[0001] The present invention relates to the coating of surfaces, in particular to the production
of oil- and water- repellent surface, as well as to coated articles obtained thereby.
[0002] Oil- and water- repellent treatments for a wide variety of surfaces are in widespread
use. For example, it may be desirable to impart such properties to solid surfaces,
such as metal, glass, ceramics, paper, polymers etc. in order to improve preservation
properties, or to prevent or inhibit soiling.
[0003] A particular substrate which requires such coatings are fabrics, in particular for
outdoor clothing applications, sportswear, leisurewear and in military applications.
Their treatments generally require the incorporation of a fluoropolymer into or more
particularly, fixed onto the surface of the clothing fabric. The degree of oil and
water repellency is a function of the number and length of fluorocarbon groups or
moieties that can be fitted into the available space. The greater the concentration
of such moieties, the greater the repellency of the finish.
[0004] In addition however, the polymeric compounds must be able to form durable bonds with
the substrate. Oil- and water-repellent textile treatments are generally based on
fluoropolymers that are applied to fabric in the form of an aqueous emulsion. The
fabric remains breathable and permeable to air since the treatment simply coats the
fibres with a very thin, liquid-repellent film. In order to make these finishes durable,
they are sometimes co-applied with cross-linking resins that bind the fluoropolymer
treatment to fibres. Whilst good levels of durability towards laundering and dry-cleaning
can be achieved in this way, the cross-linking resins can seriously damage cellulosic
fibres and reduce the mechanical strength of the material. Chemical methods for producing
oil- and water-repellent textiles are disclosed for example in
WO 97/13024 and British patent No
1,102,903 or
M. Lewin et al., 'Handbood of Fibre Science and Technology' Marcel and Dekker Inc.,
New York, (1984) Vol 2, Part B Chapter 2.
[0005] Plasma deposition techniques have been quite widely used for the deposition of polymeric
coatings onto a range of surfaces. This technique is recognised as being a clean,
dry technique that generates little waste compared to conventional wet chemical methods.
Using this method, plasmas are generated from small organic molecules, which are subjected
to an ionising electrical field under low pressure conditions. When this is done in
the presence of a substrate, the ions, radicals and excited molecules of the compound
in the plasma polymerise in the gas phase and react with a growing polymer film on
the substrate. Conventional polymer synthesis tends to produce structures containing
repeat units which bear a strong resemblance to the monomer species, whereas a polymer
network generated using a plasma can be extremely complex.
[0006] The success or otherwise of plasma polymerisation depends upon a number of factors,
including the nature of the organic compound. Reactive oxygen containing compounds
such as maleic anhydride, has previously been subjected to plasma polymerisation (
Chem. Mater. Vol. 8, 1, 1996).
[0007] US Patent No 5,328,576 describes the treatment of fabric or paper surfaces to impart liquid repellent properties
by subjecting the surfaces to a pre-treatment with an oxygen plasma, followed by plasma
polymerisation of methane.
[0009] A process in which textiles are subjected to plasma discharge in the presence of
an inert gas and subsequently exposed to an F-containing acrylic monomer is described
in
SU-1158-634. A similar process for the deposition of a fluroalkyl acrylate resists on a solid
substrate is described in European Patent Application No.
0049884.
[0010] Japanese application no.
816773 describes the plasma polymerisation of compounds including fluorosubstituted acrylates.
In that process, a mixture of the fluorosubstituted acrylate compounds and an inert
gas are subjected to a glow discharge.
[0011] The applicants have found an improved method of producing polymer and particular
halopolymer coatings which are water and/or oil repellent on surfaces.
[0012] According to the present invention there is provided a method of coating a surface
with a polymer layer, which method comprises exposing said surface to a plasma comprising
a monomeric unsaturated organic compound which comprises an optionally substituted
hydrocarbon group, wherein the optional substituents are halogen; provided that where
the compound is a straight chain perhalogenated alkene, it includes at least 5 carbon
atoms; so as to form an oil or water repellent coating on said substrate.
[0013] Unsaturated organic compounds are those which contain at least one double bond which
is capable of reaching to form a polymeric compound. The compounds used in the method
of the invention suitably include at least one optionally substituted hydrocarbon
chain. Suitable chains, which may be straight or branched, have from 3 to 20 carbon
atoms, more suitably from 6 to 12 carbon atoms
[0014] Monomeric compounds used in the method may include the double bond within a chain
and so comprise alkenyl compounds. Alternatively, the compounds may comprise an alkyl
chain, optionally substituted by halogen, as a substitutent which is attached to an
unsaturated moiety either directly or by way of an functional group, such as a ester
or sulphonamide group.
[0015] As used therein the term "halo" or "halogen" refers to fluorine, chlorine, bromine
and iodine. Particularly preferred halo groups are fluoro. The term hydrocarbon includes
to alkyl, alkenyl or aryl groups. The term "aryl" refers to aromatic cyclic groups
such as phenyl or napthyl, in particular phenyl. The term "alkyl" refers to straight
or branched cha of carbon atoms, suitably of up to 20 carbon atoms in length. The
term "alkenyl" refers to straight or branched unsaturated chains suitably having from
2 to 20 carbon atoms.
[0016] Monomeric compounds where the chains comprise unsubstituted alkyl or alkenyl groups
are suitable for producing coatings which are water repellent. By substituting at
least some of the hydrogen atoms in these chains with at least some halogen atoms,
oil repellency may also be conferred by the coating.
[0017] Thus in a preferred aspect , the monomeric compounds include haloalkyl moieties or
comprise haloalkenyls. Therefore, preferably the plasma used in the method of the
invention will comprise a monomeric unsaturated haloalkyl containing organic compound.
[0018] Suitable plasmas for use in the method of the invention include non-equilibrium plasmas
such as those generated by radiofrequencies (Rf), microwaves or direct current (DC).
They may operate at atmospheric or sub-atmospheric pressures as are known in the art.
[0019] The plasma may comprise the monomeric compound alone, in the absence of other gases
or in mixture with for example an inert gas. Plasmas consisting of monomeric compound
alone may be achieved as illustrated hereinafter, by first evacuating the reactor
vessel as far as possible, and then purging the reactor vessel with the organic compound
for a period sufficient to ensure that the vessel is substantially free of other gases.
[0020] Particularly suitable monomeric organic compounds are those of formula (I)

where R
1, R
2 and R
3 are independently selected from hydrogen, alkyl, haloalkyl or aryl optionally substituted
by halo; and R
4 is a group X-R
5 where R
5 is an alkyl or haloalkyl group and X is a bond; a group of formula -C(O)O(CH
2)
nY- where n is an integer of from 1 to 10 and Y is a bond or a sulphonamide group;
or a group -(O)
pR
6(O)
q(CH
2)
t- where R
6 is aryl optionally substituted by halo, p is 0 or 1, q is 0 or 1 and t is 0 or an
integer of from 1 to 10, provided than where q is 1, t is other than 0.
[0021] Suitable haloalkyl groups for R
1, R
2, R
3 and R
5 are fluoroalkyl groups. The alkyl chains may be straight or branched and may include
cyclic moieties,
[0022] For R
5, the alkyl chains suitably comprise 2 or more carbon atoms, suitably from 2-20 carbon
atoms and preferably from 6 to 12 carbon atoms.
[0023] For R
1, R
2 and R
3, alkyl chains are generally preferred to have from 1 to 6 carbon atoms.
[0024] Preferably R
5 is a haloalkyl, and more preferably a perhaloalkyl group, particularly a perfluoroalkyl
group of formula C
mF
2m+1 where m is an integer of 1 or more, suitably from 1-20, and preferably from 6-12
such as 8 or 10.
[0025] Suitable alkyl groups for R
1, R
2 and R
3 have from 1 to 6 carbon atoms.
[0026] Preferably however, at least one of R
1, R
2 and R
3 is hydrogen and preferably R
1, R
2, R
3 are all hydrogen.
[0027] Where X is a group -C(O)O(CH
2)
nY-, n is an integer which provides a suitable spacer group. In particular, n is from
1 co 5, preferably about 2.
[0028] Suitable sulphonamide groups for Y include those of formula -N(R
7)SO
2- where R
7 is hydrogen or alkyl such as C
1-4alkyl, in particular methyl or ethyl.
[0029] In a preferred embodiment, the compound of formula (I) is a compound of formula (II)
CH
2=CH-R
5 (II)
where R
5 is as defined above in relation to formula (I).
[0030] In compounds of formula (II), X in formula (I) is a bond.
[0031] In an alternative preferred embodiment, the compound of formula (I) is an acrylate
of formula (III)
CH
2=CR
7C(O)O(CH
2)
nR
5 (III)
where n and R
5 as defined above in relation to formula (I) and R
7 is hydrogen or C
1-6 alkyl, such as methyl.
[0032] Using these compounds, coatings with waster hydrophobicity values of up to 10 and
oleophobicity values of up to 8 have been achieved as illustrated hereinafter.
[0033] Other compounds of formula (I) are styrene derivatives as are well known in the polymer
art.
[0034] All compounds of formula (I) are either known compounds or they can be prepared from
known compounds using conventional methods.
[0035] The surface coated in accordance with the invention may be of any solid substrate,
such as fabric, metal, glass, ceramics, paper or polymers. In particular, the surface
comprises a fabric substrate such as a cellulosic fabric, to which oil- and/or water-repellency
is to be applied. Alternatatively, the fabric may be a synthetic fabric such as an
acrylic/nylon fabric.
[0036] The fabric may be untreated or it may have been subjected to earlier treatments.
For example, it has been found that treatment in accordance with the invention can
enhance the water repellency and confer a good oil-repellent finish onto fabric which
already has a silicone finish which is water repellent only.
[0037] Precise conditions under which the plasma polymerisation takes place in an effective
manner will vary depending upon factors such as the nature of the polymer, the substrate
etc. and will be determined using routine methods and/or the techniques illustrated
hereinafter. In general however, polymerisation is suitably effected using vapours
of compounds, of formula (I) at pressures of from 0.01 to 10 mbar, suitably at about
0.2mbar.
[0038] A glow discharge is then ignited by applying a high frequency voltage, for example
at 13.56MHz.
[0039] The applied fields are suitably of average power of up to 50W. Suitable conditions
include pulsed or continuous fields, but are preferably pulsed fields. The pulses
are applied in a sequence which yields very low average powers, for example of less
than 10W and preferably of less than 1W. Examples of such sequences are those in which
the power is on for 20µs and off for from 10000µs to 20000µs.
[0040] The fields are suitably applied for a period sufficient to give the desired coating.
In general this will be from 30 seconds to 20 minutes, preferably from 2 to 15 minutes,
depending upon the nature of the compound of formula (I) and the substrate etc.
[0041] Plasma polymerisation of compounds of formula (I), particularly at low average powers
has been found to result in the deposition of highly fluorinated coatings which exhibit
super-hydrophobicity. In addition, a high level of structural retention of the compound
of formula (I) occurs in the coating layer, which may be attributed to the direct
polymerisation of the alkene monomer for instance a fluoroalkene monomer via its highly
susceptible double bond.
[0042] It has been noted, particularly in the case of the polymerisation of compounds of
formula (III) above, that low power pulsed plasma polymerisation produces well-adhered
coatings which exhibit excellent water and oil repellency. The greater level of structural
retention in the case of pulsed plasma polymerisation can be attributed to free radical
polymerisation occurring during the duty cycle off-time and less fragmentation during
the on-time.
[0043] In a particularly preferred embodiment of the invention, a surface is exposing a
surface to a plasma comprising a compound of formula (III) as defined above, wherein
the plasma being created by a pulsed voltage also as described above.
[0044] Suitably the compound of formula (I) includes a perfluoroalkylated trail or moiety,
the process of the invention may have oleophobic as well as hydrophobic surface properties.
[0045] Thus the invention further provides a hydrophobic or oleophobic substrate which comprises
a substrate comprising a coating of a alkyl polymer and particularly a haloalkyl polymer
which has been applied by the method described above. In particular, the substrates
are fabrics but whey may be solid materials such as biomedical devices.
[0046] The invention will now be particularly described by way of example with reference
to the accompanying diagrammatic drawings in which:
Figure 1 shows a diagram of the apparatus used to effect plasma deposition;
Figure 2 is a graph showing the characteristics of continuous wave plasma polymerisation
of 1H, 1H, 2H-pefluoro-1-dodecene;
Figure 3 is a graph showing the characteristics of pulsed plasma polymerisation of
1H, 1H, 2H-pefluoro-1-dodecene at 50W Pp, Ton=20µs and Toff = 10000µs for 5 minutes; and
Figure 4 is a graph showing the characteristics of (a) continuous and (b) pulsed plasma
polymerisation of 1H, 1H, 2H, 2H-heptadecafluorodecyl acrylate.
Example 1
Plasma Polymerisation of Alkene
[0047] 1H, 1H, 2H-perfluoro-1-dodecene (C
10F
21CH=CH
2) (Fluorochem F06003, 97% purity) was placed into a monomer tube (I) (Fig. 1) and
further purified using freeze-thaw cycles. A series of plasma polymerisation experiments
were carried out in an inductively coupled cylindrical plasma reactor vessel (2) of
5cm diameter, 470cm
3 volume, base pressure of 7x10
-3mbar, and with a leak rate of better than 2x10
-3 cm
3min The reactor vessel (2) was connected by way of a "viton" O-ring (3), a gas inlet
(4) and a needle valve (5) to the monomer tube (1).
[0048] A thermocouple pressure gauge (6) was connected by way of a Young's tap (7) to the
reactor vessel (2). A further Young's tap (8) connected with an air supply and a third
(9) lead to an E2M2 two stage Edwards rotary pump (not shown) by way of a liquid nitrogen
cold trap (10). All connections were grease free.
[0049] An L-C matching unit (11) and a power meter (12) was used to couple the output of
a 13.56 Mhz R.F. generator (13), which was connected to a power supply (14), to copper
coils (15) surrounding the reactor vessel (2). This arrangement ensured that the standing
wave ratio (SWR) of the transmitted power to partially ionised gas in the reactor
vessel (2) could be minimised. For pulsed plasma deposition, a pulsed signal generator
(16) was used to trigger the R.F power supply, and a cathode ray oscilloscope (17)
was used to monitor the pulse width and amplitude. The average power <P> delivered
to the system during pulsing is given by the following formula:

where T
on/ (
Ton + T
off) is defined as the duty cycle and P
cw is the average continuous wave power.
[0050] In order to carry out polymerization/deposition reactions the reactor vessel (2)
was cleaned by soaking overnight: in a chloro bleach bath, then scrubbing with detergent:
and finally rinsing with isopropyl alcohol followed by oven drying. The reactor vessel
(2) was then incorporated into the assembly as shown in Figure 1 and further cleaned
with a 50W air plasma for 30 minutes. Next the reactor (2) vessel was vented to air
and the substrate to be coated (19), in this case a glass slide, was placed in the
centre of the chamber defined by the reactor vessel (2) on a glass plate (18). The
chamber was then evacuated back down to base pressure (7.2 x 10
-3mbar).
[0051] Perfluoroalkene vapour was then introduced into the reaction chamber at a constant
pressure of ∼0.2mbar and allowed to purge the plasma reactor, followed by ignition
of the glow discharge. Typically 2-15 minutes deposition time was found to be sufficient
to give complete coverage of the substrate. After this, the R.F generator was switched
off and the perfluoroalkene vapour allowed to continue to pass over the substrate
for a further 5 minutes before evacuating the reactor back down to base pressure,
and finally venting up to atmospheric pressure.
[0052] The deposited plasma polymer coatings were characterised immediately after deposition
by X-ray photoelectron spectroscopy (XPS). Complete plasma polymer coverage was confirmed
by the absence of any Si (2p) XPS signals showing through from the underlying glass
substrate.
[0053] A control experiment, where the fluoroalkene vapour was allowed to pass over the
substrate for 15 minutes and then pumped down to base pressure was found to show the
presence of a large Si (2p) XPS signal from the substrate. Hence the coating obtained
during plasma polymerisation are not just due to absorption of the fluoroalkene monomer
onto the substrate.
[0054] The experiments were carried out with average powers in the range of from 0.3 to
50W. The results of the XPS spectrum of a 0.3W continuous wave plasma polymer deposition
onto a glass slide for 13 minutes is shown in Figure 2.
[0055] It can be seen that in this instance,
CF
3 and
CF
3 groups are the prominent environments in the C(1s) XPS envelope:
CF2 |
(291.2eV) |
61% |
CF3 |
(293.3eV) |
12% |
[0056] The remaining carbon environments comprised partially fluorinated carbon centres
and a small amount of hydrocarbon (
CxH
y). The experimental and theoretically expected (taken from the monomer) values are
given in Table 1
Table 1
|
Experimental |
Theoretical |
F:C ratio |
1.70 ± 0.3 |
1.75 |
%CF3 group |
61% ± 2% |
75% |
%CF3 group |
12% ± 2% |
8% |
[0057] The difference between theoretical and experimental
CF
2 group and
CF
3 group percentages can be attributed to a small amount of fragmentation of the perfluoroalkene
monomer.
[0058] Figure 3 shows the C (1s) XPS spectrum for a 5 minute pulsed plasma polymerisation
experiment where: - P
cw = 50M

[0059] The chemical composition of the deposited coating for pulsed plasma deposition is
given in Table 2 below.
Table 2
|
Experimental |
Theoretical |
F:C ratio |
1.75 ± 0.7 |
1.75 |
%CF2 group |
63% ± 2% |
75% |
%CF3 group |
10% ± 2% |
8% |
[0060] It can be seen that the
CF
2 region is better resolved and has greater intensity which means less fragmentation
of the perfluoroalkyl tail compared to continuous wave plasma polymerisation.
[0061] Surface energy measurements were carried out on slides produced in this way using
dynamic contact angle analysis. The results showed that the surface energy was in
the range of 5-6mJm
-1.
Example 2
Oil and Water Repellency Test
[0062] The pulsed plasma deposition conditions described in Example 1 above were used to
coat a piece of cotton (3x8cm) which was then tested for wettability using "3M Test
Methods" (3M oil repellency Test 1, 3M Test Methods Oct.1, 1988). As a Water repellency
test, the 3M water repellency Test II, water/alcohol drop test, 3M Test 1, 3M Test
methods, October 1, 1988 was used. These tests are designed to detect a fluorochemical
finish on all types of fabrics by measuring:
- (a) aqueous stain resistance using mixtures of water and isopropyl alcohol.
- (b) the fabric's resistance to wetting by a selected series of hydrocarbon liquids
of different surface tensions.
[0063] These tests are not intended to give an absolute measure of the fabric's resistance
to staining by watery or oily materials, since other factors such as fabric construction,
fibre type, dyes, other finishing agents, etc., also influence stain resistance. These
tests can, however, be used to compare various finishes. The water repellency tests
comprises placing 3 drops of a standard test liquid consisting of specified proportions
of water and isopropyl alcohol by volume onto the plasma polymerised surface. The
surface is considered to repel this liquid if after 10 seconds, 2 of the 3 drops do
not wet the fabric. Prom this, the water repellency rating is taken as being the test
liquid with the greater proportion of isopropyl alcohol which passes the test. In
the case of the oil repellency test, 3 drops of hydrocarbon liquid are placed on the
coated surface. If after 30 seconds no penetration or wetting of the fabric at the
liquid-fabric interface occurs around 2 of the 3 drops is evident, then the test is
passed.
[0064] The oil repellency rating is taken to be cline highest-numbered test liquid which
does not wet the fabric surface (where the increasing number corresponds to decreasing
hydrocarbon chain and surface tension).
[0065] The ravings obtained for the pulsed plasma deposition of 1H, 1H, 2H perfluoro-1-dodecene
onto cellulose were: -
Water |
9 |
(10% water, 90% isopropyl alcohol) |
Oil |
5 |
(dodecane) |
[0066] These values compare well with commercial treatments.
Example 3
Plasma Polymerisation of Acrylates
[0067] The method of Example 1 described above was repealed using 1H, 1H, 2H, 2H-heptadecafluorodecyl
acrylate (Fluorochem F04389E, 98% purity) in place of the perfluoroalkene. As in Example
1, low average powers were used for continuous wave and pulsed plasma polymerisation
experiments. For example, the XPS spectrum of a 1W continuous wave plasma polymer
deposited onto a glass slide for 10 minutes is shown in Figure 4(a). Figure 4 (b)
shows the C(ls) XPS spectrum for a 10 minutes pulsed plasma polymerisation were
Pcw = 40W (average continuous wave power)
Ton = 20µs (pulsed time on)
Toff = 20000µs (pulsed time off)
<P> = 0.04W (average pulsed power)
[0068] Table 3 compares the theoretical (taken from the monomer, CH
2=CHCO
2CH
2CH
2C
8F
17) environments with what is actually found for polymer coatings.
Table 3
Environment |
eV |
Theoretical percentages |
Experimental percentages |
CF3 |
293.2 |
7.7 |
7.8 |
CF3 |
291.2 |
53.8 |
47.0 |
O-C=O |
289.0 |
7.7 |
13.0 |
CF |
287.8 |
- - |
0.7 |
C-CFn/C-O |
286.6 |
15.4 |
13.4 |
C-C(O)=O |
285.7 |
7.7 |
3.9 |
CxCy |
285.0 |
7.7 |
7.2 |
[0069] It can be seen that the
CF
2 group is the prominent environment in the C(ls) XPS envelope at 291.2eV. The remaining
carbon environments being
CF
3, partially fluorinated and oxygenated carbon centres and a small amount of hydrocarbon
(
CxH
y). The chemical composition of the coatings deposited for continuous wave and pulsed
plasma conditions are given below in Table 4 (excluding satellite percentages) along
with the theoretically expected compositions).
Table 4
|
Theoretical |
CW Plasma |
Pulsed Plasma |
F:C ratio |
1.31 |
0.94 |
1.49 |
%CF2 group |
53.8% |
27.2% |
47.0% |
%CF3 group |
7.7% |
3.8% |
7.8% |
[0070] It can be seen from Figure 4(b) that the
CF
2 region is better resolve and has greater intensity, which means less fragmentation
of the perfluoroalkyl tail occurs during pulsed plasma conditions compared to continuous
wave plasma polymerisation. In the case of the continuous wave plasma experiments,
the low percentages of
CF
2 and
CF
3 groups occur.
[0071] Surface energy measurements as described in Example 1 shows a surface energy of 6mJm
-1.
Example 4
Oil and Water Repellency Test
[0072] Using the pulsed plasma deposition conditions of Example 3 except that these were
applied for 15 minutes, pieces of cotton (3x 8cm) were coated with 1H, 1H, 2H, 2H-heptadecafluorodecyl
acrylate. Similar pieces of cotton were coated with the same compound using a continuous
wave at 1W fo 15 minutes. These were then subjected to oil and water repellency tests
as described in Example 2 above.
[0073] Samples were then subjected to a benzotrifluoride Soxhlet extraction for either 1.
or 7 hours and the oil and water repellency tests repeated. The results, expressed
as described in Example 2,
Time (hours) |
Continuous wave |
Pulsed wave |
Oil-repellency |
Water repellency |
Oil repellency |
Water repellency |
0 |
7 |
4 |
8 |
10 |
1 |
- |
2 |
6 |
7 |
7 |
- |
2 |
5 |
7 |
[0074] Hence these coatings are highly hydrophobic and oleophobic and the coatings have
good durability.
Example 5
Treatment of silicone coated synthetic fabric
[0075] A sample of a modifed acrylic/nylon fabric which already contained a silicone coating
to impart water repellency, was subjected to the a pulsed acrylate plasma consisting
of the compound CH
2=CHCCO(CH
2)
2C
8F
17 and using the conditions described in Example 3.
[0076] A sample of the same material was subjected to a two stage deposition process in
which the fabric was first exposed to a continuous wave 30W air plasma for 5 seconds
followed by exposure to the same acrylate vapour only.
The products were then tested for oil and water repellency as described in Example
2.
[0077] In addition, the durability of the coating was tested by then subjecting the products
to a 1 hour Soxhlet extraction with trichloroethylene.
[0078] The results are as shown in Table 5
Table 5
Treatment |
Repellency Ratings |
Before Plasma |
After Plasma |
After extraction with solvent |
Pulsed phase |
W2 |
O7, |
O6, |
acrylate plasma |
|
W10 |
W8 |
Air plasma followed |
W2 |
O1, |
O1(borderline) |
by exposure to acylate monomer |
|
W3 |
M2 |
[0079] It appears therefore that the process of the invention can not only enhance the water
repellency of such as fabric, and also confer oil repellency, the durability of the
coating is higher than that obtained using the known two step grafting polymerisation
process.