Thermosetting powder coating material and coated article

Patent metadata

Field	Value
Publication number	US-10040949-B2
Application number	US-201514806039-A
Country	US
Kind code	B2
Filing date	Jul 22, 2015
Priority date	Mar 23, 2015
Publication date	Aug 7, 2018
Grant date	Aug 7, 2018

Abstract

A thermosetting powder coating material includes powder particles containing a mixture of a vinyl resin A including a block isocyanate group and a carboxyl group and a vinyl resin B including a hydroxyl group and a carboxyl group, or a vinyl resin C including a block isocyanate group, a hydroxyl group and a carboxyl group, wherein a content of the isocyanate group is from 0.4 mmol/g to 1.4 mmol/g, and a functional group molar ratio of [NCO/(COOH+OH)], which is obtained by dividing the content of the isocyanate group by a total content of the hydroxyl group and the carboxyl group, is from 0.5 to 1.2.

First claim

What is claimed is:

1. A thermosetting powder coating material comprising:
powder particles containing:
a mixture of a vinyl resin A including a block isocyanate group and a carboxyl group and a vinyl resin B including a hydroxyl group and a carboxyl group, or
a vinyl resin C including a block isocyanate group, a hydroxyl group, and a carboxyl group,

wherein a content of the isocyanate group is from 0.4 mmol/g to 1.4 mmol/g, and a functional group molar ratio of [NCO/(COOH +OH)], which is obtained by dividing the content of the isocyanate group by a total content of the hydroxyl group and the carboxyl group, is from 0.5 to 1.2.

2. The thermosetting powder coating material according to claim 1 ,
wherein the vinyl resin A is at least one resin obtained by polymerization of at least one monomer selected from the group consisting of styrene, butyl methacrylate, butyl acrylate, methyl methacrylate, and methylacrylate.

3. The thermosetting powder coating material according to claim 1 ,
wherein the vinyl resin B is at least one resin obtained by polymerization of at least one monomer selected from the group consisting of hydroxyethyl methacrylate and hydroxyethyl acrylate.

4. The thermosetting powder coating material according to claim 1 ,
wherein a volume average particle diameter distribution index GSDv of the powder particles is equal to or less than 1.5.

5. The thermosetting powder coating material according to claim 1 ,
wherein the vinyl resins A to C each independently have a weight average molecular weight falling within the range of from 20,000 to 100,000.

6. The thermosetting powder coating material according to claim 1 ,
wherein the powder particles are particles having a core/shell structure.

7. The thermosetting powder coating material according to claim 6 ,
wherein any one of the vinyl resin A and the vinyl resin B is included in the core of the powder particles.

8. The thermosetting powder coating material according to claim 6 ,
wherein the resin of the shell portion is equal to or greater than 90% by weight with respect to an entire shell portion.

9. The thermosetting powder coating material according to claim 6 ,
wherein a coverage of the shell portion is from 30% to 100%.

10. The thermosetting powder coating material according to claim 6 ,
wherein a thickness of the shell portion is from 0.2μm to 4μm.

11. The thermosetting powder coating material according to claim 1 ,
wherein the powder particles contain a di- or higher-valent metal ion in an amount of from 0.002% by weight to 0.2% by weight.

12. The thermosetting powder coating material according to claim 11 ,
wherein the metal ion is at least one metal ion selected from the group consisting of aluminum ion, magnesium ion, iron ion, zinc ion, and calcium ion.

13. The thermosetting powder coating material according to claim 1 , further comprising a colorant in an amount of from 1% by weight to 70% by weight with respect to the entire resins contained in the powder particles.

14. The thermosetting powder coating material according to claim 13 ,
wherein the colorant includes titanium.

15. The thermosetting powder coating material according to claim 1 ,
wherein a volume average particle diameter D50v of the powder particles is from 1 μm to 25μm.

16. The thermosetting powder coating material according to claim 1 ,
further comprising inorganic particles as an external additive.

17. The thermosetting powder coating material according to claim 16 ,
wherein the inorganic particles include silica or titania.

18. The thermosetting powder coating material according to claim 16 ,
wherein the inorganic particles are those subjected to a hydrophobizing treatment.

19. The thermosetting powder coating material according to claim 1 ,
wherein the powder particles are those obtained by: aggregating at least resin particles which include the vinyl resin A and resin particles which include the vinyl resin B, which are dispersed in a dispersion, or at least resin particles which include the vinyl resin C and are dispersed in a dispersion to form aggregated particles; and coalescing the aggregated particles by heating.

20. A coated article comprising a coating film formed on a surface of a material to be coated, with the thermosetting powder coating material according to claim 1 .

Assignees

• Fuji Xerox Co Ltd

Inventors

• Ishizuka Takahiro

Classifications

• C09D5/035

  Coloring agents, e.g. pigments (C09D5/032 takes precedence) · CPC title

• C09D133/066

  containing -OH groups · CPC title

• C09D5/031 Primary

  characterised by particle size or shape · CPC title

• C09D125/14

  with unsaturated esters · CPC title

• C08L33/08

  Homopolymers or copolymers of acrylic acid esters · CPC title