Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Compositions to be polymerized by wave energy wherein said...
Reexamination Certificate
2000-06-12
2002-03-12
Seidleck, James J. (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Compositions to be polymerized by wave energy wherein said...
C522S079000, C522S080000, C522S083000, C522S084000, C522S091000, C522S099000, C522S178000, C522S120000, C522S148000, C522S121000, C522S122000, C522S116000, C528S032000, C528S026000, C526S243000, C526S243000, C526S243000, C526S243000
Reexamination Certificate
active
06355703
ABSTRACT:
DETAILED DESCRIPTION OF THE INVENTION
1. Field of the Invention
The present invention relates to a liquid curable resin composition, and, particularly, to a liquid curable resin composition from which a cured coating exhibits superior scratch resistance, excellent abrasion resistance, superior adhesion to a substrate, and/or fine appearance. Such cured coating can be formed, for example, on the surface of plastic moldings, paintings, and the like. The liquid resin composition can form a coating when dried by volatilization of solvent, which coating can be printed or embossed prior to exposure to activation energy, and can still be molded after a cured coating is formed by the exposure to activation energy. More particularly, the present invention relates to a liquid curable resin composition which can be used as a hard coating for transfer foil films, plastic optical parts, touch panels, film liquid crystal elements, plastic moldings, and the like, and as a stain-proof or scratch-resistant coating for interior flooring materials, wall materials and the like.
2. Prior Art
Conventionally, as a method for protecting the surface of plastic moldings such as transfer foil films, plastic optical parts, touch panels, and film liquid crystal elements, or the surface of paintings for interior flooring materials and wall materials, hard coatings have been applied to the surface of such materials. As these hard coating materials, ultraviolet radiation-curable acrylic hard coating materials such as polyester acrylate, urethane acrylate, and epoxy acrylate were used. However, a scratch resistance, abrasion resistance coating that had adhered to a substrate while having a suitable appearance was unobtainable using only these materials.
As a method for providing scratch resistance, abrasion resistance, and the like for plastic moldings, a method of adding inorganic fillers represented by silica or organic fillers such as polyethylene powder and polycarbonate powder, and a method comprising the addition of additives such as silicone are well known. However, the haze value of the resulting coating is increased or the appearance of the coating is impaired by adding inorganic or organic fillers. Moreover, although the slip characteristics of the surface of the coating are improved by the use of additives such as silicone, the scratch resistance, as demonstrated by Taber's abrasive wheel test, is not exhibited.
A hard coating material using polyfunctional (meth)acrylate having three or more functional groups is disclosed in Japanese Patent Applications Laid-open No. 104683/1978 and No. 97633/1979. In order to improve scratch resistance of the above hard coating material, a method comprising the addition of micro-powdered inorganic fillers or colloidal silica is disclosed in Japanese Patent Applications Laid-open No. 106969/1981 and No. 272041/1990, a method comprising the addition of colloidal silica and silane coupling agents is disclosed in Japanese Patent Applications Laid-open No. 64138/1990 and No. 18423/1992, a method comprising the addition of colloidal silica and an amino-organofunctional silane modified multifunctional acrylate is disclosed in the patents U.S. Pat. Nos. 5,374,483 and 5,260,350,and a method comprising the addition of a reaction product of colloidal silica and alkoxysilylacrylate is disclosed in GB-A-2292946. These hard coating materials are curable by exposure to activation energy and exhibit superior scratch resistance, however, coatings of this type are not printable before curing even after volatilization of the solvent. In addition, moldability of the above coatings after curing by exposure to activation energy is insufficient.
An object of the present invention is to provide a liquid curable resin composition from which a cured coating can be produced having superior scratch resistance, excellent abrasion resistance, superior adhesion to a substrate, and/or fine appearance. The liquid curable resin composition can form a coating when dried by removing solvent which can be printed or embossed prior to irradiation by activation energy, and the composition can be molded after irradiation by activation energy.
Another object of the present invention is to provide a liquid curable resin composition which is particularly useful as a hard coating for transfer foil films, plastic optical parts, touch panels, film liquid crystal elements, plastic moldings, and the like, interior flooring materials, stain-proof and/or scratch-resistant wall materials and the like.
Other objects and advantages of the present invention will be apparent from the following descriptions.
SUMMARY OF THE INVENTION
The above objects and advantages can be achieved in the present invention by a liquid curable resin composition comprising:
(A) a polyfunctional (meth)acrylic compound containing at least three (meth)acryloyl groups in the molecule (herein referred to as “component (A)”),
(B) a crosslinkable inorganic particle, specifically a silica particle having a surface with a silane compound comprising a radiation-curable group; (herein referred to as “component (B)”),
(C) a radiation-curable acrylic resin having a a Tg of 50° C. or more (herein referred to as “component (C)”), (wherein said radiation-curable acrylic resin preferably comprises a carboxylic acid group; and optionally,
(D) a radiation polymerization initiator (hereinafter called “component (D)”), and/or
(E) a solvent.
A further embodiment relates to a substrate having a coating which is obtained by applying the radiation curable resin composition, and by evaporation of the solvent (E). Yet a further embodiment relates to the cured coating obtained after irradiation of said resin composition.
DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS
Component A
Component A is a polyfunctional (meth)acrylic compound having at least three (meth)acryloyl groups in a molecule. Component A generally has less than 12 (meth)acryloyl groups, preferably less than 8. The molecular weight of component A is generally less than 1000.
Examples of the polyfunctional (meth)acrylic compound having at least three (meth)acryloyl groups in the moleculeinclude trimethylolpropane tri(meth)acrylate, trimethylolpropanetrioxyethyl (meth)acrylate, tris(2-hydroxyethyl)isocyanurate tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol hexa(meth)acrylate, and the like.
Examples of commercially available products of the polyfunctional monomer containing at least three (meth)acryloyl groups in the molecule include Kayarad DPHA, DPCA-20, DPCA-30, DPCA-60, DPCA-120, D-310, D-330, PET-30, GPO-303, TMPTA, THE-330, TPA-330 (manufactured by Nippon Kayaku Co., Ltd.), Aronix M-315, M-325 (manufactured by Toagosei Co., Ltd.), and the like.
The component (A) may be present in an amount preferably from 5 to 30 wt % relative to the total amount of the components (A), (B), and (C), in the composition of the present invention. If this amount is less than 5 wt %, formation of the coating and hardness of the resulting coating tend to be insufficient. On the other hand, if this amount is more than 30 wt %, the dried coating tends to exhibit tackiness.
Component B
Generally, component B of the present invention includes a crosslinkable inorganic particle; this is an inorganic particle, preferably a silica particle, having on its surface a silane compound comprising a radiation curable group.
Preferably, compound B has a silane compound, which is the reaction product of the inorganic particle with alkoxysilane compound having a linking group represented by formula (1)
wherein X represents a divalent group including —NH—, —O—, or —S— and Y represents an oxygen atom or a sulfur atom, provided that when X is —O—, Y is a sulfur atom;
Furthermore, compound B preferably comprises an alkoxysilane compound comprising a linking group represented by formula (1) and a urethane linking group —C(O)NH—;
A preferred alkoxysilane compound can be formed by the addition reaction of alkoxysilane having a mercapto group, specifically, merca
Baba Atsushi
Eriyama Yuichi
Ukachi Takashi
DSM N. V.
McClendon Sanza L.
Pillsbury & Winthrop LLP
Seidleck James J.
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