Stock material or miscellaneous articles – Composite – Of silicon containing
Reexamination Certificate
1999-05-24
2001-09-11
Pyon, Harold (Department: 1772)
Stock material or miscellaneous articles
Composite
Of silicon containing
C428S447000, C524S588000, C525S474000, C525S476000, C528S041000, C427S387000
Reexamination Certificate
active
06287701
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to resin compositions, processes for their production, their uses, and their coated products.
2. Discussion of Background
In recent years, attention has been drawn to a resin composition comprising an organic silicon compound and various types of polymer including an acrylic resin, as a material having merits of both organic and inorganic natures. The resin composition comprising these components usually employs one or more organic solvents such as higher alcohols, ketones, esters or aromatic substances, in a substantial amount in order to attain compatibility among the components, storage stability of the liquid or good physical properties of the coating film thereby formed.
These organic solvents are likely to evaporate during coating and thus create a problem from the viewpoint of global environmental protection. Accordingly, there have been worldwide movements to restrict their uses. Especially when coating is applied to a metal, cement or various ceramic base materials, treatment at a relatively high temperature is required, whereby evaporation of solvents is likely to bring about a danger of inflammation, which adds to the problem. Accordingly, it is desired to develop a resin composition containing an organic silicon compound which employs an aqueous solvent and which contains at least 10 wt % of water. However, when an aqueous solvent is employed, the organic silicon compound is poor in compatibility with water in addition to inadequate affinity between the organic silicon compound and the organic polymer in a curable composition. Accordingly, the presence of an organic solvent in the aqueous solvent has been required, and it has been impossible to exclude an organic solvent. Further, the resin composition employing an aqueous solvent may sometimes undergo solidification during storage, and it has been difficult to practically use it.
As a method for producing a stable aqueous resin, JP-A-10-36514 discloses a technique wherein a polymer containing both hydrolyzable silyl groups and acid groups and a silicon compound having hydroxyl groups or hydrolyzable silyl groups, are subjected to a condensation reaction, followed by neutralization with a basic compound for stabilization. However, the physical properties of the coating film thereby obtainable, are not fully satisfactory, and further, depending upon the type of the silicon compound used, gelation is likely to result, and it has been difficult to obtain a stable liquid composition, or film forming has been difficult.
SUMMARY OF THE INVENTION
Under these circumstances, the present inventors have conducted extensive studies on the above problems and as a result, have found it possible to solve the problems with a resin composition obtained by blending a specific siloxane compound and a specific water-soluble resin, or with a resin composition obtained by blending a specific siloxane compound and a specific water-dispersible resin. The present invention has been accomplished on the basis of this discovery. Further, it has been found that as the water-soluble resin or the water-dispersible resin, one having the pH adjusted to a certain level, is particularly preferred.
According to a first aspect, the present invention provides:
1. A resin composition comprising the following components (1) and (2):
(1) a water-soluble resin having siloxane bonds, and
(2) a siloxane compound represented by the formula (A1):
SiO
a
X
b
Y
c
(A1)
wherein X is a hydrolyzable group, Y is a non-hydrolyzable group, 0≦a≦1.4, and b/(b+c)=0.01 to 1.0, provided 2a+b+c=4.
2. The resin composition according to Item 1, wherein the component (1) is a water-soluble resin having a pH of from 2 to 11.
3. The resin composition according to Item 1, wherein the component (1) is a water-soluble resin obtained by neutralizing a resin having carboxyl groups.
4. The resin composition according to Item 1, wherein the component (1) is a water-soluble resin composed of a resin having hydroxyl groups.
5. The resin composition according to Item 1, wherein the component (1) is a water-soluble resin obtained by neutralizing a resin having sulfonic groups.
6. The resin composition according to Item 1, wherein in the siloxane compound of the component (2), c=0.
7. A resin composition comprising a siloxane component represented by the formula (B1):
SiO
a′
X
b′
Y
c′
(B1)
wherein X is a hydrolyzable group, Y is a non-hydrolyzable group, 1.4<a′<2, and b′/(b′+c′)=0.0l to 1.0, provided 2a′+b′+c′=4.
8. The resin composition according to Item 7, wherein the siloxane component is in the form of particulates having an inertia radius of from 20 Å to 200 Å as measured by a small angle X-ray scattering method.
9. A coating composition comprising the resin composition as defined in Item 1 and a pigment and/or a powder dispersed in the resin composition.
10. A curable resin composition comprising the resin composition as defined in Item 1 and an epoxy resin, a polyisocyanate resin, a melamine resin or a resin having aziridine rings, oxazoline rings or carbodiimide groups, blended thereto.
11. A method for producing a resin composition, which comprises blending and aging the following components (1) and (2) within a pH of from 2 to 11 at a temperature of from 0 to 200° C.:
(1) a water-soluble resin having siloxane bonds, and
(2) a siloxane compound represented by the formula (A1):
SiO
a
X
b
Y
c
(A1)
wherein X is a hydrolyzable group, Y is a non-hydrolyzable group, 0≦a≦1.4, and b/(b+c)=0.01 to 1.0, provided 2a+b+c=4.
12. The method for producing a resin composition according to item 11, wherein an organic solvent is present at the time of blending the components (1) and (2), and the blending and aging are carried out within a temperature range of from 0 to 200° C.
According to a second aspect, the present invention provides:
13. A resin composition comprising the following components (1′) and (2′):
(1′) a water-dispersible resin having hydrolyzable silyl groups, and
(2′) a siloxane compound represented by the formula (A2):
SiO
a
X
b
(A2)
wherein X is a hydrolyzable group, 0≦a≦1.4, and b=1.2 to 4.0, provided 2a+b=4.
14. The resin composition according to Item 13, wherein the component (1′) is a water-dispersible resin having a pH of from 6 to 12.
15. The resin composition according to Item 13, wherein the component (1′) is a water-dispersible resin obtained by neutralizing a resin having carboxyl groups.
16. The resin composition according to Item 13, wherein the component (1′) is a water-dispersible resin composed of a resin having hydroxyl groups.
17. The resin composition according to Item 13, wherein the component (1′) is a water-dispersible resin obtained by neutralizing a resin having sulfonic groups.
18. A resin composition comprising a siloxane component represented by the formula (B2):
SiO
a′
X
b′
(B2)
wherein X is a hydrolyzable group, 1.4<a′<2, provided 2a′+b′=4.
19. A coating composition comprising the resin composition as defined in Item 13 and a powder dispersed in the resin composition.
20. A curable resin composition comprising the resin composition as defined in Item 13 and at least one member selected from the group consisting of an epoxy resin, a polyisocyanate resin, a melamine resin and a resin having at least one type of rings selected from the group consisting of aziridine rings, oxazoline rings and carbodiimide groups, blended thereto
21. A method for producing a resin composition, which comprises blending and aging the following components (1′) and (2′) within a pH of from 6 to 12 at a temperature of from 0 to 200° C.:
(1′) a water-dispersible resin having hydrolyzable silyl groups,
Miki Daisuke
Oochi Ikurou
Sawai Takeshi
Tanaka Seiichirou
Chuo Rika Kogyo Corporation
Oblon & Spivak, McClelland, Maier & Neustadt P.C.
Pyon Harold
Tsoy Elena
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