45 wt. % of the Al
2
O
3
content.
In still another preferred high-gloss, heat-resistant paint according to the present invention, the inorganic pigment powder comprises primary particles of oxides having an average particle size of not more than 0.2 &mgr;m.
In still another preferred high-gloss, heat-resistant paint according to the present invention, the hydrophilic organic solvent comprises alcohols.
In still another preferred high-gloss, heat-resistant paint according to the present invention, 2~10 wt. % of the inorganic pigment having hiding power is replaced with ultrafine alumina powder having primary-particle sizes of not more than 35 nm.
The invention of manufacturing method as the second invention employs technical means in which a mixture obtained by adding a hydrophilic organic solvent of a boiling point of not less than 100° C. and not more than 220° C. to inorganic pigment powder having hiding power, in which primary particles of an average particle size of not more than 0.3 &mgr;m is treated with dispersing means to produce slurry in which primary particles of inorganic pigment powder are dispersed in the hydrophilic organic solvent; the slurry being mixed with a binder solution chiefly comprising an alcoholic solution of polysilicon alkoxide.
In a preferred method for manufacturing a high-gloss, heat-resistant paint composition, an effective amount of dispersant is added to a mixture of a hydrophilic organic solvent and inorganic pigment powder.
A pa
Endo Yasuhiko
Sakai Hisayuki
Sakai Tomio
Shimada Saburou
Dawson Robert
Feely Michael J
Institute of Technology Precision Electrical Discharge Work&apos
McGlew and Tuttle , P.C.
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