Patent Application
20160017198
The present invention relates to fluorine-containing nano-silica composite particles and a method for producing the same. More particularly, the present invention relates to fluorine-containing nano-silica composite particles using a fluorine-containing alcohol, and a method for producing the same.
Patent Document 1 discloses a liquid, fluorine-containing and single-component composition for the permanent oil- and water-repellent surface treatment of porous and nonporous substrates, wherein the composition comprises a suitable stabilizing component and a hydrophilic silane component in combination, and has excellent storage stability, and hydrophobic, oleophobic and dust proof properties.
However, in the preparation of a surface treating agent for mineral and non-mineral substrates, a highly toxic isocyanate compound is used to introduce a silyl group into a fluorine compound. Therefore, its implementation requires the regulation of the production environment. Moreover, perfluorooctanoic acid and a fluorine-containing alcohol containing a perfluoroalkyl group having 8 or more carbon atoms, which is a precursor of perfluorooctanoic acid, are used, although less use of them is currently desired in terms of the current state of the environment.
Patent Document 1: JP-A-2011-511113
Patent Document 2: JP-B-4674604
Patent Document 3: WO 2007/080949 A1
Patent Document 4: JP-A-2008-38015
Patent Document 5: U.S. Pat. No. 3,574,770
An object of the present invention is to provide fluorine-containing nano-silica composite particles having excellent water- and oil-repellency, and using a fluorine-containing alcohol which does not produce perfluorooctanoic acid and the like, even when released into the environment, in the case of a perfluoroalkyl group having less than 8 carbon atoms, and to provide a method for producing the same.
The present invention provides fluorine-containing nano-silica composite particles comprising a condensate of a fluorine-containing alcohol represented by the general formula:
RF-A-OH [I]
wherein RF is a perfluoroalkyl group or a polyfluoroalkyl group in which some of the fluorine atoms of the perfluoroalkyl group are replaced by hydrogen atoms, and A is an alkylene group having 1 to 6 carbon atoms; and an alkoxysilane with nano-silica particles.
The fluorine-containing nano-silica composite particles are produced by a method comprising subjecting the above fluorine-containing alcohol [I] and an alkoxysilane to a condensation reaction in the presence of nano-silica particles using an alkaline or acidic catalyst. The obtained fluorine-containing nano-silica composite particles are used as an active ingredient of surface treating agents, such as water- and oil-repellents.
Moreover, the present invention provides fluorine-containing nano-silica composite particles comprising a condensate of a fluorine-containing alcohol represented by the general formula:
RF′-A-OH [Ia]
or the general formula:
HO-A-RF″-A-OH [Ib]
wherein RF′ is a linear or branched perfluoroalkyl group containing an O, S, or N atom, RF″ is a linear or branched perfluoroalkylene group containing an O, S, or N atom, and A is an alkylene group having 1 to 6 carbon atoms; and an alkoxysilane with nano-silica particles.
The fluorine-containing nano-silica composite particles are produced by a method comprising subjecting the above fluorine-containing alcohol [Ia] or [Ib] and an alkoxysilane to a condensation reaction in the presence of nano-silica particles using an alkaline or acidic catalyst. The obtained fluorine-containing nano-silica composite particles are used as an active ingredient of surface treating agents, such as water- and oil-repellents.
The fluorine-containing nano-silica composite particles according to the present invention not only have excellent water- and oil-repellency, but also can be stably dispersed in polar solvents, such as water, alcohol, and tetrahydrofuran. The fluorine-containing nano-silica composite particles also have excellent heat resistance at a high temperature (e.g., 800° C.). Specifically, the increase in the composite particle diameter and the value of weight loss at a high temperature are reduced. Moreover, a perfluoroalkyl group having less than 8 carbon atoms do not lead to environmental pollution because they do not produce perfluorooctanoic acid and the like when released into the environment.
The fluorine-containing alcohol [I] is, for example, a polyfluoroalkyl alcohol represented by the general formula:
CnF2n+1(CH2)jOH [II]
The alkylene group A is, for example, a —CH2— group, —CH2CH2— group, or the like. Examples of perfluoroalkyl alkyl alcohols having such an alkylene group include 2,2,2-trifluoroethanol (CF3CH2OH), 3,3,3-trifluoropropanol (CF3CH2CH2OH), 2,2,3,3,3-pentafluoropropanol (CF3CF2CH2OH), 3,3,4,4,4-pentafluorobutanol (CF3CF2CH2CH2OH), 2,2,3,3,4,4,5,5,5-nonafluoropentanol (CF3CF2CF2CF2CH2OH), 3,3,4,4,5,5,6,6,6-nonafluorohexanol (CF3CF2CF2CF2CH2CH2OH), 3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluorooctanol (CF3CF2CF2CF2CF2CF2CH2CH2OH), and the like.
Moreover, a polyfluoroalkyl group refers to a group in which the terminal —CF3 group of a perfluoroalkyl group is replaced by, for example, a —CF2H group. Examples thereof include 2,2,3,3-tetrafluoropropanol (HCF2CF2CH2OH), 2,2,3,4,4,4-hexafluorobutanol (CF3CHFCF2CH2OH), 2,2,3,3,4,4,5,5-octafluoropentanol (HCF2CF2CF2CF2CH2OH), and the like.
The polyfluoroalkyl alcohol represented by the general formula [II] is described, for example, in Patent Document 2, and is synthesized through the following series of steps.
First, a polyfluoroalkyl iodide represented by the general formula:
CnF2n+1(CF2CF2)b(CH2CH2)cI
is reacted with N-methylformamide HCONH(CH3) to form a mixture of polyfluoroalkyl alcohol and its formate. Then, the mixture is hydrolyzed in the presence of an acid catalyst, thereby forming a polyfluoroalkyl alcohol of the formula:
CnF2n+1(CF2CF2)b(CH2CH2)cOH
Examples of the polyfluoroalkyl iodide include the following:
CF3(CH2CH2)I
CF3(CH2CH2)2I
C2F5(CH2CH2)I
C2F5(CH2CH2)2I
C3F7(CH2CH2)I
C3F7(CH2CH2)2I
C4F9(CH2CH2)I
C4F9(CH2CH2)2I
C2F5(CF2CF2)(CH2CH2O
C2F5(CF2CF2)(CH2CH2)2I
C2F5(CF2CF2)2(CH2CH2)I
C2F5(CF2CF2)2(CH2CH2)2I
C2F5(CF2CF2)3(CH2CH2)I
C4F9(CF2CF2)(CH2CH2O
C4F9(CF2CF2)2(CH2CH2)I
C4F9(CF2CF2)(CH2CH2)2I
C4F9(CF2CF2)2(CH2CH2)2I
C4F9(CF2CF2)3(CH2CH2)I
The fluorine-containing alcohol [I] may also be a fluorine-containing alcohol wherein the RF group is a polyfluoroalkyl group having 3 to 20 carbon atoms, preferably 6 to 10 carbon atoms, and A is an alkylene group having 2 to 6 carbon atoms, preferably 2 carbon atoms. Examples thereof include a polyfluoroalkyl alcohol represented by the general formula:
CnF2n+1(CH2CF2)a(CF2CF2)b(CH2CH2)cOH [III]
The polyfluoroalkyl alcohol represented by the general formula [III] is disclosed in Patent Document 2, and synthesized through the following series of steps.
First of all, a polyfluoroalkyl iodide represented by the general formula:
CnF2n+1(CH2CF2)a(CF2CF2)b(CH2CH2)cI
is reacted with N-methylformamide HCONH(CH3) to form a mixture of polyfluoroalkyl alcohol and its formate. The mixture is then subjected to a hydrolysis reaction in the presence of an acid catalyst to form a polyfluoroalkyl alcohol of the formula:
CnF2n+1(CH2CF2)a(CF2CF2)b(CH2CH2)cOH
Examples of the polyfluoroalkyl iodide include the following:
CF3(CH2CF2)(CH2CH2)I
C2F5(CH2CF2)(CH2CH2)I
C2F5(CH2CF2)(CH2CH2)2I
C3F7(CH2CF2)(CH2CH2O
C3F7(CH2CF2)(CH2CH2)2I
C4F9(CH2CF2)(CH2CH2O
C4F9(CH2CF2)(CH2CH2)2I
C2F5(CH2CF2)(CF2CF2)(CH2CH2O
C2F5(CH2CF2)(CF2CF2)(CH2CH2)2I
C2F5(CH2CF2)2(CF2CF2)(CH2CH2O
C2F5(CH2CF2)2(CF2CF2)(CH2CH2)2I
C4F9(CH2CF2)(CF2CF2)(CH2CH2O
C4F9(CH2CF2)2(CF2CF2)(CH2CH2O
C4F9(CH2CF2)(CF2CF2)(CH2CH2)2I
C4F9(CH2CF2)2(CF2CF2)(CH2CH2)2I
The fluorine-containing alcohol [Ia] is, for example, a fluorine-containing alcohol wherein the RF′ group is a perfluoroalkyl group having 3 to 305 carbon atoms, preferably 8 to 35 carbon atoms, and A is an alkylene group having 1 to 3 carbon atoms, preferably 1 carbon atom. Examples thereof include a hexafluoropropene oxide oligomer alcohol represented by the general formula:
CmF2m+1O[CF(CF3)CF2O]dCF(CF3)(CH2)eOH [IIa]
Moreover, the fluorine-containing alcohol [Ib] may be a fluorine-containing alcohol wherein the RF″ group is a perfluoroalkylene group having 5 to 160 carbon atoms, and A is an alkylene group having 1 to 3 carbon atoms, preferably 1 carbon atom. Examples thereof include a perfluoroalkylene ether diol represented by the general formula:
HO(CH2)fCF(CF3)[OCF2CF(CF3)]gO(CF2)hO[CF(CF3)CF2O]iCF(CF3)(CH2)fOH [IIb]
Among hexafluoropropene oxide oligomer alcohols represented by the general formula [IIa], a compound wherein m is 1 and e is 1 is described in Patent Document 3, and synthesized through the following step.
A fluorine-containing ether carboxylic acid alkyl ester represented by the general formula: CF3O[CF(CF3)CF2O]nCF(CF3)COOR (R: an alkyl group, n: an integer of 0 to 12) is subjected to a reduction reaction using a reducing agent, such as sodium boron hydride.
Moreover, a perfluoroalkylene ether diol represented by the general formula [IIb] wherein f=1 is disclosed in Patent Documents 4 and 5, and synthesized via the following series of steps:
FOCRfCOF→H3COOCRfCOOCH3→HOCH2RfCH2OH
Rf:—C(CF3)[OCF2C(CF3)]aO(CF2)cO[CF(CF3)CF2O]bCF(CF3)—
Such a fluorine-containing alcohol and an alkoxysilane are reacted in the presence of an alkaline or acidic catalyst, thereby forming fluorine-containing nano composite particles.
The alkoxysilane is represented by the general formula:
(R1O)psi(OR2)q(R3)r [IV]
The reaction between these components is performed in the presence of an alkaline or acid catalyst, such as aqueous ammonia, an aqueous solution of a hydroxide of an alkali metal or alkaline earth metal (e.g., sodium hydroxide, potassium hydroxide, or calcium hydroxide), hydrochloric acid, or sulfuric acid, at a temperature of about 0 to 100° C., preferably about 10 to 30° C., for about 0.5 to 48 hours, preferably about 1 to 10 hours.
The amount of fluorine-containing alcohol in the obtained fluorine-containing nano composite particles is about 1 to 50 mol %, preferably about 5 to 30 mol %. The composite particle size (measured by a dynamic light scattering method) is about 30 to 200 nm.
In the production of such a fluorine-containing nano composite, a condensation reaction with coexistence of organo nano-silica particles in the reaction system can produce fluorine-containing nano-silica composite particles in which a condensate comprising three components, i.e., a fluorine-containing alcohol, an alkoxysilane, and nano-silica particles, is formed.
As the nano-silica particles, organosilica sol having an average particle diameter (measured by a dynamic light scattering method) of 5 to 200 nm, preferably 10 to 100 nm, and having a primary particle diameter of 40 nm or less, preferably 5 to 30 nm, more preferably 10 to 20 nm, is used. Practically used are commercial products of Nissan Chemical Industries, Ltd., such as Methanol Silica Sol, Snowtex IPA-ST (isopropyl alcohol dispersion), Snowtex EG-ST (ethylene glycol dispersion), Snowtex MEK-ST (methyl ethyl ketone dispersion), and Snowtex MIBK-ST (methyl isobutyl ketone dispersion).
The ratio of these components is such that about 1 to 99 parts by weight, preferably about 10 to 50 parts by weight, of fluorine-containing alcohol, and about 1 to 99 parts by weight, preferably about 10 to 50 parts by weight, of alkoxysilane are used based on 100 parts by weight of the nano-silica particles. When the ratio of the fluorine-containing alcohol used is less than this range, water- and oil-repellency decreases. In contrast, when the ratio of the fluorine-containing alcohol used is greater than this range, dispersibility in solvents becomes poor. Moreover, when the ratio of alkoxysilane used is less than this range, dispersibility in solvents becomes poor. In contrast, when the ratio of alkoxysilane used is greater than this range, water- and oil-repellency decreases.
In the fluorine-containing nano-silica composite particles obtained as a reaction product, it is considered that the fluorine-containing alcohol is linked to a hydroxyl group on the surface of the nano-silica particles via a siloxane bond as a spacer. Therefore, the chemical and thermal stability of silica, and the excellent water- and oil-repellency, antifouling properties, and the like of fluorine are effectively exhibited. In fact, a glass surface treated with the fluorine-containing nano-silica composite particles exhibits excellent water- and oil-repellency, and also has the effect of, for example, reducing the weight loss at 800° C. Moreover, the particle size of the nano-silica composite particles, and the variation of the particle size show small values. The nano-silica composite particles are formed as a reaction product of a fluorine-containing alcohol, an alkoxysilane, and nano-silica particles; however, other components are allowed to be mixed as long as the object of the present invention is not impaired.
The following describes the present invention with reference to Examples.
CF3(CF2)3(CH2)2OH [FA-4] (0.25 g) was added and dissolved in 30 ml of methanol. To the resulting solution, 1.67 g (0.50 g as nano-silica) of silica sol (Methanol Silica Sol, a product of Nissan Chemical Industries, Ltd.; nano-silica content: 30 wt. %, average particle diameter: 11 nm) and 0.25 ml of tetraethoxysilane (a product of Tokyo Chemical Industry Co., Ltd.; density: 0.93 g/ml) were added. While stirring the mixture with a magnetic stirrer, 0.25 ml of 25 wt. % aqueous ammonia was added, and the mixture was reacted for 5 hours.
After completion of the reaction, the methanol and aqueous ammonia were removed using an evaporator under reduced pressure, and the resulting powder was redispersed in approximately 20 ml of methanol overnight. The next day, centrifugation was performed using a centrifuge tube, the supernatant was removed, and fresh methanol was added to perform rinsing. After rinsing was performed 3 times, the opening of the centrifuge tube was covered with aluminum foil, and the tube was placed in an oven at 70° C. overnight. The next day, the tube was placed and dried in a vacuum dryer at 50° C. overnight, thereby obtaining 0.582 g (yield: 71%) of white powder.
The particle size of the obtained white powdery fluorine-containing nano-silica composite particles, and the variation of the particle size were measured in a methanol dispersion having a solid matters content of 1 g/L at 25° C. by a dynamic light scattering (DLS) measurement method. Further, thermogravimetric analysis (TGA) was performed before calcining and after calcining up to 800° C. The heating rate in this case was 10° C./min. Moreover, the percentage of the weight loss due to calcining sintering with respect to the initial weight was also calculated.
Further, the dispersibility of the composite particles dispersed with a solid matters content of 1 wt. % in water [H2O], methanol [MeOH], ethanol [EtOH], 1,2-dichloroethane [DCE], and tetrahydrofuran [THF] was visually observed, and the results were evaluated according to the following evaluation criteria.
◯: Uniformly dispersed, transparent dispersion
Δ: Slightly dispersed, cloudy dispersion
x: Not dispersed, precipitated in dispersion medium
In Example 1, the amount of 25 wt. % aqueous ammonia was variously changed.
In Examples 1 to 5, the same amount (0.25 g) of CF3(CF2)5(CH2)2OH [FA-6; C2F5(CF2CF2)2(CH2CH2)OH] was used as the fluorine-containing alcohol.
In Examples 1 to 5, the same amount (0.25 g) of CF3(CF2)7(CH2)2OH [FA-8; C2F5(CF2CF2)3(CH2CH2)OH] was used as the fluorine-containing alcohol.
Table 1 below shows the amount of aqueous ammonia, recovered amount, yield, and various measurement results in the above Examples. Further, Table 2 shows the evaluation of dispersibility.
The yield was calculated by the following formula on the assumption that tetraalkoxysilane underwent a self-condensation reaction to form three-dimensional siloxane bonds Si—O and generate a —O—Si—O—[SiO2] skeleton among them. When silica is not used, the yield is calculated based on C═O.
Yield (%)=A/[B+C+(D×E×F/G)]×100
A: weight of produced composite (g)
B: weight of fluorine-containing alcohol (g)
C: weight of silica (g)
D: volume of tetraalkoxysilane (ml)
E: density of tetraalkoxysilane (g/ml)
F: molar weight (g/mol) of SiO2 derived from tetraalkoxysilane
G: molar weight (g/mol) of tetraalkoxysilane
In Examples 13 to 15, methanol silica sol was not used.
Table 3 below shows the amount of aqueous ammonia, produced fluorine-containing nano composite particle, recovered amount, yield, and various measurement results in the above Reference Examples 1 to 3. Further, Table 4 shows the evaluation of dispersibility.
Prepared glass slides were dipped in methanol dispersions (particle concentration: 5 g/L) of the fluorine-containing nano-silica composite particles before calcining (Examples 21 to 35) and the fluorine-containing nano composite particles before calcining (Reference Examples 11 to 13) obtained in Examples 1 to 15 and Reference Examples 1 to 3, and then dried at room temperature. Droplets (4 μl) were gently brought into contact with the obtained thin layer surfaces at room temperature, and the contact angle (unit: °) of the droplets adhering to n-dodecane or water was measured by the θ/2 method using a contact angle meter (Drop Master 300, produced by Kyowa Interface Science Co., Ltd.). The contact angle with water was measured with time. Table 5 below shows the obtained results.
In Examples 1 to 5, the same amount (0.25 g) of CF3(CF2)3CH2(CF2)5(CH2)2OH [DTFA; C4F9(CH2CF2)(CF2CF2)2(CH2CH2)OH] was used as the fluorine-containing alcohol.
Table 6 below shows the amount of aqueous ammonia, recovered amount, yield, and various measurement results in the above Examples 41 to 45. Further, Table 7 shows the evaluation of dispersibility.
In Examples 43 to 45, methanol silica sol was not used.
Table 8 below shows the amount of aqueous ammonia, produced fluorine-containing nano composite particle, recovered amount, yield, and various measurement results in the above Reference Examples 21 to 23. Further, Table 9 shows the evaluation of dispersibility.
Using methanol dispersions (particle concentration: 5 g/L) of the fluorine-containing nano-silica composite particles before calcining obtained in Examples 41 to 45, the contact angle (unit: °) of the droplets adhering to n-dodecane or water was measured by the above mentioned method. The contact angle with water was measured with time. Table 10 below shows the obtained results.
In Example 2, the same amount (0.25 g) of each of the following compounds was used as the fluorine-containing alcohol.
CF3(CF2)2OCF(CF3)CF2OCF(CF3)CH2OH[PO-3-OH] Ex.61:
CF3(CF2)2O[CF(CF3)CF2O]4CF(CF3)CH2OH[PO-6-OH] Ex.62:
HOCH2CF(CF3)OCF2CF(CF3)OCF2CF2OCF(CF3)CH2OH[OXF3PO—OH] Ex.63:
HOCH2CF(CF3)[OCF2CF(CF3)]nOCF2CF2O[CF(CF3)CF2O]m—CF(CF3)CH2OH(n+m=6)[OXF8PO—OH] Ex.64:
HOCH2CF(CF3)[OCF2CF(CF3)]nOCF2CF2O[CF(CF3)CF2O]m—CF(CF3)CH2OH(n+m=12)[OXF14PO—OH] Ex.65:
Table 11 below shows the amount of aqueous ammonia, recovered amount, yield, and various measurement results in the above Examples 61 to 65. Further, Table 12 shows the evaluation of dispersibility.
In Example 61, methanol silica sol was not used, and the amount of 25% aqueous ammonia was variously changed.
In Example 62, methanol silica sol was not used, and the amount of 25% aqueous ammonia was variously changed.
In Example 63, methanol silica sol was not used, and the amount of 25% aqueous ammonia was changed to 4.0 ml.
In Example 64, methanol silica sol was not used, and the amount of 25% aqueous ammonia was changed to 4.0 ml.
In Example 65, methanol silica sol was not used, and the amount of 25% aqueous ammonia was changed to 4.0 ml.
Table 13 below shows the amount of aqueous ammonia, produced fluorine-containing nano composite particle, recovered amount, yield, and various measurement results in the above Reference Examples 31 to 39. Further, Table 14 shows the evaluation of dispersibility.
Using the methanol dispersions (particle concentration: 5 g/L) of the fluorine-containing nano-silica composite particles before calcining obtained in above Examples 61 to 65, the contact angle (unit: °) of the droplets adhering to n-dodecane or water was measured by the above mentioned method. The contact angle with water was measured with time. Table 15 below shows the obtained results.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-044081 | Mar 2013 | JP | national |
| 2013-044082 | Mar 2013 | JP | national |
| 2013-044083 | Mar 2013 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2014/055818 | 3/6/2014 | WO | 00 |
