Surface treatment agent
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Solution Overview
Problem
Existing fluorine-containing water- and oil-repellent agents face issues such as environmental concerns due to the accumulation of PFOA and telomers, high energy requirements for application, and high costs, while fluorine-free alternatives offer inferior water repellency.
Innovation Solution
A fluorine-free polymer-based water- and oil-repellent agent comprising a fluorine-free (meth)acrylate ester monomer, wax, and an emulsifier, specifically a sorbitan ester, which is formulated and applied using a method that includes polymerizing the monomer and dispersing the wax in an aqueous medium to create a stable emulsion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluorine-containing water- and oil-repellent agents are used, then good water- and oil-repellency is achieved, but environmental harm occurs due to PFOA accumulation and high energy consumption is required for heat treatment
Solution Approach 1:
The invention changes the chemical composition parameters by using fluorine-free (meth)acrylate ester monomers with specific carbon chain lengths (18-30 carbons) instead of traditional fluorine-containing compounds. This parameter change eliminates PFOA accumulation risks while maintaining water- and oil-repellency through the hydrophobic properties of long-chain hydrocarbon groups.
Solution Approach 2:
The invention replaces expensive fluorine-containing polymers with cheaper fluorine-free polymer alternatives. The fluorine-free polymer can be produced more economically from readily available (meth)acrylate ester monomers, reducing both material costs and processing energy requirements.
2Object-affected harmful factors
If fluorine-free polymers are used to avoid environmental concerns, then cost is reduced and environmental harm is minimized, but water repellency becomes inferior
Solution Approach 1:
The invention optimizes the carbon chain length parameter of the (meth)acrylate ester monomer to 18-30 carbons, which provides sufficient hydrophobicity for excellent water repellency. This parameter optimization ensures that fluorine-free alternatives can match or exceed the water-repellent performance of fluorine-containing compounds.
Solution Approach 2:
The invention creates a composite water-repellent system by combining fluorine-free polymer with specific emulsifiers and optional waxes. This composite approach enhances the overall water-repellent performance and durability of the coating, compensating for any individual component limitations.
3Reliability
If conventional water-repellent agents are applied, then water repellency is achieved, but processing stability deteriorates due to gum-up property and chemical stability is reduced
Solution Approach 1:
The invention introduces sorbitan ester emulsifiers as intermediary substances that facilitate the uniform dispersion and stable adhesion of the fluorine-free polymer to substrates. These emulsifiers prevent gum-up during processing and enhance the chemical stability and durability of the water-repellent coating.
Solution Approach 2:
The invention modifies the molecular structure parameters of the polymer by using specific (meth)acrylate ester monomers with 18-30 carbon atoms in the ester portion. This structural optimization improves both the processing stability (reducing gum-up) and the durability of the water-repellent effect.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides excellent water repellency, antifouling properties, and soil releasability, with improved durability and mechanical stability, avoiding the environmental concerns associated with fluorine-containing agents.
Implementation Method 1
an aqueous dispersion of a fluorine-free polymer and a wax in the presence of an emulsifier
Implementation Method 2
the emulsifier comprises a sorbitan ester
Implementation Method 3
excellent water repellency... avoiding the environmental concerns associated with fluorine-containing agents
Data Source
AI summary
A water- and oil-repellent agent that is an aqueous dispersion containing (A) a fluorine-free polymer having repeating units derived from a fluorine-free (meth)acrylic acid ester monomer, (B) a wax, (C) an aqueous medium, and (D) an emulsifier. The fluorine-free (meth)acrylic acid ester monomer is a compound represented by the formula CH2═CA11-C(═O)—O-A12 where A11 is a hydrogen atom or a methyl group and A12 is a linear or branched C18-30 hydrocarbon group. The emulsifier includes a sorbitan ester and another emulsifier, and the emulsifier has a hydrophilic-lipophilic balance (HLB) of 7.5 to 13.5. Also disclosed is a method of producing the water- and oil-repellent agent and a method of producing a treated substrate by applying the water- and oil-repellent agent to a substrate.