Coating processes – Applying superposed diverse coating or coating a coated base – Metallic compound-containing coating
Reexamination Certificate
1999-09-21
2002-07-16
Yoon, Tae H. (Department: 1714)
Coating processes
Applying superposed diverse coating or coating a coated base
Metallic compound-containing coating
C427S388100, C427S407100, C524S521000, C526S274000, C526S277000
Reexamination Certificate
active
06419990
ABSTRACT:
This invention relates to a non-aqueous dispersion which comprises, as dispersed particles, a phosphoric acid group-containing polymer, and to a process for the formation of a leafing type aluminum flake-containing metallic multi-layer coating film which is formed with use of said non-aqueous dispersion.
There has already been known a technique to form, on a substrate such as an automobile body panel, a multi-layer coating film, by applying an aluminum flake pigment-containing metallic coating on said substrate, and then applying, on the resultant coated surface, a clear coating which is capable of forming a transparent film.
The aluminum flake pigment to be compounded in a metallic coating is classified into a leafing type one and a non-leafing type one. In a metallic coating film which contains a leafing type aluminum flake pigment, the aluminum flake pigment floats up to the surface of said coating film (which phenomenon is called leafing) to form a continuous and dense aluminum plane which is oriented substantially parallel to the coated surface, resulting in the achievement of special effects such as a chrome plating-like finish, glittering brightness and strong flip-flop properties.
This metallic coating film per se is, however, inferior in chemical resistance such as acid resistance since aluminum flake pigment floats up to the surface of said coating film. In order to overcome this defect, the coated surface of said metallic coating film is usually coated with a clear coating. However, when a clear coating is applied onto the coated surface of a metallic coating film while the metallic coating is uncured, the orientation of leafing type aluminum flake is disturbed, resulting in the deterioration of a chrome plating-like finish (which phenomenon is called mottling). On the other hand, when a clear coating is applied after the metallic coating film is heat-cured, the interlayer adhesivity between the metallic coating film and the clear coating film is caused to be insufficient. Hence, it has been impossible to fully produce the above-mentioned various advantageous effects of a leafing type aluminum flake-containing metallic coating film.
As for a non-leafing type aluminum flake, it is uniformly dispersed in the whole of a coating film without causing leafing. Hence, when a clear coating is applied onto the surface of a metallic coating, there occurs neither mottling nor the reduction in interlayer adhesivity. However, brightness feeling and flip-flop effects are weak, and, moreover, it is difficult to achieve a metallic coating film having a chrome plating-like finish.
In view of the above situation, the inventors of this invention made an assiduous study on how to improve the interlayer adhesivity between a metallic coating film and an adjacent film, without causing reduction in the above-mentioned special effects (e.g., dense metallic appearance of the coated surface, a chrome plating-like finish, strong brightness and flip-flop effects) possessed by a leafing type aluminum flake pigment-containing metallic coating film.
As a result, the inventors have newly developed a phosphoric acid group-containing non-aqueous dispersion, and have found out that, when a clear coating which contains said non-aqueous dispersion is applied on a metallic cured film which contains the above-mentioned leafing type aluminum flake pigment, the interlayer adhesivity between the metallic coating film and the clear coating can be improved.
The inventors have further found out that the interlayer adhesivity between a leafing type aluminum flake pigment-containing metallic coating film and another coating film can be improved by applying a base coating which contains a phosphoric acid group-containing resin composition, and, without curing said base coating, applying a leafing type aluminum flake pigment-containing metallic composition on the coated surface of said base coating, and, after curing these coatings, applying on the resultant coated surface a clear coating which contains the above-mentioned phosphoric acid group-containing non-aqueous dispersion.
Thus, this invention provides a non-aqueous dispersion (hereinafter referred to as non-aqueous dispersion of this invention) which comprises polymer particles dispersed in a solution of macromolecular dispersion stabilizer dissolved in an organic solvent, said polymer particles being particles of polymer which comprises, as a constitutent component, a phosphoric acid group-containing polymerizable unsaturated monomeric unit.
This invention also provides a process (hereinafter referred to as Application Process I of this invention) for the formation of a multi-layer coating film which process is characterized by using, as a clear coating, a coating which contains the non-aqueous dispersion of this invention, when forming a multi-layer coating film by applying a leafing type aluminum flake-containing metallic coating, and, after curing said coating, applying a clear coating on the resultant coated surface.
This invention further provides a process (hereinafter referred to as Application Process II of his invention) for the formation of a multi-layer coating film which process is characterized by applying base coating which contains a phosphoric acid group-containing resin composition, and, without curing said base coating, applying a leafing type aluminum flake pigment-containing metallic composition on the resultant coated surface of said base coating, and, after curing these coatings, applying on the resultant coated surface a clear coating which contains the non-aqueous dispersion of this invention.
The following is a further detailed explanation of the non-aqueous dispersion of this invention and the Application Processes I and II of this invention.
Non-Aqueous Dispersion of This Invention
A non-aqueous dispersion which comprises polymer particles dispersed in a solution of macromolecular dispersion stabilizer dissolved in an organic solvent, said polymer particles being produced by polymerizing monomeric unit which contains a phosphoric acid group-containing polymerizable unsaturated monomer.
The polymer of the polymer particles in the non-aqueous dispersion of this invention can be produced by polymerizing either a phosphoric acid group-containing polymerizable unsaturated monomer alone or a monomeric component which comprises a phosphoric acid group-containing polymerizable unsaturated monomer and another copolymerizable monomer.
Examples of said phosphoric acid group-containing polymerizable unsaturated monomer include a compound which has, in one molecule, both at least one phosphoric acid group represented by formula
—OPO (OH) (R
1
) (1)
wherein R
1
is a hydroxyl group, a phenyl group or an alkyl group having 1 to 20, especially 2 to 10, carbon atoms
and at least one polymerizable unsaturated bond. Concretely, there are mentioned acid-phosphoxy-C
1-20
(especially C
2-10
)alkyl (meth)acrylates such as acid-phosphoxyethyl acrylate, acid-phosphoxyethyl methacrylate, acid-phosphoxypropyl acrylate, acid-phosphoxypropyl methacrylate, acid-phosphoxydecyl acrylate, acid-phosphoxydecyl methacrylate and the like.
As a phosphoric acid group-containing polymerizing merizable unsaturated monomer, there can also be used an equimolar adduct of glycidyl (meth)acrylate with monomeric C
1-20
alkylphosphoric acid ester.
Furthermore, as a phosphoric acid group-containing polymerizable unsaturated monomer, there can also be used compounds represented by the formula
CH
2
═CX—COO—(YO)
n
—PO(OH)
2
(2)
wherein X denotes hydrogen atom or methyl group: Y denotes alkylene group having 2 to 4 carbon atoms; and n denotes an integer of 3 to 30, especially 3 to 20.
This monomer can be prepared for example by adding alkylene oxide to (meth)acrylic acid to form polyalkylene glycol monoester, which is then allowed to react with phosphorus oxychloride to form phosphate monoester, which is then hydrolyzed. This phosphorus oxychloride can be replaced with orthophosphoric acid, metaphosphoric acid, phosphoric acid anhydride, phosphorus tri
Masuda Yutaka
Nakahata Akimasa
Yukawa Yoshiyuki
Kansai Paint Co. Ltd.
Wenderoth , Lind & Ponack, L.L.P.
Yoon Tae H.
LandOfFree
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