Water- and oil-repellent agent and process for preparing the same

Abstract: A water-dispersible, water- and oil-repellent agent, Which comprises an aqueous emulsion comprising a copolymer of a fluoroalkyl group-containing monomer with vinylidene chloride or benzyl (meth)acrylate and a carboxyl group-containing, water-soluble polymer, dispersed in water by a nonionic surfactant, preferably the carboxyl group-containing, water-soluble polymer is used together with a sugar alcohol, contains no organic solvent and has a distinguished freeze-thaw stability.

Description: BACKGROUND OF THE INVENTION 1. FIELD OF THE INVENTION The present invention relates to a water- and oil-repellent agent and a process for preparing the same, and more particularly to a water- and oil-repellent agent having a distinguished freeze-thaw stability and a process for preparing the same. 2. DESCRIPTION OF RELATED ART Conventional water- and oil-repellent agents including water-soluble organic solvents such as acetone, ethyl acetate, etc. have a distinguished freeze-thaw stability, but still have such problems as contamination of working circumstances due to use of organic solvents or contamination of effluent water with organic solvents, resulting in an increase in BOD and COD, etc. "Freeze-thaw stability" is one of test items, which determines such a property of an emulsion of a water- and oil-repellent agent as return to the original state or not when the emulsion is once frozen and then returned to room temperature. Poor freeze-thaw stability indicates occurrence of such phenomena as precipitation, increased viscosity or sometimes solidification during the transport in cold districts. Once denaturing of the emulsion occurs due to such phenomena, the commercial value of the water- and oil-repellent agent will be entirely lost. The following water- and oil-repellent agents including water-soluble organic solvents have been so far proposed. JP-A-7-173772 discloses a water-emulsifiable, fluorine-based water- and oil-repellent agent which comprises 100 parts by weight of polyfluoroalkyl group-containing polymer and 1 to 20 parts by weight of glycol. In the conventional emulsion polymerization to form water-dispersible, water- and oil-repellent polymers, at least 50 parts by weight of a low boiling organic solvent such as acetone, ethyl acetate, etc. is used per 100 parts by weight of a monomer mixture to improve the compatibility of polyfluoroalkyl group-containing monomers with an aqueous medium or with other comonomers, where the residual organic solvent, if any, lowers the color fastness. By using a smaller amount of glycol, the disadvantage can be improved, but the glycol as an organic solvent still remains in the resulting water- and oil-repellent aqueous emulsion. JP-A-5-263070 discloses that emulsion polymerization of fluoroalkyl group-containing monomers is carried out in an aqueous solution containing a specific glycol ether or glycol ester. It is discloses that the proportion of these glycols to be used can be reduced to about 10 to about 30 parts by weight per 100 parts by weight of the monomer mixture in contrast to a proportion of the ordinary organic solvent of about 60 to about 100 part by weight, but the glycols as an organic solvent also still remains in the resulting water- and oil-repellent aqueous emulsion. JP-A-6-17034 discloses a water- and oil-repellent aqueous latex where polyfluoroalkyl group-containing polymers are dispersed in an aqueous medium containing a glycol ether-typed solvent. It is disclosed that a proportion of the glycol ether-typed solvent to be used is about 50 to about 5% by weight on the basis of total weight of the emulsion including water, and thus a considerably large amount of the organic solvent is used. JP-A-5-279541 discloses that various organic solvents such as acetone, etc. are present in the emulsion polymerization to form fluorine-containing copolymers, where it is stated that a considerable portion of the solvent can be made to remain in the resulting aqueous dispersion, but a complicated, expensive procedure for removing the solvent at 40° to 90°C in vacuum is used from the viewpoints of safety and industrial sanitation. JP-A-5-17538 discloses formation of an aqueous emulsion by once emulsifying and dispersing perfluoroalkyl acrylate, carboxyl group-containing α, β-ethylenic unsaturated monomer and hydroxy group-containing α,β-ethylenic unsaturated monomer into water to form particles having particle sizes of not more than 0.3 µ m, followed by polymerization. Though the disclosed procedure uses no organic solvent, not only a complicated means of conducting ultrasonic irradiation for 60 minutes while bubbling the emulsion having an average particle size of about 1 µ m with a nitrogen gas is used to make the particle size not more than 0.3 µ m, but also there is a possibility of precipitation when only a small amount of a cationic component is mixed therein during the water- and oil-repellent processing such as dipping, etc. because the resulting copolymers partially contain carboxyl groups. SUMMARY OF THE INVENTION An object of the present invention is to provide a water-emulsifiable waterand oil-repellent agent entirely free of an organic solvent and having a distinguished freeze-thaw stability. The object of the present invention can be attained by a water- and oil-repellent agent, which comprises an aqueous emulsion comprising a fluoroalkyl group-containing copolymer obtainable by copolymerising 30 to 90 wt.% of a fluoroalkyl group-containing monomer and 70 to 10 wt.% of vinylidene chloride or benzyl(meth)acrylate, the total sum being 100% by weight, whereby this copolymer can be further copolymerized with up to 10 % by weight, on the basis of the total copolymer, of a hydroxy group-containing monomer and/or another cross-linkable group-containing monomer, and 0.1 to 2 wt.%, on the basis of the fluoroalkyl group-containing copolymer, of a carboxy group-containing water-soluble polymer, and 1 to 10 wt.% of an non-ionic surfactant, based on the total amount of monomers. It is preferable to use a sugar alcohol together with the carboxl group-containing, water-soluble polymers. DETAILED DESCRIPTION OF THE INVENTION The present water- and oil-repellent agent can be prepared by a method for emulsion polymerization of fluoroalkyl group-containing monomers with vinylidene chloride or benzyl (meth)acrylate: (1) in the presence of a nonionic surfactant, followed by adding a carboxyl group-containing, water-soluble polymer as defined in claim 8, or (2) in the presence of a nonionic surfactant and a carboxyl group-containing, water-soluble polymer as defined in claim 10 where it is preferable to use a sugar alcohol together with the carboxyl group-containing, water-soluble polymer. The fluoroalkyl group-containing monomer for use in the present invention can be represented by the following general formula: CH 2 =CRCOOR 1 Rf where R is a hydrogen atom or a methyl group, R 1 is a divalent organic group and Rf is a perfluoroalkyl group having 4 to 20 carbon atoms and includes, for example, the following monomer compounds. CH 2 =CHCOOC 2 H 4 C n F 2n+1 CH 2 =C(CH 3 )COOC 2 H 4 C n F 2n+1 CH 2 =CHCOOC 4 H 8 C n F 2n+1 CH 2 =C(CH 3 )COOC 4 H 8 C n F 2n+1 CH 2 =CHCOOC 2 H 4 N(CH 3 )SO 2 C n F 2n+1 CH 2 =C(CH 3 )COOC 2 H 4 N(CH 3 )SO 2 C n F 2n+1 CH 2 =CHCOOC 2 H 4 N(C 2 H 5 )SO 2 C n F 2n+1 CH 2 =C(CH 3 )COOC 2 H 4 N(C 2 H 5 )SO 2 C n F 2n+1 CH 2 =CHCOOC 2 H 4 N(C 3 H 7 )SO 2 C n F 2n+1 CH 2 =C(CH 3 )COOC 2 H 4 N(C 3 H 7 )SO 2 C n F 2n+1 CH 2 =CHCOOC 2 H 4 C n F 2n CF(CF 3 ) 2 CH 2 =C(CH 3 )COOC 2 H 4 C n F 2n CF(CF 3 ) 2 Among the monomer compounds given above, compounds with R 1 =C 2 H 4 are preferably used. Generally, mixtures of linear perfluoroalkyl groups with various n values can be used from the viewpoints of performance and cost. As comonomers to be copolymerized with the perfluoroalkyl group-containing monomers, vinylidene chloride or benzyl (meth)acrylate is selected from viewpoints of both water and oil repellency and freeze-thaw stability. To satisfy these two requirements, 30 to 90% by weight, preferably 45 to 85% by weight, of the perfluoroalkyl group-containing monomer and 70 to 10% by weight, preferably 55 to 15% by weight, of vinylidene chloride or benzyl (meth)acrylate are copolymerized, sum total being 100% by weight. The fluoroalkyl group-containing copolymer comprising these essential components can be further copolymerized with not more than 10% by weight, preferably 0.5 to 7% by weight on the basis of the total copolymer, of a hydroxyl group-containing monomer such as hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, 3-chloro-2-hydroxypropyl methacrylate, glycerine monomethacrylate, alkyleneglycol mono(meth)acrylate, etc. These hydroxyl group-containing monomers can improve the adhesion of the water- and oil-repellent agent or improve the durability of the water- and oil-repellent agent by using a cross-linking agent reactive with the hydroxyl group. The copolymer can be further copolymerized with not more than 10% by weight, preferably 0.5 to 7% by weight on the basis of the total copolymer, of a cross-linkable group-containing monomer such as N-methylol (meth)acrylamide, N-methoxymethyl acrylamide, N-butoxymethyl acrylamide, acrylamide, glycidyl (meth)acrylate, etc. These cross-linkable group-containing monomers can improve the durability of the water- and oil-repellent agent by cross-linking with hydroxyl groups on fiber surfaces or self cross-linking. Copolymerization reaction is carried out by emulsion polymerization using a radical initiator in the presence of a nonionic surfactant. Preferable nonionic surfactant for use in the present invention includes, for example, polyoxyethylene ether derivatives such as polyoxyethylene lauryl ether, polyoxyethylene cetyl ether, polyoxyethylene stearyl ether, polyoxyethylene oleyl ether, polyoxyethylene octylphenyl ether, polyoxyethylene nonylphenyl ether, etc., where 1 to 10% by weight, preferably 2 to 6% by weight, of the nonionic surfactant can be used on the basis of the total monomers. Below about 1% by weight, precipitation takes place during the polymerization, whereas above about 10% by weight the carboxyl group-containing, water-soluble polymer fails to adsorb onto the emulsion particles. Thus, proportion of the nonionic surfactant is desirably as small as possible. Radial initiator for use in the present invention includes, for example, an organic peroxide, an azo compound, a persulfate, etc. Preferable are potassium persulfate, ammonium persulfate, 2,2' -azobis(2-aminodipropane) dihydrochloride, etc. The copolymerization reaction can be carried out in an aqueous medium at a temperature of about 40° to about 80°C for about 1 to about 10 hours to form an aqueous emulsion having a solid concentration of about 15 to about 35% by weight. The resulting aqueous emulsion is admixed with a carboxyl group-containing, water-soluble polymer, preferably together with sugar alcohol. Generally, water starts to freeze and growth of ice crystals starts, with decreasing temperature of the aqueous emulsion. Once the grow the of ice crystals starts, emulsion particles themselves will approach to one another to start mutual fixing. If there is a protective layer on the particle surfaces, no mutual fixing takes place by virtue of the strong protective layer even when the particles are subject to pressure exerted by ice crystals. However, if there is no effective protective layer on the particle surfaces, mutual fixing of the particles takes place and remains as it is even when the aqueous emulsion is returned to room temperature, resulting in increased viscosity, precipitate formation, entire solidification, etc. An emulsifying agent used at the polymerization reaction can serve to form a protective layer, which is, however, not strong enough to withstand the pressure exerted by ice crystal. On the other hand, the carboxyl group-containing, water-soluble polymer can be effectively adsorbed onto the emulsion particles to form an effective protective layer for withstanding the pressure exerted by ice crystals. Proportion of the carboxyl group-containing, water-soluble polymer to be added is considerably small, i.e. 0.1 to 2% by weight, preferably 0.2 to 1% by weight on the basis of total amount of monomer mixture or fluoroalkyl group-containing copolymer. The carboxyl group-containing, water-soluble polymer includes, for example, sodium salts of polyacrylic acid, polyitaconic acid, methyl acrylate-acrylic acid copolymer, acrylic acid-methacrylic acid copolymer, etc., sodium salts of acrylic add-maleic acid copolymer, acrylic acid-styrene sulfonic acid copolymer, etc., and the following carboxyl group-containing, water-soluble polymers having a low average molecular weight range (1000 ∼ 15000) can be used. When those having a higher average molecular weight are used, the resulting water- and oil-repellent agent has too high a viscosity and will be unstable. In practice, the following commercially available products are used. For sodium polyacrylate or polyacrylic acid (for Na salt formation), water-soluble polymers such as Aron A series (products commercially available from Toagosei Co., Ltd. Japan), e.g. A-200U (average molecular weight: 2,000), A-20U (average molecular weight: 6,000), A-20UK (average molecular weight: 6,000), A-20UN (average molecular weight 8,000), A-40HA (average molecular weight: 12,000), etc.; Aquaric series (products commercially available from Nippon Shokubai Kogyo K. K., Japan), e.g. DL-324 (average molecular weight 2,000), DL-40S (average molecular weight 5,000), DL-100 (average molecular weight: 5,000), DL-384 (average molecular weight 8,000), HL-415 (average molecular weight 10,000), etc,; Julymer series (products commercially available from Nippon Junyaku K. K., Japan), e. g. AC-103 (average molecular weight: 6,000), AC-107 (average molecuar weight 3,000), etc. each can be used. For methyl acrylate-sodium acrylate copolymer, Julymer AC-103A (average molecular weight 6,000), etc. can be used. For sodium acrylate-sodium methacrylate copolymer, Julymer AC-203 (average molecular weight: 6,000), etc. can be used. For sodium polyitaconate, Julymer AC-70N (average molecular weight: 10,000), etc. can be used. For sodium salts of acrylic add-maleic add copolymer, Aquaric TL-37, etc. can be used. A portion of surfactants used at the polymerization to protect the emulsion particles can be replaced with the carboxyl group-containing, water-soluble polymer, which can be strongly bonded to the emulsion particles. That is, it seems that the emulsion particles protected by the carboxyl group-containing, water-soluble polymer can be more stabilized against freezing than those protected by the surfactant. When a sugar alcohol is used together, it seems that the carboxyl group-containing, water-soluble polymer strongly bonded around the emulsion particles can be further protected by the surfactant used at the polymerization and the sugar alcohol. The carboxylic group-containing, water-soluble polymer or further the sugar alcohol can be added to the aqueous emulsion obtained by the emulsion polymerization. Furthermore, the carboxylic group-containing, water-soluble polymer or the sugar alcohol can be added to the emulsion polymerization system together with the nonionic surfactant and subjected to the emulsion polymerization, where it is preferable to used the carboxyl group-containing, water-soluble polymer and the sugar alcohol at the same time. Sugar alcohol (polyhydric alcohol obtained by reducing the carbonyl groups of sugar) for use in the present invention includes, for example, erythritol, xylitol, ribitol, arabitol, galactitol, sorbitol, iditol, mannitol, paratinit, maltitol, lactitol, maltotriitol, isomaltotriitol, maltotetraitol, isomaltotetraitol, reducing malt sugar, etc. From the viewpoint of availability, maltitol, paratinit, lactitol, erythritol, xylitol, mannitol, sorbitol, etc. can be preferably used. Together with the carboxyl group-containing, water-soluble polymer, these sugar alcohols can be used in a proportion of 2 to 20% by weight, preferably 2 to 10% by weight, on the basis of total monomer mixture or fluoroalkyl group-containing copolymer. On the other hand, glucose and sucrose have a weak protective effect on the emulsion particles like sugar alcohols, but have such a disadvantage coloration due to insufficient heat stability when used as a water- and oil-repellent agent, for example, when applied to nylon cloth, followed by heat treatment. By adding a carboxyl group-containing, water-soluble polymer, preferably together with a sugar alcohol, to a water- and oil-repellent agent, which comprises an aqueous emulsion comprising a copolymer of fluoroalkyl group-containing monomer and vinylidene chloride or benzyl (meth)acrylate dispersed in water by a nonionic surfactant, a water- and oil-repellent agent having a distinguished freeze-thaw stability can be obtained without using an organic solvent. Any special precaution is no more required for storage in winter or transportation, etc. for such a water- and oil-repellent agent. PREFERRED EMBODIMENTS OF THE INVENTION The present invention will be described in detail below, referring to Examples. POLYMERIZATION EXAMPLE 1 Into a glass separable flask having a capacity of 2,000 ml with a stirrer were charged 250g of a mixture of compounds having the following general formula: CH 2 =CHCOOC 2 H 4 C n F 2n+1 (where n is 6 to 14 and 9.0 on average), 150g of benzyl methacrylate, 25g of 2-hydroxyethyl acrylate and 1,368 ml of deionized water together with 10g of a nonioric surfactant Emulgen 930 (polyoxyethylene nonyl phenyl ether; HLB=15.1, a product commercially available from Kao Corp., Japan) and 10g of a noionic surfactant Emulgen 950 (polyoxyethylene nonyl phenyl ether; HLB=18.2, a product commercially available from the same company as above). The charged mixture was subjected to emulsification treatment under pressure of 600 kg/cm 2 , using a high pressure homogenizer (made by Nippon Seiki K. K., Japan) and then subjected to stirring for 30 minutes while injecting a nitrogen gas therein. After the inside pressure of the reactor vessel was gradually elevated to 40°C, 50g of vinylidene chloride and 25g of N-methylol acrylamide dissolved in 50 ml of deionized water were added thereto, and furtheremore 12g of 2,2'-azobis (2-amidinopropane) dihydrochloride dissolved in 50 ml of deionized water was added thereto to start polymerization reaction. The reaction was carried out at 70°C for 4 hours while gradually increasing the inside temperature to 70°C, and then the reaction mixture was cooled, whereby 1,950g of an aqueous emulsion having a solid concentration of 25.8% by weight was obtained. Polymerization yield calculated from the recovered product weight was 94.6%. POLYMERIZATION EXAMPLE 2 In polymerization Example 1, the amount of benzyl methacrylate was changed to 50g, and that of vinylidene chloride to 150g. POLYMERIZATION EXAMPLE 3 In polymerization Example 1, 53.2g of sorbitol was charged at the same time when the monomers were charged, to conduct polymerization reaction in the presence of sorbitol, whereby 2,002.3g of an aqueous emulsion having a solid concentration of 27.6% by weight was obtained. The amount of the charged sorbitol is corresponded to 10% by weight of the solid content of the water- and oil-repellent agent. POLYMERIZATION EXAMPLE 4 In Polymerization Example 3, sorbitol was charged in an amount corresponding to 20% by weight of the solid content of the water- and oil-repellent agent to conduct polymerization reaction. POLYMERIZATION EXAMPLE 5 In Polymerization Example 3, sodium polyacrylate (A-20U) was charged in an amount corresponding to 0.5% by weight of the solid content of the water- and oil-repellent agent in place of sorbitol to conduct polymerization reaction. POLYMERIZATION EXAMPLE 6 In Polymerization Example 3, the amount of sorbitol was changed to that corresponding to 5% by weight of the solid content of the water- and oil-repellent agent, and the amount of sodium polyacrylate (A-20U) to that corresponding to 0.5% by weight of the solid content of the water- and oil-repellent agent to conduct polymerization reaction. POLYMERIZATION EXAMPLE 7 In Polymerization Example 1, the amount of benzyl methacrylate was changed to 200g and the polymerization reaction was carried out without using vinylidene chloride. POLYMERIZATION EXAMPLE 8 In Polymerization Example 1, the amount of vinylidene chloride was changed to 200g, and the polymerization reaction was carried but without using benzyl methacrylate. POLYMERIZATION EXAMPLE 9 in Polymerization Example 1, 150g of methyl methacrylate and 50g of ethyl methacrylate were charged and the polymerization reaction was carried out without using benzyl methacrylate and vinylidene chloride. EXAMPLES 1 TO 15 The aqueous emulsion of Polymerization Example 1 was admixed with various commercially available carboxyl group-containing, water-soluble polymers (which will be hereinafter referred to as "commercially available resins") preferably together with sorbitol in specific amounts (which will be hereinafter referred to as "addition proportions" ) to the solid content of the aqueous emulsion (fluoroalkyl group-containing copolymer). The water- and oil-repellent agent emulsions thus prepared were applied to three kinds of doth, i.e. cotton broad cloth, nylon taffeta and polyester amunzen to conduct water- and oil-repellent treatment. Their water- and oil-repellent properties and freeze-thaw stability were evaluated. (Treatment procedure) The three kinds of cloth were dipped in treatment baths and then squeezed up to the desired pickup by a mangle and then dried and cured under conditionzs given in the following Table. Cotton Nylon Polyester Solid concentration of Treating solution(%) 0.5 0.5 0.25 Pickup (%) 100 40 60 Drying 80°C for 10 min. 80°C for 10 min. 80°C for 10 min. Curing 150°C for 3 min. 170°C for 1.5 min. 150°C for 3 min. (Water-repellent property) Designated by number according to JIS L-1092 spray test, where the number ranges from 0 to 100; the larger number shows better water repellency. (Oil-repellent property) Designated by number according to AATCC TM-118, where the number ranges from 0 to 8; the larger number shows better oil repellency. (freeze-thaw stability) Water- and oil-repellent agent emulsions were kept in a refrigerator at - 25°C for 16 hours and then kept at room temperature for 8 hours. At that time the sample state was visually inspected, and freezing and melting were repeated until such changes as precipitation, solidification, etc. were observed. The number of runs until a sample could be kept from such changes was assessed as a stability. The results are shown in the following Table 1: Ex.No. Sorbitol Addition Proportion(%) Commercial available resin Water/oil repellency Freeze-thaw Stability (run number) Trade mark Proportion (%) Cotton Nylon Polyester 1 - A-20U 0.3 100/5 100/5 100/5 1 2 - A-20U 0.5 100/5 100/5 100/5 4 3 - A-20U 1.0 70/5 100/5 100/5 4 4 - A-20U 2.0 70/5 100/5 100/5 4 5 5 A-20U 0.3 100/5 100/5 100/5 5 6 10 A-20U 0.3 100/5 100/5 100/5 7 7 5 A-20U 0.5 100/5 100/5 100/5 5 8 10 A-20U 0.5 100/5 100/5 100/5 7 9 10 A-200U 0.5 100/5 100/5 100/5 6 10 10 AC-70N 0.5 100/5 100/5 100/5 7 11 10 AC-103 0.5 100/5 100/5 100/5 7 12 10 DL-40S 0.5 100/5 100/5 100/5 5 13 10 AC-203 0.5 100/5 100/5 100/5 7 14 10 TL-37 0.5 100/5 100/5 100/5 5 15 10 AC-103A 0.5 100/5 100/5 100/5 7 EXAMPLES 16 TO 25 The aqueous emulsion of Polymerization Example 1 was admixed with specific amounts of various sugar alcohols and 0.5% of commercially available resin (A-20U) to prepare water- and oil-repellent agent emulsions. The thus obtained emulsions were tested for the water repellency, the oil repellency and the freeze-thaw stability in the same manner as in Examples 1 to 15. The results are shown in the following Table 2. Ex.No. Sugar alcohol Water/oil repellency Freeze-thaw stabity (run numbers) Compound Proportion(%) Cotton Nylon Polyester 16 Xylitol 5 100/5 100/5 100/5 5 17 Xylitol 10 100/5 100/5 100/5 7 18 Lactitol 5 100/5 100/5 100/5 5 19 Lactitol 10 100/5 100/5 100/5 6 20 Paratinit 5 100/5 100/5 100/5 5 21 Paratinit 10 100/5 100/5 100/5 6 22 Erythritol 5 100/5 100/5 100/5 5 23 Erythritol 10 100/5 100/5 100/5 7 24 Mannitol 5 100/5 100/5 100/5 5 25 Mannitol 10 100/5 100/5 100/5 6 EXAMPLES 26 TO 31 The aqueous emulsion of Polymerization Example 2 was admixed with 10% of various sugar alcohols and 0.5% of commercially available resin (A-20U) to prepare water- and oil-repellent emulsions. The thus obtained emulsions were tested for the water repellency, the oil repellency and the freeze-thaw stability in the same manner as in Examples 1 to 15. The results are shown in the following Table 3: Ex.No. Sugar alcohol Water/oil repellency Freeze-thaw Stability (run number) Cotton Nylon Polyester 26 Sorbitol 100/5 100/5 100/5 6 27 Xylitol 100/5 100/5 100/5 7 28 Lactitol 100/5 100/5 100/5 7 29 Paratinit 100/5 100/5 100/5 6 30 Erythritol 100/5 100/5 100/5 5 31 Mannitol 100/5 100/5 100/5 6 EXAMPLE 32 The aqueous emulsion of Polymerization Example 3 containing sorbitol in an amount corresponding to 10% by weight in advance was admixed with 0.5% by weight of sodium polyacrylate (A-20U) to prepare a water- and oil-repellent agent emulsion. The thus obtained emulsion was tested for the water repellency, the oil repellency and the freeze-thaw stability in the same manner as in Examples 1 to 15. EXAMPLE 33 The aqueous emulsion of Polymerization Example 5 containing sodium polyacrylate (A-20U) in an amount corresponding to 0.5% by weight in advance was admixed with 5% by weight of sorbitol to prepare a water- and oil-repellent emulsion. The thus obtained emulsion was tested for the water repellency, the oil repellency and the freeze-thaw stability in the same manner as in Examples 1 to 15. EXAMPLE 34 The aqueous emulsion of Polymerization Example 6 was tested for the water repellency, the oil repellency and the freeze-thaw stability in the same manner as in Examples 1 to 15. EXAMPLE 35 In Example 7, the aqueous emulsion of Polymerization Example 7 was used in place of the aqueous emulsion of Polymerization Example 1. EXAMPLE 36 In Example 7, the aqueous emulsiton of Polymerization Example 8 was used in place of the aqueous emulsion of Polymerization Example 1. Test results of Examples 32 to 36 are shown in the following Table 4: Ex. No. Water/oil repellency Freeze-thaw Stability (run number) Cotton Nylon Polyester 32 100/5 100/5 100/5 7 33 100/5 100/5 100/5 5 34 100/5 100/5 100/5 6 35 100/5 100/5 100/5 5 36 100/5 100/5 100/5 5 COMPARATIVE EXAMPLES 1 TO 6 The aqueous emulsions obtained in Polymerization Examples 1 to 4 and Polymerization Examples 7 to 8, respectively (Polymerization Examples 3 and 4 contain sorbitol in amounts corresponding to 10% by weight and 20% by weight, respectively) were tested for the water repellency, the oil repellency and the freeze-thaw stability in the same manner as in Examples 1 to 15. Only the following results were obtained: Water/oil repellency: Cotton 100/4 Nylon 100/5 Polyester 100/5 Freeze-thaw stability 0 (1 only for Polymerization Example 4) COMPARATIVE EXAMPLES 7 TO 11 The aqueous emulsion of Polymerization Example 9 was admixed with specific amounts (addition proportions) to the solid content of the aqueous emulsion of sorbitol and/or sodium polyacrylate (A-20U) to prepare water- and oil-repellent emulsions. The thus obtained emulsions were tested for the water repellency, the oil repellency and the freeze-thaw stability in the same manner as in Examples 1 to 15. The results are shown in the following Table 5: Comp. Ex.No. Sorbitol Addition Proportion (%) A-20U Addition Proportion (%) Water/oil repellency Freeze-thaw stability (run numbers) Cotton Nylon Polyester 7 - - 90/3 100/4 100/4 0 8 20 - 90/3 100/4 100/4 0 9 30 - 90/3 100/4 100/4 0 10 5 0.5 90/3 100/4 100/4 1 11 10 0.3 90/3 100/4 100/4 1 COMPARATIVE EXAMPLES 12 TO 22 The aqueous emulsion of Polymerization Example 1 was admixed with specific amounts (addition proportion) to the solid content of the aqueous emulsion of sorbitol and/or polyvinyl alcohol (Denkapoval, trademark of products commercially available from Denki Kagaku Kogyo K. K., Japan) to prepare water- and oil-repellent emulsions. The thus obtained emulsions were tested for the water repellency, the oil repellency and the freeze-thaw stability in the same manner as in Examples 1 to 15. The results are shown in the following Table 6: Comp. Ex. No. Sorbitol Addition Proportion (%) PVA Water/oil repellency Freeze-thaw stability (run number) Type No. Proportion (%) Cotton Nylon Polyester 12 10 - - 100/4 100/5 100/5 0 13 20 - - 100/4 100/5 100/5 1 14 30 - - 100/4 100/5 100/5 3 15 - K-17c 2.0 100/4 100/5 100/5 0 16 - B-17 2.0 100/4 100/5 100/5 0 17 - K-05 2.0 100/4 100/5 100/5 0 18 - B-05 2.0 100/4 100/5 100/5 0 19 10 K-17c 0.5 100/4 100/5 100/5 0 20 10 B-17 0.5 100/4 100/5 100/5 0 21 10 K-05 0.5 100/4 100/5 100/5 0 22 10 B-05 0.5 100/4 100/5 100/5 0 Note) K-17c: Saponification degree 99%, Polymerization degree 1700 B-17: Saponification degree 88%, Polymerization degree 1700 K-05: Saponification degree 98.5%, Polymerization degree 600 B-05: Saponification degree 88%, Polymerization degree 600

Claims: A water- and oil-repellent agent, which comprises an aqueous emulsion comprising a fluoroalkyl group-containing copolymer obtainable by copolymerising 30 to 90 wt.% of a fluoroalkyl group-containing monomer and 70 to 10 wt.% of vinylidene chloride or benzyl(meth)acrylate, the total sum being 100% by weight, whereby this copolymer can be further copolymerized with up to 10 % by weight, on the basis of the total copolymer, of a hydroxy group-containing monomer and/or another cross-linkable group-containing monomer, and 0.1 to 2 wt.%, on the basis of the fluoroalkyl group-containing copolymer, of a carboxy group-containing water-soluble polymer, and 1 to 10 wt. % of an non-ionic surfactant, based on the total amount of monomers. A water- and oil-repellent agent according to claim 1, wherein the fluoroalkyl group-containing monomer is represented by the following general formula: CH 2 =CRCOOR 1 Rf where R is a hydrogen atom or a methyl group, R 1 is a divalent organic group, and Rf is a perfluoroalkyl group having 4 to 20 carbon atoms. A water- and oil-repellent agent according according to claim 1, wherein the carboxyl group-containing, water-soluble polymer is a sodium salt of carboxyl group-containing polymer. A water- and oil-repellent agent according to claim 3, wherein the carboxyl group-containing, water-soluble polymer is a polymer having an average molecular weight range of 1000 to 15000. A water- and oil-repellent agent according to claim 1, wherein the carboxyl group-containing, water-soluble polymer is used together with the sugar alcohol. A water- and oil-repellent agent according to claim 5, wherein the sugar alcohol is a polyhydric alcohol obtained by reducing carbonyl groups of sugar. A water- and oil-repellent agent according to claim 5, wherein the sugar alcohol is used in a proportion of 2 to 20% by weight on the basis of the fluoroalkyl group-containing copolymer. A process for preparing a water- and oil-repellent agent, which comprises subjecting 30 to 90 wt.% of a fluoroalkyl group-containing monomer and 70 to 10 wt.% of vinylidene chloride or benzyl (meth)acrylate, the total sum being 100% by weight, to an emulsion polymerisation in the presence of 1 to 10 wt.% of an non-ionic surfactant, based on the total amount of monomers, optionally further copolymerising the copolymer obtained with up to 10 % by weight, on the basis of the total copolymer obtained, of a hydroxy group-containing monomer and/or another cross-linkable group-containing monomer, and adding 0.1 to 2 wt.%, on the basis of the total amount of the fluoroalkyl group-containing copolymer in the resulting aqueous emulsion, of a carboxyl group-containing, water-soluble polymer to the aqueous emulsion. A process according to claim 8, wherein the carboxyl group-containing, water-soluble polymer is added together with a sugar alcohol. A process for preparing a water- and oil-repellent agent, which comprises subjecting 30 to 90 wt.% of a fluoroalkyl group-containing monomer and 70 to 10 wt.% of vinylidene chloride or benzyl (meth)acrylate, the total sum being 100% by weight, to an emulsion polymerisation in the presence of 1 to 10 wt.% of an non-ionic surfactant, based on the total amount of monomers, and 0.1 to 2 wt.%, on the basis of the total amount of the monomers, of a carboxyl group-containing, water-soluble polymer, and optionally further copolymerising the copolymer obtained with up to 10 % by weight, on the basis of the total copolymer obtained, of a hydroxy group-containing monomer and/or another cross-linkable group containing monomer. A process according to claim 10, wherein the carboxyl group-containing, water-soluble polymer is used together with a sugar alcohol.

Inventors: ISHIDA YUZURU, YAMAMOTO KAZUHIRO, ISHIDA, YUZURU, YAMAMOTO, KAZUHIRO
Applicants: NIPPON MEKTRON KK, NIPPON MEKTRON, LIMITED
Application year: 1998
Main classification: C09K3
IPC codes: C08L33, C09D133, C09K3, C08L27