Viscosity modifier for non-aqueous coating and non-aqueous coating composition

Abstract

This invention provides a viscosity modifier for non-aqueous coatings, and a non-aqueous coating composition containing the viscosity modifier exhibiting excellent anti-sagging properties. This viscosity modifier maintains excellent viscosity-imparting effects even when an amide-based viscosity modifier, including a fatty acid diamide, is added to ultra-high solids coatings or solvent-free coatings. The invention is a viscosity modifier for non-aqueous coatings comprising a fatty acid diamide obtained by condensing a diamine component with a monocarboxylic acid component, wherein the diamine component is 1,4-diaminobutane, and the non-aqueous coating is a solvent-free coating or an ultra-high solids coating.

Description

Technical Field

[0001] This invention relates to a viscosity modifier for non-waterborne coatings and a non-waterborne coating composition containing the viscosity modifier. Background Technology

[0002] Thixotropic agents (also known as viscosity modifiers) used in marine or heavy-duty anti-corrosion coatings containing organic solvents utilize micronized powders of clay minerals such as bentonite, hydrogenated castor oil, and fatty acid diamides. Among these, viscosity modifiers using fatty acid diamide micronized powders (hereinafter referred to as "amide-based viscosity modifiers") are widely used due to their excellent anti-sagging properties, water resistance, and thermal stability.

[0003] For example, Patent Document 1 discloses a flow property modifier for organic base materials, comprising a fatty acid diamide obtained by reacting a mixture of hydrogenated castor oil fatty acids and straight-chain saturated fatty acids having 6 to 12 carbon atoms with ethylenediamine (hereinafter sometimes referred to as "EDA") or 1,4-diaminobutane (hereinafter sometimes referred to as "1,4-DAB") in an equivalent ratio to the fatty acids. The mixing ratio of hydrogenated castor oil fatty acids to straight-chain saturated fatty acids in the above mixture is in the range of 8:2 to 3:7 molar ratio.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 56-112977 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] In recent years, in order to reduce environmental impact, research has been actively conducted in the field of marine or heavy-duty anti-corrosion coatings, focusing on ultra-high solids coatings that minimize solvent content and solvent-free coatings that do not use organic solvents.

[0009] To enable amide-based viscosity modifiers to exert their viscosity-imparting and anti-sagging effects, it is necessary to heat and swell the fatty acid diamide in the coating containing the viscosity modifier. This heating and swelling of the fatty acid diamide activates it (transforming it into a needle-like morphology), thus stably imparting viscosity to the coating system.

[0010] However, when amide-based viscosity modifiers are added to ultra-high solids coatings and solvent-free coatings, it is difficult to fully activate the fatty acid diamides in the coatings and achieve sufficient viscosity-imparting effects. Therefore, sagging problems sometimes occur when coating vertical surfaces.

[0011] Thus, in ultra-high solids coatings with minimal solvent content and solvent-free coatings that do not use organic solvents, an amide-based viscosity modifier with excellent tack-improving and anti-sagging properties is sought.

[0012] Therefore, the present invention was made in view of the above circumstances, and its object is to provide a viscosity modifier for non-aqueous coatings and a non-aqueous coating composition having excellent anti-sagging properties by containing the viscosity modifier, wherein the viscosity modifier for non-aqueous coatings has excellent viscosity-imparting effect even when an amide-based viscosity modifier including fatty acid diamide is added to ultra-high solids coatings or solvent-free coatings.

[0013] Methods for solving problems

[0014] In order to solve the above-mentioned problems, the inventors have repeatedly conducted in-depth research and found that by using 1,4-DAB as the raw material diamine component in the synthesis of fatty acid diamides used as viscosity modifiers, excellent viscosity-imparting effects can be exhibited even when amide-based viscosity modifiers are added to ultra-high solids coatings and solvent-free coatings. Based on this insight, the present invention was completed.

[0015] That is, the present invention is a viscosity modifier for non-aqueous coatings, comprising a fatty acid diamide obtained by condensing a diamine component with a monocarboxylic acid component, characterized in that the diamine component is 1,4-diaminobutane, and the non-aqueous coating is a solvent-free coating or an ultra-high solids coating.

[0016] In one embodiment of the invention, preferably, the monocarboxylic acid component is a mixture of hydrogenated castor oil fatty acids and straight-chain saturated fatty acids. More preferably, in this case, the straight-chain saturated fatty acids have 8 or more but less than 10 carbon atoms.

[0017] In other embodiments of the present invention, preferably, the monocarboxylic acid component comprises a straight-chain saturated fatty acid having 8 or more but less than 10 carbon atoms.

[0018] In addition, based on another perspective, the present invention is a non-aqueous coating composition containing a viscosity modifier and a resin, characterized in that the viscosity modifier comprises a fatty acid diamide obtained by condensing a diamine component with a monocarboxylic acid component, wherein the diamine component is 1,4-diaminobutane, and the non-aqueous coating composition is a solvent-free coating or an ultra-high solids coating.

[0019] In one embodiment of the invention, preferably, the monocarboxylic acid component is a mixture of hydrogenated castor oil fatty acids and straight-chain saturated fatty acids. More preferably, in this case, the straight-chain saturated fatty acids have 8 to 10 carbon atoms.

[0020] Preferably.

[0021] In other embodiments of the present invention, preferably, the monocarboxylic acid component comprises a straight-chain saturated fatty acid having 8 or more but less than 10 carbon atoms.

[0022] Invention Effects

[0023] According to the present invention, in the viscosity modifier for non-aqueous coatings, by using 1,4-DAB as the diamine component in the synthesis of fatty acid diamides used as viscosity modifiers, excellent viscosity-imparting effects can be exhibited even when amide-based viscosity modifiers are added to ultra-high solids coatings and solvent-free coatings. Detailed Implementation

[0024] The preferred embodiments of the present invention will now be described in detail.

[0025] Viscosity modifiers for non-water-based coatings

[0026] The viscosity modifier of the present invention is an additive for non-aqueous coatings, comprising specific fatty acid diamides.

[0027] (Fatty acid diamide)

[0028] The fatty acid diamide of the present invention is obtained by condensing a diamine component with a monocarboxylic acid component, wherein the diamine component is 1,4-diaminobutane (1,4-DAB). That is, the diamine component used in the synthesis of the fatty acid diamide of the present invention is only 1,4-DAB.

[0029] As the fatty acid diamide of the present invention, for example, a fatty acid diamide (a) can be used with N-12-hydroxystearic acid-N'-alkanoic acid tetramethylene diamide, N,N'-12-hydroxystearic acid tetramethylene diamide, and N,N'-alkanoic acid tetramethylene diamide as the main components. This fatty acid diamide (a) is obtained by adding an equivalent amount of 1,4-DAB to a mixture of hydrogenated castor oil fatty acids and straight-chain saturated fatty acids (hereinafter referred to as "alkanoic acids") and carrying out an amidation reaction. Therefore, when fatty acid diamide (a) is used as the fatty acid diamide of the present invention, the diamine component is 1,4-DAB, and the monocarboxylic acid component is a mixture of hydrogenated castor oil fatty acids and alkanoic acids.

[0030] The general formula of the main components contained in the above-mentioned fatty acid diamide (a) is as follows.

[0031] (1) N-12-hydroxystearic acid N'-alkanoic acid tetramethylenediamide

[0032] CH3(CH2)5CHOH(CH2) 10 CONH(CH2)4NHCO(CH2)l CH3

[0033] (In the above general formula, l is a natural number.)

[0034] (2) N,N'-12-hydroxystearic acid tetramethylenediamide

[0035] CH3(CH2)5CHOH(CH2) 10 CONH(CH2)4NHCO(CH2) 10 CHOH(CH2)5CH3

[0036] (3) N,N'-Alkanoic acid tetramethylenediamide

[0037] CH3(CH2) n CONH(CH2)4NHCO(CH2) m CH3

[0038] (In the above general formula, n and m are natural numbers.)

[0039] In addition, fatty acid diamide (a) contains a small amount of unreacted raw materials and by-products, in addition to the three components mentioned above (1) to (3).

[0040] Here, the fatty acid diamide of the present invention is not limited to the fatty acid diamide (a) described above, and any other fatty acid diamide obtained by condensing the diamine component exemplified below with the monocarboxylic acid component can also be used. In this case, the conditions of the condensation reaction (reaction temperature, proportions of each component, etc.) can be appropriately set by known methods.

[0041] <Diamine component>

[0042] As described above, only 1,4-DAB is used as the diamine component of this invention.

[0043] <Monocarboxylic acid components>

[0044] There are no particular limitations on the monocarboxylic acid component of this invention, and it may include, for example, straight-chain saturated fatty acids (alkanoic acids). Examples of alkanoic acids that can be used as monocarboxylic acid components of this invention include acetic acid, propionic acid, butyric acid, valeric acid, hexanoic acid, heptanoic acid, octanoic acid, nonanoic acid, decanoic acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid (docoanoic acid), and other saturated aliphatic monocarboxylic acids. Among these, saturated aliphatic monocarboxylic acids with 12 or fewer carbon atoms (acetic acid, propionic acid, butyric acid, valeric acid, hexanoic acid, heptanoic acid, octanoic acid, nonanoic acid, decanoic acid, lauric acid, etc.) can be used as the aforementioned alkanoic acids. When a fatty acid diamide using such an alkanoic acid is used, the viscosity modifier of this invention can effectively exert a viscosity-imparting effect.

[0045] When using these alkanes with 8 or more but less than 10 carbon atoms, the viscosity-imparting effect of the viscosity modifier of the present invention is further enhanced. As a result, the non-aqueous coating composition of the present invention containing a viscosity modifier including a fatty acid diamide obtained by using an alkane with 8 or more but less than 10 carbon atoms exhibits very excellent anti-sagging properties.

[0046] Furthermore, hydrogenated castor oil fatty acids may also be included as the monocarboxylic acid component of this invention. When a fatty acid diamide containing hydrogenated castor oil fatty acids is used, the viscosity modifier of this invention can effectively exert a viscosity-imparting effect.

[0047] Furthermore, the monocarboxylic acid component that undergoes a condensation reaction with the diamine component for the synthesis of the fatty acid diamide of the present invention can also be combined with hydrogenated castor oil fatty acid and alkanonic acid. When a mixture of hydrogenated castor oil fatty acid and alkanonic acid is used as the monocarboxylic acid component, the viscosity-imparting effect of the viscosity modifier of the present invention is further enhanced. As a result, the non-aqueous coating composition of the present invention containing a viscosity modifier including a fatty acid diamide obtained using such a monocarboxylic acid component exhibits very excellent anti-sagging properties.

[0048] In addition, as a monocarboxylic acid component of the present invention, unsaturated aliphatic monocarboxylic acids such as oleic acid, linoleic acid, ricinoleic acid, linolenic acid, eicosenoic acid, erucic acid, and mixed fatty acids obtained from natural oils (talc fatty acids, rice bran fatty acids, soybean oil fatty acids, beef tallow fatty acids, etc.) can also be used.

[0049] <Synthetic methods of fatty acid diamides>

[0050] The fatty acid diamide of the present invention is obtained by adding an equivalent amount of the diamine component to the monocarboxylic acid component and carrying out a polycondensation (amidation) reaction at 150-200°C. For example, the diamine component (containing at least 1,4-DAB) and the monocarboxylic acid component as raw materials are added to a reaction vessel such as a four-necked flask, and the raw materials are stirred in an inert gas atmosphere (e.g., under a nitrogen gas flow) to form a mixture. Then, the mixture of raw materials is heated and subjected to a polycondensation reaction at 150-200°C for 4-10 hours, thereby synthesizing the fatty acid diamide of the present invention.

[0051] (Hydrogenated castor oil)

[0052] Furthermore, the viscosity modifier of the present invention may also contain hydrogenated castor oil, to the extent that it does not impair the effects of the present invention. Hydrogenated castor oil is a triglyceride of saturated fatty acids obtained by hydrogenating castor oil. Commercially available products can be used as hydrogenated castor oil; examples of commercially available products include C-Wax (manufactured by Kokura Synthetic Industries, Ltd.), Kao Wax 85P (manufactured by Kao Corporation), hydrogenated castor oil A (manufactured by Ito Oil Co., Ltd.), and hydrogenated castor oil (manufactured by Yamagata Sangyo Co., Ltd.).

[0053] (Manufacturing method of viscosity modifier)

[0054] The viscosity modifier of the present invention described above can be manufactured as follows. For example, the fatty acid diamide synthesized as described above can be extracted in the form of a molten solid. By pulverizing the solid fatty acid diamide to a desired particle size, a powdered viscosity modifier comprising the fatty acid diamide can be manufactured. There are no particular limitations on the pulverization method for the solid fatty acid diamide; for example, an air jet mill can be used. Furthermore, there are no particular limitations on the particle size during pulverization; for example, it can be set to approximately 1 to 50 μm.

[0055] (Uses of viscosity modifiers)

[0056] The viscosity modifier of the present invention is suitable for use as an additive in non-aqueous coatings. Examples of non-aqueous coatings include marine coatings and heavy-duty anti-corrosion coatings. When using the viscosity modifier of the present invention as an additive in non-aqueous coatings, as described above, it is preferable to pulverize the solid fatty acid diamide to prepare a powdered viscosity modifier. Here, non-aqueous coatings using the viscosity modifier of the present invention are limited to solvent-free coatings or ultra-high solids coatings. Furthermore, details regarding "solvent-free coatings" and "ultra-high solids coatings" will be described later.

[0057] [Non-waterborne coating composition]

[0058] The non-aqueous coating composition of the present invention contains the aforementioned viscosity modifier and resin as essential components. The amide-based viscosity modifier is activated in the non-aqueous coating through heating and dispersion, exerting its effect as a viscosity modifier (such as viscosity-imparting effect). However, the degree of activation is affected by the coating formulation and the conditions during heating and dispersion (temperature, dispersion shear force, dispersion time, etc.). On the other hand, under the same coating formulation and heating and dispersion conditions, the ease of activation is determined by the composition of the viscosity modifier; therefore, the effect of the present invention is not limited by the content of the viscosity modifier incorporated in the coating. However, when the content of the viscosity modifier in the coating is too low, its effect as a viscosity modifier is weak. On the other hand, when the content of the viscosity modifier in the coating is too high, the coating thickens significantly, and the dispersion of the viscosity modifier in the coating, the workability of the coating, and the application become difficult. Therefore, the content of the viscosity modifier in the non-aqueous coating composition is preferably 0.2% to 5% by mass.

[0059] The non-aqueous coating composition of the present invention is a solvent-free coating or an ultra-high solids coating. Solvent-free coatings are coatings that do not contain volatile solvents (organic solvents, etc.) used to dissolve the resin in the coating. Since solvent evaporation is not required during film formation, they have the advantage of contributing to low VOC content. Furthermore, because they do not contain volatile solvent components, the coating thickness is approximately the same as the thickness after drying, making them suitable for coating applications where a greater film thickness is desired. Ultra-high solids coatings are coatings that minimize the content of volatile solvents in the coating. In the present invention, coatings with a volatile solvent content of 15% by mass or less based on the total amount of the coating are referred to as "ultra-high solids coatings".

[0060] Furthermore, as mentioned above, "solvent-free coating" generally refers to a coating that does not contain volatile solvents. However, depending on the need, it may also contain liquid components (components that remain in the coating film), such as reactive diluents, non-reactive diluents, and silane coupling agents. Therefore, in this invention, "solvent-free coating" includes not only completely solvent-free coatings that do not contain any liquid components that can function as solvents, but also coatings that contain components that remain in the coating film as described above and do not contain volatile solvents. In addition, reactive diluents include, for example, acrylates such as methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, n-hexyl acrylate, n-hexyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, and phenyl glycidyl ether acrylate; polyurethane prepolymers such as hexamethylene diisocyanate polyurethane prepolymer and phenyl glycidyl ether acrylate-toluene diisocyanate polyurethane prepolymer; glycidyl ethers such as n-butyl glycidyl ether, 2-ethylhexyl glycidyl ether, stearic acid glycidyl ether, styrene oxide, phenyl glycidyl ether, nonylphenyl glycidyl ether, butylphenyl glycidyl ether, 1,6-hexanediol diglycidyl ether, ethylene glycol diglycidyl ether, and diethylene glycol diglycidyl ether; and chlorostyrene, methoxystyrene, butoxystyrene, and vinylbenzoic acid. Furthermore, petroleum resin-based diluents are preferred as non-reactive diluents. Examples of petroleum resin-based diluents include aliphatic or aromatic high-boiling-point oils, phenol-modified aliphatic or aromatic polymers, xylene resin, and toluene resin.

[0061] (solvent)

[0062] As a solvent in this invention, that is, a volatile solvent used to dissolve the resin in the coating, organic solvents can be listed as examples, and there is no particular limitation on any solvent used in the field of coatings.

[0063] Examples of organic solvents include: alcohols such as methanol, ethanol, isopropanol, 1-butanol (n-butanol), 2-butanol, 1-pentanol, octanol, benzyl alcohol, glycerol, ethylene glycol, and propylene glycol; carboxylic acids such as acetic acid; aliphatic hydrocarbons such as hexane, heptane, octane, and decane; aromatic hydrocarbons such as toluene and xylene; amides such as dimethyl sulfoxide, N,N-dimethylformamide, dimethylacetamide, and acetanilide; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; halogens such as dichloromethane and chloroform; carbonates such as ethylene carbonate, propylene carbonate, dimethyl carbonate, and diethyl carbonate; esters such as methyl acetate, ethyl acetate, propyl acetate, butyl acetate, methyl butyrate, and propylene glycol monomethyl ether acetate (PMA); ethers such as propylene glycol monomethyl ether (PM); and acetonitrile and propionitrile. These solvents can be used alone or in combination of two or more.

[0064] (Organic media)

[0065] In non-aqueous coating compositions (solvent-containing coatings) containing the solvents of the present invention, organic media containing reactive functional groups and non-reactive organic media can be used together with the solvents described above.

[0066] Organic media containing reactive functional groups include, for example, acrylates such as methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, n-hexyl acrylate, n-hexyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, and phenyl glycidyl ether acrylate; polyurethane prepolymers such as hexamethylene diisocyanate polyurethane prepolymer and phenyl glycidyl ether acrylate-toluene diisocyanate polyurethane prepolymer; glycidyl ethers such as n-butyl glycidyl ether, 2-ethylhexyl glycidyl ether, stearic acid glycidyl ether, styrene oxide, phenyl glycidyl ether, nonylphenyl glycidyl ether, butylphenyl glycidyl ether, 1,6-hexanediol diglycidyl ether, ethylene glycol diglycidyl ether, and diethylene glycol diglycidyl ether; and chlorostyrene, methoxystyrene, butoxystyrene, and vinylbenzoic acid.

[0067] Furthermore, as a non-reactive organic medium, petroleum resin-based organic media with a viscosity of 1-200 cps at 25°C and a heating residue of 90% or more can be preferably used. Examples of petroleum resin-based organic media include aliphatic or aromatic high-boiling-point oils, phenol-modified aliphatic or aromatic polymers, xylene resins, and toluene resins.

[0068] (Resin)

[0069] The non-aqueous coating composition of the present invention also contains resin as the main component for forming the coating film.

[0070] The coating resins that can be used in the non-aqueous coating compositions of the present invention are not particularly limited as long as they are resins that have been conventionally used as matrix resins for non-aqueous coatings, and various resins can be incorporated into the non-aqueous coating compositions. Examples of non-aqueous coating matrix resins that can be used in the non-aqueous coating compositions of the present invention include alkyd resins, acrylic resins, acrylic polyurethane resins, melamine resins, polyurethane resins, epoxy resins, coumarone resins, urea-formaldehyde resins, phenolic resins, vinyl chloride resins, phenoxy resins, silicone resins, fluoropolymers, nylon resins, styrene-butadiene resins, nitrile resins, petroleum resins, rosin, drying oils, refined oils, cellulose acetate, cellulose nitrate, etc. These resins can be, for example, resins that are cured by chemical reaction in the presence or absence of a catalyst, such as heat-curing, UV-curing, electron beam curing, oxidative curing, photocationic curing, peroxide curing, and acid / epoxy curing types, or resins with high glass transition temperatures that do not undergo chemical reaction and become a coating simply by evaporation of a diluted solvent. In addition, examples of curing agents include amino resins, melamine resins, isocyanate compounds, blocked isocyanate compounds, and epoxy compounds. A single matrix resin can be used, or two or more can be used in combination.

[0071] From the viewpoint of film-forming properties, the resin content in the non-aqueous coating composition is preferably 20 to 99.5% by mass.

[0072] (filler)

[0073] From the viewpoint of improving the appearance and properties of the coating film, the non-aqueous coating composition of the present invention may further contain fillers such as extender pigments, coloring pigments, and metallic pigments.

[0074] Examples of fillers include: calcium carbonate (heavy calcium carbonate (GCC), precipitated calcium carbonate (PCC) etc.), barium sulfate, silicon dioxide, aluminum hydroxide, talc, organic fibers, glass powder and other extender pigments; titanium dioxide, carbon black, chrome yellow, cadmium yellow, ochre, titanium yellow, zinc chromate, iron oxide red, aluminosilicates, quinacridones, phthalocyanines, anthraquinones, diketopyrrolopyrroles, benzimidazolones and isoindolinones and other coloring pigments; and aluminum flakes, copper flakes, mica iron oxide, mica and flake-like powders made by coating metal oxides on mica, etc.

[0075] The non-aqueous coating composition of the present invention does not necessarily contain fillers, but from the viewpoint of achieving the purpose of adding fillers, the filler content in the non-aqueous coating composition is preferably 0.001 to 80% by mass.

[0076] (Other additives)

[0077] Without impairing its properties or the purpose of the invention, the non-aqueous coating composition of the present invention may contain, for example, dehydrating agents (e.g., silane coupling agents), adhesion promoters, surfactants, curing catalysts, plasticizers, film-forming aids, desiccants, antifouling agents, sensitizers, antioxidants, light stabilizers, ultraviolet absorbers, water-resistant agents, preservatives and mildew inhibitors, defoamers, leveling agents, dispersants, flame retardants, antistatic agents, stripping agents, deodorizers, fragrances, and other additives.

[0078] (Method for manufacturing non-waterborne coating compositions)

[0079] The manufacturing method of the non-aqueous coating composition of the present invention is not particularly limited. A viscosity modifier including a fatty acid diamide can be pre-added to the resin and uniformly dispersed before being incorporated into the remaining raw materials. Alternatively, it can be added and mixed together with various additives, solvents, and resins during the preparation of the non-aqueous coating composition. If the viscosity modifier is not sufficiently dispersed in the non-aqueous coating composition, the effects of the present invention may not be fully realized.

[0080] (Instructions for use of non-water-based coating compositions)

[0081] The non-aqueous coating composition of the present invention can be used in the form of a dispersion, or it can be used to prepare a dry powdered non-aqueous coating composition by removing liquid components such as solvents from the dispersion through drying treatment or the like.

[0082] The non-aqueous coating composition of the present invention can be applied to the surface of various substrates to achieve a desired film thickness using known coating methods, such as roller coating, brush coating, air spraying, airless spraying, electrostatic coating, etc. Furthermore, by curing the non-aqueous coating composition applied to the surface of the substrate, a coated article having a coating film comprising the cured non-aqueous coating composition can be obtained.

[0083] Examples of substrates include: iron, aluminum, brass, copper, stainless steel, tinplate, galvanized steel, zinc alloys (Zn-Al, Zn-Ni, Zn-Fe, etc.), clad steel, and other metallic materials; polyethylene resin, polypropylene resin, acrylonitrile-butadiene-styrene (ABS) resin, polyamide resin, acrylic resin, vinylidene chloride resin, polycarbonate resin, polyurethane resin, epoxy resin, and other resins; various FRP and other plastic materials; and inorganic materials such as glass, cement, and concrete. These can be substrates that have undergone surface treatment, etc.

[0084] (Uses of non-water-based coating compositions)

[0085] The non-aqueous coating compositions of the present invention can be used, for example, in marine coatings or anti-corrosion coatings, but are not limited to these uses; they can be used in a variety of applications where non-aqueous coatings are generally applicable.

[0086] The preferred embodiments of the present invention have been described above, but the present invention is not limited to the above-described embodiments. That is, it should be understood that other embodiments or various modifications that can be conceived by those skilled in the art within the scope of the invention as described in the claims also fall within the technical scope of the present invention.

[0087] Example

[0088] The present invention will be specifically described below with reference to specific embodiments. However, the present invention is not limited to these embodiments. Additionally, unless otherwise stated, "%" and "parts" in the embodiments refer to "mass %" and "parts by mass".

[0089] (Synthesis of fatty acid diamides)

[0090] In a four-necked flask, the diamine and monocarboxylic acid components listed in Table 1 were added as raw materials in the molar ratio specified in Table 1. The mixture was reacted at 190°C for 6 hours under a nitrogen atmosphere to remove the generated water, yielding fatty acid diamides of synthetic examples E1~E2 and C1~C4.

[0091] [Table 1]

[0092] (Manufacturing of viscosity modifiers)

[0093] Next, the fatty acid diamides of synthesis examples E1~E2 and C1~C4 were pulverized to a median particle size of 1μm~10μm using a pulverizer, thereby obtaining viscosity modifiers of manufacturing examples 1~2 and comparative manufacturing examples 1~4.

[0094] [Experimental Example 1: Solvent-free Coating Formulation]

[0095] This experimental example evaluates the tack-imparting effect and anti-sagging properties of non-aqueous coating compositions when they are solvent-free coatings.

[0096] (Preparation of non-water-based coating compositions)

[0097] Using the viscosity modifiers of Manufacturing Examples 1-2 and Comparative Manufacturing Examples 1-4 obtained as described above, non-aqueous coating compositions of Examples 1-2 and Comparative Examples 1-4 were manufactured with formulation α shown in Table 2 or formulation β shown in Table 2.

[0098] <Example 1, Comparative Examples 1-3>

[0099] Regarding Example 1 and Comparative Examples 1-2, as shown in Table 2, 39.2 parts of jER (registered trademark) 806 (an epoxy resin manufactured by Mitsubishi Chemical Corporation) were used as the resin, 11.3 parts of LS-632 (a difunctional reactive diluent manufactured by Hubei Green Home Materials Technology Co., Ltd.) and 2.3 parts of Sila-Ace (registered trademark) S510 (a silane coupling agent manufactured by JNC Corporation) were used as reactive diluents, 8.8 parts of talc No. 1 (an extender pigment manufactured by Takehara Chemical Industry Co., Ltd.) and 15.0 parts of PG-K10 (Sibelco) were used as reactive diluents. The epoxy base (Part A) was obtained by dispersing 22.1 parts of barium sulfate BA (manufactured by Sakai Chemical Industry Co., Ltd.) and 1.3 parts of Tipaque R-820 (manufactured by Ishihara Sangyo Co., Ltd.) as pigments and 1.5 parts of viscosity modifier in a constant temperature water bath at 60°C for 10 minutes using a disperser (blade diameter of 5 cm) to a disperser. 21.5 parts of Ancamine 2644 (amine curing agent manufactured by Evonik Japan Co., Ltd.) were added to this base as a curing agent (Part B), and the mixture was prepared to obtain the non-aqueous coating compositions of Examples 1 and Comparative Examples 1-2. Similarly to Example 1, the non-aqueous coating composition of Comparative Example 3 was obtained, except that it did not contain a viscosity modifier. The viscosity modifiers and coating formulations used in Examples 1 and Comparative Examples 1-3 are shown in Table 4.

[0100] <Example 2 and Comparative Examples 4-6>

[0101] Regarding Examples 2 and Comparative Examples 4-5, as shown in Table 3, 39.2 parts of jER (registered trademark) 806 (an epoxy resin manufactured by Mitsubishi Chemical Corporation) were used as the resin, 11.3 parts of LS-AGE (a monofunctional reactive diluent manufactured by Hubei Green Home Materials Technology Co., Ltd.) and 2.3 parts of Sila-Ace (registered trademark) S510 (a silane coupling agent manufactured by JNC Corporation) were used as reactive diluents, 8.8 parts of talc No. 1 (an extender pigment manufactured by Takehara Chemical Industry Co., Ltd.) and 15.0 parts of PG-K10 (Sibelco) were used as reactive diluents. The epoxy base (Part A) was obtained by dispersing 22.1 parts of barium sulfate BA (manufactured by Sakai Chemical Industry Co., Ltd.) and 1.3 parts of Tipaque R-820 (manufactured by Ishihara Sangyo Co., Ltd.) as pigments and 1.5 parts of viscosity modifier in a constant temperature water bath at 60°C for 10 minutes using a disperser (blade diameter of 5 cm) to amplify the pigments. 19.0 parts of Ancamine 2644 (amine curing agent manufactured by Evonik Japan Co., Ltd.) were added to this base as curing agent (Part B), and the mixture was prepared to obtain the non-aqueous coating compositions of Examples 2 and Comparative Examples 4-5. Similarly to Example 2, the non-aqueous coating composition of Comparative Example 6 was obtained, except that it did not contain a viscosity modifier. The viscosity modifiers and coating formulations used in Examples 2 and Comparative Examples 4-6 are shown in Table 5.

[0102] [Table 2]

[0103] [Table 3]

[0104] [Table 4]

[0105] [Table 5]

[0106] (Evaluation Method)

[0107] Regarding the non-aqueous coating compositions of Examples 1-2 and Comparative Examples 1-6 obtained as described above, the effects of tack-imparting and anti-sagging properties were evaluated as follows.

[0108] <Evaluation of the effect of imparting viscosity>

[0109] The day after preparing the non-aqueous coating composition as described above, the viscosity (P) at 60 rpm was measured using a Type B viscometer at 25°C. These results are shown in Tables 4 and 5. Furthermore, a higher viscosity of the non-aqueous coating composition indicates a greater viscosity-imparting effect of the viscosity modifier.

[0110] <Evaluation of anti-sag performance>

[0111] As an indicator of anti-sagging properties, the sag limit film thickness of the non-aqueous coating composition prepared as described above is measured. Specifically, using a sagging tester (trade name "Sagging Tester BOX 100-500, 600-1000, 800μm~1200, 1100-1500, 1200-1600 or 1600-2000" sagging test device manufactured by Taiyu Machinery Co., Ltd.), the non-aqueous coating composition of any one of Examples 1-2 and Comparative Examples 1-6 was coated on sagging test paper (trade name "All Black Test Paper" manufactured by Taiyu Machinery Co., Ltd.) with five different film thicknesses (100μm~500μm, 600μm~1000μm, 800μm~1200μm, 1100μm~1500μm, 1200μm~1600μm or 1600μm~2000μm) with a thickness difference of 100μm. As a result, five coating strips of different thicknesses were arranged at predetermined intervals on the sag test paper. Next, the test paper was held vertically with the thinnest coating strip facing upwards and air-dried at room temperature. The thickness of the coating strip with a thickness thinner than the coating strip observed below was taken as the sag limit thickness (μm): the coating first drips across the intervals between the coating strips, thus contacting the coating strip below. Furthermore, in this embodiment, if the sag limit thickness evaluated by the above method is 800 μm or more, it is determined that it possesses anti-sag properties sufficient to solve the problem of the present invention.

[0112] (Evaluation Results)

[0113] The evaluation results of the adhesion-imparting effect and anti-sagging properties, as described above, are shown in Tables 4 and 5 above.

[0114] As shown in Tables 4 and 5, the non-aqueous coating compositions of Examples 1-2, which used 1,4-DAB as the diamine component, showed significant differences in viscosity and sag limit film thickness compared to the non-aqueous coating compositions of Comparative Examples 1, 2, 4, and 5, which used diamines other than 1,4-DAB (EDA or HMDA) as the diamine component, and the non-aqueous coating compositions of Comparative Examples 3 and 6, which did not contain viscosity modifiers. They also exhibited excellent viscosity-imparting effect and anti-sag properties.

[0115] [Experimental Example 2: Formulation of Ultra-High Solids Coatings]

[0116] This experimental example evaluates the tack-imparting effect and anti-sagging properties of non-aqueous coating compositions when the composition is an ultra-high solids coating.

[0117] (Preparation of non-water-based coating compositions)

[0118] Using the viscosity modifiers of Manufacturing Examples 1-2 and Comparative Manufacturing Examples 1 and 3 obtained as described above, non-aqueous coating compositions of Examples 3-4 and Comparative Examples 7 and 9 were manufactured with formulation γ shown in Table 6 or formulation δ shown in Table 7.

[0119] <Example 3, Comparative Examples 7-8>

[0120] Regarding Examples 3 and Comparative Examples 7-8, as shown in Table 6, 39.1 parts of jER (registered trademark) 806 (epoxy resin manufactured by Mitsubishi Chemical Corporation) were used as resin, 11.3 parts of LS-632 (difunctional reactive diluent manufactured by Hubei Green Home Materials Technology Co., Ltd.) and 2.3 parts of Sila-Ace (registered trademark) S510 (silane coupling agent manufactured by JNC Corporation) were used as reactive diluents, 2.0 parts of dimethyl carbonate were used as organic solvent, 8.8 parts of talc No. 1 (extender pigment manufactured by Takehara Chemical Industry Co., Ltd.) and 15.0 parts of PG-K10 (Sibelco) were used as organic solvents. The epoxy base (Part A) was obtained by dispersing 22.1 parts of barium sulfate BA (manufactured by Sakai Chemical Industry Co., Ltd.) and 1.3 parts of Tipaque R-820 (manufactured by Ishihara Sangyo Co., Ltd.) as pigments and 1.0 part of viscosity modifier in a constant temperature water bath at 60°C for 10 minutes using a disperser (blade diameter of 5 cm) to obtain the epoxy base. Part B was obtained by adding 21.5 parts of Ancamine 2644 (amine curing agent manufactured by Evonik Japan Co., Ltd.) and 9.1 parts of xylene to this base and mixing them to obtain the non-aqueous coating compositions of Example 3 and Comparative Example 7. Similarly to Example 3, except that the viscosity modifier was not present, the non-aqueous coating composition of Comparative Example 8 was obtained. The viscosity modifiers and coating formulations used in Examples 3 and Comparative Examples 7-8 are shown in Table 8.

[0121] <Example 4 and Comparative Examples 9-10>

[0122] Regarding Examples 4 and Comparative Examples 9-10, as shown in Table 7, 39.1 parts of jER (registered trademark) 806 (epoxy resin manufactured by Mitsubishi Chemical Corporation) were used as resin, 11.3 parts of LS-632 (difunctional reactive diluent manufactured by Hubei Green Home Materials Technology Co., Ltd.) and 2.3 parts of Sila-Ace (registered trademark) S510 (silane coupling agent manufactured by JNC Corporation) were used as reactive diluents, 2.0 parts of dimethyl carbonate were used as organic solvent, 8.8 parts of talc No. 1 (extender pigment manufactured by Takehara Chemical Industry Co., Ltd.) and 15.0 parts of PG-K10 (Sibelco) were used as organic solvents. The epoxy base (Part A) was obtained by dispersing 22.1 parts of barium sulfate BA (manufactured by Sakai Chemical Industry Co., Ltd.) and 1.3 parts of Tipaque R-820 (manufactured by Ishihara Sangyo Co., Ltd.) as pigments and 1.0 part of viscosity modifier in a constant temperature water bath at 60°C for 10 minutes using a disperser (blade diameter of 5 cm) to obtain the epoxy base. Part B was obtained by adding 19.0 parts of Ancamine 2644 (amine curing agent manufactured by Evonik Japan Co., Ltd.) and 9.1 parts of xylene to this base and mixing them to obtain the non-aqueous coating compositions of Example 4 and Comparative Example 9. Similarly to Example 4, except that the viscosity modifier was not present, the non-aqueous coating composition of Comparative Example 10 was obtained. The viscosity modifiers and coating formulations used in Examples 4 and Comparative Examples 9-10 are shown in Table 9.

[0123] [Table 6]

[0124] [Table 7]

[0125] [Table 8]

[0126] [Table 9]

[0127] (Evaluation Method)

[0128] The non-aqueous coating compositions of Examples 3-4 and Comparative Examples 7-10 obtained as described above were evaluated for tack-imparting effects and anti-sagging properties in the same manner as in Example 1.

[0129] (Evaluation Results)

[0130] The evaluation results of the adhesion-imparting effect and anti-sagging properties, as described above, are shown in Tables 8 and 9 above.

[0131] As shown in Tables 8 and 9, the non-aqueous coating compositions of Examples 3-4, which used 1,4-DAB as the diamine component, showed significant differences in viscosity and sag limit film thickness compared to the non-aqueous coating compositions of Comparative Examples 7 and 9, which used diamines (EDA) other than 1,4-DAB as the diamine component, and the non-aqueous coating compositions of Comparative Examples 8 and 10, which did not contain viscosity modifiers. They also exhibited excellent viscosity-imparting effect and anti-sag properties.

Claims

1. A viscosity modifier for non-aqueous coatings, comprising a fatty acid diamide obtained by condensing a diamine component with a monocarboxylic acid component, characterized in that, The diamine is 1,4-diaminobutane. The non-aqueous coating is a solvent-free coating or an ultra-high solids coating.

2. The viscosity modifier for non-water-based coatings according to claim 1, characterized in that, The monocarboxylic acid component is a mixture of hydrogenated castor oil fatty acids and straight-chain saturated fatty acids.

3. The viscosity modifier for non-water-based coatings according to claim 2, characterized in that, The straight-chain saturated fatty acid has 8 or more but less than 10 carbon atoms.

4. The viscosity modifier for non-water-based coatings according to claim 1, characterized in that, The monocarboxylic acid component comprises straight-chain saturated fatty acids with 8 or more but less than 10 carbon atoms.

5. A non-water-based coating composition comprising a viscosity modifier and a resin, characterized in that, The viscosity modifier comprises a fatty acid diamide obtained by condensing a diamine component with a monocarboxylic acid component. The diamine is 1,4-diaminobutane. The non-aqueous coating composition is a solvent-free coating or an ultra-high solids coating.

6. The non-aqueous coating composition according to claim 5, characterized in that, The monocarboxylic acid component is a mixture of hydrogenated castor oil fatty acids and straight-chain saturated fatty acids.

7. The non-aqueous coating composition according to claim 6, characterized in that, The straight-chain saturated fatty acid has 8 to 10 carbon atoms.

8. The non-aqueous coating composition according to claim 5, characterized in that, The monocarboxylic acid component contains a straight-chain saturated fatty acid with 8 to 10 carbon atoms.

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