Special receptacle or package – Combined or convertible – Packaged assemblage or kit
Reexamination Certificate
2000-11-02
2003-05-20
Dawson, Robert (Department: 1712)
Special receptacle or package
Combined or convertible
Packaged assemblage or kit
C524S858000, C528S042000, C106S287160
Reexamination Certificate
active
06564935
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a solution for treatment of an article whose surface is to have water-repellent, oil-repellent, and stain-proofing properties, and further relates to a method for manufacturing the same. In particular, the present invention relates to a solution for water-repellent, oil-repellent, and stain-proofing treatment which is suitably used for articles such as glass, ceramics, plastics, and metals, and further relates to a method for manufacturing the same.
2. Description of the Related Art
For formation of a water repellent coating film on the surface of an article such as a glass sheet etc., a coating solution containing a fluoroalkyl silane is used widely as a water-repellent treatment solution.
For example, JP-A-5-311156 discloses a water repellent treatment solution. The solution is an alcohol solution containing fluoroalkyl silane in an amount between 1.0 and 10 wt %, an acid catalyst in an amount between 0.01 and 5 wt %, and water in an amount between 0.01 wt % and 40 wt %.
Furthermore, JP-A-9-53065 discloses solutions for water repellent treatment including a first solution containing a fluoroalkyl silane and a hydrophilic organic solvent, and a second solution containing acid and water. Another water repellent treatment solution is further disclosed herein in which the first solution and/or the second solution contain either alcohol as a solvent or a solvent containing alcohol.
In addition, JP-A-9-53065 points out the following problem in the solution of JP-A-5-311156 described above. As the content of fluoroalkyl silane increases, the effectiveness of water repellency improves. On the other hand, a substance which is believed to be a hydrolyzate of excessive fluoroalkyl silane remains on the treated surface to cause significant deterioration of an initial contact angle. Furthermore, it is necessary to wipe out this substance from the treated surface.
In order to solve this problem, it is discussed in JP-A-9-53065 to reduce the content of fluoroalkyl silane to 1 wt % or less.
However, if the content of fluoroalkyl silane is reduced to 1 wt % or less, it is pointed out that the water repellent treatment solution gradually loses its effectiveness of water repellency as the storage time passes. Particularly in the case where an effective amount of acid is contained in the water repellent treatment solution, it is also pointed out that the effectiveness of water repellency deteriorates considerably as the storage time passes.
Moreover, JP-A-10-219235 discloses solutions for water repellent treatment including a first solution containing a fluoroalkyl silane and a hydrophilic organic solvent, and a second solution containing acid, water, the hydrophilic organic solvent, and/or a compound with a higher boiling point than that of the hydrophilic organic solvent.
In JP-A-10-219235, a dry process for wiping a residue of fluoroalkyl silane without using an organic solvent also is proposed.
In addition, JP-A-9-104861 discloses a two-solution type water repellent treatment solution which is used in two steps. The first treatment is conducted with a first water repellent treatment solution containing fluoroalkyl silane, and the finishing treatment is conducted with a second lower alcohol solution.
In the aforementioned JP-A-5-311156, when the prepared water repellent treatment solution is stored for a long time, the fluoroalkyl silane reacts to allow the solution to become cloudy. The initial water repellency of the film formed from this cloudy solution is degraded.
This degradation takes place also with the treatment solutions disclosed in JP-A-9-53065 or JP-A-10-219235 when the prepared water repellent treatment solutions are stored for a long time.
SUMMARY OF THE INVENTION
In order to solve the above-mentioned problems, it is an object of the present invention to provide a coating solution for water-repellent (and/or oil-repellent and/or stain-proofing) treatment that can be stored for a long time without becoming cloudy. Furthermore, it is another object of the present invention to provide a method for water-repellent treatment with the use of this coating solution.
With regard to the coating solution for water-repellent treatment and the method for manufacturing the same, it is another object of the present invention to provide a coating solution which leaves only a small amount of fluoroalkyl silane residue. In other words, the provided solution possesses excellent water-repellent properties even if the fluoroalkyl group-containing silane compound is contained in the coating solution for water-repellent treatment at a ratio of 1 wt % or less. The present invention also provides a method for preparing this coating solution.
To solve these problems, in one aspect of the invention, the fluoroalkyl group-containing silane compound is stored first in an acid- and solvent-free state.
When it is stored in this way, the coating solution for water-repellent treatment described above will not become cloudy any more. In other words, the fluoroalkyl group-containing silane compound is to be stored in such a way that hydrolysis does not take place.
For use, a solution containing a fluoroalkyl group-containing silane compound (a first solution) and a solution containing acid and a solvent (a second solution) are to be mixed for preparing a coating solution for water-repellent (and/or oil-repellent and/or stain-proofing) treatment (hereinafter referred to occationally as a coating solution).
An embodiment of the present invention provides a coating solution obtained by mixing a first solution containing a fluoroalkyl group-containing silane and a second solution containing acid and a solvent.
Another embodiment of the present invention provides a method for preparing a coating solution containing a fluoroalkyl group-containing silane, acid, and a solvent. According to the above method, the first solution containing the fluoroalkyl group-containing silane and the second solution containing the acid and the solvent first are prepared separately and then mixed together. Furthermore, the present invention provides a method for preparing a coating solution for an article, in which the coating solution prepared as above is applied to the surface of the article. Furthermore, the present invention provides an article treated by this method, whereby a coating film with water-repellent (and/or oil-repellent and/or stain-proofing) properties is formed on the article.
A further embodiment of the present invention provides a kit for preparing a coating solution for water-repellent treatment that contains a fluoroalkyl group-containing silane, acid, and a solvent. The kit includes a first container, a first solution in the first container, a second container, and a second solution in the second container. In the above kit, the fluoroalkyl group-containing silane is contained in the first solution, and the acid and the solvent are contained in the second solution.
In the present invention, it is preferable that the first solution is substantially free from the acid and the solvent, and the second solution is substantially free from the fluoroalkyl group-containing silane compound.
In the present invention, the first solution also substantially may consist of a fluoroalkyl group-containing silane compound and at least one selected from a polysiloxane compound and a hydrolyzable silane compound expressed by SiR
n
X
(4−n)
, where R represents an alkyl group with 1 to 5 carbons; n=0 to 3; and X represents one selected from an alkoxyl group, halogen, an acetoxyl group, and an isocyanate group.
The above acid preferably contains at least one selected from the group consisting of hydrochloric acid, methanesulfonic acid, and p-toluenesulfonic acid.
The above solvent preferably contains an organic solvent having compatibility with water. In this case, the above solvent also may contain water. Furthermore, the above solvent preferably contains at least one alcohol selected from alcohols with 1 to 10 carbons. In addition, t
Asai Mitsuo
Kamitani Kazutaka
Kawazu Mitsuhiro
Yamamoto Hiroaki
Feely Michael J
Merchant & Gould P.C.
Nippon Sheet Glass Co. Ltd.
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