Coating composition and process for manufacturing the same

Claim 2

The coating composition according to Claim 1, wherein said component (a) is a partial condensate of organosilane (a') and has a weight average molecular weight, in terms of polystyrene, of 500 to 50,000.

Claim 3

The coating composition according to Claim 1, wherein said organosilane (a') is at least one member selected from the group consisting of methyltrimethoxysilane, methyltriethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, n-propyltrimethoxysilane, n-propyltriethoxysilane, i-propyltrimethoxysilane, i-propyltriethoxysilane, gamma -chloropropyltrimethoxysilane, gamma -chloropropyltriethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane, 3,3,-triphloropropyltrimethoxysilane, 3,3,3-trifluoropropyltriethoxysilane, gamma -glycidoxypropyltrimethoxysilane, gamma -glycidoxypropyltriethoxysilane, gamma -methacryloxypropyltrimethoxysilane, gamma -methacryloxypropyltriethoxysilane, gamma -mercaptopropyltrimethoxysilane, gamma -mercaptopropyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane, 3,4-epoxycyclohexylethyltrimethoxysilane, and 3,4-epoxycyclohexylethyltriethoxysilane.

Claim 4

The coating composition according to Claim 1, wherein the amount of said component (b) is 5 to 100 parts by weight.

Claim 5

The coating composition according to Claim 1, wherein said at least one silyl group contained in said vinyl resin of component (c) is selected from silyl groups represented by the following formula: wherein X represents a halogen atom, alkoxy group, acyloxy group, aminoxy group, phenoxy group, thioalkoxy group, or amino group, hydroxyl group; R⁶ is a hydrogen atom, an alkyl group with 1 to 10 carbon atoms, or an aralkyl group with 1 to 10 carbon atoms; and n is an integer from 1 to 3.

Claim 6

The coating composition according to Claim 1, wherein said component (c) is (i) a reaction product of a hydrosilane compound and a vinyl resin which has a carbon-carbon double bond, or (ii) a polymerization product of a silane compound represented by the following formula: wherein X represents a halogen atom, alkoxy group, acyloxy group, aminoxy group, phenoxy group, thioalkoxy group, or amino group, hydroxyl group; R⁶ is a hydrogen atom, an alkyl group with 1 to 10 carbon atoms, or an aralkyl group with 1 to 10 carbon atoms; and R⁷ is an organic group containing a double bond polymerizable with a vinyl compound; and n is an integer from 1 to 3.

Claim 7

The coating composition according to Claim 1, wherein the amount of said component (c) is 5 to 200 parts by weight.

Claim 8

The coating composition according to Claim 1, wherein said component (c) has a number average molecular weight, in terms of polystyrene, of 2,000 to 100,000.

Claim 9

The coating composition according to Claim 1, wherein said metal chelate compound of component (d) is one or more compounds selected from the group consisting of tri-n-butoxyethylacetoacetate zirconium, di-n-butoxy·bis(ethylacetoacetate) zirconium, n-butoxytris(ethylacetoacetate) zirconium, tetrakis(n-propylacetoacetate) zirconium, tetrakis(acetylacetoacetate) zirconium, tetrakis(ethylacetoacetate) zirconium, diisopropoxy·bis(ethylacetoacetate) titanium, diisopropoxy·bis(acetylacetonate) titanium, diisopropoxyethylacetoacetate aluminum, diisopropoxyacetylacetonate aluminum, isopropoxy·bis(ethylacetoacetate) aluminum, isopropoxy·bis(acetylacetonate) aluminum, tris(ethylacetoacetate) aluminum, tris(acetylacetonate) aluminum, and monoacetylacetonate·bis(ethylacetoacetate) aluminum.

Claim 10

The coating composition according to Claim 1, wherein said component (e) is one or more solvents selected from the group consisting of alcohols, aromatic hydrocarbons, ethers, ketones, and esters.

Claim 11

The coating composition according to Claim 1, wherein said β-diketone or β-ketoester of component (f) is one or more compounds selected from the group consisting of acetylacetone, methyl acetoacetate, ethyl acetoacetate, n-propyl acetoacetate, i-propyl acetoacetate, n-butyl acetoacetate, sec-butyl acetoacetate, t-butyl acetoacetate, 2,4-hexanedione, 2,4-heptanedione, 3,5-heptanedione, 2,4-octanedione, 2,4-nonanedione, and 5-methylhexanedione.

Claim 12

The coating composition according to Claim 1, wherein the amount of said component (f) is 3 to 20 mols for component (d).

Claim 13

The coating composition according to Claim 1, containing 10 to 300 parts by weight said component (f) for 100 parts by weight of the solid portion of said composition (I) which comprises said components (a), (b), (c), (d), and (e).

Claim 14

The coating composition according to Claim 1, further comprising a hardening promoter.

Claim 15

A process for preparing a coating composition comprising, providing composition (I) which comprises the following components (a), (b), (c), (d), and (e): (a) for 100 parts by weight, in terms of organosilane, of a hydrolyzate and/or a partial condensate of an organosilane represented by formula R¹Si(OR²)₃, wherein R¹ is an organic group with 1 to 8 carbon atoms, and R² is an alkyl group with 1 to 5 carbon atoms, or an acyl group with 1 to 4 carbon atoms, (b) 0 to 150 parts by weight, in terms of diorganosilane, of a hydrolyzate and/or a partial condensate of a diorganosilane represented by formula R¹₂Si(OR²)₂ wherein R¹ and R² are the same as defined above, (c) 2 to 300 parts by weight of a vinyl resin containing a silyl group with at least one silyl group containing a silicon atom linked to a hydrolyzable group and/or a hydroxyl group at the end or a side chain in one polymer molecule, (d) 0.01 to 50 parts by weight of at least one metal chelate compound selected from a group of compounds represented by formulas Zr(OR³) p (R⁴COCHCOR⁵) 4-p , Ti(OR³)q(R⁴COCHCOR⁵) 4-q , and Al(OR³) r (R⁴COCHCOR⁵) 3-r , wherein R³ and R⁴ are the same or different alkyl groups with 1 to 6 carbon atoms, R⁵ is an alkyl group with 1 to 5 carbon atoms or an alkoxy group with 1 to 16 carbon atoms, p and q are integers from 0 to 3, and r is an integer from 0 to 2, and (e) an organic solvent; and mixing said composition (I) with component (f), which is at least 2 mols, for one mol of said metal chelate compound (d) in said composition (I), of a β-diketone compound and/or β-ketoester compound represented by formula R⁴COCH₂COR⁵, wherein R⁴ and R⁵ are the same as above.

Claim 16

A process according to Claim 15 comprising steps of, preparing a solution comprising an organosilane (a') as component (a), a diorganosilane (b') as component (b), a vinyl resin containing a silyl group as component (c), a metal chelate compound as component (d), and an organic solvent as component (e); adding 1.2 to 3 mols of water for one mol of the organosilane (a') and 0.8 to 2 mols of water for one mol of the diorganosilane (b'), to effect a hydrolysis/condensation reaction, thus producing composition (I); and adding β-diketone and/or β-ketoester which is component (f).

Claim 17

A process according to Claim 15 comprising steps of, preparing a solution containing an organosilane (a') as component (a), a diorganosilane (b') as component (b), and an organic solvent component (e); adding 1.2 to 3 mols of water for one mol of the organosilane (a') and 0.8 to 2 mols of water for one mol of the diorganosilane (b'), to effect a hydrolysis/condensation reaction; adding a vinyl resin containing a silyl group, as component (c), and a metal chelate compound, as component (d), thus producing composition (I); and adding to the resulting mixture β-diketone and/or β-ketoester which is component (f).

Claim 18

A process according to Claim 15, comprising steps of, preparing a solution containing an organosilane (a') as component (a), a diorganosilane (b') as component (b), a metal chelate compound as component (d], and an organic solvent as component (e); adding 1.2 to 3 mols of water for one mol of the organosilane (a') and 0.8 to 2 mols of water for one mol of the diorganosilane (b'), to effect a hydrolysis/condensation reaction; adding a vinyl resin containing a silyl group as component (c), thus producing composition (I); and adding to the resulting mixture β-diketone and/or β-ketoester which is component (f).