JP3693290B2 - Ceramic surface protective film composition - Google Patents
Ceramic surface protective film composition Download PDFInfo
- Publication number
- JP3693290B2 JP3693290B2 JP2001095509A JP2001095509A JP3693290B2 JP 3693290 B2 JP3693290 B2 JP 3693290B2 JP 2001095509 A JP2001095509 A JP 2001095509A JP 2001095509 A JP2001095509 A JP 2001095509A JP 3693290 B2 JP3693290 B2 JP 3693290B2
- Authority
- JP
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- Prior art keywords
- water
- ceramic surface
- protective film
- film
- ceramic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000000919 ceramic Substances 0.000 title claims description 85
- 239000000203 mixture Substances 0.000 title claims description 33
- 230000001681 protective effect Effects 0.000 title claims description 33
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 44
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 36
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 30
- 239000005871 repellent Substances 0.000 claims description 29
- 150000003839 salts Chemical class 0.000 claims description 13
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 claims description 12
- 239000012046 mixed solvent Substances 0.000 claims description 10
- CMOAHYOGLLEOGO-UHFFFAOYSA-N oxozirconium;dihydrochloride Chemical compound Cl.Cl.[Zr]=O CMOAHYOGLLEOGO-UHFFFAOYSA-N 0.000 claims description 6
- BDERNNFJNOPAEC-UHFFFAOYSA-N propan-1-ol Chemical compound CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 claims description 5
- 239000012266 salt solution Substances 0.000 claims description 5
- UJVRJBAUJYZFIX-UHFFFAOYSA-N nitric acid;oxozirconium Chemical compound [Zr]=O.O[N+]([O-])=O.O[N+]([O-])=O UJVRJBAUJYZFIX-UHFFFAOYSA-N 0.000 claims description 3
- 239000010408 film Substances 0.000 description 74
- 229910052751 metal Inorganic materials 0.000 description 19
- 239000002184 metal Substances 0.000 description 19
- 238000001035 drying Methods 0.000 description 16
- 235000019441 ethanol Nutrition 0.000 description 16
- 239000010409 thin film Substances 0.000 description 16
- 239000003921 oil Substances 0.000 description 14
- 238000000034 method Methods 0.000 description 13
- 230000002940 repellent Effects 0.000 description 13
- 238000004140 cleaning Methods 0.000 description 9
- 238000000576 coating method Methods 0.000 description 9
- 239000011248 coating agent Substances 0.000 description 8
- 238000007598 dipping method Methods 0.000 description 8
- 241000562569 Riodinidae Species 0.000 description 6
- 239000011521 glass Substances 0.000 description 6
- 150000004703 alkoxides Chemical class 0.000 description 5
- 238000010304 firing Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 150000002902 organometallic compounds Chemical class 0.000 description 5
- 239000000243 solution Substances 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 238000005406 washing Methods 0.000 description 5
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 4
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 4
- 239000007864 aqueous solution Substances 0.000 description 4
- 229910052731 fluorine Inorganic materials 0.000 description 4
- 239000011737 fluorine Substances 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- -1 and in particular Substances 0.000 description 3
- 230000003373 anti-fouling effect Effects 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 239000012212 insulator Substances 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 239000012190 activator Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000005357 flat glass Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 125000005010 perfluoroalkyl group Chemical group 0.000 description 2
- 238000001556 precipitation Methods 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000007858 starting material Substances 0.000 description 2
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- BSDOQSMQCZQLDV-UHFFFAOYSA-N butan-1-olate;zirconium(4+) Chemical compound [Zr+4].CCCC[O-].CCCC[O-].CCCC[O-].CCCC[O-] BSDOQSMQCZQLDV-UHFFFAOYSA-N 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- VZJJZMXEQNFTLL-UHFFFAOYSA-N chloro hypochlorite;zirconium;octahydrate Chemical compound O.O.O.O.O.O.O.O.[Zr].ClOCl VZJJZMXEQNFTLL-UHFFFAOYSA-N 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000003599 detergent Substances 0.000 description 1
- 239000004205 dimethyl polysiloxane Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000001879 gelation Methods 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- YZERDTREOUSUHF-UHFFFAOYSA-N pentafluorobenzoic acid Chemical compound OC(=O)C1=C(F)C(F)=C(F)C(F)=C1F YZERDTREOUSUHF-UHFFFAOYSA-N 0.000 description 1
- 230000002085 persistent effect Effects 0.000 description 1
- 229920000435 poly(dimethylsiloxane) Polymers 0.000 description 1
- 238000006068 polycondensation reaction Methods 0.000 description 1
- 229910052573 porcelain Inorganic materials 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
- 150000004756 silanes Chemical class 0.000 description 1
- 238000003980 solgel method Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- JLGNHOJUQFHYEZ-UHFFFAOYSA-N trimethoxy(3,3,3-trifluoropropyl)silane Chemical compound CO[Si](OC)(OC)CCC(F)(F)F JLGNHOJUQFHYEZ-UHFFFAOYSA-N 0.000 description 1
- QLNOVKKVHFRGMA-UHFFFAOYSA-N trimethoxy(propyl)silane Chemical group [CH2]CC[Si](OC)(OC)OC QLNOVKKVHFRGMA-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5025—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with ceramic materials
- C04B41/5042—Zirconium oxides or zirconates; Hafnium oxides or hafnates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Materials Applied To Surfaces To Minimize Adherence Of Mist Or Water (AREA)
- Paints Or Removers (AREA)
Description
【０００１】
【発明の属する技術分野】
本発明は、食器、タイル、衛生陶器、碍子などの陶磁器、またはガラスからなるセラミックスの表面保護膜用組成物に関する。
【０００２】
【従来の技術】
陶磁器は、その表面を釉薬（ガラス質）とするが、その表面にシリコン樹脂もしくはフッ素樹脂等の撥水撥油剤をコートすることにより撥水撥油化し、汚れにくくしたり、また、洗浄性を向上させることが行なわれている。しかし、これら撥水撥油剤は陶磁器表面の釉薬（ガラス質）への密着性が悪いために、洗浄等の使用回数が増加すると撥水撥油剤がとれていき、撥水撥油効果が長期間持続しないという問題がある。
【０００３】
また、自動車用フロントガラスや建築用板ガラス等のガラス分野においては、そのガラス表面の撥水撥油効果を長期間持続させるために、ガラス表面にジルコニウムブトオキシド等の金属アルコキシドやケイ酸エチル等の有機金属化合物等を塗布・焼成してセラミックス薄膜を形成した後、撥水撥油性有機物を塗膜する等の工夫がなされている（特開平７−３１５８８２号公報、特開平６−５６４７６号公報、特開平５−１７０４８８号公報）。
【０００４】
これらの方法においては、金属アルコキシドや有機金属化合物を出発原料として得られる有機ゾルを使用する、所謂ゾルゲル法が採用され、浸漬法（ディップ法）により塗布されているが、ガラスに対する濡れ性が低く、成膜しにくいという問題がある。そのため、その引き上げ速度の制御等を可能する特殊な装置を使用して成膜されるなど複雑な工程管理がなされている。
【０００５】
また、このような有機ゾルを使用する方法は、板ガラスや自動車用フロントガラスなどの表面形状が単純なものに対しては均一な膜厚に塗布することが可能であるが、食器、タイル、衛生陶器、碍子などの複雑な形状を有する陶磁器セラミックス製品においては、液だまり等が発生しやすく、膜厚が厚くなりすぎた部分においては焼成時に剥離してしまうことがあるという問題がある。また、均一な膜厚に塗布することは困難であるという問題があり、単純には適用しえない。
【０００６】
また、金属アルコキシドや有機金属化合物は、それ自体、高価であり、また、これらを出発原料としてゾル溶液を得る方法は、複雑であり、製造コストが高くなるという問題があり、製造単価が比較的安い陶磁器セラミックス製品には不向きであるという問題もある。
【０００７】
更に、金属アルコキシドや有機金属化合物ゾルは、加水分解や重縮合反応を生じやすく、粘度が時間とともに変化してしまい、取り扱いが難しいという問題がある。
【０００８】
本発明者等は、先に、特許第２９５１６１１号において、陶磁器製品の表面を撥水化する技術である撥水性セラミックスとして、洗浄性、防汚性等の耐久性を長時間持続させることができ、また、製造単価が易く、かつ、比較的複雑な形状を有する陶磁器に適した撥水性セラミックスを提案したが、洋食器や給食食器などの陶磁器製品は、ナイフやフォークまたは食器を収納する金属籠等の金属製品との摩擦で生じる陶磁器表面に発生する金属汚れ（以下、メタルマーク）の問題があり、また、上記の特許において開示する撥水性セラミックスにあっては、形成するジルコニア膜の厚みの均一性が低く、陶磁器表面に虹色の光彩が発生する問題を生じることが判明した。
【０００９】
そのため、ジルコニア膜を形成するためのオキシジルコニウム塩水溶液において、界面活性剤を加えることで比較的均一な成膜を可能とはできるが、添加する活性剤によっては不純物となり、焼成後作成した膜にピンホール等の欠陥を生じるという問題がある。また、ジルコニア膜を形成するためのオキシジルコニウム塩水溶液は水が多く含有されているため室温での乾燥性が悪く、作業性が悪いのみでなく、乾燥時間の長さから乾燥工程によっては均一な成膜ができないとの課題があることが判明した。
【００１０】
【発明が解決しようとする課題】
本発明は、セラミックス表面に均一な膜厚で光彩等の問題のない撥水膜が容易に形成され、焼成時に剥離したりすることがなく、比較的複雑な形状を有する陶磁器に適し、乾燥性にすぐれ容易にセラミックス表面保護膜を形成することができるセラミックス表面保護膜用組成物であって、得られる保護膜が洗浄性、防汚性等の耐久性を長期間持続すると共にピンホールやメタルマーク等の問題の生じないものとでき、また、作業性に優れたセラミックス表面保護膜用組成物の提供を目的とする。
【００１１】
【課題を解決するための手段】
本発明のセラミックス表面保護膜用組成物は、オキシジルコニウム塩を、水１重量部に対して低級アルコール９重量部〜１００重量部からなる混合溶媒に０．１重量％〜２０重量％の割合で溶解させたことを特徴とする。
【００１２】
上記のオキシジルコニウム塩が、オキシ塩化ジルコニウム、オキシ硝酸ジルコニウムから選ばれた少なくとも１つであることを特徴とする。
上記の低級アルコールが、メタノール、エタノール、プロパノールから選ばれた少なくとも１つであることを特徴とする。
上記のオキシジルコニウム塩溶液がセラミックス表面に塗布形成された後、１５０℃〜１０００℃で焼成され、撥水性ジルコニア膜とされるものであることを特徴とする。
上記のセラミックスが、陶磁器であることを特徴とする。
【００１３】
【発明の実施の形態】
本発明のセラミックス表面保護膜用組成物におけるセラミックスとしては、ガラス質よりなる釉薬層を有する陶磁器やガラス器であり、特に、食器、衛生陶器、碍子、タイル等の比較的複雑な形状を有する陶磁器やガラス器である。
【００１４】
セラミックス表面保護膜用組成物におけるオキシジルコニウム塩、例えばオキシ塩化ジルコニウム８水和物（分子量３２２）の飽和濃度は約５ｍｏｌ／ｌ（水溶液）と水には易溶性を有する。しかしながら、低級アルコール類には難溶性であるが、オキシジルコニウム塩を少量の水に溶解させた後、低級アルコールを添加した混合溶媒には可溶性となることを見出した。
【００１５】
本発明におけるオキシジルコニウム塩としては、例えばオキシ塩化ジルコニウム（ＺｒＯＣｌ2 ）、オキシ硝酸ジルコニウム｛ＺｒＯ（ＮＯ3 ）2 ｝等の一種または混合物が挙げられる。オキシジルコニウム塩は、水１重量部に対して低級アルコール９重量部〜１００重量部の割合の混合溶媒に０．１重量％〜２０重量％、好ましくは１重量％〜１１重量％の割合で溶解させてセラミックス表面保護膜用組成物とされる。
【００１６】
低級アルコールは、メタノール、エタノール、プロパノールから選ばれた少なくとも１つである。また、水と低級アルコールとの混合比において、低級アルコールが少ないと乾燥性が悪く、乾燥工程によっては塗膜の不均一化の原因となり、不均一化に伴う光彩等の問題が発生し、生産効率が低下する。また、低級アルコールが１００重量部より多いとオキシジルコニウム塩の溶解性が悪化し、析出等の問題により塗膜における不均一化の原因ともなる。また、水−アルコール混合溶媒におけるオキシジルコニウム塩の濃度が、２０重量％より高いとオキシジルコニウム塩の溶解性が悪化し、析出等の問題により塗膜における不均一化の原因ともなる。なお、本発明のセラミックス表面保護膜用組成物には、ゲル化防止を目的として塩酸、硫酸、酢酸、硝酸等を０．０１重量％〜１重量％の割合で添加してもよい。
【００１７】
セラミックス表面保護膜用組成物は、セラミックス表面に、浸漬法（ディップ法）、スプレー法等により塗布される。
【００１８】
オキシジルコニウム塩溶液は、金属アルコキシドや有機金属化合物を用いて作製した有機ゾルに比して、加水分解や重縮合性がなく、取り扱いが簡単で、さらに低価格であり、また、オキシジルコニウム塩水溶液に比して作業性に優れるものである。また、セラミックス表面への濡れ性に優れるので、複雑な形状の陶磁器表面にも均一な膜厚で付着させることができる。塗膜の膜厚を厚くしたい場合には、浸漬−乾燥−浸漬を適宜繰り返し、目的の膜厚とするとよい。
【００１９】
オキシジルコニウム塩溶液は塗膜後、乾燥され、次いで１５０℃〜１０００℃で焼成され、透明な撥水性ジルコニア膜とされる。撥水性ジルコニア膜の焼成後膜厚としては０．００５μｍ〜０．５μｍ、好ましくは０．０１μｍ〜０．２μｍとするとよい。
【００２０】
得られたジルコニア膜は、その詳細な理由は不明であるが、無処理の陶磁器表面に比して疎水性を示すものである。また、陶磁器釉薬表面にジルコニア膜を形成するためのオキシジルコニウム塩溶液として、本発明のセラミックス表面保護膜用組成物を使用することにより、陶磁器釉薬表面と溶液との濡れ性が向上すると共に、界面活性剤として不揮発性のものを使用しないでも均一な成膜が可能となる。更に、乾燥後にあっても不純物が残留しないため、ピンホール等の問題を生じない。また、乾燥時間が短く、均一な成膜化を短時間で可能とすることができ、生産効率を高めることができ、また、光彩等の問題を生じないものとできる。また、本発明のセラミックス表面保護膜用組成物を使用すると耐洗浄試験を行った後にもメタルマーク等の付着が大幅に抑制されるセラミックス表面保護膜とできる。
【００２１】
また、本発明のセラミックス表面保護膜用組成物を使用して形成された保護膜上には、更に、フッ素系またはシリコン系撥水撥油性物質層を、塗布形成−乾燥−焼成工程を経て、成膜してもよい。本発明のセラミックス表面保護膜用組成物を使用して形成されたジルコニア膜は、耐洗浄試験後にあっては撥水性が低下するが、撥水撥油性物質層を設けることにより、撥水撥油性を付与することができる。
【００２２】
フッ素系またはシリコン系撥水撥油性物質としては、CF3(CH2)2Si(OCH3)3、CF3(CF2)5(CH2)2Si(OCH3)3、CF3(CF2)7(CH2)2Si(OCH3)3、CF3(CF2)7(CH2)2SiCH3(OCH3)2 、CF3(CF2)3(CH2)2Si(OCH3)3、CF3(CF2)7(CH2)2SiCl3等の炭素数が１〜２０のパーフルオロアルキル基を含むシラン化合物またはその加水分解した縮合体、その他、ノニオン系フッソ系界面活性剤、パーフルオロ安息香酸、Ｎ−〔３−（トリメトキシシリル）プロピル〕−Ｎ−ｎ−プロピルパーフルオロオクチルスルホンアミド、ポリジメチルシロキサン等が挙げられる。
【００２３】
これらの撥水撥油性物質は、単独または溶液状とし、ジルコニア膜上へディップ法、スプレー法等により塗布された後、撥水撥油性物質の種類により相違するが、乾燥または焼成されて透明な撥水撥油性膜とされる。撥水撥油性膜の乾燥後または焼成後の膜厚としては１μｍ以下とするとよい。
【００２４】
撥水撥油性物質として、特にパーフルオロアルキル基を含むシラン化合物またはその加水分解した縮合体を使用すると、ジルコニア膜表面と、その詳細な理由は不明であるが、単なる物理的な結合ではなく、化学的結合をするものと考えられ、強固で耐久性に優れ、よりメタルマーク等の問題の生じない撥水撥油性セラミックスとできる。
【００２５】
【実施例】
以下、本発明を実施例により詳細に説明するが、下記の実施例に記載する評価方法は下記の通りである。
（耐洗浄試験）
業務用食器洗浄機及び業務用アルカリ洗剤を用いて５００回（一回当たり約９０秒間の洗浄）洗浄する。
（メタルマーク付着試験）
保護膜を形成した陶磁器表面をステンレス製のスプーンで擦り、メタルマーク（金属汚れ）の付着具合を、保護膜を形成していない陶磁器表面における付着具合と比較して、目視で確認する。
【００２６】
（実施例１）
水２ｍｌ、エチルアルコール９８ｍｌからなる混合溶媒にオキシ塩化ジルコニウム（ＺｒＯＣｌ2 ）を３重量％の濃度となるように添加し、セラミックス表面保護膜用組成物とした。この組成物を用い、表面に釉薬を有する陶磁器表面に浸漬法（ディップ法）でコーティングした後、室温で乾燥した。乾燥時間は３分程度で終了した。更に３００℃で焼成して、焼成後膜厚０．０１５μｍの透明なジルコニア薄膜を形成した。ジルコニア薄膜を形成した陶磁器表面には、光彩は生じなく、薄膜の均一性に優れるものであることが確認できた。
【００２７】
この陶磁器表面と水との接触角を測定したところ、８０度であった。本実施例を５回繰り返したが、いずれの試験片も７０〜８５度の範囲にあった。
【００２８】
また、洗浄試験の実施前、また、実施後の陶磁器表面のメタルマーク付着試験を実施したところ、いずれの場合も明らかにメタルマークが減少していることが目視で確認できた。
【００２９】
また、比較として、濃度０．１ｍｏｌ／リットルのＺｒＯＣｌ2 水溶液に、エチルアルコールを１０重量％添加してセラミックス表面保護膜用組成物とした。この組成物を用い、上記と同様にして陶磁器表面にコーティングした後、室温で乾燥した。乾燥時間は約２０分と長く、また、乾燥工程を早めるため塗布面を傾斜させて６０℃の熱風を１分間、吹き付け乾燥させた後、更に２５０℃で焼成して、焼成後膜厚０．１μｍの透明なジルコニア薄膜を形成した。陶磁器表面を観察すると虹色の光彩が発生しており、薄膜の膜厚の不均一なものとなった。
【００３０】
（実施例２）
水７ｍｌ、メチルアルコール９３ｍｌからなる混合溶媒にオキシ塩化ジルコニウム（ＺｒＯＣｌ2 ）を７重量％の濃度となるように添加し、セラミックス表面保護膜用組成物とした。この組成物を用い、表面に釉薬を有する陶磁器表面に浸漬法（ディップ法）でコーティングした後、室温で乾燥した。乾燥時間は３分程度で終了した。更に３００℃で焼成して、焼成後膜厚０．０２μｍの透明なジルコニア薄膜を形成した。陶磁器表面には、光彩は生じなく、薄膜の均一性に優れるものであることが確認できた。
【００３１】
また、洗浄試験の実施前、また、実施後の陶磁器表面のメタルマーク付着試験を実施したところ、いずれの場合も明らかにメタルマークが減少していることが目視で確認できた。
【００３２】
上記で得たジルコニア薄膜上に、パーフルオロアルキルシラン（商品名「ＫＢＭ−７８０３」信越化学（株）製）の２％エタノール溶液を刷毛による塗布法で塗布、乾燥させた後、２００℃で焼成して撥水撥油膜を成膜した。
【００３３】
この陶磁器表面と水との接触角を測定したところ、１００度以上であった。また、耐洗浄試験後、同様に水との接触角を測定したところ９０度以上あり、高い耐久性を示した。また、撥水撥油膜を形成したものについて、メタルマーク付着試験を実施したところ、同様の結果が得られた。
【００３４】
（実施例３）
水７ｍｌ、プロパノール９３ｍｌからなる混合溶媒にオキシジルコニウム（ＺｒＯＣｌ2 ）を７重量％の濃度となるように添加し、セラミックス表面保護膜用組成物とした。この組成物を用い、表面に釉薬を有する陶磁器表面に浸漬法（ディップ法）でコーティングした後、室温で乾燥した。乾燥は３分程度で終了した。次いで３００℃で焼成して、焼成後膜厚０．０３μｍの透明なジルコニア薄膜を形成した。陶磁器表面には、光彩は生じなく、薄膜の均一性に優れるものであることが確認できた。
【００３５】
この陶磁器表面と水との接触角を測定したところ、８０度であった。本実施例を５回繰り返したが、いずれの試験片も７０〜８５度の範囲にあった。
【００３６】
また、洗浄試験の実施前、また、実施後の陶磁器表面のメタルマーク付着試験を実施したところ、いずれの場合も明らかにメタルマークが減少していることが目視で確認できた。
【００３７】
（実施例４）
水７ｍｌ、プロパノール９７ｍｌからなる混合溶媒にオキシジルコニウム（ＺｒＯＣｌ2 ）を３重量％の濃度となるように添加し、セラミックス表面保護膜用組成物とした。この組成物を用い、表面に釉薬を有する陶磁器表面に浸漬法（ディップ法）でコーティングした後、室温で乾燥した。乾燥は３分程度で終了した。次いで３００℃で焼成して、焼成後膜厚０．０２μｍの透明なジルコニア薄膜を形成した。陶磁器表面には、光彩は生じなく、薄膜の均一性に優れるものであることが確認できた。
【００３８】
また、洗浄試験の実施前、また、実施後の陶磁器表面のメタルマーク付着試験を実施したところ、いずれの場合も明らかにメタルマークが減少していることが目視で確認できた。
【００３９】
上記で得られたジルコニア薄膜上に、パーフルオロアルキルシラン（商品名「ＫＢＭ−７８０３」信越化学（株）製）の３％エタノール溶液を刷毛による塗布法で塗布、乾燥させた後、１５０℃で焼成して撥水撥油膜を成膜した。
【００４０】
この陶磁器表面と水との接触角を測定したところ、１００度以上であった。また、耐洗浄試験後、同様に水との接触角を測定したところ９０度以上あり、高い耐久性を示した。また、撥水撥油膜を形成したものについて、メタルマーク付着試験を実施したところ、同様の結果が得られた。
【００４１】
（実施例５）
水１ｍｌ、エチルアルコール９９ｍｌからなる混合溶媒にオキシ塩化ジルコニウム（ＺｒＯＣｌ2 ）を１重量％、塩酸を０．１重量％の濃度となるようにそれぞれ添加し、セラミックス表面保護膜用組成物とした。この組成物を用い、表面に釉薬を有する陶磁器表面に浸漬法（ディップ法）でコーティングした後、室温で乾燥した。乾燥時間は３分程度で終了した。更に３００℃で焼成して、焼成後膜厚０．０１μｍの透明なジルコニア薄膜を形成した。ジルコニア薄膜を形成した陶磁器表面には、光彩は生じなく、薄膜の均一性に優れるものであることが確認できた。
【００４２】
この陶磁器表面と水との接触角を測定したところ、８０度であった。本実施例を５回繰り返したが、いずれの試験片も７０〜８５度の範囲にあった。
【００４３】
また、洗浄試験の実施前、また、実施後の陶磁器表面のメタルマーク付着試験を実施したところ、いずれの場合も明らかにメタルマークが減少していることが目視で確認できた。
【００４４】
【発明の効果】
本発明のセラミックス表面保護膜用組成物は、セラミックス表面に均一な膜厚で光彩等の問題のない撥水膜が容易に形成され、焼成時に剥離したりすることのなく比較的複雑な形状を有する陶磁器に適するものであり、乾燥性にすぐれ容易にセラミックス表面保護膜を形成することを可能とする。また、得られる保護膜は、洗浄性、防汚性等の耐久性を長期間持続すると共にピンホールやメタルマーク等の問題を生じないものである。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a composition for a surface protective film of ceramics made of ceramics such as tableware, tiles, sanitary ware, insulators, or glass.
[0002]
[Prior art]
Porcelain has a glaze (glassy) on its surface, but its surface is coated with a water- and oil-repellent agent such as silicon resin or fluorine resin to make it water and oil repellent. Improvements are being made. However, these water and oil repellents have poor adhesion to the glaze (glassy) on the surface of the ceramics. Therefore, the water and oil repellents will be removed when the number of uses such as washing increases, and the water and oil repellent effect will last for a long time. There is a problem of not persisting.
[0003]
In addition, in the field of glass such as automotive windshields and architectural flat glass, in order to maintain the water and oil repellency of the glass surface for a long period of time, metal alkoxides such as zirconium butoxide and ethyl silicate are used on the glass surface. After applying and baking an organometallic compound or the like to form a ceramic thin film, a device such as coating a water- and oil-repellent organic material has been made (Japanese Patent Laid-Open Nos. 7-315882 and 6-56476, JP-A-5-170488).
[0004]
In these methods, a so-called sol-gel method using an organic sol obtained using a metal alkoxide or an organometallic compound as a starting material is employed, and coating is performed by a dipping method (dip method), but the wettability to glass is low. There is a problem that film formation is difficult. For this reason, complicated process management is performed, for example, a film is formed using a special apparatus capable of controlling the pulling speed.
[0005]
In addition, the method using such an organic sol can be applied to a uniform film thickness for a simple surface shape such as a plate glass or an automotive windshield, but it can be applied to tableware, tiles, and hygiene. In ceramic ceramic products having a complicated shape such as ceramics and insulators, there is a problem that liquid puddles are easily generated, and a portion where the film thickness is too thick may be peeled off during firing. Further, there is a problem that it is difficult to apply a uniform film thickness, and it cannot be simply applied.
[0006]
In addition, metal alkoxides and organometallic compounds are expensive per se, and the method of obtaining a sol solution using these as starting materials is complicated and has a problem of high production cost, and the production unit price is relatively low. There is also a problem that it is not suitable for cheap ceramic products.
[0007]
Furthermore, metal alkoxides and organometallic compound sols are prone to hydrolysis and polycondensation reactions, and have a problem that their viscosity changes with time and are difficult to handle.
[0008]
The inventors of the present invention previously described in Japanese Patent No. 2951611 can maintain durability such as detergency and antifouling properties for a long period of time as water-repellent ceramics, which is a technology for making the surface of ceramic products water repellent. In addition, we proposed water-repellent ceramics that are easy to manufacture and that are suitable for ceramics with relatively complex shapes. However, ceramic products such as western dishes and school dishes are made of metal bowls that store knives, forks, or dishes. In the water-repellent ceramic disclosed in the above patent, there is a problem of the thickness of the zirconia film to be formed. It has been found that the uniformity is low, causing a problem of rainbow-colored glow on the ceramic surface.
[0009]
For this reason, in the oxyzirconium salt aqueous solution for forming a zirconia film, it is possible to form a relatively uniform film by adding a surfactant. There is a problem that defects such as pinholes occur. In addition, since the oxyzirconium salt aqueous solution for forming a zirconia film contains a large amount of water, it does not have a good drying property at room temperature and has poor workability, and it is uniform depending on the drying process due to the length of the drying time. It was found that there was a problem that the film could not be formed.
[0010]
[Problems to be solved by the invention]
The present invention easily forms a water-repellent film having a uniform film thickness on the ceramic surface and does not cause problems such as iridescence, and is suitable for ceramics having a relatively complicated shape without peeling during firing. A ceramic surface protective film composition capable of easily and easily forming a ceramic surface protective film, wherein the obtained protective film has long-lasting durability such as cleaning and antifouling properties, as well as pinholes and metals An object of the present invention is to provide a composition for a ceramic surface protective film that does not cause problems such as marks and has excellent workability.
[0011]
[Means for Solving the Problems]
In the ceramic surface protective film composition of the present invention, the oxyzirconium salt is mixed in a mixed solvent composed of 9 to 100 parts by weight of a lower alcohol with respect to 1 part by weight of water at a ratio of 0.1 to 20% by weight. It is characterized by being dissolved.
[0012]
The oxyzirconium salt is at least one selected from zirconium oxychloride and zirconium oxynitrate.
The lower alcohol is at least one selected from methanol, ethanol, and propanol.
The oxyzirconium salt solution is formed on a ceramic surface and then fired at 150 to 1000 ° C. to form a water-repellent zirconia film.
The ceramics is a ceramic.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
The ceramic in the ceramic surface protective film composition of the present invention is a ceramic or glassware having a glaze layer made of glass, and in particular, ceramics having a relatively complicated shape such as tableware, sanitary ware, insulators, tiles, etc. And glassware.
[0014]
The oxyzirconium salt, for example, zirconium oxychloride octahydrate (molecular weight 322) in the ceramic surface protective film composition has a saturation concentration of about 5 mol / l (aqueous solution) and is readily soluble in water. However, it has been found that although it is hardly soluble in lower alcohols, it is soluble in a mixed solvent to which the lower alcohol is added after the oxyzirconium salt is dissolved in a small amount of water.
[0015]
Examples of the oxyzirconium salt in the present invention include one or a mixture of zirconium oxychloride (ZrOCl 2 ), zirconium oxynitrate {ZrO (NO 3 ) 2 }, and the like. The oxyzirconium salt is dissolved in a mixed solvent at a ratio of 9 to 100 parts by weight of a lower alcohol to 1 part by weight of water at a ratio of 0.1 to 20% by weight, preferably 1 to 11% by weight. Thus, a ceramic surface protective film composition is obtained.
[0016]
The lower alcohol is at least one selected from methanol, ethanol, and propanol. Also, in the mixing ratio of water and lower alcohol, if there is little lower alcohol, the drying property will be poor, and depending on the drying process, it may cause unevenness of the coating film, causing problems such as iridescence due to unevenness, and production. Efficiency is reduced. On the other hand, when the amount of the lower alcohol is more than 100 parts by weight, the solubility of the oxyzirconium salt is deteriorated, and this may cause unevenness in the coating film due to problems such as precipitation. On the other hand, if the concentration of the oxyzirconium salt in the water-alcohol mixed solvent is higher than 20% by weight, the solubility of the oxyzirconium salt is deteriorated, and this may cause unevenness in the coating film due to problems such as precipitation. In addition, you may add hydrochloric acid, a sulfuric acid, an acetic acid, nitric acid etc. to the composition for ceramic surface protective films of this invention in the ratio of 0.01 weight%-1 weight% in order to prevent gelation.
[0017]
The ceramic surface protective film composition is applied to the ceramic surface by a dipping method (dip method), a spray method or the like.
[0018]
Oxyzirconium salt solution is not hydrolyzed or polycondensable, easy to handle and less expensive than organic sols prepared using metal alkoxides or organometallic compounds. Compared to the above, it is excellent in workability. Moreover, since it is excellent in wettability to the ceramic surface, it can be adhered to a ceramic surface having a complicated shape with a uniform film thickness. When it is desired to increase the film thickness of the coating film, immersion-drying-immersion is repeated as appropriate to obtain the desired film thickness.
[0019]
The oxyzirconium salt solution is dried after coating, and then baked at 150 to 1000 ° C. to form a transparent water-repellent zirconia film. The film thickness after firing of the water-repellent zirconia film is 0.005 μm to 0.5 μm, preferably 0.01 μm to 0.2 μm.
[0020]
Although the detailed reason is unknown, the obtained zirconia film | membrane shows hydrophobicity compared with the untreated ceramic surface. Further, by using the ceramic surface protective film composition of the present invention as an oxyzirconium salt solution for forming a zirconia film on the surface of the ceramic glaze, the wettability between the ceramic glaze surface and the solution is improved, and the interface Even if a non-volatile activator is not used, uniform film formation is possible. Further, since impurities do not remain even after drying, problems such as pinholes do not occur. In addition, the drying time is short, and uniform film formation can be achieved in a short time, so that the production efficiency can be increased, and problems such as luminosity can be prevented. Moreover, when the composition for a ceramic surface protective film of the present invention is used, a ceramic surface protective film in which adhesion of a metal mark or the like is significantly suppressed even after a cleaning resistance test is performed can be obtained.
[0021]
Further, on the protective film formed using the ceramic surface protective film composition of the present invention, a fluorine-based or silicon-based water / oil repellent substance layer is further subjected to a coating formation-drying-firing step, A film may be formed. The zirconia film formed using the ceramic surface protective film composition of the present invention has a decreased water repellency after the cleaning resistance test, but by providing a water / oil repellency substance layer, the water / oil repellency is improved. Can be granted.
[0022]
Fluorine-based or silicon-based water and oil repellent materials include CF 3 (CH 2 ) 2 Si (OCH 3 ) 3 , CF 3 (CF 2 ) 5 (CH 2 ) 2 Si (OCH 3 ) 3 , CF 3 (CF 2 ) 7 (CH 2 ) 2 Si (OCH 3 ) 3 , CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCH 3 (OCH 3 ) 2 , CF 3 (CF 2 ) 3 (CH 2 ) 2 Si (OCH 3 ) 3 , CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl 3 and other silane compounds containing a perfluoroalkyl group having 1 to 20 carbon atoms, or their hydrolyzed condensates, and other nonionic fluorine-based interfaces Activators, perfluorobenzoic acid, N- [3- (trimethoxysilyl) propyl] -Nn-propyl perfluorooctylsulfonamide, polydimethylsiloxane and the like.
[0023]
These water- and oil-repellent substances may be used alone or in a solution, and after being applied onto the zirconia film by dipping or spraying, the water- and oil-repellent substances vary depending on the type of the water- and oil-repellent substance, but are transparent when dried or baked. A water / oil repellent film is used. The film thickness after drying or baking of the water / oil repellent film is preferably 1 μm or less.
[0024]
When a silane compound containing a perfluoroalkyl group or a hydrolyzed condensate thereof is used as the water / oil repellent material, the surface of the zirconia film and the detailed reason are unknown, but it is not a mere physical bond. It is considered to be chemically bonded, and can be made of a water- and oil-repellent ceramic that is strong and excellent in durability and does not cause a problem such as a metal mark.
[0025]
【Example】
EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, the evaluation method described in the following Example is as follows.
(Washing resistance test)
Wash 500 times (about 90 seconds of washing each time) using a commercial dishwasher and a commercial alkaline detergent.
(Metal mark adhesion test)
The surface of the ceramics on which the protective film is formed is rubbed with a stainless steel spoon, and the degree of adhesion of the metal mark (metal stain) is compared with the degree of adhesion on the surface of the ceramics where no protective film is formed.
[0026]
(Example 1)
Zirconium oxychloride (ZrOCl 2 ) was added to a mixed solvent composed of 2 ml of water and 98 ml of ethyl alcohol so as to have a concentration of 3% by weight to obtain a composition for a ceramic surface protective film. Using this composition, a ceramic surface having a glaze on the surface was coated by a dipping method (dip method) and then dried at room temperature. The drying time was about 3 minutes. Furthermore, it baked at 300 degreeC and formed the transparent zirconia thin film with a film thickness of 0.015 micrometer after baking. It was confirmed that the surface of the ceramics on which the zirconia thin film was formed did not produce a glow and had excellent thin film uniformity.
[0027]
The contact angle between the ceramic surface and water was measured and found to be 80 degrees. This example was repeated 5 times, but all specimens were in the range of 70-85 degrees.
[0028]
Moreover, when the metal mark adhesion test on the surface of the ceramics before and after the cleaning test was performed, it was visually confirmed that the metal marks were clearly reduced in all cases.
[0029]
For comparison, a ceramic surface protective film composition was prepared by adding 10% by weight of ethyl alcohol to a ZrOCl 2 aqueous solution having a concentration of 0.1 mol / liter. Using this composition, the ceramic surface was coated in the same manner as described above, and then dried at room temperature. The drying time is as long as about 20 minutes. Further, in order to accelerate the drying process, the coated surface is tilted and hot air at 60 ° C. is blown and dried for 1 minute, followed by further baking at 250 ° C. A 1 μm transparent zirconia thin film was formed. When the surface of the ceramic was observed, a rainbow-colored glow was generated, and the film thickness was uneven.
[0030]
(Example 2)
Zirconium oxychloride (ZrOCl 2 ) was added to a mixed solvent composed of 7 ml of water and 93 ml of methyl alcohol so as to have a concentration of 7% by weight to obtain a composition for a ceramic surface protective film. Using this composition, a ceramic surface having a glaze on the surface was coated by a dipping method (dip method) and then dried at room temperature. The drying time was about 3 minutes. Furthermore, it baked at 300 degreeC, and formed the transparent zirconia thin film with a film thickness of 0.02 micrometer after baking. It was confirmed that the ceramic surface had no irradiance and had excellent thin film uniformity.
[0031]
Moreover, when the metal mark adhesion test on the surface of the ceramics before and after the cleaning test was performed, it was visually confirmed that the metal marks were clearly reduced in all cases.
[0032]
A 2% ethanol solution of perfluoroalkylsilane (trade name “KBM-7803”, manufactured by Shin-Etsu Chemical Co., Ltd.) is applied onto the zirconia thin film obtained above by a coating method using a brush, dried, and then fired at 200 ° C. Thus, a water / oil repellent film was formed.
[0033]
The contact angle between the ceramic surface and water was measured and found to be 100 degrees or more. Moreover, when the contact angle with water was similarly measured after the washing resistance test, it was 90 degrees or more, and high durability was exhibited. Further, when a metal mark adhesion test was carried out on the water- and oil-repellent film formed, the same result was obtained.
[0034]
(Example 3)
Oxyzirconium (ZrOCl 2 ) was added to a mixed solvent consisting of 7 ml of water and 93 ml of propanol so as to have a concentration of 7% by weight to obtain a ceramic surface protective film composition. Using this composition, a ceramic surface having a glaze on the surface was coated by a dipping method (dip method) and then dried at room temperature. Drying was completed in about 3 minutes. Subsequently, it baked at 300 degreeC, and formed the transparent zirconia thin film with a film thickness of 0.03 micrometer after baking. It was confirmed that the ceramic surface had no irradiance and had excellent thin film uniformity.
[0035]
The contact angle between the ceramic surface and water was measured and found to be 80 degrees. This example was repeated 5 times, but all specimens were in the range of 70-85 degrees.
[0036]
Moreover, when the metal mark adhesion test on the surface of the ceramics before and after the cleaning test was performed, it was visually confirmed that the metal marks were clearly reduced in all cases.
[0037]
(Example 4)
Oxyzirconium (ZrOCl 2 ) was added to a mixed solvent composed of 7 ml of water and 97 ml of propanol so as to have a concentration of 3% by weight to obtain a ceramic surface protective film composition. Using this composition, a ceramic surface having a glaze on the surface was coated by a dipping method (dip method) and then dried at room temperature. Drying was completed in about 3 minutes. Subsequently, it baked at 300 degreeC and formed the transparent zirconia thin film with a film thickness of 0.02 micrometer after baking. It was confirmed that the ceramic surface had no irradiance and had excellent thin film uniformity.
[0038]
Moreover, when the metal mark adhesion test on the surface of the ceramics before and after the cleaning test was performed, it was visually confirmed that the metal marks were clearly reduced in all cases.
[0039]
A 3% ethanol solution of perfluoroalkylsilane (trade name “KBM-7803” manufactured by Shin-Etsu Chemical Co., Ltd.) was applied onto the zirconia thin film obtained above by a brush application method and dried, then at 150 ° C. Baking was performed to form a water / oil repellent film.
[0040]
The contact angle between the ceramic surface and water was measured and found to be 100 degrees or more. Moreover, when the contact angle with water was similarly measured after the washing resistance test, it was 90 degrees or more, and high durability was exhibited. Further, when a metal mark adhesion test was carried out on the water- and oil-repellent film formed, the same result was obtained.
[0041]
(Example 5)
Zirconium oxychloride (ZrOCl 2 ) was added to a mixed solvent consisting of 1 ml of water and 99 ml of ethyl alcohol so as to have a concentration of 1% by weight and hydrochloric acid to a concentration of 0.1% by weight, thereby preparing a composition for a ceramic surface protective film. Using this composition, a ceramic surface having a glaze on the surface was coated by a dipping method (dip method) and then dried at room temperature. The drying time was about 3 minutes. Furthermore, it baked at 300 degreeC and formed the transparent zirconia thin film with a film thickness of 0.01 micrometer after baking. It was confirmed that the surface of the ceramics on which the zirconia thin film was formed did not produce a glow and had excellent thin film uniformity.
[0042]
The contact angle between the ceramic surface and water was measured and found to be 80 degrees. This example was repeated 5 times, but all specimens were in the range of 70-85 degrees.
[0043]
Moreover, when the metal mark adhesion test on the surface of the ceramics before and after the cleaning test was performed, it was visually confirmed that the metal marks were clearly reduced in all cases.
[0044]
【The invention's effect】
The composition for a ceramic surface protective film of the present invention has a uniform film thickness and a water repellent film that is free from problems such as iridescence, and has a relatively complex shape without peeling during firing. The ceramic surface protection film can be easily formed because of its excellent drying property. Further, the obtained protective film maintains durability such as cleaning properties and antifouling properties for a long time and does not cause problems such as pinholes and metal marks.
Claims (5)
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