COATING COMPOSITION FOR FORMING HYDROPHILIC COATING FILM

To provide a coating composition capable of forming a hydrophilic coating film which has high transparency and which is excellent in abrasion resistance (adhesion), hydrophilicity (anti-fogging, wettability and anti-fouling properties) and hydrophilic durability. A coating composition for forming a hydrophilic coating film, which comprises boehmite particles, silica particles, a binder and water, wherein the crystallite diameter of the boehmite particles, as calculated from the diffraction peak of the (120) plane, is from 20 to 50 nm, the average particle diameter of the silica particles is from 5 to 50 nm, the proportion of the boehmite particles is from 20 to 80 mass % based on the total amount of the boehmite particles and the silica particles, and the proportion of the binder is from 0.5 to 15 parts by mass per 100 parts by mass in total of the boehmite particles and the silica particles. The article having a hydrophilic coating film on a surface of a base material, has a hydrophilic coating film formed from the above coating composition.

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Description
TECHNICAL FIELD

The present invention relates to a coating composition for forming a hydrophilic coating film.

BACKGROUND ART

Transparent base materials made of glass, plastics, etc. are used in various applications to e.g. various lamp covers, lenses for eyeglasses, goggles, various instrument covers, transparent roof materials or transparent side wall materials in plant cultivation installations such as greenhouses. However, with these base materials, the hydrophilicity is not high, and they have a trouble such that dew condensation or fogging is likely to take place. For example, in the case of an instrument cover which is likely to be always exposed to outside air, dew condensation is likely to take place on the inner surface of the cover to form fogging, thus leading to a problem such that a sign or indication becomes invisible. Further, in the case of a plastic film to be used as a transparent roof material or a transparent side wall material of a plant cultivation installation, the transmittance of sunlight may be deteriorated by water drops or fogging, and the growth of plants may be thereby adversely affected. Accordingly, it has been attempted to form a hydrophilic coating film on the surface for the purpose of improving the anti-fogging property, wettability (property whereby water droplets are uniformly wettingly spread to form a water film), anti-fouling property, etc.

The following ones are known as coating compositions capable of forming hydrophilic coating films.

(1) An anti-fogging composition comprising silica sol and alumina sol having different average particle diameters, a surfactant and a liquid dispersion medium (Examples 4 to 6 in Patent Document 1).

(2) A coating fluid comprising colloidal alumina, colloidal silica and an anionic surfactant in a specific ratio (Examples 1 to 7 in Patent Document 2).

(3) A coating anti-fogging agent comprising an aqueous medium, colloidal alumina, colloidal silica and a water-soluble resin in a specific ratio (Examples 1 to 14 in Patent Document 3).

(4) An inorganic coating composition comprising alumina particles, of which an average of aspect ratios of agglomerated particles in a dispersion medium is from 3 to 20, an average particle diameter in a long axis direction is from 100 to 500 nm, and an average particle diameter in a short axis direction is from 2 to 100 nm, silica/alumina composite particles, of which an average particle diameter of agglomerated particles in a dispersion medium is at most 150 nm, and water (Patent Document 4).

However, in the hydrophilic coating films formed by the coating compositions (1) and (2), alumina particles and silica particles are merely attached by a surfactant on the surface of a base material film, and the adhesion between the coating film and the base material film is inadequate. Accordingly, the abrasion resistance of the hydrophilic coating film is inadequate. Further, the water resistance of the hydrophilic coating film is low, whereby the hydrophilicity cannot be maintained for a long period of time.

The hydrophilic coating film formed by the coating composition (3) contains a water-soluble resin (binder), whereby the adhesion is improved as compared with the hydrophilic coating films formed by the coating compositions (1) and (2), but the adhesion to the base material is still inadequate. Accordingly, the abrasion resistance of the hydrophilic coating film is inadequate. Further, the water resistance of the hydrophilic coating film is low, and the hydrophilicity cannot be maintained for a long period of time.

As compared with the hydrophilic coating films formed by the coating compositions (1) to (3), the hydrophilic coating film formed by the coating composition (4) has high adhesion to the base material, and the abrasion resistance is good. Further, in an accelerated weather resistance test, the hydrophilicity can be maintained for a long period of time. However, in a real outdoor exposure test, the hydrophilicity abruptly drops at some time. Therefore, it is desired to further improve the durability of hydrophilicity (hereinafter referred to as hydrophilic durability).

PRIOR ART DOCUMENTS Patent Documents

Patent Document 1: JP-A-60-69181

Patent Document 2: JP-A-7-53747

Patent Document 3: JP-A-2003-49003

Patent Document 4: JP-A-2007-63477

DISCLOSURE OF INVENTION Technical Problem

The present invention is to provide a coating composition for forming a hydrophilic coating film capable of forming a hydrophilic coating film which has a high transparency and which is excellent in abrasion resistance (adhesion), hydrophilicity (anti-fogging property, wettability and anti-fouling property) and hydrophilic durability.

Solution to Problem

The coating composition for forming a hydrophilic coating film of the present invention comprises boehmite particles, silica particles, a binder and water, wherein:

the crystallite diameter of the boehmite particles, as calculated from the diffraction peak of the (120) plane, is from 20 to 50 nm,

the average particle diameter of the silica particles is from 5 to 50 nm,

the proportion of the boehmite particles is from 20 to 80 mass % based on the total amount of the boehmite particles and the silica particles, and

the proportion of the binder is from 0.5 to 15 parts by mass per 100 parts by mass in total of the boehmite particles and the silica particles.

The solid content concentration in the coating composition for forming a hydrophilic coating film of the present invention, is preferably from 0.1 to 20 mass %.

The above binder is preferably a water-soluble organic binder.

Such a water-soluble organic binder is preferably a water-soluble polyvinyl alcohol.

The coating composition for forming a hydrophilic coating film preferably has a pH of from 2.5 to 7.

The coating composition for forming a hydrophilic coating film preferably further contains a water-soluble alcohol, wherein the proportion of the water-soluble alcohol is from 10 to 70 mass %, based on the total amount of the water and the water-soluble alcohol.

Further, the present invention provides an article having, on a surface of a base material, a hydrophilic coating film formed from the above coating composition for forming a hydrophilic coating film.

The hydrophilic coating film preferably has a film thickness of from 100 to 700 nm.

The material for the base material is preferably a resin material, more preferably a fluororesin.

ADVANTAGEOUS EFFECTS OF INVENTION

According to the coating composition for forming a hydrophilic coating film of the present invention, it is possible to form a hydrophilic coating film which has high transparency and which is excellent in abrasion resistance (adhesion), hydrophilicity (anti-fogging property, wettability and anti-fouling property) and hydrophilic durability.

DESCRIPTION OF EMBODIMENT Coating Composition for Forming Hydrophilic Coating Film

The coating composition for forming a hydrophilic coating film of the present invention comprises the boehmite particles, the silica particles, the binder and water and may further contain, as the case requires, an organic solvent, a surfactant, metal oxide particles other than the boehmite particles and the silica particles, an additive, etc.

The solid content concentration of the coating composition for forming a hydrophilic coating film is preferably from 0.1 to 20 mass %, more preferably from 0.1 to 10 mass %. When the solid content concentration is at least 0.1 mass %, non-uniformity is less likely to occur when the coating composition for forming a hydrophilic coating film is applied to the surface of the base material, and the performance of hydrophilicity, etc. becomes easily obtainable. When the solid content concentration is at most 20 mass %, the operation efficiency at the time of coating will be good, deterioration of the transparency of the hydrophilic coating film is suppressed, and further, the storage stability of the coating composition for forming a hydrophilic coating film of the present invention will be good. Such a solid content concentration is preferably from 1 to 15 mass %, more preferably from 3 to 10 mass %.

The pH of the coating composition for forming a hydrophilic coating film of the present invention is preferably from 2.5 to 7, more preferably from 3.5 to 7, further preferably from 4 to 6. When the pH is at least 2.5, dissolution of the boehmite particles can be prevented. When the pH is at most 7, the dispersion stability of the silica particles and the boehmite particles will be good.

Boehmite Particles

As the coating composition for forming a hydrophilic coating film of the present invention contains boehmite particles, it is possible to form a hydrophilic coating film which has high hydrophilicity and which is excellent in adhesion to the base material and abrasion resistance.

The crystallite diameter of the boehmite particles, as calculated from the diffraction peak of the (120) plane, is from 20 to 50 nm. When such a crystallite diameter is at least 20 nm, a dense hydrophilic coating film can be obtained, the abrasion resistance will be good, and the hydrophilic durability of the hydrophilic coating film will be improved. When such a crystallite diameter is at most 50 nm, the transparency and hydrophilicity of the hydrophilic coating film will be good. The crystallite diameter is more preferably from 30 to 40 nm.

The crystallite diameter of the boehmite particles, as calculated from the diffraction peak of the (120) plane, can be calculated by the X-ray diffraction (XRD) analysis.

The shape of the boehmite particles may, for example, be a plate-shape, a needle-shape, a fiber-shape or a feather-shape, preferably a plate-shape. When the hydrophilic coating film contains plate-shaped boehmite particles, crystal alignment will be obtained, whereby adhesion of the hydrophilic coating film to the base material is further improved, the abrasion resistance will be maintained for a long period of time, and the hydrophilic coating film can sufficiently follow a flexible base material (such as a film).

The boehmite particles may be commercially available ones or may be ones obtainable by a known production method. A method for producing boehmite particles may, for example, be a method wherein an alkali metal aluminate and an acidic aluminum salt (such as aluminum chloride, aluminum nitrate or aluminum sulfate), and, if required, an acidic solution, are mixed to obtain a hydrated gel, which is aged and then deflocculated by adding an acid; a method wherein an acidic aluminum salt is ion-exchanged to obtain a hydrated gel, which is aged and then deflocculated; or a method wherein an aluminum alkoxide is hydrolyzed and then deflocculated.

The proportion of the boehmite particles is from 20 to 80 mass %, preferably from 40 to 60 mass %, based on the total amount of the boehmite particles and the silica particles. When the boehmite particles are at least 20 mass %, the adhesion to the base material or the hydrophilicity of the hydrophilic coating film will be good. When the boehmite particles are at most 80 mass %, deterioration of the film strength of the hydrophilic coating film can be suppressed, and deterioration of the transparency can also be suppressed.

Silica Particles

As the coating composition for forming a hydrophilic coating film of the present invention contains silica particles, a porous hydrophilic coating film is formed by agglomeration with the boehmite particles, whereby the hydrophilicity of the hydrophilic coating film will be improved. Further, the storage stability of the coating composition for forming a hydrophilic coating film will be good. Further, it is possible to form a hydrophilic coating film having high transparency and high abrasion resistance.

The average particle diameter of the silica particles is from 5 to 50 nm. The average particle diameter of the silica particles is more preferably from 5 to 30 nm, most preferably from 8 to 15 nm. When the average particle diameter is from 5 to 50 nm, agglomeration of the silica particles and the boehmite particles can be properly controlled, and as a result, it is possible to form a porous coating film having a large pore volume to exhibit hydrophilicity and to form a transparent coating film. The average particle diameter of agglomerated particles of the silica particles in a dispersion medium is preferably at most 700 nm.

The average particle diameter of the silica particles is one obtained by measuring the lengths of the long axes and short axes of 20 silica particles randomly selected among ones in a transmission electron microscopic (TEM) image and averaging them. As mentioned above, the boehmite particles are particles having a shape of e.g. a plate, and as mentioned hereinafter, the silica particles are particles having a shape of e.g. a spherical shape. Therefore, in the TEM image, the boehmite particles and the silica particles which are different in the shape and size, can clearly be distinguished.

The shape of the silica particles may, for example, be a chain-shape, a linked-shape or a spherical shape, and is preferably a spherical shape.

The silica particles may be commercially available ones or may be ones obtainable by a known production method.

The proportion of the silica particles is from 20 to 80 mass %, preferably from 40 to 60 mass %, based on the total amount of the boehmite particles and the silica particles. When the silica particles are at least 20 mass %, deterioration of the film strength of the hydrophilic coating film can be suppressed, and the transparency of the hydrophilic coating film will also be improved. When the silica particles are at most 80 mass %, the adhesion to the base material or the hydrophilicity of the hydrophilic coating film will be good.

Binder

The coating composition for forming a hydrophilic coating film contains a binder, whereby the abrasion resistance of the hydrophilic coating film will be improved.

As such a binder, an organic binder or an inorganic binder may be mentioned, and an organic binder is preferred. Further, the binder is preferably a hydrophilic binder. If a hydrophobic binder is used, the contact angle of the hydrophilic coating film to water may increase, whereby the hydrophilicity may decrease. The binder is particularly preferably a water-soluble hydrophilic binder. Further, in a case where the coating composition contains an organic solvent, it is possible to use a binder which is soluble in the organic solvent.

As the organic binder, a water-soluble organic binder is preferred. The water-soluble organic binder may, for example, be polyvinyl alcohol, a modified polyvinyl alcohol, polyethylene glycol, a polyacrylic acid or its salt, a water-soluble polyurethane, or a water-soluble cellulose derivative such as hydroxyethyl cellulose. Further, among water-soluble organic binders, a nonionic water-soluble organic binder is more preferred. As compared with an ionic water-soluble organic binder, the nonionic water-soluble organic binder brings about no substantial agglomeration of inorganic particles whereby the storage stability of the liquid is high. As such a nonionic water-soluble organic binder, polyvinyl alcohol, a modified polyvinyl alcohol or polyethylene glycol is, for example, preferred.

Here, in the present invention, the modified polyvinyl alcohol means one having some of hydroxy groups in a polyvinyl alcohol changed to another group. For example, it may be one having the hydroxy groups esterified by e.g. a carboxylic acid (excluding acetic acid), one having the hydroxy groups formal-modified by an aldehyde, one having the hydroxy groups alkyl-etherified, or the like. As the modified polyvinyl alcohol, a modified product having a reactive group introduced to some of hydroxy groups, is preferred. For example, a modified polyvinyl alcohol (tradename: Gohsefimer Z100) used in Examples is a modified polyvinyl alcohol having an acetoacetyl group introduced to some of hydroxy groups.

Further, as the nonionic water-soluble organic binder, for the following reasons, polyvinyl alcohol and a modified polyvinyl alcohol (hereinafter these may generally be referred to as a water-soluble polyvinyl alcohol) are more preferred. It is possible to use, as the binder, a combination of a plurality of water-soluble polyvinyl alcohols of different types in e.g. the saponification degree, molecular weight, modification, etc.

When the coating composition for forming a hydrophilic coating film contains a water-soluble polyvinyl alcohol, the pore characteristics of the hydrophilic coating film will be good, it becomes possible to simultaneously attain high hydrophilicity and transparency and to impart abrasion resistance, and further, the uniform forming property of the hydrophilic coating film will be excellent. Further, as compared with a case where polyethylene glycol is used as the water-soluble binder, the adhesion to the base material is improved, and the abrasion resistance tends to be good, and accordingly, by using such a water-soluble polyvinyl alcohol, the abrasion resistance can be improved by its addition in a small amount.

Whether or not the hydrophilic coating film contains a water-soluble polyvinyl alcohol can be ascertained by a 1H-NMR analysis. A sample liquid for measurement may be prepared in such a manner that from the base material, the hydrophilic coating film is scraped to recover a powder sample, which is diluted with water to 5 mass %, followed by dispersion treatment by an ultrasonic dispersing apparatus for 30 minutes to obtain a dispersion, which is subjected to centrifugal separation to a supernatant and a precipitate, whereupon the supernatant is concentrated.

As the inorganic binder, a precursor for a metal oxide may be mentioned, and a precursor for silica or alumina is preferred. The precursor for silica or alumina is obtainable by a known production method.

The silica precursor may be one obtained by a method of hydrolyzing a silicic acid alkoxide (such as ethyl silicate); one obtained by a method of decomposing an alkali metal silicate with an acid, followed by electrolytic dialysis; one obtained by a method of deflocculating an alkali metal silicate; or one obtained by a method of dialyzing an alkali metal silicate by an ion exchange resin.

The alumina precursor may, for example, be one obtained by a method of hydrolyzing an aluminum alkoxide; or a water-soluble aluminum salt or an aluminum chelate compound.

The proportion of the binder is from 0.5 to 15 parts by mass, preferably from 1 to 5 parts by mass, per 100 parts by mass in total of the boehmite particles and the silica particles. When the binder is at most 15 parts by mass, pores of the hydrophilic coating film are less likely to be embedded by the binder, whereby a large pore volume can be obtained. When the binder is at least 0.5 part by mass, the effect to improve the abrasion resistance can readily be obtainable.

Water

In the coating composition for forming a hydrophilic coating film, water plays a role as a dispersion medium to disperse the boehmite particles and the silica particles.

The proportion of water is preferably from 500 to 100,000 parts by mass, more preferably from 600 to 10,000 parts by mass, further preferably from 1,000 to 3,000 parts by mass, per 100 parts by mass of the total solid content in the coating composition for forming a hydrophilic coating film. When the water is at least 500 parts by mass, the concentration of the coating composition for forming a hydrophilic coating film is not too high, and the storage stability will be good. When the water is at most 100,000 parts by mass, the concentration of the coating composition for forming a hydrophilic coating film is not too low, and it is possible to form a hydrophilic coating film having an adequate thickness.

Organic Solvent

The coating composition for forming a hydrophilic coating film of the present invention may contain an organic solvent within a range not to impair the dispersion stability of the boehmite particles and the silica particles. As such an organic solvent, a water-soluble organic solvent is preferred, and as its amount, it is preferred to use an amount of at most its solubility in water. Further, the boiling point of the organic solvent is preferably at most 120° C., particularly preferably at most 100° C.

As such an organic solvent, a water-soluble alcohol may be mentioned such as methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol, sec-butanol, t-butanol or ethylene glycol.

In order to obtain a defoaming property at the time of coating a base material with the coating composition for forming a hydrophilic coating film, it is preferred to incorporate a water-soluble organic solvent. As such a water-soluble organic solvent, a water-soluble alcohol is preferred which may be mixed at an optional proportion with water. In such a case, the amount of the alcohol is preferably adjusted so that the proportion of the alcohol will be from 10 to 70 mass % based on the total amount of water and the alcohol. When the alcohol is at least 10 mass %, a defoaming effect can be obtained, and when the alcohol is at most 70 mass %, the stability of the coating composition for forming a hydrophilic coating film is good. As such a water-soluble alcohol, methanol, ethanol or isopropanol is preferred from the viewpoint of the stability. Such alcohols may be used alone, or two or more of them may be used in combination. The proportion of the alcohol based on the total amount of water and the alcohol is more preferably from 30 to 60 mass %.

Other Components

The coating composition for forming a hydrophilic coating film of the present invention may contain, in addition to the boehmite particles and the silica particles, other additives such as metal oxide particles, a surfactant, a defoaming agent, a crosslinking agent, a water resistant curing agent, a coloring dye, a pigment, an ultraviolet absorber, an antioxidant, etc., as the case requires. The total amount of other components to constitute a solid content is preferably at most 50 parts by mass, more preferably at most 30 parts by mass, per 100 parts by mass in total of the boehmite particles and the silica particles. If the total amount of other components to constitute a solid content becomes too large, the properties obtainable by the essential components may be deteriorated.

The coating composition for forming a hydrophilic coating film of the present invention may contain metal oxide particles other than the boehmite particles and the silica particles, as the case requires. For example, in a case where cerium oxide particles are contained, an ultraviolet shielding function may be imparted. In a case where titanium oxide particles are contained, an ultraviolet shielding performance or a photocatalytic performance may be imparted. In a case where indium-doped tin oxide (ITO) particles, antimony-doped tin oxide (ATO) particles or tin oxide particles are contained, electroconductivity or an ultraviolet shielding performance may be imparted. In a case where alumina particles other than boehmite particles are contained, the hydrophilicity (such as wettability) or the film strength of the hydrophilic coating film may be further improved.

The average particle diameter of the metal oxide particles is preferably from 1 to 500 nm, more preferably from 1 to 200 nm. When the average particle diameter of the metal oxide particles is at least 1 nm, the properties of the metal oxide particles can readily be obtainable. When the average particle diameter of the metal oxide particles is at most 500 nm, deterioration of the transparency of the hydrophilic coating film can be suppressed.

The proportion of the metal oxide particles is preferably at most 30 parts by mass, per 100 parts by mass in total of the boehmite particles and the silica particles. In order to obtain the above-mentioned properties by using the metal oxide particles, their amount is preferably at least 1 part by mass per 100 parts by mass in total of the boehmite particles and the silica particles.

In a case where the coating composition contains a surfactant, the coating property of the coating composition will be improved, whereby a uniform hydrophilic coating film having a good appearance can be formed, and the hydrophilicity is also improved.

The surfactant may be an anionic surfactant, a cationic surfactant, an amphoteric surfactant or a nonionic surfactant. Such a surfactant may be a surfactant having hydrogen atoms of an alkyl group moiety substituted by fluorine atom (i.e. a fluorinated surfactant). As the surfactant, a nonionic surfactant is preferred in that the dispersion stability of the boehmite particles and the silica particles in the coating composition for forming a hydrophilic coating film will thereby be good.

The nonionic surfactant is preferably a compound having at least one type of structural unit selected from the group consisting of —CH2CH2CH2O—, —CH2CH2O—, —SO2—, —NR— (wherein R is a hydrogen atom or an organic group), —NH2, —SO3Y and —COOY (wherein Y is a hydrogen atom, a sodium atom, a potassium atom or an ammonium group). Such a compound may, for example, be an alkylpolyoxyethylene ether, an alkylpolyoxyethylene-polyoxypropylene ether, a fatty acid polyoxyethylene ester, a fatty acid polyoxyethylene sorbitane ester, a fatty acid polyoxyethylene sorbitol ester, an alkylpolyoxyethyleneamine, an alkylpolyoxyethyleneamide or a polyether-modified silicone surfactant.

The proportion of the surfactant in the coating composition for forming a hydrophilic coating film is preferably at most 15 parts by mass, more preferably at most 10 parts by mass, per 100 parts by mass in total of the boehmite particles and the silica particles. When the surfactant is at most 15 parts by mass, deterioration of the abrasion resistance of the hydrophilic coating film can be suppressed. In order to obtain the above-described properties by using the surfactant, its amount is preferably at least 1 part by mass per 100 parts by mass in total of the boehmite particles and the silica particles.

The crosslinking agent for the binder may, for example, be an inorganic compound such as an inorganic aluminum compound, an inorganic boron compound, an inorganic zirconium compound or an inorganic titanium compound, or an organic compound such as glyoxal, a hydrazide compound or an isocyanate compound. By crosslinking the binder by using such a crosslinking agent, it is possible to suppress deterioration of the abrasion resistance of the hydrophilic coating film and to improve the durability of wettability. The proportion of the crosslinking agent in the coating composition for forming a hydrophilic coating film is preferably at most 10 parts by mass, more preferably at most 5 parts by mass, per 100 parts by mass in total of the boehmite particles and the silica particles. When the crosslinking agent is at most 10 parts by mass, the stability of the coating liquid can be obtained, and it is possible to suppress an increase of the haze of the hydrophilic coating film. In order to obtain the above-described properties by using the crosslinking agent, its amount is preferably at least 0.1 part by mass per 100 parts by mass in total of the boehmite particles and the silica particles.

The water resistant curing agent may, for example, be an aqueous emulsion, aqueous dispersion or the like, of an acrylic resin, a polyester resin, a polyolefin resin, an urethane resin or a vinyl acetate resin.

Preparation Method

The coating composition for forming a hydrophilic coating film of the present invention can be prepared by mixing a boehmite sol containing boehmite particles, a silica sol containing silica particles and a binder. At the time of preparing the coating composition for forming a hydrophilic coating film, water or an organic solvent (such as ethanol or methanol) may be added, as the case requires.

The boehmite sol is one having boehmite particles dispersed in water, a mixed solvent of water and a water-soluble organic solvent, or another aqueous medium. The water-soluble organic solvent is preferably a water-soluble alcohol such as ethanol, methanol or isopropanol. The solid content concentration of the boehmite sol is preferably from 0.1 to 30 mass %, more preferably from 3 to 20 mass %.

In order to stabilize the boehmite particles in the dispersion medium, the boehmite sol preferably contains anions derived from an inorganic acid or organic acid (such as chlorine ions, sulfate ions or acetate ions). The concentration of anions is preferably at most 35 parts by mass per 100 parts by mass of Al. When the concentration of anions is at most 35 parts b mass, it is possible to suppress deterioration of the water resistance or hydrophilicity of the hydrophilic coating film. In a case where the concentration of anions in the boehmite sol is high, it is preferred to reduce the anion concentration by means of an ion exchange resin, electrical dialysis, ultrafiltration or the like.

The pH of the boehmite sol is preferably from 4 to 6.8, since it is thereby possible to obtain a coating film excellent in the water resistance and transparency. When the pH is at least 4, the anions may not be too much, and the water resistance of the hydrophilic coating film will be good. When the pH is at most 6.8, the boehmite particles are less likely to be agglomerated, and it is possible to secure the transparency of the hydrophilic coating film and the adhesion to the base material and to suppress deterioration of the abrasion resistance.

The solid content concentration of the silica sol is preferably from 5 to 40 mass %, more preferably from 10 to 35 mass %. The pH of the silica sol is preferably from 9 to 10.5 from the viewpoint of the stability. It is also possible to use a silica sol having a pH of at most 7, or it is also possible to adjust the pH to be at most 7 before mixing a silica sol having a pH of from 9 to 10.5 with the boehmite sol.

As mentioned above, the pH of the coating composition for forming a hydrophilic coating film of the present invention is preferably from 2.5 to 7. Even if a silica sol having a pH of from 9 to 10.5 is used, the pH of the coating composition for forming a hydrophilic coating film can be made to be from 2.5 to 7 by mixing it with a boehmite sol having a low pH. Otherwise, as the case requires, after mixing with the boehmite sol, etc., the pH of the composition may be adjusted to a level of from 2.5 to 7. The adjustment of the pH of the composition is preferably carried out by adding an inorganic acid such as nitric acid.

Hydrophilic Coating Film

The hydrophilic coating film is a coating film formed by applying the coating composition for forming a hydrophilic coating film of the present invention to a base material.

The base material may be an inorganic base material (base material made of an inorganic material such as glass) or an organic base material (base material made of a resin material such as a polyethylene terephthalate resin, an acrylic resin, a polycarbonate resin, a polyolefin resin, a polyvinylchloride resin or a fluororesin). The base material is preferably made of a transparent material. From the viewpoint of the durability, weather resistance, chemical resistance, adhesion to the hydrophilic coating film, etc., a base material made of a fluororesin is preferred. The fluororesin is negatively chargeable at its surface, and thus, its adhesion to boehmite particles which are positively charged, becomes high.

The shape of the base material is not particularly limited, and it may be one formed into various shapes. Preferred is a base material of a film form or sheet form, and by using such a base material, a hydrophilic coating film having a uniform thickness can efficiently be formed. The hydrophilic coating film may be formed on one side or each side of the base material of e.g. film form, depending upon the purpose.

Hereinafter, a film-form base material and a sheet-form base material will be generally referred to as a film. Further, in the present invention, an article means a product having a base material having a hydrophilic coating film formed thereon.

The fluororesin may be a homopolymer of a fluoroolefin, a copolymer of two or more fluoroolefins, or a copolymer of at least one fluoroolefin with one or more other monomers.

A fluoroolefin is a monomer having a polymerizable unsaturated bond and fluorine atoms and may further have hydrogen atoms, chlorine atoms, oxygen atoms, etc. As such a fluoroolefin, for example, tetrafluoroethylene, vinyl fluoride, vinylidene fluoride, a perfluoro(alkyl vinyl ether), chlorotrifluoroethylene or hexafluoropropylene is preferred. As the perfluoro(alkyl vinyl ether), perfluoro(propyl vinyl ether) is particularly preferred.

Other monomers are preferably non-fluorinated monomers. For example, olefins such as ethylene, propylene, butene, norbornene, etc.; alkenyl ethers such as cyclohexylmethyl vinyl ether, isobutyl vinyl ether, cyclohexyl vinyl ether, ethyl vinyl ether, 2-ethylhexyl vinyl ether, ethylallyl ether, etc.; and alkenyl esters such as vinyl acetate, vinyl pivalate, vinyl versatate, allyl pivalate, allyl versatate, etc., are preferred.

As fluororesins obtained by polymerizing such monomers, a tetrafluoroethylene/ethylene copolymer, a tetrafluoroethylene/perfluoro(alkyl vinyl ether) copolymer, polyvinyl fluoride, polyvinylidene fluoride, polychlorotrifluoroethylene, a chlorotrifluoroethylene/ethylene copolymer, a vinylidene fluoride/tetrafluoroethylene copolymer, a vinylidene fluoride/hexafluoropropylene copolymer, a tetrafluoroethylene/hexafluoropropylene copolymer, a vinylidene-fluoride/tetrafluoroethylene/hexafluoropropylene copolymer, a tetrafluoroethylene/propylene copolymer and a tetrafluoroethylene/hexafluoropropylene/ethylene copolymer are preferred. Among tetrafluoroethylene/perfluoro(alkyl vinyl ether) copolymers, a tetrafluoroethylene/perfluoro(propyl vinyl ether) copolymer is preferred. Among them, a tetrafluoroethylene/ethylene copolymer is particularly preferred from the viewpoint of the processability and the physical properties of the film to be used.

To the base material, surface treatment may preliminarily be applied to the surface on which the hydrophilic coating film is to be formed. By applying such surface treatment, wettability of the base material will be improved, whereby it is possible to improve the adhesion of the hydrophilic coating film to the base material or the uniformity of the hydrophilic coating film. Especially when a fluororesin base material is used, it is preferred to preliminarily apply surface treatment to the surface on which the hydrophilic coating film is formed, in order to improve wettability. The surface treatment may, for example, be discharge treatment (plasma treatment, corona discharge treatment, etc.), UV treatment, ozone treatment, chemical treatment using an acid, alkali, etc., or physical treatment using an abrasive material.

The coating method may, for example, be brush coating, roller coating, manual coating, spin coating, dip coating, coating by various printing systems, bar coating, curtain flow coating, die coating, flow coating or spray coating. In a case where the base material is a film, coating by means of a gravure coater is preferred, since it is thereby possible to carry out uniform coating over a large area.

For the purpose of improving the film strength of the hydrophilic coating film, heating or irradiation with ultraviolet rays, electron rays, etc. may be carried out. The heating temperature may be decided taking into consideration the heat resistance of the base material. For example, in the case of a fluororesin film, the heating temperature is preferably from 40 to 100° C.

The thickness of the hydrophilic coating film is preferably from 100 to 700 nm, more preferably from 250 to 450 nm. When the thickness of the hydrophilic coating film is at least 100 nm, it is possible to suppress deterioration of the hydrophilicity and hydrophilic durability. When the thickness of the hydrophilic coating film is at most 700 nm, the hydrophilic coating film is less susceptible to cracking, interference fringe is less likely to occur, and even if scratched, such a scratch mark is unnoticeable.

The hydrophilic coating film is required to have transparency. The transparency of the hydrophilic coating film can be evaluated by its haze value. The haze value of the hydrophilic coating film is preferably at most 5.0%, more preferably at most 3.0%. When the haze value is at most 5.0%, the hydrophilic coating film can be regarded as having sufficient transparency.

The haze value of the hydrophilic coating film can be calculated by subtracting the haze value of the base material from the haze value of the article having the hydrophilic coating film formed on the surface of the base material.

The hydrophilicity of the hydrophilic coating film can be evaluated by its contact angle to water. The contact angle of the hydrophilic coating film to water is preferably at most 40°, more preferably at most 20°, further preferably at most 10°. When the contact angle is at most 40°, the hydrophilicity of the hydrophilic coating film becomes sufficient, and the wettability can easily be obtainable. If soil is deposited on the surface of the hydrophilic coating film, the contact angle to water may increase, and the wettability may be lost in many cases. In the case of the hydrophilic coating film in the present invention, the surface is gradually washed out and renewed, whereby the wettability can be maintained for a long period of time.

The hydrophilic coating film may be used as a hydrophilic primer layer, and another coating film may further be formed on the hydrophilic primer layer. For example, in a case where on the hydrophilic coating film, a photocatalytic film containing fine particles of e.g. anatase type titanium oxide, rutile type titanium oxide, tin oxide, zinc oxide, tungsten trioxide, ferric oxide or strontium titanate, is formed, it is possible to suppress deterioration by decomposition of an organic base material, by the photocatalytic film.

Agricultural Film

The coating composition for forming a hydrophilic coating film of the present invention is useful particularly as a coating composition to form a hydrophilic coating film on a base material to be used as an agricultural film (a plastic film to be used as a transparent roof material or transparent side wall material of a plant cultivation installation). The hydrophilic coating film is formed on at least one side of the agricultural film. Further, in a case where the hydrophilic coating film is formed on one side only, an anti-fouling film, an antistatic film, a heat-shielding film or an ultraviolet-shielding film may, for example, be formed on the other side.

The material for such an agricultural film may, for example, be a polyethylene terephthalate resin, an acrylic resin, a polycarbonate resin, a polyolefin resin, a polyvinylchloride resin or a fluororesin, and a fluororesin is preferred. In a case where the agricultural film is a fluororesin film, the surface is negatively chargeable, whereby the adhesion to the hydrophilic coating film containing boehmite particles which are positively charged, will be high. As the material for the agricultural film, a tetrafluoroethylene/ethylene copolymer is particularly preferred.

In the coating composition for forming a hydrophilic coating film of the present invention as described in the foregoing, the crystallite diameter of boehmite particles, as calculated from the diffraction peak of the (120) plane, is from 20 to 50 nm, and the average particle diameter of the silica particles is from 5 to 50 nm, whereby it is possible to form a hydrophilic coating film which has high transparency and which is excellent in abrasion resistance (adhesion), hydrophilicity (anti-fogging property, wettability, anti-fouling property) and hydrophilic durability.

EXAMPLES

Now, Examples will be described.

Examples 1 to 3, 8 to 10, 12, 13 and 15 to 17 are Working Examples of the present invention, and Examples 4 to 7, 11,14 and 18 to 20 are Comparative Examples. As the base material, a tetrafluoroethylene/ethylene copolymer film having corona discharge treatment applied to one side on which a hydrophilic coating film is to be formed (tradename: Aflex manufactured by Asahi Glass Company, Limited, surface wetting index after the corona discharge treatment: 42, thickness: 100 μm) was used (hereinafter referred to as an ETFE film). In the following Examples, an ETFE film provided with a hydrophilic coating film was evaluated as an agricultural film.

Crystallite Diameter of Boehmite Particles as Calculated from the Diffraction Peak of the (120) Plane

With respect to a powder sample recovered by drying the coating composition for forming a hydrophilic coating film, the XRD analysis was carried out twice, and the crystallite diameter of the boehmite particles was calculated from the diffraction peak of the (120) plane of the boehmite particles.

(XRD apparatus) Model: TTR-III manufactured by Rigaku Corporation

(Measuring conditions) X-ray output: 50 kV-300 mA, optical system: parallel beam, scan speed: 2°/min, rotation: yes (100 RPM), sampling interval: 0.02°/step

(Analytical conditions) Software: JADE7, correction standard: Si powder (NIST SRM640c), analytical peak: boehmite (120) plane, fitting function: Pearson-VII, exponent: 1.5, baseline: fourth ordered polynominal

Average Particle Diameter of Silica Particles

The coating composition for forming a hydrophilic coating film was diluted with water to obtain a diluted liquid having a solid content concentration of about 0.1 mass %, and then, such a diluted liquid was dropped on a collodion film and dried to form an observation film. Such an observation film was observed by TEM, and the lengths of the long axes and short axes of 20 silica particles randomly selected among ones in the TEM image were measured, and they were averaged to obtain an average particle diameter of the silica particles.

(TEM) Model: JEM-1230, manufactured by JEOL Ltd.

Thickness of Hydrophilic Coating Film

An ETFE film having a hydrophilic coating film formed on one side was cut by a razor, and the cut surface was observed by a scanning electron microscope (SEM), whereby the thicknesses at three portions of the hydrophilic coating film were measured, and they were averaged.

(SEM) Model: S-4300 manufactured by Hitachi, Ltd.

(Measuring conditions) Accelerating voltage: 5 kV, conductive coating: Pt

Appearance

The appearance of the hydrophilic coating film in the ETFE film having a hydrophilic coating film formed on one side was visually evaluated, whereby one free from foreign matter defects, warpage, cracking and non-uniformity was designated by ◯ (good), and one having any one of such defects was designated by × (no good).

Haze Value

In accordance with JIS K7105, the haze values of the ETFE film before forming a hydrophilic coating film and the ETFE film having a hydrophilic coating film formed on one side were measured by means of a haze computer (model: HGM-3DP manufactured by Suga Test Instruments Co., Ltd.), and the haze value of the hydrophilic coating film was calculated by subtracting the haze value of the ETFE film before forming a hydrophilic coating film from the haze value of the ETFE film having a hydrophilic coating film formed on one side.

One having a haze value of at most 5% was regarded as acceptable, and one having a haze value exceeding 5% was regarded as unacceptable.

Transmittance

In accordance with JIS K7105 (1981), the total light transmittance of the ETFE film having a hydrophilic coating film formed on one side was measured by means of a haze meter (model: HGM-2K, SM color computer model SM-5, manufactured by Suga Test Instruments Co., Ltd.).

Contact Angle

The contact angles of the hydrophilic coating film of the ETFE film having a hydrophilic coating film formed on one side to water were measured at optional five different portions by means of a contact angle meter (model: CA-X150 manufactured by Kyowa Interface Science Co., LTD.), and they were averaged. The contact angle serves as an index for the hydrophilicity.

Low Temperature Wettability

From the ETFE film having a hydrophilic coating film formed on one side, a sample of 14 cm×8 cm was cutout. A roof-form frame made of an acrylic resin was set at an angle of 15° to a horizontal plane, on a constant temperature water tank set in a constant temperature environment test room, and the sample was set on the frame so that the hydrophilic coating film faced down. The environment test room was adjusted to be 10° C., and the constant temperature water tank was adjusted to be 20° C. The state of water droplets on the surface of the hydrophilic coating film was observed and evaluated by the following standards. ⊚, ◯ and Δ are regarded as acceptable, and × and ×× are regarded as unacceptable.

⊚ (excellent): After one hour from initiation of evaluation, the film surface is uniformly wet.

◯ (good): After two hours from initiation of evaluation, the film surface is uniformly wet.

Δ (permissible): After 3 hours from initiation of evaluation, the film surface is uniformly wet.

× (not permissible): After 3 hours from initiation of evaluation, water droplet-deposited portions are partially observed on the film surface.

×× (bad): After 3 hours from initiation of evaluation, water droplets are deposited and white fogging is observed over the entire film surface.

Durability of Wettability

A sample was set in the same environment test room as for the evaluation of the low temperature wettability, and left to stand for three months while maintaining the environment test room at 20° C. and the constant temperature water tank at 80° C. Upon expiration of the three months, the sample was taken out. Then, with respect to such a sample, evaluation of the low temperature wettability was carried out, whereby the state of water droplets on the surface of the hydrophilic coating film was observed, and the durability of wettability was evaluated by the same standards as for the evaluation of the low temperature wettability.

In an agricultural house, in a winter time, early in the morning or evening when outside air temperature is low, an agricultural film is likely to have fogging, and suppression of fogging is required for the agricultural film. For such suppression of fogging, “low temperature wettability” will be an index. Further, an agricultural film is required to show wettability even after exposure for a long period of time, and for this purpose, “durability of wettability” will be an index.

Abrasion Resistance

A sample of the ETFE film having a hydrophilic coating film formed on one side was set in a flat surface abrasion tester (model: TESTER SANGYO AB-301 COLOR FASTNESS RUBBING TESTER, manufactured by Coating Tester Kougyo, Inc.), and BEMCOT (tradename: BEMCOT M-1, manufactured by Asahi Chemical Industry Co., Ltd.) was attached as an abrading material, whereupon an abrasion test of the hydrophilic coating film was carried out under such conditions that the load was 200 g, the contact area was 15 mm×20 mm and the number of abrasion was one reciprocation, whereby the Al-deposited amounts (μg/cm2) before and after the test were measured by a fluorescent X-ray apparatus (model: RIX3000 manufactured by Rigaku Corporation), and the abrasion resistance was evaluated by Al-deposited amount after the test/initial Al-deposited amount×100 (%). One wherein the Al-deposited amount was at least 70% to the initial Al-deposited amount, was regarded as acceptable.

Example 1

To 792 g of ion-exchanged water, 8 g of 1N nitric acid was added, then 200 g of boehmite (tradename: DISPAL 11N7-80 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 5.0.

To 100 g of the boehmite dispersion, 81.8 g of silica sol (tradename: SNOWTEX OS manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 20 mass %, pH: 3.0), 315.4 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 29.1 g of an aqueous solution containing 5 mass % of polyvinyl alcohol (tradename: PVA105 manufactured by Kuraray Co., Ltd., saponification degree: 98 to 99 mol %, polymerization degree: 500) and 104.5 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 55 parts by mass of boehmite, 45 parts by mass of silica and 4 parts by mass polyvinyl alcohol and having a solid content concentration of 6 mass % and a pH of 4.1.

2 mL of the above coating composition for forming a hydrophilic coating film was applied to the corona discharge-treated surface of an ETFE film having A4 size by a bar coater and then dried at 80° C. for 5 minutes to form a hydrophilic coating film having a thickness of 0.35 μm thereby to obtain an ETFE film having a hydrophilic coating film formed on one side.

The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 2

A coating composition for forming a hydrophilic coating film having pH 4.5 was obtained in the same manner as in Example 1 except that as the boehmite, tradename: DISPAL 10F4 manufactured by SASOL Ltd. was used instead of tradename: DISPAL 11N7-80 manufactured by SASOL Ltd., and instead of the polyvinyl alcohol (tradename: PVA105 manufactured by Kuraray Co., Ltd.), a modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) was used. Further, an ETFE film having a hydrophilic coating film formed on one side was obtained in the same manner as in Example 1 except that such a coating composition for forming a hydrophilic coating film was used.

The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 3

A boehmite dispersion was obtained in the same manner as in Example 1.

To 100 g of the boehmite dispersion, 66.7 g of silica sol (tradename: Organosilica sol IPA-ST manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 30 mass %), 56 g of an aqueous solution containing 10 mass % of polyethylene glycol (PEG2000, molecular weight: 2000), 0.8 g of a surfactant (tradename: SN Wet L manufactured by San Nopco Limited), 280 g of ion-exchanged water and 270 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited) were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 50 parts by mass of boehmite, 50 parts by mass of silica, 14 parts by mass of PEG2000 and 2 parts by mass of the surfactant and having a solid content concentration of 6 mass % and a pH of 5.5. Further, an ETFE film having a hydrophilic coating film formed on one side was obtained in the same manner as in Example 1 except that such a coating composition for forming a hydrophilic coating film was used.

The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 4 Comparative Example

An ETFE film provided with a hydrophilic coating film was produced in the same manner as in Example 1 except that as the boehmite, tradename: DISPAL 18N4-80 manufactured by SASOL Ltd. was used instead of tradename: DISPAL 11N7-80 manufactured by SASOL Ltd.

The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 5 Comparative Example

An ETFE film provided with a hydrophilic coating film was obtained in the same manner as in Example 1 except that the amount of the boehmite dispersion was changed to 163.6 g, and the amount of the silica sol was changed to 18.2 g.

The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 6 Comparative Example

An ETFE film provided with a hydrophilic coating film was obtained in the same manner as in Example 1 except that the amount of the boehmite dispersion was changed to 18.2 g, and the amount of the silica sol was changed to 163.6 g.

The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 7 Comparative Example

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 18N4-80 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 3.6.

To 19.0 g of the boehmite dispersion, 10.3 g of silica sol (tradename: SNOWTEX S manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 30 mass %, pH: 10), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 1.5 g of 1N nitric acid, 6.0 g of an aqueous solution containing 7 mass % of polyvinyl alcohol (tradename: PVA105 manufactured by Kuraray Co., Ltd., saponification degree: 98 to 99 mol %, polymerization degree: 500), and 18.9 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 55 parts by mass of boehmite, 45 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 5.0.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 8

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 14N4-80 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 4.0.

To 19.0 g of the boehmite dispersion, 10.3 g of silica sol (tradename: SNOWTEX S manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 30 mass %, pH: 10), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 1.5 g of 1N nitric acid, 6.0 g of an aqueous solution containing 7 mass % of polyvinyl alcohol (tradename: PVA105 manufactured by Kuraray Co., Ltd., saponification degree: 98 to 99 mol %, polymerization degree: 500), and 19.0 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 55 parts by mass of boehmite, 45 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 5.1.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 9

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 11 N7-80 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 5.3.

To 19.0 g of the boehmite dispersion, 10.3 g of silica sol (tradename: SNOWTEX S manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 30 mass %, pH: 10), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 1.5 g of 1N nitric acid, 4.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.), 1.0 g of an aqueous solution containing 10% of zirconium oxychloride octahydrate, 19.0 g of ion-exchanged water and 1.0 g of an aqueous solution containing 10 mass % of a surfactant (tradename: SN Wet L manufactured by San Nopco Limited) were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 55 parts by mass of boehmite, 45 parts by mass of silica and 4 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 5.8.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 10

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 10F4 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 4.0.

To 19.0 g of the boehmite dispersion, 10.3 g of silica sol (tradename: SNOWTEX S manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 30 mass %, pH: 10), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 1.5 g of 1N nitric acid, 6.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 19.0 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 55 parts by mass of boehmite, 45 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 5.2.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 11 Comparative Example

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 60 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 7.0.

To 19.0 g of the boehmite dispersion, 10.3 g of silica sol (tradename: SNOWTEX S manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 30 mass %, pH: 10), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 1.5 g of 1N nitric acid, 6.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 19.0 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 55 parts by mass of boehmite, 45 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 6.8.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 12

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 11 N7-80 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 5.3.

To 19.0 g of the boehmite dispersion, 15.5 g of silica sol (tradename: SNOWTEX XS manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 20 mass %, pH: 10), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 1.2 g of 1N nitric acid, 6.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 13.8 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 55 parts by mass of boehmite, 45 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 5.5.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 13

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 11 N7-80 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 5.3.

To 19.0 g of the boehmite dispersion, 15.5 g of silica sol (tradename: SNOWTEX 20L manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 20 mass %, pH: 10), 50 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 1.2 g of 1N nitric acid, 6.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 13.8 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 55 parts by mass of boehmite, 45 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 4.9.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 14 Comparative Example

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 11 N7-80 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 5.3.

To 19.0 g of the boehmite dispersion, 7.7 g of silica sol (tradename: Cataloid SI80P manufactured by Catalysts & Chemicals Industries Co., Ltd., solid content concentration: 40 mass %, pH: 10), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 1.5 g of 1N nitric acid, 6.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 21.6 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 55 parts by mass of boehmite, 45 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 4.7.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 15

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 11 N7-80 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 5.3.

To 15.5 g of the boehmite dispersion, 12.6 g of silica sol (tradename: SNOWTEX S manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 30 mass %, pH: 10), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 1.8 g of 1N nitric acid, 6.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 12.6 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 45 parts by mass of boehmite, 55 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 4.9.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 16

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 11 N7-80 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 5.3.

To 27.6 g of the boehmite dispersion, 4.6 g of silica sol (tradename: SNOWTEX S manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 30 mass %, pH: 10), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 0.6 g of 1N nitric acid, 6.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 17.0 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 80 parts by mass of boehmite, 20 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 5.0.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 17

To 800 g of ion-exchanged water, 200 g of boehmite (tradename: DISPAL 11 N7-80 manufactured by SASOL Ltd.) was added with stirring, and after continuing the stirring for 30 minutes, the system was left to stand at room temperature for one day, to obtain a boehmite dispersion having a solid content concentration of 20 mass % and a pH of 5.3.

To 6.9 g of the boehmite dispersion, 18.4 g of silica sol (tradename: SNOWTEX S manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 30 mass %, pH: 10), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 2.6 g of 1N nitric acid, 6.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 21.6 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising, by a solid content ratio, 20 parts by mass of boehmite, 80 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 4.7.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 18 Comparative Example

By using a coating composition having the modified polyvinyl alcohol omitted from the hydrophilic coating material in Example 11, coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 19 Comparative Example

35.0 g of silica sol (tradename: SNOWTEX OS manufactured by Nissan Chemical Industries, Ltd., solid content concentration: 20 mass %, pH: 3), 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 6.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 15.0 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising 100 parts by mass of silica and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 3.3.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

Example 20 Comparative Example

35.0 g of boehmite dispersion in Example 3, 50.0 g of industrial ethanol (tradename: SOLMIX AP-1 manufactured by Japan Alcohol Trading Company Limited), 6.0 g of an aqueous solution containing 7 mass % of modified polyvinyl alcohol (tradename: Gohsefimer Z100 manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 15.0 g of ion-exchanged water were added with stirring, followed by stirring for 5 minutes, to obtain a coating composition for forming a hydrophilic coating film comprising 100 parts by mass of boehmite and 6 parts by mass of polyvinyl alcohol and having a solid content concentration of 7 mass % and pH 5.0.

Coating and evaluations were carried out in the same manner as in Example 1. The composition of the solid content, the solid content concentration and the sizes of the respective particles in the coating composition for forming a hydrophilic coating film, are shown in Table 1, and the evaluation results are shown in Table 2.

TABLE 1 Coating composition for forming hydrophilic coating film Composition of solid content (parts by mass) Crystallite Average Solid content diameter of particle Boehmite Silica Crosslinking concentration boehmite diameter of particles particles Binder Surfactant agent (mass %) (nm) silica (nm) Ex. 1 55 45 4 6 32 12 Ex. 2 55 45 4 6 40 12 Ex. 3 50 50 14 2 6 32 12 Ex. 4 (Comp. Ex.) 55 45 4 6 15 12 Ex. 5 (Comp. Ex.) 90 10 4 6 32 12 Ex. 6 (Comp. Ex.) 10 90 4 6 32 12 Ex. 7 (Comp. Ex.) 55 45 6 7 15 12 Ex. 8 55 45 6 7 23 12 Ex. 9 55 45 4 1 1 7 32 12 Ex. 10 55 45 6 7 40 12 Ex. 11 (Comp. Ex.) 55 45 6 7 61 12 Ex. 12 55 45 6 7 32 5 Ex. 13 55 45 6 7 32 45 Ex. 14 (Comp. Ex.) 55 45 6 7 32 80 Ex. 15 45 55 6 7 32 12 Ex. 16 80 20 6 7 32 12 Ex. 17 20 80 6 7 32 12 Ex. 18 (Comp. Ex.) 20 80 7 32 12 Ex. 19 (Comp. Ex.) 100 6 7 15 Ex. 20 (Comp. Ex.) 100 6 7 32

TABLE 2 Low Thickness Haze Transmittance Contact temperature Durability of Abrasion (nm) Appearance value (%) (%) angle (°) wettability wettability resistance Ex. 1 350 ◯ 1.5 95 15 ⊚ ◯ 92 Ex. 2 350 ◯ 3 94 15 ◯ ◯ 95 Ex. 3 280 ◯ 2.5 94 15 ⊚ ◯ 75 Ex. 4 (Comp. Ex.) 350 ◯ 3 93 20 X — 50 Ex. 5 (Comp. Ex.) 350 ◯ 8 95 15 ◯ Δ 30 Ex. 6 (Comp. Ex.) 350 ◯ 1 95 15 ◯ X 90 Ex. 7 (Comp. Ex.) 350 ◯ 1 94 27 Δ Δ 61 Ex. 8 350 ◯ 1.1 94 26 ◯ ◯ 93 Ex. 9 350 ◯ 1.5 94 7 ⊚ ⊚ 94 Ex. 10 350 ◯ 3 94 9 ⊚ ◯ 92 Ex. 11 (Comp. Ex.) 350 ◯ 60 93 10 ◯ Δ 90 Ex. 12 350 ◯ 1.3 94 7 ⊚ Δ 95 Ex. 13 350 ◯ 4.7 94 8 ◯ ◯ 80 Ex. 14 (Comp. Ex.) 350 ◯ 8 94 15 ◯ Δ 75 Ex. 15 600 ◯ 2.5 94 12 ⊚ ⊚ 82 Ex. 16 350 ◯ 5 93 15 ◯ ◯ 70 Ex. 17 350 ◯ 1 94 12 ◯ Δ 90 Ex. 18 (Comp. Ex.) 100 ◯ 0.8 94 8 ⊚ X 74 Ex. 19 (Comp. Ex.) 350 ◯ 0.9 94 20 ◯ XX 90 Ex. 20 (Comp. Ex.) 350 ◯ 1 93 25 ◯ X 55

INDUSTRIAL APPLICABILITY

By the coating composition for forming a hydrophilic coating film of the present invention, it is possible to form a hydrophilic coating film on various articles such as various lamp covers, lenses for eyeglasses, goggles, various instrument covers, sign boards, protective films, laminated films, agricultural films or solar cell sheets.

The entire disclosures of Japanese Patent Application No. 2009-030955 filed on Feb. 13, 2009 and Japanese Patent Application No. 2009-030956 filed on Feb. 13, 2009 including specifications, claims, drawings and summaries are incorporated herein by reference in their entireties.

Claims

1. A coating composition for forming a hydrophilic coating film, which comprises boehmite particles, silica particles, a binder and water, wherein:

the crystallite diameter of the boehmite particles, as calculated from the diffraction peak of the (120) plane, is from 20 to 50 nm,
the average particle diameter of the silica particles is from 5 to 50 nm,
the proportion of the boehmite particles is from 20 to 80 mass % based on the total amount of the boehmite particles and the silica particles, and
the proportion of the binder is from 0.5 to 15 parts by mass per 100 parts by mass in total of the boehmite particles and the silica particles.

2. The coating composition according to claim 1, wherein the solid content concentration is from 0.1 to 20 mass %.

3. The coating composition according to claim 1, wherein the binder is a water-soluble organic binder.

4. The coating composition according to claim 1, wherein the binder is a water-soluble polyvinyl alcohol.

5. The coating composition according to claim 1, which has a pH of from 2.5 to 7.

6. The coating composition according to claim 1, which further contains a water-soluble alcohol, wherein the proportion of the water-soluble alcohol is from 10 to 70 mass %, based on the total amount of the water and the water-soluble alcohol.

7. An article having, on a surface of a base material, a hydrophilic coating film formed from the coating composition as defined in claim 1.

8. The article according to claim 7, wherein the hydrophilic coating film has a film thickness of from 100 to 700 nm.

9. The article according to claim 7, wherein the material for the base material is a resin material.

10. The article according to claim 7, wherein the material for the base material is a fluororesin.

Patent History
Publication number: 20110274914
Type: Application
Filed: Jul 20, 2011
Publication Date: Nov 10, 2011
Applicant: Asahi Glass Company, Limited (Chiyoda-ku)
Inventors: Takuya Nakao (Tokyo), Akemi Kato (Tokyo), Keisuke Abe (Tokyo), Takashige Yoneda (Tokyo)
Application Number: 13/186,510
Classifications
Current U.S. Class: Glass Or Ceramic (i.e., Fired Or Glazed Clay, Cement, Etc.) (porcelain, Quartz, Etc.) (428/325); Aluminum Dnrm (524/437); Nanoparticle (structure Having Three Dimensions Of 100 Nm Or Less) (977/773)
International Classification: B32B 5/16 (20060101); C08K 3/22 (20060101); B32B 27/06 (20060101); B82Y 30/00 (20110101);