Anticorrosion coating composition kit, method for producing anticorrosion coating composition, anticorrosion coating film, substrate with anticorrosion coating film, and method for manufacturing substrate with anticorrosion coating film

Abstract

An embodiment of the present invention relates to an anticorrosion coating composition kit, a method for producing an anticorrosion coating composition, an anticorrosion coating film, a substrate with an anticorrosion coating film, and a method for manufacturing a substrate with an anticorrosion coating film. The anticorrosion coating composition kit contains: a first agent including a non-aqueous epoxy compound (A); and a second agent including a water-dilutable component (B) containing an amine compound, a non-aqueous component (C) containing an amine compound, a pigment (D), and water.

Description

Anticorrosion coating composition kit, method for producing anticorrosion coating composition, anticorrosion coating film, substrate with anticorrosion coating film, and method for producing substrate with anticorrosion coating film

[0001] One embodiment of the present invention relates to an anticorrosion coating composition kit, a method for producing an anticorrosion coating composition, an anticorrosion coating, a substrate with an anticorrosion coating, or a method for producing a substrate with an anticorrosion coating.

[0002] BACKGROUND ART Solvent-based epoxy resin anticorrosive paints have conventionally been applied to substrates such as ships, marine structures, plants, bridges, and land-based tanks in order to ensure their long-term use.

[0003] In recent years, with the strengthening of regulations on organic solvent emissions aimed at considering the natural environment and the painting work environment, efforts are being made to reduce the VOC (volatile organic compound) content of solvent-based paints such as those mentioned above. One method for reducing VOCs is to use water-based paints. Water-based anticorrosion paints use water primarily as the solvent and dispersion medium, so they can significantly reduce VOCs compared to conventional solvent-based paints while maintaining appropriate paint viscosity.

[0004] As such water-based anticorrosive coatings, for example, Patent Document 1 discloses an aqueous epoxy resin composition containing an epoxy resin emulsion and a water-soluble amine curing agent, and Patent Document 2 discloses a two-component water-based epoxy resin composition containing an epoxy resin emulsion and an amine compound emulsion, etc.

[0005] However, the anticorrosion coating films formed from the conventional water-based anticorrosive paints described in Patent Documents 1 and 2 do not have sufficient anticorrosion performance, and in this respect there is room for improvement. As an anticorrosion coating composition with improved anticorrosion performance, Patent Document 3 discloses a kit for an anticorrosion coating composition containing a first part containing a non-aqueous epoxy compound and a second part containing a water-dilutable component containing an amine compound and a non-aqueous component containing an amine compound.

[0006] JP 2008-247958 A JP 2016-186021 A JP 2022-154829 A

[0007] As a result of intensive investigations, the present inventors have found that the second agent in the kit described in Patent Document 3 leaves room for improvement in terms of storage stability, and that the anticorrosion coating composition described in Patent Document 3 leaves room for improvement in terms of spray coating workability, particularly atomization properties during spray coating.

[0008] One embodiment of the present invention provides an anticorrosion coating composition kit that includes a second agent having excellent storage stability, can obtain an anticorrosion coating composition that has excellent spray coating workability, particularly excellent atomization properties during spray coating, and can form an anticorrosion coating film having excellent corrosion resistance.

[0009] An example of the configuration of the present invention is as follows.

[0010] [1] An anticorrosion coating composition kit comprising: a first agent containing a non-aqueous epoxy compound (A); and a second agent containing a water-dilutable component (B) containing an amine compound, a non-aqueous component (C) containing an amine compound, a pigment (D), and water.

[0011] [2] The kit according to [1], wherein the second agent contains a viscosity adjuster.

[0012] [3] The kit according to [1] or [2], wherein the second agent contains a divalent or higher polycarboxylic acid.

[0013] [4] The kit according to any one of [1] to [3], wherein the water content in the second agent is 10 to 50 mass%.

[0014] [5] The kit according to any one of [1] to [4], wherein the pigment volume concentration (PVC) of the second agent is 35 to 75%.

[0015] [6] The kit according to any one of [1] to [5], which is for spray painting.

[0016] [7] A method for producing an anticorrosion coating composition, comprising: Step 1: preparing a first agent using a non-aqueous epoxy compound (A); Step 2: preparing a second agent containing water using a water-dilutable component (B) containing an amine compound, a non-aqueous component (C) containing an amine compound, and a pigment (D); and Step 3: mixing the first agent and the second agent.

[0017] [8] A corrosion-protective coating film formed using the kit according to any one of [1] to [6]. [9] A substrate with a corrosion-protective coating film, comprising a substrate and the corrosion-protective coating film according to [8].

[0018]

[10] A method for producing a substrate with a corrosion-protective coating film, comprising the following steps I and II: Step I: applying to a substrate the corrosion-protective coating composition obtained using the kit according to any one of [1] to [6]; and Step II: drying the corrosion-protective coating composition applied to the substrate to form a corrosion-protective coating film.

[0019]

[11] The method for producing a substrate with a corrosion-protective coating according to

[10] , wherein the coating in step I is spray coating.

[0020] According to one embodiment of the present invention, it is possible to obtain an anticorrosion coating composition that contains a second agent having excellent storage stability and that exhibits excellent spray coating workability, particularly excellent atomization during spray coating, and that can form an anticorrosion coating film that exhibits excellent corrosion resistance, particularly corrosion resistance under salt spray and high temperature and humidity.Furthermore, according to one embodiment of the present invention, it is possible to obtain an anticorrosion coating composition that has a long usable time after mixing the first and second agents and that is less likely to deteriorate over time in spray coating workability, particularly atomization during spray coating.

[0021] Increasing the solidity of a paint is an effective way to improve the efficiency of painting work, such as by reducing the number of coats required to form a corrosion-resistant coating film of a predetermined thickness. However, in the case of conventional corrosion-resistant paints, the high viscosity associated with high solidity reduces painting workability. In other words, with conventional corrosion-resistant paints, there is a trade-off between high solidity and painting workability, and it has been difficult to achieve both. On the other hand, according to one embodiment of the present invention, it is possible to obtain an anticorrosion coating composition that is high solid but also has excellent painting workability, particularly spray painting workability. It is also possible to obtain an anticorrosion coating composition that has excellent drying properties, is less likely to sag during painting, can form a thick film in a single coat, and has little adverse effect on the natural environment or painting workers.

[0022] Figure 1 is a photograph of the spray state during spray coating, corresponding to evaluation standard 5 in the atomization test in the Examples below. Figure 2 is a photograph of the spray state during spray coating, corresponding to evaluation standard 4 in the atomization test in the Examples below. Figure 3 is a photograph of the spray state during spray coating, corresponding to evaluation standard 3 in the atomization test in the Examples below. Figure 4 is a photograph of the spray state during spray coating, corresponding to evaluation standard 2 in the atomization test in the Examples below. Figure 5 is a photograph of the spray state during spray coating, corresponding to evaluation standard 1 in the atomization test in the Examples below.

[0023] <<Anti-corrosion coating composition kit (kit for anti-corrosion coating composition)>> A kit for an anti-corrosion coating composition (hereinafter also referred to as “the composition”) (hereinafter also referred to as “the kit”) according to one embodiment of the present invention comprises: a first agent containing a non-aqueous epoxy compound (A); and a second agent containing a water-dilutable component (B) containing an amine compound, a non-aqueous component (C) containing an amine compound, a pigment (D), and water.

[0024] Because pigments can cause separation, sedimentation, and agglomeration, it is not common to incorporate pigments to improve the storage stability of compositions with poor storage stability. However, with this kit, it has been found that, although the reason for this is unclear, incorporating pigment (D) into a specific second agent can produce a second agent with excellent storage stability and, further, an anticorrosion coating composition with a long usable life. It is also known that pigments can adversely affect spray coating operability, particularly atomization during spray coating. However, with this kit, it has been found that, although the reason for this is unclear, incorporating pigment (D) into a specific second agent can produce an anticorrosion coating composition with excellent spray coating operability, particularly atomization during spray coating. In other words, the present invention, which solves the problems of improving storage stability and spray coating operability, particularly atomization during spray coating, by means that are not typically used, can be said to be an invention that would not have been conceived by a person skilled in the art.

[0025] The present kit can obtain the present composition by mixing the first agent and the second agent. When obtaining the present composition from the present kit, an nth agent (n is 3 or more) other than the first agent and the second agent may be used if necessary, but it is preferable not to use the nth agent. In other words, the present kit may be a kit for the present composition of two or more components, but is preferably a kit for the present composition of two components (a kit consisting of (only) the first agent and the second agent).

[0026] The first agent, second agent, etc. constituting this kit are usually stored, preserved, transported, etc. in separate containers, and are mixed together immediately before use of the composition.

[0027] The first agent is preferably prepared by the following step 1. The second agent is preferably prepared by the following step 2.

[0028] <<Method for Producing Anticorrosive Coating Composition>> A method for producing an anticorrosive coating composition according to one embodiment of the present invention (hereinafter also referred to as "the method") is a method for producing the composition, and includes the steps of: Step 1 of preparing a first agent using a non-aqueous epoxy compound (A); Step 2 of preparing a second agent containing water using a water-dilutable component (B) containing an amine compound, a non-aqueous component (C) containing an amine compound, and a pigment (D); and Step 3 of mixing the first agent and the second agent.

[0029] The method may also include a step of preparing an nth agent (n is 3 or more), in which case step 3 may be a step of mixing the first agent, the second agent, and the nth agent.

[0030] <Step 1> Step 1 is a step of preparing a first agent using a nonaqueous epoxy compound (A). Step 1 is not particularly limited as long as a nonaqueous epoxy compound (A) is used, and the nonaqueous epoxy compound (A) itself may be used as the first agent (in this case, step 1 can also be said to be a step of using the nonaqueous epoxy compound (A)), or it may be a step of mixing the nonaqueous epoxy compound (A) with other components described below, but the latter is preferred.

[0031] Step 1, in which the nonaqueous epoxy compound (A) is mixed with the other components described below, is specifically a step of mixing (or kneading) the components to be incorporated into the first agent. During this mixing (or kneading), the components may be added and mixed all at once, or may be added and mixed in multiple batches. For the mixing (or kneading), a conventionally known device such as a mixer, disperser, or stirrer can be used. Examples of such devices include a disperser, a mixing / dispersion mill, a mortar mixer, a roll, a paint shaker, and a homogenizer. The mixing (or kneading) may be performed while heating or cooling, depending on the season, environment, etc.

[0032] In step 1, water may or may not be used. That is, the first agent may or may not contain water. One embodiment of the first agent is a solvent-based agent. When the first agent contains water, the content of the water is preferably less than the amount that allows the first agent to become an emulsion of the non-aqueous epoxy compound (A), and specifically, the content of water is preferably 20% by mass or less, more preferably 10% by mass or less, relative to 100% by mass of the non-aqueous epoxy compound (A) in the first agent.

[0033] [Non-aqueous epoxy compound (A)] The first agent contains a non-aqueous epoxy compound (A), and the method uses the non-aqueous epoxy compound (A) as the first agent. The non-aqueous epoxy compound (A) used in the first agent may be one type or two or more types.

[0034] The term "non-aqueous" in the non-aqueous epoxy compound (A) refers to a state in which the epoxy compound is not freely miscible with water, or is substantially insoluble in water. The "non-aqueous" can also be considered a non-aqueous dispersion. Specifically, when an epoxy compound and water are mixed at 23°C so that the epoxy compound is 3% by mass, the mixture is thoroughly stirred, and the mixture is allowed to stand at 23°C for 1 hour. If the resulting mixture is not homogeneous, and 90% by mass or more of the epoxy compound mixed with water separates, precipitates, or floats, the epoxy compound is considered to be a non-aqueous epoxy compound (A).

[0035] In the mixed solution, if more than 10% by mass of the epoxy compound mixed with water is stably present in water and the mixed solution is maintained in an emulsion state, the epoxy compound is considered to be a water-dilutable epoxy compound.In addition, in the mixed solution, if more than 10% by mass of the epoxy compound mixed with water is stably present in water and the epoxy compound mixed with water has an average particle size of less than 10 nm as measured with a laser diffraction particle size distribution analyzer (e.g., Mastersizer 3000 (manufactured by Spectris Co., Ltd.)), the epoxy compound is considered to be a water-soluble epoxy compound.

[0036] The nonaqueous epoxy compound (A) is preferably a liquid epoxy compound that is liquid (has fluidity) at room temperature (e.g., 15 to 25°C). Such liquid epoxy compounds are preferred because they can be used to make the first part a relatively small amount of solvent, and can be easily dispersed uniformly in the first part even when the first part contains components other than the nonaqueous epoxy compound (A). They also have good reactivity with the water-dilutable component (B) and nonaqueous component (C), which will be described later. The nonaqueous epoxy compound (A) may be a solid or semi-solid epoxy compound at room temperature (e.g., 15 to 25°C). In one embodiment of the present invention, it is preferable to use a liquid epoxy compound in combination with a solid or semi-solid epoxy compound.

[0037] The viscosity of the non-aqueous epoxy compound (A) at 25°C, measured with an E-type viscometer (FMD type, manufactured by TOKIMEC Corporation, rotation speed: 60 rpm), is preferably 1,500 mPa s or more, more preferably 3,000 mPa s or more, and is preferably 120,000 mPa s or less, more preferably 30,000 mPa s or less.

[0038] Examples of the non-aqueous epoxy compound (A) include bisphenol A type epoxy resins, bisphenol F type epoxy resins, glycidyl ester type epoxy resins, glycidyl amine type epoxy resins, novolac type epoxy resins, cresol type epoxy resins, dimer acid-modified epoxy resins, aliphatic epoxy resins, alicyclic epoxy resins, and epoxidized oil-based epoxy resins.

[0039] As the non-aqueous epoxy compound (A), bisphenol A or bisphenol F type epoxy resins are preferred from the viewpoint of being able to easily form an anticorrosive coating film that is excellent in anticorrosion properties and adhesion to substrates, and bisphenol F type epoxy resins are further preferred from the viewpoint of being able to easily obtain an anticorrosive coating composition that is excellent in spray coating workability, particularly atomization properties during spray coating.

[0040] The number average molecular weight of the non-aqueous epoxy compound (A) is preferably 1,000 or less, more preferably 500 or less, from the viewpoint that an anticorrosion coating composition that is high solid yet has excellent coating workability can be easily obtained.

[0041] The non-aqueous epoxy compound (A) may be a compound synthesized by a conventionally known method, or a commercially available product. Examples of commercially available products that are liquid at room temperature (e.g., 15 to 25°C) include "E-028" (manufactured by Ohtake Meishin Chemical Co., Ltd.), "jER 828" (manufactured by Mitsubishi Chemical Corporation), "Cardura E10P" (manufactured by Hexion), and "ADEKA RESIN EP-4901" (manufactured by ADEKA Corporation). Examples of commercially available products that are semi-solid at room temperature include "jER 834" (manufactured by Mitsubishi Chemical Corporation) and "EPICLON 860" (manufactured by DIC Corporation). Examples of commercially available products that are solid at room temperature include "EPICLON 1050" (manufactured by DIC Corporation) and "Epotohto YD-011" (manufactured by Kukudo Chemicals Co., Ltd.).

[0042] The amount of solids of the nonaqueous epoxy compound (A) used in Step 1 (the content of the solids of the nonaqueous epoxy compound (A) in the first agent) is preferably within the following range. The amount of solids of the nonaqueous epoxy compound (A) used is preferably 15 to 35 mass%, more preferably 18 to 30 mass%, based on 100 mass% of the nonvolatile content of the composition. The amount of solids of the nonaqueous epoxy compound (A) used is preferably 40 to 90 mass%, more preferably 45 to 85 mass%, based on 100 mass% of the solids of the first agent. When the content of the nonaqueous epoxy compound (A) is within the above range, a corrosion-resistant coating film that exhibits excellent corrosion resistance and adhesion to substrates can be easily formed.

[0043] [Other Components] In Step 1, if desired, other components other than the nonaqueous epoxy compound (A), such as reactive diluents, plasticizers, silane coupling agents, pigments, (pigment) dispersants, antifoaming agents, viscosity modifiers (anti-sagging agents, anti-settling agents, thixotropic agents), flash rust inhibitors, curing accelerators, dehydrating agents, film-forming aids, organic solvents, etc. may be used within the scope that does not impair the effects of the present invention (the first agent may contain the other components). Each of these other components may be used alone or in combination of two or more.

[0044] The other components can be conventionally known components, and examples of the pigment, (pigment) dispersant, and viscosity modifier include the same components as those described in the section on the second agent below. Commercially available products may be used as the other components, and in this case, the commercially available products may be available for both solvent-based and aqueous systems. When a commercially available product for solvent-based systems is used, it is preferable to blend it into the first agent, and when a commercially available product for aqueous systems is used, it is preferable to blend it into the second agent.

[0045] <Reactive Diluent> The present composition (present kit) may contain a reactive diluent. It is preferable that the present composition (present kit) contains a reactive diluent, since it is easy to obtain a low-viscosity present composition. The reactive diluent is preferably an epoxy group-containing reactive diluent. When using a reactive diluent that is reactive with the water-dilutable component (B) or the non-aqueous component (C), such as an epoxy group-containing reactive diluent, the reactive diluent is preferably blended in the first agent. One type of reactive diluent may be used, or two or more types may be used.

[0046] The epoxy group-containing reactive diluent is a compound other than the nonaqueous epoxy compound (A). The epoxy group-containing reactive diluent is not particularly limited as long as it is an epoxy compound having a viscosity of 500 mPa s or less at 25°C as measured with an E-type viscometer (manufactured by TOKIMEC Corporation, FMD model, rotation speed: 60 rpm), and may be either a monofunctional or polyfunctional type.

[0047] Examples of the monofunctional epoxy group-containing reactive diluent include alkyl glycidyl ethers (suitable examples of the alkyl group: carbon number 1 to 13), phenyl glycidyl ether, o-cresyl glycidyl ether, alkylphenyl glycidyl ethers (suitable examples of the alkyl group: carbon number 1 to 20, preferably 1 to 5, e.g., methylphenyl glycidyl ether, ethylphenyl glycidyl ether, propylphenyl glycidyl ether, p-tert-butylphenyl glycidyl ether), phenol glycidyl ether, alkylphenol glycidyl ether, phenol (EO) n Examples include glycidyl ether (repeating number n=3 to 20, EO: —C 2 H 4 O—), alkyl glycidyl ester (preferable example of alkyl group: carbon number 3 to 10), and polyglycol glycidyl ether.

[0048] Examples of polyfunctional epoxy group-containing reactive diluents include 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, neopentyl glycol diglycidyl ether, cyclohexanedimethanol diglycidyl ether, resorcinol diglycidyl ether, polyglycol diglycidyl ether, mono- or polyalkylene glycol diglycidyl ethers (preferable examples of alkylene groups: having 1 to 5 carbon atoms, e.g., ethylene glycol diglycidyl ether, dipropylene glycol diglycidyl ether, polypropylene glycol diglycidyl ether), trimethylolpropane triglycidyl ether, alkyl diglycidyl ethers, and alkyl diglycidyl esters. Preferred examples of the alkyl group include alkyl groups having 3 to 10 carbon atoms, such as neopentyl and 2-ethylhexyl groups.

[0049] When producing the present composition containing a reactive diluent, it is preferable to use the reactive diluent so that the solid content of the reactive diluent is preferably 0.1 to 10 mass%, more preferably 0.5 to 8 mass%, and even more preferably 0.5 to 6 mass%, based on 100 mass% of the nonvolatile content of the present composition. When the content of the reactive diluent is within the above range, a corrosion-resistant coating film excellent in oil resistance, solvent resistance, chemical resistance, corrosion prevention, etc. can be easily formed, and this can contribute to a decrease in the viscosity of the present composition and an extension of the usable life.

[0050] <Plasticizer> The present composition (present kit) may contain a plasticizer. It is preferable that the composition contains a plasticizer, since this can improve the flexibility of the obtained corrosion-protective coating film.

[0051] As the plasticizer, a wide variety of conventionally known plasticizers can be used, including liquid hydrocarbon resins such as low-boiling fractions obtained by thermal decomposition of naphtha, petroleum resins that are solid at room temperature, xylene resins, coumarone-indene resins, etc. Specific examples include the liquid hydrocarbon resins and flexibility-imparting resins described in JP-A-2006-342360.

[0052] Among these, liquid hydrocarbon resins are preferred, and phenol-modified hydrocarbon resins are more preferred, from the viewpoint of excellent compatibility with the nonaqueous epoxy compound (A). Examples of the phenol-modified hydrocarbon resins include resins obtained using diolefins, monoolefins, or α-methylstyrene contained in petroleum or coal cracked oil fractions with phenols (phenolic compounds), as described in JP-A-9-268209 and JP-A-7-196793.

[0053] More specifically, examples of the phenol-modified hydrocarbon resin include resins obtained by reacting phenols with C5 (aliphatic) petroleum resins made from C5 fractions; C9 (aromatic) petroleum resins made from C9 fractions; C5-C9 copolymer petroleum resins; dicyclopentadiene resins made from dicyclopentadiene obtained by thermally dimerizing cyclopentadiene contained in C5 fractions; and α-methylstyrene. Among these, resins obtained by addition polymerization of phenols with styrene, vinyltoluene, coumarone, indene, α-methylstyrene, or the like contained in petroleum or coal cracked oil fractions are preferred.

[0054] The average molecular weight of the phenol-modified hydrocarbon resin is usually 200 to 1,000, and the viscosity is usually 30 to 10,000 mPa·s / 25°C.

[0055] As the liquid hydrocarbon resin, commercially available products may be used, and examples of such commercially available products include "Nesiles EPX-L" and "Nesiles EPX-L2" (phenol-modified hydrocarbon resins manufactured by NEVCIN Corporation) and "Hirenol PL-1000S" (phenol-modified hydrocarbon resin manufactured by Kolon Industries, Inc.).

[0056] When producing the present composition containing a plasticizer, it is preferable to use the plasticizer so that the solid content of the plasticizer is preferably 0.5 to 15 mass %, more preferably 1 to 10 mass %, relative to 100 mass % of the nonvolatile content of the present composition. When the plasticizer content is within this range, a corrosion-protective coating film with excellent crack resistance and the like can be easily formed.

[0057] <Silane Coupling Agent> By using a silane coupling agent, it is possible to further improve the adhesion of the obtained anticorrosion coating film to the substrate, and also to improve the corrosion resistance, such as water resistance and saltwater resistance, and heat resistance, of the obtained anticorrosion coating film.

[0058] The silane coupling agent is not particularly limited, and any conventionally known compound can be used, but it is preferable that the silane coupling agent is a compound that has at least two functional groups in the same molecule and can contribute to improving adhesion to the substrate and reducing the viscosity of the composition.

[0059] The silane coupling agent is, for example, a compound represented by the formula: "X-SiMe n Y 3-n " [n is 0 or 1, X is a functional group capable of reacting with an organic substance (e.g., an amino group, a vinyl group, an epoxy group, a mercapto group, a halogeno group, a group in which a hydrocarbon group is partially substituted with any of these groups, or a group in which a hydrocarbon group is partially substituted with an ether bond or the like and is partially substituted with any of these groups], Me is a methyl group, and Y is a hydrolyzable group (e.g., an alkoxy group such as a methoxy group or an ethoxy group).]

[0060] When a silane coupling agent reactive with the water-dilutable component (B) or the non-aqueous component (C), such as an epoxy group-containing silane coupling agent, is used, it is preferable to blend the silane coupling agent in the first part. When a silane coupling agent reactive with the non-aqueous epoxy compound (A), such as an amino group-containing silane coupling agent, is used, it is preferable to blend the silane coupling agent in the second part.

[0061] Among the above-mentioned silane coupling agents, preferred are epoxy group-containing silane coupling agents in which X is an epoxy group, a group in which a hydrocarbon group is partly substituted with an epoxy group, or a group in which a hydrocarbon group is partly substituted with an ether bond or the like and partly substituted with an epoxy group.

[0062] As the silane coupling agent, commercially available products may be used, and examples of such commercially available products include 3-glycidoxypropyltrimethoxysilane "KBM-403" (manufactured by Shin-Etsu Chemical Co., Ltd.) and "Sila-Ace S-510" (manufactured by JNC Corporation).

[0063] When preparing the present composition containing a silane coupling agent, the silane coupling agent is preferably used so that the solids content of the silane coupling agent is preferably 0.1 to 15 mass%, more preferably 0.3 to 10 mass%, and even more preferably 0.5 to 8 mass%, based on 100 mass% of the nonvolatile content of the present composition. When the content of the silane coupling agent is within this range, the viscosity of the present composition can be reduced, thereby improving not only the coating workability but also the adhesion to the substrate, corrosion protection, and heat resistance of the resulting corrosion-protective coating film. Furthermore, when the solids content of the silane coupling agent is preferably 3 to 25 mass parts, more preferably 4 to 20 mass parts, based on 100 mass parts of the nonvolatile content of the present composition, the present composition can be easily obtained with excellent low-temperature drying and curing properties.

[0064] <Antifoaming Agent> The present composition (present kit) preferably contains an antifoaming agent, since this can suppress the generation of bubbles during the production or application of the composition, or can break up bubbles that have generated in the present composition, thereby making it possible to easily form a corrosion-protective coating film with desired physical properties.

[0065] As the defoaming agent, commercially available products may be used, and examples of such commercially available products include "BYK-392", "BYK-066N", "BYK-1770", and "BYK-1790" (all manufactured by BYK Japan K.K.), "TEGO Airex 902W" (manufactured by Evonik), and "Spectrasyn 40" (manufactured by Exxonmobil Chemical Company).

[0066] When preparing the present composition containing an antifoaming agent, the antifoaming agent is preferably used so that the solid content of the antifoaming agent is preferably 0.005 to 1 mass %, more preferably 0.01 to 0.5 mass %, based on 100 mass % of the nonvolatile content of the present composition. When the content of the antifoaming agent is within this range, foam generation can be sufficiently suppressed, and a corrosion-protective coating film with the desired physical properties can be easily formed.

[0067] <Flash Rust Inhibitor> In order to prevent rust on the metal surface from bleeding onto the coating surface and causing rust spots (flash rust) when the composition is applied to a metal surface, the composition (kit) may contain a flash rust inhibitor. There are no particular restrictions on the flash rust inhibitor as long as it is a component that can inhibit flash rust, and any conventionally known flash rust inhibitor can be used.

[0068] Examples of the flash rust inhibitor include nitrites such as sodium nitrite, potassium nitrite, calcium nitrite, strontium nitrite, barium nitrite, and ammonium nitrite; benzoates such as sodium benzoate, potassium benzoate, calcium benzoate, and ammonium benzoate; phytates such as sodium phytate and potassium phytate; salts of fatty acids such as sebacic acid and dodecanoic acid; phosphoric acid derivatives such as alkyl phosphoric acid and polyphosphoric acid; tannates; metal sulfonates; N-(2-hydroxyethyl)ethylenediaminetriacetic acid (HEDTA), ethylenediaminetetraacetic acid (EDTA), Examples of suitable chelating agents include amine-based chelating agents such as diethylenetriaminepentaacetic acid (DTPA), propylenediaminetetraacetic acid (PDTA), iminodiacetic acid, nitrilotriacetic acid (NTA), diethylenetriaminepentamethylenephosphonic acid (DTPMP), and alkali metal salts thereof; addition reaction products of 4-methyl-γ-oxo-benzenebutanoic acid and N-ethylmorpholine; intercalation compounds obtained by intercalating monoalkylamines, polyamines, quaternary ammonium ions, etc. into layered phosphates such as aluminum dihydrogen tripolyphosphate; and hydrazine derivatives such as hydrazide compounds, semicarbazide compounds, and hydrazone compounds.

[0069] As the flash rust inhibitor, commercially available products may be used, and examples of such commercially available products include "Killesrite W-410" and "Killesrite W-16B" (both manufactured by Chelest Co., Ltd. / organic acid salt type), and "HALOX FLASH-X 150" (manufactured by ICL Additives-Hammond / nitrite, benzoate type).

[0070] When producing the present composition containing a flash rust inhibitor, it is preferable to use the flash rust inhibitor so that the content of the flash rust inhibitor is preferably 0.01 to 5 mass %, more preferably 0.05 to 3 mass %, based on 100 mass % of the nonvolatile content of the present composition.

[0071] <Film-forming Aid> The present composition (present kit) may contain a film-forming aid because the composition may freeze in winter or the like due to the inclusion of water, and from the viewpoint of improving film-forming properties at low temperatures and the finished appearance of the obtained corrosion-protective coating film, etc.

[0072] The coalescent may be any of those typically used in aqueous coating compositions, such as organic compounds having a boiling point of 180°C or higher at room temperature. Examples of the coalescent include linear or branched aliphatic alcohols having 5 to 15 carbon atoms; alcohols having an aromatic ring, such as benzyl alcohol; monoethers, such as (poly)ethylene glycol or (poly)propylene glycol; (poly)ethylene glycol ether esters; and (poly)propylene glycol ether esters.

[0073] When producing the present composition containing a coalescing agent, it is preferred to use the coalescing agent in an amount of preferably 1 to 10 mass %, more preferably 2 to 8 mass %, relative to 100 mass % of the nonvolatile content of the present composition, in order to facilitate the formation of a corrosion-protective coating film that is excellent in film-forming properties at low temperatures and in appearance.

[0074] <Curing Accelerator> For the purpose of accelerating the drying and curing properties when forming a corrosion-resistant coating film from the composition, a curing accelerator may be blended into the composition (the kit) as needed. Examples of the curing accelerator include polymerizable (meth)acrylate monomers (provided that the monomers are compounds other than polycarboxylic acids) and tertiary amines. When a polymerizable (meth)acrylate monomer is used, it is blended into the first agent, and when a tertiary amine is used, it is blended into the second agent described below.

[0075] Commercially available polymerizable (meth)acrylate monomers include "M-CURE 100" (monofunctional aromatic acrylate, functional group equivalent weight 257 to 267), "M-CURE 200" (difunctional aromatic acrylate, functional group equivalent weight 130 to 140), "M-CURE 201" (difunctional aliphatic acrylate, functional group equivalent weight 95 to 105), "M-CURE 300" (trifunctional aliphatic acrylate, functional group equivalent weight 112 to 122), and "M-CURE 400" (tetrafunctional aliphatic acrylate, functional group equivalent weight 80 to 90) (all manufactured by SARTOMER COMPANY, INC.).

[0076] Specific examples of the tertiary amine include triethanolamine, dialkylaminoethanol, triethylenediamine (1,4-diazabicyclo[2.2.2]octane), and 2,4,6-tris(dimethylaminomethyl)phenol, and a commercially available product thereof is "Ancamine K-54" (manufactured by Evonik, 2,4,6-tri(dimethylaminomethyl)phenol).

[0077] When producing the present composition containing a curing accelerator, it is preferable to use the curing accelerator so that the solid content of the curing accelerator is preferably 0.1 to 5 mass% relative to 100 mass% of the nonvolatile content of the present composition.

[0078] <Organic Solvent> The organic solvent is preferably an organic solvent having a boiling point of less than 180°C under normal pressure, and examples thereof include aromatic hydrocarbon solvents such as toluene and xylene, ketone solvents such as methyl ethyl ketone (MEK) and methyl isobutyl ketone (MIBK), ether solvents such as butyl cellosolve, ester solvents such as butyl acetate, alcohol solvents such as isopropanol, isobutyl alcohol, n-butanol, and methoxypropanol, and aliphatic hydrocarbon solvents such as n-hexane, n-octane, 2,2,2-trimethylpentane, isooctane, n-nonane, cyclohexane, and methylcyclohexane.

[0079] When producing the present composition containing an organic solvent, it is preferable to use an organic solvent so that the VOC content in the present composition falls within the following range. The first agent is preferably a solvent-based agent containing an organic solvent. When preparing the first agent containing an organic solvent, it is preferable to use an organic solvent so that the content of the organic solvent is preferably 12% by mass or less, more preferably 10% by mass or less, preferably 1% by mass or more, and more preferably 4% by mass or more, relative to 100% by mass of the first agent.

[0080] <Step 2> Step 2 is a step of preparing a second agent containing water using a water-dilutable component (B) containing an amine compound, a non-aqueous component (C) containing an amine compound, and a pigment (D). In Step 2, the following other components may also be used.

[0081] Specifically, step 2 is a step of mixing (or kneading) the components to be incorporated into the second agent. During this mixing (or kneading), the components may be added and mixed all at once, or may be added and mixed in multiple batches. A suitable example of the latter case is a method comprising the steps of preparing a pigment dispersion containing water and a pigment (D), preparing an amine dispersion containing a water-dilutable component (B), a non-aqueous component (C), and water, and mixing the pigment dispersion with the amine dispersion. The step of preparing the pigment dispersion is desirably a step of obtaining a pigment dispersion having a particle size measured with a particle gauge (in accordance with JIS K 5600-2-5:1999) of 70 μm or less, preferably 60 μm or less.

[0082] The mixing (or kneading) can be carried out using a conventionally known device such as a mixer, disperser, or stirrer, and examples of such devices include a disperser, a mixing / dispersing mill, a mortar mixer, a roll, a paint shaker, and a homogenizer. The mixing (or kneading) may be carried out while heating or cooling depending on the season, environment, etc.

[0083] In the present invention, the water-dilutable component (B) containing an amine compound refers to a component containing an epoxy-curable amine compound that is emulsified and dispersed in a relatively large amount in a water-containing dispersion medium (hereinafter also referred to as an "aqueous medium"). Specifically, a component containing an amine compound is mixed with water so that the solids content is 50% by mass at 23°C, or the solvent / dispersion medium is volatilized, followed by thorough stirring and standing at 23°C for 1 hour. In this mixed liquid, if 80% by mass or more of the solids of the components mixed with water are stably present in the water and the mixed liquid is maintained in an emulsion state, this component is considered to be the water-dilutable component (B). Note that a component containing an amine compound with a solids content of less than 50% by mass is adjusted using an evaporator or the like so that the solids content is 50% by mass.

[0084] Furthermore, the non-aqueous component (C) containing an amine compound refers to a component containing an epoxy-curing amine compound that is not freely miscible with water, i.e., a component containing an epoxy-curing amine compound that is substantially insoluble in water. Specifically, when a component containing an amine compound is mixed with water so that the solids content is 3% by mass at 23°C, the mixture is thoroughly stirred, and the mixture is allowed to stand at 23°C for 1 hour. If the resulting mixture is not homogeneous and 50% or more by mass of the solids of the component mixed with water are separated, precipitated, or suspended, the component is considered to be non-aqueous component (C). In addition, if 90% or more by mass of the solids of the component mixed with water are stably present in water and the solids of the component mixed with water have an average particle size of less than 10 nm as measured with a laser diffraction particle size analyzer (e.g., Mastersizer 3000 (Spectris Co., Ltd.)), the component is considered to be a water-soluble component in this specification. In addition, in this specification, components containing an amine compound other than the water-dilutable component (B), the non-aqueous component (C), and the water-soluble component are referred to as other amine components.

[0085] From the viewpoint of easily forming an anticorrosion coating film that is excellent in anticorrosion properties, coating film strength, and drying properties, it is desirable to use the water-dilutable component (B) and the non-aqueous component (C) in amounts such that the reaction ratio calculated by the following formula (1) is preferably 0.3 to 1.5, more preferably 0.4 to 1.2.

[0086] Reactivity ratio={(amount of solids of water-dilutable component (B) / active hydrogen equivalent of solids of water-dilutable component (B))+(amount of solids of non-aqueous component (C) / active hydrogen equivalent of solids of non-aqueous component (C))+(amount of solids of component reactive with non-aqueous epoxy compound (A) / functional group equivalent of solids of component reactive with non-aqueous epoxy compound (A))} / {(amount of solids of non-aqueous epoxy compound (A) / epoxy equivalent of solids of non-aqueous epoxy compound (A))+(amount of solids of component reactive with water-dilutable component (B) or non-aqueous component (C) / functional group equivalent of solids of component reactive with water-dilutable component (B) or non-aqueous component (C))} (1)

[0087] Here, in formula (1), "component reactive with water-dilutable component (B) or non-aqueous component (C)" and "component reactive with non-aqueous epoxy compound (A)" can be exemplified by the silane coupling agent.As the silane coupling agent, the silane coupling agent having amino group or epoxy group as reactive group can be used, therefore, it is necessary to determine whether the silane coupling agent is reactive with water-dilutable component (B) or non-aqueous component (C), or whether it is reactive with non-aqueous epoxy compound (A) according to the type of reactive group, and then calculate the reactivity ratio.

[0088] The "functional group equivalent" of each component means the mass (g) per 1 mol of functional group obtained by dividing the mass of 1 mol of the component by the number of moles of the functional group contained therein.

[0089] [Water-dilutable component (B)] The water-dilutable component (B) is not particularly limited as long as it satisfies the definition of a water-dilutable component and contains an amine compound. By using the water-dilutable component (B) together with component (C) and pigment (D) in the second agent, a uniform composition can be obtained when mixed with the first agent, a second agent with excellent storage stability can be obtained, and a composition with excellent spray coating workability, particularly atomization during spray coating, can be obtained. The water-dilutable component (B) used in the second agent may be one type or two or more types.

[0090] The active hydrogen equivalent of the solid content of the water-dilutable component (B) is preferably 50 to 200, more preferably 60 to 190, from the viewpoint of being able to easily form a corrosion-protective coating film that is excellent in curability and corrosion resistance.

[0091] The amount of solids of the water-dilutable component (B) used in step 2 is preferably an amount that satisfies the above formula (1), and more preferably an amount that falls within the following range. The content of the solids of the water-dilutable component (B) is preferably 1 to 15 mass%, more preferably 2 to 10 mass%, based on 100 mass% of the nonvolatile content of the composition. The content of the solids of the water-dilutable component (B) is preferably 3 to 20 mass%, more preferably 4 to 15 mass%, based on 100 mass% of the solids of the second part. When the content of the water-dilutable component (B) is within the above range, a corrosion-resistant coating film that has excellent corrosion prevention properties and drying properties can be easily formed.

[0092] Specific examples of the water-dilutable component (B) include a component containing a hydrophilic amine compound obtained by reacting a conventionally known amine compound used as a curing agent for epoxy compounds with a glycidyl ether of polyalkylene glycol, a polyoxyalkylene amine, or the like; a component containing an amine compound having an amide structure obtained by using a fatty acid and an aliphatic amine compound; and a component obtained by forcibly dispersing in water an amine compound that has been given emulsifying ability by neutralizing a conventionally known amine compound used as a curing agent for epoxy compounds with an acid or by mixing with an emulsifier.

[0093] The amine compound used as a curing agent for the epoxy compound is not particularly limited as long as it is a tertiary amine (an amine compound having only a tertiary amino group) and an amine compound other than the flash rust inhibitor. Examples of such an amine compound include an amine compound containing two or more amino groups in one molecule, and aliphatic, alicyclic, aromatic, and heterocyclic amine compounds are preferred.

[0094] Examples of the aliphatic amine compounds include alkylene polyamines, polyalkylene polyamines, and alkylamino alkyl amines.

[0095] Examples of the alkylene polyamine include alkylene polyamines represented by the formula: 1 -NH2" (R 1 is a divalent hydrocarbon group having 1 to 12 carbon atoms. Specific examples include methylenediamine, ethylenediamine, 1,2-diaminopropane, 1,3-diaminopropane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,7-diaminoheptane, 1,8-diaminooctane, 1,9-diaminononane, 1,10-diaminodecane, and trimethylhexamethylenediamine.

[0096] Examples of the polyalkylene polyamine include those represented by the formula: "HN-(C m H 2m NH) n Specific examples include diethylenetriamine, dipropylenetriamine, triethylenetetramine, tripropylenetetramine, tetraethylenepentamine, tetrapropylenepentamine, pentaethylenehexamine, nonaethylenedecamine, bis(hexamethylene)triamine, and triethylene-bis(trimethylene)hexamine.

[0097] Examples of the alkylaminoalkylamine include those represented by the formula: 2 2N-(CH2) p -NH2" (R 2 are independently a hydrogen atom or an alkyl group having 1 to 8 carbon atoms (provided that at least one R 2 is an alkyl group having 1 to 8 carbon atoms, and p is an integer of 1 to 6. Specific examples include dimethylaminoethylamine, diethylaminoethylamine, dibutylaminoethylamine, dimethylaminopropylamine, diethylaminopropylamine, dipropylaminopropylamine, dibutylaminopropylamine, and dimethylaminobutylamine.

[0098] Other aliphatic amine curing agents include, for example, tetra(aminomethyl)methane, tetrakis(2-aminoethylaminomethyl)methane, 1,3-bis(2'-aminoethylamino)propane, tris(2-aminoethyl)amine, bis(cyanoethyl)diethylenetriamine, polyoxyalkylenepolyamines (particularly, diethylene glycol bis(3-aminopropyl)ether), bis(aminomethyl)cyclohexane, isophoronediamine (IPDA), menthenediamine (MDA), o-xylylenediamine, m-xylylenediamine (MXDA), p-xylylenediamine, bis(aminomethyl)naphthalene, bis(aminoethyl)naphthalene, 1,4-bis(3-aminopropyl)piperazine, 1-(2'-aminoethylpiperazine), and 1-[2'-(2''-aminoethylamino)ethyl]piperazine.

[0099] Specific examples of the alicyclic amine curing agent include cyclohexanediamine, diaminodicyclohexylmethane (particularly, 4,4'-methylenebiscyclohexylamine), 4,4'-isopropylidenebiscyclohexylamine, norbornanediamine, and 2,4-di(4-aminocyclohexylmethyl)aniline.

[0100] Examples of the aromatic amine curing agent include aromatic polyamine compounds having two or more primary amino groups bonded to an aromatic ring such as a benzene ring or a naphthalene ring. Specific examples of the aromatic amine curing agent include phenylenediamine, naphthalenediamine, diaminodiphenylmethane, 2,2-bis(4-aminophenyl)propane, 4,4'-diaminodiphenyl ether, 4,4'-diaminobenzophenone, 4,4'-diaminodiphenyl sulfone, 3,3'-dimethyl-4,4'-diaminodiphenylmethane, diaminodiethylphenylmethane, 2,4'-diaminobiphenyl, 2,3'-dimethyl-4,4'-diaminobiphenyl, 3,3'-dimethoxy-4,4'-diaminobiphenyl, and diethylmethylbenzenediamine.

[0101] Specific examples of the heterocyclic amine curing agent include 1,4-diazacycloheptane, 1,4-bis(3-aminopropyl)piperazine, 1-[2'-(2''-aminoethylamino)ethyl]piperazine, 1,11-diazacycloeicosane, and 1,15-diazacyclooctacosane.

[0102] Further examples of the amine compound used as a curing agent for the epoxy compound include modified products of the above-mentioned amine compounds, such as fatty acid modified products such as polyamidoamine, amine adducts with epoxy compounds, Mannich-modified amines (e.g., Mannich-modified amines having a phenol-derived skeleton (phenalkamine, phenalkamide, etc.)), Michael adducts, ketimines, and aldimines. Among these, polyamidoamines, amine adducts with epoxy compounds, and Mannich-modified amines having a phenol-derived skeleton are preferred.

[0103] The water-dilutable component (B) may be one obtained by a conventionally known method or a commercially available product.

[0104] The polyamidoamine may be, for example, a compound formed by a condensation reaction between an amine compound used as a curing agent for the epoxy compound and a fatty acid such as a dimer acid.The amine adduct with the epoxy compound may be, for example, an addition reaction product obtained by using an amine compound used as a curing agent for the epoxy compound and an epoxy compound listed in the non-aqueous epoxy compound (A) section.The Mannich-modified amine having a phenol-derived skeleton may be, for example, a Mannich-modified amine compound formed by a Mannich condensation reaction between a phenol such as cardanol, an aldehyde such as formaldehyde, and an amine compound used as a curing agent for the epoxy compound.

[0105] The water-dilutable component (B) may be a dispersion (amine emulsion) in which an amine compound is dispersed in an aqueous medium, or the amine compound itself (100% amine compound). The solid content of the water-dilutable component (B) is preferably 30 to 100% by mass, more preferably 40 to 100% by mass, based on 100% by mass of the water-dilutable component (B). The content of the amine compound in the solid content of the water-dilutable component (B) is preferably 70 to 100% by mass, more preferably 80 to 100% by mass, based on 100% by mass of the solid content of the water-dilutable component (B). Note that solids other than the amine compound in the water-dilutable component (B) include, for example, solids contained in components commercially available as water-dilutable amine curing agents. Specific examples include surfactants and organic compounds such as benzyl alcohol that have a boiling point of 180°C or higher at room temperature.

[0106] The aqueous medium only needs to contain water, and may also contain a medium other than water that has a boiling point of less than 180°C under normal pressure. Examples of the medium other than water that has a boiling point of less than 180°C under normal pressure include acetone, methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, isobutyl alcohol, 2-methoxyethanol, 2-ethoxyethanol, 2-butoxyethanol, 1-methoxy-2-propanol, 1-ethoxy-2-propanol, diacetone alcohol, dioxane, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, and ethylene glycol monopropyl ether. These may be used alone or in combination of two or more.

[0107] The amine emulsion can be prepared, for example, by emulsifying an amine compound with one or more surfactants to form an emulsion.

[0108] [Non-aqueous Component (C)] The non-aqueous component (C) is not particularly limited as long as it is a component that satisfies the definition of a non-aqueous component and contains an amine compound. Specific examples include amine compounds that satisfy the definition among the amine compounds used as curing agents for the epoxy compounds. By using the non-aqueous component (C) together with component (B) and pigment (D) in the second part, a corrosion-resistant coating film that exhibits excellent corrosion resistance, particularly under salt spray and high temperature and humidity conditions, can be formed. The non-aqueous component (C) used in the second part may be one type or two or more types.

[0109] The non-aqueous component (C) preferably has a molecular weight of 3,000 or less, more preferably 2,500 or less, and desirably contains an amine compound having a cyclic structure, and more desirably is an amine compound, from the viewpoints of being able to easily form an anticorrosive coating film having excellent anticorrosive properties and being able to easily obtain an anticorrosive coating composition having a low viscosity.

[0110] The solid content of the non-aqueous component (C) is preferably 30 to 100% by mass, more preferably 40 to 100% by mass, and even more preferably 100% by mass, relative to 100% by mass of the non-aqueous component (C), and it is particularly preferable that the non-aqueous component (C) consists of the amine compound (only). Note that examples of solid components other than the amine compound in the non-aqueous component (C) include solid components contained in components commercially available as non-aqueous amine curing agents (e.g., benzyl alcohol).

[0111] The active hydrogen equivalent of the solid content of the non-aqueous component (C) is preferably 30 to 200, more preferably 40 to 150, from the viewpoint of being able to easily form an anticorrosion coating film that is excellent in curability and anticorrosion properties.

[0112] The amount of solids used in non-aqueous component (C) in step 2 is preferably an amount that satisfies the above formula (1), and more preferably an amount that falls within the following range. The solids content of non-aqueous component (C) is preferably 2 to 25 mass%, more preferably 3 to 20 mass%, based on 100 mass% of the non-volatile content of the composition. Furthermore, the solids content of non-aqueous component (C) is preferably 5 to 30 mass%, more preferably 6 to 25 mass%, based on 100 mass% of the solids content of the second part. When the content of non-aqueous component (C) is within the above range, the composition can be easily obtained with excellent drying properties, and an anticorrosion coating film with excellent corrosion prevention properties can be easily formed.

[0113] The non-aqueous component (C) may be one obtained by a conventionally known method or a commercially available product.

[0114] [Pigment (D)] Examples of the pigment (D) include extender pigments, coloring pigments, and anti-rust pigments, and they may be organic or inorganic. By using the pigment (D) together with component (B) and component (C) in the second agent, a second agent having excellent storage stability can be obtained, and the present composition having excellent spray coating workability, particularly excellent atomization properties during spray coating, can be obtained. The pigment (D) used in the second agent may be one type or two or more types.

[0115] Examples of the extender pigment include talc, mica, (precipitated) barium sulfate, (potassium) feldspar, kaolin, alumina white, bentonite, wollastonite, clay, glass flake, aluminum flake, magnesium carbonate, barium carbonate, calcium carbonate, dolomite, and silica, with talc, mica, silica, (precipitated) barium sulfate, and (potassium) feldspar being particularly preferred.

[0116] When producing the present composition containing an extender pigment, it is preferable to use the extender pigment so that the content of the extender pigment is preferably 5 to 80 mass %, more preferably 10 to 70 mass %, relative to 100 mass % of the nonvolatile content of the present composition.

[0117] Examples of the color pigment include inorganic pigments such as carbon black, titanium dioxide (titanium white), iron oxide (red iron oxide), yellow iron oxide, scaly iron oxide, and ultramarine, and organic pigments such as cyanine blue and cyanine green. Titanium white, carbon black, and red iron oxide are particularly preferred.

[0118] When producing the present composition containing a coloring pigment, it is preferable to use the coloring pigment so that the content of the coloring pigment is preferably 0.1 to 30% by mass, more preferably 1 to 20% by mass, relative to 100% by mass of the nonvolatile content of the present composition.

[0119] Examples of the rust-preventive pigment include zinc powder, zinc alloy powder, zinc phosphate compounds, calcium phosphate compounds, aluminum phosphate compounds, magnesium phosphate compounds, zinc phosphite compounds, calcium phosphite compounds, aluminum phosphite compounds, strontium phosphite compounds, aluminum tripolyphosphate compounds, molybdate compounds, zinc cyanamide compounds, borate compounds, nitro compounds, and composite oxides.

[0120] When producing the present composition containing a rust-preventive pigment, it is preferable to use the rust-preventive pigment so that the content of the rust-preventive pigment is preferably 0.5 to 20 mass%, more preferably 1 to 10 mass%, relative to 100 mass% of the nonvolatile content of the present composition.

[0121] The amount of solids of pigment (D) used in step 2 is more preferably within the following range. Pigment (D) is preferably used so that the pigment volume concentration (PVC) in the composition is preferably 10 to 70%, more preferably 20 to 60%. Furthermore, pigment (D) is preferably used so that the pigment volume concentration (PVC) in the second part is preferably 35 to 75%, more preferably 40 to 70%. When the PVC is within the above range, a composition with excellent coating workability can be easily obtained, and an anticorrosion coating film with excellent adhesion to the substrate due to stress relaxation and excellent corrosion protection can be easily formed.

[0122] The PVC in the composition refers to the total volume concentration of the pigment (D) relative to the volume of the nonvolatile content of the composition, and the PVC in the second pack refers to the total volume concentration of the pigment (D) relative to the volume of the solid content of the second pack. These PVCs can be specifically calculated using the following formula: PVC [%] in the composition = total volume of all pigments (D) in the composition × 100 / volume of nonvolatile content of the composition PVC [%] in the second pack = total volume of all pigments (D) in the second pack × 100 / volume of solid content of the second pack

[0123] The volume of the nonvolatile content of the composition can be calculated from the mass and true density of the nonvolatile content of the composition, and the volume of the solid content of the second part can be calculated from the mass and true density of the solid content of the second part. The mass and true density of the nonvolatile content may be measured values ​​or values ​​calculated from the raw materials used. The volume of the pigment (D) can be calculated from the mass and true density of the pigment (D) used. The mass and true density of the pigment (D) may be measured values ​​or values ​​calculated from the raw materials used. For example, the volume can be calculated by separating the pigment (D) from other components from the nonvolatile content of the composition or the solid content of the second part, and measuring the mass and true density of the separated pigment (D).

[0124] <Water> The second agent contains water, and step 2 is a step of preparing a water-containing second agent. Raw materials such as the water-dilutable component (B) used in preparing the second agent may contain water. When using such water-containing raw materials, it is not necessary to use water other than the water contained in the raw materials. However, in order to facilitate the preparation of the present composition, to easily obtain a second agent having superior storage stability, and to easily obtain the present composition having superior coating workability, it is preferable to use additional water in step 2 in addition to the water that may be contained in the raw materials such as the water-dilutable component (B). The additional water is not particularly limited, and tap water or the like may be used, but ion-exchanged water, distilled water, or the like is preferably used.

[0125] The water content in the second agent (including water that may be contained in raw materials such as the water-dilutable component (B)) is not particularly limited, but is preferably 10 to 50% by mass, more preferably 15 to 40% by mass, from the viewpoint of easily obtaining a second agent with excellent storage stability. Furthermore, the water content in the second agent is preferably 50% by mass or more, more preferably 70 to 100% by mass, and particularly preferably 80 to 100% by mass, relative to 100% by mass of the total amount of the dispersion medium and solvent in the second agent, from the viewpoint of easily obtaining a desired anticorrosion coating composition.

[0126] [Other Components] The second agent is not particularly limited as long as it contains a water-dilutable component (B), a non-aqueous component (C), a pigment (D), and water. If desired, it may contain other components other than the water-dilutable component (B), the non-aqueous component (C), the pigment (D), and water, such as divalent or higher polycarboxylic acids, viscosity modifiers (anti-sagging agents, anti-settling agents, thixotropic agents), water-soluble components containing amine compounds, other amine components, (pigment) dispersants, plasticizers, silane coupling agents, defoamers, flash rust inhibitors, curing accelerators, curing catalysts, film-forming aids, organic solvents, etc. (The second agent may contain the other components.) These other components may each be used alone or in combination with two or more. Conventional known components may be used as the other components. Examples of the plasticizers, silane coupling agents, defoamers, flash rust inhibitors, film-forming aids, curing accelerators, and organic solvents include the same components as those listed in the first agent.

[0127] <Divalent or higher polycarboxylic acid> The divalent or higher polycarboxylic acid is an organic acid having two or more carboxy groups in one molecule. From the viewpoints of easily obtaining the present composition having a long pot life and easily forming a corrosion-resistant coating film having excellent corrosion resistance, it is preferable that the second agent contains a divalent or higher polycarboxylic acid rather than an inorganic acid such as hydrochloric acid or a monocarboxylic acid such as acetic acid.

[0128] The polycarboxylic acid is not particularly limited, but examples thereof include oxalic acid, malonic acid, succinic acid, malic acid, tartaric acid, glutaric acid, adipic acid, maleic acid, and citric acid. Among these, malic acid, succinic acid, and tartaric acid are preferred because they can easily form an anticorrosion coating film with superior anticorrosion properties.

[0129] The molecular weight of the polycarboxylic acid is preferably 500 or less, more preferably 300 or less, and even more preferably 200 or less, from the viewpoint that the present composition having a well-balanced excellent pot life and drying property can be easily obtained.

[0130] When producing the present composition containing a polycarboxylic acid, the amount of the polycarboxylic acid used is preferably 5 parts by mass or more, more preferably 10 parts by mass or more, and preferably 30 parts by mass or less, more preferably 25 parts by mass or less, per 100 parts by mass of the total solid content of components (B) and (C) used in step 2, from the viewpoints that a present composition having a long pot life can be easily obtained and a corrosion-resistant coating film having excellent corrosion resistance can be easily formed.

[0131] <Viscosity Adjuster> The viscosity adjuster is not particularly limited, but is preferably a material that can suppress sedimentation of the pigment, etc. in the composition and improve its storage stability, or a material that can improve the anti-sagging properties of the composition during or after application. By using a viscosity adjuster in the second part together with component (B), component (C), and pigment (D), it tends to be easy to obtain a second part that has excellent storage stability, and it tends to be easy to obtain a composition that has excellent spray coating workability, particularly atomization properties during spray coating.

[0132] As the viscosity modifier, any of the conventionally known viscosity modifiers that can be used, such as stearate salts of Al, Ca, and Zn, lecithin salts, organic clay waxes such as alkylsulfonates, polyethylene wax, amide viscosity modifiers, amide neutralized salt viscosity modifiers, mixtures of amide viscosity modifiers, hydrogenated castor oil wax, mixtures of hydrogenated castor oil wax and amide wax, synthetic finely powdered silica, oxidized polyethylene wax, and urea viscosity modifiers, are preferred among these, from the viewpoint of being able to further improve the anti-sagging properties of the composition during and after application.

[0133] Commercially available viscosity modifiers may be used, and examples of such commercially available products include "Disparlon 305," "Disparlon 4200-20," "Disparlon 6650," and "Disparlon AQ600" manufactured by Kusumoto Chemical Co., Ltd.; "A-S-A T-250F," "A-S-A T-75F," "A-S-A TW-121," "A-S-A TW-123," and "A-S-A TW-124" manufactured by Itoh Oil Refining Co., Ltd.; "Flonon RCM-300" manufactured by Kyoeisha Chemical Co., Ltd.; "RHEOBYK-420" manufactured by BYK Japan KK; and "Benton" manufactured by Elements Specialties, Inc. SD-2 manufactured by Nippon Aerosil Co., Ltd., Aerosil R972 manufactured by Nippon Aerosil Co., Ltd., and Crayvallac Optima and Crayvallac REV manufactured by Arkema Coating Resins Co., Ltd.

[0134] When producing the present composition containing a viscosity modifier, it is preferable to use the viscosity modifier so that the solids content of the viscosity modifier is preferably 0.1 to 10 mass%, more preferably 0.3 to 8 mass%, based on 100 mass% of the nonvolatile content of the present composition. Furthermore, when preparing a second part containing a viscosity modifier, it is preferable to use the viscosity modifier so that the solids content of the viscosity modifier is preferably 0.3 to 12 mass%, more preferably 0.5 to 10 mass%, based on 100 mass% of the nonvolatile content of the second part. When the viscosity modifier content is within the above range, a second part with excellent storage stability can be easily obtained, and a present composition with excellent spray coating workability, particularly excellent atomization and sagging resistance during spray coating, can be easily obtained.

[0135] <(Pigment) Dispersant> The (pigment) dispersant is preferably a dispersant that can uniformly wet-disperse the pigment, etc., in the present composition and prepare a stable dispersion. Examples of the (pigment) dispersant include polymer dispersants. When producing the present composition containing a (pigment) dispersant, it is preferable to use the (pigment) dispersant so that the solid content of the (pigment) dispersant is preferably 0.01% by mass or more, more preferably 0.1% by mass or more, even more preferably 0.2% by mass or more, and preferably 5% by mass or less, relative to 100% by mass of the nonvolatile content of the present composition.

[0136] <Step 3> Step 3 is a step of mixing the first and second agents prepared in steps 1 and 2, respectively, with the nth agent being used as needed. The present composition can be produced by mixing (or kneading) the first and second agents and the nth agent, which is used as needed. The mixing (or kneading) can be performed using a conventionally known device such as a mixer, disperser, or stirrer, and examples of such devices include a disperser, a mixing / dispersion mill, a mortar mixer, a roll, a paint shaker, and a homogenizer. The mixing (or kneading) may be performed while heating or cooling, depending on the season, environment, etc.

[0137] <Present Composition> The present composition is obtained from the present kit. Because the present composition has excellent coating workability, it can be applied by various conventionally known coating methods, but because it has excellent spray coating workability, particularly excellent atomization during spray coating, it is particularly suitable for use in spray coating.

[0138] The content of nonvolatile matter in the present composition is preferably 60% by mass or more, more preferably 70% by mass or more, and the upper limit is not particularly limited, but is, for example, 90% by mass. The content of nonvolatile matter in the present composition corresponds to the heating residue percentage described below. The present composition having a nonvolatile matter content within the above range can be said to be a high-solids composition. When the nonvolatile matter content is within the above range, the present composition has excellent drying properties, is less likely to sag during application, can form a thick film in a single application, and has excellent application workability.

[0139] The viscosity of this composition measured at 23°C is preferably 7000 mPa·s or less, more preferably 5500 mPa·s or less, and even more preferably 5000 mPa·s or less. There is no particular lower limit, but it is preferably 1500 mPa·s or more, more preferably 2000 mPa·s or more, and even more preferably 2500 mPa·s or more. This kit and method can easily produce a corrosion-resistant coating composition having a viscosity within these ranges and a non-volatile content within the above range. When the viscosity is within the above range, this composition has excellent handling and sagging resistance, is not limited by the coating method, and can be applied using various desired coating methods, resulting in a composition with excellent coating workability. Note that this composition may be diluted with a solvent or dispersant (e.g., water) depending on the coating method. However, according to one embodiment of the present invention, the viscosity is within the above range even without dilution with a solvent or dispersant, making it possible to apply the composition without dilution with a solvent or dispersant. Each description in this specification describes the composition before dilution with a solvent or dispersant.

[0140] The VOC content of the present composition is preferably 100 g / L or less, more preferably 80 g / L or less, and even more preferably 60 g / L or less, in order to provide a composition that has little impact on the natural environment and the coating work environment.

[0141] The VOC content in the present composition can be calculated from the following formula (2) using the values ​​of the composition specific gravity, heating residue percentage (mass ratio of non-volatile content), and moisture percentage. The composition specific gravity, heating residue percentage, and moisture percentage may be measured values ​​as described below, or may be values ​​calculated from the raw materials used. VOC content (g / L) = composition specific gravity × 1000 × (100 - heating residue percentage - moisture percentage) / 100 (2)

[0142] Composition specific gravity (g / cm 3 ): A value calculated by filling a 100 ml density cup with the composition (the composition immediately after mixing the first and second agents (and the nth agent, if an nth agent is included) at a temperature of 23°C) and measuring the mass of the composition.

[0143] Heat residue percentage (mass%): 1±0.1 g of this composition (the composition immediately after mixing the first and second agents (and the nth agent, if an nth agent is included)) is weighed onto a flat-bottom dish, spread evenly using a wire of known mass, dried at 23°C for 24 hours, and then heated at 125°C for 1 hour (at normal pressure). The heat residue (non-volatile content) and the mass of the wire are measured to calculate the mass percentage. In this specification, the heat residue is referred to as the "non-volatile content of this composition." In this specification, the components of the first and second agents (e.g., non-aqueous epoxy compound (A)) other than the solvent and dispersion medium (e.g., water) in the first and second agents that have a boiling point of less than 180°C at normal pressure are referred to as the "solid content."

[0144] Moisture content (mass%): the mass percentage of water contained in 100% by mass of the composition, measured by the Karl Fischer method

[0145] <<Anti-corrosion coating film, substrate with anti-corrosion coating film>> The anti-corrosion coating film according to one embodiment of the present invention (hereinafter also referred to as "the present coating film") is formed using the present kit, and specifically, is formed from the present composition obtained from the present kit or the present composition produced by the present method. The present coating film is preferably used as a substrate with a anti-corrosion coating film (hereinafter also referred to as "substrate with the present coating film") comprising a substrate and the present coating film. The substrate with the present coating film is a laminate having the present coating film and a substrate.

[0146] The material of the substrate is not particularly limited, and examples thereof include steel (iron, steel, ferroalloy, carbon steel, mild steel, alloy steel, etc.), non-ferrous metals (zinc, aluminum, copper, brass, zinc plating, zinc thermal spraying, etc.), and stainless steel (SUS304, SUS410, etc.). When mild steel (SS400, etc.) is used as the substrate, it is desirable to perform surface preparation (e.g., adjustment so that the arithmetic mean roughness (Ra) is about 30 to 75 μm) by polishing the substrate surface by grit blasting or the like, as necessary. The substrate may also be a substrate that has been subjected to pretreatment such as cleaning or blasting to remove rust, dirt, paint (old paint film), etc. adhering to the substrate.

[0147] The substrate is not particularly limited, and the composition can be used without limitation on substrates that require corrosion resistance. However, in terms of the effects of using the composition of the present invention being more pronounced, preferred examples include (steel) structures such as ships, marine structures, plants, bridges, tanks, and containers.

[0148] The dry film thickness of the coating is not particularly limited, but is usually 10 to 500 μm, preferably 15 to 400 μm, in order to obtain a coating having sufficient anticorrosion properties.

[0149] The substrate with the coating film is a laminate comprising the coating film and a substrate, and may have an undercoat coating (primer coating) intended to improve adhesion to the substrate and corrosion resistance, an intermediate coating intended to improve corrosion resistance, and a topcoat coating intended to improve weather resistance and aesthetics. Specifically, when the composition is used as a substitute for a zinc primer, an intermediate coating and a topcoat coating may be formed on the coating film. Examples of the undercoat coating include coatings formed from various primer compositions such as epoxy resin-based coatings. Examples of the intermediate coating include coatings formed from various intermediate coating compositions such as (meth)acrylic resin-based, epoxy resin-based, and urethane resin-based coatings. Examples of the topcoat coating include coatings formed from various topcoat coating compositions such as (meth)acrylic resin-based, (meth)acrylic silicone resin-based, urethane resin-based, silicone resin-based, and fluororesin-based coatings. Furthermore, the composition of the composition may be changed to form an undercoat coating, intermediate coating, and topcoat coating using the composition.

[0150] <<Method for producing a substrate with a corrosion-protective coating>> A method for producing a substrate with a corrosion-protective coating according to one embodiment of the present invention includes the following steps I and II. Step I: A step of applying the composition obtained using the kit or the composition produced by the method to a substrate. Step II: A step of drying the composition applied to the substrate to form the coating.

[0151] <Step I> The coating method in Step I is not particularly limited, and examples thereof include conventionally known methods such as spray coating such as airless spray coating and air spray coating, brush coating, roller coating, etc. Among these, spray coating is preferred because it allows the effects of the present invention to be more effectively exhibited and allows for easy coating of large-area substrates such as the structure.

[0152] The spray coating conditions may be adjusted as appropriate depending on the desired dry film thickness. For example, in the case of airless spray coating, the following conditions are preferred: primary (air) pressure: approximately 0.3 to 0.6 MPa; secondary (paint) pressure: approximately 10 to 15 MPa; and gun movement speed: approximately 50 to 120 cm / sec.

[0153] The coating is preferably carried out so that the dry film thickness of the main coating film formed in step II falls within the above-mentioned range. In this case, the main coating film of the desired film thickness may be formed in one coating (single coating), or may be formed in two or more coatings (two or more coatings). Note that "two coatings" refers to carrying out steps I and II, and then carrying out step I or the like on the coating film obtained in step II.

[0154] When applying the present composition to a substrate, it is preferable to treat the surface of the substrate as necessary (for example, by blasting (ISO8501-1 Sa2 1 / 2) or degreasing to remove oil and dust) in order to remove rust, oil, moisture, dust, salt, etc. from the substrate and to improve the adhesion of the resulting coating film to the substrate. Furthermore, the substrate may be coated with a shop primer or the like for the purpose of primary rust prevention.

[0155] <Step II> The drying conditions in Step II are not particularly limited and may be set appropriately depending on the coating film formation method, type of substrate, intended use, coating environment, etc., but the drying temperature is typically 5 to 35°C in the case of room temperature drying, and typically 30°C or higher but lower than 100°C, more preferably 40 to 80°C, in the case of forced drying using a hot air dryer or the like. According to the present composition, the composition can be dried and cured even by such room temperature drying. The drying time varies depending on the coating film drying method, and is, for example, about 1 to 7 days in the case of room temperature drying, and about 5 to 60 minutes in the case of forced drying.

[0156] Hereinafter, one embodiment of the present invention will be further described with reference to examples, but the present invention is not limited to these examples.

[0157] Example 1 First Agent 16 parts by mass of non-aqueous epoxy compound A-1, 5 parts by mass of non-aqueous epoxy compound A-3, 2 parts by mass of a reactive diluent, 2 parts by mass of a hydrocarbon resin, 1 part by mass of a silane coupling agent, 2 parts by mass of an organic solvent, and 0.1 parts by mass of an antifoaming agent-1 were dispersed using a high-speed disper at room temperature (23°C) for 30 minutes to prepare a first agent.

[0158] <Second Agent> A pigment dispersion was prepared by placing 12.59 parts by mass of deionized water, 1.5 parts by mass of dispersant, 0.1 parts by mass of antifoaming agent-2, 15 parts by mass of potassium feldspar, 10 parts by mass of talc, 10 parts by mass of precipitated burr, 5 parts by mass of titanium white, and 0.01 parts by mass of carbon in a container and stirring using a high-speed disper at room temperature (23°C) until the particle size reached 60 μm or less. Next, a separate container was charged with 4 parts by mass of deionized water, 5 parts by mass of water-dilutable amine compound B-1, 1.2 parts by mass of polycarboxylic acid, 4 parts by mass of nonaqueous amine compound C-1, and 2 parts by mass of nonaqueous amine compound C-2, and stirring for 30 minutes using a high-speed disper. Thereafter, the prepared amine dispersion and the pigment dispersion were mixed, 1.5 parts by mass of viscosity modifier-1 was added thereto, and the mixture was stirred using a high-speed disperser until the temperature reached 45 to 50°C, thereby preparing a second agent.

[0159] The components listed in Table 1 are described in Table 3.

[0160] Examples 2 to 17 and Comparative Examples 1 to 8 Anticorrosion coating compositions were prepared in the same manner as in Example 1, except that the components shown in Table 1 or 2 were used in the amounts (numeric values, parts by mass) shown in Table 1 or 2. The amount of water shown in Table 1 or 2 is the total amount used in preparing the pigment dispersion and the amine dispersion, but the amount of deionized water used in preparing the amine dispersion was 4 parts by mass in all examples. In other words, the amount of water used in preparing the pigment dispersion was the amount shown in Table 1 or 2 minus 4 parts by mass.

[0161]

[0162]

[0163]

[0164] <Storage stability of second agent> 50 g of the second agent prepared in the examples and comparative examples was weighed out immediately after preparation, placed in a 50 mL glass bottle, and stored at 23°C for one month. The state of the second agent (presence or absence of separation, precipitation, and aggregates) was visually observed, and the state of the second agent when stirred with a medicine spoon was visually confirmed and evaluated according to the following evaluation criteria. The results are shown in Table 4. Note that the storage stability of the second agent can be said to be satisfactory for practical use if it was evaluated as 3 or higher.

[0165] (Evaluation criteria) 5: No separation, sedimentation, or agglomeration was observed in the second formulation after storage for one month. 4: Slight separation was observed in the second formulation after storage for one month, but no sedimentation or agglomeration was observed, and it was easily homogenized by stirring with a spoon. 3: Slight separation, sedimentation, and agglomeration was observed in the second formulation after storage for one month, but it was easily homogenized by stirring with a spoon. 2: Separation, sedimentation, and agglomeration was observed in the second formulation after storage for one month, and it was homogenized by stirring with a spoon, but it took some time to become homogenous. 1: Separation, sedimentation, and agglomeration was observed in the second formulation after storage for one month, and it was not homogenized by stirring with a spoon.

[0166] <Atomization Properties> The first and second parts prepared in the Examples and Comparative Examples were kept at 23°C, and the first and second parts were mixed. The viscosity was adjusted with deionized water so that the paint viscosity at 23°C was 30 to 40 dPa·s, as measured with a No. 1 rotor on a Viscometer VT-04F (manufactured by Rion Co., Ltd.). Each anticorrosion coating composition was sprayed for 10 seconds using an airless sprayer (compression ratio 30:1, primary pressure 0.4 to 0.5 MPa, hose length 10 m, tip size: 519, manufactured by Graco) immediately after the viscosity adjustment (0 minutes), after 30 minutes of standing at 23°C from the viscosity adjustment, and after 1 hour of standing at 23°C from the viscosity adjustment. The atomization properties (spray pattern) of each anticorrosion coating composition were evaluated visually according to the following evaluation criteria. The results are shown in Table 4. It should be noted that if the atomization property is rated as 4 or higher, it can be said that there is no problem in practical use.

[0167] (Evaluation criteria) 5: When the anticorrosion coating composition is applied to a substrate using an airless spray, the anticorrosion coating composition is sprayed in the form of a mist of fine particles, and the spray pattern formed is uniform and free of streaks or tails. 4: When the anticorrosion coating composition is applied to a substrate using an airless spray, the anticorrosion coating composition is sprayed in the form of a mist of fine particles, and the spray pattern formed spreads without streaks, but slight tails are observed. 3: When the anticorrosion coating composition is applied to a substrate using an airless spray, the anticorrosion coating composition is sprayed in the form of a mist of fine particles, and the spray pattern formed spreads, but streaks are observed and a tail is also observed. 2: When the anticorrosion coating composition is applied to a substrate using an airless spray, the anticorrosion coating composition is sprayed in the form of a mist of fine particles, but the spray pattern formed is narrow and free of streaks or tails. 1: When the anticorrosion coating composition was applied to a substrate using an airless spray, the anticorrosion coating composition was not sprayed in the form of fine particles in a mist, the spray pattern did not spread at all, and coating was impossible.

[0168] Photographs of the spray state during spray coating corresponding to the evaluation criteria 5 to 1 are shown in Figures 1 to 5. The "tail" refers to the phenomenon in which thick lines appear at both ends of the spray pattern, and the "streaks" refers to the phenomenon in which thick lines appear due to uneven spreading within the spray pattern.

[0169] [Preparation of Substrate (Test Plate) with Anticorrosion Coating] An SS400 sandblasted steel plate (arithmetic mean roughness (Ra): 30 to 75 μm) having dimensions of 150 mm × 70 mm × 1.6 mm (thickness) was prepared. An anticorrosion coating composition obtained by mixing the first and second parts prepared as described above was applied to the surface of this steel plate using an air spray to a dry film thickness of 150 μm. The anticorrosion coating composition applied to the steel plate was then dried at 23°C for 7 days to prepare a test plate. Note that with the anticorrosion coating composition obtained in Comparative Example 8, the first and second parts could not be mixed uniformly, and a coating film could not be formed by air spraying, and the following anticorrosion properties (salt spray) and anticorrosion properties (high temperature and high humidity) tests could not be performed.

[0170] <Corrosion resistance (salt spray)> A salt spray test was carried out in accordance with JIS K 5600-7-1:1999 by holding the test plate in a salt spray tester under salt spray conditions of a salt concentration of 5% by mass, a temperature of 35°C, and a relative humidity of 98% for one month or three months, and the corrosion resistance (salt spray) was evaluated according to the following evaluation criteria. The results are shown in Table 4. It should be noted that a rating of 4 or higher for corrosion resistance (salt spray) can be said to be satisfactory for practical use.

[0171] (Evaluation criteria) 5: Neither rust nor blisters have occurred. 4: No blisters have occurred, but the area of ​​rust on the surface of the substrate under the paint film is less than 0.03% of the entire surface of the substrate under the paint film. 3: A very small amount of small blisters have occurred, and the area of ​​rust on the surface of the substrate under the paint film is 0.03% or more but less than 0.1% of the entire surface of the substrate under the paint film. 2: Blisters have occurred, and the area of ​​rust on the surface of the substrate under the paint film is 0.1% or more but less than 0.3% of the entire surface of the substrate under the paint film. 1: Blisters have occurred, and the area of ​​rust on the surface of the substrate under the paint film is 0.3% or more of the entire surface of the substrate under the paint film.

[0172] <Corrosion resistance (high temperature and high humidity)> According to JIS K 5600-7-1:1999, the test plate was kept in a high temperature and high humidity tester at a temperature of 50±1°C and a humidity of 95% or more for one month or three months, and then the appearance of the test plate was visually evaluated according to the following criteria. The results are shown in Table 4. It should be noted that a rating of 2 or higher for corrosion resistance (high temperature and high humidity) can be said to be satisfactory for practical use.

[0173] (Evaluation criteria) 3: No change in blister, crack, rust, peeling, or color 2: Slight defect (change) observed in blister, crack, rust, peeling, or color 1: Clear defect (change) observed in blister, crack, rust, peeling, or color

[0174]

Claims

1. An anticorrosive coating composition kit comprising a first agent containing a non-aqueous epoxy compound (A) and a second agent containing a water-dilutable component (B) containing an amine compound, a non-aqueous component (C) containing an amine compound, a pigment (D) and water.

2. The kit of claim 1, wherein the second agent comprises a viscosity adjusting agent.

3. The kit according to claim 1, wherein the second agent contains a polycarboxylic acid having two or more valences.

4. The kit according to claim 1, wherein the water content in the second agent is 10 to 50 mass %.

5. The kit according to claim 1, wherein the pigment volume concentration (PVC) of the second agent is 35 to 75%.

6. A method for producing an anticorrosive coating composition, comprising: step 1 of preparing a first agent using a non-aqueous epoxy compound (A); step 2 of preparing a second agent containing water using a water-dilutable component (B) containing an amine compound, a non-aqueous component (C) containing an amine compound, and a pigment (D); and step 3 of mixing the first agent and the second agent.

7. A corrosion-resistant coating film formed using the kit according to any one of claims 1 to 5.

8. A substrate with an anticorrosive coating film, comprising a substrate and the anticorrosive coating film according to claim 7.

9. A method for producing a substrate with an anticorrosive coating film, comprising the following steps I and II: Step I: A step of coating a substrate with an anticorrosive coating composition obtained by using the kit according to any one of claims 1 to 5; and Step II: A step of drying the anticorrosive coating composition coated on the substrate to form an anticorrosive coating film.

10. The method for producing a substrate with a corrosion-resistant coating according to claim 9, wherein the coating in step I is spray coating.

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