Antiviral article and manufacturing method thereof

Abstract

To provide an antiviral article which is excellent in antiviral durability, and a method for producing the same.SOLUTION: An antiviral article includes a base material, and a coating layer coating the surface of the base material. The coating layer contains a resin, and a quaternary ammonium salt. The quaternary ammonium salt is partially exposed to the surface of the coating layer. A method for producing an antiviral article includes: a first step of forming a coating layer containing a resin and a quaternary ammonium salt on a surface of a base material; and a second step of removing the resin on the surface of the coating layer by polishing or dissolving, and partially exposing the quaternary ammonium salt to the surface of the coating layer, after the first step.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to an antiviral article and a method for manufacturing the same, and more particularly to an antiviral article having excellent durability of antiviral properties and a method for manufacturing the same. [Background technology]

[0002] It has been known that some quaternary ammonium salts can be used as antiviral agents against enveloped viruses. As a method for immobilizing such quaternary ammonium salts on the surface of an article, a method for immobilizing an antiviral agent using a silane coupling agent as a binder has been proposed (see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2010 / 073825 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the case of masks using antiviral articles manufactured using the antiviral agent fixation method as described in Patent Document 1, the antiviral durability of masks that are washed and reused is only about 50 times after washing, which poses a problem that the durability of the antiviral property is insufficient to meet the improved performance requirements of such masks.

[0005] On the other hand, the present inventors have discovered that, in order to improve the durability of the antiviral properties, they have used a thermosetting resin instead of a silane coupling agent to bind a quaternary ammonium salt to the surface of a fiber assembly. However, contrary to expectations, this resulted in the article losing its antiviral properties.

[0006] The present invention has been made in consideration of the problems and technical knowledge of the conventional art, and an object of the present invention is to provide an antiviral article having excellent durability of antiviral properties and a method for producing the same. [Means for solving the problem]

[0007] As a result of extensive research into achieving the above-mentioned object, the present inventors have found that the above-mentioned object can be achieved by partially exposing the quaternary ammonium salt on the surface of a coating layer that is disposed on the surface of a substrate and contains a resin and a quaternary ammonium salt, and have thus completed the present invention.

[0008] That is, the antiviral article of the present invention comprises a substrate and a coating layer that coats the surface of the substrate. the substrate is partially exposed on the surface of the coating layer, The coating layer contains a resin and a quaternary ammonium salt, and the quaternary ammonium salt is partially exposed on the surface of the coating layer.

[0009] Furthermore, the method for producing an antiviral article of the present invention is the same as the method for producing an antiviral article of the present invention described above, and includes the following steps 1 and 2. Step 1 is a step of forming a coating layer containing a resin and a quaternary ammonium salt on the surface of a substrate. Step 2 is performed after Step 1 and is a step of removing the resin on the surface of the coating layer by polishing or dissolving, thereby partially exposing the quaternary ammonium salt on the surface of the coating layer. [Effects of the Invention]

[0010] According to the present invention, since the quaternary ammonium salt is partially exposed on the surface of a coating layer that is disposed on the surface of a substrate and contains a resin and a quaternary ammonium salt, it is possible to provide an antiviral article with excellent antiviral durability and a method for producing the same. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a schematic cross-sectional view showing the configuration of a first embodiment of an antiviral article of the present invention. [Figure 2]2 is a schematic cross-sectional view showing an enlarged view of a portion of the coating layer shown in FIG. 1 surrounded by line II. [Figure 3] FIG. 2 is a schematic cross-sectional view showing the configuration of a second embodiment of the antiviral article of the present invention. [Figure 4] FIG. 2 is an explanatory view schematically showing the procedure for polishing in the first embodiment of the method for producing an antiviral article of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, some embodiments of the antiviral article and the method for producing the same of the present invention will be described in detail with reference to the drawings.

[0013] [Antiviral products] First, the antiviral article of the present invention will be described. Fig. 1 is a schematic cross-sectional view showing the configuration of a first embodiment of the antiviral article of the present invention. Fig. 2 is a schematic cross-sectional view showing an enlarged view of the portion of the coating layer surrounded by line II shown in Fig. 1.

[0014] As shown in FIG. 1, the antiviral article 1 of this embodiment includes a substrate 3 and a coating layer 5 that coats the surface of the substrate 3. In the illustrated example, rubber is used as the substrate 3. Furthermore, as shown in FIG. 2, the coating layer 5 contains a resin 7 and a quaternary ammonium salt 9 held in the resin 7. Furthermore, the quaternary ammonium salt 9 is partially exposed on the surface of the coating layer 5.

[0015] The antiviral article of the present embodiment is disposed on the surface of the substrate, and the quaternary ammonium salt is partially exposed on the surface of the coating layer containing a resin and a quaternary ammonium salt. This is thought to result in excellent durability of the antiviral properties.

[0016] In particular, artificial leather to which such an antiviral article is applied is thought to have excellent antiviral durability against washing. Covering layer The substrate is partially exposed on the surface of do.

[0017] In addition, such an antiviral article has the secondary advantage that it may further have at least one of shape stability, deodorizing properties, and antibacterial properties.

[0018] Each component will be described in more detail below.

[0019] The substrate 3 preferably includes, for example, wallpaper, rubber, a coating film, a film, a tape, a resin, a paper material, a fiber, or a fiber assembly. Among these, rubber, a coating film, a film, and a tape are preferred. Covering layer By being exposed on the surface of Covering layer It is thought that this makes it easier to generate negative ions, which were previously prevented from being generated by the resin, and that this greatly increases the ability to adsorb viruses. Covering layer By being exposed on the surface of Covering layer It is believed that this facilitates the generation of static electricity, for example negative ions, in the fiber assembly, which was previously prevented by the resin, and greatly increases the ability to adsorb viruses.

[0020] Examples of wallpaper include resin wallpaper used in buildings, Japanese paper wallpaper, and diatomaceous earth wallpaper. Examples of rubber include rubber used in building fixtures and transportation machinery and equipment, and rubber used in kitchenware, office equipment, furniture, etc. Examples of coating films include coating films formed on products used in building fixtures and transportation machinery and equipment, and coating films formed on kitchenware, office equipment, furniture, etc. Examples of films include films used in building fixtures and transportation machinery and equipment, and films used in kitchenware, office equipment, furniture, etc. Examples of tapes include tapes used in kitchenware, office equipment, furniture, etc. Examples of resins include resins used in building fixtures and transportation machinery and equipment, and resins used in kitchenware, office equipment, furniture, etc. Examples of paper materials include newspaper rolls, printing and communication paper, packaging paper, sanitary paper, miscellaneous paper, and other paperboards such as cardboard, paperboard for paper containers, building material paper, paper tube paper, wrap, and other paperboards. Examples of fibers include carbon fiber, aramid fiber, and glass fiber. These fibers may be used in the form of a fiber assembly. The fiber assembly preferably includes, for example, twisted yarn, nonwoven fabric, woven fabric, or knitted fabric.

[0021] Among these, it is more preferable to use a woven fabric as the fiber assembly from the viewpoint of ease of application to masks that can be washed and reused, which is an example of an application of an antiviral article.

[0022] Although not particularly limited, examples of the material of the fiber assembly include synthetic fibers, semi-synthetic fibers, and natural fibers.

[0023] The fiber assembly preferably contains, for example, cotton fiber, hemp fiber, wool fiber, silk fiber, rayon fiber, acetate fiber, polyester fiber, polyamide fiber, polyvinyl alcohol fiber, polyvinylidene chloride fiber, polyolefin fiber, polyurethane fiber, polytetrafluoroethylene fiber, or carbon fiber. Furthermore, any combination of two or more of these fibers may be used.

[0024] Although not particularly limited, preferred synthetic fibers include, for example, polyester fibers such as polyethylene terephthalate fibers, polypropylene terephthalate fibers, polybutylene terephthalate fibers, and polyhexamethylene terephthalate fibers; polyamide fibers such as nylon 6 fibers and nylon 6,6 fibers; polyacrylic fibers; polypropylene fibers; polyvinyl chloride fibers; and polyvinyl alcohol fibers.

[0025] Although not particularly limited, among the semi-synthetic fibers, for example, acetate fiber and rayon fiber are preferable.

[0026] Although not particularly limited, among natural fibers, preferred are wool fiber, silk fiber, cotton fiber, and hemp fiber.

[0027] Among these, it is more preferable to use a woven fabric made of a combination of cotton fibers and polyester fibers as the fiber assembly, from the viewpoint that static electricity is likely to occur between the two types of fibers, making it easier to adsorb viruses.

[0028] The resin 7 used as the binder for binding the quaternary ammonium salt can be, for example, a thermoplastic resin, a thermosetting resin, an ultraviolet-curable resin, or a two-component room-temperature curable resin. However, a thermosetting resin is preferred. Examples of the thermoplastic resin include acrylic resin, vinyl acetate resin, polyethylene resin, polystyrene resin, polyvinyl chloride resin, polypropylene resin, polymethyl methacrylate resin, acrylonitrile butadiene styrene resin, butadiene resin latex, polycarbonate resin, polyacetal resin, nylon resin, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyphenylene oxide resin, polyphenylene sulfide resin, polysulfone resin, polyethersulfone resin, polyetheretherketone resin, polyarylsulfone resin, polyimide resin, polyaminobismaleimide resin, polyamideimide resin, polyetherimide resin, bismaleimide triazine resin, polymethylpentene resin, fluorinated resin, olefin-vinyl alcohol copolymer resin, polyurethane resin, and polyarylate resin. These may be used alone or in any combination of two or more. The thermosetting resin preferably includes, for example, an alkyd resin, a melamine resin, a phenolic resin, an unsaturated polyester, a diallyl phthalate resin, an epoxy resin, a silicone resin, or a urea resin. These may also be used alone or in any combination of two or more.

[0029] Among these, it is more preferable to use melamine resin as the thermosetting resin from the viewpoint of improving the water resistance and weather resistance of the antiviral article.

[0030] As the quaternary ammonium salt 9, a conventionally known quaternary ammonium salt that exhibits antiviral activity against enveloped viruses can be used.

[0031] Quaternary ammonium salts are known as a type of surfactant. Mixed solutions of cationic and anionic surfactants are known to form various molecular aggregates even in more dilute systems than general surfactant solutions. In particular, vesicles, which have attracted attention as such molecular aggregates, are bag-like self-assemblies in which amphiphilic molecules with both hydrophilic and hydrophobic properties are closely spaced in water to form a lipid bilayer. It is also known that when forming such molecular aggregates, it is preferable that the molar ratio of the two surfactants mixed is not nearly equimolar.

[0032] For example, when an anionic antibacterial agent, which is an anionic surfactant, is used to produce antiviral functional fibers with washing durability, a binder must be added to improve washing durability. To further improve durability, the amount of resin used as the binder or the amount of crosslinking agent added to the resin must be increased. However, this can impair the soft texture of the textile product and increase costs.

[0033] On the other hand, when manufacturing antiviral functional fibers with wash durability using two types of antibacterial finishing agents, for example, a cationic surfactant (Niccanon RB) and an anionic surfactant (anionic surfactant), the molecular aggregates bond strongly with the binder. Here, Nikcanon RB contains a quaternary ammonium salt. This allows for a reduction in the amount of resin used as the binder to bind the quaternary ammonium salt to the substrate. As a result, the soft texture of the textile product can be maintained while reducing costs.

[0034] Furthermore, a cationic surfactant, cationic antibacterial finishing agent (Niccanon RB), is diluted with an anionic surfactant, anionic antibacterial finishing agent, and then a binder is added to the mixture. The resulting binder mixture containing a quaternary ammonium salt is then applied to fibers, firmly binding the quaternary ammonium salt to the fibers. While a single binder may be used, using multiple binders can more firmly bind the quaternary ammonium salt to the fibers. While not particularly limited, a combination of an acrylic emulsion and a nonionic crosslinking agent is preferred as the resin functioning as the binder. "Acrylic emulsion" refers to an emulsion containing finely divided acrylic polymers. A typical example is a self-crosslinking acrylic ester copolymer emulsion that appears as a milky white emulsion (a milky white liquid). It is also preferred to mix the cationic surfactant and anionic surfactant in a molar ratio that is different from an equimolar mixture.

[0035] Until now, it has been considered difficult to use a binder to bind a quaternary ammonium salt to fibers such as polyester or nylon to turn them into antiviral functional fibers that are durable to washing. However, as described above, by using a mixture of a cationic surfactant, an anionic surfactant, and a binder, it is possible to turn fibers such as polyester or nylon into antiviral functional fibers.

[0036] Although not particularly limited, for example, from the viewpoint of further improving the durability of the antiviral property of the antiviral article, the quaternary ammonium salt is Covering layer It is preferable that the polymer is present in a dispersed state.

[0037] Although not particularly limited, the content of the quaternary ammonium salt relative to the fiber assembly is preferably 0.5 to 3.0% owf (on the weight of fiber). If the content of the quaternary ammonium salt relative to the fiber assembly is less than 0.5% owf, the washing durability of the antiviral article may decrease. On the other hand, if the content of the quaternary ammonium salt relative to the fiber assembly exceeds 3.0% owf, the soft texture of the textile product after processing may be impaired.

[0038] Examples of rubber products to which the antiviral article of the present invention can be applied include toys, play equipment, sporting goods, condoms, and the like.

[0039] Examples of painted products to which the antiviral article of the present invention can be applied include articles painted with water-based paint, oil-based paint, acrylic paint, furniture / floor paint, etc.

[0040] Examples of film products to which the antiviral article of the present invention can be applied include keyboard protective films, elevator button protective films, desk protective films, touch panel films for smartphones and tablet computers, touch panel films for medical devices and public facilities, panel films for various digital signage, face shields, window films, and touch panel films for automotive in-vehicle displays.

[0041] Examples of tape products to which the antiviral article of the present invention can be applied include gymnasium line tape, medical protective tape, and contact infection prevention tapes (doorknobs, staircase handrails, bathroom handrails, toilet handrails, etc.) used in buildings and offices, stores and commercial facilities, schools and educational facilities, hospitals and medical facilities, nursing homes, exercise and play facilities, etc.

[0042] Examples of resin products to which the antiviral article of the present invention can be applied include toys, play equipment, and sporting goods.

[0043] Examples of paper products to which the antiviral article of the present invention can be applied include cardboard, magazines, newspapers, and the like.

[0044] Examples of fibers to which the antiviral article of the present invention is applied include those applied to fiber-reinforced plastics, such as carbon fiber, aramid fiber, and glass fiber.

[0045] Examples of textile products to which the antiviral article of the present invention can be applied include clothing, nursing care products, miscellaneous goods, interior goods, and bedding.

[0046] Examples of clothing items include outdoor wear, sportswear, home wear, relaxation wear, pajamas, sleepwear, underwear, office wear, work clothes, food coats, nursing coats, patient wear, care wear, school uniforms, and kitchen wear.

[0047] Examples of care products include supports, corsets, rehabilitation shoes, underwear, diaper covers, and small items.

[0048] Examples of miscellaneous items include aprons, towels, gloves, scarves, socks, hats, shoes, sandals, bags, umbrellas, etc.

[0049] Examples of interior goods include curtains, carpets, mats, kotatsu covers, sofa covers, cushion covers, sofa coverings, toilet seat covers, toilet seat mats, tablecloths, and the like.

[0050] Examples of bedding products include futon cover, futon wadding, blankets, blanket cover, pillow filling, sheets, waterproof sheets, futon covers, pillowcases, and the like.

[0051] 3 is a schematic cross-sectional view showing the configuration of a second embodiment of the antiviral article of the present invention. The enlarged schematic cross-sectional view of the part surrounded by line II in FIG. 3 is the same as FIG.

[0052] As shown in Fig. 3, the antiviral article 1A of this embodiment includes a substrate 3 and a coating layer 5 that coats the surface of the substrate 3. In the illustrated example, a woven fabric, which is an example of a fiber assembly, is used as the substrate 3. Furthermore, as shown in Fig. 2, the coating layer 5 contains a resin 7 and a quaternary ammonium salt 9 held in the resin 7. Furthermore, the quaternary ammonium salt 9 is partially exposed on the surface of the coating layer 5. In the illustrated example, a thermosetting resin is used as the resin 7.

[0053] As described above, the antiviral article of the present embodiment is disposed on the surface of a fiber assembly, and the quaternary ammonium salt is partially exposed on the surface of the coating layer containing a thermosetting resin and a quaternary ammonium salt. This is thought to result in excellent durability of the antiviral properties.

[0054] In particular, a mask to which such an antiviral article is applied is thought to have excellent antiviral durability against washing. Covering layer As described above, it is preferable that the fiber aggregate is partially exposed on the surface of the fiber aggregate. Covering layer By being exposed on the surface of Covering layer It is believed that this facilitates the generation of static electricity, for example, negative ions, in the fiber aggregate, which was previously prevented from occurring by the thermosetting resin, and greatly increases the virus adsorption ability. Note that the detailed explanation of each component has been given above, so redundant explanations will be omitted.

[0055] [Method for manufacturing antiviral products] Next, a method for producing an antiviral article of the present invention will be described. The method for producing an antiviral article of the present invention is one embodiment of the method for producing an antiviral article of the present invention described above. Therefore, the antiviral article of the present invention is not limited to those obtained by the method for producing an antiviral article of the present invention.

[0056] A first embodiment of the method for producing an antiviral article of the present invention includes the following first and second steps. The first step is to apply a coating containing a resin and a quaternary ammonium salt to the surface of a substrate. Covering layer This is a process for forming the above. The second step is carried out after the first step, and is a step in which the resin on the surface of the coating layer is removed by polishing or dissolving, thereby partially exposing the quaternary ammonium salt on the surface of the coating layer.

[0057] 4A and 4B are explanatory diagrams schematically illustrating the polishing procedure in the first embodiment of the method for producing an antiviral article of the present invention. In the figure, (A) shows the state before polishing, and (B) shows the state after polishing. As shown in FIGS. 4A and 4B, in the second step, the resin 7 in the polished portion 11 on the surface of the coating layer 5 is removed by polishing, and the quaternary ammonium salt 9 is partially exposed on the surface of the coating layer 5.

[0058] Although not shown, in the first embodiment of the method for producing an antiviral article of the present invention, Covering layer The resin in the dissolved portion of the surface (corresponding to the polished portion in FIG. 4) may be removed by dissolution, thereby partially exposing the quaternary ammonium salt on the surface of the coating layer.

[0059] The method for producing an antiviral article of the present embodiment can partially expose the quaternary ammonium salt on the surface of the coating layer that is disposed on the surface of the substrate and contains a resin and a quaternary ammonium salt, and is therefore thought to be able to provide an antiviral article with excellent antiviral durability.

[0060] In particular, a mask using the antiviral article obtained in this manner is thought to have excellent washing durability of antiviral properties.

[0061] Furthermore, the antiviral article thus obtained has the secondary advantage that it may further have at least one of shape stability, deodorizing properties, and antibacterial properties.

[0062] Each step will be described in more detail below.

[0063] In the first step, for example, a substrate (preferably a fiber assembly) is first contacted with and impregnated with a liquid containing a quaternary ammonium salt as an antiviral agent to obtain a substrate (preferably a fiber assembly) containing the liquid containing a quaternary ammonium salt, and then the substrate (preferably a fiber assembly) containing the liquid containing a quaternary ammonium salt is dried to obtain a substrate (preferably a fiber assembly). Next, the quaternary ammonium salt-containing substrate (preferably a fiber assembly) is contacted with and impregnated with a liquid containing a resin (preferably a thermosetting resin) raw material as an adhesive to obtain a substrate (preferably a fiber assembly) containing a liquid containing a resin (preferably a thermosetting resin) raw material and a quaternary ammonium salt, and then the resin (preferably a thermosetting resin) raw material-containing substrate (preferably a fiber assembly) is heated to impregnate the substrate (preferably a fiber assembly) with a liquid containing a resin (preferably a thermosetting resin) raw material and a quaternary ammonium salt. Covering layer From the viewpoint of being able to firmly bond the quaternary ammonium salt to the substrate (preferably a fiber assembly), it is preferable to carry out the first step in this manner.

[0064] In the first step, for example, a substrate (preferably a fiber assembly) is contacted with and impregnated in this order with a quaternary ammonium salt-containing liquid and a resin (preferably a thermosetting resin) raw material-containing liquid, or with and impregnated in a mixed liquid of a quaternary ammonium salt-containing liquid and a resin (preferably a thermosetting resin) raw material-containing liquid to obtain a substrate (preferably a fiber assembly) containing a quaternary ammonium salt-containing liquid and a resin (preferably a thermosetting resin) raw material-containing liquid, and then the substrate (preferably a fiber assembly) containing a quaternary ammonium salt-containing liquid and a resin (preferably a thermosetting resin) raw material-containing liquid is heated to form a film containing a resin (preferably a thermosetting resin) and a quaternary ammonium salt on the surface of the substrate (preferably a fiber assembly). Covering layer It is preferable to form a quaternary ammonium salt. Covering layer Quaternary ammonium salts, which are easily exposed on the surface of Covering layer From the viewpoint of facilitating the dispersion of the components in the solution, it is preferable to carry out the first step in this manner.

[0065] Here, although not particularly limited, the solvent applied to the quaternary ammonium salt and resin (preferably thermosetting resin) raw material is preferably a solvent that dissolves the quaternary ammonium salt and resin (preferably thermosetting resin) raw material. However, without being limited thereto, a solvent that forms an emulsion state can also be applied. Furthermore, although not particularly limited, examples of the solvent applied to the quaternary ammonium salt and resin (preferably thermosetting resin) raw material include alcohols such as water, methanol, ethanol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, isobutyl alcohol, and sec-butyl alcohol.

[0066] Among these, from the viewpoint of preventing the viscosity of the quaternary ammonium salt-containing liquid or the resin (preferably thermosetting resin) raw material-containing liquid from becoming too high, the solvents to be applied to the quaternary ammonium salt and the resin (preferably thermosetting resin) raw material are preferably methanol and ethanol, and also preferred are mixtures of water and alcohols such as methanol and ethanol.

[0067] Also, Covering layer When forming the adhesive, instead of the resin raw material-containing liquid described above, for example, solvent-based lacquer paints, water-based emulsion paints, thermoplastic powder paints, and other paints that form a coating by drying and curing without chemical reaction, such as solvent-based lacquer paints, water-based emulsion paints, and thermoplastic powder paints, or paints that form a coating by drying and curing with chemical reaction, such as drying oil-based alkyd paints, unsaturated polyester paints, UV-curable paints, ambient-drying epoxy paints, ambient-drying urethane paints, thermosetting liquid paints, and thermosetting powder paints, can be used. For example, a quaternary ammonium salt can be mixed into such paints in advance. Examples of resins contained in adhesives and paints include the thermoplastic resins and thermosetting resins described above. Furthermore, adhesives and paints may be one-component or two-component types. Commercially available adhesives and paints can be used as the adhesives and paints, respectively.

[0068] Although not particularly limited, when the substrate is a fiber assembly, the drying conditions are preferably 90 to 150°C and 30 seconds to 5 minutes. If the drying temperature is less than 90°C, the washing durability of the antiviral article may decrease. On the other hand, if the drying temperature exceeds 150°C, the quaternary ammonium salt, which is the antiviral agent, may deteriorate.

[0069] Although not particularly limited, when the substrate is a fiber assembly, the heating conditions are preferably 120 to 200° C. and 30 seconds to 10 minutes. During such heating, it is preferable to apply pressure to the same extent as when ironing clothing, for example, by using a roller.

[0070] In one example of the second step, the resin (preferably a thermosetting resin) on the surface of the coating layer obtained in the first step is removed in a dry state by polishing with a grindstone, sandpaper, or the like to expose the quaternary ammonium salt on the surface of the coating layer, thereby obtaining an antiviral article.

[0071] In another example of the second step, the resin (preferably a thermosetting resin) on the surface of the coating layer obtained in the first step is removed by using water, an aqueous solution of hypochlorous acid, or the like. Covering layer is removed by polishing with a grindstone or sandpaper in a wet state, in other words, by wet sanding, to expose the quaternary ammonium salt on the surface of the coating layer, thereby obtaining an antiviral article.

[0072] In yet another example of the second step, the resin (preferably a thermosetting resin) on the surface of the coating layer obtained in the first step is removed by polishing in a dry state by rubbing it against, for example, a resin (preferably a thermosetting resin) on the surface of another coating layer obtained in the first step, exposing the quaternary ammonium salt on the surface of the coating layer, thereby obtaining an antiviral article.

[0073] In yet another example of the second step, the resin (preferably a thermosetting resin) on the surface of the coating layer obtained in the first step is removed by using water, an aqueous solution of hypochlorous acid, or the like. Covering layerIn a wet state, the quaternary ammonium salt is removed by polishing, in other words, by rubbing it against a resin (preferably a thermosetting resin) on the surface of another coating layer obtained in the first step, to expose the quaternary ammonium salt on the surface of the coating layer, thereby obtaining an antiviral article.

[0074] Although not particularly limited, the conditions for the above-mentioned polishing are as follows: 2 Apply a pressure of 5 to 50 kgf per area and use a grinding stone, sandpaper, or another Covering layer It is preferable to perform polishing at a sliding speed of about 0.5 to 5 m / s and for a rubbing time of about 0.5 seconds to 5 minutes.

[0075] Although not particularly limited, the above-mentioned polishing Covering layer The temperature is set so that the coating layer does not get heated by friction and lose adhesion. Covering layer It is preferable that the temperature is equal to or lower than the glass transition temperature of the resin contained in the resin.

[0076] The resin (preferably a thermosetting resin) on the surface of the coating layer obtained in the first step is removed by polishing in a dry state, but by polishing with water, a hypochlorous acid solution, etc. Covering layer Polishing the surface in a wet state, in other words, removing it by wet sanding, has the advantage that the shape and structure of the substrate (preferably a fiber aggregate) can be maintained and the durability of the antiviral properties can be further improved.

[0077] The resin (preferably a thermosetting resin) on the surface of the coating layer of the article obtained in the first step is removed by polishing in a dry state, but by polishing with water, a hypochlorous acid aqueous solution, etc. Covering layer Polishing the surface in a wet state, in other words, removing the stains by wet sanding, allows the shape and structure of the substrate (preferably a fiber aggregate) to be maintained. Furthermore, if the fiber aggregate is formed from two types of fibers that are prone to static electricity, static electricity will be generated between the two types of fibers, allowing the substrate to maintain a shape and structure that is prone to adsorbing viruses. This has the advantage of further improving the durability of the antiviral properties.

[0078] Thermosetting resins may contain formalin, but the thermosetting resin on the surface of the coating layer obtained in the first step can be removed by using an acid or alkali, especially a hypochlorous acid solution. Covering layer The method has the advantage that the formalin can be removed by polishing the surface of the coating layer of another article obtained in the first step with a grindstone or sandpaper while the surface is wet, or by polishing the surface of the coating layer with a thermosetting resin, for example, obtained in the first step, or by polishing the surface of the coating layer with water.

[0079] In the above-mentioned examples of the second step, the thermosetting resin on the surface of the coating layer obtained in the first step is removed with water, a hypochlorous acid aqueous solution, etc. Covering layer It is preferable to remove the coating layer by abrasion, in other words, by rubbing the coating layer in a wet state against the thermosetting resin on the surface of another article obtained in the first step, for example, by water sanding.

[0080] In another example of the second step, the resin (preferably a thermosetting resin) on the surface of the coating layer obtained in the first step is dissolved with a solvent, and then the dissolved portion is removed, after which the quaternary ammonium salt is exposed on the surface of the coating layer to obtain an antiviral article.

[0081] The solvent used to dissolve the resin is: Covering layer The solvent can be appropriately selected from conventionally known solvents depending on the type of resin contained in the solvent.

[0082] Although not particularly limited, the above-mentioned dissolution Covering layer The temperature of Covering layer is heated Covering layer To prevent a significant decrease in adhesion, Covering It is preferable that the temperature is equal to or lower than the glass transition temperature of the resin contained in the layer. [Example]

[0083] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples.

[0084] Example 1 A fiber assembly (plain woven fabric, 40% polyester, 60% cotton) was contacted with a mixed solution (Nikkanon RB (manufactured by Nicca Chemical Co., Ltd.)) containing a quaternary ammonium salt as an antiviral agent and a thermosetting resin raw material-containing liquid as an adhesive for 0.5 seconds so that the quaternary ammonium salt was supported on the fiber assembly at 2.0% owf, to obtain a fiber assembly containing the quaternary ammonium salt-containing liquid and the thermosetting resin raw material-containing liquid. This was then squeezed at a squeezing rate of 100% using a padder, and then heated at 120°C for 5 minutes to form a mixture containing the thermosetting resin and the quaternary ammonium salt on the surface of the fiber assembly. Covering layer This will be referred to as "Item 1" below.

[0085] Thereafter, the thermosetting resin on the surface of the coating layer of the obtained article 1 was wetted with an aqueous solution of hypochlorous acid and then mixed with the thermosetting resin on the surface of another coating layer by 1 m. 2 While applying a pressure of 10 kgf per Covering layer The quaternary ammonium salt was removed by polishing, in other words, by wet grinding, by rubbing the coating layer at a sliding speed of 1 m / s for 1 second, to partially expose the quaternary ammonium salt on the surface of the coating layer, thereby obtaining the antiviral article of this example.

[0086] Example 2 A fiber assembly (woven fabric, 40% polyester, 60% cotton) was contacted with an antiviral processing solution containing 5 parts by mass of a cationic quaternary ammonium salt (Niccanon RB (manufactured by Nicca Chemical Co., Ltd.)) as an antiviral agent, 5 parts by mass of an anionic quaternary ammonium salt, 5 parts by mass of an acrylic emulsion as a binder, 2 parts by mass of a nonionic crosslinking agent as a binder aid, and 80 parts by mass of water for 0.5 seconds so that the quaternary ammonium salt was carried at 2.0% owf relative to the fiber assembly, to obtain a fiber assembly containing the antiviral processing solution, which was then squeezed at a squeezing rate of 100% using a padder, and then heated at 120°C for 5 minutes, to form a coating containing a resin and a quaternary ammonium salt on the surface of the fiber assembly. Covering layer This will be referred to as "Item 2" below.

[0087] Thereafter, the resin on the surface of the coating layer of the obtained article 2 was wetted with an aqueous solution of hypochlorous acid, and in a wet state, it was mixed with the thermosetting resin on the surface of another coating layer by 1 m. 2 While applying a pressure of 10 kgf per Covering layer The quaternary ammonium salt was removed by polishing, in other words, by wet grinding, by rubbing the coating layer at a sliding speed of 1 m / s for 1 second, to partially expose the quaternary ammonium salt on the surface of the coating layer, thereby obtaining the antiviral article of this example.

[0088] (Comparative Example 1) Article 1 (unpolished article) obtained in Example 1 was used as the article of this example.

[0089] [Performance evaluation] (Antiviral test) The antiviral products and articles in each example were evaluated in accordance with the method described in the 2014 edition of ISO 18184. The following two types of viruses were tested: Influenza A virus (H3N2) (ATCC VR-1679) Feline calicivirus (F-9) (ATCC VR-782)

[0090] (Washing method) In accordance with the "Washing Method for SEK Mark Textile Products" (revised April 1, 2014, document number JEC326) issued by the Product Certification Department of the Japan Textile Evaluation Technology Council, the garments were washed 150 times using the standard washing method (method described in 1995 edition of JIS L0217 103) and then hung to dry.

[0091] It was found that the antiviral articles of Examples 1 and 2 within the scope of the present invention exhibited excellent antiviral properties even when the articles were unwashed or washed 150 times. The antiviral article of the present invention exhibits excellent antiviral properties due to the following: Covering layer Not only because the quaternary ammonium salt was exposed on the surface of Covering layer By removing the thermosetting resin on the surface by polishing, Covering layerThis is thought to be because the generation of ions in the fiber aggregate, which had been inhibited by the thermosetting resin, became easier, greatly increasing the ability to adsorb viruses. On the other hand, it was found that the article of Comparative Example 1, which is not in accordance with the present invention, did not exhibit antiviral properties.

[0092] Example 3 A fiber assembly (woven fabric, 40% polyester, 60% cotton) was contacted with an antiviral processing solution containing 10 parts by mass of a cationic quaternary ammonium salt (Niccanon RB (manufactured by Nicca Chemical Co., Ltd.)) as an antiviral agent, 5 parts by mass of an acrylic emulsion as a binder, 2 parts by mass of a nonionic crosslinking agent as a binder aid, and 80 parts by mass of water for 0.5 seconds so that the quaternary ammonium salt was carried at 2.0% owf relative to the fiber assembly, to obtain a fiber assembly containing the antiviral processing solution, which was then squeezed at a squeezing rate of 100% using a padder, and then heated at 120°C for 5 minutes, to form a coating containing a resin and a quaternary ammonium salt on the surface of the fiber assembly. Covering layer This will be referred to as "Item 3" below.

[0093] Thereafter, the resin on the surface of the coating layer of the obtained article 3 was wetted with an aqueous solution of hypochlorous acid, and in a wet state, it was mixed with the thermosetting resin on the surface of another coating layer by 1 m. 2 While applying a pressure of 10 kgf per Covering layer The quaternary ammonium salt was removed by polishing, in other words, by wet grinding, by rubbing the coating layer at a sliding speed of 1 m / s for 1 second, to partially expose the quaternary ammonium salt on the surface of the coating layer, thereby obtaining the antiviral article of this example.

[0094] Example 4 A fiber assembly (woven fabric, 40% polyester, 60% cotton) was brought into contact with an antiviral processing solution containing 2.5 parts by mass of a cationic quaternary ammonium salt (Niccanon RB (manufactured by Nicca Chemical Co., Ltd.)) as an antiviral agent, 2.5 parts by mass of an anionic quaternary ammonium salt, 2.5 parts by mass of an acrylic emulsion as a binder, 1 part by mass of a nonionic crosslinking agent as a binder aid, and 80 parts by mass of water, for 0.5 seconds in the same manner as in Example 4 to obtain a fiber assembly containing the antiviral processing solution, which was then squeezed at a squeezing rate of 100% using a padder, and then heated at 120°C for 5 minutes to form a film containing a resin and a quaternary ammonium salt on the surface of the fiber assembly. Covering layer This is hereinafter referred to as "Item 4."

[0095] Thereafter, the resin on the surface of the coating layer of the obtained article 4 was wetted with an aqueous solution of hypochlorous acid, and in a wet state, it was mixed with the thermosetting resin on the surface of another coating layer by 1 m. 2 While applying a pressure of 10 kgf per Covering layer The quaternary ammonium salt was removed by polishing, in other words, by wet grinding, by rubbing the coating layer at a sliding speed of 1 m / s for 1 second, to partially expose the quaternary ammonium salt on the surface of the coating layer, thereby obtaining the antiviral article of this example.

[0096] (Comparative Example 2) Article 4 (unpolished article) obtained in Example 4 was used as the article of this example.

[0097] [Performance evaluation] (Antiviral test) The antiviral articles and articles of each example were evaluated in accordance with the antiviral test method for textile products (JIS L1922:2016 plaque measurement method). Some of the test conditions and the results obtained are shown in Tables 1 and 2.

[0098] [Table 1]

[0099] [Table 2]

[0100] Tables 1 and 2 show that the antiviral articles of Examples 3 and 4, which fall within the scope of the present invention, also exhibit excellent antiviral properties. Furthermore, the results of the antiviral articles of Examples 3 and 4 show that Example 4, in which the blending ratio of the binder and other materials was reduced by 50%, also exhibits excellent antiviral properties. In other words, it was found that the amount of resin used as the binder can be reduced when binding a quaternary ammonium salt to a substrate such as polyester. Furthermore, it was found that the reduction in the amount of resin used allows the soft texture of textile products to be maintained while also reducing costs. On the other hand, it was found that the article of Comparative Example 2, which is not in accordance with the present invention, did not exhibit antiviral properties.

[0101] Although the present invention has been described above with reference to some embodiments and examples, the present invention is not limited to these and various modifications are possible within the scope of the gist of the present invention. [Explanation of symbols]

[0102] 1,1A Antiviral products 3 Base material 5 Covering layer 7. Resin 9. Quaternary ammonium salts 11 Part to be polished

Claims

1. A substrate and a coating layer that coats the surface of the substrate, the substrate is partially exposed on a surface of the coating layer, the coating layer contains a resin and a quaternary ammonium salt, The quaternary ammonium salt is partially exposed on the surface of the coating layer. An antiviral article characterized by:

2. the substrate is a fiber assembly, The resin is a thermosetting resin.

2. The antiviral article according to claim 1 .

3. The antiviral article according to claim 2, wherein the fiber assembly comprises a twisted yarn, a nonwoven fabric, a woven fabric, or a knitted fabric.

4. 4. The antiviral article according to claim 2 or 3, wherein the fiber assembly contains at least one fiber selected from the group consisting of cotton fibers, hemp fibers, wool fibers, silk fibers, rayon fibers, acetate fibers, polyester fibers, polyamide fibers, polyvinyl alcohol fibers, polyvinylidene chloride fibers, polyolefin fibers, polyurethane fibers, polytetrafluoroethylene fibers, and carbon fibers.

5. 5. The antiviral article according to claim 2, wherein the fiber assembly contains cotton fibers and polyester fibers.

6. The antiviral article according to any one of claims 2 to 5, wherein the thermosetting resin contains at least one selected from the group consisting of melamine resin, phenolic resin, unsaturated polyester, diallyl phthalate resin, epoxy resin, silicone resin, and urea resin.

7. 7. The antiviral article according to any one of claims 2 to 6, wherein the content of the quaternary ammonium salt relative to the fiber assembly is 0.5 to 3.0% o.w.f. (on the weight of fiber).

8. 8. The antiviral article according to claim 1, wherein the quaternary ammonium salt is present in a dispersed state in the coating layer.

9. 9. The antiviral article according to claim 1, wherein the resin contains anions.

10. A method for producing an antiviral article according to any one of claims 1 to 9, comprising: a first step of forming a coating layer containing a resin and a quaternary ammonium salt on the surface of a substrate; a second step, which is carried out after the first step, of removing the resin on the surface of the coating layer by polishing or dissolving it to partially expose the quaternary ammonium salt on the surface of the coating layer. A method for producing an antiviral article, comprising:

11. the substrate is a fiber assembly, the resin is a thermosetting resin, The removal of the resin in the second step is carried out by polishing the coating layer with a grindstone or sandpaper in a wet state in which the coating layer is moistened with water or an aqueous solution of hypochlorous acid. The method for producing an antiviral article according to claim 10.

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