Resin molded article and method for producing the same

Details Resin molded article and method for producing the same Resin molded article and method for producing the same

2000-12-08

2003-08-26

Tentoni, Leo B. (Department: 1732)

Plastic and nonmetallic article shaping or treating: processes

Disparate treatment of article subsequent to working,...

Effecting temperature change

C525S055000, C525S199000, C525S200000, C525S227000, C525S276000, C525S408000, C525S245000

Reexamination Certificate

active

06610236

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a resin molded article and a method for producing the same. In particular, the present invention relates to a molded article of a thermoplastic or thermosetting resin having good surface hydrophilicity, which is produced by compounding a polymer or a compound having a perfluoroalkyl group in the thermoplastic or thermosetting resin, and molding the resin, and a method for producing such a molded article. The molded article of the present invention has particularly good stain-proofing properties, and thus can be used as a molded product which is severely stained such as kitchenware, bathroom ware, etc.
BACKGROUND ART
In these years, the analysis of stains have been advanced from the viewpoint of the maintenance of the beauty and cleanliness of articles. Meanwhile, the function of “stain-proofing” has been sought in connection with buildings, structures, and further daily necessaries. In particular, surface treatment, which can impart a function for preventing the deposition of stains or a function for easily removing once deposited stains by washing to materials, has been sought.
To improve the stain-proofing properties, it is known that it is effective to make the surface of a material hydrophilic (or to reduce the contact angle of water). For example, “KOBUNSHI” POLYMERS), Vol. 44, page 307, May 1995 describes that the hydrophilic coating films have good stain-proofing properties in the field of exterior coating.
To make the surfaces hydrophilic, in general, it is contemplated to “apply a compound which imparts hydrophilicity” to the surfaces. Apart from this, it is contemplated to “blend (internally add) a hydrophilic compound”, when substrates are formed of resins.
For example, in relation to the method to “apply a compound which imparts hydrophilicity”, the invention of JP-A-62-196192 makes the surfaces hydrophilic with the application of a water-soluble composition containing an ethylene diamine derivative having a polyalkylene glycol group, polyvinyl alcohol a water-soluble melamine resin, etc.
Furthermore, the method of JP-A-5-59203 makes a surface hydrophilic by applying a colloidal silica in an organic solvent as a dispersion medium and a surfactant to the surface and drying it.
However, the method to “apply a compound which imparts hydrophilicity” has some drawbacks that it requires a further processing step of the once molded article and that the applied compound is easily removed by abrasion and so on and thus the hydrophilic effect disappears. Therefore, when the substrate is made of the resin, it is desirable that the hydrophilic effect can be imparted to the substrate by “blending a hydrophilic compound” from the viewpoint of the process steps and the practical application.
As an organic compound which is compounded in the resin to impart the hydrophilicity, a compound having a polyoxyethylene group or polyvinyl alcohol is well known.
When the commercially distributed polyoxyethylene compound is applied to the surface or kneaded in the resin, the surface may not have hydrophilic properties, or the hydrophilicity may be initially imparted to the surface but its durability is not good.
DISCLOSURE OF THE INVENTION
One object of the present invention is to provide an additive which can impart durable hydrophilicity to the surface of a resin by the internal addition of the additive, and a resin molded article having a hydrophilic surface.
As a result of the extensive study, it has been found that a molded article of a thermoplastic or thermosetting resin having good hydrophilicity can be obtained by compounding a polymer having a perfluoroalkyl group comprising repeating units derived from a (meth)acrylate having a perfluoroalkyl group and repeating units derived from a (meth)acrylate having a hydrophilic group, or a compound having a perfluoroalkyl group obtained by reacting an epoxy compound having a perfluoroalkyl group with a polyalkylene oxide having a terminal hydroxyl group in the resin, and molding the resin, and thus the present invention has been completed.
Accordingly, the present invention provides
(1) a resin molded article of a resin composition comprising 100 wt. parts of a resin and 0.1 to 5 wt. parts of a polymer having a perfluoroalkyl group which comprises repeating units derived from a (meth)acrylate having a C
5
-C
18
perfluoroalkyl group and repeating units derived from a (meth)acrylate having a hydrophilic group in a weight ratio of 1:1 to 1:10, wherein a contact angle of water is 50 degrees or less on the surface of said molded article;
(2) a method for producing a resin molded article having a contact angle of water of 50 degrees or less on its surface comprising the steps of:
molding a resin composition comprising 100 wt. parts of a resin and 0.1 to 5 wt. parts of a polymer having a perfluoroalkyl group which comprises repeating units derived from a (meth)acrylate having a C
5
-C
18
perfluoroalkyl group and repeating units derived from a (meth)acrylate having a hydrophilic group in a weight ratio of 1:1 to 1:10, and
heating the molded article at a temperature in the range between 70° C. and 130° C.;
(3) a resin molded article of a resin composition comprising 100 wt. parts of a resin and 0.1 to 5 wt. parts of a compound having a perfluoroalkyl group which is obtained by reacting an epoxy compound having a C
5
-C
18
perfluoroalkyl group with a polyalkylene oxide having a terminal hydroxyl group, wherein a contact angle of water is 50 degrees or less on the surface of said molded article; and
(4) a method for producing a resin molded article having a contact angle of water of 50 degrees or less on its surface comprising the steps of:
molding a resin composition comprising 100 wt. parts of a resin and 0.1 to 5 wt. parts of a compound having a perfluoroalkyl group which is obtained by reacting an epoxy compound having a C
5
-C
18
perfluoroalkyl group with a polyalkylene oxide having a terminal hydroxyl group, and
heating the molded article at a temperature in the range between 70° C. and 130° C.
DETAILED DESCRIPTION OF THE INVENTION
The (meth) acrylate having a C
5
-C
18
perfluoroalkyl group used in the present invention is not limited and any known one may be used. The perfluoroalkyl group and the (meth)acrylate group may be directly bonded each other, or bonded through a suitable linking group. Herein, the term “(meth)acrylate” is intended to mean an acrylate ester or a methacrylate ester.
A preferable example of the (meth)acrylate having a C
5
-C
18
perfluoroalkyl group used in the present invention is a (meth)acrylate of the formula:
CH
2
═CR
1
—COO—(CH
2
)
a
—R
2
—Rf  (1)
wherein R
1
is a hydrogen atom or a methyl group, R
2
is a single bound or a group of the formula: —SO
2
NR
3
— in which R
3
is a hydrogen atom or a C
1
-C
3
alkyl group, Rf is a linear or branched C
5
-C
18
perfluoroalkyl group, and a is an integer of 0 to 3.
Specific examples of the compound of the formula (1) include (meth)acrylates having a linear or branched perfluoroalkyl group such as CH
2
═CHCOOC
2
H
4
C
6
F
13
, CH
2
═C(CH
3
)COOC
2
H
4
C
6
F
13
, CH
2
═CHCOOC
2
H
4
C
8
F
17
, CH
2
═C(CH
3
)COOC
2
H
4
C
8
F
17
, CH
2
═CHCOOC
2
H
4
C
16
F
33
, CH
2
═C(CH
3
)COOC
2
H
4
C
16
F
33
, CH
2
═CHCOOC
3
H
6
(CF
2
)
6
CF(CF
3
)
2
, CH
2
═C(CH
3
)COOC
3
H
6
(CF
2
)
6
CF(CF
3
)
2
, CH
2
═CHCOOC
3
H
6
(CF
2
)
10
CF(CF
3
)
2
, CH
2
═C(CH
3
)COOC
3
H
6
(CF
2
)
6
CF(CF
3
)
2
, CH
2
═CHCOOC
2
H
4
N(C
2
H
5
)SO
2
(CF
2
)
6
CF
3
, CH
2
═C(CH
3
)COOC
2
H
4
N(C
2
H
5
)SO
2
(CF
2
)
6
CF
3
, etc. Among them, the (meth)acrylates having 8 to 12 carbon atoms are preferable. These compounds may be used independently or in admixture of two or more of them.
A preferable example of the (meth)acrylate having a hydrophilic group is a (meth)acrylate of the formula:
CH
2
═CR
1
—COOR
4
  (2)
wherein R
1
is the same as defined above, and R
4
is a polyoxyalkylene group having 2 to 150 carbon atoms or a C
1
-C
18
alkyl group having a hydroxyl g

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