WO2022157653A1 - Coated textile-based substrate - Google Patents

Coated textile-based substrate Download PDF

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Publication number
WO2022157653A1
WO2022157653A1 PCT/IB2022/050459 IB2022050459W WO2022157653A1 WO 2022157653 A1 WO2022157653 A1 WO 2022157653A1 IB 2022050459 W IB2022050459 W IB 2022050459W WO 2022157653 A1 WO2022157653 A1 WO 2022157653A1
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WO
WIPO (PCT)
Prior art keywords
based substrate
textile
coating layer
fatty acid
hydrophobizing agent
Prior art date
Application number
PCT/IB2022/050459
Other languages
French (fr)
Inventor
Robin GRANKVIST
Emma ÖSTMARK
Adeel SHAHZAD
Mikael GÄLLSTEDT
Mikael Pelcman
Carl-Magnus BRANDÊN
Original Assignee
Stora Enso Oyj
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Stora Enso Oyj filed Critical Stora Enso Oyj
Publication of WO2022157653A1 publication Critical patent/WO2022157653A1/en

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Classifications

    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06MTREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/01Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with natural macromolecular compounds or derivatives thereof
    • D06M15/03Polysaccharides or derivatives thereof
    • D06M15/05Cellulose or derivatives thereof
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C53/00Saturated compounds having only one carboxyl group bound to an acyclic carbon atom or hydrogen
    • C07C53/38Acyl halides
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C53/00Saturated compounds having only one carboxyl group bound to an acyclic carbon atom or hydrogen
    • C07C53/38Acyl halides
    • C07C53/42Acyl halides of acids containing three or more carbon atoms
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06MTREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M13/00Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/10Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
    • D06M13/11Compounds containing epoxy groups or precursors thereof
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06MTREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M13/00Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/10Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
    • D06M13/184Carboxylic acids; Anhydrides, halides or salts thereof
    • D06M13/203Unsaturated carboxylic acids; Anhydrides, halides or salts thereof
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06MTREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M13/00Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/10Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
    • D06M13/184Carboxylic acids; Anhydrides, halides or salts thereof
    • D06M13/207Substituted carboxylic acids, e.g. by hydroxy or keto groups; Anhydrides, halides or salts thereof
    • D06M13/21Halogenated carboxylic acids; Anhydrides, halides or salts thereof
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06MTREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M13/00Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/10Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
    • D06M13/224Esters of carboxylic acids; Esters of carbonic acid
    • D06M13/2246Esters of unsaturated carboxylic acids
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21FPAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/02Synthetic cellulose fibres
    • D21H13/08Synthetic cellulose fibres from regenerated cellulose
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/03Non-macromolecular organic compounds
    • D21H17/05Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
    • D21H17/14Carboxylic acids; Derivatives thereof
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00Coated paper; Coating material
    • D21H19/10Coatings without pigments
    • D21H19/14Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
    • D21H19/34Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising cellulose or derivatives thereof
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/16Sizing or water-repelling agents
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06MTREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2200/00Functionality of the treatment composition and/or properties imparted to the textile material
    • D06M2200/10Repellency against liquids
    • D06M2200/12Hydrophobic properties

Definitions

  • the present disclosure relates to coating of textile-based substrates to improve the liquid repellency of the substrate.
  • Repellency to liquids is an important property in many textile applications.
  • the repellency of a textile fabric depends upon the resistance to wetting and penetration by a liquid.
  • Water and oil are the most important liquids for normal textile fabric end-uses.
  • a common practice for improving the liquid repellency is to apply a polymeric or resinous coating to textile fabrics.
  • Various chemical compounds such as vinyl, acrylic, and urethane polymers, as well as fluorocarbon and silicone chemicals, have been employed for this purpose.
  • Coating of textiles with polymeric or resinous coatings can combine the mechanical properties of the textile with the barrier properties of a plastic film.
  • polymeric materials when polymeric materials are applied to textile fabrics in amounts sufficient to provide the degree of water resistance required, they tend to make the fabrics stiff and boardy and provide an undesirable slick, waxy feel, or they exhibit poor durability and are easily washed out of the fabrics during cleaning.
  • the inventors have found that coating of the textile-based substrate with a regenerated cellulose (RC) and hydrophobizing the RC coated textile-based substrate with a hydrophobizing agent provides a hydrophobic coated textilebased substrate with good wash fastness, i.e. the coating is not easily washed out of the textile-based substrate during cleaning.
  • RC regenerated cellulose
  • inventive coated substrate compared to an uncoated substrate include improved water repellency, improved oil repellency, improved wind resistance, adjustable stiffness, reduced surface roughness, and substrate less prone to linting.
  • a coated textilebased substrate comprising a textile-based substrate, and a coating layer disposed on said textile-based substrate, wherein said coating layer comprises regenerated cellulose and wherein said coating layer has been hydrophobized with a hydrophobizing agent.
  • textile-based substrate also referred to herein as “the substrate” as used herein refers generally to substrates formed of textile fibers.
  • the textilebased substrate may for example be a woven or nonwoven textile fabric, or a yam.
  • the textile-based substrate is a woven or nonwoven textile fabric.
  • the textile fibers of the textile-based substrate can be obtained from natural sources, by semisynthetic methods from natural sources, or by synthetic methods from synthetic sources.
  • textile fibers from natural sources include, but are not limited to, animal hair or fur, insect cocoons as with silk worm cocoons.
  • textile fibers obtained from natural sources by semisynthetic methods include, but are not limited to, cotton and Rayon.
  • textile fibers from synthetic sources include, but are not limited to, acrylic, polyester and nylon.
  • the textile-based substrate is formed of biobased fibers.
  • the textile-based substrate is cellulose based, i.e. based on natural cellulose fibers of or fibers derived from cellulose.
  • natural cellulose fibers include cotton, flax, hemp, jute, and ramie.
  • man-made fibers derived from cellulose include Rayon and Lyocell produced by regeneration of dissolved forms of cellulose.
  • the combination of a textile-based substrate based on cellulose fibers with an RC coating is expected to be especially advantageous due to interactions formed between the RC and cellulose in the textile-based substrate during the regeneration process.
  • the inventive coating can be applied to increase liquid repellency in any textilebased substrate, but is envisaged to be of particular interest for textile fabric having a basis weight in the range of 50-500 g/m 2
  • the present invention is based on the surprising finding that a textile-based substrate can be provided with a coating of regenerated cellulose (RC) and subsequently hydrophobized with a hydrophobizing agent to provide a hydrophobic coating with good wash fastness, i.e. the coating is not easily washed out of the textile-based substrate during cleaning.
  • RC regenerated cellulose
  • Regenerated cellulose is a colorless, transparent and non-toxic pure cellulose product. It is produced from wood pulp, which is dissolved with a specific solvent or solvent system to obtain a cellulose solution. The solution can subsequently be used for forming regenerated cellulose fibers or films. Examples of regenerated cellulose fibers include Rayon and Lyocell. An example of a regenerated cellulose film is Cellophane. The regenerated cellulose may be obtained from any suitable cellulose source. In some embodiments, the regenerated cellulose is obtained from dissolving pulp, also referred to as dissolving cellulose. Dissolving pulp is bleached wood pulp or cotton linters that has a high cellulose content (> 90%).
  • Dissolving pulp is manufactured for uses that require a high chemical purity, and particularly low hemicellulose content, since the chemically similar hemicellulose can interfere with subsequent processes. Dissolving pulp is so named because it is not made into paper, but dissolved either in a solvent or by derivatization into a homogeneous solution, which makes it completely chemically accessible and removes any remaining fibrous structure. Once dissolved, the dissolving pulp can be spun into textile fibers or formed into films.
  • Coating of the textile-based substrate with a coating comprising regenerated cellulose can be achieved by at least partially dissolving cellulose in a solvent or solvent system capable of dissolving the cellulose, applying the formed cellulose solution onto the textile-based substrate, and regenerating the dissolved cellulose to obtain a coating comprising the regenerated cellulose on the substrate surface.
  • solvents and derivatizing solvent systems useful for dissolving cellulose include, but are not limited to, an NaOH solution, /V-methylmorpholine A/- oxide (NMMO), ionic liquids, urea/NaOH solution, thiourea/urea/NaOH solution, and NaOH/carbon disulfide (CS2).
  • NMMO /V-methylmorpholine A/- oxide
  • ionic liquids urea/NaOH solution
  • thiourea/urea/NaOH solution thiourea/urea/NaOH solution
  • NaOH/carbon disulfide NaOH/carbon disulfide
  • the concentration of cellulose in the cellulose solution may be selected depending on the intended coating technique and desired coating layer thickness.
  • the concentration of cellulose in the cellulose solution may be in the range of 0.01-20 wt%, preferably in the range of 0.1-10 wt%.
  • cellulose solution onto the textile-based substrate may be done by various coating techniques known in the art. Examples include, but are not limited to, dip coating, curtain coating, roll coating, blade coating and spray coating.
  • the coating may be provided on one or more surfaces of the textile-based substrate.
  • the coating can be achieved by applying the cellulose solution to one or both sides of the textile-based substrate.
  • the coating can also be achieved by impregnating the textile-based substrate with the cellulose solution.
  • Regeneration of the dissolved cellulose can be achieved by subjecting the cellulose solution to a treatment with a coagulation medium.
  • the coagulation medium is selected depending on the solvent or solvent system used. Suitable combinations of solvents and coagulation media are known in the art.
  • the regeneration of the dissolved cellulose is achieved by treating the cellulose solution with an acidic solution, preferably a sulfuric acid solution.
  • the regenerated cellulose may be subjected to one or more washing steps to remove solvent residues and other contaminants.
  • the regenerated cellulose may be subjected to treatment with a plasticizer.
  • the plasticizer may for example be glycerol.
  • the RC coated textile-based substrate is dried.
  • dry as used herein means that the coated textile-based substrate has a dry content above 80 %, preferably above 90 %, and more preferably above 95 % by weight.
  • the coating of the textile-based substrate with regenerated cellulose reduces the pore size and the permeability of the substrate. Accordingly, the coated substrate will typically have a lower air permeability then the uncoated textile-based substrate.
  • the RC coated textile-based substrate has good wash fastness, i.e. the coating is not easily washed out of the textile-based substrate during cleaning.
  • the coating layer may be comprised entirely of the regenerated cellulose, or it can comprise a mixture of the regenerated cellulose and other ingredients or additives.
  • the coating layer preferably includes regenerated cellulose as its main component based on the total dry weight of the coating layer.
  • the coating layer comprises at least 50 wt%, preferably at least 70 wt%, and more preferably at least 90 wt% of regenerated cellulose, based on the total dry weight of the coating layer.
  • the coating layer comprises at least 95 wt%, preferably at least 98 wt% of regenerated cellulose, based on the total dry weight of the coating layer.
  • the dry basis weight of the coating layer is in the range of 0.1-30 gsm, preferably in the range of 1-25 gsm, more preferably in the range of 2- 15 gsm.
  • the basis weight of the coating layer may be selected e.g. depending on the desired flexibility and permeability and feel of the coated textile-based substrate. For example, a lower basis weight of the coating layer may provide a more breathable coated textile-based substrate than a higher basis weight of the coating layer.
  • the RC coated textile-based substrate can be hydrophobized with a hydrophobizing agent to provide a hydrophobic coating with good wash fastness.
  • hydrophobic, hydrophobized and hydrophobizing as used herein generally refer to surfaces that exhibit an apparent water contact angle that is greater than 90°, or to methods for modifying a surface to impart an apparent water contact angle that is greater than 90°.
  • the hydrophobizing agent should preferably be selected so as to provide good adhesion to the RC coated textile-based substrate and good wash fastness.
  • the hydrophobizing agent can be applied to RC coated surfaces only, or to both RC coated and uncoated surfaces of the textile-based substrate.
  • the hydrophobizing agent is preferably covalently bound to the regenerated cellulose.
  • a covalently bound hydrophobizing agent is preferred since it will generally have higher wash fastness than a non-covalently bound hydrophobizing agent.
  • the hydrophobizing agent is a hydrophobizing agent capable of being covalently grafted to the regenerated cellulose.
  • the hydrophobizing agent has i) a hydrophobic portion and ii) a reactive portion capable of forming a covalent bond to the regenerated cellulose.
  • the hydrophobizing agent is selected from the group consisting of fatty acid halides, fatty acid anhydrides, epoxidized fatty acids, epoxidized fatty acid (methyl) esters, and combinations thereof.
  • the hydrophobizing agent is a fatty acid halide, preferably a fatty acid halide having an aliphatic chain length of 8-22 carbon atoms.
  • fatty acid halides include octanoyl chloride (C8), lauroyl chloride (C12), myristoyl chloride (C14), palmitoyl chloride (C16), and stearoyl chloride (C18), and/or a mixture thereof.
  • the fatty acid halide grafted on the RC coated substrate is palmitoyl chloride or stearoyl chloride.
  • the coated substrate surface has a high content of cellulose molecules.
  • Grafting with fatty acid halide has been identified as an interesting alternative for rendering cellulose based substrates hydrophobic.
  • the high reactivity of the fatty acid halides results in that the reagent will be covalently bound to the substrate to a high extent, reducing issues related to leaching and migration.
  • Grafting of the fatty acid halide to the RC coated substrate having available hydroxyl groups can be achieved by applying a fatty acid halide to the surface of the coating, followed by penetration of the reagent upon heating, which also promotes the formation of covalent bonds between the fatty acid halide and the hydroxyl groups of the regenerated cellulose.
  • the fatty acid halide grafting is preferably performed on the RC coated and dried textile-based substrate.
  • the grafting typically involves contacting the RC coated substrate with a fatty acid halide in a liquid, spray and/or vapor state. The reaction between the fatty acid halide, e.g.
  • fatty acid chloride and the hydroxyl groups of the regenerated cellulose results in ester bonds between the reagent and the cellulose. Ungrafted and thereby unbound fatty acids may also be present to a certain extent.
  • hydrohalic acid e.g. hydrochloric acid
  • the grafting may preferably be followed by removal of the formed hydrohalic acid, and optionally by removal of the ungrafted residues.
  • a grafting process which could be used in production of the coated textile-based substrate of the present disclosure is described in detail in the international patent application WO2012066015A1.
  • a grafting process which could be used in production of the coated textile-based substrate in the present disclosure, is described in detail in the international patent application W02017002005A1.
  • the grafting process may also be repeated, in order to increase the amount of grafted and free fatty acids in the coating.
  • the coated textile-based substrate is preferably dry when the fatty acid halide grafting is performed.
  • dry as used herein means that the coated textilebased substrate has a dry content above 80 %, preferably above 90 %, and more preferably above 95 % by weight.
  • the fatty acid halide grafting preferably results in a total amount of grafted and free fatty acids in the coated textile-based substrate in the range of 0.05-5 kg/ton of the total dry weight of the coated textile-based substrate.
  • inventive coated substrate compared to an uncoated substrate include improved water repellency, improved oil repellency, improved wind resistance, adjustable stiffness, reduced surface roughness, and substrate less prone to linting.
  • the coated textile-based substrate is preferably water repellent.
  • water repellent generally means that the coated textile-based substrate has a higher resistance to water absorption than the same textile-based substrate without the coating.
  • Water repellency of textile-based substrates may for example be tested using the spray test method (AATCC test method 22-2001 or ISO 4920:2012).
  • the spray test method measures the resistance of fabrics to wetting by water. It is applicable to any textile fabric, but is especially suitable for measuring the water repellent efficacy of finishes applied to fabrics, particularly on plain woven fabrics.
  • the test method is not intended for use in predicting the probable rain penetration resistance of fabrics, since it does not measure the penetration of water through the fabric.
  • water sprayed against the taut surface of a test specimen under controlled conditions produce a wetted pattern whose size depends on the relative repellency of the fabric.
  • the wetted pattern on the fabric is compared with a standard chart of fabric water repellency ratings of 0, 50, 70, 80, 90 and 100.
  • a rating of zero (0) is assigned to fabrics whose surfaces are completely wetted by water, whereas a rating of 100 corresponds to fabrics with no wetting of water on their surfaces.
  • a surface of said coating layer treated with the hydrophobizing agent has a water contact angle above 90°, preferably above 100°.
  • a method for manufacturing a coated textile-based substrate comprising: a) providing a textile-based substrate, b) coating the textile-based substrate with a coating layer comprising a regenerated cellulose, and c) hydrophobizing the coating layer with a hydrophobizing agent.
  • the coating layer is formed by applying cellulose dissolved in a solvent onto the textile-based substrate and treating the dissolved cellulose with a coagulation medium to obtain the coating layer comprising regenerated cellulose (also referred to herein as “RC coating”).
  • the solvent is a non-derivatizing solvent selected form the group consisting of an alkaline aqueous solution, /V-methylmorpholine A/-oxide (NMMO), and an ionic liquid.
  • a non-derivatizing solvent selected form the group consisting of an alkaline aqueous solution, /V-methylmorpholine A/-oxide (NMMO), and an ionic liquid.
  • the solvent is a derivatizing solvent system selected form the group consisting of urea and NaOH solution, thiourea, urea, and NaOH solution, and NaOH and carbon disulfide (CS2).
  • a derivatizing solvent system selected form the group consisting of urea and NaOH solution, thiourea, urea, and NaOH solution, and NaOH and carbon disulfide (CS2).
  • the concentration of cellulose in the cellulose solution may be in the range of 0.01-20 wt%, preferably in the range of 0.1-10 wt%.
  • cellulose solution onto the textile-based substrate may be done by various coating techniques known in the art. Examples include, but are not limited to, dip coating, curtain coating, roll coating, blade coating and spray coating.
  • the RC coating may be provided on one or more surfaces of the textile-based substrate.
  • the coating can be achieved by applying the cellulose solution to one or both sides of the textile-based substrate.
  • the coating can also be achieved by impregnating the textile-based substrate with the cellulose solution.
  • Regeneration of the dissolved cellulose can be achieved by subjecting the cellulose solution to a treatment with a coagulation medium.
  • the coagulation medium is selected depending on the solvent or solvent system used. Suitable combinations of solvents and coagulation media are known in the art.
  • the regeneration of the dissolved cellulose is achieved by treating the cellulose solution with an acidic solution, preferably a sulfuric acid solution.
  • the RC coating may be subjected to one or more washing steps to remove solvent residues and other contaminants.
  • the RC coating may further be subjected to treatment with a plasticizer.
  • the plasticizer may for example be glycerol.
  • the RC coated textile-based substrate is dried.
  • dry as used herein means that the coated textile-based substrate has a dry content above 80 %, preferably above 90 %, and more preferably above 95 % by weight.
  • the coating step b) preferably further comprises drying the formed textile-based substrate, preferably to a dry content above 80 %, more preferably above 90 %, and more preferably above 95 % by weight.
  • the dry basis weight of the coating layer is in the range of 0.1-30 gsm, preferably in the range of 1-25 gsm, more preferably in the range of 2- 15 gsm.
  • the hydrophobizing agent should preferably be selected so as to provide good adhesion to the RC coated textile-based substrate and good wash fastness.
  • the hydrophobizing agent can be applied to RC coated surfaces only, or to both RC coated and uncoated surfaces of the textile-based substrate
  • the hydrophobizing agent is preferably covalently bound to the regenerated cellulose.
  • a covalently bound hydrophobizing agent is preferred since it will generally have higher wash fastness than a non-covalently bound hydrophobizing agent.
  • the hydrophobizing agent is a hydrophobizing agent capable of being covalently grafted to the regenerated cellulose.
  • the hydrophobizing agent has i) a hydrophobic portion and ii) a reactive portion capable of forming a covalent bond to the regenerated cellulose.
  • the hydrophobizing agent is selected from the group consisting of fatty acid halides, fatty acid anhydrides, epoxidized fatty acids, epoxidized fatty acid (methyl) esters, and combinations thereof.
  • the hydrophobizing agent is a fatty acid halide, preferably a fatty acid halide having an aliphatic chain length of 8-22 carbon atoms.
  • fatty acid halides include octanoyl chloride (C8), lauroyl chloride (C12), myristoyl chloride (C14), palmitoyl chloride (C16), and stearoyl chloride (C18), and/or a mixture thereof.
  • the fatty acid halide grafted on the RC coated substrate is palmitoyl chloride or stearoyl chloride.
  • the hydrophobizing agent may for example involve contacting the RC coating layer with a fatty acid halide in a liquid, spray and/or vapor state.
  • the method further comprises the step d) heat treating the hydrophobized coating layer.
  • the heat treatment is performed at a temperature of at least 100 °C.
  • the heat treatment comprises treatment with steam at a temperature of at least 100 °C.
  • the heat treatment may also be combined with a pressure treatment, e.g. calendaring or ironing.
  • Figure 1 shows SEM images of uncoated reference samples (Fig. 1a: 65x magnification; Fig. 1 b: 500x magnification) and RC and hydrophobized samples on both sides, sample B (Fig. 1c: 67x magnification; Fig. 1d: 500x magnification).
  • Figure 2 shows SEM images of single side coated sample A on the uncoated side (Fig. 2a: 65x magnification; Fig. 2b: 500x magnification) and single side coated sample A on the coated side (Fig. 2c: 65x magnification; Fig. 2d: 500x magnification).
  • Figure 3 is a diagram showing water contact angles for treated and untreated samples during 12 seconds.
  • Figure 4 shows SEM images of Sample B (RC coated and hydrophobized) after one washing cycle (Fig. 4a: 65x magnification; Fig. 4b: 500x magnification).
  • FIG. 5 is photographs showing water repellency of treated fabrics before washing (A-C) and after washing (D-F).
  • Example 1 (comparative) - Cotton substrate coated with regenerated cellulose Hardwood dissolving pulp sheets from Stora Enso (alpha cellulose ca 95 wt%) were used for the experiments.
  • the intrinsic viscosity of the pulp was determined by measurements in cupriethylenediamine (CED) solution.
  • the intrinsic viscosity of the starting material was ca 450 ml/g.
  • the viscosity was lowered to ca 215-250 mg/l using hydrolysis before the dope preparation.
  • a coating dope was prepared by dissolving the dissolving pulp in an aqueous sodium hydroxide solution.
  • the process used for the dope preparation was adopted from the patent WO2017178531 A1 .
  • Coating of the dope on the fabric The prepared dope (6% cellulose) was manually applied on one side of ca 0.21 m x 0.297m cotton fabric samples (100% organic cotton, Twill, off-white) with a 200 pm spiral film applicator. Thereafter the coated fabric was soaked in 1 g/mol sulfuric acid bath for 10 min and washed in 3 subsequent DI water baths for 10 min in each. Thereafter it was dipped for 1 min in a 5% glycerol bath. The coated samples were dried at 23°C and 50% RH, while clamped to avoid shrinkage. This same procedure was followed to produce double side coated fabric. The amount of cellulose applied per gram of fabric is shown in Table 1.
  • Example 2 (comparative) - Cotton substrate hydrophobized with fatty acid chloride Hydrophobization treatment: Two concentrations of palmitoyl chloride ca 4 % and 0.39 % were prepared in petroleum ether (BP 40-60°C). The hydrophobization treatment was conducted by distributing the solution, using a Pasteur pipette, over the whole fabric (100% organic cotton, Twill, off-white), wetting the substrate with the solution. The treated fabric was then allowed to dry for 5 min in a fume hood before inserting it into a solvent-compatible oven. The treated fabric was heated for 2 minutes in the oven preheated to 160°C. The applied amount of palmitoyl chloride (PC) per meter square of fabric is shown in Table 2. Analyses of the treated fabric’s surface properties were done on the dried fabrics.
  • Example 3 Cotton substrate coated with regenerated cellulose and hydrophobized with fatty acid chloride
  • the RC coating of the fabric samples was done as described in Example 1.
  • the amount of cellulose applied per gram of fabric is shown in Table 1 .
  • the coated fabrics were then subjected to hydrophobization treatment, as described in Example 2, and the amounts applied are found in Table 2.
  • Table 2 Amount of Palmitoyl Chloride per square meter of fabric & parameters.
  • the wash fastness was investigated using a domestic laundry cycle that consisted of 30 min washing at 30°C with color A+ detergent (according to washing instructions). The cycle ended with centrifugation at 800 RPM, after which the fabric was dried at RT. Analyses of the fabric’s surface properties were done on the dried fabrics. A more intense laundry cycle was also applied with 90 min washing and 40 °C on some of the samples. It was observed that the surface structure of the samples was mostly unchanged after washing. Some small water channels could be observed as showed in Figure 4.

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Abstract

The present invention relates to a coated textile-based substrate, comprising a textile-based substrate, and a coating layer disposed on said textile-based substrate, wherein said coating layer comprises regenerated cellulose and wherein said coating layer has been hydrophobized with a hydrophobizing agent. The invention further relates to a method for manufacturing the coated textile-based substrate.

Description

COATED TEXTILE-BASED SUBSTRATE
Technical field
The present disclosure relates to coating of textile-based substrates to improve the liquid repellency of the substrate.
Background
Repellency to liquids is an important property in many textile applications. The repellency of a textile fabric depends upon the resistance to wetting and penetration by a liquid. Water and oil are the most important liquids for normal textile fabric end-uses.
A common practice for improving the liquid repellency is to apply a polymeric or resinous coating to textile fabrics. Various chemical compounds, such as vinyl, acrylic, and urethane polymers, as well as fluorocarbon and silicone chemicals, have been employed for this purpose.
Coating of textiles with polymeric or resinous coatings can combine the mechanical properties of the textile with the barrier properties of a plastic film. Often, when polymeric materials are applied to textile fabrics in amounts sufficient to provide the degree of water resistance required, they tend to make the fabrics stiff and boardy and provide an undesirable slick, waxy feel, or they exhibit poor durability and are easily washed out of the fabrics during cleaning.
Furthermore, in order to reduce the carbon footprint and increase the recyclability of textile products it is of general interest to replace the fossil-based synthetic polymers often used for improving liquid repellency today, with biobased materials. However, it has been found difficult to achieve an acceptable combination of properties, including water resistance or water repellency, durability and feel, using biobased components.
Thus, there remains a need in the industry for improved solutions for rendering textile products water resistant or water repellent, which are based on biobased materials. Such solutions could reduce the need for fossil-based plastics in textile production, which is beneficial both from a sustainability and recyclability perspective.
Description of the invention
It is an object of the present disclosure to provide a method for rendering textilebased substrates liquid repellent, which alleviates at least some of the above- mentioned problems.
It is a further object of the present disclosure to provide a method for rendering textile-based substrates liquid repellent, which uses mainly biobased materials.
It is a further object of the present disclosure to provide liquid repellent coating for a textile-based substrate, wherein the coating is based mainly on biobased materials.
The above-mentioned objects, as well as other objects as will be realized by the skilled person in the light of the present disclosure, are achieved by the various aspects of the present disclosure.
The inventors have found that coating of the textile-based substrate with a regenerated cellulose (RC) and hydrophobizing the RC coated textile-based substrate with a hydrophobizing agent provides a hydrophobic coated textilebased substrate with good wash fastness, i.e. the coating is not easily washed out of the textile-based substrate during cleaning.
Advantages of the inventive coated substrate compared to an uncoated substrate include improved water repellency, improved oil repellency, improved wind resistance, adjustable stiffness, reduced surface roughness, and substrate less prone to linting.
According to a first aspect illustrated herein, there is provided a coated textilebased substrate, comprising a textile-based substrate, and a coating layer disposed on said textile-based substrate, wherein said coating layer comprises regenerated cellulose and wherein said coating layer has been hydrophobized with a hydrophobizing agent.
The term textile-based substrate (also referred to herein as “the substrate”) as used herein refers generally to substrates formed of textile fibers. The textilebased substrate may for example be a woven or nonwoven textile fabric, or a yam. In some embodiments the textile-based substrate is a woven or nonwoven textile fabric.
The textile fibers of the textile-based substrate can be obtained from natural sources, by semisynthetic methods from natural sources, or by synthetic methods from synthetic sources. Examples of textile fibers from natural sources include, but are not limited to, animal hair or fur, insect cocoons as with silk worm cocoons. Examples of textile fibers obtained from natural sources by semisynthetic methods include, but are not limited to, cotton and Rayon. Examples of textile fibers from synthetic sources include, but are not limited to, acrylic, polyester and nylon.
In preferred embodiments, the textile-based substrate is formed of biobased fibers. In some embodiments, the textile-based substrate is cellulose based, i.e. based on natural cellulose fibers of or fibers derived from cellulose. Examples of natural cellulose fibers include cotton, flax, hemp, jute, and ramie. Examples of man-made fibers derived from cellulose include Rayon and Lyocell produced by regeneration of dissolved forms of cellulose. The combination of a textile-based substrate based on cellulose fibers with an RC coating is expected to be especially advantageous due to interactions formed between the RC and cellulose in the textile-based substrate during the regeneration process.
The inventive coating can be applied to increase liquid repellency in any textilebased substrate, but is envisaged to be of particular interest for textile fabric having a basis weight in the range of 50-500 g/m2 The present invention is based on the surprising finding that a textile-based substrate can be provided with a coating of regenerated cellulose (RC) and subsequently hydrophobized with a hydrophobizing agent to provide a hydrophobic coating with good wash fastness, i.e. the coating is not easily washed out of the textile-based substrate during cleaning.
Regenerated cellulose is a colorless, transparent and non-toxic pure cellulose product. It is produced from wood pulp, which is dissolved with a specific solvent or solvent system to obtain a cellulose solution. The solution can subsequently be used for forming regenerated cellulose fibers or films. Examples of regenerated cellulose fibers include Rayon and Lyocell. An example of a regenerated cellulose film is Cellophane. The regenerated cellulose may be obtained from any suitable cellulose source. In some embodiments, the regenerated cellulose is obtained from dissolving pulp, also referred to as dissolving cellulose. Dissolving pulp is bleached wood pulp or cotton linters that has a high cellulose content (> 90%). It has special properties including a high level of brightness and uniform molecular- weight distribution. Dissolving pulp is manufactured for uses that require a high chemical purity, and particularly low hemicellulose content, since the chemically similar hemicellulose can interfere with subsequent processes. Dissolving pulp is so named because it is not made into paper, but dissolved either in a solvent or by derivatization into a homogeneous solution, which makes it completely chemically accessible and removes any remaining fibrous structure. Once dissolved, the dissolving pulp can be spun into textile fibers or formed into films.
Coating of the textile-based substrate with a coating comprising regenerated cellulose can be achieved by at least partially dissolving cellulose in a solvent or solvent system capable of dissolving the cellulose, applying the formed cellulose solution onto the textile-based substrate, and regenerating the dissolved cellulose to obtain a coating comprising the regenerated cellulose on the substrate surface.
Examples of solvents and derivatizing solvent systems useful for dissolving cellulose include, but are not limited to, an NaOH solution, /V-methylmorpholine A/- oxide (NMMO), ionic liquids, urea/NaOH solution, thiourea/urea/NaOH solution, and NaOH/carbon disulfide (CS2). In the majority of the cases, cellulose is not dissolved down to a molecular level but rather forms stable colloidal dispersions where ordered cellulose aggregates of, at least, several hundred chains, are present. The term cellulose solution as used herein is therefore intended to include solutions of fully dissolved cellulose as well as stable colloidal dispersions comprising partially dissolved cellulose.
The concentration of cellulose in the cellulose solution may be selected depending on the intended coating technique and desired coating layer thickness. The concentration of cellulose in the cellulose solution may be in the range of 0.01-20 wt%, preferably in the range of 0.1-10 wt%.
Application of the cellulose solution onto the textile-based substrate may be done by various coating techniques known in the art. Examples include, but are not limited to, dip coating, curtain coating, roll coating, blade coating and spray coating.
The coating may be provided on one or more surfaces of the textile-based substrate. The coating can be achieved by applying the cellulose solution to one or both sides of the textile-based substrate. The coating can also be achieved by impregnating the textile-based substrate with the cellulose solution.
Regeneration of the dissolved cellulose can be achieved by subjecting the cellulose solution to a treatment with a coagulation medium. The coagulation medium is selected depending on the solvent or solvent system used. Suitable combinations of solvents and coagulation media are known in the art. In some embodiments, the regeneration of the dissolved cellulose is achieved by treating the cellulose solution with an acidic solution, preferably a sulfuric acid solution.
The regenerated cellulose may be subjected to one or more washing steps to remove solvent residues and other contaminants.
The regenerated cellulose may be subjected to treatment with a plasticizer. The plasticizer may for example be glycerol. Finally, the RC coated textile-based substrate is dried. The term “dry” as used herein means that the coated textile-based substrate has a dry content above 80 %, preferably above 90 %, and more preferably above 95 % by weight.
The coating of the textile-based substrate with regenerated cellulose reduces the pore size and the permeability of the substrate. Accordingly, the coated substrate will typically have a lower air permeability then the uncoated textile-based substrate.
The inventors have found that the RC coated textile-based substrate has good wash fastness, i.e. the coating is not easily washed out of the textile-based substrate during cleaning.
The coating layer may be comprised entirely of the regenerated cellulose, or it can comprise a mixture of the regenerated cellulose and other ingredients or additives. The coating layer preferably includes regenerated cellulose as its main component based on the total dry weight of the coating layer. In some embodiments, the coating layer comprises at least 50 wt%, preferably at least 70 wt%, and more preferably at least 90 wt% of regenerated cellulose, based on the total dry weight of the coating layer. In a preferred embodiment, the coating layer comprises at least 95 wt%, preferably at least 98 wt% of regenerated cellulose, based on the total dry weight of the coating layer.
In some embodiments, the dry basis weight of the coating layer is in the range of 0.1-30 gsm, preferably in the range of 1-25 gsm, more preferably in the range of 2- 15 gsm. The basis weight of the coating layer may be selected e.g. depending on the desired flexibility and permeability and feel of the coated textile-based substrate. For example, a lower basis weight of the coating layer may provide a more breathable coated textile-based substrate than a higher basis weight of the coating layer.
The inventors have further found that the RC coated textile-based substrate can be hydrophobized with a hydrophobizing agent to provide a hydrophobic coating with good wash fastness. The terms hydrophobic, hydrophobized and hydrophobizing as used herein generally refer to surfaces that exhibit an apparent water contact angle that is greater than 90°, or to methods for modifying a surface to impart an apparent water contact angle that is greater than 90°.
The hydrophobizing agent should preferably be selected so as to provide good adhesion to the RC coated textile-based substrate and good wash fastness. The hydrophobizing agent can be applied to RC coated surfaces only, or to both RC coated and uncoated surfaces of the textile-based substrate.
The hydrophobizing agent is preferably covalently bound to the regenerated cellulose. A covalently bound hydrophobizing agent is preferred since it will generally have higher wash fastness than a non-covalently bound hydrophobizing agent.
In some preferred embodiments, the hydrophobizing agent is a hydrophobizing agent capable of being covalently grafted to the regenerated cellulose.
Thus, in some embodiments, the hydrophobizing agent has i) a hydrophobic portion and ii) a reactive portion capable of forming a covalent bond to the regenerated cellulose.
In some preferred embodiments, the hydrophobizing agent is selected from the group consisting of fatty acid halides, fatty acid anhydrides, epoxidized fatty acids, epoxidized fatty acid (methyl) esters, and combinations thereof.
In some preferred embodiments, the hydrophobizing agent is a fatty acid halide, preferably a fatty acid halide having an aliphatic chain length of 8-22 carbon atoms. Examples of fatty acid halides include octanoyl chloride (C8), lauroyl chloride (C12), myristoyl chloride (C14), palmitoyl chloride (C16), and stearoyl chloride (C18), and/or a mixture thereof. In some preferred embodiments, the fatty acid halide grafted on the RC coated substrate is palmitoyl chloride or stearoyl chloride. The coated substrate surface has a high content of cellulose molecules. Grafting with fatty acid halide has been identified as an interesting alternative for rendering cellulose based substrates hydrophobic. The high reactivity of the fatty acid halides results in that the reagent will be covalently bound to the substrate to a high extent, reducing issues related to leaching and migration.
Grafting of the fatty acid halide to the RC coated substrate having available hydroxyl groups can be achieved by applying a fatty acid halide to the surface of the coating, followed by penetration of the reagent upon heating, which also promotes the formation of covalent bonds between the fatty acid halide and the hydroxyl groups of the regenerated cellulose. The fatty acid halide grafting is preferably performed on the RC coated and dried textile-based substrate. The grafting typically involves contacting the RC coated substrate with a fatty acid halide in a liquid, spray and/or vapor state. The reaction between the fatty acid halide, e.g. fatty acid chloride, and the hydroxyl groups of the regenerated cellulose results in ester bonds between the reagent and the cellulose. Ungrafted and thereby unbound fatty acids may also be present to a certain extent. Upon the reaction with the hydroxyl groups in the regenerated cellulose, and/or with water in the substrate and/or in the air, hydrohalic acid, e.g. hydrochloric acid, is formed as a reaction byproduct. The grafting may preferably be followed by removal of the formed hydrohalic acid, and optionally by removal of the ungrafted residues. One example of a grafting process which could be used in production of the coated textile-based substrate of the present disclosure is described in detail in the international patent application WO2012066015A1. Another example of a grafting process, which could be used in production of the coated textile-based substrate in the present disclosure, is described in detail in the international patent application W02017002005A1. The grafting process may also be repeated, in order to increase the amount of grafted and free fatty acids in the coating.
The coated textile-based substrate is preferably dry when the fatty acid halide grafting is performed. The term “dry” as used herein means that the coated textilebased substrate has a dry content above 80 %, preferably above 90 %, and more preferably above 95 % by weight. The fatty acid halide grafting preferably results in a total amount of grafted and free fatty acids in the coated textile-based substrate in the range of 0.05-5 kg/ton of the total dry weight of the coated textile-based substrate.
Advantages of the inventive coated substrate compared to an uncoated substrate include improved water repellency, improved oil repellency, improved wind resistance, adjustable stiffness, reduced surface roughness, and substrate less prone to linting.
The coated textile-based substrate is preferably water repellent. The term “water repellent” generally means that the coated textile-based substrate has a higher resistance to water absorption than the same textile-based substrate without the coating. Water repellency of textile-based substrates may for example be tested using the spray test method (AATCC test method 22-2001 or ISO 4920:2012). The spray test method measures the resistance of fabrics to wetting by water. It is applicable to any textile fabric, but is especially suitable for measuring the water repellent efficacy of finishes applied to fabrics, particularly on plain woven fabrics. The test method is not intended for use in predicting the probable rain penetration resistance of fabrics, since it does not measure the penetration of water through the fabric. For this test method, water sprayed against the taut surface of a test specimen under controlled conditions produce a wetted pattern whose size depends on the relative repellency of the fabric. The wetted pattern on the fabric is compared with a standard chart of fabric water repellency ratings of 0, 50, 70, 80, 90 and 100. A rating of zero (0) is assigned to fabrics whose surfaces are completely wetted by water, whereas a rating of 100 corresponds to fabrics with no wetting of water on their surfaces.
In some embodiments, a surface of said coating layer treated with the hydrophobizing agent has a water contact angle above 90°, preferably above 100°.
According to a second aspect illustrated herein, there is provided a method for manufacturing a coated textile-based substrate, said method comprising: a) providing a textile-based substrate, b) coating the textile-based substrate with a coating layer comprising a regenerated cellulose, and c) hydrophobizing the coating layer with a hydrophobizing agent.
In some embodiments, the coating layer is formed by applying cellulose dissolved in a solvent onto the textile-based substrate and treating the dissolved cellulose with a coagulation medium to obtain the coating layer comprising regenerated cellulose (also referred to herein as “RC coating”).
In some embodiments, the solvent is a non-derivatizing solvent selected form the group consisting of an alkaline aqueous solution, /V-methylmorpholine A/-oxide (NMMO), and an ionic liquid.
In some embodiments, the solvent is a derivatizing solvent system selected form the group consisting of urea and NaOH solution, thiourea, urea, and NaOH solution, and NaOH and carbon disulfide (CS2).
The concentration of cellulose in the cellulose solution may be in the range of 0.01-20 wt%, preferably in the range of 0.1-10 wt%.
Application of the cellulose solution onto the textile-based substrate may be done by various coating techniques known in the art. Examples include, but are not limited to, dip coating, curtain coating, roll coating, blade coating and spray coating.
The RC coating may be provided on one or more surfaces of the textile-based substrate. The coating can be achieved by applying the cellulose solution to one or both sides of the textile-based substrate. The coating can also be achieved by impregnating the textile-based substrate with the cellulose solution.
Regeneration of the dissolved cellulose can be achieved by subjecting the cellulose solution to a treatment with a coagulation medium. The coagulation medium is selected depending on the solvent or solvent system used. Suitable combinations of solvents and coagulation media are known in the art. In some embodiments, the regeneration of the dissolved cellulose is achieved by treating the cellulose solution with an acidic solution, preferably a sulfuric acid solution.
The RC coating may be subjected to one or more washing steps to remove solvent residues and other contaminants.
The RC coating may further be subjected to treatment with a plasticizer. The plasticizer may for example be glycerol.
Finally, the RC coated textile-based substrate is dried. The term “dry” as used herein means that the coated textile-based substrate has a dry content above 80 %, preferably above 90 %, and more preferably above 95 % by weight. Thus, the coating step b) preferably further comprises drying the formed textile-based substrate, preferably to a dry content above 80 %, more preferably above 90 %, and more preferably above 95 % by weight.
In some embodiments, the dry basis weight of the coating layer is in the range of 0.1-30 gsm, preferably in the range of 1-25 gsm, more preferably in the range of 2- 15 gsm.
The hydrophobizing agent should preferably be selected so as to provide good adhesion to the RC coated textile-based substrate and good wash fastness. The hydrophobizing agent can be applied to RC coated surfaces only, or to both RC coated and uncoated surfaces of the textile-based substrate
The hydrophobizing agent is preferably covalently bound to the regenerated cellulose. A covalently bound hydrophobizing agent is preferred since it will generally have higher wash fastness than a non-covalently bound hydrophobizing agent.
In some preferred embodiments, the hydrophobizing agent is a hydrophobizing agent capable of being covalently grafted to the regenerated cellulose. Thus, in some embodiments, the hydrophobizing agent has i) a hydrophobic portion and ii) a reactive portion capable of forming a covalent bond to the regenerated cellulose.
In some preferred embodiments, the hydrophobizing agent is selected from the group consisting of fatty acid halides, fatty acid anhydrides, epoxidized fatty acids, epoxidized fatty acid (methyl) esters, and combinations thereof.
In some preferred embodiments, the hydrophobizing agent is a fatty acid halide, preferably a fatty acid halide having an aliphatic chain length of 8-22 carbon atoms. Examples of fatty acid halides include octanoyl chloride (C8), lauroyl chloride (C12), myristoyl chloride (C14), palmitoyl chloride (C16), and stearoyl chloride (C18), and/or a mixture thereof. In some preferred embodiments, the fatty acid halide grafted on the RC coated substrate is palmitoyl chloride or stearoyl chloride.
The hydrophobizing agent may for example involve contacting the RC coating layer with a fatty acid halide in a liquid, spray and/or vapor state.
The inventors have further found that the advantageous properties of the coating, including water repellence and wash fastness, can be further improved by subjecting the hydrophobized coating layer to heat treatment. In some embodiments, the method further comprises the step d) heat treating the hydrophobized coating layer. In some embodiments, the heat treatment is performed at a temperature of at least 100 °C. In some embodiments, the heat treatment comprises treatment with steam at a temperature of at least 100 °C. The heat treatment may also be combined with a pressure treatment, e.g. calendaring or ironing.
Generally, while the products, polymers, materials, layers and processes are described in terms of “comprising” various components or steps, the products, polymers, materials, layers and processes can also “consist essentially of” or “consist of” the various components and steps. While the invention has been described with reference to various exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
Brief description of the drawings
Figure 1 shows SEM images of uncoated reference samples (Fig. 1a: 65x magnification; Fig. 1 b: 500x magnification) and RC and hydrophobized samples on both sides, sample B (Fig. 1c: 67x magnification; Fig. 1d: 500x magnification).
Figure 2 shows SEM images of single side coated sample A on the uncoated side (Fig. 2a: 65x magnification; Fig. 2b: 500x magnification) and single side coated sample A on the coated side (Fig. 2c: 65x magnification; Fig. 2d: 500x magnification).
Figure 3 is a diagram showing water contact angles for treated and untreated samples during 12 seconds.
Figure 4 shows SEM images of Sample B (RC coated and hydrophobized) after one washing cycle (Fig. 4a: 65x magnification; Fig. 4b: 500x magnification).
Figure 5 is photographs showing water repellency of treated fabrics before washing (A-C) and after washing (D-F). A: Sample A and D (RC coated and hydrophobized); B and E: Sample B (RC coated only); and Sample C and F: hydrophobized only. Examples
Example 1 (comparative) - Cotton substrate coated with regenerated cellulose Hardwood dissolving pulp sheets from Stora Enso (alpha cellulose ca 95 wt%) were used for the experiments. The intrinsic viscosity of the pulp was determined by measurements in cupriethylenediamine (CED) solution. The intrinsic viscosity of the starting material was ca 450 ml/g. The viscosity was lowered to ca 215-250 mg/l using hydrolysis before the dope preparation.
A coating dope was prepared by dissolving the dissolving pulp in an aqueous sodium hydroxide solution. The process used for the dope preparation was adopted from the patent WO2017178531 A1 .
Coating of the dope on the fabric: The prepared dope (6% cellulose) was manually applied on one side of ca 0.21 m x 0.297m cotton fabric samples (100% organic cotton, Twill, off-white) with a 200 pm spiral film applicator. Thereafter the coated fabric was soaked in 1 g/mol sulfuric acid bath for 10 min and washed in 3 subsequent DI water baths for 10 min in each. Thereafter it was dipped for 1 min in a 5% glycerol bath. The coated samples were dried at 23°C and 50% RH, while clamped to avoid shrinkage. This same procedure was followed to produce double side coated fabric. The amount of cellulose applied per gram of fabric is shown in Table 1.
Example 2 (comparative) - Cotton substrate hydrophobized with fatty acid chloride Hydrophobization treatment: Two concentrations of palmitoyl chloride ca 4 % and 0.39 % were prepared in petroleum ether (BP 40-60°C). The hydrophobization treatment was conducted by distributing the solution, using a Pasteur pipette, over the whole fabric (100% organic cotton, Twill, off-white), wetting the substrate with the solution. The treated fabric was then allowed to dry for 5 min in a fume hood before inserting it into a solvent-compatible oven. The treated fabric was heated for 2 minutes in the oven preheated to 160°C. The applied amount of palmitoyl chloride (PC) per meter square of fabric is shown in Table 2. Analyses of the treated fabric’s surface properties were done on the dried fabrics. Example 3 - Cotton substrate coated with regenerated cellulose and hydrophobized with fatty acid chloride
The RC coating of the fabric samples was done as described in Example 1. The amount of cellulose applied per gram of fabric is shown in Table 1 .
Table 1 : Amount of cellulose applied per gram of fabric
Figure imgf000016_0001
The coated fabrics were then subjected to hydrophobization treatment, as described in Example 2, and the amounts applied are found in Table 2.
Table 2: Amount of Palmitoyl Chloride per square meter of fabric & parameters.
Figure imgf000016_0002
Analysis was performed on the samples with SEM. The samples were first coated with gold sputtering. From the samples in Figure 1 , it can be seen that the RC coated and hydrophobized samples are different in the surface structure from the unmodified samples and a smoother surface is observed.
It could also be seen for single-side coated samples that the coating did not penetrate to the uncoated side, which is displayed in Figure 2. Water contact angles were measured using the standard TAPPI T558 om-15 method using 4 pl droplets and the Young-Laplace Model as water droplet model. 5 measurements were recorded for each sample and the average was reported.
10 frames per second were recorded during 12 seconds. The results show that the RC and hydrophobized samples have the highest contact angles, always higher than 90°, independent if a low or a high amount of hydrophobization agent was added, whereas the uncoated side showed immediate absorption of the water droplet. The sample with only RC coating (no hydrophobization treatment) showed a water contact angle in between the RC coated and hydrophobized samples and the uncoated sample (Figure 3). During this short time interval of 12 seconds, the sample that is only hydrophobized shows similar water contact angle as the RC coated and hydrophobized sample and is not included in the Figure 3. Over a longer period of time, the water repellency is much poorer for this sample, which is shown in Figure 5.
Example 4 - Wash fastness
The wash fastness was investigated using a domestic laundry cycle that consisted of 30 min washing at 30°C with color A+ detergent (according to washing instructions). The cycle ended with centrifugation at 800 RPM, after which the fabric was dried at RT. Analyses of the fabric’s surface properties were done on the dried fabrics. A more intense laundry cycle was also applied with 90 min washing and 40 °C on some of the samples. It was observed that the surface structure of the samples was mostly unchanged after washing. Some small water channels could be observed as showed in Figure 4.
Water repellency tests were done by dripping 2 ml colored water when samples were tilted with a 30° angle onto the fabric samples before and after one cycle of the intensive washing. It could be observed that the RC coated and hydrophobized samples showed the best water repellency as the droplets rinsed off and the liquid was spread and absorbed on the other samples (Figure 5). The washed samples were subjected to ironing after washing, which made them more water repellent than the unwashed reference samples.

Claims

1. A coated textile-based substrate, comprising a textile-based substrate, and a coating layer disposed on said textile-based substrate, wherein said coating layer comprises regenerated cellulose and wherein said coating layer has been hydrophobized with a hydrophobizing agent.
2. The coated textile-based substrate according to claim 1 , wherein the coating layer comprises at least 50 wt%, preferably at least 70 wt%, and more preferably at least 90 wt% of regenerated cellulose, based on the total dry weight of the coating layer.
3. The coated textile-based substrate according to any one of the preceding claims, wherein the regenerated cellulose is obtained from dissolving pulp.
4. The coated textile-based substrate according to any one of the preceding claims, wherein the dry basis weight of the coating layer is in the range of 0.1 -30 gsm, preferably in the range of 1 -25 gsm, more preferably in the range of 2-15 gsm.
5. The coated textile-based substrate according to any one of the preceding claims, wherein the hydrophobizing agent is covalently bound to the regenerated cellulose.
6. The coated textile-based substrate according to any one of the preceding claims, wherein the hydrophobizing agent has i) a hydrophobic portion and ii) a reactive portion capable of forming a covalent bond to the regenerated cellulose.
7. The coated textile-based substrate according to any one of the preceding claims, wherein the hydrophobizing agent is selected from the group consisting of fatty acid halides, fatty acid anhydrides, epoxidized fatty acids, epoxidized fatty acid (methyl) esters, and combinations thereof.
8. The coated textile-based substrate according to any one of the preceding claims, wherein the hydrophobizing agent is a fatty acid halide, preferably a fatty acid halide having an aliphatic chain length of 8-22 carbon atoms.
9. The coated textile-based substrate according to any one of the preceding claims, wherein the textile-based substrate is a, woven or nonwoven fabric.
10. The coated textile-based substrate according to any one of the preceding claims, wherein the textile-based substrate is formed of biobased fibers.
11 . The coated textile-based substrate according to any one of the preceding claims, wherein the textile-based substrate is cellulose based.
12. The coated textile-based substrate according to any one of the preceding claims, wherein a surface of said coating layer treated with the hydrophobizing agent has a water contact angle above 90°, preferably above 100°.
13. A method for manufacturing a coated textile-based substrate, said method comprising: a) providing a textile-based substrate, b) coating the textile-based substrate with a coating layer comprising a regenerated cellulose, and c) hydrophobizing the coating layer with a hydrophobizing agent.
14. The method according to claim 13, wherein the coating layer is formed by applying cellulose dissolved in a solvent onto the textile-based substrate and treating the dissolved cellulose with a coagulation medium to obtain the coating layer comprising regenerated cellulose. 19
15. The method according to claim 14, wherein the solvent is a non-derivatizing solvent selected form the group consisting of an alkaline aqueous solution, A/- methylmorpholine A/-oxide (NMMO), and an ionic liquid, or a combination thereof.
16. The method according to claim 14, wherein the solvent is a derivatizing solvent system selected form the group consisting of urea and NaOH solution, thiourea, urea, and NaOH solution, and NaOH and carbon disulfide (CS2), or a combination thereof.
17. The method according to any one of claims 13-16, wherein the dry basis weight of the coating layer is in the range of 0.1-30 gsm, preferably in the range of 1-25 gsm, more preferably in the range of 2-15 gsm.
18. The method according to any one of claims 13-17, wherein step b) further comprises drying the coated textile-based substrate.
19. The method according to any one of claims 13-18, wherein the hydrophobizing agent is covalently bound to the regenerated cellulose.
20. The method according to any one of claims 13-19, wherein the hydrophobizing agent has i) a hydrophobic portion and ii) a reactive portion capable of forming a covalent bond to the regenerated cellulose.
21 . The method according to any one of claims 13-20, wherein the hydrophobizing agent is selected from the group consisting of fatty acid halides, fatty acid anhydrides, epoxidized fatty acids, epoxidized fatty acid (methyl) esters, and combinations thereof.
22. The method according to any one of claims 13-21 , wherein the hydrophobizing agent is a fatty acid halide, preferably a fatty acid halide having an aliphatic chain length of 8-22 carbon atoms.
23. The method according to any one of claims 13-22, further comprising the step d) heat treating the hydrophobized coating layer.
24. The method according to claim 23, wherein the heat treatment is performed at a temperature of at least 100 °C.
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US2390780A (en) * 1943-10-02 1945-12-11 Sylvania Ind Corp Process of making coated textile materials and the articles produced therefrom
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