Water-and oil repellent apparel material

Abstract: A durable and extremely water- and oil repellent ultra thin film is formed on the surface of a substates such as glass, ceramics, fabrics, fur and cloth by a dehydrochlorination reaction between a functional group such as a hydroxyl group or an imino group on the surface of the substrate. The coating film of the material comprises a plurality of chlorosilyl groups was formed on the surface of the substrate by dipping and holding the substrate comprising functional groups on its surface in a solution prepared by dissolving a material comprising fluorocarbon groups and a plurality of chlorosily groups in a non-aqueous solvent and drying the substrate which is then taken out from the solution in a substantially moistureless or low moisture atomosphere and removing the non-aqueous solvent remaining on the substrate. Further, when the coating film is left in an atomosphere comprising moisture, i.e., humid air, the coating film is polymerized by a dehydrochlorination reaction between the coating film and the moisture in the atomosphere. The film is formed on the surface of the substrate containing hydroxyl groups, imino groups or carboxyl groups through -SiO- bonds or -SiN< bonds.

Description: FIELD OF THE PRESENT INVENTION This invention relates to water- and oil repellent materials for apparel. Particularly, this invention relates to an efficient water- and oil repellent and antifouling materials for apparel such as rainwear, coats, sportwear (for example ski wear), cloth for gloves, fur and leather. BACKGROUND OF THE INVENTION In the prior art, the surface of the materials such as metal, ceramics, glass, plastic, fiber, paper and wood were made water- and oil repellent by impregnating or coating resins and paints or by applying or baking an emulsion of a fluorocarbon resin such as polytetrafluoroethylene. In addition, making rainwear, coats, sportwear (including ski wear), cloth for gloves, fur and leather water- and oil repellent is an important object for antifouling materials for apparel and for rainy weather measures. In the prior art, a method of spraying a fluorocarbon based emulsion (fluorocarbon resin) and forming a loose coating film having minute holes was proposed to make materials for apparel such as textiles with keeping air permeability to some extent. Another method of coating resins such as with a thin urethane resin to form a loose coating film having minute holes was proposed. Another method of densely weaving thin fiber having a relatively high shrinkage percentage and shrinking the textiles by a high temperature processing is also known. Further, a natural fur such as mink is polish processed by applying materials comprising a silicon compound or a fluorine compound. However, in the prior art, the coated film was not chemically bonded to the surface of the substrate, thus it was a serious drawback that the durablity of the coated film was extremely poor. In addition, there was a problem that the appearance of the substrate was damaged by the prior art methods. In addition, the prior method of coating water repellent materials had only a minor effect on the substrate, thus the durability of the coating was extremely poor. The body also gets sweaty when wearing clothes whose surface was coated with resin. It is an extremely important improvement in material for apparel that only the surface fiber is made water repellent without damaging the luster of the fiber and the comfortable feeling of texitiles and air permeability of the fiber is maintained. EP-A-0 508 136 (relevant with respect to Art 54(3) EPC) discloses in Figure 7 (c) a chemically adsorbed monomolecular film comprising a siloxane-based inner layer and a fluorocarbon-based outer layer. SUMMARY OF THE INVENTION It is the object of this invention to provide water- and oil repellent materials for apparel which are durable and the body does not get sweaty in wearing clothes made of the materials for apparel. This object is solved by providing the water- and oil-repellent apparel material according to claim 1. It is preferable in this invention that the covalent bonds are siloxane bonds. It is preferable in this invention that the non-aqueous solvent is selected from the group consisting of a hydrocarbon-based organic solvent and a fluorocarbon-based organic solvent. It is preferable in this invention that surface functional group is a hydroxyl group provided by a plasma or corona treatment. According to the invention, a durable, water- and oil repellent material for apparel can be provided by forming an extremely water- and oil repellent ultra thin film on the surface of the substrate via covalent bonds at a lower cost. According to the invention, an extremely durable water- and oil repellent treatment was made easily by forming an extremely water- and oil repellent ultra thin film on the surface of the material via chemical bonds. Subsequently, the water- and oil repellent treatment of the materials for apparel will be described with concrete examples. A coating film of material containing at least one chlorosilyl group was formed on its surface of the substrate as follows: by dipping and holding a material for apparel comprising a hydroxyl group, an imino group or a carboxyl group on its surface in a solution prepared by dissolving a material having a fluorocarbon group and a at least one chlorosilyl groups dissolved in a non-aqueous solvent; by drying the substrate which is taken out from the solution in an atomosphere containing substantially no moisture and removing the non-aqueous solvent remaining on the substrate. Further, when the coating film was left in air, the coating film was polymerized by a dehydrochlorination reaction between the coating film and moisture in the air. Thus, an extremely water- and oil repellent ultra thin film comprising numerous fluorine groups was formed on the surface of the materials for apparel via chemical bonds. BRIEF DESCRIPTION OF DRAWINGS Figures 1 (a) to (c) show a cross section explaining the preparation of the water- and oil repellent material as in Example 1 and Example 3 of the invention. Figures 2 (a) to (c) show a cross section explaining the preparation of the water- and oil repellent material as in Example 2 and Example 4 of the invention. DETAILED DESCRIPTION OF THE INVENTION According to the invention, a durable and extremely water- and oil repellent ultra thin film is formed on the surface of a substate such as fabrics, fur and cloth by a dehydrochlorination reaction between functional groups such as hydroxyl groups or imino groups on the surface of the substrate. The coating film of the material comprising a plurality of chlorosilyl groups was formed on the surface of the substrate by dipping and holding the substrate comprising the functional groups on its surface in a solution prepared by dissolving a material comprising a fluorocarbon group and a plurality of chlorosilyl groups in a non-aqueous solvent and drying the substrate which is then taken out of the solution in a substantially moistureless atmosphere and removing the unreacted non-aqueous solvent remaining on the substrate. Further, when the coating film is left in an atmosphere comprising moisture, the coating film is polymerized by a dehydrochlorination reaction between the coating film and moisture in the atmosphere. The polymerized coating film contains numerous fluorine groups and reacts to moisture in the air. The substrate surface contains numerous hydroxyl groups, imino groups or carboxyl groups and thus the film is formed at the surface of the substrate through -SiO- bond or -SiN< bond. A method of making the surface of the substrate water- and oil repellent comprises steps as follows: dipping and holding a substrate, whose surface has at least one functional group such as a hydroxyl group, an imino group and a carboxyl group, in a non-aqueous solution containing a material having a fluorocarbon group and a plurality of chlorosilyl groups, drying the substrate which is taken out of the solution in a substantially moistureless or low moisture atmosphere and removing the unreacted non-aqueous solvent remaining on the substrate, removing the substrate covered by the material having a fluorocarbon group and a plurality of chlorosilyl groups in an atmosphere comprising moisture (i.e., a humid atmosphere). It is preferable to use a hydrocarbon based solvent or a fluorocarbon based solvent as a non-aqueous solvent. A durable water- and oil repellent material can be provided by forming an ultra thin film comprising numerous, extremely water- and oil repellent fluorines via chemical bonds. Therefore, a coating film whose surface monomolecular film comprised a plurality of chlorosilyl groups was formed by dipping and holding a substrate whose surface comprised a hydroxyl group or an imino group or a carboxyl group in a non-aqueous solution containing a material having fluorocarbon groups and a plurality of chlorosilyl groups, taking the substate out of the solution, and removing the unreacted non-aqueous solution remaining on the substrate by drying in a substantially moistureless or low moisture atmosphere. Further, the coating film was polymerized by a dehydrochlorination reaction between the moisture in the air by exposing to an atmosphere containing moisture (i.e., humid air). Then an extremely water- and oil repellent ultra thin polymer film was formed on the surface of the substrate via chemical bonds as a dehydrochlorination reaction was also brought about between the coating film and the surface of the substrate. CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl 3 , CF 3 (CF 2 ) 5 (CH 2 ) 2 SiCl 3 , CF 3 CH 2 O(CH 2 ) 15 SiCl 3 , CF 3 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 15 SiCl 3 , F(CF 2 ) 4 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 9 SiCl 3 , CF 3 COO(CH 2 ) 15 SiCl 3 are examples of a surface active material comprising a fluorocarbon group and a plurality of chlorosilyl groups. It is preferable to use a hydrocarbon based solvent or a hydrogen fluoride based solvent as a non-aqueous solvent as they are not substantially toxic. According to the invention, a water- and oil repellent material for apparel has an ultra thin film comprising numerous water- and oil repellent functional groups formed on the surface of the material via covalent bonds containing -Si- bonds. According to the invention, it is preferable that the covalent bonds are siloxane bonds. According to the invention, a durable water- and oil repellent material for apparel can be provided by forming an ultra thin film containing numerous water- and oil repellent functional groups via covalent bonds having -Si- groups on the surface of the material. Further, as an ultra thin film at the nanometer level was formed on the surface of the material, the ultra thin film does not substantially prevent breathability and a body does not get sweaty in wearing clothes made of the substrate above mentioned. Subsequently, a detailed description of the invention will be described with concrete examples. Example 1 A coating film 2, being about 200 angstroms in thickness and comprising fluorocarbon groups and a plurality of chlorosilane groups, was formed as follows: washing a fabric substrate with pure water, dipping and holding the substrate in a solution prepared by dissolving 1% by weight of a chemical compound comprising fluorocarbon groups and a plurality of chlorosilane groups, namely CF 3 (CF 2 ) 7 (CH 2 ) 7 (CH 2 ) 2 SiCl 3 , in a fluorocarbon based solvent e.g. (Afluid: Asahi Glass Co.,) for about ten minutes; drying the unreacted solvent remaining on the substrate in a substantially moistureless or low moisture atomosphere (preferably less than about 5% relative humidity) without washing with an organic solvent. When the coating film 2 was formed, a material comprising some fluorocarbon groups and a chlorosilane group was fixed on the surface of the substrate via siloxane bonds which was brought about by a dehydrochlorination reaction between the material above mentioned and a hydroxyl group 3 on the surface of the substrate (Figure 1 (b)). Then, when the substrate was left in an atmosphere comprising moisture (i.e., a humid atmosphere of more than about 30% of relative humidity such as air), the coating film and the unreacted chlorosilyl groups of the material having the fixed fluorocarbon groups and chlorosilane groups were polymerised by a dehydrochlorination reaction between moisture in the air. The coating film contained numerous fluorine groups and it was bonded to the surface of the substrate via siloxane bonds 4. Hence, an extremely water- and oil repellent ultra thin polymerized film 5 was formed on the surface of the substrate (Figure 1 (c)). Further, the ultra thin polymer film was covalently bonded to the substrate via siloxane bonds, and was inseparable by scraping and washing the substrate. A wetting angle to water of the substrate was about 150° . Example 2 A coating film 12, being about 100 angstroms in thickness and comprising fluorocarbon groups and a plurality of chlorosilane groups, was formed as follows: washing processed nylon-ABC resin substrate (polymer alloy or polymer blend) with pure water, dipping and holding the substrate in a solution prepared by dissolving 1% by weight of a material having fluorocarbon groups and a plurality of chlorosilyl groups e.g. CF 3 (CF 2 ) 5 (CH 2 ) 2 SiCl 3 in a hydrocarbon based solvent (n-hexane) for about twenty minutes, evaporating the unreacted solvent remaining on the substrate and drying the substrate in a substantially moistureless or low moisture atomosphre (preferably less than about 5% relative humidity) without washing with an organic solvent. When the coating film 12 was formed, a material comprising some fluorocarbon groups and the chlorosilane groups was fixed on the surface of the substrate via siloxane bonds which was made by a dehydrochlorination reaction between the material above mentioned and an imino group 13 on the surface of the substrate (Figure 2 (b)). Then, when the substrate was left in an atmosphere comprising moisture, i.e., a humid atmosphere such as air, the coating film above mentioned and the unreacted chlorosilyl groups of the material comprising the fixed florocarbon groups and chlorosilane groups were polymerized by a dehydrochlorination reaction with the moisture in the air. The coating film above mentioned contains numerous fluorine groups and was bonded to the surface of the substrate via -SiN< bonds. Hence, an extremely water- and oil repellent ultra thin polymerized film 15 was formed on the surface of the substrate (Figure 2 (c)). Further, the ultra thin film was covalently bonded to the substrate via -SiN< bonds and was inseparable by scraping and washing the substrate. A wetting angle of the substrate to water was extremely high, 130° . In the example above mentioned, CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl 3 , and CF 3 (CF 2 ) 5 (CH 2 ) 2 SiCl 3 were used as a material comprising a fluorocarbon group and a chlorosilane group and CF 3 CH 2 O(CH 2 ) 15 SiCl 3 , CF 3 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 9 SiCl 3 , CF 3 COO(CH 2 ) 15 SiCl 3 were also availabe. In addition, the substrate whose surface was roughened about 10-0.1 µm was used in Example 1 and Example 2 and in that case, a water-repellent angle of the substrate was about 160° or 150° . Example 3 Processed cotton fabrics for a rain coat or any fabrics such as fur or leather comprising a functional group on its surface which brings about a dehydrochlorination reaction between a chlorosilane group such as a hydroxyl group, an imino group and a carboxyl group was washed with pure water and dipped and held in a solution prepared by dissolving CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl 3 . The material above mentioned was diluted with a non-aqueous solvent. Coating film 2, being about 200 angstroms (20 nm) in thickness and comprising an unreacted fluorocarbon group and a plurality of chlorsilane groups remaining on the surface of the cotton fiber of the fabric 1 was formed as follows: dipping and holding a cotton fabric, for about ten minutes, in a solution prepared by dissolving 1% by weight of the chemical compound above mentioned in a fluorocarbon based solvent (for example, Afluid: Asahi Glass Co.,) drying the solvent of the fabric in a substantially moistureless or low moisture atmosphere (preferably less than about 5% relative humidity) without washing with an organic solvent. When the coating film 2 was formed on the cotton fiber surface, a material comprising some fluorocarbon groups and a chlorosilane group was fixed on the surface of the cotton fiber via siloxane bonds which was brought by a dehydrochlorination reaction between the hydroxyl groups on the surface of the cotton fiber 3 (Figure 1 (b)). Then, when the cotton fabric above mentioned was left in an atmosphere containing moisture such as humid air (preferably more than about 30% relative humidity), an unreacted chlorosilyl group of the material comprising the coating film with the fixed fluorocarbon groups and chlorosilane groups on the surface of the cotton fiber, the film was polymerised by a dehydrochlorination reaction between moisture in the air. The coating film above mentioned contained numerous fluorine groups and was bonded to the surface of the cotton fiber via siloxane bonds 4. Thus, an extremely water- and oil repellent ultra thin polymerized film 5 was formed on the surface of the cotton fabric (Figure 1 (c)). When a cotton fabric was dipped and held in a solution prepared by dissolving an equal ratio of CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl 3 and pyridine (any alkali which does not react with a chlorosilyl group and contains no moisture is available) in a fluorocarbon based solvent, a coating film was formed without deteriorating the cotton fabric. By adding of pyridine, hydrochloric acid which was formed during the reaction was neutralizated. Thus, the cotton fabric was not deteriorated. The ultra thin film above mentioned comprising a fluorocarbon group was covalently bonded to the cotton fiber via siloxane bonds, and was inseparable by scraping and washing the substrate. A wetting angle to water of water- and oil repellent cotton fabric substrate was about 170° . Example 4 A coating film 12, being about 100 angstroms (10 nm) in thickness and comprising fluorocarbon groups and a plurality of chlorosilyl groups was formed as follows: washing processed nylon fabric with pure water, dipping and holding the nylon fabric in a solution, for about twenty minutes, prepared by dissolving 1% by weight of CF 3 (CF 2 ) 5 (CH 2 ) 2 SiCl 3 in a hydrocarbon based solvent (normal hexane). drying the substrate in a substantially moistureless or low moisture atomosphere (preferably less than about 5% relative humidity) without washing with an organic solvent. When the coating film 12 was formed, a material comprising some fluorocarbon groups and a chlorosilyl group was fixed on the surface of the nylon fiber via siloxane bonds (-SiO-) 14 which was brought about by a dehydrochlorination reaction between an imino group on the surface of the nylon fiber (Figure 2 (b)). Then, when the fabric was left in an atmosphere comprising moisture such as humid air (more than about 30% relative humidity), unreacted chlorsilyl groups of the material comprising the coating film, the fixed the fluorocarbon groups and the chlorosilane groups was polymerized by a dehydrochlorination reaction between moisture in the air. The coating film above mentioned contained numerous fluorocarbon groups and was bonded to the fiber of the substrate via -SiN< bonds. Hence, an extremely water- and oil repellent ultra thin polymerized film 15 was formed on the surface of the nylon fiber (Figure 2 (c)). Further, the ultra thin film was covalently bonded to a nylon fiber via -SiN< bonds, and was inseparable by scraping and washing the substrate. A wetting angle to water of nylon cloth which was made of nylon fabrics was extremely high, about 170° . In the example of the invention, CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl 3 , CF 3 (CF 2 ) 5 (CH 2 ) 2 SiCl 3 was used as a material comprising a fluorocarbon group and a chlorosilane group. However, material shown as follows were also available. CF 3 CH 2 O(CH 2 ) 15 SiCl 3 , CF 3 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 15 SiCl 3 , F(CF 2 ) 4 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 9 SiCl 3 , CF 3 COO(CH 2 ) 15 SiCl 3 As has been shown, the invention is greatly beneficial to industry.

Claims: A water- and oil-repellent apparel material comprising a chemically adsorbed polymer film as a surface layer covalently bonded to said apparel material by -Si- bonds, said apparel material being a material selected from fur, leather, fiber, fabric, cloth and paper, said chemically adsorbed film containing numerous -CF 3 groups, said water- and oil-repellent apparel material being obtainable by a process comprising the steps of: a) dipping and holding an apparel material having at least one functional group selected from a hydroxyl group, an amino group, an imino group and a carboxyl group on its surface into a solution prepared by dissolving a surface active material containing a fluorocarbon group and a chlorosilyl group in a non-aqueous solvent, said surface active material being represented by the general formula CF 3 -(CF 2 ) n -R-SiX p Cl 3-p where n represents an integer, R represents an alkylene group or a substituted group comprising a silicon atom or an oxygen atom or a chemical bond, X represents H or a substituted group selected from the group consisting of an alkyl group and an alkoxy group, and p represents 0, 1 or 2, with the proviso that said surface active material does not contain a Si-O-Si group, b) taking said apparel material out of said solution, c) drying said apparel material in a substantially moistureless atmosphere and removing non-aqueous solvent remaining on the surface of said apparel material to form a coating film, and d) reacting said coating film by exposing it to a moisture containing atmosphere, with the proviso that said apparel material is not washed with an organic solvent prior to the drying step (c). The water- and oil-repellent apparel material according to claim 1, wherein said covalent bonds are siloxane bonds.

Inventors: OGAWA KAZUFUMI, SOGA MAMORU, OGAWA, KAZUFUMI, SOGA, MAMORU
Applicants: MATSUSHITA ELECTRIC IND CO LTD, MATSUSHITA ELECTRIC INDUSTRIAL CO., LTD.
Application year: 1992
Main classification: B05D1
IPC codes: B05D5, D06M15, C09D4, B05D1, D06M23