Patent Application
20240309136
A silicone-(meth)acrylate copolymer (copolymer) and method for its preparation via emulsion polymerization are provided. The aqueous emulsion of the copolymer can be combined with an aqueous emulsion of a silicone additive to form an emulsion formulation suitable for treating textiles to impart durable water repellency and softness thereto.
In water repellent textile treatment applications, fluorocarbon materials have dominated the market due to their ability to provide excellent durable water repellency. However, regulatory and customer pressures are contributing to an industry need for non-fluorocarbon based textile treatments. Previously disclosed fluorocarbon-free textile treatments suffer the drawback of providing poor durability, where water repellency of textiles treated therewith decreases significantly after multiple washings.
An emulsion formulation suitable for treating a textile comprises: (I) a silicone-(meth)acrylate copolymer, (II) an additive, (III) a water dispersible crosslinker, (IV) a surfactant, and (V) water. A textile can be treated by coating the textile with the emulsion formulation and heating the textile.
A process for forming the emulsion formulation suitable for treating the textile comprises combining a first aqueous emulsion comprising (I) the silicone-(meth)acrylate copolymer, a second aqueous emulsion comprising (II) the additive, (III) the water dispersible crosslinker, and optionally one or more additional starting materials as described below. Alternatively, the process of preparing the emulsion formulation described above may comprise:
The silicone-(meth)acrylate copolymer (copolymer) comprises unit formula:
where each R1 is an independently selected alkyl group of 16 to 24 carbon atoms; each R2 is independently selected from the group consisting of H and methyl; each D2 is a divalent hydrocarbon group of 2 to 12 carbon atoms; each R3 is a group of formula OSi(R4)3; where each R4 is independently selected from the group consisting of R and DSi(R5)3, where each R is an independently selected monovalent hydrocarbon group of 1 to 12 carbon atoms, and each D is independently selected from the group consisting of an oxygen atom, a (poly)alkylene oxide group of 1 to 12 units, and a divalent hydrocarbon group of 2 to 4 carbon atoms; each R5 is independently selected from the group consisting of R and DSi(R6)3; where each R6 is independently selected from the group consisting of R and DSiR3; with the proviso that R4, R5, and R6 are selected such that the silicone-(meth)acrylate macromonomer unit with subscript w has at least 6 silicon atoms; each R7 is independently selected from the group consisting of an oxygen atom and NH; D3 is a divalent hydrocarbon group of 1 to 12 carbon atoms; D4 is an alkylene group of 2 to 4 carbon atoms or a divalent alkylarylene group; subscript v represents the number of units of formula (OD4) in the unit with subscript y, and subscript v has a value of 0 to 12; each R8 is a crosslinkable group; each R9 is a monovalent hydrocarbon group of 1 to 14 carbon atoms; each R10 is independently selected from the group consisting of a halogen (e.g., chloride), an acetate group, or a monovalent hydrocarbon group of 1 to 14 carbon atoms; subscripts w, x, y, z1, and z2 represent relative weights of each unit in the copolymer, subscript x has a value of 0.25 to 15; subscript w has a value of 80 to 98.75; subscript y has a value of 1 to 5; subscript z1 has a value of 0 to 18.75; and subscript z2 has a value of 0 to 18.75, and a quantity (w+x+y+z1+z2)=100. The copolymer further comprises a terminal moiety.
In the unit formula above, R1 has 16 to 24 carbon atoms. Alternatively, R1, may have 16 to 22 carbon atoms, alternatively 18 to 24 carbon atoms, and alternatively 18 to 22 carbon atoms. R1 may be selected from the group consisting of stearyl, eicosyl, and behenyl. Alternatively, R1 may be stearyl.
In the unit formula above, each R3 is a group of formula OSi(R4)3; where each R4 is independently selected from the group consisting of R and DSi(R5)3, where each R is an independently selected monovalent hydrocarbon group of 1 to 12 carbon atoms, and each D is independently selected from the group consisting of an oxygen atom, a (poly)alkylene oxide group of 1 to 12 units, and a divalent hydrocarbon group of 2 to 4 carbon atoms; each R5 is independently selected from the group consisting of R and DSi(R6)3; where each R6 is independently selected from the group consisting of R and DSiR3; with the proviso that R4, R5, and R6 are selected such that the silicone-(meth)acrylate macromonomer unit with subscript w has at least 6 silicon atoms. Alternatively, R4, R5, and R6 are selected such that the unit has at least 6 silicon atoms, alternatively 6 to 20 silicon atoms, alternatively 7 to 19 silicon atoms, alternatively 8 to 18 silicon atoms, alternatively 9 to 17 silicon atoms, and alternatively 10 to 16 silicon atoms, per unit.
In the silicone-(meth)acrylate macromonomer unit, each R is a monovalent hydrocarbon group of 1 to 12 carbon atoms. The monovalent hydrocarbon group for R may be an alkyl group, such as an alkyl group of 1 to 6 carbon atoms. Alternatively, the alkyl groups may have 1 to 3 carbon atoms, alternatively 1 to 2 carbon atoms. Alternatively, each R group may be methyl.
Each D is independently selected from the group consisting of an oxygen atom, a (poly)alkylene oxide group of 1 to 12 units, and a divalent hydrocarbon group of 2 to 4 carbon atoms. Each D2 is a divalent hydrocarbon group of 2 to 12 carbon atoms. Alternatively, D2 may have 2 to 10, alternatively 3 to 5, and alternatively 3 carbon atoms. Each D3 is a divalent hydrocarbon group of 1 to 12 carbon atoms. Alternatively, each D3 may be an alkylene group; alternatively ethylene. D4 is an alkylene group of 2 to 4 carbon atoms or a divalent alkylarylene group.
The divalent hydrocarbon group for D4 may be exemplified by an alkylene group such as ethylene, propylene, or butylene; an arylene group such as phenylene, or an alkylarylene group such as:
where each subscript u is independently 1 to 6, alternatively 1 to 2. Alternatively, the divalent hydrocarbon group may be alkylene, and alternatively the divalent hydrocarbon group may be ethylene. The divalent hydrocarbon group for D2 and D3 may be as described above, and alternatively may be methylene. The divalent hydrocarbon group for D may be alkylene, such as ethylene, propylene, or butylene. Alternatively, each D may be ethylene.
The (poly)alkylene oxide group for D may have 2 to 4 carbon atoms per unit, e.g., have formula D5(OD6)v′-OR, where D5 is an alkylene group of 2 to 4 carbon atoms, D6 is an alkylene group of 2 to 4 carbon atoms, R is as described above, and subscript v′ is 0 to 12. Alternatively subscript v′ may be 0 or 1. Alternatively, subscript v′ may be 0. Examples of (poly)alkylene oxide groups include ethyleneoxide-propyleneoxide.
Alternatively, each D may be selected from an oxygen atom and a divalent hydrocarbon group. Alternatively, each divalent hydrocarbon group for D may be an alkylene group such as ethylene. Alternatively, each D may be oxygen. Alternatively, some instances of D may be oxygen and other instances of D may be alkylene in the same unit.
In the unit formula above each R7 is independently selected from the group consisting of an oxygen atom and NH. Alternatively, each R7 may be oxygen.
In the unit formula above, each R8 is a crosslinkable group. Each R8 may be independently selected from the group consisting of hydroxy, amino, epoxy, ureido, and acetoxy. Alternatively, each R8 may be independently selected from the group consisting of hydroxy and ureido, and alternatively each R8 may be hydroxy.
In the unit formula above, each R9 is a monovalent hydrocarbon group, which is free of aliphatic unsaturation and which may be linear, branched, or cyclic (i.e., monocyclic or polycyclic), or combinations thereof. R9 may be an alkyl group or an aryl group, which may be monocyclic or polycyclic, and which may optionally have linear or branched groups. Examples of suitable alkyl groups for R9 may include methyl, t-amyl, butyl (including t-butyl), cyclohexyl, iso-decyl, isobornyl, and 2-ethylhexyl. Examples of suitable aryl groups include phenyl, naphthyl, anthracyl, and benzyl.
In the unit formula above, R10 may be a halide, an acetate, or a monovalent hydrocarbon group, as described above for R9. The halide may be bromide (Br), chloride (Cl), fluoride (F) or iodide (I); alternatively Br, Cl or F; alternatively Br or Cl; and alternatively Cl.
In the unit formula above, subscripts w, x, y, and z are relative weights of each unit, and a quantity (w+x+y+z) may total 100. Subscript w has a value of 80 to 98.75. Alternatively, subscript w may be at least 80, alternatively at least 81, alternatively at least 82, alternatively at least 83, alternatively at least 84, and alternatively at least 85. At the same time, subscript w may be up to 98.75, alternatively up to 98, alternatively up to 97, alternatively up to 96, alternatively up to 97, alternatively up to 96, alternatively up to 95, alternatively up to 94, alternatively up to 93, alternatively up to 92, alternatively up to 91, and alternatively up to 90. Alternatively, subscript w may be 80 to 98, alternatively 81 to 97, alternatively 82 to 96, alternatively 82 to 95, and alternatively 85 to 90.
Subscript x has a value of 0.25 to 15. Alternatively, subscript x is at least 0.25, alternatively at least 0.5, alternatively at least 0.75, alternatively at least 1, alternatively at least 2, alternatively at least 3, alternatively at least 4, alternatively at least 5. At the same time, subscript x may be up to 15, alternatively up to 14, alternatively up to 13, alternatively up to 12, alternatively up to 11, and alternatively up to 10. Alternatively, subscript x may be 1 to 14, alternatively 2 to 13, alternatively 3 to 12, alternatively 4 to 11, alternatively 5 to 10, alternatively 5 to 15; and alternatively 10.
Subscript y has a value of 1 to 5. Alternatively, subscript y may be at least 1, alternatively at least 1.25, alternatively at least 1.5, alternatively at least 2, and alternatively at least 1.75. At the same time, subscript y may be up to 5, alternatively up to 4, alternatively up to 3, alternatively up to 2.75, alternatively up to 2.5, and alternatively up to 2.25. Alternatively, subscript y may be 1 to 3, alternatively 1 to 2, alternatively 1.5 to 2.5, alternatively 1.75 to 2.25, and alternatively 2.
Subscript z1 may be 0. Alternatively, subscript z1 may be at least 0.5, alternatively at least 1, and alternatively at least 2; while at the same time, subscript z1 may be up to 18.75, alternatively up to 15, alternatively up to 10, alternatively up to 8, and alternatively up to 5. Alternatively, subscript z1 may be 0 to 18.75, alternatively >0 to 18.75, alternatively 0.5 to 7, alternatively 1 to 6, and alternatively 2 to 5.
Subscript z2 may be 0. Alternatively, subscript z2 may be at least 0.5, alternatively at least 1, and alternatively at least 2; while at the same time, subscript z2 may be up to 8, alternatively up to 7, alternatively up to 6, alternatively up to 5, and alternatively up to 4. Alternatively, subscript z2 may be 0 to 8, alternatively >0 to 8, alternatively 0.5 to 7, alternatively 1 to 6, and alternatively 2 to 5.
The total number of units per molecule of copolymer is not specifically restricted. However, the copolymer may have a number average molecular weight of 100,000 g/mol to 4,000,000 g/mol; alternatively 200,000 g/mol to 3,000,000 g/mol measured by GPC using the method described below. The units shown above may be in any order, e.g., the copolymer may be a random copolymer or a block copolymer.
One skilled in the art would recognize that the copolymer may be prepared by radical polymerization, via a process as described below, and that this process would form the terminal moiety for the copolymer. The copolymer further comprises a terminal moiety which may be derived from an initiator, a chain transfer agent, or both, as described, for example in Odian, George (2004). Principles of Polymerization (4th ed.). New York: Wiley-Interscience. ISBN 978-0-471-27400-1.
The copolymer may be prepared via a process comprising:
The process for preparing the emulsion formulation suitable for preparing the textile may comprise practicing step 1) described above, thereby forming a first aqueous emulsion, and 2) combining the first aqueous emulsion prepared in step 1), a second aqueous emulsion comprising (II) the additive (as introduced above and described in detail below), (III) the water dispersible crosslinker (as introduced above and described in detail below), and optionally one or more additional starting materials.
Alternatively, one or more additional starting materials may be added in step 1) for making the copolymer. For example, a starting material selected from the group consisting of (H) a chain transfer agent; (J) an additional non-crystallizable monomer that is distinct from each of (A), (B) and (C); (K) an inhibitor; and a combination of two or more of (H), (J), and (K) may be added in step 1).
Step 1) of the process described above may comprise forming an emulsion comprising starting materials (A), (B), (C), (D), (E), and (F) (and optionally (H), (J), and/or (K)). If starting material (A) is a solid at RT, the starting materials may be heated to a temperature and for a time sufficient to melt starting material (A), e.g., 30° C. to 50° C. for 5 minutes to 15 minutes. The resulting starting materials may be mixed under shear to form the aqueous emulsion. Mixing under shear may be performed by any convenient means for forming an aqueous emulsion, such as sonication and with subsequent microfluidization. Equipment for mixing under shear, such as sonicators, homogenizers, microfluidizers, and speedmixers are known in the art and are commercially available. Without wishing to be bound by theory, it is thought that mixing under shear may be used to obtain a submicron particle size in the emulsion. In step 1), starting materials comprising (A), (B), (C), and (F) (and when present (H) and (J)) copolymerize to form (I) the silicone-(meth)acrylate copolymer in the aqueous emulsion with starting materials (D) and (E) (and when present, (K)).
Step 2) of the process described above for making the emulsion formulation may be performed by any convenient means, such as mixing using in a jacketed vessel equipped with an agitator. Step 1) and step 2) may be performed sequentially in the same vessel. Alternatively, step 1) and step 2) may be performed in different equipment. Step 1) and/or step 2) may be performed at RT or elevated temperature, e.g., up to 100° C., alternatively 40° C. to 80° C. Alternatively, heating may be performed in step 1) and step 2) may be performed at RT. Alternatively, one or both of steps 1) and 2) may be performed at lower temperatures and elevated pressures, such as up to 5 atmospheres.
Alternatively, the copolymer described above may be prepared by a method comprising dissolving one or more of the starting materials in an organic solvent (such as a monohydric alcohol) and copolymerizing starting materials (A), (B), (C), (F), and when present (H) and/or (J) in a process such as that disclosed in U.S. Pat. No. 10,047,199 to Iimura et al. by varying appropriate starting materials and their amounts. The resulting copolymer may be solvent borne. All or a portion of the solvent may be removed by any convenient means, such as by stripping or distillation with heat and optionally reduced pressure. The copolymer may be emulsified using (D) the surfactant and (E), the water. The starting materials for making the copolymer, and the emulsion formulation comprising the copolymer, are further described below.
Starting material (A) is a crystallizable monomer of formula (A-1):
where R1 and R2 are as described above. Examples of crystallizable monomers for starting material (A) include stearyl (meth)acrylate, eicosyl (meth)acrylate, behenyl (meth)acrylate, and combinations thereof. Alternatively, when R2 is hydrogen, starting material (A) may be an acrylate selected from stearyl acrylate, eicosyl acrylate, behenyl acrylate, and combinations thereof. Crystallizable monomers suitable for starting material (A) are commercially available, e.g., from Millipore Sigma of St. Louis, Missouri, USA and from BASF SE of Ludwigshafen, Germany. Crystallizable means that the starting monomer has a melting point) ≥25° C.±5° C.
Starting material (A) is used in an amount of 80% to 98.75%, based on combined weights of starting materials (A), (B), and (C), and when present (J). The amount of starting material (A) may be at least 80%, alternatively at least 81%, alternatively at least 82%, alternatively at least 83%, alternatively at least 84%, and alternatively at least 85% on the same basis. At the same time, the amount of starting material (A) may be up to 98.75%, alternatively up to 98%, alternatively up to 97%, alternatively up to 96%, alternatively up to 97%, alternatively up to 96%, alternatively up to 95%, alternatively up to 94%, alternatively up to 93%, alternatively up to 92%, alternatively up to 91%, and alternatively up to 90%, on the same basis. Alternatively, the amount of starting material (A) may be 80% to 98%, alternatively 81% to 97%, alternatively 82% to 96%, alternatively 82% to 95%, alternatively 85% to 90%; on the same basis.
Starting material (B) is a silicone-(meth)acrylate macromonomer of formula (B-1):
where R2, D2, and R3 are as described above.
Alternatively, starting material (B) may comprise formula (B-2):
where R2, R4, and R5 are as described above.
Alternatively, starting material (B) may comprise a macromonomer selected from the group consisting of: 3-(5-((1,1,1,3,5,5,5-heptamethyltrisiloxan-3-yl)oxy)-1,1,1,3,7,9,9,9-octamethyl-3,7-bis((trimethylsilyl)oxy)pentasiloxan-5-yl)propyl methacrylate of formula
(Si10); 3-(1,5-bis(2-(1,1,1,5,5,5-hexamethyl-3-((trimethylsilyl)oxy)trisiloxan-3-yl)ethyl)-3-(((2-(1,1,1,5,5,5-hexamethyl-3-((trimethylsilyl)oxy)trisiloxan-3-yl)ethyl)dimethylsilyl)oxy)-1,1,5,5-tetramethyltrisiloxan-3-yl)propyl methacrylate, which has formula
and a combination thereof. Starting material (B) may be prepared by known methods, such as those disclosed in PCT Publication WO2020/142388 and U.S. Pat. No. 6,420,504.
Starting material (B) is used in an amount of 0.25% to 15%, based on combined weights of starting materials (A), (B), and (C), and when present (J). Alternatively, starting material (B) may be used in an amount of at least 0.25%, alternatively at least 0.5%, alternatively at least 0.75%, alternatively at least 1%, alternatively at least 2%, alternatively at least 3%, alternatively at least 4%, alternatively at least 5%, on the same basis. At the same time, starting material (B) may be present in an amount up to 15%, alternatively up to 14%, alternatively up to 13%, alternatively up to 12%, alternatively up to 11%, and alternatively up to 10%, on the same basis. Alternatively, the amount of starting material (B) may be 1% to 14%, alternatively 2% to 13%, alternatively 3% to 12%, alternatively 4% to 11%, alternatively 5% to 10%, alternatively 5% to 15%; and alternatively 10%, on the same basis described above.
Starting material (C) is a crosslinkable (meth)acrylate monomer of formula (C-1):
where R2, R7, D3, R8, and subscript v are as described above. Examples of suitable crosslinkable (meth)acrylates for starting material (C) include (2-acetoacetoxy)ethyl methacrylate, hydroxybutyl (meth)acrylate, hydroxyethyl (meth)acrylate, hydroxyethylcaprolactone (meth)acrylate, hydroxypropyl (meth)acrylate, ureido (meth)acrylate, glycidyl (meth)acrylate (GMA), poly(ethylene glycol) (meth)acrylate (PEGMA), and combinations thereof. The ureido (meth)acrylate monomer may have formula:
where R11 is an oxygen atom or an NH moiety. Examples of ureido monomers are known in the art and are disclosed, for example, in U.S. Pat. No. 9,212,292 to Pressley, et al. Other crosslinkable (meth)acrylate monomers are known in the art and are commercially available, e.g., from BASF SE. Other crosslinkable (meth)acrylates are commercially available as Sipomer WAM1 and 2.
Starting material (C) is used in an amount 1% to 5%, based on combined weights of starting materials (A), (B), and (C), and when present, (J). The amount of starting material (C) may be at least 1%, alternatively at least 1.25%, alternatively at least 1.5%, alternatively at least 2%, and alternatively at least 1.75%, on the same basis. At the same time, the amount of starting material (C) may be up to 5%, alternatively up to 4%, alternatively up to 3%, alternatively up to 2.75%, alternatively up to 2.5%, and alternatively up to 2.25%, on the same basis. Alternatively, the amount of starting material (C) may be 1% to 3%, alternatively 1% to 2%, alternatively 1.5% to 2.5%, alternatively 1.75% to 2.25%, and alternatively 2%; on the same basis.
Starting material (D) is a surfactant. The surfactant may be selected from the group consisting of (D-1) a cationic surfactant, (D-2) a nonionic surfactant, and (D-3) a combination of both the cationic surfactant and the nonionic surfactant. Cationic surfactants useful herein include compounds containing quaternary ammonium hydrophilic moieties in the molecule which are positively charged, such as quaternary ammonium salts, which may be represented by formula (D-1-1): R12R13R14R15N+X′− where R12 to R15 are alkyl groups containing 1-30 carbon atoms, or alkyl groups derived from tallow, coconut oil, or soy; and X′ is a halogen, e.g., chlorine or bromine. Alternatively, the quaternary ammonium compounds may be alkyl trimethylammonium and dialkyldimethylammonium halides, or acetates, having at least 8 carbon atoms in each alkyl substituent. Dialkyl dimethyl ammonium salts can be used and are represented by formula (D-1-2): R16R17N+(CH3)2X′− where R16 and R17 are alkyl groups containing 12-30 carbon atoms or alkyl groups derived from tallow, coconut oil, or soy; and X′ is halogen. Monoalkyl trimethyl ammonium salts can be used and are represented by formula (D-1-3): R18N+(CH3)3X″− where R18 is an alkyl group containing 12-30 carbon atoms or an alkyl group derived from tallow, coconut oil, or soy; and X″ is halogen or acetate.
Representative quaternary ammonium halide salts are dodecyltrimethyl ammonium chloride/lauryltrimethyl ammonium chloride (LTAC), cetyltrimethyl ammonium chloride (CTAC), hexadeclyltrimethyl ammonium chloride, didodecyldimethyl ammonium bromide, dihexadecyldimethyl ammonium chloride, dihexadecyldimethyl ammonium bromide, dioctadecyldimethyl ammonium chloride, dieicosyldimethyl ammonium chloride, and didocosyldimethyl ammonium chloride. These quaternary ammonium salts are commercially available under trademarks such as ADOGEN™, ARQUAD™, TOMAH™, and VARIQUAT™.
Other suitable cationic surfactants which can be used include fatty acid amines and amides and their salts and derivatives, such as aliphatic fatty amines and their derivatives. Such cationic surfactants that are commercially available include compositions sold under the names ARQUAD™ T27 W, ARQUAD™ 16-29, by Akzo Nobel Chemicals Inc., Chicago, Illinois; and Ammonyx Cetac-30 by the Stepan Company, Northfield, Illinois, USA.
The amount of (D-1) the cationic surfactant may be 0.1% to 5%, based on weight of starting material (I) the silicone-(meth)acrylate copolymer in the aqueous emulsion. Alternatively, the amount of cationic surfactant may be at least 0.1%, alternatively at least 0.2%, alternatively at least 0.3%, alternatively at least 0.4%, alternatively at least 0.5%; while at the same time the amount of cationic surfactant may be up to 5%, alternatively up to 4%, alternatively up to 3%, alternatively up to 2%, alternatively up to 1%, on the same basis. Alternatively, the amount of cationic surfactant may be 0.2% to 4%, alternatively 0.3% to 3%, alternatively 0.4% to 2.5%, and alternatively 0.5% to 2%; on the same basis.
Starting material (D-2) is a nonionic surfactant. Some suitable nonionic surfactants which can be used include polyoxyethylene alkyl ethers, polyoxyethylene alkyl phenyl ethers, alkylglucosides, polyoxyethylene fatty acid esters, sorbitan fatty acid esters, and polyoxyethylene sorbitan fatty acid esters. Nonionic surfactants which are commercially available include compositions such as (i) 2,6,8-trimethyl-4-nonyl polyoxyethylene ether sold under the names TERGITOL™ TMN-6 and TERGITOL™ TMN-10; (ii) the C11-15 secondary alkyl polyoxyethylene ethers sold under the names TERGITOL™ 15-S-7, TERGITOL™ 15-S-9, TERGITOL™ 15-S-15, TERGITOL™ 15-S-30, and TERGITOL™ 15-S-40, by the Dow Chemical Company, of Midland, Michigan, USA; octylphenyl polyoxyethylene (40) ether sold under the name TRITON™ X405 by the Dow Chemical Company; (iii) nonylphenyl polyoxyethylene (10) ether sold under the name MAKON™ 10 by the Stepan Company; (iv) ethoxylated alcohols sold under the name Trycol 5953 by Henkel Corp./Emery Group, of Cincinnati, Ohio, USA; (v) ethoxylated alcohols sold under the name BRIJ™ L23 and BRIJ™ L4 by Croda Inc. of Edison, New Jersey, USA, (vi) alkyl-oxo alcohol polyglycol ethers such as GENAPOL™ UD 050, and GENAPOL™ UD110, (vii) alkyl polyethylene glycol ether based on C10-Guerbet alcohol and ethylene oxide such as LUTENSOL™ XP 79.
Suitable nonionic surfactants also include poly(oxyethylene)-poly(oxypropylene)-poly(oxyethylene) tri-block copolymers. Poly(oxyethylene)-poly(oxypropylene)-poly(oxyethylene) tri-block copolymers are also commonly known as Poloxamers. They are nonionic triblock copolymers composed of a central hydrophobic chain of polyoxypropylene (poly(propylene oxide)) flanked by two hydrophilic chains of polyoxyethylene (poly(ethylene oxide)). Poly(oxyethylene)-poly(oxypropylene)-poly(oxyethylene) tri-block copolymers are commercially available from BASF of Florham Park, New Jersey, USA, and are sold under the tradename PLURONIC™, such as PLURONIC™ L61, L62, L64, L81, P84.
Other suitable nonionic surfactants include polyoxyethylene alkyl ethers, polyoxyethylene alkylphenol ethers, polyoxyethylene lauryl ethers, polyoxyethylene sorbitan monooleates, polyoxyethylene alkyl esters, polyoxyethylene sorbitan alkyl esters, polyethylene glycol (such as polyethylene glycol having 23 ethylene-oxide units), polypropylene glycol, diethylene glycol, ethoxylated trimethylnonanols, and polyoxyalkylene glycol modified polysiloxane surfactants. Commercially available nonionic surfactants which can be used include compositions such as 2,6,8-trimethyl-4-nonyloxy polyethylene oxyethanols (6EO) and (10EO) sold under the trademarks TERGITOL™ TMN-6 and TERGITOL™ TMN-10; alkyleneoxy polyethylene oxyethanol (C11-15 secondary alcohol ethoxylates 7EO, 9EO, and 15EO) sold under the trademarks TERGITOL™ 15-S-7, TERGITOL™ 15-S-9, TERGITOL™ 15-S-15; other C11-15 secondary alcohol ethoxylates sold under the trademarks TERGITOL™ 15-S-12, 15-S-20, 15-S-30, 15-S-40; octylphenoxy polyethoxy ethanol (40EO) sold under the trademark TRITON™ X-405; and alcohol ethoxylates with tradename ECOSURF™ EH, such as ECOSURF™ EH-40. All of these surfactants are sold by the Dow Chemical Company.
Other useful commercial nonionic surfactants are nonylphenoxy polyethoxy ethanol (10EO) sold under the trademark MAKON™ 10 by Stepan Company; polyoxyethylene 23 lauryl ether (Laureth-23) sold commercially under the trademark BRIJ™ 35L by ICI Surfactants, of Wilmington, Delaware, USA; and RENEX™ 30, a polyoxyethylene ether alcohol also sold by ICI Surfactants.
The nonionic surfactant may also be a silicone polyether (SPE). The silicone polyether as an emulsifier may have a rake type structure wherein the polyoxyethylene or polyoxyethylene-polyoxypropylene copolymeric units are grafted onto the siloxane backbone, or the SPE can have an ABA block copolymeric structure wherein A represents the polyether portion and B the siloxane portion of an ABA structure. Suitable SPE's include DOWSIL™ OFX-5329 Fluid from Dow Silicones Corporation of Midland, Michigan, USA. Alternatively, the nonionic surfactant may be selected from polyoxyalkylene-substituted silicones, silicone alkanolamides, silicone esters and silicone glycosides. Such silicone-based surfactants may be used to form such aqueous emulsions and are known in the art, and have been described, for example, in U.S. Pat. No. 4,122,029 to Gee et al., U.S. Patent 5,387,417 to Rentsch, and U.S. Patent 5,811,487 to Schulz et al.
Starting material (D-2) the nonionic surfactant may be delivered in a dilution, and the amount used may be sufficient to provide 0.1% to 6% of the surfactant, based on weight of starting material (I) the silicone-(meth)acrylate copolymer in the aqueous emulsion. Alternatively, the amount of nonionic surfactant may be at least 0.1%, alternatively at least 0.2%, alternatively at least 0.3%, alternatively at least 0.4%, alternatively at least 0.5%; while at the same time the amount of nonionic surfactant may be up to 5%, alternatively up to 4%, alternatively up to 3%, alternatively up to 2%, alternatively up to 1%, on the same basis. Alternatively, the amount of nonionic surfactant may be 0.2% to 4%, alternatively 0.3% to 3%, alternatively 0.4 to 2.5%, and alternatively 0.5% to 2%; on the same basis. Alternatively, starting materials (D-1) the cationic surfactant and (D-2) the nonionic surfactant may be present in combined amounts ≤10%, based on weight of starting material (I) the silicone-(meth)acrylate copolymer in the aqueous emulsion.
Starting material (E) is water. The water is not generally limited, for example, the water may be processed or unprocessed. Examples of processes that may be used for purifying the water include distilling, filtering, deionizing, and combinations of two or more thereof, such that the water may be deionized, distilled, and/or filtered. Alternatively, the water may be unprocessed (e.g. may be tap water, i.e., provided by a municipal water system or well water, used without further purification). The amount of water is sufficient to form an aqueous emulsion for emulsion polymerization in step 1) of the process described above. Additional water may be added after step 1). For example, the first aqueous emulsion prepared as described above and/or the second aqueous emulsion may be diluted with additional water to achieve a desired amount of starting materials before treating a textile with the emulsion formulation. In step 1), the water may be added in an amount of 20% to 97%, alternatively 30% to 90%, and alternatively 40% to 80%, alternatively 50% to 97%, alternatively 50% to 90%, and alternatively 60% to 80%; based on combined weights of all starting materials in step 1). Alternatively, the water may be added in an amount of at least 20%, alternatively at least 30%, alternatively at least 40%, alternatively at least 50%, and alternatively at least 60%; while at the same time the amount of water may be up to 97%, alternatively up to 96%, alternatively up to 95%, and alternatively up to 80%, on the same basis.
Without wishing to be bound by theory, it is thought that starting materials (A), (B), and (C), and when present (J), copolymerize to form (I) the silicone-(meth)acrylate copolymer described herein as starting material (I). It is further thought that starting materials (D) surfactant and (E) water do not participate in the copolymerization reaction, however, a copolymer including one or both of starting materials (D) and (E) is not excluded from the scope herein.
The silicone-(meth)acrylate copolymer may be prepared by emulsion copolymerization of starting materials comprising (A), (B), (C), and (F) described above. Alternatively, the silicone-(meth)acrylate copolymer may be a reaction product of starting materials consisting essentially of starting materials (A), (B), (C), and (F) (and when present, (H) the chain transfer agent and/or (J) the additional monomer). Alternatively, the silicone-(meth)acrylate copolymer may be a reaction product of starting materials consisting of starting materials (A), (B), (C), and (F) (and, when present, (H) and/or (J)). Without wishing to be bound by theory, it is thought that none of starting materials (D) and (E) copolymerize with starting materials (A), (B), and (C), but merely serve as a vehicle for copolymerization. However, nothing herein shall exclude the possibility that a portion of one or more of starting materials (D) and/or (E), or any other starting material added during the method, may participate in the copolymerization reaction of starting materials comprising (A), (B), (C), and (F).
In the emulsion formulation suitable for treating the textile, (I) the silicone-(meth)acrylate copolymer may be present in an amount of 57.2% to 88.5%, based on combined weight of all starting materials in the emulsion formulation, excluding water. Alternatively, the amount of (I) the silicone-(meth)acrylate copolymer may vary depending on factors such as the type of fabric to be treated. For example, the amount of (I) the silicone-(meth)acrylate copolymer may be 58.2% to 88.5%, on the same basis, when the textile to be treated is polyester. Alternatively, the amount of (I) the silicone-(meth)acrylate copolymer may be 57.2% to 79.3%, on the same basis, when the textile to be treated is a polyamide, such as a Nylon.
Starting material (III) is a water dispersible crosslinker (crosslinker) that may be added to the emulsion formulation for treating textiles, e.g., to facilitate cure of (I) the silicone-(meth)acrylate copolymer and (II) the additive. Starting material (III) may be combined with the first aqueous emulsion prepared in step 1). Alternatively, starting material (III) may be combined with the second aqueous emulsion in step 2) of the process for preparing the emulsion formulation suitable for treating the textile. Alternatively, the first aqueous emulsion and the second aqueous emulsion may be combined to form a third aqueous emulsion, and thereafter (III) the water dispersible crosslinker may be added thereto. Suitable water dispersible crosslinkers include blocked isocyanates and diols. The term “blocked isocyanates” encompasses mono-, di-and polyisocyanates in which an isocyanate group has been reacted with a blocking agent, which upon heating, release the isocyanate and the blocking agent. Suitable blocking agents are known in the art such as amines, amides, compounds having an active hydrogen atom, alcohols, or oximes. Blocked isocyanates are commercially available, such as ARKOPHOB™ DAN and ARKOPHOB™ SR from Archroma of Reinach, Switzerland; RUCO-GUARD™ WEB from Rudolf GmbH of Geretsreid, Bayern, Germany, and PHOBOL™ XAN from Huntsman Corporation of the Woodlands, Texas, USA. Diols include, for example, 1,2-propoanediol; 1,3-propanediol; 1,2-butanediol; 1,3-butanediol; 1,4-butanediol; 2,3-butanediol; 2-methyl-1,2-propanediol; 1,5-pentanediol; 2-methyl-2,3-butanediol; 1,6-hexanediol; 1,2-hexanediol; 2,5-hexanediol; 2-methyl-2,4-pentanediol; 2,3-dimethyl-2,3-butanediol; 2-ethylhexanediol; 1,2-octanediol; 1,2-decanediol; 2,2,4-trimethylpentanediol; 2-butyl-2-ethyl-1,3-propanediol; 2,2-diethyl-1,3-propanediol. Examples of suitable crosslinkers are known in the art and are disclosed, for example, in U.S. Patent Application 2017/0204558 to Knaup; U.S. Pat. No. 9,777,105 to Hamajima et al., beginning at col. 11, line 54, which are hereby incorporated by reference for the purpose of describing suitable crosslinkers. The exact amount of crosslinker (III) depends on various factors including the type and amount of (I) silicone-(meth)acrylate copolymer formed in step 1) and the textile to be treated, however, the weight of the crosslinker (III) may be sufficient to provide 0.25% to 3.75% on fabric weight, alternatively 0.25% to 1%, and alternatively 0.25% to 0.5%, on the same basis. Alternatively, the amount of crosslinker may be 9.1% to 30%, based on combined weights of all starting materials in the emulsion formulation suitable for treating the textile, excluding water. Alternatively, the amount of (III) the crosslinker may vary depending on factors such as the type of fabric to be treated. For example, the amount of (III) the crosslinker may be 9.2% to 20.1% when the textile to be treated is polyester. Alternatively, the amount of (III) the crosslinker may be 9.1% to 30.7%, when the textile to be treated is a polyamide, such as a Nylon.
An additional starting material that may be added in step 1) of the process described above comprises (H) a chain transfer agent. Suitable chain transfer agents include mercaptans such as alkyl mercaptans, e.g., n-octyl mercaptan, n-dodecyl mercaptan, dodecyl mercaptan (dodecane thiol), and/or 2,2-dimethyldecyl mercaptan. Alternatively, the chain transfer agent may be water soluble, such as mercaptoacetic acid and/or 2-mercaptoethanol. Suitable chain transfer agents are known in the art and have been disclosed, for example, in “Radical Polymerization in Industry” by Peter Nesvadba, Performance Chemical Research, GASF Schweiz AG, Basel, Switzerland, Encyclopedia of Radicals in Chemistry, Biology and Materials, Online© 2012 John Wiley & Sons, Ltd.
Starting material (H), the chain transfer agent, is optional and may be added in an amount of 0 to 1%, based on combined weights of starting materials (A), (B), and (C) (and when present (J). Alternatively, (H) the chain transfer agent may be used in an amount of 0.5% to 0.6% on the same basis.
Starting material (F), an initiator, is also added in step 1) described above. Suitable initiators include azo compounds and peroxide compounds. For example, the azo compound may be an aliphatic azo compound such as 1-t-amylazo-1-cyanocyclohexane, azo-bis-isobutyronitrile and 1-t-butylazo-cyanocyclohexane, 2,2′-azo-bis-(2-methyl)butyronitrile, 2,2′-azobis(2-methylpropionitrile), 2,2′-azobis(2-methylpropionamidine) dihydrochloride, 2,2′-azobis(cyanovaleric acid), or a combination of two or more thereof. Azo compounds are known in the art and are commercially available, e.g., under the tradename VAZO™ WSP from The Chemours Company of Wilmington, Delaware, USA. The peroxide compound may be a peroxide or a hydroperoxide, such as t-butylperoctoate, t-butyl perbenzoate, dicumyl peroxide, di-t-butyl peroxide, t-butyl hydroperoxide, cumene hydroperoxide, di-t-amyl peroxide and combinations of two or more thereof. Additionally, di-peroxide initiators may be used alone or in combination with other initiators. Such di-peroxide initiators include, but are not limited to, 1,4-bis-(t-butyl peroxycarbo)cyclohexane, 1,2-di(t-butyl peroxy)cyclohexane, and 2,5-di(t-butyl peroxy)-3-hexyne. Suitable peroxide compounds are known in the art and are commercially available from various sources, such as Sigma-Aldrich, Inc. Alternatively, the initiator may comprise isoascorbic acid.
An initiator may be used alone as starting material (F). Alternatively, starting material (F) may be a redox pair, which comprises an initiator as the oxidizing component and a reducing component. Alternatively, a redox pair including isoascorbic acid and a hydrophobic organic hydroperoxide such as t-amyl hydroperoxide or t-butyl hydroperoxide may be used as starting material (F). Examples of suitable initiators and/or redox pairs for starting material (F) are disclosed in U.S. Pat. No. 6,576,051 to Bardman et al., beginning at col. 11, line 16. How the initiator is added depends on various factors including whether the initiator is water soluble and the type of initiator (e.g., whether a thermal initiator or a redox pair is used). Typically, when a thermal initiator is used, all the initiator is added at once at the beginning of step 1). Alternatively, when a redox pair is used, it may be metered in over time. The initiator (F) may be used in an amount sufficient to provide 0.01% to 3%, alternatively 0.1% to 1.5%, based on weight of the silicone-(meth)acrylate copolymer.
Starting material (J) is an optional additional monomer that may be added in step 1). Starting material (J) is a non-crystallizable monomer that is distinct from starting materials (A), (B), and (C), described above. The additional monomer, when present, may be used in an amount of >0 to 18.75 weight % based on weight of (I) the silicone-(meth)acrylate copolymer. Suitable monomers include (meth)acrylate monomers such as methyl methacrylate, t-amyl methacrylate, butyl (meth)acrylate such as t-butyl methacrylate, cyclohexyl (meth)acrylate, iso-decyl (meth)acrylate, isobornyl(meth)acrylate, 2-naphthyl acrylate, benzyl (meth)acrylate, 2-ethylhexyl(meth)acrylate, and combinations of two or more thereof. Alternatively the additional monomer may be styrene or vinyl chloride. Suitable monomers for starting material (J) are known in the art and are commercially available, e.g., from Polysciences, Inc. Alternatively, the additional monomer (J) may be selected from the group consisting of isobornyl methacrylate (IBMA), isobornyl acrylate (IBA), and a combination thereof. The additional monomer is optional and may be present in an amount of 0 to 18.75%, based on combined weights of starting materials (A), (B), and (C), and when present, (J). Alternatively, (J) the additional monomer may be present in an amount of at least 0.5%, alternatively at least 1%, and alternatively at least 2%; while at the same time the additional monomer may be present in an amount up to 18.75%, alternatively up to 15%, alternatively up to 10%, alternatively up to 8%, and alternatively up to 5%, on the same basis. Alternatively, the amount of (J) the additional monomer may be >0 to 18.75%, alternatively 0.5% to 7%, alternatively 1% to 6%, and alternatively 2% to 5%, on the same basis.
Starting material (K) is an inhibitor that may optionally be added in step 1) of the process described above. When present, starting material (K), the inhibitor, may be used in an amount >0 to <0.01% based on weight of (I) the silicone-(meth)acrylate copolymer, alternatively >0 to <2,000 ppm, alternatively 1 ppm to 1818 ppm, alternatively 10 ppm to 500 ppm, on the same basis. Suitable inhibitors for starting material (K) are commercially available, and include, for example, nitrobenzene, butylated hydroxyl toluene, diphenyl picryl hydrazyl (DPPH), p-methoxyphenol, 2,4-di-t-butyl catechol, phenothiazine, N,N-diethylhydroxylamine, salts of N-nitroso phenylhydroxylamine, (2,2,6,6-tetramethylpiperidin-1-yl)oxidanyl (TEMPO), and 4-hydroxy-(2,2,6,6-tetramethylpiperidin-1-yl)oxidanyl (4-hydroxy TEMPO).
An additional starting material may optionally be added after step 1) and/or after step 2) of the process for preparing the emulsion formulation suitable for treating the textile. The starting material may be selected from the group consisting of (VI) an additional surfactant (as described above for starting material (D)), (VII) a wax, (VIII) a biocide, (IX) additional water (as described above for starting material (E)), (X) a flame retardant, (XI) a wrinkle reducing agent, (XII) an antistatic agent, (XIII) a penetrating agent, or a combination of two or more of the additional starting materials.
Starting material (VII) is a wax, which may optionally be added to provide improved water repellency or softness to the textile to which the emulsion formulation will be applied. The amount of wax will vary depending on factors including the type of wax selected, the benefit desired, and the fabric to be treated with the emulsion formulation. However, the amount of wax may be 0 to 75%, alternatively 0 to 50%, alternatively 25% to 50% based on weight of (I) the silicone-(meth)acrylate copolymer. Alternatively, when used, the amount of wax may be >0%, alternatively at least 10%, and alternatively at least 25%, while at the same time the amount of wax may be up to 75%, alternatively up to 50% on the same basis. Examples of suitable waxes include paraffin waxes (e.g., n-paraffins, iso-paraffins, and/or cycloparaffins), silicone waxes such as silicone wax with long chain alkyl groups (e.g., alkyl methyl silicone wax) and/or amino-silicone wax, and a combination of two or more thereof. Suitable waxes are disclosed, for example, in U.S. Patent Application 2017/0204558 to Knaup and U.S. Pat. No. 10,844,151 to Probst, et al. Waxes may be delivered as water-based dispersions, for example Michelman wax 743 and others from Michelman of Cincinnati, Ohio, U.S.A. Other waxes are also commercially available, for example, from Sasol Wax of Hamburg, Germany, and silicone waxes, such as DOWSIL™ AMS-C30, are available from Dow Silicones Corporation of Midland, Michigan, U.S.A.
Starting material (VIII) is an optional biocide. The amount of biocide will vary depending on factors including the type of biocide selected and the benefit desired. However, when used, the amount of biocide may be >0% to 5% based on the combined weights of all starting materials in the emulsion formulation. Starting material (VIII) is exemplified by (M-1) a fungicide, (M-2) an herbicide, (M-3) a pesticide, (M-4) an antimicrobial agent, or a combination thereof. Suitable biocides are disclosed, for example, in U.S. Pat. No. 9,480,977.
Starting material (XIII) is a penetrating agent. Suitable penetrating agents are exemplified by glycol ethers, which are commercially available from The Dow Chemical Company and include DOWANOL™ DPM, TPM, PPh, EPh, Methyl CARBITOL™, and Butyl CARBITOL™.
The emulsion formulation suitable for treating the textile further comprises an amount sufficient to impart softness to a textile without significantly decreasing water repellency of (II) an additive selected from (II-1) an alkylpolysiloxane of formula
where each R19 is an independently selected monovalent saturated hydrocarbon group having 1 to 18 carbon atoms, and subscript a has an average value of 20 to 300, or (II-2) a combination comprising 60 to 70 weight %, based on combined weights of all starting materials in (II-2), the combination, of (II-1) the alkylpolysiloxane, 29 to 39 weight %, based on combined weights of all starting materials in (II-2), the combination, of (II-2-1) a silicone resin having a hardness ≥20 measured by Type A durometer according to JIS K 6249:2003, and 0 to 2 weight %, based on combined weights of all starting materials in (II-2), the combination, of (II-2-2) an amino-functional polyorganosiloxane having a functional group equivalent of 100 to 20,000 g/mol, wherein the equivalent means molecular weight of the amino-functional polyorganosiloxane per 1 mole of nitrogen atoms, and having a kinematic viscosity at 25° C. of 10 to 100,000 mm2/s measured by the method of JIS K 2283:2000. Alternatively, (II-2-2) the amino-functional polyorganosiloxane may be present in an amount of 1% to 2%, on the same basis.
The (II-1) alkylpolysiloxane has formula
where each R19 is an independently selected monovalent saturated hydrocarbon group having 1 to 18 carbon atoms, and subscript a has an average value of 20 to 300. The monovalent saturated hydrocarbon group for R19 may be an alkyl group, alternatively an alkyl group of 1 to 6 carbon atoms. Alternatively, the alkyl groups may have 1 to 3 carbon atoms, alternatively 1 to 2 carbon atoms. Alternatively, each R19 may be methyl. Suitable alkylpolysiloxanes, e.g., bis-trimethylsiloxy-terminated polydimethylsiloxanes, are known in the art and are commercially available, e.g., as XIAMETER™ 200 Fluids from DSC.
Alternatively, (II) the additive may comprise a (II-2) combination comprising: 60 to 70 weight %, based on combined weights of all starting materials in (II-2), the combination, of (II-1) the alkylpolysiloxane described above, 29 to 39 weight %, based on combined weights of all starting materials in (II-2), the combination, of (II-2-1) a silicone resin having a hardness ≥20 measured by Type A durometer according to JIS K 6249:2003, and 1 to 2 weight %, based on combined weights of all starting materials in (II-2), the combination, of (II-2-2) an amino-functional polyorganosiloxane having a functional group equivalent of 100 to 20,000 g/mol, wherein the equivalent means molecular weight of the amino-functional polyorganosiloxane per 1 mole of nitrogen atoms, and having a kinematic viscosity at 25° C. of 10 to 100,000 mm2/s measured by the method of JIS K 2283:2000.
Starting material (II) the additive may be delivered in a second aqueous emulsion, which comprises (II) the additive, (D′) a surfactant (which may be as described above for starting material (D)) and (E′) water (which may be as described above for starting material (E)). The second aqueous emulsion may be prepared by known methods, such as those described in U.S. Patent Application Publication 2020/0332148, by varying the types and amounts of starting materials as described herein.
In the emulsion formulation suitable for treating the textile, (II) the additive may be present in an amount of 0.4% to 29.3%, based on combined weights of all starting materials in the emulsion formulation, excluding water. Alternatively, the amount of (II) the additive may vary depending on the type of additive selected and/or the type of textile to be treated. For example, when the additive is (II-1) the alkylpolysiloxane, the alkylpolysiloxane may be present in an amount of 0.7% to 28.5%. Alternatively, the alkyl polysiloxane may be present in an amount of 0.7% to 28.5% when the textile to be treated is polyester. Alternatively, the alkylpolysiloxane may be present in an amount of 1% to 28.5% when the textile to be treated is a polyamide, such as a Nylon. Alternatively, when the additive is (II-2) the combination described above, the additive may be present in an amount of 0.4% to 29.3%, based on combined weights of all starting materials in the emulsion formulation, excluding water. Alternatively, the combination may be present in an amount of 0.4% to 29.3% when the textile to be treated is polyester. Alternatively, the combination may be present in an amount of 0.8% to 28.5% when the textile to be treated is a polyamide, such as a Nylon.
When selecting starting materials to add to the first aqueous emulsion and the second aqueous emulsion described above, and the emulsion formulation suitable for treating the textile, there may be overlap between types of starting materials because certain starting materials described herein may have more than one function. The starting materials used in the first aqueous emulsion, the second aqueous emulsion, and/or the emulsion formulation, may be distinct from one another.
The emulsion formulation suitable for treating the textile comprises: (I) the silicone-(meth)acrylate copolymer, (II) the additive, (III) the water dispersible crosslinker, (IV) the surfactant (described above as starting material (D)), and (V) the water (described above as starting material (E)). The emulsion formulation may optionally further comprise an additional starting material selected from the group consisting of (VII) the wax, (VIII) the biocide, (IX) additional water, (X) the flame retardant, (XI) the wrinkle reducing agent, (XII) the antistatic agent, (XIII) the penetrating agent, and a combination of two or more of starting materials (VII), (VIII), (IX), (X), (XI), (XII) and (XIII), which may be added during preparation of the first aqueous emulsion comprising (I) the silicone-(meth)acrylate copolymer, or thereafter in the process for preparing the emulsion formulation. These additional starting materials and their amounts are as described above. Furthermore, the emulsion formulation described herein may be formulated with starting materials that are fluorocarbon-free. For example, the emulsion formulation may be free of any starting material that contains a fluorine atom covalently bonded to a carbon atom.
The emulsion formulation prepared as described above may be used for treating a textile. For example, a method for treating a textile comprises: I) coating the textile with the emulsion formulation described above, and II) heating the textile. Step I) may be performed by any convenient method, such as padding, dipping, or spraying the textile with the emulsion formulation. However, the method should be sufficient to deliver on fabric weight of 0.25 weight % to 7.5 weight % of (I) the silicone-(meth)acrylate copolymer, on fabric weight of 0.01 weight % to 0.5 weight % of (II) the additive, and on fabric weight of 0.05 weight % to 0.5 weight %, of (III), the water dispersible crosslinker, each based on weight of the textile. When (II) the additive is (II-2) the combination, the amount of (I) the silicone-(meth)acrylate copolymer and the amount of (II-2) the combination are sufficient to provide a weight ratio (I):(II-2) of 2:1 to <200:1.
Step II) may be performed by any convenient method, such as placing the textile in an oven. Heating the textile may be performed to remove all or a portion of the water and/or cure the emulsion formulation. The exact temperature depends on various factors including the temperature sensitivity of the type of textile selected and the desired drying time. However, heating may be performed at a temperature >100° C. to remove water. Alternatively, the temperature may be >100° C. to 200°° C. for a time sufficient to remove all or a portion of the water, de-block the blocked isocyanate crosslinker, and/or cure (I) the silicone-(meth)acrylate copolymer and (II) the additive.
The textile to be treated is not specifically restricted. Suitable textiles include naturally derived textiles such as fabrics of cotton, silk, linen, and/or wool; textiles derived from synthetic sources such as rayon, acetate, polyesters, polyamides (such as Nylons), polyacrylonitriles, and polyolefins such as polyethylenes and/or polypropylenes, and combinations of two or more thereof (e.g., blends such as polyester/cotton blend). The form of the textile is also not specifically restricted. The emulsion formulation described herein is suitable for use on textiles in any form, e.g., woven fabrics, knitted fabrics, carpet, or nonwoven textiles.
The following examples are provided to illustrate the invention to one skilled in the art and are not to be interpreted as limiting the invention set forth in the claims. Starting materials used herein were as follows. A textile to be treated was Nylon (style #01194), which was purchased from Burlington and contained 98.61% of Nylon and 1.39% of Spandex. The weight was 6.84 Oz/Lin Yd and plain weave. Another textile to be treated was polyester or PES Woven (crepe), also from Burlington, style 4774 075, basis weight 220 g/m2. The water dispersible crosslinker (H-1) was PHOBOL™ XAN Extender (an oxime-blocked isocyanate emulsion) purchased from Huntsman and used as received. The crystallizable monomer (A-1) was stearyl acrylate and/or lauryl methacrylate, the crosslinkable (meth)acrylate monomer (C-1) was 2-hydroxyethyl methacrylate (HEMA), nonionic surfactant BRIJ™ L23-69 (69% actives), cationic surfactant ARQUAD™ 16-29 (hexadecyltrimethylammonium chloride, 29% actives), and 2,2′-azobis(2-methylpropionitrile) (AIBN), EcoSurf™ EH-14 non-ionic surfactant(90% actives), EcoSurf™ EH-40 non-ionic surfactant (75% actives), Synperonic™ 13/6 Co-emulsifier and wetting agent, Synperonic™ 13/12 Co-emulsifier and wetting agent, an emulsion prepared according to U.S. Patent Application Publication 2020/0332148 including an alkylpolysiloxane, a silicone resin, and an amino-functional polyorganosiloxane (Emulsion 1); Nicca BG2 a penetrating agent, t-butylhydroperoxide, Isoascorbic acid, dodecanethiol, dipropylene glycol, XIAMETER™ PMX-200 silicone fluid (100 cSt bis-trimethylsiloxy-terminated polydimethylsiloxane), and XIAMETER™ OHX-0750 polymer (bis-silanol-terminated polydimethylsiloxane with DP˜200), were commercially available and were obtained from commercial sources. The terminal aminosiloxane (TAS, bis-amino-alkyl-terminated polydimethylsiloxane with DP˜16 was prepared as described in PCT Publication 2021108068. Starting material (B-1) was 3-(1,5-bis(2-(1,1,1,5,5,5-hexamethyl-3-((trimethylsilyl)oxy)trisiloxan-3-yl)ethyl)-3-(((2-(1,1,1,5,5,5-hexamethyl-3- (trimethylsilyl)oxy)trisiloxan-3-yl)ethyl)dimethylsilyl)oxy)-1,1,5,5-tetramethyltrisiloxan-3-yl)propyl methacrylate (abbreviated Si16) prepared as described in U.S. Pat. No. 6,420,504. A Fisherbrand™ Model 705 sonic dismembrator was used for sonication. The microfluidizer was a Microfluidics Microfluidizer Model 110Y homogenizer. DT-resin-ALMA was a polymethylsilsesquioxane resin comprising difunctional and trifunctional siloxane units, wherein said resin further comprised methacryloxypropyl groups.
In this Reference Example A, silicone-(meth)acrylate copolymer emulsions were prepared as follows. Initiator solution A was prepared as follows: 0.702 g 70% t-butylhydroperoxide was diluted in 45 mL of DI water to form a stock solution. The final solution was made by taking 5 g of this stock solution and mixing with 5 g of DI water.
Initiator solution B was prepared as follows: 0.96 g Isoascorbic acid was added to 45 mL of DI water to form a stock solution. The final solution was made by taking 5 g of this stock solution and mixing with 5 g of DI water.
Stearyl acrylate (47.5 g), Si16 (1.5 g), HEMA (1 g), dodecanethiol (0.05 g), Ecosurf™ EH-40 non-ionic surfactant (1.67 g) and deionized water (200 g) were placed in a 400 ml jar. The mixture was heated in a 40° C. water bath for 10 min to melt the stearyl acrylate. The material was sonicated at an amplitude of 50 Joules for two minutes using a sonicator to create a coarse emulsion. The coarse emulsion was then passed through a microfluidizer operating at 40° C. and 10-15k PSI. The emulsion was then transferred to a 1000 mL 4 neck flask equipped with a reflux condenser, nitrogen inlet, overhead stirrer (IKA RW20) and thermocouple probe. The emulsion was stirred at 200 RPM using a Teflon blade and heated to 60° C. After reaching temperature, a redox initiator was fed into the solution at 0.25 mL/min (Initiator Solution A and Initiator Solution B in separate feeds) and after an hour at 60° C., the resulting emulsion formulation was then allowed to cool to <35° C. with stirring before pouring off. The silicone-(meth)acrylate copolymers of samples 1 to 16 and 23-34 were prepared according to this Reference Example A by varying amounts of the appropriate starting materials.
In this Reference Example 1, acrylate emulsion samples 17, 18, 35, and 36 were prepared as follows: Stearyl acrylate (37.5 g), Lauryl Methacrylate (11.5 g), HEMA (1 g), dipropylene glycol (20 g), Brij L23-69 (5 g), Arquad 16-29 (hexadecyltrimethylammonium chloride, 3 g), and deionized water (180 g) were placed in a 400 ml jar. The mixture was heated in a 40° C. water bath for 10 min to melt the stearyl acrylate. The material was sonicated at an amplitude of 50 J for 2 minutes using a sonicator to create an emulsion. The emulsion was then transferred to a 1000 mL 4 neck flask equipped with a reflux condenser, nitrogen inlet, overhead stirrer (IKA RW20) and thermocouple probe. The emulsion was stirred at 200 RPM using a Teflon blade and 0.3 g of 2-2′-Azobis(2-methylpropionamidine) dihydrochloride initiator was added, and the mixture was heated to 60° C. The reaction mixture was held at 60° C. for 6 hours. The material was then allowed to cool to 30 to 40° C. with stirring before pouring off.
In this Reference Example 2, acrylate emulsion samples 19, 20, 37, and 38 were prepared as described in U.S. Patent Application Publication 2020/0332148. Stearyl acrylate (49 g), HEMA (1 g), Brij L23-69 (5 g), Arquad 16-29 (hexadecyltrimethylammonium chloride, 3 g), and deionized water (200 g) were placed in a 400 ml jar. The mixture was heated in a 40° C. water bath for 10 min to melt the stearyl acrylate. The material was sonicated at an amplitude of 50 J for 2 minutes using a sonicator to create an emulsion. The emulsion was then transferred to a 1000 mL 4 neck flask equipped with a reflux condenser, nitrogen inlet, overhead stirrer (IKA RW20) and thermocouple probe. The emulsion was stirred at 200 RPM using a Teflon blade and 0.3 g of 2-2′-Azobis(2-methylpropionamidine) dihydrochloride initiator was added, and the mixture was heated to 60° C. The reaction mixture was held at 60° C. for 6 hours. The material was then allowed to cool to 30 to 40° C. with stirring before pouring off.
In this Reference Example 3, 35 g of PMX-200 fluid and 1.5 g EcoSurf™ EH-14 were placed in a plastic beaker and mixed with an IKA Ultra Turrax T25 with an 18 mm dispersing tool at 10,000 RPM. Deionized water (15.5 g) was added, dropwise, to the mixture to make the emulsion.
In this Reference Example 4, 10 g of a comparative polymer (either OHX-0750 polymer or terminal aminosiloxane), 0.5 g Synperonic 13/6, 0.5 g Synperonic 13/12, and 0.75 g deionized water were placed in a SpeedMixer cup and mixed at 3500 RPM for 30 seconds, two times. The resulting emulsion was diluted by adding 1.25 g and 3.67 g aliquots of deionized water and mixing at 3500 RPM after addition of each aliquot.
In this Reference Example 5, Emulsion Formulations suitable for treating textiles were prepared by combining water, penetrating agent, an emulsified additive (PMX-200 silicone fluid, OHX-0750 polymer, or TAS, or EMULSION 1), silicone-(meth)acrylate copolymer emulsion, and water dispersible crosslinker (PHOBOL™ XAN Extender) were combined in a plastic bottle and shaken by hand to mix. The resulting formulations are described below in Table X.
In the columns describing the starting materials in Table X, the first value represents grams of the starting material and the second value in (parentheses) represents the on fabric weight in the emulsion formulation. Copolymer refers to the silicone-(meth)acrylate copolymer.
In this Reference Example 6, a Water Repellency and Washing Durability Evaluation Procedure was performed as follows. The nylon/polyester sheets were treated with the Emulsion Formulations prepared according to Reference Example 5, and then the sheets were laundered using a 90° F. wash/cold rinse cycle and dried at ˜150° F. This method was repeated up to 20 times. 37 g of Tide detergent (non-scent) for every 6 pounds of sheets was used. The AATCC-22 Spray test was performed after initial treatment (0 washes), after 10 washes, and after 20 washes. In the spray test, values <90 were considered failures. The results are in Table Y.
In this Reference Example 7, a Softness Evaluation Procedure was performed as follows. The nylon/polyester sheets were evaluated after being dried at ˜150° F. for both stiffness and hand-feel. For stiffness, the sheets were folded in ½ and the stiffness/drape was ranked on a scale of 1-5, with 5 being the best. For hand-feel, the fabric touch was ranked on a scale of 1-5 with 5 being the best. Failures were considered to be <4). The results are in Table Y.
In Table Y, “*” denotes the sample did not pass the spray test after initial treatment, therefore, washings additional spray testing were not performed; and “-” denotes not tested.
Samples 1-6 showed that treating a PES fabric with an emulsion formulation that provided 1 to 2% silicone-(meth)acrylate copolymer and 0.01 to 0.5% EMULSION 1 provided durable water repellency (as shown by passing the spray test after 10 and 20 washes) and good softness (as shown by drape and feel test values ≥4). Example 7 showed that treating a PES fabric with an emulsion formulation that provided 1 to 2% silicone-(meth)acrylate copolymer and 0.01% trimethyl-siloxy terminated polydimethylsiloxae als provided durable water repellency (as shown by passing the spray test after 10 and 20 washes) and good softness (as shown by drape and feel test values ≥4). Examples 10 and 11 showed that treating a PES fabric with an emulsion formulation that provided 1 to 2% silicone-(meth)acrylate copolymer but no additive corresponding to starting material (II) described herein did not provide sufficient softness. Examples 13, 14, 15, and 16 showed that insufficient water repellency was achieved when additives outside the scope of this invention were used instead of starting material (II) defined herein under the conditions tested. Examples 17, 18, 19, and 20 showed that insufficient water repellency was achieved when copolymers outside the scope of this invention were used instead of starting material (I) defined herein under the conditions tested. Examples 21 and 22 showed that insufficient water repellency was achieved in the absence of starting material (I) defined herein under the conditions tested.
Silicone-(meth)acrylate hybrid copolymers can impart excellent durable water resistance to different textiles, however, they may suffer from the drawback of imparting negative aesthetics of stiffness and poor hand feel. Known compositions for treating textiles, such as those disclosed in U.S. Patent Application Publication 2020/0332148 may impart sufficient aesthetics but insufficient durable water repellency for some applications.
The present invention provides an emulsion formulation, that when used to treat textiles, imparts both good durable water repellency, as measured by a score of at least 90 in the spray test after 10 to 20 washes and desirable aesthetics, as measured by a score of at least 4 in the stiffness and hand feel tests described above in Reference Example 7.
All amounts, ratios, and percentages herein are by weight, unless otherwise indicated. The SUMMARY and ABSTRACT are hereby incorporated by reference. The articles, “a”, “an”, and “the” each refer to one or more, unless otherwise indicated by the context of the specification. The transitional phrases “comprising”, “consisting essentially of”, and “consisting of” are used as described in the Manual of Patent Examining Procedure Ninth Edition, Revision 08.2017, Last Revised January 2018 at section § 2111.03 I., II., and III. The use of “for example,” “e.g.,” “such as,” and “including” to list illustrative examples does not limit to only the listed examples. Thus, “for example” or “such as” means “for example, but not limited to” or “such as, but not limited to” and encompasses other similar or equivalent examples. The abbreviations used herein have the definitions in Table Z.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. With respect to any Markush groups relied upon herein for describing particular features or aspects, different, special, and/or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.
Furthermore, any ranges and subranges relied upon in describing the present invention independently and collectively fall within the scope of the appended claims, and are understood to describe and contemplate all ranges including whole and/or fractional values therein, even if such values are not expressly written herein. One of skill in the art readily recognizes that the enumerated ranges and subranges sufficiently describe and enable various embodiments of the present invention, and such ranges and subranges may be further delineated into relevant halves, thirds, quarters, fifths, and any other subrange subsumed within the range. As just one example, a range of “16 to 24” may be further delineated into a lower third, i.e., 16 to 18, a middle third, i.e., 19 to 21, and an upper third, i.e., from 22 to 24, and alternatively, the range “16 to 24” includes the subrange “18 to 22”, each which individually and collectively are within the scope of the appended claims, and may be relied upon individually and/or collectively and provide adequate support for specific embodiments within the scope of the appended claims. In addition, with respect to the language which defines or modifies a range, such as “at least,” “greater than,” “less than,” “no more than,” and the like, it is to be understood that such language includes subranges and/or an upper or lower limit.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/277,671 filed on 10 Nov. 2021 under 35 U.S.C. § 119 (e). U.S. Provisional Patent Application Ser. No. 63/277,671 is hereby incorporated by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US22/75435 | 8/25/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63277671 | Nov 2021 | US |
