BACKGROUND OF THE INVENTION
Field of the Invention

The present invention relates to a mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates and a method of producing the same, and more particularly to a mixed water-based dispersion of polyimide-fluororesin-polar crystal particulates with excellent handleability (e.g., safety, environmental burden, equipment cost) as well as excellent adhesion performance and heat resistance performance without the use of an organic solvent; and a method of producing the same.

Further, the present invention relates to a new mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates and a method of producing the same, that can form a coating film or a coating having high-performance attachment and adhesion functions substantially exceeding conventional products and, in addition, being provided with excellent heat resistance, insulation, heat radiation dissipation property, and rust and corrosion resistance by the coexistence of polar crystal particulates in a mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates.

Description of Related Art

Conventionally, mixtures of polyimide and fluororesin such as polytetrafluoroethylene (PTFE) have been known. These mixtures have a low coefficient of friction and are excellent in properties such as non-attachment, chemical resistance, and heat resistance; thus, they are widely used for surface treatment on articles for the food industry, kitchen utensils, such as frying pans and pots, articles for the household, such as irons, articles for the electric industry, articles for the machine industry, and the like.

For example, Japanese Unexamined Patent Application Publication No. 2016-210886 discloses a composition of a polyimide precursor solution in which the dispersion state of the fluorine-based resin is uniformly controlled; polyimide and a polyimide film obtained from this composition, which are excellent in heat resistance, mechanical properties, electrical properties such as low dielectric constant and low dielectric loss tangent, and processability; a method of producing the same; and a circuit board and cover lay film of the polyimide film.

More particularly, Japanese Unexamined Patent Application No. 2016-210886 discloses a composition of a polyimide precursor solution containing fluorine-based resin, comprising at least: a non-water-based dispersion of fluorine-based resin comprising a micropowder of fluorine-based resin, and a fluorine-based additive containing at least a fluorine-containing group and a lipophilic group, wherein the amount of water measured by the Karl Fischer method is 5000 ppm or less; and a polyimide precursor solution.

Japanese Unexamined Patent Application Publication No. 2016-210886 is to provide the composition of the polyimide precursor solution in which the dispersion state of the fluorine-based resin is uniformly controlled, the polyimide and the polyimide film obtained from this composition, which are excellent in heat resistance, mechanical properties, slidability, insulation, electrical properties such as low dielectric constant and low dielectric loss tangent, and processability, and the method of producing the same, as well as the circuit board, cover lay film, insulating film, interlayer insulating film for wiring substrates, surface protecting layer, sliding layer, peeling layer, fiber, filter material, wire coating material, bearing, coating, heat insulating shaft, trays, various belts such as a seamless belt, tape, tube, and the like of the polyimide or the polyimide film. However, the composition described in Japanese Unexamined Patent Application Publication No. 2016-210886 comprises an organic solvent as a solvent to uniformly disperse the polyimide and the fluororesin, there has been a problem with handleability (e.g., safety, environmental burden, equipment cost). For this reason, there has been a need for a mixed aqueous dispersion of polyimide and fluororesin excellent in handleability without the use of an organic solvent.

The present inventors have attempted to develop a mixed water-based dispersion of polyimide-fluororesin with excellent adhesion performance and heat resistance performance even without the use of an organic solvent. As a result, the present inventors have accomplished, as such a dispersion, a mixed aqueous dispersion comprising polyimide, fluororesin, alumina, and potassium persulfate, in which the polyimide and the fluororesin are uniformly dispersed, and a mixed powder produced from this dispersion, as well as a method of producing the same. This dispersion is provided with excellent adhesion performance and heat resistance performance and has excellent coating property, and, in addition, has excellent handleability (e.g. safety, environmental burden, equipment cost), since this mixed aqueous dispersion of polyimide-fluororesin does not comprise an organic solvent (Japanese Unexamined Patent Application No. 2019-98015).

SUMMARY OF THE INVENTION
Technical Problem

The present inventors have established the technique of providing polyimide (PI) in an aqueous form in the above Japanese Unexamined Patent Application No. 2019-98015 (a mixture of polyimide-fluororesin and a method of producing the same, which have been successfully developed and granted a patent), resulting in the commercialization of the mixture of this PI and water-dispersed PTFE as a coating. However, while being sufficiently applicable as a regular coating, this mixture of polyimide-fluororesin still has non-attachment or non-adhesion property; and thus, in the sense that it does not exceed such range of property, it is significantly far from the present inventors' ideal, high-level attachment and adhesion, and, for this reason, this mixture of polyimide-fluororesin has not been satisfactory as the present inventors' ideal, high-performance coating exceeding the conventional art.

Thus, the inventors have reconsidered the material formulation from every angle and analyzed the results as well as conducted various experiments associated with attachment and adhesion for the purpose of improving attachment and adhesion properties of the “mixture of polyimide-fluororesin”.

In these experiments, as a result of the reconsideration of the mechanism of adhesion property, the present inventors have discovered that the utilization of electrical interaction is effective in adhering a mixture (adhesive) to metals, SUS, aluminum, steel, copper, and the like in a perfect bonding state. That is, the present inventors have thought of obtaining favorable adhesion performance by using raw materials that have a positive (+) voltage (positive ion) for all the metals that are to be adhered and by using a raw material that has a (−) voltage for the raw material (mixture) configured as a coating.

As such raw material that has a (−) voltage, the present inventors have selected black tourmaline, pink tourmaline, and Rokusyo Stones (Registered Trademark), which are minerals having a naturally occurring voltage, and attempted to prepare a new mixture of polyimide-fluororesin by formulating them in a dispersion comprising PI and PTFE after converting them to a powder having a particle diameter of 3 μm or less. As a result of conducting over about 100 experiments in total, changing the formulation ratio, finally the present inventors have successfully developed a coating having (−) and (+) voltages, a natural electrodeposition coating in which the PI, PTFE, and tourmaline having a (−) voltage are formulated together with A1 sol and potassium persulfate. The development of such coating was succeeded, to the best of the present inventors' knowledge, for the first time in the world. This coating achieved perfect adhesion and bond, substantially exceeding the level of conventional coatings in the evaluation after firing at 380° C.

The Means for Solving the Problem

That is, the present inventors have found that more outstanding adhesion performance, heat resistance performance, insulation performance, and the like than conventional coating agents of a mixture in which polyimide and fluororesin are mixed, are achieved by using an aqueous dispersion comprising polyimide, fluororesin, and polar crystal particulates, and have completed the present invention.

The invention according to a first aspect relates to a production method, comprising steps of: obtaining polar crystal particulates having a particle diameter of 3 μm or less by grinding and sieving a polar crystal; preparing an aqueous dispersion 1 containing the polar crystal particulates; preparing an aqueous dispersion 2 containing a polyimide precursor or polyimide; preparing an aqueous dispersion 3 containing fluororesin; preparing an aqueous potassium persulfate solution by adding potassium persulfate to water; preparing an aqueous dispersion 4 containing alumina; and mixing the aqueous dispersion 1, the aqueous dispersion 2, the aqueous dispersion 3, the aqueous dispersion 4, and the aqueous potassium persulfate solution, wherein the polyimide precursor comprises polyamide acid, polyamide ester, polyamide imide, or polyamic acid, or a mixture thereof.

The invention according to a second aspect relates to the production method of the first aspect, wherein the polar crystal particulates are one or more selected from the group consisting of pink tourmaline and black tourmaline.

The invention according to a third aspect relates to the production method of the first aspect, wherein the fluororesin is fluororesin particulates consisting of polymers or copolymers of monomers selected from the group consisting of tetrafluoroethylene, hexafluoropropylene, chlorotrifluoroethylene, perfluoro (alkyl vinyl ether), vinylidene fluoride, and vinyl fluoride.

Effects of the Invention

In accordance with the invention according to the first aspect, the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates can be produced which can enhance dispersibility in an aqueous solution not comprising an organic solvent, is more excellent in dispersibility, and has more excellent coating property, since the invention is a method of producing an aqueous dispersion of a polyimide precursor or polyimide-fluororesin-polar crystal particulates, comprising steps of: obtaining polar crystal particulates having a particle diameter of 3 μm or less by grinding and sieving a polar crystal; preparing an aqueous dispersion 1 containing the polar crystal particulates; preparing an aqueous dispersion 2 containing a polyimide precursor or polyimide; preparing an aqueous dispersion 3 containing fluororesin; preparing an aqueous potassium persulfate solution by adding potassium persulfate to water; preparing an aqueous dispersion 4 containing alumina; and mixing the aqueous dispersion 1, the aqueous dispersion 2, the aqueous dispersion 3, the aqueous dispersion 4, and the aqueous potassium persulfate solution, wherein the polyimide precursor comprises polyamide acid, polyamide ester, polyamide imide, or polyamic acid, or a mixture thereof. Furthermore, this method can form a coating film or a coating having high-performance attachment and adhesion functions substantially exceeding conventional products and, in addition, being provided with excellent heat resistance, insulation, heat radiation dissipation property, and rust and corrosion resistance.

In accordance with the invention according to the second aspect, the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates with more excellent coatability can be made, since the polar crystal particulates are one or more selected from the group consisting of pink tourmaline and black tourmaline.

In accordance with the invention according to the third aspect, the aqueous dispersion with more excellent processability and formability can be provided, since the fluororesin is fluororesin particulates consisting of polymers or copolymers of monomers selected from the group consisting of tetrafluoroethylene, hexafluoropropylene, chlorotrifluoroethylene, perfluoro (alkyl vinyl ether), vinylidene fluoride, and vinyl fluoride.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a figure showing results of a thermogravimetric reduction TG-DTA test on a coating film of a mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention. The coating film of the present invention, a regular PTFE membrane, and a PI film were each heated at 10° C./min, and the thermal reduction rates (TG %) were measured.

FIG. 2 is a photograph showing a result of a cross cut test on a coating film of a mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention.

FIG. 3 is a photograph showing a result of a cross cut test on a comparative example, a coating film of a mixed aqueous dispersion of polyimide-fluororesin.

FIG. 4 is a photograph showing a result of a tape peel test on a coating film of a mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention.

FIG. 5 is a photograph showing an example of a coated frying pan using a mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention.

FIG. 6 is a photograph showing another example of a coated frying pan using a mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention.

FIG. 7 is a photograph showing an example of a coated heat sink for electronic devices using a mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention.

FIG. 8 is a figure showing thickness measurement positions of a test specimen by numbers (1) to (9).

FIG. 9 is an explanatory diagram showing the results of a heat resistance test on a coating film (3 μm in thickness) prepared using an aqueous dispersion of the invention comprising propylene glycol monomethyl ether (PM).

FIG. 10 is an explanatory diagram showing the results of a heat resistance test on a coating film (6 μm in thickness) prepared using an aqueous dispersion of the invention comprising PM.

FIG. 11 is an explanatory diagram showing the results of a heat resistance test on a coating film (6 μm in thickness) prepared using an aqueous dispersion of the invention comprising PM, PTFE, and alumina filler.

FIG. 12 is an explanatory diagram showing the results of a heat resistance test on a coating film (11 μm in thickness) prepared using an aqueous dispersion of the invention comprising PM, PTFE, and alumina filler.

FIG. 13 is an explanatory diagram showing the results of a boiling water resistance test on a coating film (6 μm and 11 μm in thickness) prepared using an aqueous dispersion of the invention comprising PM and PTFE, and on a coating film (5 μm and 9 μm in thickness) prepared using tourmaline in addition to PM and PTFE.

FIG. 14 is an explanatory diagram showing the results of a boiling water resistance test on a coating film (7 μm and 14 μm in thickness) prepared using an aqueous dispersion of the invention comprising PM and a cresol novolac epoxy resin emulsion, and on a coating film (7 μm and 14 μm in thickness) prepared using tourmaline in addition to PM and a cresol novolac epoxy resin emulsion.

DESCRIPTION OF EMBODIMENTS

Suitable embodiments of the composition according to the present invention, comprising polyimide-fluororesin-polar crystal particulates and water are discussed below.

The water used in the aqueous dispersion of the present invention is ion exchange water. Electrical interaction between structural components is important in order for the mixed aqueous dispersion of the present invention to exhibit its functions. Therefore, in the present invention, ion exchange water is suitably used, and basically tap water is not used.

The above composition may be a mixed aqueous dispersion (hereinafter, referred to merely as a mixed aqueous dispersion). This mixed aqueous dispersion comprises a polyimide precursor or polyimide, fluororesin, polar crystal particulates, and water.

Polyamide acid is also referred to as amic acid, and is known as a precursor of polyimide widely used as a chemical material. In recent years, polyamide acid has been industrially obtained by the degradation of polyimide as a waste material, and this has newly been used as a raw material to synthesize polyimide (Japanese Patent No. 6402283, 6487501, and 6186171).

Polyimide (P1) is resin consisting of polymers having imide bonds in their molecular structures. Polyimide can be synthesized by, for example, a general synthesis method as shown in the below formula. In this synthesis method, tetracarboxylic acid dianhydride and diamine are polymerized in equimolar amounts as raw materials to obtain polyamide acid, which is a precursor of polyimide.

[Image Omitted]

By heating this polyamide acid at 200° C. or higher or using a catalyst, dehydration and cyclization (imidization) reaction is proceeded, and polyimide is obtained. If a catalyst is used, usually an amine-based compound is used, and a carboxylic anhydride may be used together as a dehydrator to quickly remove water generated by the imidization.

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Herein, a polyimide precursor is a compound that may be a raw material of polyimide, and preferably indicates polyamide acid, polyamide imide, polyamic acid, or a mixture thereof. The polyimide precursor may comprise substances described in Japanese Patent No. 5695675 or Japanese Patent No. 6186171. The polyimide precursor is, for example, one shown below.

[Image Omitted]

(Wherein the symbol X is an alkali metal (lithium/Li, sodium/Na, potassium/K, rubidium/Rb, or cesium/Ce), the subscripts n and I are symbols indicative of the abundances (numbers of moles) of the polyamide acid structures located on the sides of the polyimide structures and are regularly values in a range of 0.1 to 0.8, and the subscript m is a symbol indicative of the abundance (number of moles) of the polyimide structures and is regularly a value in a range of 0.2 to 0.9.)

The polyimide used for the mixed aqueous dispersion is not particularly limited; the polyimide includes, for example, a resin consisting of high molecular weight polymers obtained by the reaction of an aromatic tetravalent carboxylic anhydride such as pyromellitic dianhydride, or the like, and any can be used as long as it is obvious to a person skilled in the art. Further, the polyimide used for the mixed aqueous dispersion may be one that used polyimide has been grinded and recycled, or it may be unused one. The shape of the polyimide is not particularly limited, but the polyimide is in particulates and the size of the particles is preferably in a range of 1 μm to 100 μm from the point of view that they can be easily maintained in a suspended, dispersed state in the mixed aqueous dispersion for a long period of time. The content of the polyimide is preferably 5% by weight to 40% by weight with respect to the mixed aqueous dispersion, and more preferably 10% by weight to 40% by weight, 15% by weight to 30% by weight, 10% by weight to 30% by weight, or 10% by weight to 20% by weight.

The mixed aqueous dispersion of the present invention preferably comprises polyamide acid, which is a precursor of polyimide. By heating the polyamide acid at 200° C. or higher, dehydration and cyclization (imidization) can be carried out. Through this imidization process, the polyamide acid-containing mixed aqueous dispersion can form a stronger coating.

Further, the mixed aqueous dispersion of the present invention may comprise polyimide analogs of one or more selected from polyamide acid or polyamide ester. These polyimide analogs bring positive effects to adhesion performance of the mixed aqueous dispersion and are essential components to create a highly heat-resistant and strong coating film. The mixed aqueous dispersion of the present invention preferably comprises a polyimide dispersion comprising polyamide acid.

The amount of the polyamide acid included in the aqueous dispersion of the present invention is 1 to 50% by weight, 5 to 40% by weight, or 10 to 30% by weight with respect to the total aqueous dispersion, and preferably 10 to 30% by weight. By including 10 to 30% by weight of the polyamide acid, an aqueous dispersion with more excellent coatability can be made.

As such, it should be understood that the term polyimide herein is used as polyimide in a broad sense to cover even a precursor of polyimide and polyimide analogs in addition to the polyimide included in the mixed aqueous dispersion.

The formulations preferably used in the present invention, which contain polyimide as a raw material, include, for example but not limited to, W-20 produced by NAKATA COATING CO., LTD. Further, such formulations may comprise phosphoric acid, ethanol dispersion, amine, propylene glycol, nonionic component (neutral additive), carbon black as a colorant component, and the like.

The polar crystal herein refers to a crystal having a positive electrode (+) on one side and a negative electrode (−) on the opposite side. The polar crystal generates an unstable state (potential difference) at all times, and due to this potential difference, electrons are continuously emitted, flowing from the negative electrode toward the positive electrode. The polar crystal particulates herein refer to one or more selected from the group consisting of pink tourmaline, black tourmaline, and Rokusyo Stone (Registered Trademark) and suitably used, but not limited thereto.

Among the polar crystals, particularly well-known is tourmaline. Tourmaline refers to crystals of the chemical formula XY₃Al₆(BO₃)₃SiO₁₈(O,OH,F)₄, and among such crystals, dravite NaMg₃Al₆(BO₃)₃Si₆O₁₈(OH)₄, elbaite Na(Li,Al)₃Al₆(BO₃)₃Si₆O₁₈(OH)₄, schorl NaFe₃Al₆(BO₃)₃Si₆O₁₈(OH)₄, and uvite CaMg₃(Al₅Mg)(BO₃)₃Si₆O₁₈(OH,F)₄are so-called tourmaline.

It is said that tourmaline was excavated in the island of Ceylon, current Sri Lanka, in 1703 and brought to Europe. Later, in 1880, Pierre Curie, who received the Nobel Prize in Physics, found that an electric charge is generated on the crystal's surface upon the appliance of external pressure to the tourmaline. Further, it was revealed that an electric charge is also generated upon the addition of heat energy to the tourmaline. The phenomenon caused upon the addition of pressure to the tourmaline is called pressure-electricity (piezo electricity), and the phenomenon in which, upon the addition of heat, electrons are separated to both poles of the crystal and positive and negative charges are generated is called pyroelectricity. When pressure or heat is added to the tourmaline, positive and negative electrodes are generated in both electrodes of the stone and electricity is generated. The positive electrode attracts electrons and emits the electrons from the negative electrode to the outside of the crystal (where the electricity flows easily, such as the inside of water or the skin surface of the body). The generated water or moisture in the air is electrolyzed to emit hydroxyl ions (H³O²⁻), negative ions.

In the present invention, a coating agent or a coating with outstanding coating property can be obtained by using the polar crystals; however, this is presumed to be due to, but not limited to, electrical properties such as the above properties of tourmaline. The polar crystal of the present invention can be made by grinding a polar crystal mineral to particulates (e.g., particle diameter of 10 μm or less, 5 μm or less, or 1 μm or less), and this can be used as an aqueous dispersion. The aqueous dispersion of polar crystal is, for example, a suspension having a concentration of 5% by weight to 40% by weight.

As the polar crystal, Rokusyo Stone (Registered Trademark) may be used. Rokusyo Stone (Registered Trademark) is a tuffaceous basalt rock, which consists of strip-like plagioclase; clinopyroxene, opaque minerals, and a small amount of olivine filled therebetween; and spherical or amorphous ceradonite, and it is a so-called mineral distributed around in the surrounding rocks of an amethyst. With regard to the components, the one comprising 5% or more by weight of Fe₂O₃is preferable, and the one comprising 7% or more is particularly preferable.

Further, as the polar crystal of the present invention, substances with a piezoelectric effect can be used. Such substances comprise ones known as raw materials of a piezoelectric element or a piezoelectric body. Specifically, they comprise natural and synthetic crystals, and ceramic materials of barium titanate (BaTiO₃), lead zirconate titanate (PZT), zinc oxide (ZnO), lithium niobate (LiNbO₃), lithium tantalate (LiTaO₃), and the like. Among such ceramic materials, the PZT piezoelectric ceramic material exists in multiple variations, and, by doping the PZT ceramic with ions such as nickel, bismuth, lanthanum, neodymium, and niobium, the piezoelectric parameters and dielectric parameters can be optimized.

The fluororesin used for the mixed aqueous dispersion is not particularly limited, but includes, for example, resin particulates consisting of polymers or copolymers of monomers selected from tetrafluoroethylene, hexafluoropropylene, chlorotrifluoroethylene, perfluoro (alkyl vinyl ether), vinylidene fluoride, and vinyl fluoride. Among these, ones that can be dispersed in water are used for the preparation of the mixed aqueous dispersion. The shape of the fluororesin is not particularly limited, but is preferably in particulates, having an average molecular weight in a range of 1×10⁴to 1×10⁷and a particle size in a range of 100 to 500 nm from the point of view that it can be easily maintained in a suspended, dispersed state in the mixed aqueous dispersion for a long period of time. The content of the fluororesin (content of fluororesin solid content) is preferably 20% by weight to 60% by weight with respect to the mixed aqueous dispersion, and more preferably 35% by weight to 45% by weight.

As above, the fluororesin used for the mixed aqueous dispersion is not particularly limited, but A-1: Polyflon D-111 produced by DAIKIN INDUSTRIES, LTD., (PTFE solid content: 55 to 65% by weight, average molecular weight: 2×10⁴to 1×10⁷, particle size: 0.25 μm, pH: 9.7), A-2: AD911E produced by ASAHI GLASS CO., LTD. (PTFE solid content: 60% by weight, average molecular weight: 2×10⁴to 1×10⁷, particle size: 0.25 μm, pH: 10), A-3: 31-JR produced by MITSUI FLUORO CO., LTD. (PTFE solid content: 60% by weight, average molecular weight: 2×10⁴to 1×10⁷, particle size: 0.25 μm, pH: 10.5), or the like can be used. The particle size refers to the average particle diameter of PTFE primary particles.

Further, the fluororesin used for the mixed aqueous dispersion may be a PTFE dispersion, and this PTFE dispersion may comprise a neutral surfactant, nonionic surfactant, amine, glycol, and the like. As such dispersion, PTFE-D (produced by DAIKIN INDUSTRIES, LTD.,) or the like is preferably used.

The mixed aqueous dispersion may comprise alumina. The alumina in the present invention covers aluminum oxide particulates of aluminum oxide [composition formula: Al₂O₃], amorphous aluminum hydroxide, gibbsite, and bialite [composition formula: Al (OH)₃], and/or boehmite and diaspore [composition formula: AlOOH]. The alumina preferably has a particulate particle size in a range of 5 to 4500 nm from the point of view that they can be easily maintained in a suspended, dispersed state in the mixed aqueous dispersion for a long period of time. The content of the alumina is preferably 1% by weight to 10% by weight with respect to the mixed aqueous dispersion, more preferably 3% by weight to 7% by weight. This is because when the content of the alumina is less than 1% by weight, sufficient alumina-induced adhesion performance and heat resistance performance cannot be given to the mixed aqueous dispersion and when the content of the alumina is over 10% by weight, further effects cannot be expected to be given. The mixed aqueous dispersion with excellent adhesion performance and heat resistance performance can be made by containing the alumina in the mixed aqueous dispersion.

Further, the shape of the alumina of the alumina sol is not particularly limited, and may be in any shape, such as a tabular, columnar, fiber, or hexagonal tabular shape. If the alumina sol has a fiber shape, the alumina is an alumina crystal in a fiber shape. More specifically, the alumina includes an alumina fiber formed of alumina anhydrate, an alumina hydrate fiber formed of an alumina comprising a hydrate, and the like.

The alumina used for the mixed aqueous dispersion is not particularly limited, but includes, for example, Alumina Sol-10A (% by weight in terms of Al₂O₃: 9.8 to 10.2, particle size (nm): 5 to 15, viscosity: 25° C., mPa/s: <50, pH: 3.4 to 4.2, produced by KAWAKEN FINE CHEMICALS CO., LTD.), Alumina Sol-A2 (% by weight in terms of Al₂O₃: 9.8 to 10.2, particle size (nm): 10 to 20, viscosity: 25° C., mPa/s: <200, pH: 3.4 to 4.2, produced by KAWAKEN FINE CHEMICALS CO., LTD.), Alumina Sol-CSA-110AD (% by weight in terms of Al₂O₃: 6.0 to 6.4, particle size (nm): 5 to 15, viscosity: 25° C., mPa/s: <50, pH: 3.8 to 4.5, produced by KAWAKEN FINE CHEMICALS CO., LTD.), Alumina Sol-F1000 (% by weight in terms of Al₂O₃: 4.8 to 5.2, particle size (nm): 1400, viscosity: 25° C., mPa/s: <1000, pH: 2.9 to 3.3, produced by KAWAKEN FINE CHEMICALS CO., LTD.), Alumina Sol-F3000 (% by weight in terms of Al₂O₃: 4.8 to 5.2, particle size (nm): 2000 to 4500, viscosity: 25° C., mPa/s: <1000, pH: 2.7 to 3.3, produced by KAWAKEN FINE CHEMICALS CO., LTD.), and the like, and any can be used as long as it is alumina sol obvious to a person skilled in the art.

As above, the alumina used for the mixed aqueous dispersion is not particularly limited, but alumina particulates having hydroxyl groups (OH groups) are preferably used. By using alumina having OH groups, the chemical bond strength (adhesion strength) due to the OH groups of the alumina increases, and thus, the mixed aqueous dispersion can be given more excellent adhesion performance.

Further, other metal oxide particulates may be added instead of the alumina, or in addition of the alumina. As the other metal oxide particulates, titanium oxide, zirconium oxide, lanthanum oxide, neodymium oxide, cerium oxide, tin oxide, and the like can be used, but are not particularly limited thereto. By adding other metal oxide particulates instead of the alumina, or in addition of the alumina, mixed aqueous dispersions of polyimide-fluororesin-polar crystal particulates that has a different coating property from the one produced when only the alumina is added can be produced.

The mixed aqueous dispersion comprises potassium persulfate. Since potassium persulfate is a compound containing an OH group, the number of OH groups included in the mixed aqueous dispersion can be increased and the chemical bond strength (adhesion strength) due to the OH groups will be increased, and thus, the mixed aqueous dispersion can be given excellent adhesion. The content of the potassium persulfate is preferably 0.1% by weight to 5% by weight with respect to the mixed aqueous dispersion, more preferably 1% by weight to 3% by weight. This is because when the content of the potassium persulfate is less than 0.1% by weight, sufficient potassium persulfate-induced adhesion performance cannot be given to the mixed aqueous dispersion, and when the content of the potassium persulfate is over 5% by weight, further effects cannot be expected to be given.

Further, other compounds containing OH groups may be added instead of the potassium persulfate, or in addition of the potassium persulfate. As the other compounds containing OH groups, acetic acid, benzoic acid, phenylphosphonic acid, a benzoyl compound, and the like may be used, but are not particularly limited thereto.

The mixed aqueous dispersion may further comprise polyvinyl alcohol (PVA). The PVA has a structural formula shown below and contains a number of OH groups. Therefore, the number of OH groups included in the mixed aqueous dispersion can be increased and the chemical bond strength (adhesion strength) due to the OH groups will be increased, and thus, the mixed aqueous dispersion can be given excellent adhesion. Further, the PVA remains stably in the mixed aqueous dispersion even after being formulated in the mixed aqueous dispersion, and the adhesion is less likely to reduce. Therefore, excellent adhesion of the mixed aqueous dispersion can be maintained stably over a long period of time. The content of the PVA is preferably 0.5% by weight to 10% by weight with respect to the mixed aqueous dispersion, more preferably 3% by weight to 6% by weight. This is because when the content of the PVA is less than 0.5% by weight, sufficient PVA-induced adhesion performance cannot be given to the mixed aqueous dispersion, and when the content of the PVA is over 10% by weight, further effects cannot be expected to be given.

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The mixed aqueous dispersion may further comprise phosphoric acid. Since phosphoric acid is a compound containing an OH group, the number of OH groups included in the mixed aqueous dispersion can be increased and the chemical bond strength (adhesion strength) due to the OH groups will increase, and thus, the mixed aqueous dispersion can be given excellent adhesion. The content of the phosphoric acid is preferably 0.1% by weight to 5% by weight with respect to the mixed aqueous dispersion, more preferably 1% by weight to 3% by weight. This is because when the content of the phosphoric acid is less than 0.1% by weight, sufficient phosphoric acid-induced adhesion performance cannot be given to the mixed aqueous dispersion, and when the content of the phosphoric acid is over 5% by weight, further effects cannot be expected to be given.

The phosphoric acid may be used for pretreatment of the polyimide used for the mixed aqueous dispersion. The polyimide is added to and mixed with a phosphoethanol containing phosphoric acid and then the ethanol is vaporized, so that mixed powder of polyimide-phosphoric acid can be obtained. The mixed powder of polyimide-phosphoric acid can be more easily dispersed by a water-based solvent, compared to polyimide alone.

The mixed aqueous dispersion may further comprise amines. The term “amine” as used herein has the meaning ordinarily understood by a person skilled in the art, namely, amine is a general term for compounds in which a hydrogen atom of ammonia is replaced with a hydrocarbon group or aromatic atomic group. If the number of substitutions is one, this amine is a primary amine; if two, a secondary amine; and if three, a tertiary amine. In addition, an alkyl group bonds to a tertiary amine making a quaternary ammonium cation. Ammonia also belongs to amines. Amines used in the present invention include, but are not limited to, methyl diethanolamine (MDEA). While chemically it is widely used as a base and ligand, industrial applications include use as synthetic catalysts, as a raw material for electronics-related, integrated circuit and solution crystal display, semiconductor-related, and electronic devices, and as a polymer and resin additive. Here, the term “electronic device” is a general term for elements that apply the function of electrons to perform active tasks such as amplification.

The amount of amine contained in the aqueous dispersion of the present invention is 1 to 50% by weight, 2 to 30% by weight, or 5 to 20% by weight of the total aqueous dispersion, and preferably 5 to 20% by weight. By including 5 to 20% by weight of the polyamide acid, an aqueous dispersion with more excellent coatability can be provided.

The mixed aqueous dispersion may further comprise propylene glycol monomethyl ether. The term “propylene glycol monomethyl ether” as used herein has the meaning ordinarily understood by a person skilled in the art, namely, a chemical compound having the below-mentioned chemical formula (C4H1002) and a molecular weight of 90.12, also known as 1-methoxy-2-propanol. Propylene glycol mono methyl ethers include low toxicity solvents, ink solvents, flux cleaners for electronic materials, copying fluids, substitute for glycol-based solvents, industrial detergents, and adhesive solvents.

[Image Omitted]

The amount of propylene glycol monomethyl ether contained in the aqueous dispersion of the present invention is 1 to 50% by weight, 2 to 30% by weight, or 5 to 20% by weight of the total aqueous dispersion, and preferably 5 to 20% by weight. By including 5 to 20% by weight of the polyamide acid, an aqueous dispersion with more excellent coatability can be provided.

The aqueous dispersion of the present invention may comprise lignin. A lignin is a phenolic polymer that is one of the major components of wood and functions to glue fibers together in wood. In other words, it is a polymer phenolic compound involved in the lignification of higher plants. The lignin is a giant biopolymer, wherein among phenylpropanoids, which are synthesized when carbon compounds assimilated by photosynthesis (primary metabolism) undergo further metabolism (secondary metabolism), three lignin monomers (monolignols), p-coumaryl alcohol (p-hydroxycinnamyl alcohol), coniferyl alcohol, and sinapyl alcohol, are one-electron oxidized under the catalyst of enzymes (laccase peroxidase) to phenoxy radicals and this formed a three-dimensional network structure by highly polymerizing with random radical coupling.

Although lignin is one of the main components of wood, since lignin turns to be dark reddish-brown when exposed to sunlight (ultraviolet rays), it is essential to remove lignin from wood chips when manufacturing pulp from wood, depending on the required paper quality. Thus, since a large amount of lignin is generated as a waste product in the paper manufacturing process, methods for making an effective industrial use of this lignin have been sought for. Since lignin can be described as a naturally occurring phenolic resin, it can be used as an alternative raw material for synthetic phenolic resins.

Since the lignin in the present invention is used as a substitute for resin in aqueous paint compositions, and its dosage use is not particularly limited, but is 1 to 50% by weight, 5 to 40% by weight, or 10 to 30% by weight of the total aqueous dispersion, and 10 to 30% by weight is the most preferable. By containing 10 to 30% by weight of lignin, an aqueous dispersion with more excellent coatability can be made.

The aqueous dispersion may further comprise at least one selected from the group consisting of epoxy, phenol, urethane, acrylic, FRP, and inorganic filler. In the present specification, the terms “epoxy,” “phenol,” “urethane,” “acrylic,” “FRP (fiber reinforced plastic),” and “inorganic filler” have meanings ordinarily understood by a person skilled in the art.

The term “epoxy” herein means “epoxy resin,” which is a general term for a thermosetting resin that can be cross-linked into a network with epoxy groups remaining in the polymer. An epoxy resin has a heat resistance temperature of 80° C. and a cold resistance temperature of −30° C., and it is easy to handle because of its low toxicity and flammability.

The term “phenol” herein means “phenolic resin,” which is one of the thermosetting resins made from phenol and formaldehyde, and is the world's first resin artificially synthesized from non-plant materials. The aforementioned lignin is a natural phenolic resin. A phenolic resin is characterized by its heat resistance of 150-180° C., high adhesiveness, strong acid resistance, and high electrical insulation properties.

The aqueous dispersion may comprise an inorganic filler. This inorganic filler is preferably a fine particle of any mineral origin with at least some kind of electrical properties. More preferably, this inorganic filler is preferably a polar crystal. In this specification, polar crystal herein refers to a crystal having a positive electrode (+) on one side and a negative electrode (−) on the opposite side. The polar crystal generates an unstable state (potential difference) at all times, and due to this potential difference, electrons are continuously emitted, flowing from the negative electrode toward the positive electrode. In the specification of the present application, the polar crystal particulates are particles of one or more selected from the group consisting of pink tourmaline, black tourmaline, and hexahedrite (registered trademark).

The present invention may use an inorganic filler that has been treated with a silane coupling agent. The examples of silane coupling agents include, but are not limited to, one or more selected from vinyltrimethoxysilane, vinyltriethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-glycidoxypropyl methyldimethoxysilane, 3-glycidoxypropyl trimethoxysilane, 3-glycidoxypropyl methyl diethoxysilane, 3-glycidoxypropyl triethoxysilane, p-styryltrimethoxysilane, 3-methacryloxypropylmethyldimethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-methacryloxypropyl methyl diethoxysilane, 3-methacryloxypropyltriethoxysilane, 3-acryloxypropyltrimethoxysilane, N-2-(aminoethyl 3-aminopropyl methyl dimethoxysilane, N-2-(aminoethyl)-3-aminopropyl trimethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-triethoxysilyl-N-(1,3 (dimethyl-butylidene) propylamine, N-phenyl-3-aminopropyltrimethoxysilane, N-(vinylbenzyl)-2-aminoethyl-3-aminopropyltrimethoxysilane hydrochloride, tris-(trimethoxysilylpropyl)isocyanurate, 3-ureidopropyltrialkoxysilane, 3-mercaptopropylmethyldimethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-isocyanate propyltriethoxysilane, 3 trimethoxysilylpropylsuccinic anhydride. The additives include, for example but not limited to, solvents, tackifiers, plasticizer, hardener, vernetzer, diluents, fillers, thickeners, pigments, and the like, and any can be used as long as it is regularly used to reform the property of the mixed aqueous dispersion and is obvious to a person skilled in the art.

The mixed aqueous dispersion may contain different additives or the like other than the above elements, to reform the mixed aqueous dispersion.

The mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates may comprise, optionally, colorants such as carbon black. It is important that this mixed aqueous dispersion has a pH maintained in the neutral range of 7.0 to 8.0. If this mixed aqueous dispersion has a pH on the acid side (e.g., pH 6.0), heat shock may occur upon the formation of a coating film, which may result in the occurrence of cracks in the coating film or the occurrence of solid content.

A method of producing the mixed aqueous dispersion of a polyimide precursor or polyimide-fluororesin-polar crystal particulates is discussed below.

This method of producing the mixed aqueous dispersion comprises steps of: obtaining polar crystal particulates having a particle diameter of 3 μm or less by grinding and sieving polar crystal particulates; preparing a dispersion 1 containing the above polar crystal particulates; preparing a dispersion 2 containing a polyimide precursor or polyimide; preparing a dispersion 3 containing fluororesin; and mixing all the above dispersions 1, 2, and 3.

This method of producing the mixed aqueous dispersion may further comprise steps of: preparing an aqueous potassium persulfate solution by adding potassium persulfate to water; preparing a dispersion 4 containing alumina; and mixing all the above dispersions and the aqueous potassium persulfate solution.

In another aspect, the method of producing this mixed aqueous dispersion comprises steps of: preparing an aqueous potassium persulfate solution by adding potassium persulfate to water; and mixing polyimide, fluororesin, polar crystal particulates, alumina, and the above aqueous potassium persulfate solution. Further, the method of producing the mixed aqueous dispersion may comprise, as the step of pretreatment, a step of prepare mixed powder of polyimide-phosphoric acid by mixing the polyimide with a phosphoric acid ethanol solution and then drying it. The mixing method, the mixing temperature, and the mixing time in these steps are not particularly limited, and any can be used as long as it is a mixing method that can produce a mixed aqueous dispersion and has been used conventionally.

The aqueous potassium persulfate solution is prepared by adding solid potassium persulfate to water. More specifically, the aqueous potassium persulfate solution is prepared by adding potassium persulfate to water so that the amount of the potassium persulfate becomes 1% by weight and heating it to the extent that the water will not boil, to dissolve the potassium persulfate.

In some cases, difficulty arises in dissolving the polyimide in a water-based solvent. Thus, to improve the water of the polyimide, the polyimide can be pretreated before formulation of the mixed aqueous dispersion. The step of pretreatment comprises producing mixed powder of polyimide-phosphoric acid by mixing the polyimide with a phosphoric acid ethanol solution and then drying the mixed solution to evaporate water. By using the mixed powder of polyimide-phosphoric acid, the polyimide can have greatly improved water dispersibility compared to when the polyimide is used alone, and thus the mixed aqueous dispersion according to the present invention can be more easily produced. It is needless to say that the mixed aqueous dispersion according to the present invention can be produced without execution of this step of pretreatment.

The prepared mixed aqueous dispersion can be converted to mixed powder of polyimide-fluororesin by evaporation of water. The mixed powder of polyimide-fluororesin can be used as an excellent molding material that can be used for a wide range of products such as highly heat-resistant products, since it comprises polyimide and fluororesin uniformly mixed and also it comprises alumina and potassium persulfate that give excellent adhesion and heat resistance.

The mixed powder of polyimide-fluororesin can be produced by drying the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention and evaporating water. The drying method to produce the mixed powder of polyimide-fluororesin is not particularly limited, and any method may be used as long as it is a method that can evaporate water in the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention and convert it to powder.

The coating method of the present invention, using the mixed aqueous dispersion of the polyimide precursor or polyimide-fluororesin-polar crystal particulates, comprises steps of applying the above mixed aqueous dispersion of the polyimide precursor or polyimide-fluororesin-polar crystal particulates to a coating surface, and carrying out a heat treatment at 350 to 400° C. The heat treatment is also referred to as firing, and it is a step required for the generation of the coating of the present invention; however, the method of the heat treatment is not particularly limited, and a regular heater used in the subject field can be used. The step of carrying out the heat treatment is considered to be an essential step for the strengthening of the coating surface. The step of carrying out the heat treatment may be referred to as “heat shock” herein.

Further, the coating method of the present invention, using the mixed aqueous dispersion of the polyimide precursor or polyimide-fluororesin-polar crystal particulates, further comprises the step of carrying out a cold treatment on the above metal material at 0 to 40° C. The method of the cold treatment is not particularly limited, a regular cooling method used in the subject field can be used. The cooling method include, as specific examples, soaking the metal material having the coating surface into water. The cold treatment is carried out at any temperature between 0 to 40° C.; for example, the lower limit to the temperature of the cold treatment includes 0° C., 5° C., 10° C., 15° C., 20° C., 25° C., and 30° C., and the upper limit to the temperature of the cold treatment includes 20° C., 25° C., 30° C., 35° C., and 40° C. The step of carrying out the cold treatment is also referred to as a quenching step, and it is considered to be an essential step for the strengthening of the coating surface. The cold treatment may be referred to as “cold shock” herein.

Example

The present invention is discussed in more detail below, using an example, but the present invention is not limited to such example.

The performance as a coating agent of the aqueous dispersion according to the present invention is examined by means of cross cut tests. The configurations and the production methods of an example and a comparative example are as below.

Example

The composition of the example is as below.

- Polyimide dispersion (W-20; produced by NAKATA COATING CO., LTD.): 30% by weight
- PTFE dispersion (PTFE-D; produced by DAIKIN INDUSTRIES, LTD.): 70% by weight
- Alumina sol (A1-L7; produced by TAKI CHEMICAL CO., LTD.): 5% by weight
- Potassium persulfate: 1% by weight
- Pink tourmaline dispersion: pink tourmaline having a particle diameter of 3 μm or below (originated from Sri Lanka) was prepared as a 30%, 10% and 5% dispersion.

The example was prepared as below.

- 1. The pink tourmaline powder was converted into a 5% suspension by carrying out a grinding process by a standard method, passing it through a 3 μm sieve to separate particulates having a particle diameter of 3 μm or below, and adding water.
- 2. An aqueous potassium persulfate solution was prepared by adding the potassium persulfate to pure water such that the potassium persulfate became 1% by weight, and heating at 95° C. to dissolve the potassium persulfate.
- 3. The polyimide dispersion, the PTFE dispersion, the alumina sol, the aqueous potassium persulfate solution, and the pink tourmaline dispersion were mixed, to thereby produce the example (mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates). At this moment, the PH was confirmed to be 7.0 to 8.0.

Comparative Examples

The composition of the comparative example is as below.

- Polyimide dispersion (W-20; produced by NAKATA COATING CO., LTD.): 30% by weight
- PTFE dispersion (PTFE-D; produced by DAIKIN INDUSTRIES, LTD.): 70% by weight
- Alumina sol (A1-L7; produced by TAKI CHEMICAL CO., LTD.): 5% by weight
- Potassium persulfate: 1% by weight

The comparative example was prepared as below.

- 1. An aqueous potassium persulfate solution was prepared by adding the potassium persulfate to pure water such that the potassium persulfate became 1% by weight, and heating at 95° C. to dissolve the potassium persulfate.
- 2. The polyimide dispersion, the PTFE dispersion, the alumina sol, and the aqueous potassium persulfate solution were mixed, to thereby produce the comparative example (mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates). At this moment, the PH was confirmed to be 7.0 to 8.0.

(Performance Evaluation Test 1—Cross Cut Test)
(Test Method)

Cross cut tests were conducted as below.

- 1. The compositions of the example and the comparative example were each stirred with a constant-temperature shaker at 60° C. for 2 hours.
- 2. By coating the stirred compositions of the example and the comparative example on aluminum plates having a thickness of 2 mm (each n=2), using a bar coater, samples were prepared.
- 3. The samples were fired at 380° C. for 15 to 20 minutes.
- 4. The fired samples were cooled in tap water at room temperature (25° C.).
- 5. Cross cut tests (cross cut method) specified in JIS K5600 5-6 were conducted, using the fired and cooled samples.

(Test Results)

The results of the cross cut tests are shown in FIGS. 2-3. FIG. 2 is a figure showing the result of the cross cut test using the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates (example) according to the present invention. FIG. 3 is a figure showing the result of the cross-cut test using the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates of the comparative example. As shown in FIG. 2, it was discovered that the example coated on the aluminum plate had perfect adhesion at the highest level as the applicability of the coating was favorable and no peel of the coating film was found at all. In contrast, as shown in FIG. 3, the comparative example coated on the aluminum plate remained to have a conventional level of adhesion although the applicability of the coating was favorable and few peels of the coating film were found.

Based on the result of the cross cut tests, the comparative example comprising the polyimide, the PTFE, the alumina sol, and the potassium persulfate, and not comprising the pink tourmaline remained to have standard adhesion performance. In contrast, the example comprising the pink tourmaline in addition to the polyimide, the PTFE, the alumina sol, and the potassium persulfate, showed unprecedented strong adhesion performance. This is assumed to be due to the electrostatic interaction between negative ions emitted from the tourmaline upon heating and the metal surface of the base material, which increased adhesion performance of the coating (coating film).

(Performance Evaluation Test 2—Peel Test with Fabric Tape (Tape Peel Test))

(Tape Peel Test)

A tape peel test was conducted as below.

- 1. The compositions of the example and the comparative example were each stirred with a constant-temperature shaker at 60° C. for 2 hours.
- 2. Fabric tape (1 cm×10 cm) was taped along the entire length of an aluminum plate having a size of 50 mm×100 mm×2 mm (each n=2). The entire length of the fabric tape was longer than the entire length of the aluminum plate. The aluminum plate was used as a test piece. On up to the upper half of the fabric tape in the length direction of the test piece, the stirred example and comparative example were coated, using a bar coater.
- 3. The coating surface of the test piece was fired at 380° C. for 15 to 20 minutes.
- 4. The fired test piece was cooled in tap water at room temperature (25° C.).
- 5. The PTFE dispersion (60% solid content and 40% water) was applied to the entire test piece (35 μm to 60 μm in thickness) as a top coat, and was dried.
- 6. In the dried test piece, the fabric tape was peeled off by pulling the tape upwardly from the side to which only the top coat had been applied, and the degree of peeling of the fabric tape from the border between the part to which only the top coat had been applied and the part to which the example or the comparative example had been applied was evaluated.

(Test Results)

The result of the tape peel test is shown in FIG. 4. The upper part of FIG. 4 is a figure showing the result of the tape peel test using the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates (the example) according to the present invention. The lower part of FIG. 4 is a figure showing the result of the tape peel test using the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates of the comparative example. As shown in FIG. 4, it was discovered that the example coated on the aluminum plate had perfect adhesion at the highest level as no peel of the coating film was found at all regardless of the force of pulling of the fabric tape. In contrast, the comparative example coated on the aluminum plate had strong adhesion of the coating film, but to the extent in which peel occurs when pulled with a force (Data not shown).

Based on the result of the tape peel test, the comparative example comprising the polyimide, the PTFE, the alumina sol, and the potassium persulfate, and not comprising the pink tourmaline remained to have standard adhesion performance. In contrast, the example comprising the pink tourmaline in addition to the polyimide, the PTFE, the alumina sol, and the potassium persulfate, showed unprecedented strong adhesion performance. This is assumed to be due to the electrostatic interaction between negative ions emitted from the tourmaline upon heating and the metal surface of the base material, which increased adhesion performance of the coating (coating film).

(Heat Resistance)

A thermogravimetric reduction TG-DTA test on a coating film that uses the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention was performed, and the coating film of the present invention, a regular PTFE membrane, and a PI film were each heated at 10° C./min, and the thermal reduction rates (TG %) were measured. The result was shown in FIG. 1. It was revealed that the coating film of the present invention has heat resistance of about 450° C.

Example 2: When Imitron #300 is Used

Evaluating whether replacing Imitron PIW-20 with Imitron #300 W improves dielectric strength. The reason for using Imitron #300 W is that Local Incorporated Administrative Agency, the Izumi Center of the Osaka Industrial Technology Research Institute confirmed the dielectric strength reached an unmeasurable value when evaluating a metal plate coated only with Imitron #300 W.

Materials Used

- Imitron #300 W (by NAKATA Coating Co., Ltd.)
- PIA 8% (by NAKATA Coating Co., Ltd.), epoxy resin Ucalegin KE-278 20% (by Yoshimura Oil Chemical Co., Ltd.),
- PTFE-dispersion SFN-2H (by Zhonghao Chenguang Chemical Research Institute Co.)
- Black tourmaline powder (by Eiga-do Group, Seishin Enterprises Co.)

(Formulation Ratio)

The following table shows the formulation ratios of prototype solutions (i) to (iii) according to Example 2.

TABLE 1

Formulation ratio (when 100 g is prepared)

Prototype
Prototype
Prototype

solution (i)
solution (ii)
solution (iii)

(g)
(g)
(g)

Imitron #300
54.2
74.7
93.6

PTFE-dispersion SFN-2H
42.2
23.3
5.3

Black tourmaline powder
3.6
2.0
1.1

Prototype solution (i) is prepared by replacing PIW-20 with Imitron #300 W. Prototype solution (ii) is prepared by using Imitron #300 W as PI and formulating PI, PTFE, and BT at a solid content ratio of PI:PTFE:BT=30:70:10. Prototype solution (iii) is prepared by using Imitron #300 W as PI and formulating PI, PTFE, and BT at a solid content ratio of PI:PTFE:BT=70:30:10.

The following table shows the detailed formulation ratios of prototype solutions (i) to (iii) according to Example 2.

TABLE 2

Prototype solution (i)

Solid
Solution

content
weight

(g)
(g)

Imitron #300
Polyimide
4.3
54.2

Epoxy resin
10.8

PTFE-dispersion SFN-2H
Fluororesin
25.3
42.2

Black tourmaline powder
Tourmaline
3.6
3.6

TABLE 3

Prototype solution (ii)

Solid content and solution weight

(solid content ratio PI:PTFE:BT = 30:70:10)

Before 100 g
After 100 g

conversion
conversion

Solid
Solution
Solid
Solution

content
weight
content
weight

(g)
(g)
(g)
(g)

Imitron #300
Polyimide
[Image Omitted]

Epoxy resin
[Image Omitted]

PTFE-dispersion
Fluororesin
[Image Omitted]

SFN-2H

Black tourmaline
Tourmaline
[Image Omitted]

powder

indicates data missing or illegible when filed

TABLE 4

Prototype solution (iii)

Solid content and solution weight

(solid content ratio PI:PTFE:BT = 30:70:10)

Before 100 g
After 100 g

conversion
conversion

Solid
Solution
Solid
Solution

content
weight
content
weight

(g)
(g)
(g)
(g)

Imitron #300
Polyimide
[Image Omitted]

Epoxy resin
[Image Omitted]

PTFE-dispersion
Fluororesin
30.0
[Image Omitted]

SFN-2H

Black tourmaline
Tourmaline
10.0
[Image Omitted]

powder

indicates data missing or illegible when filed

(Preparing Process of Prototype Solution (i) to Prototype Solution (iii))

The process for making prototype solution (i), prototype solution (ii), and prototype solution (iii) is as follows:

- 1. Put all the ingredients for each prototype solution into a power homogenizer (500 mL standard) container.
- 2. After lightly stirring and mixing the entire ingredients using a medicine spoon, agitate at 800 rpm for 30 minutes.
- 3. After the process 2, filter the mixture through a 140 mesh strainer. (Preparing of test specimens)

Prototypes solutions (i) to (iii) were applied to the substrates, and the substrates were fired to form coating films, which were used as test specimens. The number of trials for each of the solutions (i) to (iii) was set to N=5. The detailed test specimen preparation conditions are as follows.

- (1) Substrate: SUS304-2B 100 mm×100 mm×1.5 mm (with blasting)
- (2) Number of sheets: 15 sheets (3 types of prototype solutions (i) to (iii) x number of trials N=5)
- (3) Coating: Coating was performed with an ultra-compact hand spray gun F55-G08 (C) manufactured by Meiji Machine CO., Ltd. to achieve a thickness of 30 μm. (dry)
- (4) After coating, heat at 120° C. for 30 minutes.
- (5) After the process (4), heat at 380° C. for 15 minutes.
- (6) After the process (5), quench with water.

(Evaluation of Test Specimens: Dielectric Strength)

The test specimens prepared with the prototype solutions (i) to (iii) were measured for dielectric strength using the “Dielectric Withstanding Voltage/Insulation Resistance Tester” at Local Incorporated Administrative Agency, the Izumi Center of the Osaka Industrial Technology Research Institute. As shown in FIG. 8, the test specimens were assigned numbers (1) to (9) for film thickness measurement positions, and the coating film thickness (measured with a UMAREX Coating Test Master), the measured value and destruction time of the dielectric strength were measured at each location. The obtained measurement data were converted to kV/mm and the average values were calculated.

The following table shows the measured film thicknesses of the coating films prepared with the prototype solutions (i) to (iii) according to Example 2.

TABLE 5

Prototype table (i) (Unit: μm)

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Average

N = 1
[Image Omitted]

N = 2

N = 3

N = 4

N = 5

indicates data missing or illegible when filed

TABLE 6

Prototype table (ii) (Unit μm)

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Average

N = 1
[Image Omitted]

N = 2

N = 3

N = 4

N = 5

indicates data missing or illegible when filed

TABLE 7

Prototype table (iii) (Unit: μm)

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Average

N = 1
[Image Omitted]

N = 2

N = 3

N = 4

N = 5

indicates data missing or illegible when filed

(Measurement Result 1)

The measured value and destruction time of the dielectric strength were measured when the average value of the measured value of each test specimen at the film thickness measurement positions (1) to (9) was used each test specimen. The data of the obtained measurements were converted to kV/mm and the average values are listed in the following table.

TABLE 8

When the coating film thickness is the average of 9 points

measurement value

Portotype soulution (i)

average coating
measurement
Destruction
Conversion

film thickness
value
time
value

(μm)
(kV)
(seconds)
kV/mm

N = 1
21.5
0.998
2.2
46.4

N = 2
23.9
1.199
3.6
50.2

N = 3
21.2
0.599
0.9
42.4

N = 4
17.8
0.645
0.8
26.9

N = 5
17.7
0.649
0.2
36.7

Average
40.9

TABLE 9

When the coating film thickness is the average of 9 points

measurement value

Prototype solution (ii)

average coating
measurement
Destruction
Conversion

film thickness
value
time
value

(μm)
(kV)
(seconds)
kV/mm

N = 1
17.6
0.746
0.9
42.5

N = 2
20.9
0.590
0.8
29.1

N = 3
18.7
1.098
8.6
[Image Omitted]

N = 4
19.2
1.200
6.1
62.5

N = 5
16.6
0.749
3.0
45.1

Average
[Image Omitted]

indicates data missing or illegible when filed

TABLE 10

When the coating film thickness is the average of 9 points

measurement value

Prototype solution (iii)

average coating
measurement
Destruction
Conversion

film thickness
value
time
value

(μm)
(kV)
(seconds)
kV/mm

N = 1
19.3
[Image Omitted]

0.7
72.5

N = 2
15.9
0.436
0.3
27.4

N = 3
12.8
[Image Omitted]

0.8
38.3

N = 4
19.6
0.898
3.2
44.8

N = 5
15.4
[Image Omitted]

0.7
28.2

Average
41.6

[Image Omitted]

indicates data missing or illegible when filed

(Measurement Result 2)

The measured value and destruction time of the dielectric strength were measured when the average value of the measured value of each test specimen. at the film thickness measurement position (5) was used. The data of the obtained measurements were converted to kV/mm and the average values are listed in the following table.

TABLE 11

when the coating film thickness is the measurement value measured at the

center of the coating surface (position (5) is Fig. 7)

Prototype solution (i)

average coating
measurement
Destruction
Conversion

film thickness
value
time
value

(μm)
(kV)
(seconds)
kV/mm

N = 1
[Image Omitted]

2.2
40.1

N = 2
[Image Omitted]

N = 3
17.1
[Image Omitted]

52.5

N = 4
17.7
[Image Omitted]

N = 5
17.4
0.849
0.2
[Image Omitted]

Average
40.1

[Image Omitted]

indicates data missing or illegible when filed

TABLE 12

when the coating film thickness is the measurment value at the center

of the coating surface (position (5) in Fig. 7)

Prototype solution (ii)

average coating
measurement
Destruction
Conversion

film thickness
value
time
value

(μm)
(kV)
(seconds)
kV/mm

N = 1
17.7
0.748
[Image Omitted]

42.3

N = 2
23.9
[Image Omitted]

N = 3
20.2
[Image Omitted]

8.6

N = 4
17.6
[Image Omitted]

6.1
68.2

N = 5
[Image Omitted]

0.749

44.6

Average
[Image Omitted]

indicates data missing or illegible when filed

TABLE 13

when the coating film thickness is the measurement value at the

center of the coating surface (position (5) in Fig, 7)

Prototype solution (iii)

average coating
measurement
Destruction
Conversion

film thickness
value
time
value

(μm)
(kV)
(seconds)
kV/mm

N = 1
22.2
1.399
0.7
68.0

N = 2
19.0
0.436
0.3
22.9

N = 3
19.7
9.426
0.8
[Image Omitted]

N = 4
17.3
0.898
3.2
51.9

N = 5
[Image Omitted]

0.462
0.7
[Image Omitted]

Average

indicates data missing or illegible when filed

(Coating Surface after Testing)

The coating surface after testing of the test specimen was observed with a microscope (Digital Microscope VH-5000 by Keyence Corporation) at a magnification of 175×. The coated surface after testing of prototype solutions (i) and (ii) was destroyed by a dielectric breakdown and the coated film in the areas where the dielectric breakdown occurred was lost. The coated surface after testing of prototype solutions (iii) was deformed in such a disordered and irregular manner that the broken parts were unidentifiable.

From Example 2, the coating film improved the voltage resistance when Imitron #300 W (manufactured by NAKATA Coating Co., Ltd.) was used. The average value before changing the PI to Imitron #300 W was about 20 kV/mm, but in the case of the coating films of prototype solutions (i) to (iii), the average value exceeded 40 kV/mm and the maximum value exceeded 70 kV/mm in all cases. Comparing prototype solution (i) with prototype solution (ii), prototype solution (ii) has higher voltage resistance because it contains high amount of Imitron #300 W. A prototype solution (iii), which contains the highest amount of Imitron #300 W, resulted in a lower average value than prototype solution (ii), but because the maximum value was also observed by a prototype solution (iii), the average value is still expected to increase depending on the condition of the coating. Although no problem has occurred due to the large amount of PTFE-dispersion in the prototype solution (i) and the prototype solution (ii), the prototype solution (iii), in which the majority of amount ratio is Imitron #300 W, the coating film was discolored black and a surface was in a rough condition. It is considered that a low dielectric strength measurement is caused by the cracks on the coating surface, even though it was not confirmed visually or with a microscope. Since the firing temperature recommended for Imitron #300 W alone is 250° C., it is considered that Example 2, which was performed under firing conditions of 380° C. was unsuitable. (Specimen evaluation: Cross-cut test)

The test specimen prepared by the prototype solution (i) to prototype solution (iii) were cut by making 11 vertical and horizontal cuts at 1 mm intervals using a cutter, taped and peeled off according to the rules of JIS K5400-8.5. The following table lists the results of test specimen evaluated according to the rules of JIS K5400-8.5 and in accordance with the evaluation criteria.

TABLE 14

Evaluation results

Sample name
Assessment

Prototype solution (i)
10 points

Prototype solution (ii)
10 points

Prototype solution (iii)
10 points

(Test Results)

In the case of the coating film of prototype solution (iii), there were many areas where the coating film around the path of the cutter blade was chipped when a cutter was used to make a cut. However, the results of the evaluation according to JIS K5400-8.5 Adhesion—Cross-Cut Test showed that none of the prototype solutions (i) to (iii) was peeled off, and has the highest rating of 10.

(A Mixed Aqueous Dispersion of Polyimide-Fluororesin-Polar Crystal Particulates Comprising Active Ingredients)
(Preparation of Base Material Solution Mixture)

The pH was adjusted to 10 by mixing PIA powder 20% by weight, amine 12% by weight, propylene glycol monomethyl ether 10% by weight, and ion exchange water 58% by weight and adding the appropriate amount of amine.

(Preparation of Lignin Solution)

The pH was adjusted to 10 by mixing lignin powder 20% by weight (modified lignin, with PEG), propylene glycol monomethyl ether 20% by weight, amine 13% by weight, and ion exchanged water 47% by weight, and adding the appropriate amount of amine.

Example 3: Lignin Hybrid Paint Formulation

The lignin hybrid paint was formulated by mixing base material solution mixture 30% by weight and lignin solution 70% by weight.

Example 4: Formulation of PTFE Hybrid Paint

The PTFE hybrid paint was formulated by mixing base material solution mixture 30% by weight and PTFE dispersion 70% by weight (40% moisture by weight and 60% solid content by weight).

Example 5: Formulation of Epoxy Hybrid Paint

An epoxy hybrid paint was formulated by mixing base material solution mixture 49% by weight and cresol novolac epoxy resin emulsion 51% by weight (45% solid content by weight).

((Performance Evaluation Test 1—Cross-Cut Test)
(Test Method)

Cross-cut tests were conducted as below.

- 1. The compositions of the example and comparative example were each stirred with a constant-temperature shaker at 60° C. for 2 hours.
- 2. By coating the stirred compositions of the example and the comparative example on aluminum plates having a thickness of 2 mm (each n=2), using a bar coater, samples were prepared.
- 3. The samples were fired at 380° C. for 15 to 20 minutes.
- 4. Cross cut tests (cross cut method) specified in JIS K5600 5-6 were conducted, using the fired samples.

(Test Results)

The results of a cross cut test showed that the comparative examples remained to have an adhesion level of conventional coating. On the other hand, the example comprising lignin, PTFE resin, or epoxy resin showed stronger adhesion compared to comparative example.

(Performance Evaluation Test 2—Peel Test with Fabric Tape (Tape Peel Test))

(Tape Peel Test)

Cross cut tests were conducted as below.

- 1. The example and comparative example were each stirred with a constant-temperature shaker at 60° C. for 2 hours.
- 2. Fabric tape (1 cm×10 cm) was taped along the entire length of an aluminum plate having size of 50 mm×100 mm×2 mm (each n=2). The entire length of the fabric tape was longer than the entire length of the aluminum plate. This aluminum plate was used as the test piece. On up to the upper half of the fabric tape in the length direction of the test piece, the stirred example and comparative example were coated, using a bar coater.
- 3. The coating surface of the test piece was fired at 380° C. for 15 to 20 minutes.
- 4. The PTFE dispersion (60% solid content and 40% water) was applied to the entire test piece (35 μm to 60 μm in thickness) as a top coat, and was dried.
- 5. In the dried test piece, the fabric tape was peeled off by pulling the tape upwardly from the side to which only the top coat had been applied, and the degree of peeling of the fabric tape from the border between the part to which only the top coat had been applied and the part to which the example or the comparative example had been applied was evaluated.

(Test Results)

The results of the tape peel test showed that the comparative example remained to have an adhesion performance of conventional coating level. On the other hand, the example comprising lignin, PTFE resin, or epoxy resin showed stronger adhesion compared to comparative example.

The performance of the paints for the aqueous mixtures of the present invention is summarized in Table 15 below.

TABLE 15

The exterior

appearance of the
Heat

Tape peel

coating film
resistance
Cross-cut test
test

Comparative
◯
◯
Δ
Δ

examples

Example 3
⊚
⊚
◯
◯

Example 4
⊚
⊚
◯
◯

Example 5
⊚
⊚
◯
◯

(Performance Evaluation Test 3—Coating Heat Resistance Test)
(Process)

The heat resistance test of the coating film was conducted as below.

- 1. The aqueous dispersion of the invention were each stirred with a constant-temperature shaker at 60° C. for 2 hours.
- 2. Samples were prepared by coating the stirred aqueous dispersion with a #14 bar coater on a 2 mm thick pure aluminum plate to obtain a film thickness of 3 μm or 6 μm.
- 3. The samples were fired under the following conditions, respectively.
- (1) 60-420° C. for 45 minutes
- (2) 150-440° C. for 45 minutes
- (3) 150-460° C. for 58 minutes
- (4) 60-500° C. for 75 minutes.
- 4. Curing was conducted simultaneously as the temperature was raised to the target temperature, and when the target temperature was reached, the material was removed, quenched, and then evaluated for the exterior appearance and tested for tape peeling.

(Test Results)

While the heat resistance of the coating film in the comparative example was below 420° C., the heat resistance of the aqueous dispersion in the example (with silane coupling agent) was visually at the upper limit of 460° C., and the upper limit of adhesion was regarding the adhesion 420° C. was the upper limit. This tendency was also seen in the cases similar when where the coating film thicknesses was 3 μm and 6 μm. Furthermore, in the PTFE/alumina filler example, the upper limit of film heat resistance was 480° C. visually, and the upper limit of adhesion was 480° C. This tendency was similar for the cases with a coating film thickness of 6 μm and 11 μm.

(Performance Evaluation Test 4—Boiling Water Resistance Test After Coating)
(Process)

The boiling water resistance test after coating was conducted as below.

- 1. The aqueous dispersions of the invention was stirred with a constant-temperature shaker at 60° C. for 2 hours.
- 2. The stirred aqueous dispersion of the present invention was coated so as to have a film thickness of 5 μm, 6 μm, 9 μm or 11 μm on a pure aluminum plate of 2 mm thickness using a #14, 28 bar coater to prepare samples.
- 3. The cured samples were placed in a pot of boiling water under the below-mentioned conditions and left for 120 minutes, and the adhesion was then evaluated by the exterior appearance and peeling off the tape.

(Test Results)

The aqueous dispersion of the present invention comprising PTFE and the original aqueous dispersion comprising PTFE and epoxy passed the boiling water resistance test under the above-mentioned effect conditions.

(The Detailed Description of the Test Results is Shown in the Figures)

Each of the details of the experiments shown in FIGS. 9-14 is shown as Tables 16-21 below. FIG. 9 shows the results of a heat resistance test of a coating film (3 μm thick) prepared using an aqueous dispersion of the invention comprising propylene glycol monomethyl ether (PM). The details of the test in FIG. 9 are shown in Table 16. The heat resistance of this coating has a limit near 440° C., and the resin transformation or shedding was observed at any temperature higher than the limit, and it could not be used as a coating film.

FIG. 10 shows the results of a heat resistance test of a coating film (6 μm thick) prepared using an aqueous dispersion of the invention comprising PM. The details of the test in FIG. 10 are shown in Table 17. The heat resistance of this coating has a limit near 440° C., the resin transformation or shedding was observed at any temperature higher than the limit, and it could not be used as a coating film.

FIG. 11 shows the results of a heat resistance test on a coating film (6 μm in thickness) prepared with an aqueous dispersion of the invention comprising PM, PTFE, and alumina filler. The details of the test in FIG. 11 are shown in Table 18. The coating had a favorable heat resistance even at 460° C., but found to fail the test to some extent at 480° C. Transformation or loss of the resin was observed at 500° C., and it could not be used as a coating film.

FIG. 12 shows the results of a heat resistance test on a coating film (11 μm in thickness) prepared with an aqueous dispersion of the invention comprising PM, PTFE, and alumina filler. The details of the tests in FIG. 12 are shown in Table 19. The coating had a favorable heat resistance even at 460° C., but found to fail the test to some extent at 480° C. Transformation or loss of the resin was observed at 500° C.

FIG. 13 shows the results of a boiling water resistance test of a coatings film (6 μm and 11 μm in thickness) prepared with aqueous dispersions of the invention comprising PM and PTFE. The details of the tests in FIG. 13 are shown in Table 20. This coating film showed highly favorable results in the boiling water resistance test.

FIG. 14 shows the results of a boiling water resistance test of a coating film (7 μm and 14 μm thick) prepared with aqueous dispersions of the invention comprising PM and a cresol novolac epoxy resin emulsion. The details of the test in FIG. 14 are shown in Table 21. This coating film has obtained good results in the boiling water resistance test.

Application Example 1— Coating on Frying Pan

The mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates of the example was applied on the surface of a household frying pan as a coating agent. A 30% dispersion of the pink tourmaline was used. The coating had a thickness of 40 μm (Application Example 1-1 with a photo shown in FIG. 5). The frying pan in Application Example 1-1 showed heat resistance and durability exceeding conventional Teflon (Registered Trademark) coated frying pans. Further, another household frying pan was obtained and the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates was applied thereon as a coating agent in the same manner. The coating had a thickness of 40 μm (Application Examples 1-2 with a photo shown in FIG. 6). The frying pan in Application Examples 1-2 also showed heat resistance and durability exceeding conventional Teflon (Registered Trademark) coated frying pans, and it was also confirmed that the effect obtained from this coating agent is reproducible.

Application Example 2—Coating on Heat Sink for Electronic Devices

The mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates of the example was applied on a general heat sink for computer components as a coating agent. The coating had a thickness of 40 μm. The photo of this heat sink is shown in FIG. 7. The heat sink in Application Example 2 showed excellent heat radiation dissipation function and excellent insulation in addition to heat resistance and durability, and exhibited sufficient performance as a heat sink.

INDUSTRIAL APPLICABILITY

In accordance with the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention, the mixed aqueous dispersion in which polyimide and fluororesin are uniformly dispersed can be provided, since the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates comprises polyimide, fluororesin, and polar crystal particulates. Further, the mixed aqueous dispersion which exhibits adhesion performance and heat resistance performance exceeding conventional products can be provided, since the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates of the present invention comprises polar crystal particulates. Therefore, the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates with exceptional coating property can be made without the use of an organic solvent. Further, the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates has excellent handleability (e.g., safety, environmental burden, equipment cost), since it does not comprise an organic solvent. Therefore, the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention is suitably used as a heat resistant coating for pods, kettles, frying pans, and the like, a heat resistant impregnant for knitted fabrics, woven fabrics, glass fabric materials, carbon fibers, carbonized fibers, and the like, and a coating agent and a coating for other various products.

Further, in accordance with the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention, a molding material can be provided in which polyimide and fluororesin are uniformly dispersed and which can be used for a wide range of products such as highly heat-resistant products, since the mixed powder of polyimide-fluororesin comprises polyimide, fluororesin, alumina, and potassium persulfate. The mixed powder with excellent heat resistance performance, processability, and moldability can be made, since the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates comprises alumina and potassium persulfate. Therefore, the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention is suitably used as a mold powder for bearings, friction materials, sliding bearings, corrosion resistant materials, insulation material, and the like, and other various products. Further, the mixed aqueous dispersion of polyimide-fluororesin-polar crystal particulates according to the present invention can be broadly used for components, exteriors, and the like of electrical products such as mobile phones and smart phones, since the mixed aqueous dispersion achieves excellent insulation performance.