JP7126954B2 - 防汚性物品の製造方法、粉体コーティングを備えた物品、及び粉体コーティング組成物 - Google Patents
防汚性物品の製造方法、粉体コーティングを備えた物品、及び粉体コーティング組成物 Download PDFInfo
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- JP7126954B2 JP7126954B2 JP2018567825A JP2018567825A JP7126954B2 JP 7126954 B2 JP7126954 B2 JP 7126954B2 JP 2018567825 A JP2018567825 A JP 2018567825A JP 2018567825 A JP2018567825 A JP 2018567825A JP 7126954 B2 JP7126954 B2 JP 7126954B2
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- powder coating
- fluorosurfactant
- antimicrobial
- powder
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- JOYRKODLDBILNP-UHFFFAOYSA-N urethane group Chemical group NC(=O)OCC JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
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Description
全体を通して使用される際、範囲は、この範囲内のあらゆる値を表すために簡略化した表現として使用される。この範囲内の任意の値は、この範囲の終点として選択され得る。さらに、本明細書に引用される全ての参考文献は、全体が参照により本明細書に援用される。本開示における定義と、引用される参考文献における定義との間に矛盾がある場合、本開示が優先される。
本発明によれば、第1の成分の金属ホウ酸塩は、塩基性、二塩基性、三塩基性及び多塩基性金属ホウ酸塩に対応する化合物、及びそれらの混合物を指す。例えば、「ホウ酸亜鉛」は、ホウ酸亜鉛(ZnB4O7)、対応する塩基性ホウ酸亜鉛のいずれか(構造Zn(OH).B4O7の一塩基性ホウ酸亜鉛、構造2Zn(OH)2.B4O7の二塩基性ホウ酸亜鉛、構造3Zn(OH)3.B4O7の三塩基性ホウ酸亜鉛など)、及びそれらの混合物からなる一連の化合物を指す。別の例として、「ホウ酸銅」は、ホウ酸銅(CuB4O7)、その対応する塩基性ホウ酸銅のいずれか(構造Cu(OH).B4O7の一塩基性ホウ酸銅、構造2Cu(OH)2.B4O7の二塩基性ホウ酸銅、構造3Cu(OH)3.B4O7の三塩基性ホウ酸銅など)、及びそれらの混合物からなる群から選択される一連の化合物を指す。金属ホウ酸塩は、2種以上の金属を含み得る。好適な実施形態において、金属ホウ酸塩は、ホウ酸亜鉛である。
式中、R1、R3、R4、R5、及びR6が、H、ハロゲン原子(例えば、Br、I、Cl)、及びC1~C6鎖から選択され得る。R2が、チアゾリル基などの硫黄含有複素環化合物から選択され得る。ベンズイミダゾール化合物は、4-チアゾリル基であるR2基を有し得る。ベンズイミダゾール化合物は、水素原子である、R1、R3、R4、R5、及びR6基を有し得る。好適な実施形態において、ベンズイミダゾール化合物は、式II:
ある実施形態において、本発明のベンズイミダゾール化合物は、カルボニル基を実質的に含まなくてもよい。
式I:(Rf 1AO)P(O)(O-M+)2
式II:(Rf 1AO)2P(O)(O-M+)
の少なくとも1つが挙げられ、式中、Rf 1が、1、2又は3個のエーテル酸素原子で任意選択的に介在され得る、C1~C16直鎖状又は分枝鎖状パーフルオロアルキルである。
mが、0~4であり;
n、o、p、及びrがそれぞれ、独立して、2~20であり;
qが2であり;
Eが、酸素、硫黄、又は窒素原子で任意選択的に介在されるC2~C20直鎖状又は分枝鎖状アルキル基;環状アルキル基、又はC6~C10アリール基であり;
Mが、第I族金属又はアンモニウムカチオン(NHx(R2)y)+であり、ここで、R2がC1~C4アルキルであり;xが1~4であり;yが0~3であり;x+yが4である。
式III:(Rf 2CH2CH2O)P(O)(ONH4)2
のアニオン性フッ素系界面活性剤からなり得、式中、Rf 2が、式:F[CF2-CF2]3~8で表されるC4~C8パーフルオロアルキル基である。好適な実施形態において、フッ素系界面活性剤は、無溶媒アニオン性フッ素系界面活性剤である。好適なアニオン性フッ素系界面活性剤は、市販されている。
ΔE=[(L2-L1)2+(a2-a1)2+(b2-b1)2]1/2
式中、L1、a1、及びb1がそれぞれ、ミノルタコーポレーション(Minolta Corporation)製のミノルタクロマメータ(Minolta Chroma Meter)CR 410を用いて測定される、建築用パネル100の汚れていない第1の主面111の初期明度である。L2、a2、及びb2値が、建築用パネル100の各第1の主面111が、汚れ組成物(すなわち、指の油、汗など)によって汚された後、ミノルタクロマメータ(Minolta Chroma Meter)CR 410によって測定される明度である。より小さいΔE値は、向上した汚れ付着抵抗性を示す。本発明によれば、第1のコーティング130と第2のコーティング140との組合せは、2未満のΔE値を有する建築用パネルを提供することができる。
以下の実施例は、本発明にしたがって調製される。本発明は、本明細書に記載される実施例に限定されない。
上塗りの防汚試験プロトコル
以下の実験は、本発明に係る建築用パネルの主面における撥油性及び防汚性を測定する。前駆体成分(すなわち、ポリマーバインダ、架橋剤、及びフッ素系界面活性剤)を一緒に混合することによって調製される粉体コーティング前駆体から形成されるポリマー粉体コーティングを有する建築用パネルを作製した。フッ素系界面活性剤は、100%の固形分を有し、少なくとも1つのリン酸基を有するアニオン性フッ素系界面活性剤を含む。アニオン性フッ素系界面活性剤は、50℃~70℃の溶融温度及び1~5のpH値を有する。例示的な好適なアニオン性フッ素系界面活性剤は、キャプストン(Capstone)(登録商標)FS-66の商標で、デュポン(Du Pont)から市販されている。
実施例1
次に、液体系コーティングは、粉体コーティングの上面に塗布し、ここで、液体系コーティングは、80重量%の水及び20重量%の第1の撥性成分を含む。第1の撥性成分は、約4~約6の範囲のpH及び1.06g/cm3の密度を有するカチオン性フッ素系界面活性剤である。液体系コーティングは、10g/m2の量で粉体コーティング上に塗布する。次に、得られた液体系コーティングは、15℃~40℃の温度で乾燥させて、実施例1の建築用パネルを形成した。実施例1の得られた建築用パネルは、約2g/m2の量で、粉体コーティング上に塗布されたフッ素系界面活性剤を有する。
実施例2
0.2重量%の第2の撥性成分の濃度に液体系コーティング組成物を希釈したことを除いて、実施例1の同じ方法にしたがって、第2の建築用パネル(実施例2)を作製した。第2の撥性成分は、約9~約11の範囲のpH及び約1.1g/cm3の密度を有するアニオン性フッ素系界面活性剤である。次に、液体系コーティング組成物は、10g/m2の率で粉体コーティングを含有するフッ素系界面活性剤に塗布し、液体系コーティング組成物を乾燥させた。実施例2の得られた建築用パネルは、約0.02g/m2の量で、粉体コーティング上に塗布されたフッ素系界面活性剤を有する。
比較例1
第2の撥性成分の代わりに第1の非イオン性フッ素系界面活性剤を使用することを除いて、実施例2の同じ方法にしたがって、第3の建築用パネル(比較例1)を作製した。非イオン性フッ素系界面活性剤は、約7~約8.5の範囲のpH及び約1.4g/cm3の密度を有し、デュポン(DuPont)からFS-3100として市販されている。比較例1の得られた建築用パネルは、粉体コーティング上に塗布された0.02g/m2のフッ素系界面活性剤を有する。
比較例2
粉体コーティングに第2の非イオン性フッ素系界面活性剤を塗布することを除いて、実施例2の同じ方法にしたがって、第4の建築用パネル(比較例2)を作製した。第2のフッ素系界面活性剤は、約7~約9の範囲のpH及び約1.1g/cm3の密度を有し、デュポン(DuPont)からFS-65として市販されている。比較例1の得られた建築用パネルは、粉体コーティング上に塗布された0.02g/m2のフッ素系界面活性剤を有する。
粉体コーティング中の液体フッ素系界面活性剤の防汚試験プロトコル
以下の実験は、粉体コーティング中の液体系フッ素系界面活性剤を用いた本発明に係る建築用パネルの主面における撥油性及び防汚性を測定する。この実験を行う際、一連の建築用パネルは、それに塗布された粉体コーティングを用いて作製した。フッ素系界面活性剤を含まない粉体コーティングを有する第1の建築用パネル(対照1)を作製した。対照1の建築用パネルは、上塗りを含まない。
抗菌試験プロトコル
抗菌試験プロトコルを用いて、実施例7~13、比較例5~11、及び対照2~8の建築用パネルサンプルを作製し、試験した。各建築用パネルサンプルは、粉体コーティング組成物を、50mm×50mmの金属基材上に塗布することによって作製した。粉体コーティング組成物のそれぞれは、ポリマー樹脂前駆体と、架橋剤と、顔料とのブレンドを含み、少なくとも99%の固形分を有する。
90%の減少=1log減少(すなわち、100,000に減少される1,000,000は、1log減少である)
99%の減少=2log減少(すなわち、10,000に減少される1,000,000は、2log減少である)
99.9%の減少=3log減少(すなわち、1,000に減少される1,000,000は、3log減少である)
99.99%の減少=4log減少(すなわち、100に減少される1,000,000は、4log減少である)
99.999%の減少=5log減少(すなわち、10に減少される1,000,000は、5log減少である)
抗菌性コーティングの性能は、下式にしたがって計算される抗菌活性(「R」)に対して正規化した:
R=(Ut-Uo)-(At-Uo)=Ut-At
式中、
R:抗菌活性
Uo:t=0における対照からの生菌の対数の平均
Ut:t=24における対照からの生菌の対数の平均
At:t=24における試験サンプルからの生菌の対数の平均
本発明によれば、抗菌性コーティングは、抗菌活性が2.0以上である場合、抗菌有効性を有するものと見なされる。各細菌試験の結果が、本明細書に示される。
黄色ブドウ球菌(Staphylococcus aureus)に対する抗菌有効性
黄色ブドウ球菌(Staphylococcus aureus)細菌に対する有効性を測定する試験は、9.7×10CFU/mLの開始細菌濃度で行った。黄色ブドウ球菌(Staphylococcus aureus)を用いた第1の試験の結果が、以下の表3に示される。
大腸菌(Escherichia coli)に対する抗菌有効性
大腸菌(Escherichia coli)細菌に対する有効性を測定する試験は、7.2×105CFU/mLの開始細菌濃度で行った。結果が表5に示される。
セレウス菌(Bacillus cereus)に対する抗菌有効性
セレウス菌(Bacillus cereus)細菌に対する有効性を測定する試験は、4.1×105CFU/mLの開始細菌濃度で行った。結果が表7に示される。
アシネトバクター・バウマニ(Acinetobachter baumannii)に対する抗菌有効性
アシネトバクター・バウマニ(Acinetobachter baumannii)細菌に対する有効性を測定する試験は、9.2×105CFU/mLの開始細菌濃度で行った。結果が表8に示される。
肺炎桿菌(Klebsiella pneumoniae)に対する抗菌有効性
肺炎桿菌(Klebsiella pneumoniae)細菌に対する有効性を測定する試験は、6.4×105CFU/mLの開始細菌濃度で行った。結果が表9に示される。
抗菌有効性の概要
各建築用パネルの抗菌有効性が、表10に要約されている。
防カビ試験プロトコル
防カビプロトコルを用いて、実施例14、15、比較例12、及び対照例9のサンプル建築用パネルを作製し、試験した。各建築用パネルサンプルは、粉体コーティング組成物を、76.2mm(3インチ)×101.6mm(4インチ)の金属基材上に塗布することによって作製した。粉体コーティング組成物のそれぞれは、少なくとも99%の固形分を有し、ポリマー樹脂前駆体と、架橋剤と、顔料とのブレンドを含んでいた。
Claims (13)
- 防汚性物品の製造方法において、
a)液体担体、アニオン性フッ素系界面活性剤、及びポリマーバインダを含有する混合物を混合する工程と、b)前記混合物を乾燥させて、液体担体を実質的に含有しない粉体コーティング前駆体混合物を形成する工程と、c)前記粉体コーティング前駆体混合物を基材に塗布する工程と、d)前記粉体コーティング前駆体混合物を硬化して、前記防汚性物品を形成する工程とを備え、工程a)の混合が、前記アニオン性界面活性剤及び前記ポリマーバインダの溶融温度未満の温度で行われ、
前記アニオン性界面活性剤は13~15%の固形含量を有する液体系アニオン性フッ素系界面活性剤である、防汚性物品の製造方法。 - 前記温度が、48.9℃(120°F)未満である、請求項1に記載の防汚性物品の製造方法。
- 工程b)中、前記ポリマーバインダ及びアニオン性界面活性剤が、90℃~110℃の範囲の温度で、押出機中で混合される、請求項1又は2に記載の防汚性物品の製造方法。
- 工程b)の後かつ工程c)の前に、前記粉体コーティング混合物がペレット化される、請求項3に記載の防汚性物品の製造方法。
- 前記アニオン性フッ素系界面活性剤が、前記粉体コーティング前駆体混合物の総重量を基準にして、約0.05重量%~約4重量%の範囲の量で存在する、請求項1~4のいずれか一項に記載の防汚性物品の製造方法。
- 前記ポリマーバインダが、45℃~80℃の範囲のガラス転移温度を有する、請求項1~5のいずれか一項に記載の防汚性物品の製造方法。
- 前記アニオン性界面活性剤及び前記液体担体が、前記ポリマーバインダと組み合わされる前に一緒に予め混合される、請求項1~6のいずれか一項に記載の防汚性物品の製造方法。
- 前記液体担体が水である、請求項1~7のいずれか一項に記載の防汚性物品の製造方法。
- 前記粉体コーティング前駆体混合物が、約160℃~約210℃の範囲の温度で硬化される、請求項1~8のいずれか一項に記載の防汚性物品の製造方法。
- 基材に塗布された粉体コーティングを備えた物品において、前記粉体コーティングが、ポリマー樹脂と、架橋剤と、液体担体及びフッ素系界面活性剤のブレンドとを含有する前駆体から形成され、前記フッ素系界面活性剤は13~15%の固形含量を有する液体系アニオン性フッ素系界面活性剤であり、
前記フッ素系界面活性剤が少なくとも1つのリン酸基を有し、1~5のpH値、及び50℃~70℃の溶融温度を有する、物品。 - 前記液体担体が水である、請求項10に記載の物品。
- ポリマー樹脂と、
架橋剤と、
液体担体と、
イオン性のフッ素系界面活性剤とのブレンドを含有し、
前記イオン性のフッ素系界面活性剤は13~15%の固形含量を有する液体系アニオン性フッ素系界面活性剤であり、
前記ブレンドはPVDFポリマーを実質的に含まない、粉体コーティング組成物。 - 前記液体担体は水である、請求項12に記載の粉体コーティング組成物。
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