Functional coated product and process for producing the same and the use thereof

A functional coated product having a first coating layer formed of a cured coating of an acryl-modified silicone resin coating material comprising the following components (A), (B), (C) and (D) on a surface of a substrate, and a second coating layer formed of a cured coating of a functional coating material comprising the following components (A), (B), (C), (E) and (F), over the first coating layer;

• Component (A):
• a silica-dispersed organosilane oligomer solution obtained by partially hydrolyzing a hydrolyzable organosilane represented by the general formula
• R1mSiX4-m (I)
• wherein R1 indicates a monovalent hydrocarbon group having 1 to 8 carbon atoms, which may be the same or different, m indicates an integer of 0 to 3, and X indicates a hydrolyzable group
• in colloidal silica dispersed in an organic solvent, water or at mixed solvent of them, under the condition that 0.001 to 0.5 mol of water is used based on 1 mol equivalent of the above-mentioned hydrolyzable group (X);
• Component (B):
• a polyorganosiloxane represented by the average compositional formula
• R2aSi(OH)bO(4-a-b)/2 (II)
• wherein R2 indicates a monovalent hydrocarbon group having 1 to 8 carbon atoms, which may be the same or different, a and b separately satisfy the following condition:
• 0.2≦a≦2, 0.0001≦b≦3, a+b<4,
• which contains a silanol group in the molecule structure and has an average molecular weight (in terms of polystyrene) of 700 to 20,000;
• Component (C):
• a curing catalyst;
• Component (D):
• an acrylic resin of copolymer of first (meth)acrylate represented by the general formula (III)
• CH2═CR3(COOR4) (III)
• in which R3 is a hydrogen atom or a methyl group, and R4 is a hydrocarbon group having 1 to 9 carbon atoms,
• the second (meth)acrylate of the general formula (III) in which R3 is a hydrogen atom or a methyl group, and R4 is at least one group selected from the group consisting of an epoxy group, a glycidyl group, and a hydrocarbon group containing at least either of the above, and
• the third (meth)acrylate of the general formula (III) in which R3 is a hydrogen atom or a methyl group, and R4 is a hydrocarbon group containing an alkoxy silyl group or a halogenated silyl group, and said acrylic resin having an average molecular weight (in terms of polystyrene) of 1,000 to 50,000;
• Component (E):
• an organosiloxane comprising a hydrolyzed polycondensate of;
• 5 to 30,000 parts by weight of a silica compound represented by the general formula:
• Si(OR5)4
• and/or colloidal silica, 100 parts by weight of a silica compound represented by the general formula:
• R6Si(OR5)3
• and 0 to 60 parts by weight of a silica compound represented by the general formula:
• R6Si(OR5)2
• wherein R5 and R6 indicate a monovalent hydrocarbon group and said weight-average molecular weight being adjusted to 800 or more in terms of polystyrene;
• and
• Component (F):
• a photocatalyst.

A process for producing a functional coating material comprising the following steps:

• forming a first coating layer by applying an acryl-modified silicone resin coating material containing the following components (A), (B), (C) and (D) to surface of a substrate,
• forming a semi-cured layer by semi-curing the first coating layer,
• forming a second coating layer by applying a functional coating material containing the following components (E) and (F) to surface of said semi-cured layer, and
• curing said semi-cured layer and said second coating layer;
• Component (A):
• a silica-dispersed organosilane oligomer solution obtained by partially hydrolyzing a hydrolyzable organosilane represented by the general formula
• R1mSiX4-m (I)
• wherein R1 indicates a monovalent hydrocarbon group having 1 to 8 carbon atoms, which may be the same or different, m indicates an integer of 0 to 3, and X indicates a hydrolyzable group
• in colloidal silica dispersed in an organic solvent, water or a mixed solvent of them, under the condition that 0.001 to 0.5 mol of water is used based on 1 mol equivalent of the above-mentioned hydrolyzable group (X);
• Component (B):
• a polyorganosiloxane represented by the average compositional formula
• R2aSi(OH)bO(4-a-b)/2 (II)
• wherein R2 indicates a monovalent hydrocarbon group having 1 to 8 carbon atoms, which may be the same or different, a and b separately satisfy the following condition:
• 0.2≦a≦2, 0.0001≦b≦3, a+b<4,
• which contains a silanol group in the molecule structure and has an average molecular weight (in terms of polystyrene) of 700 to 20,000;
• Component (C):
• a curing catalyst;
• Component (D):
• an acrylic resin of copolymer of first (meth)acrylate represented by the general formula (III)
• CH2═CR3(COOR4) (III)
• in which R3 is a hydrogen atom or a methyl group, and R4 is a hydrocarbon group having 1 to 9 carbon atoms,
• the second (meth)acrylate of the general formula (III) in which R3 is a hydrogen atom or a methyl group, and R4 is at least one group selected from the group consisting of an epoxy group, a glycidyl group, and a hydrocarbon group containing at least either of the above, and
• the third (meth)acrylate of the general formula (III) in which R3 is a hydrogen atom or a methyl group, and R4 is a hydrocarbon group containing an alkoxy silyl group or a halogenated silyl group, and said acrylic resin having an average molecular weight (in terms of polystyrene) of 1,000 to 50,000;
• Component (E):
• an organosiloxane comprising a hydrolyzed polycondensate of;
• 5 to 30,000 parts by weight of a silica compound represented by the general formula
• Si(OR5)4
• and/or colloidal silica, 100 parts by weight of a silica compound represented by the general formula:
• R6Si(OR5)3
• and 0 to 60 parts by weight of a silica compound represented by the general formula:
• R6Si(OR5)2
• wherein R5 and R6 indicate a monovalent hydrocarbon group and said weight-average molecular weight being adjusted to 800 or more in terms of polystyrene;
• and
• Component (F):
• a photocatalyst.

A process for producing a functional coating material comprising the following steps:

• forming a first coating layer by applying an acryl-modified silicone resin coating material containing the following components (A), (B), (C) and (D) to surface of a substrate,
• forming a semi-cured layer by semi-curing the first coating layer,
• forming a second coating layer by applying a functional coating material containing the following components (A), (B), (C) and (F) to surface of said semi-cured layer, and
• curing said semi-cured layer and said second coating layer;
• Component (A):
• a silica-dispersed organosilane oligomer solution obtained by partially hydrolyzing a hydrolyzable organosilane represented by the general formula
• R1mSiX4-m (I)
• wherein R1 indicates a monovalent hydrocarbon group having 1 to 8 carbon atoms, which may be the same or different, m indicates an integer of 0 to 3, and X indicates a hydrolyzable group in colloidal silica dispersed in an organic solvent, water or a mixed solvent of them, under the condition that 0.001 to 0.5 mol of water is used based on 1 mol equivalent of the above-mentioned hydrolyzable group (X);
• Component (B):
• a polyorganosiloxane represented by the average compositional formula
• R2aSi(OH)bO(4-a-b)/2 (II)
• wherein R2 indicates a monovalent hydrocarbon group having 1 to 8 carbon atoms, which may be the same or different, a and b separately satisfy the following condition:
• 0.2≦a≦2, 0.0001≦b≦3, a+b<4,
• which contains a silanol group in the molecule structure and has an average molecular weight (in terms of polystyrene) of 700 to 20,000;
• Component (C):
• a curing catalyst;
• Component (D):
• an acrylic resin of copolymer of first (meth)acrylate represented by the general formula (III)
• CH2═CR3(COOR4) (III)
• in which R3 is a hydrogen atom or a methyl group, and R4 is a hydrocarbon group having 1 to 9 carbon atoms,
• the second (meth)acrylate of the general formula (III) in which R3 is a hydrogen atom or a methyl group, and R4 is at least one group selected from the group consisting of an epoxy group, a glycidyl group, and a hydrocarbon group containing at least either of the above, and
• the third (meth)acrylate of the general formula (III) in which R3 is a hydrogen atom or a methyl group, and R4 is a hydrocarbon group containing an alkoxy silyl group or a halogenated silyl group, and said acrylic resin having an average molecular weight (in terms of polystyrene) of 1,000 to 50,000;
• Component (E):
• an organosiloxane comprising a hydrolyzed polycondensate of;
• 5 to 30,000 parts by weight of a silica compound represented by the general formula:
• Si(OR5)4
• and/or colloidal silica, 100 parts by weight of a silica compound represented by the general formula:
• R6Si(OR5)3
• and 0 to 60 parts by weight of a silica compound represented by the general formula:
• R6Si(OR5)2
• wherein R5 and R6 indicate a monovalent hydrocarbon group and said weight-average molecular weight being adjusted to 800 or more in terms of polystyrene;
• and
• Component (F):
• a photocatalyst.