Patent Application
20140378018
The present invention relates to a fluorine-containing copolymer and a water- and oil-repellent comprising the same as an active ingredient. More particularly, the present invention relates to a fluorine-containing copolymer that can be used as an active ingredient of a stain-proof-type water- and oil-repellent having excellent washing durability, and also relates to a water- and oil-repellent comprising the copolymer as an active ingredient.
Conventionally, stain-proof finish and stain removal finish are applied to fiber fabrics by, for example, imparting hydrophilicity to the fiber fabrics, or treating the fiber fabrics with fluororesin. To impart hydrophilicity, for example, fibers are graft-polymerized with a hydrophilic monomer, or the fiber surface is coated with a hydrophilic polymer. These methods are mainly used for highly lipophilic fabrics, such as synthetic fiber fabrics and synthetic fiber/cotton blended fabrics. On the other hand, the treatment with fluororesin is generally performed by, for example, applying fluororesin alone or a mixture of fluororesin and a resin-processing agent for fibers as a solution to fabrics, followed by drying and curing.
Moreover, in order to improve their processability and washing durability, the following methods are employed:
However, stain-proof finish and stain removal finish cannot be applied to highly hydrophilic cotton fabrics or cotton blended fabrics by imparting hydrophilicity thereto. Conversely, in doing so fabrics with stain-proof finish and stain removal finish may become easily stained, or stains on the fabrics may become hard to remove. Moreover, when fabrics are treated with fluorine-based resin, the fabrics repel stains and are less likely to be stained; nevertheless, there is a problem that oil stains once made on the fabrics cannot be removed by washing. Even though these methods have effects on synthetic fiber fabrics, they do not work on cotton fabrics or cotton blended fabrics with a high cotton content. Even though stain removal properties are improved to some extent, washing durability is insufficient. Thus, satisfactory performance has not been accomplished yet. In addition, these processing methods have defects, such as complicated procedures, and lack of practicality because mass treatment cannot be performed in terms of devices and facilities.
Furthermore, due to the nature of fibers, i.e., repeated swelling and shrinkage depending on the moisture content during washing, etc., it is very difficult to apply long-lasting, stain-proof finish with resin, or the like, to fiber fabrics. Various studies are made on polymerizable monomers for improving durability; however, the actual situation is that stain-proof finish and stain removal finish with improved washing durability have not been placed on the market.
Patent Document 1: JP-B-7-30513
Patent Document 2: JP-B-2-19233
Patent Document 3: JP-A-5-59669
Patent Document 4: WO 2009/034773 A1
Patent Document 5: WO 2010/101091 A1
Patent Document 6: WO 2005/118737 A1
An object of the present invention is to provide a fluorine-containing copolymer used as an active ingredient of a stain-proof-type, water- and oil-repellent that can apply effective stain-proof finish and stain removal finish to fiber fabrics, particularly cotton fabrics and cotton blended fabrics, and that has excellent washing durability; and also to provide a water- and oil-repellent comprising this fluorine-containing copolymer as an active ingredient.
The above object of the present invention can be achieved by a fluorine-containing copolymer that is a copolymer of a polyfluoroalkyl alcohol (meth)acrylic acid derivative represented by the general formula:
CnF2n+1(CH2CF2)a(CF2CF2)b(CH2CH2)cOCOCR═CH2 [I]
wherein R is a hydrogen atom or a methyl group, n is an integer of 1 to 6, a is an integer of 1 to 4, b is an integer of 1 to 3, and c is an integer of 1 to 3; and a (meth)acrylic acid polyoxyalkylene ester represented by the general formula:
R1(OR2)p(OR3)qOCOCR═CH2 [II]
wherein R is a hydrogen atom or a methyl group, R1 is a hydrogen atom, a linear or branched alkyl group having 1 to 30 carbon atoms, or an aromatic group, R2 and R3 are different each other and each is a linear or branched alkylene group having 1 to 6 carbon atoms, p is an integer of 1 to 100, and q is an integer of 0 or 1 to 50, provided that when p is 1 and q is 0, R1 is an aforementioned alkyl group or an aromatic group; and by a water- and oil-repellent comprising this fluorine-containing copolymer as an active ingredient. The term “(meth)acrylic acid” as used herein refers to acrylic acid or methacrylic acid.
The present invention provides a novel fluorine-containing copolymer that is a copolymer of a polyfluoroalkyl alcohol (meth)acrylic acid derivative represented by the general formula [I] and a (meth)acrylic acid polyoxyalkylene ester represented by the general formula [II].
When a water- and oil-repellent comprising this novel fluorine-containing copolymer as an active ingredient is applied to fiber fabrics, particularly cotton fabrics or cotton blended fabrics, it can apply effective stain-proof finish and stain removal finish to the fiber fabrics. In addition, the stain-proof-type, water- and oil-repellent has excellent washing durability.
The polyfluoroalkyl alcohol (meth)acrylic acid derivative represented by the general formula:
CnF2n+1(CH2CF2)a(CF2CF2)b(CH2CH2)cOCOCR═CH2 [I]
The (meth)acrylic acid polyoxyalkylene ester to be copolymerized with this polyfluoroalkyl alcohol (meth)acrylic acid derivative and represented by the general formula:
R1(OR2)p(OR3)qOCOCR═CH2 [II]
R2 and R3 are different each other and each is a linear or branched alkylene group having 1 to 6 carbon atoms, such as —CH2CH2—, —CH2CH2CH2—, —CH2CH(CH3)—, —CH2CH2CH2CH2—, —CH2CH2CH2CH2CH2CH2—, etc. Preferably, R2 is an ethylene group, and R3 is a propylene group or a butylene group. However, when p is 1 and q is 0, R1 is an aforementioned alkyl group or an aromatic group. In this embodiment, when R1 is a hydrogen atom, this forms 2-hydroxyethyl (meth)acrylate HOCH2CH2OCOCR═CH2, which is a crosslinkable group-containing monomer; thus, R1 is limited to an alkyl group or an aromatic group. On the other hand, q is an integer of 0 or 1 to 50. When q is 0 and R2 is an ethylene group, a (poly)ethylene glycol mono(meth)acrylate derivative is formed.
Practically, commercial products, such as Blemmer (registered trademark; produced by NOF Corporation) represented by the formula:
R1(OC4H8)q(OC3H6)q(OC2H4)OCOCR═CH2
can be directly used singly or in combination.
Such a polyfluoroalkyl alcohol (meth)acrylic acid derivative [I] and a (meth)acrylic acid polyoxyalkylene ester [II] can be copolymerized at any ratio. More specifically, the weight ratio of [I] and [II] is 1 to 99:99 to 1, preferably 20 to 70:80 to 30 (provided that the total of both is 100). Their copolymerization ratio is determined by the relationship between the water- and oil-repellency and solubility in a solvent of the fluorine-containing copolymer. When the copolymerization ratio of the polyoxyalkylene ester [II] is less than this range, the copolymer is poorly soluble in the reaction solvent and the diluent solvent, and stain removal effect is not sufficient. In contrast, when the copolymerization ratio of the polyoxyalkylene ester [II] is greater than this range, the water- and oil-repellency is impaired. The obtained copolymer has a weight average molecular weight (Mw; polystyrene conversion) of 1,000 to 1,000,000, preferably 2,000 to 500,000.
The copolymer can be further copolymerized with a fluorine atom-free polymerizable monomer and/or another fluorine-containing polymerizable monomer. When another fluorine-containing polymerizable monomer is used, the number of carbon atoms of the polyfluoroalkyl group, preferably perfluoroalkyl group, of the monomer must be 1 to 6, preferably 2 to 4.
As the fluorine atom-free polymerizable monomer to be copolymerized with the polyfluoroalkyl alcohol (meth)acrylic acid derivative [I] and the (meth)acrylic acid polyoxyalkylene ester [II], at least one of (meth)acrylic acid esters represented by the following general formulae [III], [IV], and [V] is preferably used.
CH2═CR1COOR3 [III]
CH2═CR1COOR6Y [IV]
CH2═CR1COO(R7O)1R8 [V]
Moreover, examples of the fluorine atom-free polymerizable monomer, including the above compounds [III], [IV], and [V], are acrylic acid esters or methacrylic acid esters etherified with alkyl groups, such as methyl, ethyl, propyl, isopropyl, n-butyl, n-hexyl, 2-ethylhexyl, n-octyl, lauryl, and stearyl; cycloalkyl groups, such as cyclohexyl; aralkyl groups, such as benzyl; alkoxyalkyl groups, such as methoxymethyl, 2-methoxyethyl, 2-ethoxyethyl, 2-butoxyethyl, and 3-ethoxypropyl; fumaric acid or maleic acid ester esterified with monoalkyl esters or dialkyl esters, such as monomethyl, dimethyl, monoethyl, diethyl, monopropyl, dipropyl, monobutyl, dibutyl, mono-2-ethylhexyl, di-2-ethylhexyl, monooctyl, and dioctyl; and vinyl esters, such as vinyl acetate and vinyl caprylate. Preferably, alkyl (meth)acrylate containing a long chain alkyl group having 8 or more carbon atoms are used. Specific examples thereof include acrylic acid esters etherified with alkyl groups, such as 2-ethylhexyl, n-octyl, lauryl, and stearyl; cycloalkyl groups, such as cyclohexyl; and aralkyl groups, such as benzyl. More preferably, a combination of an acrylic acid ester etherified with an alkyl group, such as 2-ethylhexyl or stearyl, and a (meth)acrylic acid ester etherified with an aralkyl group, such as benzyl, is used in terms of the balance between water-repellency and oil-repellency.
Usable fluorine-containing polymerizable monomers are represented by the general formula:
CH2═CRCOOR9(NR10SO2)mRf [VI]
Further, if necessary, a polyfunctional monomer or oligomer can be copolymerized in a ratio of 10 wt. % or less in the copolymer. Examples of the polyfunctional monomer or oligomer include ethyleneglycol di(meth)acrylate, propyleneglycol di(meth)acrylate, 1,4-butanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, 1,9-nonanediol di(meth)acrylate, neopentylglycol di(meth)acrylate, tetraethyleneglycol di(meth)acrylate, tripropyleneglycol di(meth)acrylate, polypropyleneglycol di(meth)acrylate, Bisphenol A·ethylene oxide adduct diacrylate, dimethylol tricyclodecane diacrylate, glycerin methacrylate acrylate, 3-acryloyloxyglycerin monomethacrylate, and the like.
In terms of cost, a copolymer with a fluorine atom-free polymerizable comonomer is advantageous. It is preferable, in terms of both water- and oil-repellency and cost, to copolymerize a fluorine atom-free polymerizable monomer in about 30 wt. % or less, preferably about 1 to 30 wt. %, more preferably about 1 to 10 wt. %, in the copolymer.
Furthermore, a crosslinkable group-containing monomer, such as 2-hydroxyethyl (meth)acrylate, 3-hydroxypropyl (meth)acrylate, (meth)acrylamide, N-methylol (meth)acrylamide, N-methoxymethyl acrylamide, N-butoxymethyl acrylamide, or glycidyl (meth)acrylate, can be added and copolymerized in a ratio of about 10 wt. % or less, preferably about 0.5 to 10 wt. %, in the copolymer. When such a crosslinkable group-containing monomer is further copolymerized, crosslinking with the hydroxyl group on the fiber surface or self-crosslinking occurs to thereby enhance the durability of the water- and oil-repellent.
Although the copolymerization reaction may be performed by emulsion polymerization or suspension polymerization, the reaction is preferably performed by solution polymerization. Usable reaction solvents for solution polymerization are alcohol-based solvents, ester-based solvents, ketone-based solvents, glycol-based solvents, etc. These solvents can be used singly or in combination of two or more.
Examples of alcohol solvents include linear or branched alkanols having 1 to 8 carbon atoms. Usable alkanols are not only 1-alkanol, but also 2-alkanol, etc. Examples of ester solvents include methyl, ethyl, propyl, and butyl ester of acetic acid; methyl propionate; methyl, ethyl, and pentyl ester of lactic acid; and the like. Examples of ketone solvents include acetone, methyl ethyl ketone, methyl isobutyl ketone, 2-pentanone, 3-pentanone, 2-hexanone, and the like. Examples of glycol solvents include ethylene glycol, propylene glycol, dipropylene glycol, or monomethyl ethers thereof, tripropylene glycol, and the like.
Examples of polymerization initiators include oil-soluble or water-soluble peroxides or azobis compounds, such as benzoyl peroxide, lauroyl peroxide, tert-butyl peroxide, cumene hydroperoxide, tert-butyl peroxypivalate, diisopropyl peroxydicarbonate, tert-butyl perbenzoate, 1-hydroxycyclohexyl hydroperoxide, 3-carbonyl propionyl peroxide, acetyl peroxide, azobis(isobutylamidine) dihydrochloride, azobis(isobutyronitrile), azobis(2,4-dimethylvaleronitrile), sodium peroxide, potassium peroxide, and ammonium peroxide. Such a polymerization initiator is used at about 0.01 to 5 wt. %, preferably about 0.1 to 5 wt. %, based on the total amount of the comonomers. The polymerization initiator is added to the reaction system as a polymerization initiator solution, wherein part of the reaction solvent in used.
Further, in order to adjust the molecular weight, a chain transfer agent can be used, if necessary. Examples of chain transfer agents include alkyl mercaptans, such as n-octyl mercaptan, n-dodecyl mercaptan, and t-dodecyl mercaptan; dimethyl ether, methyl tert-butyl ether, C1-C6 alkanes, methanol, ethanol, 2-propanol, cyclohexane, carbon tetrachloride, chloroform, dichloromethane, methane, ethyl acetate, ethyl malonate, acetone, and the like.
The copolymerization reaction is performed using such a reaction solvent, reaction initiator, etc., at a reaction temperature of at about 0 to 100° C., preferably about 5 to 70° C., particularly preferably about 40 to 65° C. After completion of the reaction, a copolymer solution having a solid matters content of about 5 to 30 wt. % is obtained. The solvent is removed from this reaction mixture, thereby obtaining a fluorine-containing copolymer. Generally, the copolymer solution is further diluted with water or an organic solvent to a solid matters content of about 0.05 to 10 wt. %, preferably about 0.1 to 5 wt. %, as required. This diluted solution can be used to prepare a water- and oil-repellent. Examples of organic solvents usable herein include alcohol solvents, ester solvents, ketone solvents, and glycol organic solvents, as mentioned above. The organic solvent used herein may be different from the polymerization reaction solvent.
To the resulting diluted copolymer solution, a blocked isocyanate is added as an cross-linking agent in a weight ratio of 0.05 to 3.0, preferably 0.2 to 2.0, to the weight of solid matters content of the copolymer solution. The blocked isocyanate can impart excellent water-repellency and high washing resistance to also natural fibers such as cotton. When the amount of the blocked isocyanate is lower than the above-mentioned ratio, the washing resistance is decreased. On the other hand, when the blocked isocyanate is used in an amount higher than the ratio, the textile feeling of a fabric is deteriorated. (see Patent Document 6)
The blocked isocyanate herein is a compound having one or more blocked isocyanate group and not having a polymerizable carbon-carbon unsaturated bond, i.e., a compound having a structure in which the isocyanate group is blocked with a blocking agent. As such a blocked isocyanate, a preferred structure is obtained by reacting a polyisocyanate and a compound having two or more active hydrogen atoms in a molecule thereof and blocking the isocyanate group of the resulting compound with a blocking agent.
Examples of the polyisocyanate include aromatic isocyanates such as 4,4′-diphenylmethane diisocyanate, 2,4′-diphenylmethane diisocyanate, and tolylene diisocyanate; aliphatic isocyanates such as trimethylene diisocyanate, tetramethylene diisocyanate, pentamethylene diisocyanate, hexamethylene diisocyanate, 1,2-propane diisocyanate, 1,2-butane diisocyanate, trimethylhexamethylene diisocyanate, isophorone diisocyanate, 4,4′-dicyclohexylmethane diisocyanate, and cyclohexylene diisocyanate; and their isocyanurate modified compounds, prepolymer modified compounds, biuret modified compounds, and allophanate modified compounds.
The compound having two or more active hydrogen atoms in the molecule is preferably a polyvalent alcohol or a polyvalent amine. Examples of the polyvalent alcohol include ethylene glycol, propylene glycol, butanediols, pentanediols, hexanediols, glycerin, trimethylolpropane, pentaerythritol, sorbitol, neopentyl glycol, bisphenol A, xylylene glycol, and at least one of modified compounds of these alcohols. Examples of the polyvalent amine include hexamethylenediamine and 3,3′-iminobispropylamine. The polyvalent alcohol herein may be a polyester polyol, and as the polyester polyol, those having an ester bond obtained by a reaction of a polyvalent alcohol and a polyvalent carboxylic acid such as phthalic acid, adipic acid, fumaric acid, pyromellitic acid, trimellitic acid, aliphatic dicarboxylic acid, or a derivative thereof are used.
As the blocking agent for the isocyanate, alkyl ketone oximes, phenols, alcohols, β-diketones, and lactams are used, and preferably, methyl ethyl ketone oxime, ε-caprolactam, phenol, cresol, acetylacetone, diethyl malonate, isopropyl alcohol, tert-butyl alcohol, and maleic acid imide, more preferably compounds having a dissociation temperature of from 120 to 180° C. represented by dialkyl ketone oximes such as methyl ethyl ketone oxime and lactams such as ε-caprolactam are used.
The blocked isocyanate is obtained by, as described above, reacting a polyvalent alcohol to an isocyanate compound and then reacting the resulting compound to a blocking agent. These reactions are preferably performed in a non-aqueous solvent such as ketones, ethers, or hydrocarbons. In addition, it is preferable that the equivalent weights of the isocyanate compound, the compound having two or more active hydrogen atoms, and the blocking agent become equal to one another at the time of completion of all the reactions.
After the above-described blocking reaction, the blocked isocyanate is preferably emulsified with water and a nonionic emulsifier, a nonionic/cationic emulsifier, or a nonionic/anionic emulsifier, in particular, a nonionic/cationic emulsifier. The solvent is removed after the emulsification, according to need.
As the blocked isocyanate, commercially available products, for example, RucoGuard XTS, a Rudolf product; RucoGuard WEB, a Rudolf product; NK Assist-NY, a Nikka Chemical product; NK Assist-V, a Nikka Chemical product; NK Assist-FU, a Nikka Chemical product; Prominate XC-830, a Gantsu Chemical product; Prominate XC-915, a Gantsu Chemical product; Prominate XC-950, a Gantsu Chemical product; and Elastron BN-69, a Daiichi Kogyo Seiyaku product can be used as such.
The copolymer solution can further contain other additives indispensable for the water- and oil-repellent use, for example, a cross-linking agent other than the blocked isocyanate, such as a melamine resin or a urea resin, a polymer extender, another water-repellent such as a silicone resin or oil, or wax, an insecticide, an antistatic agent, a dye stabilizer, an anticreasing agent, and a stain blocker.
The thus obtained copolymer solution containing the blocked isocyanate is effectively applied, as a water- and oil-repellent, to, for example, fibers, a fabric, a woven fabric, paper, a film, a carpet, or a fabric product made of filaments, threads, or fibers. The application is performed by coating, dipping, spraying, padding, roll coating, or a combination thereof. For example, a bath containing a solid matters content in a concentration of about 0.1 to 10% by weight is used as a pad bath. A material to be treated is padded in this pad bath and is then subjected to removal of excessive liquid with a squeezing roller, followed by drying, thereby allowing the fluorine-containing copolymer to adhere to the material to be treated in a ratio of about 0.01 to 10% by weight to the amount of the material. Subsequently, drying, which varies depending on the type of the material to be treated, is usually conducted at about 100 to 120° C. for about from 1 minute to 2 hours to complete the water- and oil-repellent treatment.
The present invention will be described with reference to examples below.
(1) In a 1200-mL autoclave equipped with a stirrer and a thermometer, 603 g (1.17 mol) of
CF3(CF2)3(CH2CF2)(CF2CF2)I (99.8GC %)
and 7 g of di-tertiary butyl peroxide were charged, and the autoclave was deaerated with a vacuum pump. When the inner temperature was increased to 80° C., ethylene was sequentially introduced into the autoclave to adjust the inner pressure to 0.5 MPa. When the inner pressure was decreased to 0.2 MPa, ethylene was introduced again to increase the inner pressure to 0.5 MPa. This process was repeated to introduce 49 g (1.7 mol) of ethylene over about 3 hours, while maintaining the inner temperature at 80 to 115° C. The content was collected at an inner temperature of 50° C. or lower to obtain 635 g (yield: 98.8%) of
CF3(CF2)3(CH2CF2)(CF2CF2)(CH2CH2)I (98.3GC %).
(2) In a 200-mL three-neck flask equipped with a condenser and a thermometer, 100 g (0.18 mol) of
CF3(CF2)3(CH2CF2)(CF2CF2)(CH2CH2)I (98.3GC %)
prepared in the above (1) and 100 g (1.68 mol) of N-methyl formamide were charged, followed by stirring at 150° C. for 4 hours. After the completion of the reaction, the reaction mixture was washed with 30 mL of water. The lower layer (82.8 g) was mixed with 83 g of a 15 wt % p-toluenesulfonic acid aqueous solution, followed by stirring at 80° C. for 8 hours. The reaction mixture was left standing, and then 60 g of a reaction product (78.4GC %), being a transparent, colorless liquid at room temperature, was obtained as the lower layer (yield: 62.6%).
The reaction product was subjected to reduced pressure distillation under conditions of an inner pressure of 0.2 kPa, an inner temperature of 100 to 144° C., and a column top temperature of 58 to 59° C. to obtain 43.7 g (distillation yield: 88.2%) of a purified reaction product (95.4GC %).
The resulting purified reaction product was confirmed by the results of 1H-NMR and 19F-NMR to be the compound represented by the following formula:
CF3(CF2)3(CH2CF2)(CF2CF2)(CH2CH2)OH
(3) 40.0 g (0.09 mol) of the reaction product (95.4GC %) prepared in the above (2), 21 g of toluene, 1.7 g of p-toluenesulfonic acid, and 0.05 g of hydroquinone were charged in a 100-mL three-neck flask equipped with a condenser and a thermometer. After the inner temperature was increased to 100° C., 10.2 g (0.14 mol) of acrylic acid was added in the flask, followed by stirring at an inner temperature of 115° C. for 2 hours. After the completion of the reaction, 72 g of the reaction solution was collected after being cooled. Toluene was removed with an evaporator, and 44.5 g of the residue was washed with tap water to obtain 40.9 g (yield: 82.6%) of a reaction product (86.3GC %), being a transparent, colorless liquid at room temperature, was obtained as the lower layer.
The reaction product was subjected to reduced pressure distillation under conditions of an inner pressure of 0.2 kPa, an inner temperature of 103 to 143° C., and a column top temperature of 60 to 61° C. to obtain 15.7 g (distillation yield: 44.1%) of a purified reaction product (99.2GC %).
The resulting purified reaction product was confirmed by the results of 1H-NMR and 19F-NMR to be the compound represented by the following formula:
CF3(CF2)3(CH2CF2)(CF2CF2)(CH2CH2)OCOCH═CH2 [Fluorine-containing monomer A]
(1) A reaction for introducing 34 g (1.2 mol) of ethylene was performed, as in Synthesis Example 1 (1), using 529 g (0.86 mol) of
CF3(CF2)3(CH2CF2)(CF2CF2)2I (99.9GC %)
and 5 g of the di-tertiary butyl peroxide to obtain 550 g (yield: 99.4%) of
CF3(CF2)3(CH2CF2)(CF2CF2)2(CH2CH2)I (99.1GC %).
(2) In a 200-mL three-neck flask equipped with a condenser and a thermometer, 150 g (0.24 mol) of
CF3(CF2)3(CH2CF2)(CF2CF2)2(CH2CH2)I (99.1GC %)
prepared in the above (1) and 105 g (1.78 mol) of N-methyl formamide were charged, followed by stirring at 150° C. for 5 hours. After the completion of the reaction, the reaction mixture was washed with 40 mL of water. The lower layer (132.3 g) was mixed with 135 g of a 15 wt % p-toluenesulfonic acid aqueous solution, followed by stirring at 80° C. for 7 hours. The reaction mixture was left standing, and then 103 g (yield: 53.5%) of a reaction product (65.5GC %), being a white solid, was obtained as the lower layer.
The reaction product was subjected to reduced pressure distillation under conditions of an inner pressure of 0.2 kPa, an inner temperature of 121 to 163° C., and a column top temperature of 76 to 77° C. to obtain 66.9 g (distillation yield: 94.2%) of a purified reaction product (95.3GC %).
The resulting purified reaction product was confirmed by the results of 1H-NMR and 19F-NMR to be the compound represented by the following formula:
CF3(CF2)3(CH2CF2)(CF2CF2)2(CH2CH2)OH
(3) 60.0 g (0.11 mol) of the reaction product (95.4GC %) prepared in the above (2), 29 g of toluene, 1.6 g of p-toluenesulfonic acid, and 0.07 g of hydroquinone were charged in a 100-mL three-neck flask equipped with a condenser and a thermometer. After the inner temperature was increased to 100° C., 10 g (0.14 mol) of acrylic acid was added in the flask, followed by stirring at an inner temperature of 118° C. for 3 hours. After the completion of the reaction, 82 g of the reaction solution was collected after being cooled. Toluene was removed with an evaporator, and 63.9 g of the residue was washed with tap water to obtain 60.8 g (yield: 86.4%) of a reaction product (89.3GC %), being a transparent, colorless liquid at room temperature, was obtained as the lower layer.
The reaction product was subjected to reduced pressure distillation under conditions of an inner pressure of 0.2 kPa, an inner temperature of 125 to 155° C., and a column top temperature of 84 to 86° C. to obtain 42.2 g (distillation yield: 77.2%) of a purified reaction product (99.4GC %).
The resulting purified reaction product was confirmed by the results of 1H-NMR and 19F-NMR to be the compound represented by the following formula:
CF3(CF2)3(CH2CF2)(CF2CF2)2(CH2CH2)OCOCH═CH2 [Fluorine-containing monomer B]
60.0 g (0.11 mol) of the reaction product (95.4GC %) prepared in Synthesis Example 2 (2), 29 g of toluene, 1.6 g of p-toluenesulfonic acid, and 0.07 g of hydroquinone were charged in a 100-mL three-neck flask equipped with a condenser and a thermometer. After the inner temperature was increased to 100° C., 12 g (0.14 mol) of methacrylic acid was added in the flask, followed by stirring at an inner temperature of 118° C. for 3 hours. After the completion of the reaction, 82 g of the reaction solution was collected after being cooled. Toluene was removed with an evaporator, and 64 g of the residue was washed with tap water to obtain 60.8 g (yield: 86%) of a reaction product (89GC %), being a transparent, colorless liquid at room temperature, was obtained as the lower layer.
The reaction product was subjected to reduced pressure distillation under conditions of an inner pressure of 0.2 kPa, an inner temperature of 125 to 155° C., and a column top temperature of 84 to 86° C. to obtain 42.2 g (distillation yield: 77.2%) of a purified reaction product (99.4GC %).
The resulting purified reaction product was confirmed by the results of 1H-NMR and 19F-NMR to be the compound represented by the following formula:
CF3(CF2)3(CH2CF2)(CF2CF2)(CH2CH2)OCOCH═CH2 [Fluorine-containing monomer C]
(1) In a 1200-mL autoclave equipped with a stirrer and a thermometer, 603 g (1.17 mol) of
CF3(CF2)(CH2CF2)(CF2CF2)2I (97GC %)
and 7 g of di-tertiary butyl peroxide were charged, and the autoclave was deaerated with a vacuum pump. When the inner temperature was increased to 80° C., ethylene was sequentially introduced into the autoclave to adjust the inner pressure to 0.5 MPa. When the inner pressure was decreased to 0.2 MPa, ethylene was introduced again to increase the inner pressure to 0.5 MPa. This process was repeated to introduce 49 g (1.7 mol) of ethylene over about 3 hours, while maintaining the inner temperature at 80 to 115° C. The content was collected at an inner temperature of 50° C. or lower to obtain 630 g (yield: 98.8%) of
CF3(CF2)(CH2CF2)(CF2CF2)2(CH2CH2)I (98GC %).
(2) In a 200-mL three-neck flask equipped with a condenser and a thermometer, 100 g (0.18 mol) of
CF3(CF2)(CH2CF2)(CF2CF2)2(CH2CH2)I (98GC %)
prepared in the above (1) and 100 g (1.68 mol) of N-methyl formamide were charged, followed by stirring at 150° C. for 4 hours. After the completion of the reaction, the reaction mixture was washed with 30 mL of water. The lower layer (82.8 g) was mixed with 83 g of a 15 wt % p-toluenesulfonic acid aqueous solution, followed by stirring at 80° C. for 8 hours. The reaction mixture was left standing, and then 60 g (yield: 62%) of a reaction product (78GC %), being a transparent, colorless liquid at room temperature, was obtained as the lower layer.
The reaction product was subjected to reduced pressure distillation under conditions of an inner pressure of 0.2 kPa, an inner temperature of 100 to 144° C., and a column top temperature of 58 to 59° C. to obtain 43 g (distillation yield: 88%) of a purified reaction product (95GC %).
The resulting purified reaction product was confirmed by the results of 1H-NMR and 19F-NMR to be the compound represented by the following formula:
CF3(CF2)(CH2CF2)(CF2CF2)2(CH2CH2)OH
(3) 40.0 g (0.09 mol) of the reaction product (95GC %) prepared in the above (2), 21 g of toluene, 1.7 g of p-toluenesulfonic acid, and 0.05 g of hydroquinone were charged in a 100-mL three-neck flask equipped with a condenser and a thermometer. After the inner temperature was increased to 100° C., 10.2 g (0.14 mol) of acrylic acid was added in the flask, followed by stirring at an inner temperature of 115° C. for 2 hours. After the completion of the reaction, 72 g of the reaction solution was collected after being cooled. Toluene was removed with an evaporator, and 44.5 g of the residue was washed with tap water to obtain 41 g (yield: 82%) of a reaction product (86GC %), being a transparent, colorless liquid at room temperature, was obtained as the lower layer.
The reaction product was subjected to reduced pressure distillation under conditions of an inner pressure of 0.2 kPa, an inner temperature of 103 to 143° C., and a column top temperature of 60 to 61° C. to obtain 16 g (distillation yield: 44%) of a purified reaction product (99GC %).
The resulting purified reaction product was confirmed by the results of 1H-NMR and 19F-NMR to be the compound represented by the following formula:
CF3(CF2)(CH2CF2)(CF2CF2)2(CH2CH2)OCOCH═CH2 [Fluorine-containing monomer D]
The above components, other than the AIBN ethanol solution, were placed in a 500-ml glass reactor and mixed, and the air in the reactor was replaced with nitrogen gas for 30 minutes. Then, the temperature in the reactor was gradually raised. When the temperature reached 40° C., 15 g of AIBN ethanol solution (polymerization initiator solution) was supplied. The internal temperature of the reactor was further gradually raised to 65° C., and the mixture was reacted at that temperature for 24 hours. The polymerization reaction was carried out by stirring at a rotation frequency of 400 rpm.
After completion of the reaction, the reaction mixture was cooled, thereby obtaining 283.0 g (recovery rate: 94.3%) of an ethanol dispersion having a solid matters content of 28.60 wt. %. The dispersion was further diluted with ethanol to form an ethanol dispersion having a solid matters content of 20 wt. %. The viscosity (25° C.) of the ethanol dispersion measured was 21.8 mPa·s.
The obtained ethanol dispersion was placed in a vacuum oven at 120° C., and the solvent was removed to isolate a fluorine-containing polymer, which had a weight average molecular weight Mw of 35,000 and an Mw/Mn value of 2.5. Here, the weight average molecular weight Mw and the number average molecular weight Mn were measured by GPC using Shodex GPC KD 806+KD-802 at a temperature of 40° C., and using 10-mM THF as an eluate at a flow rate of 1 ml/min. A differential refractometer was used as the detector, and an SIC Labchart 180 (polystyrene conversion) was used for analysis.
(2) The ethanol dispersion before dilution (11.2 g) and 2.0 g of a blocked isocyanate crosslinking agent (CL-40, produced by Unimatec Co., Ltd.; active ingredient concentration: 60 wt. %) were added and mixed with 186.8 g of water (total amount: 200.0 g), thereby obtaining a treatment solution.
A polyester-cotton (65:35) blended fabric was immersed in the treatment solution, and squeezed by a mangle (two-roll wringer), thereby attaching the treatment solution to the fabric in an amount of 100 wt. % based on the weight of the fabric. Then, the fabric was heated at 160° C. for 120 seconds, followed by drying and curing.
(3) The obtained cured blended fabric was measured for the following items. Stain-proof and stain removal performance test (AATCC evaluation value):
A drop of dirty motor oil after 4,000-km running was added to the treated fabric, and a load of 7 gf/cm2 (686 Pa) was applied for 1 minute. The fabric was then allowed to stand at room temperature for 1 hour. Thereafter, the fabric was washed by a washing method 1 [using 30 L of an aqueous solution of a detergent (Attack, produced by Kao Corporation; concentration: 0.67 g/L) at 40° C. (bath ratio=1:30; the amount of detergent aqueous solution per kg of fabric was 30 L), the fabric was washed in a washing machine for 15 minutes and then dehydrated for 3 minutes, followed by rinsing for 15 minutes, dehydration for 10 minutes, and air-drying or drying in an oven at 80° C. for 5 minutes]. The dried test fabric was evaluated by the following criteria (according to AATCC-TM130-1966).
Evaluation criteria:
The treated fabric that had been stained with dirty motor oil in the same manner as in the initial performance evaluation was washed by a washing method 2 [in the washing method 1, the amount of detergent aqueous solution was changed to 20 L (bath ratio=1:30), the washing time was changed to 50 minutes, the time of the final dehydration was changed to 5 minutes, and the drying time in the oven was changed to 10 minutes]. Then, the washing durability was evaluated in the same manner as the initial performance.
The reflectance of the test fabric after washing and drying used in the initial performance evaluation (Initial) and the washing durability evaluation (Washing) was measured by a spectrocolorimeter (CM-1000, produced by Konica Minolta Sensing, Inc.), and the white coefficient (W.I %) was calculated. The degree of stain removal was evaluated from the size of the white coefficient (the evaluation was such that the lower the white coefficient was, the higher the degree of stain was). Water- and oil-repellency evaluation:
The water repellency (according to JIS L1092) and oil repellency (according to AATCC-TM118-1992) of the test fabric after washing and drying used in the initial performance evaluation (Initial) and the washing durability evaluation (Washing) were measured. The evaluation criteria of the water repellency were determined in accordance with the standard of the above-mentioned JIS.
The evaluation criteria of the oil repellency were determined in accordance with the standard of the above-mentioned AATCC-TM118. A drop of a test solution was added to the fabric, to which oil-repellent finish had been applied, and the status of the drop after 30 seconds was observed. When the drop of the test solution remained on the fabric, another test was performed using a test solution of a larger number. Using a test solution that marginally remained on the fabric, the oil repellency was evaluated by criteria shown in the following table (the value when 100% Nujol was not maintained was 0).
In Example 1,
(1) The amounts of the components and the polymerization conditions were changed in various ways. However, in Example 2, a polymerization initiator solution comprising 1.0 g of azobis(2,4-dimethylvaleronitrile) and 16.0 g of polypropylene glycol monomethyl ether was used, the polymerization time was changed to 6 hours, and the polymerization temperature was changed to 70° C.
(2) The preparation of a treatment solution and the treatment with the treatment solution were performed in the same manner.
(3) The obtained cured blended fabrics were subjected to the same measurement.
Table 1 below shows the amounts of the components, the polymerization conditions, and the measurement results in the Examples.
In Example 1,
(1) The same amount (41.0 g) of FAAC-8, FAMAC-6, or FAAC-6 was used, respectively, in place of the fluorine-containing monomers A to C. Moreover, in Comparative Example 1, the amount of chain transfer agent was changed to 0.4 g, and the amount of polymerization initiator was changed to 3.1 g.
(2) The preparation of a treatment solution and the treatment with the treatment solution were performed in the same manner.
(3) The obtained cured blended fabrics were treated in the same manner.
(1) In Comparative Example 2, neither 2HEA nor B-MAM was used, and each amount of FAMAC-6 and PPOEOMA was changed to 45.0 g (50.0 wt. %).
(2) The preparation of a treatment solution and the treatment with the treatment solution were performed in the same manner as in Comparative Example 2.
(3) The obtained cured blended fabric was treated in the same manner as in Comparative Example 2.
In Example 1,
PEG-PPG monomethacrylate was not used, the amount of fluorine-containing monomer was changed to 82.0 g (91.1%), the amount of chain transfer agent was changed to 0.4 g, and the amount of azobis(isobutyronitrile) was changed to 3.1 g.
The obtained copolymer was coagulated and precipitated, and a stable ethanol dispersion was not obtained. Accordingly, the properties of the produced dispersion and copolymer, the treatment solution, and the measurement results are not shown.
In Example 2,
the same amount (40.0 g; 49.4%) of stearyl acrylate was used in place of methoxy polyethylene glycol monomethacrylate.
The obtained copolymer was coagulated and precipitated, and a stable ethanol dispersion was not obtained. Accordingly, the properties of the produced dispersion and copolymer, the treatment solution, and the measurement results are not shown.
Table 2 below shows the amounts of the components, the polymerization conditions, and the measurement results in Comparative Examples 1 to 4.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-271275 | Dec 2011 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2012/079785 | 11/16/2012 | WO | 00 | 6/12/2014 |
