Functional member, method for producing functional member and functional film

Abstract

To provide a functional member with antibacterial and antiviral properties which can suppress a decrease in the antibacterial and antiviral properties over time.SOLUTION: A functional member includes a substrate containing a surfactant (A), and a hypochlorous acid component (B) held on the substrate.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present disclosure generally relates to a functional member, a method for manufacturing a functional member, and a functional film, and more particularly, to a functional member having antibacterial and antiviral properties, a method for manufacturing a functional member, and a functional film including a functional member. [Background technology]

[0002] Hypochlorous acid is used for sterilization. For example, Patent Document 1 describes an antibacterial method that sterilizes an antibacterial product containing an antibacterial agent and / or a place where the product is handled with a sterilizing solution that is an aqueous solution containing hypochlorous acid. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2003-171203 A Summary of the Invention [Problem to be solved by the invention]

[0004] When sterilization is performed with a sterilizing solution that is an aqueous solution containing hypochlorous acid, the bactericidal performance of hypochlorous acid is quickly lost over time, and therefore hypochlorous acid does not inherently exhibit continuous antibacterial and antiviral properties.

[0005] An object of the present disclosure is to provide a functional member that has antibacterial and antiviral properties and that can suppress deterioration of the antibacterial and antiviral properties over time, a method for manufacturing the functional member, and a functional film that includes the functional member. [Means for solving the problem]

[0006] A functional member according to one embodiment of the present disclosure includes a substrate containing a surfactant (A) and a hypochlorous acid component (B) held on the substrate.

[0007] A method for producing a functional member according to one embodiment of the present disclosure includes contacting a hypochlorite solution with a substrate containing a surfactant, and then drying the substrate.

[0008] A functional film according to one embodiment of the present disclosure includes a base film and the functional member overlying the base film. Effect of the Invention

[0009] According to one aspect of the present disclosure, it is possible to provide a functional member that has antibacterial and antiviral properties and that can suppress deterioration of the antibacterial and antiviral properties over time, a method for manufacturing the functional member, and a functional film including the functional member. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, embodiments of the present disclosure will be described. Note that the following embodiments are merely a part of various embodiments of the present disclosure. In addition, the following embodiments can be modified in various ways depending on the design, etc., as long as the object of the present disclosure can be achieved. The mechanism of action of the embodiments shown below is presumed, and the present disclosure is not bound by the following explanation of the mechanism of action.

[0011] The functional member of the embodiment includes a substrate containing a surfactant (A) and a hypochlorous acid component (B) held on the substrate.

[0012] The hypochlorous acid component (B) is a chemical species having chlorine derived from hypochlorous acid, and includes, for example, at least one of hypochlorous acid and hypochlorite ion. The hypochlorous acid component (B) is, for example, held on the surface or near the surface of the substrate.

[0013] The functional member of the embodiment has antibacterial and antiviral properties, and the deterioration of the antibacterial and antiviral properties over time can be suppressed. That is, the durability of the antibacterial and antiviral properties of the functional member can be improved. Note that the antibacterial and antiviral properties refer to either or both of the antibacterial and antiviral properties.

[0014] In the embodiment, it is presumed that the hypochlorous acid component (B) held on the substrate causes the functional member to exhibit antibacterial and antiviral properties. In addition, normally, the bactericidal action of hypochlorous acid and hypochlorite ions is lost over time, so hypochlorous acid and hypochlorite ions do not exhibit continuous antibacterial and antiviral properties. Nevertheless, as described above, in the embodiment, the deterioration of the antibacterial and antiviral properties of the functional member over time can be suppressed. In the embodiment, it is presumed that the hypochlorous acid component (B) is stably held on the substrate by the action of the surfactant (A), so that the deterioration of the antibacterial and antiviral properties of the functional member over time can be suppressed.

[0015] The functional member will now be described in more detail.

[0016] The substrate in the functional member has, for example, a parent phase (matrix) which is the main component of the substrate, and a surfactant (A) is dispersed in the parent phase.

[0017] The matrix of the substrate is, for example, composed of a resin (C). The resin (C) contains at least one of a cured product of a reactive curing compound and a thermoplastic resin. The resin (C) may contain at least one selected from the group consisting of an alkyd resin, an acrylic resin, a melamine resin, a urethane resin, an epoxy resin, a silicone resin, a polyester resin, a polyamic acid resin, a polyimide resin, a styrene-maleic acid resin, a styrene-maleic anhydride resin, a cured product (polymer) of an acrylic acid monomer, and a cured product (polymer) of an acrylate monomer.

[0018] When the resin (C) contains a cured product of a reactive curable compound, the reactive curable compound may contain an active energy ray curable compound such as a photocurable compound. In this case, by irradiating a composition containing the active energy ray curable compound with active energy rays, the composition can be cured without heating to produce a mother phase.

[0019] The active energy ray curable compound contains, for example, a compound having a radically polymerizable unsaturated bond. The active energy ray curable compound can contain, for example, a polyfunctional (meth)acrylate. More specifically, the active energy ray curable compound can contain at least one selected from the group consisting of pentaerythritols such as pentaerythritol tri(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol tetra(meth)acrylate, pentaerythritols such as dipentaerythritol tri(meth)acrylate and dipentaerythritol di(meth)acrylate, methylols such as trimethylolpropane di(meth)acrylate, and epoxy acrylates such as bisphenol A diepoxy acrylate. It is preferable that the active energy ray curable compound contains at least one selected from the group consisting of pentaerythritol tri(meth)acrylate and dipentaerythritol penta(meth)acrylate.

[0020] In addition, "(meth)acrylic" is a generic term that is a higher-level concept of "acrylic" and "methacrylic", and means either "acrylic" or "methacrylic", or both "acrylic" and "methacrylic".

[0021] The surfactant (A) preferably contains an anionic surfactant. In this case, the durability of the antibacterial and antiviral properties of the functional member can be further improved. It is more preferable that the surfactant (A) contains a phosphoric acid surfactant such as a phosphoric acid ester surfactant. In this case, the durability of the antibacterial and antiviral properties of the functional member can be further improved.

[0022] The proportion of the surfactant (A) is preferably 0.1% by mass or more and 10% by mass or less with respect to the parent phase of the substrate, i.e., the resin (C). If the proportion is 0.1% by mass or more, the durability of the antibacterial and antiviral properties can be improved. If the proportion is 10% by mass or less, for example, when the functional member is layered on another member such as a base film, there is an advantage that peeling of the functional member due to the load of water can be suppressed. This proportion is more preferably 0.5% by mass or more, and even more preferably 1% by mass or more. This proportion is more preferably 8% by mass or less, and even more preferably 5% by mass or less.

[0023] The substrate may contain an inorganic filler (D). The inorganic filler (D) can increase the strength of the substrate. The inorganic filler (D) can be present in a dispersed state in the substrate. The inorganic filler (D) contains, for example, a metal oxide.

[0024] The inorganic filler (D) may contain cuprous oxide (cuprous oxide). When the inorganic filler (D) contains cuprous oxide, the cuprous oxide inhibits the metabolic functions of fungi, viruses, and the like and promotes the decomposition of organic matter, which can further enhance the antibacterial and antiviral properties of the functional component.

[0025] The inorganic filler (D) may contain a photocatalyst. When the inorganic filler (D) contains a photocatalyst, a reduction-oxidation reaction occurs on the surface of the photocatalyst due to the photocatalytic action of the photocatalyst when the functional member is irradiated with light, and this can further enhance the antibacterial and antiviral properties of the functional member. The photocatalyst contains at least one selected from the group consisting of titanium dioxide, tungsten oxide, strontium titanate, niobium oxide, zinc oxide, and tin oxide. The photocatalyst preferably contains titanium dioxide because of its high chemical resistance and easy availability. The titanium dioxide may contain at least one of anatase titanium dioxide and rutile titanium dioxide.

[0026] It is also preferred that the inorganic filler (D) contains cuprous oxide and titanium dioxide. In this case, the antibacterial and antiviral properties of the functional component can be particularly enhanced.

[0027] The inorganic filler (D) may contain a material other than copper oxide and a photocatalyst, for example, the inorganic filler (D) may contain at least one selected from the group consisting of alumina, titania, zirconia, calcium carbonate, magnesium carbonate, calcium phosphate, apatite, calcium silicate, and talc.

[0028] The average particle size of the inorganic filler (D) is preferably 500 nm or less. In this case, the transparency of the functional member can be increased. Therefore, for example, when the functional member is provided on a suitable substrate, the appearance of the substrate is not easily damaged by the functional member. The average particle size is more preferably 300 nm or less, and even more preferably 200 nm or less. In addition, this average particle size is, for example, 100 nm or more. The average particle size is the cumulant arithmetic mean diameter calculated from the particle size distribution based on the scattering intensity measured by the dynamic light scattering method.

[0029] The ratio of the inorganic filler (D) to the functional member is preferably 60% by mass or more and 80% by mass or less. If this ratio is 60% by mass or more, the strength of the functional member can be satisfactorily increased. If this ratio is 80% by mass or less, the functional member can be satisfactorily molded. If this ratio is 60% by mass or more, it is more preferable, and if it is 65% by mass or more, it is even more preferable.

[0030] There is no limitation on the shape of the functional member. The functional member is, for example, in the form of a film. In this case, the thickness of the functional member is, for example, 0.1 μm or more and 10 μm or less. If the thickness is 0.1 μm or more, the functional member can have good hardness and durability. If the thickness is 10 μm or less, for example, when the functional member is layered on another member such as a base film, there is an advantage that warping, peeling, cracking, etc. due to shrinkage caused by the difference in thermal expansion coefficient can be suppressed.

[0031] The functional film of the embodiment includes a film-like functional member and a base film. The functional member is overlaid on the base film. The base film is a resin film such as a polyethylene terephthalate film. By overlaying the film-like functional member on the base film, the handling of the film-like functional member becomes good. For example, when the functional film is attached to an appropriate member, antibacterial and antiviral properties can be imparted to the surface of the member.

[0032] A method for producing a functional member and a functional film will be described.

[0033] The substrate in the functional member is produced, for example, by molding a composition (X) containing a surfactant (A). When the substrate contains a resin (C), the composition (X) may contain a resin component (c) that is a raw material for the resin (C). When the substrate contains an inorganic filler (D), the composition (X) may contain the inorganic filler (D).

[0034] The resin component (c) contains at least one of a constituent component of the resin (C), such as a thermoplastic resin, and a component that becomes a constituent component of the resin (C) upon polymerization, such as a reactive curing compound.

[0035] When the resin component (c) contains a reactive curable compound, the reactive curable compound may contain an active energy ray curable compound such as a photocurable compound. In this case, the composition (X) can be cured without heating by irradiating the composition with active energy rays to produce a mother phase.

[0036] The active energy ray curable compound contains, for example, a compound having a radically polymerizable unsaturated bond. The active energy ray curable compound can contain, for example, a polyfunctional (meth)acrylate. More specifically, the active energy ray curable compound can contain at least one selected from the group consisting of pentaerythritols such as pentaerythritol tri(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol tetra(meth)acrylate, pentaerythritols such as dipentaerythritol tri(meth)acrylate and dipentaerythritol di(meth)acrylate, methylols such as trimethylolpropane di(meth)acrylate, and epoxy acrylates such as bisphenol A diepoxy acrylate. It is preferable that the active energy ray curable compound contains at least one selected from the group consisting of pentaerythritol tri(meth)acrylate and dipentaerythritol penta(meth)acrylate.

[0037] When the resin component (c) contains an active energy ray-curable compound, the composition (X) may further contain a photopolymerization initiator. Examples of the photopolymerization initiator include benzoin compounds having 14 to 18 carbon atoms, such as benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin propyl ether, and benzoin isobutyl ether; acetophenone compounds having 8 to 18 carbon atoms, such as acetophenone, 2,2-diethoxy-2-phenylacetophenone, 2,2-diethoxy-2-phenylacetophenone, and 1,1-dichloroacetophenone; 2-hydroxy-2-methyl-phenylpropan-1-one, diethoxyacetophenone, 1-hydroxycyclohexyl phenyl ketone, and 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropan-1-one; anthraquinone compounds having 14 to 19 carbon atoms, such as 2-ethylanthraquinone, 2-t-butylanthraquinone, 2-chloroanthraquinone, and 2-amylanthraquinone; the like; ketal compounds having 16 to 17 carbon atoms, such as acetophenone dimethyl ketal and benzyl dimethyl ketal; benzophenone compounds having 13 to 21 carbon atoms, such as benzophenone, 4-benzoyl-4'-methyldiphenyl sulfide and 4,4'-bismethylaminobenzophenone; phosphine oxide compounds having 22 to 28 carbon atoms, such as 2,4,6-trimethylbenzoyldiphenylphosphine oxide and bis-(2,6-dimethoxybenzoyl)-2,4,4-trimethylpentylphosphine oxide; and phosphine oxide compounds, such as bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide.

[0038] The amount of the photopolymerization initiator is, for example, 0.1 parts by mass or more and 5 parts by mass or less with respect to 100 parts by mass of the active energy ray-curable compound.

[0039] The composition (X) may contain a solvent. When the composition (X) contains a solvent, the solvent contains at least one selected from the group consisting of aromatic hydrocarbons such as toluene and xylene, alcohols such as methanol, ethanol, propanol, 2-propanol, 2-butanol, 1,1,1-trimethylmethanol, ethylene glycol, and propylene glycol, ketones such as acetone, methyl ethyl ketone, and methyl isobutyl ketone, aliphatic hydrocarbons such as hexane and heptane, ethers such as tetrahydrofuran, amide solvents such as N,N-dimethylformamide (DMF) and dimethylacetamide (DMAc), and nitrile solvents such as acetonitrile, propionitrile, and pivalonitrile.

[0040] The composition (X) may contain additives other than those described above, as long as they do not excessively impair the effects of the embodiment. The additives include at least one selected from the group consisting of dispersants, antifoaming agents, silane coupling agents, thixotropic agents, thickeners, antioxidants, and ultraviolet absorbers. The proportion of each component in the additives is preferably 5% by mass or less, more preferably 2% by mass or less, based on the total amount of the composition (X).

[0041] Composition (X) can be prepared by mixing the components of composition (X) described above.

[0042] The composition (X) is formed into a film on a base film, and if necessary, the composition (X) is dried and, if necessary, cured, to produce a film-like substrate on the base film.

[0043] The method for forming the composition (X) into a film is, for example, a spin coating method, a dip coating method, a roll coating method or a spray coating method, but is not limited to these.

[0044] After molding the composition (X), the composition (X) is dried as necessary to remove the solvent from the composition (X). Then, the composition (X) is cured as necessary by a method according to the composition of the composition (X). For example, when the composition (X) contains a photocurable compound, the composition (X) is cured by irradiating the composition (X) with light such as ultraviolet light to produce a substrate.

[0045] Next, the hypochlorous acid component (B) is supported on the substrate, thereby producing a functional film.

[0046] When the hypochlorous acid component (B) is held on the substrate, for example, a hypochlorite solution is brought into contact with the substrate. Then, if necessary, the substrate is dried. This allows the hypochlorous acid component (B) to be held on the substrate.

[0047] The hypochlorite is, for example, sodium hypochlorite, but is not limited thereto. The solvent in the hypochlorite solution is, for example, water. The solvent may contain water and a hydrophilic organic solvent. That is, for example, an aqueous solution of sodium hypochlorite is brought into contact with a substrate. The concentration (mass ratio) of the hypochlorite in the hypochlorite solution is, for example, 40 ppm or more and 1000 ppm or less in terms of chlorine.

[0048] In order to contact the hypochlorite solution with the substrate, for example, the substrate is immersed in the hypochlorite solution. The hypochlorite solution may be applied to the substrate, and in this case, a suitable application method may be adopted, for example, spin coating, dip coating, roll coating or spray coating, but is not limited thereto. It is preferable to maintain the state in which the hypochlorite solution is contacted with the substrate for 1 hour or more. That is, for example, it is preferable to immerse the substrate in the hypochlorite solution for 1 hour or more.

[0049] When drying the substrate, the substrate may be air-dried or may be dried by heating.

[0050] The functional film is laminated on an appropriate substrate, and the functional film is further adhered to the substrate as necessary, thereby imparting antibacterial and antiviral properties to the substrate. The substrate material may be, for example, metal, ceramics, glass, fiber, nonwoven fabric, film, plastic, rubber, paper, wood, etc., but is not limited thereto. The shape of the member may be, for example, a simple shape such as a plate, a sphere, a cylinder, a rod, a prism, or a hollow prism, or a complex shape, but is not limited thereto. Examples of substrates include wiring devices such as switches and outlets; building materials such as ceiling materials, tiles, glass, wallpaper, wall materials, floors, and fittings; interior materials such as instrument panels, seats, and ceiling materials for automobiles; home appliances such as refrigerators and air conditioners; textile products such as clothing and curtains; industrial equipment; medical equipment; doors, door handles, pull handles, handrails, interior counters, furniture, kitchens, toilets, baths, lighting equipment, and touch panels.

[0051] Instead of using a functional film, a film-like functional member may be directly laminated on the surface of a suitable substrate to impart antibacterial and antiviral properties to the substrate. EXAMPLES

[0052] Specific examples of the embodiment will be described below.

[0053] 1. Preparation of functional materials Compositions were prepared by mixing the raw materials shown in Tables 1 and 2. Details of the raw materials are as follows. -Resin component: Polymer type acrylate. Manufactured by DIC Corporation. Product name: Unidic V-6841. Solid content: 60% by mass. -Photopolymerization initiator: BASF Japan Co., Ltd. Product name: IRGACURE754. - Alumina: Manufactured by Nippon Aerosil Co., Ltd. Product name: AEROXIDE (registered trademark) Alu C. -Titanium oxide: manufactured by Nippon Aerosil Co., Ltd. Product name: AEROXIDE (registered trademark) P-25. -Cuprous oxide: Primary particle diameter approx. 50 nm. Manufactured by Furukawa Chemicals Co., Ltd. Product name: FRC-10N. -Surfactant: Phosphate ester surfactant. Manufactured by BYK Japan Co., Ltd. Product name: DISPERBYK-111.

[0054] The composition was applied onto a glass plate using a bar coater #6 to form a coating film, which was then dried by heating at 120°C for 1 minute, after which ultraviolet light was applied to the coating film using a high-pressure mercury lamp as a light source with an integrated light intensity of 300 mJ / cm 2 The coating was cured by irradiating the glass plate under the conditions of 1.0 μm. As a result, a film-like substrate with a thickness of 5 μm was formed on the glass plate.

[0055] In the cases where "Yes" is written in the "Retention Treatment" column in Tables 1 and 2, the substrate was immersed in a sodium hypochlorite aqueous solution (sold by MonotaRO Co., Ltd. Product name: MonotaRO hypochlorous acid molecular water. Effective chlorine concentration: 200 ppm) for 15 hours, then washed with ion-exchanged water and left to stand at room temperature for 24 hours to dry. In this way, a functional member was produced on the glass plate.

[0056] 2.Evaluation Test (1) Antibacterial activity value According to JIS R1752, the functional components were stored in a dark place for 4 hours and their antibacterial activity against Staphylococcus aureus was evaluated. The results are shown in Tables 1 and 2.

[0057] (2) Antibacterial activity after 2 months The functional member was left for 2 months under conditions of 25°C and 60% RH, which simulates an indoor environment, and then the antibacterial activity value of the functional member was evaluated after storing it in a dark place for 4 hours in accordance with JIS R1752, as in the above "(1) Antibacterial activity value". The results are shown in Tables 1 and 2.

[0058] [Table 1]

[0059] [Table 2]

[0060] As shown in Tables 1 and 2, higher antibacterial activity values ​​were achieved in Examples 1 to 6 compared to Comparative Examples 1 to 3. Moreover, the antibacterial activity values ​​were significantly improved in Examples 2 to 6 compared to Example 1. This is believed to be because the proportion of resin in the functional member in Examples 2 to 4 was lower compared to Example 1, and therefore the concentration of the surfactant in the resin was higher than in Example 1.

[0061] A comparison between Example 2 and Example 4 confirms that the use of titanium oxide enhances antibacterial and antiviral performance. A comparison between Example 2 and Example 5 confirms that the use of cuprous oxide also enhances antibacterial and antiviral performance. A comparison between Examples 4 and 5 and Example 6 confirms that the combined use of titanium oxide and cuprous oxide further enhances antibacterial and antiviral performance.

[0062] Furthermore, in Examples 1 to 6, the evaluation results of "antibacterial activity value" and "antibacterial activity value after two months" confirm that the antibacterial and antiviral performance is not likely to decrease over time.

[0063] [Aspects] The functional member according to a first aspect comprises a substrate containing a surfactant (A) and a hypochlorous acid component (B) held on the substrate.

[0064] According to this embodiment, the functional member has antibacterial and antiviral properties, and deterioration of the antibacterial and antiviral properties over time can be suppressed.

[0065] In the second embodiment, the surfactant (A) in the first embodiment contains a phosphate surfactant.

[0066] According to this embodiment, the decrease in antibacterial and antiviral properties over time can be further suppressed.

[0067] In a third embodiment, the substrate in the first or second embodiment contains a resin (C) that constitutes the matrix of the substrate.

[0068] In a fourth embodiment, in any one of the first to third embodiments, the substrate contains an inorganic filler (D).

[0069] According to this embodiment, the strength of the functional member (1) can be increased.

[0070] In a fifth embodiment, in the fourth embodiment, the inorganic filler (D) contains a metal oxide.

[0071] In a sixth embodiment, in the fifth embodiment, the metal oxide contains cuprous oxide.

[0072] According to this embodiment, the antibacterial and antiviral properties of the functional member can be further improved.

[0073] In a seventh aspect, in any one of the fourth to sixth aspects, a ratio of the inorganic filler (D) to the functional member is 60% by mass or more and 80% by mass or less.

[0074] According to this embodiment, the strength of the functional member can be further increased.

[0075] In an eighth embodiment, in any one of the fourth to sixth embodiments, the inorganic filler (D) has an average particle size of 500 nm or less.

[0076] According to this embodiment, the transparency of the functional member can be increased.

[0077] In a ninth aspect, in any one of the first to eighth aspects, the hypochlorite solution is contacted with the substrate, and then the substrate is dried, so that the hypochlorous acid component (B) is retained on the substrate.

[0078] According to this embodiment, the functional member has antibacterial and antiviral properties, and deterioration of the antibacterial and antiviral properties over time can be suppressed.

[0079] In a tenth aspect, in any one of the first to ninth aspects, the functional member is in the form of a film.

[0080] A method for producing a functional member according to an eleventh aspect includes contacting a hypochlorite solution with a substrate containing a surfactant (A) and then drying the substrate.

[0081] According to this embodiment, the functional member has antibacterial and antiviral properties, and deterioration of the antibacterial and antiviral properties over time can be suppressed.

[0082] A functional film according to a twelfth aspect includes a base film and the functional member according to the tenth aspect overlaid on the base film.

Claims

1. A substrate containing a surfactant (A); A hypochlorous acid component (B) held on the substrate; Functional components.

2. The surfactant (A) contains a phosphoric acid surfactant. The functional member according to claim 1 .

3. The substrate contains a resin (C) constituting a mother phase of the substrate. The functional member according to claim 1 .

4. The substrate contains an inorganic filler (D). The functional member according to claim 1 .

5. The inorganic filler (D) contains a metal oxide. The functional member according to claim 4.

6. The metal oxide contains cuprous oxide. The functional member according to claim 5 .

7. The ratio of the inorganic filler (D) to the functional member is 60% by mass or more and 80% by mass or less. The functional member according to claim 4.

8. The inorganic filler (D) has an average particle size of 500 nm or less. The functional member according to claim 4.

9. The hypochlorite solution is contacted with the substrate, and then the substrate is dried, so that the hypochlorous acid component (B) is retained on the substrate. The functional member according to claim 1 .

10. It is membranous, The functional member according to claim 1 .

11. The method includes contacting a hypochlorite solution with a substrate containing a surfactant (A) and then drying the substrate. A method for manufacturing a functional member.

12. A base film; The functional member according to claim 10 overlapping the base film. Functional film.

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