Compositions: coating or plastic – Coating or plastic compositions – Heavy metal compound containing
Reexamination Certificate
2003-04-08
2004-05-11
Brunsman, David (Department: 1755)
Compositions: coating or plastic
Coating or plastic compositions
Heavy metal compound containing
Reexamination Certificate
active
06733580
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a coating composition capable of forming a titanium oxide film showing good properties in photoactivity, antibacterial properties, hydrophilic properties, pollution resistance, hazeproofness, gas decomposition properties, deodorizing properties, water treatment properties, energy transformation properties, decoloring properties, etc., a method of preparing the coating composition, and a method of forming the inorganic film.
2. Background Art
The titanium oxide film-forming methods known in the art may include, for example, (1) a method of coating a titanium oxide sol onto a substrate, followed by sintering, (2) a method of coating an aqueous solution of titanium chloride or titanium sulfate onto a substrate, followed by heat treating, (3) a plasma spray coating method which comprises fusing titanium oxide solid particles in the presence of plasma generated in atmosphere, followed by spraying onto a substrate, (4) a spatter spraying method of spattering the oxide as a target under vacuum, followed by spraying onto a substrate, (5) a chemical vapor deposition method of volatilizing an organic metal compound or the like, followed by decomposing in an electric furnace, and forming a film onto a substrate, (6) a sol-gel method of coating a sol obtained by hydrolysis of a metal alkoxide onto a substrate, followed by sintering, and the like.
However, the above methods (1) to (6) have such drawbacks that the method (1) is such that a film thickness of 0.1 &mgr;m or more may develop cracks and peelings, resulting in showing poor film-forming properties, and sintering at a temperature of hundreds is required, resulting in requiring much time and labor, the method (2) is such that adverse effects of thermal decomposition products on the substrate and necessity of sintering at a temperature of hundreds require much time and labor, the method (3) is unable to form a fine film and results in poor adhesion properties, the methods (4) and (5) are such that a satisfactory film may be obtained under vacuum, so that a vacuumizing reactor may be required, and that a film-forming speed may be so low that it may require heating the substrate at a temperature of hundreds to obtain a fine film, and the method (6) is such that the acid, alkali and organic compounds contained in the sol of the method (6) may produce problems of corrosion of a substrate, and that removal of the organic compounds requires heating at 400° C. or higher.
In addition to the above methods, the methods free of the step of sintering at high temperatures may include (7) a method of forming a titanium oxide film from an aqueous fluoride solution of titanium oxide and boric acid, (8) a method which comprises precipitating a titanium hydroxide gel from an aqueous solution of titanium chloride or titanium sulfate and an alkali solution such as ammonia, caustic soda and the like, followed by separating the titanium hydroxide gel by decantation, thoroughly washing with water, and adding hydrogen peroxide water (see Japanese Patent Application Laid-Open No. 71418/97), and the like.
However, the method (7) has the drawbacks that formation of the film requires much time, and handling of the fluoride is troublesome, and the method (8) has the drawbacks that the method (8) comprises complicated steps, removal of the alkali salt is troublesome, inclusion of other metals may make it difficult to obtain a high purity film, and difficulty in control of pH results in films different from each other depending on variation of pH, and so forth.
BROAD DESCRIPTION OF THE INVENTION
It is an object of the present invention to provide a coating composition suitable for use in forming an inorganic film, and free of byproducts such as alkali salt, fluoride and the like as in the prior art so as to show good properties in storage stability, film performances, etc.
It is another object of the present invention to provide a coating composition for use in forming an inorganic film, particularly a titanium oxide film, a preparation method of the coating composition and a method of forming an inorganic film, particularly a titanium oxide film, so that the titanium oxide film may be formed at such a low temperature that the resulting titanium oxide film may show characteristic film performances such as photoactivity, antibacterial properties, hydrophilic properties, pollution resistance, hazeproofness, gas decomposition properties, deodorizing properties, water treatment, energy transformation, decoloring properties and the like.
That is, the present invention provides an inorganic film-forming coating composition prepared by reacting a titanium monomer and/or a low condensation product thereof containing a group hydrolyzed to form hydroxyl group with a hydrogen peroxide water, a heat modified, inorganic film-forming coating composition prepared by heat treating at 80° to 100° C. or autoclaving at 80° to 200° C. the inorganic film-forming coating composition to form titanium oxide fine particles, a method of preparing the inorganic film-forming coating composition, which method comprises adding the titanium monomer and/or the low condensation product thereof containing the group hydrolyzed to form hydroxyl group into the hydrogen peroxide water for reacting preferably at a temperature in the range of 10° to 70° C., a method of forming an inorganic film, which method comprises coating the inorganic film-forming coating composition or the heat-modified inorganic film-forming coating composition onto the substrate, or impregnating the substrate with the coating composition, followed by drying or heat treating to form an inorganic film preferably showing good properties in photoactivity, antibacterial properties, hydrophilic properties, pollution resistance, hazeproofness, gas decomposition properties, deodorizing properties, water treatment properties, energy transformation properties and decoloring properties.
The present invention preferably relates to a method of preparing the inorganic film-forming coating composition. The invention method comprises adding a titanium monomer and/or a low condensation product thereof containing the group hydrolyzed to form hydroxyl group into a mixture of hydrogen peroxide water with water in such an amount that the titanium monomer and/or the low condensation product thereof may be hydrolyzed, followed by reacting to form a hydroxyl group-containing titanium compound, and immediately following such reaction with coordination of the hyroxyl group-containing titanium compound with hydrogen peroxide to form a chelate solution. An inorganic film-forming coating composition comprising the chelate solution is obtained. The titanium monomer containing the group hydrolyzed to form hydroxyl group is represented by the formula Ti(OR)
4
, wherein R is the same or different, and represents an alkyl group having 1 to 5 carbon atoms. The low condensation product has a degree of condensation of 2 to 30. A mixing ratio of the titanium monomer and/or the low condensation product thereof containing the group hydrolyzed to form hydroxyl group to the hydrogen peroxide water is such that the hydrogen peroxide water is in the range of 0.1 to 100 parts by weight as hydrogen peroxide per 10 parts by weight of the titanium monomer and/or the low condensation product thereof. The reaction temperature is in the range of 10° to 70° C.
The present invention preferably also relates to a method of forming an inorganic film. The invention method comprises coating an inorganic film-forming coating composition onto a substrate or impregnating the substrate with the coating composition, followed by drying or heat treating to form an inorganic film. The inorganic film-forming coating composition is prepared by a preparation method. The preparation method comprises adding titanium monomer and/or a low condensation product thereof containing the group hydrolyzed to form hydroxyl group into a mixture of a hydrogen peroxide water with water in such an amount that the titanium mon
Brunsman David
Fisher Christen & Sabol
Kansei Paint Co., LTD
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