CN106795693A - 包括水性聚氨酯组合物的分散体和膜 - Google Patents

包括水性聚氨酯组合物的分散体和膜 Download PDF

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Publication number
CN106795693A
CN106795693A CN201580030966.2A CN201580030966A CN106795693A CN 106795693 A CN106795693 A CN 106795693A CN 201580030966 A CN201580030966 A CN 201580030966A CN 106795693 A CN106795693 A CN 106795693A
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China
Prior art keywords
product
dispersion
fiber array
prepolymer
dispersions
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Pending
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CN201580030966.2A
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English (en)
Inventor
K.E.马丁
刘洪�
K.比萨
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Invista Technologies SARL Switzerland
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Invista Technologies SARL Switzerland
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Publication of CN106795693A publication Critical patent/CN106795693A/zh
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Abstract

本发明涉及一种包含聚氨酯组合物和纤维阵列的制品,其中所述纤维阵列嵌入所述聚氨酯组合物中,使得所述纤维的一部分延伸超出所述成型制品的内表面和所述成型制品的外表面。

Description

包括水性聚氨酯组合物的分散体和膜
技术领域
包括的是聚氨酯制品,其包括纤维或织物。这些可以是包括嵌入表面中的纤维阵列或浸渍有聚氨酯的织物的成型聚氨酯制品。使用聚氨酯分散体制备所述制品。
背景技术
已知乳胶或橡胶被用于各种成型制品,如手套、手指套等。然而,鉴于过敏,特别是对乳胶过敏的普遍存在,可能需要替代的聚合物。
发明内容
当包括在具有皮肤接触表面的衣服、成型制品或其它基底中时,聚氨酯组合物可能更适合替代天然胶乳或橡胶。理想地,聚氨酯将提供现有产品的柔性和弹性。
一些实施例提供包括聚氨酯组合物和纤维阵列的成型制品,其中所述纤维阵列嵌入聚氨酯组合物中,使得纤维的一部分延伸超出成型制品的内表面和成型制品的外表面。
一种合适的聚氨酯分散体包括作为以下物质的反应产物的聚合物:
(a)选自聚醚、聚酯、聚碳酸酯和其组合的至少一种多元醇,其中所述多元醇的数均分子量为600至4000;
(b)包含选自由芳香族二异氰酸酯、脂肪族二异氰酸酯、脂环族二异氰酸酯和其组合组成的群组的成员的多异氰酸酯;
(c)至少一种二醇化合物,其包含:(i)能够与多异氰酸酯反应的羟基,和(ii)在中和时能够形成盐的至少一个羧酸基团,其中所述至少一个羧酸基团不能与多异氰酸酯反应;
(d)中和剂;和
(e)扩链剂。还提供一种制备成型制品的方法。所述方法包括:
(a)提供具有制品接触表面的模具,其中所述制品接触表面包括表面活性剂或润湿剂;
(b)将内部纤维阵列施用到所述制品接触表面;
(c)将聚氨酯分散体施用到所述纤维阵列;
(d)将外部纤维阵列施用到所述分散体;
(e)干燥所述制品;
(f)从所述模具中移出所述制品。
还提供一种制备成型制品的方法。所述方法包括:
(a)提供具有制品接触表面的模具,其中所述制品接触表面包括表面活性剂或润湿剂;
(b)任选地将内部纤维阵列施用到所述制品接触表面,这可在仅外表面上需要纤维的情况下被排除;
(c)将聚氨酯分散体施用到所述纤维阵列;
(d)任选地将外部纤维阵列施用到分散体,这可在仅内表面上需要纤维的情况下被排除;
(e)干燥所述制品;
(f)从所述模具中移出所述制品。
还包括已经用聚氨酯脲组合物涂布和/或浸渍的制品。所述制品可以包括织物,例如非织造片材。非织造物可以是任何合适的非织造物,例如水刺或水力缠结的非织造物。
还提供包括聚氨酯脲组合物和纤维和/或织物阵列的制品,其可以是非织造物。聚氨酯脲组合物包括分散体,其可以施用于制品、基底、模具等。分散体可以包括一种包括聚合物的合适的聚氨酯分散体,聚合物是以下物质的反应产物:
(a)选自聚醚、聚酯、聚碳酸酯及其组合的至少一种多元醇,其中所述多元醇的数均分子量为600至4000;
(b)包含选自由芳香族二异氰酸酯、脂肪族二异氰酸酯、脂环族二异氰酸酯及其组合组成的群组的成员的多异氰酸酯,例如仅包括脂肪族二异氰酸酯的多异氰酸酯;
(c)至少一种二醇化合物,其包含:(i)能够与多异氰酸酯反应的羟基,和(ii)在中和时能够形成盐的至少一个羧酸基团,其中所述至少一个羧酸基团不能与多异氰酸酯反应;
(d)中和剂;和
(e)扩链剂。
在另一个实施例中是制备可用于成型制品的聚氨酯脲水性分散体的方法。稳定的分散体可以商业规模制备,包括大于约500加仑和大于约1000加仑的批次。
具体实施方式
可用于制备成型制品的水性聚氨酯分散体由特定的氨基甲酸酯预聚物提供,其也形成一些实施例的一个方面。
在一些实施例中,用于制备聚氨酯脲分散体的嵌段聚氨酯脲包括:a)数均分子量在500至5000(例如约600至4000和600至3500)的多元醇或多元醇共聚物或多元醇混合物,包括但不限于聚醚二醇、聚酯二醇、聚碳酸酯二醇、聚丁二烯二醇或其氢化衍生物,和羟基封端的聚二甲基硅氧烷;b)包括二异氰酸酯例如脂肪族二异氰酸酯、芳香族二异氰酸酯和脂环族二异氰酸酯的多异氰酸酯;和c)二醇化合物d,其包括:(i)能够与多异氰酸酯反应的羟基,和(ii)在中和时能够形成盐的至少一个羧酸基团,其中所述至少一个羧酸基团不能与多异氰酸酯反应;d)扩链剂,例如水或二胺扩链剂;和e)任选的一元醇或单胺,伯胺或仲胺,作为封端剂或链终止剂;和任选地具有至少三个伯或仲胺基团的有机化合物或聚合物。
一些实施例的氨基甲酸酯预聚物,也称为加帽的二醇类,在将预聚物分散在水中和链扩展之前,通常可概念化为多元醇、异氰酸酯和在中和之后能够成盐的化合物的反应产物。此类预聚物通常可以在一个或多个步骤中制备,使用或不使用可用于降低预聚物组合物的粘度的溶剂。
取决于预聚物是否溶解在将保留在分散体中的不易挥发的溶剂(例如NMP)中;溶解在挥发性溶剂如丙酮或甲基乙基酮(MEK)中,其随后可以除去;或分散在没有任何溶剂的水中;分散体制备方法在实践中可以分别分类为溶剂方法、丙酮方法或预聚物混合方法。预聚物混合方法具有环境和经济优点,并且可用于制备基本上没有添加溶剂的水性分散体。
在预聚物混合过程中,重要的是有或没有被溶剂稀释,预聚物的粘度足够低,以便被运输和分散在水中。一个实施例涉及衍生自此类预聚物的聚氨酯脲分散体,其满足所述粘度要求并且在预聚物或分散体中不具有任何有机溶剂。根据本发明,预聚物是多元醇、二异氰酸酯和二醇化合物的反应产物。
一些实施例是无溶剂、稳定的水性聚氨酯分散体,通过常规技术,其可以作为用于涂布、粘结和层压到基底的直接的粘合剂材料(即,不需要任何额外的粘合剂材料)被加工和施用。水性聚氨酯分散体可以提供:基本上无挥发性有机材料的排放;生产中可接受的固化时间;以及在成品和实际应用中良好的粘合强度、耐热性和拉伸/恢复性。
基底可以是许多不同织物或制品中的任何一种。
如本文所用,术语“分散体”是指其中分散相由细碎颗粒组成的体系,且连续相可以是液体、固体或气体。
如本文所用,术语“水性聚氨酯分散体”是指包含至少一种聚氨酯或聚氨酯脲聚合物或预聚物(例如本文所述的聚氨酯预聚物)的组合物,任选地包括溶剂,其已经分散在水性介质,例如水,包括去离子水中。
如本文所用,除非另有说明,否则术语“溶剂”是指非水性介质,其中非水性介质包括有机溶剂,包括挥发性有机溶剂(例如丙酮)和稍微有点挥发性的有机溶剂(例如N-甲基吡咯烷酮(NMP))。
如本文所用,术语“无溶剂”或“无溶剂体系”是指其中组合物或分散组分的主体没有溶解或分散在溶剂中的组合物或分散体。
如本文所用,术语“织物”意在包括任何针织、纺织或非织造材料。针织织物可以是平针织、圆形针织、经编、窄弹性或花边。纺织织物可以是任何结构,例如缎纹、斜纹、平织、牛津编织、篮形编织或窄弹性。非织造材料可以是熔喷、纺粘、湿法成网、梳理纤维类短纤维网等中的一种。
如本文所用,术语“硬纱”是指基本上是非弹性的纱线。
如本文所用,术语“衍生自”是指从另一物体形成物质。例如,膜或成型制品可以衍生自已经干燥的分散体。
由一些实施例的水性分散体铸造(cast)的膜的另一个优点是关于膜的感觉或触感。与硅橡胶或市售的热塑性膜相比,它们提供更柔软的感觉,同时保持所需的摩擦以减少运动,这对于皮肤接触应用是进一步的优点。此外,较低的弯曲模量赋予更好的悬垂性和织物手感。包含纤维阵列提供了对形成制品的膜的感觉的额外改进。
取决于聚氨酯或聚氨酯脲组合物作为分散体从本文所述的水性分散体施用时的期望效果,膜中聚合物的重均分子量可在约40,000至约250,000,包括约40,000至约150,000;约100,000至约150,000;和约120,000至约140,000内变化。
各种不同的纤维和纱线可以与一些实施例的制品(其可以是成型制品)一起使用。这些包括棉、羊毛、丙烯酸类、聚酰胺(尼龙)、聚酯、氨纶、再生纤维素、橡胶(天然或合成)、竹,丝绸、大豆、聚烯烃如聚乙烯或聚丙烯,其可以是或可以不是弹性体,或其组合。纤维可以是弹性的,例如弹性纤维或来自并排或偏心壳核横截面中的非弹性聚合物的弹性纤维。短纤维对于获得延伸超出制品表面的纤维阵列是最有用的。纤维可以称为短纤维。或者,短纤维可以称为絮屑(flock)。
以下更详细地描述聚氨酯组合物的组分:
多元醇类
适合作为用于制备根据本发明的氨基甲酸酯预聚物的原料的多元醇组分是数均分子量为约600至约3,500或约4,000的聚醚二醇、聚碳酸酯二醇和聚酯二醇。
可以使用的聚醚多元醇的实例包括具有两个或更多个羟基的那些二醇,来自环氧乙烷、环氧丙烷、三亚甲基氧化物、四氢呋喃和3-甲基四氢呋喃的开环聚合和/或共聚,或者来自在每个分子中具有小于12个碳原子的多元醇,优选二醇或二醇混合物,例如乙二醇、1,3-丙二醇、1,4-丁二醇、1,5-戊二醇、1,6-己二醇、新戊二醇、3-甲基-1,5-戊二醇、1,7-庚二醇、1,8-辛二醇、1,9-壬二醇、1,10-癸二醇和1,12-十二烷二醇的缩聚。线性双官能聚醚多元醇是优选的,并且分子量为约1,700至约2,100的聚(四亚甲基醚)二醇,例如官能度为2的Terathane®1800(Invista)在本发明中是特别优选的。
可以使用的聚酯多元醇的实例包括具有两个或更多个羟基的那些酯二醇,其通过脂肪族多元羧酸和多元醇或它们的混合物的缩聚制备,所述多元醇或它们的混合物具有每分子不超过12个碳原子的低分子量。合适的多元羧酸的实例是丙二酸、琥珀酸、戊二酸、己二酸、庚二酸、辛二酸、壬二酸、癸二酸、十一烷二羧酸和十二烷二羧酸。用于制备聚酯多元醇的合适的多元醇的实例是乙二醇、1,3-丙二醇、1,4-丁二醇、1,5-戊二醇、1,6-己二醇、新戊二醇、3-甲基-1,5-戊二醇、1,7-庚二醇、1,8-辛二醇、1,9-壬二醇、1,10-癸二醇和1,12-十二烷二醇。优选熔融温度为约5℃至约50℃的线性双官能聚酯多元醇。
可以使用的聚碳酸酯多元醇的实例包括具有两个或更多个羟基的那些碳酸酯二醇,其通过低分子量每分子具有不超过12个碳原子的光气、氯甲酸酯、碳酸二烷基酯或碳酸二烯丙酯和脂肪族多元醇或它们的混合物的缩聚制备。用于制备聚碳酸酯多元醇的合适的多元醇的实例是二甘醇、1,3-丙二醇、1,4-丁二醇、1,5-戊二醇、1,6-己二醇、新戊二醇、3-甲基-1,5-戊二醇、1,7-庚二醇、1,8-辛二醇、1,9-壬二醇、1,10-癸二醇和1,12-十二烷二醇。优选熔融温度为约5℃至约50℃的线性双官能聚碳酸酯多元醇。
多异氰酸酯类
合适的多异氰酸酯组分的实例包括二异氰酸酯如1,6-二异氰酸酯己烷、1,12-二异氰酸酯十二烷、异佛尔酮二异氰酸酯、三甲基-六亚甲基二异氰酸酯、1,5-二异氰酸酯-2-甲基戊烷、二异氰酸酯环己烷、亚甲基-双(4-环己基异氰酸酯)、四甲基二甲苯二异氰酸酯、双(异氰酸酯甲基)环己烷、甲苯二异氰酸酯、亚甲基双(4-苯基异氰酸酯)、亚苯基二异氰酸酯、二甲苯二异氰酸酯和此类二异氰酸酯的混合物。例如,二异氰酸酯可以是芳香族二异氰酸酯,例如亚苯基二异氰酸酯、甲苯二异氰酸酯(TDI)、亚二甲苯基二异氰酸酯、联苯二异氰酸酯、萘二异氰酸酯、二苯基甲烷二异氰酸酯(MDI)及其组合。
适合作为用于制备根据本发明的氨基甲酸酯预聚物的另一原料的多异氰酸酯组分可以是包含4,4'-亚甲基双(苯基异氰酸酯)和2,4'-亚甲基双(苯基异氰酸酯)的二苯基甲烷二异氰酸酯(MDI)的异构体混合物,其中4,4'-MDI与2,4'-MDI异构体之比的范围在约65:35至约35:65的范围内,优选约55:45至约45:55,并且更优选约50:50的范围内。合适的多异氰酸酯组分的实例包括Mondur® ML(Bayer)、Lupranate® MI(BASF)和Isonate®50O,P'(Dow Chemical)。
二醇类
适合作为用于制备根据本发明的氨基甲酸酯预聚物的其它原料的二醇化合物包括至少一种二醇化合物,其具有:(i)能够与多异氰酸酯反应的两个羟基;和(ii)在中和时能够形成盐并且不能与多异氰酸酯(b)反应的至少一种羧酸基团。具有羧酸基团的二醇化合物的典型实例包括2,2-二甲基丙酸(DMPA)、2,2-二甲基丁酸(2,2-dimethylobutanoicacid)、2,2-二甲基戊酸和DMPA引发的己内酯例如CAPA®HC 1060(Solvay)。在本发明中DMPA是优选的。
中和剂
将酸基团转化成盐基团的合适中和剂的实例包括:叔胺类(例如三乙胺、N,N-二乙基甲胺、N-甲基吗啉、N,N-二异丙基乙胺和三乙醇胺)和碱金属氢氧化物(例如锂、钠和钾的氢氧化物)。伯胺和/或仲胺类也可以用作酸基团的中和剂。中和度通常在酸基团的约60%至约140%之间,例如在约80%至约120%的范围内。
扩链剂
可用于本发明的扩链剂包括二胺扩链剂和水。有用的扩链剂的许多实例是本领域普通技术人员已知的。合适的二胺扩链剂的实例包括:1,2-乙二胺、1,4-丁二胺、1,6-六亚甲基二胺、1,12-十二烷二胺、1,2-丙二胺、2-甲基-1,5-戊二胺、1,4-环己烷二胺、4,4'-亚甲基-双(环己胺)、异佛尔酮二胺、2,2-二甲基-1,3-丙二胺、间四甲基二甲苯二胺和分子量小于500的Jeffamine®(Texaco)。当期望聚氨酯时,可以包括二醇扩链剂。
表面活性剂
合适的表面活性试剂(表面活性剂)的实例包括:阴离子、阳离子或非离子分散剂或表面活性剂,例如十二烷基硫酸钠、二辛基磺基琥珀酸钠、十二烷基苯磺酸钠、乙氧基化烷基酚类如乙氧基化壬基酚类和乙氧基化脂肪醇类、月桂基溴化吡啶鎓、聚醚磷酸酯类和磷酸酯类、改性醇-乙氧基化物类,及其组合。
封端剂
用于异氰酸酯基团的封端剂可以是单官能醇或单官能胺。封端剂可以在形成预聚物之前,形成预聚物期间或形成预聚物之后的任何时间加入,包括在将预聚物分散在水性介质如去离子水中之前和之后。在一些实施例中,封端剂是任选的,或可以被排除。在其它实施例中,以预聚物的重量计,封端剂可以约0.05%至约10.0%,包括约0.1%至约6.0%和约1.0%至约4.0%的量纳入。以最终分散体的重量计,封端剂可以以约0.01%至约6.0%,包括约0.05%至约3%和约0.1%至约1.0%的量存在。
封端剂的纳入允许控制分散体中聚合物的重均分子量以及提供对聚合物分子量分布的控制。封端剂提供此类控制的有效性取决于封端剂的类型和在制备分散体期间加入封端剂的时间。例如,可以在形成预聚物之前,期间或之后加入单官能醇。单官能醇封端剂也可以加入分散有预聚物的水性介质中,或在预聚物分散在水性介质中后立即加入。然而,当需要控制聚合物分子量和在最终分散体中的分子量分布时,如果加入单官能醇并且在分散之前作为预聚物的一部分反应,则单官能醇可能是最有效的。如果在分散预聚物期间或之后将单官能醇加入到水性介质中,则由于竞争性扩链反应,其在控制聚合物分子量方面的有效性将降低。
可用于本发明的单官能醇的实例包括选自由具有1至18个碳的脂肪族和脂环族伯和仲醇类、酚、取代的酚类、乙氧基化的烷基酚类和分子量小于约750,包括分子量小于500的乙氧基化的脂肪醇类、羟胺类,羟甲基和羟乙基取代的叔胺类,羟甲基和羟乙基取代的杂环化合物及其组合组成的群组的至少一个成员,包括糠醇、四氢糠醇、N-(2-羟乙基)琥珀酰亚胺、4-(2-羟乙基)吗啉、甲醇、乙醇、丁醇、新戊醇、己醇、环己醇、环己烷甲醇、苯甲醇、辛醇、十八烷醇、N,N-二乙基羟胺、2-(二乙基氨基)乙醇、2-二甲基氨基乙醇,和4-哌啶乙醇,及其组合。
当单官能胺化合物如单官能二烷基胺用作异氰酸酯基团的封端剂时,也可以在制备分散体期间的任何时候加入,期望地在预聚物分散体期间或之后将单官能胺封端剂加入水中。例如,可以在预聚物分散后立即将单官能胺封端剂加入水混合物中。
合适的单官能二烷基胺封端剂的实例包括:N,N-二乙胺、N-乙基-N-丙胺、N,N-二异丙胺、N-叔丁基-N-甲胺、N-叔丁基-N-苄基胺、N,N-二环己基胺、N-乙基-N-异丙基胺、N-叔丁基-N-异丙基胺、N-异丙基-N-环己基胺、N-乙基-N-环己基胺、N,N-二乙醇胺和2,2,6,6-四甲基哌啶。在水中分散之前,胺封端剂与预聚物的异氰酸酯基团的摩尔比通常应在约0.05至约0.50的范围内,例如约0.20至约0.40。催化剂可用于去封端反应。
任选地,在预聚物分散和加入封端剂后,可以向水性介质中加入每摩尔聚合物具有至少三个或更多个伯和/或仲氨基的至少一种聚合物组分(MW>约500)。合适的聚合物组分的实例包括聚乙烯亚胺、聚(乙烯基胺)、聚(烯丙基胺)和聚(酰胺基胺)树枝状聚合物及其组合。
其它添加剂
合适的消泡剂或去泡剂或泡沫控制剂的实例包括:Additive 65和Additive 62(来自Dow Corning的硅氧烷类添加剂),FoamStar® I 300(来自Cognis的矿物油类无硅去泡剂)和SurfynolTMDF 110L(来自Air Products&Chemicals的高分子量炔属二醇非离子表面活性剂)。
合适的流变改性剂的实例包括:疏水改性的乙氧基化氨基甲酸酯(HEUR)、疏水改性的碱溶胀性乳液(HASE)和疏水改性的羟乙基纤维素(HMHEC)。
可任选地包括在水性分散体或预聚物中的其它添加剂包括:抗氧化剂、UV稳定剂、着色剂、颜料、交联剂、相变材料(即,Outlast®,可从Outlast Technologies,Boulder,科罗拉多州商购)、抗微生物剂、矿物质(即铜)、微胶囊化的健康添加剂(即芦荟、维生素E凝胶、芦荟、海带、尼古丁、咖啡因、气味剂(scents)或熏香料(aromas))、纳米颗粒(即二氧化硅或碳)、碳酸钙、阻燃剂、防粘添加剂、耐氯降解添加剂、维生素、药物、香料(fragrances)、电传导添加剂和/或染料助剂。可以加入到预聚物或水性分散体中的其它添加剂包含粘合促进剂、抗静电剂、抗缩孔剂、抗爬行剂、荧光增白剂、聚结剂、导电添加剂、发光添加剂、流平剂、冻融稳定剂、润滑剂、有机和无机填料、防腐剂、增稠剂、热变色添加剂、驱虫剂和润湿剂。
可以在预聚物分散之前、期间或之后将任选的添加剂加入水性分散体中。
在预聚物混合过程中,预聚物可以通过在一个步骤中将原料即多元醇、多异氰酸酯和二醇化合物混合在一起并且通过在约50℃至约100℃的温度下反应足够时间直到所有羟基基本上被消耗并达到异氰酸酯基的所需%NCO。或者,所述预聚物可以两个步骤制备,首先使多元醇与过量的多异氰酸酯反应,然后与二醇化合物反应,直到实现预聚物的最终所需的%NCO。例如,%NCO可以在约1.3至约6.5的范围内,例如约1.8至约2.6。重要的是,不需要有机溶剂,但可以在反应之前、期间或之后与原料一起添加或混合。任选地,可以使用催化剂以促进预聚物形成。
在一些实施例中,预聚物包括多元醇、多异氰酸酯和二醇,它们组合在一起并且以预聚物的总重量计以以下重量百分比范围提供:
约34%至约89%的多元醇,包括约61%至约80%;
约10%至约59%的多异氰酸酯,包括约18%至约35%;和
约1.0%至约7.0%的二醇化合物,包括约2.0%至约4.0%。
单官能醇可以与预聚物一起纳入以控制完全分散体中的聚氨酯脲聚合物的重均分子量。
由多元醇、多异氰酸酯、二醇化合物和任选的封端剂如单官能醇制备的预聚物可具有低于约6000泊(包括低于约4,500泊)的体积粘度(存在或不存在溶剂),通过在40℃下的落球法测量。沿着聚合物链(来自二醇化合物)含有羧酸基团的这种预聚物可以用高速分散机分散到去离子水介质中,所述去离子水介质包括:至少一种中和剂,以与酸形成离子盐;至少一种表面活性剂(离子和/或非离子分散剂或表面活性剂);和任选的至少一种扩链组分。或者,中和剂可以在分散到水性介质中之前与预聚物混合。可以在预聚物分散之前、期间或之后将至少一种消泡剂和/或去泡剂和/或至少一种流变改性剂加入到水性介质中。
聚氨酯水性分散体可具有宽范围的固体含量,这取决于分散体的所需最终用途。对于一些实施例的分散体的合适的固体含量的实例包括约10重量%至约50重量%,例如约30重量%至约45重量%。
聚氨酯水性分散体的粘度也可以在约10厘泊至约100,000厘泊的宽范围内变化,这取决于加工和应用要求。例如,在一个实施例中,粘度在约500厘泊至约30,000厘泊的范围内。可以通过使用适当量,例如以水性分散体的总重量计约0至约2.0重量%的增稠剂来改变粘度。
在溶剂法或丙酮法中,有机溶剂也可用于制备一些实施例的膜和分散体。有机溶剂通过溶解和稀释可以用于降低预聚物粘度和/或有助于具有羧酸基团例如2,2-二甲基丙酸(DMPA)的二醇化合物的固体颗粒的分散以提高分散质量。它还可以用于改善膜均匀性,例如减少涂布/成膜过程中的条纹和裂纹的目的。
为这些目的选择的溶剂对异氰酸酯基团基本上或完全不反应,在水中稳定,并且对DMPA、DMPA和三乙胺形成的盐和预聚物具有良好的溶解能力。合适的溶剂的实例包括N-甲基吡咯烷酮、N-乙基吡咯烷酮、二丙二醇二甲醚、丙二醇正丁醚乙酸酯、N,N-二甲基乙酰胺、N,N-二甲基甲酰胺、2-丙酮(丙酮)和2-丁酮(丁酮或MEK)。
在溶剂法中,加入到一些实施例的膜/分散体中的溶剂的量可以变化。当包括溶剂时,溶剂的合适范围包括小于分散体的50重量%的量。还可以使用较小的量,例如小于分散体重量的20重量%,小于分散体重量的10重量%,小于分散体重量的5重量%和小于分散体重量的3重量%。
在丙酮法中,在制备分散体之前,可以将较大量的溶剂加入到预聚物组合物中。或者,预聚物可以在溶剂中制备。在预聚物分散之后,例如在真空下,也可以从分散体中除去溶剂。
在制造过程的不同阶段有许多方式将有机溶剂引入分散体中,例如:
1)在聚合完成之后转移和分散预聚物之前,可以将溶剂加入到预聚物中并与其混合,当其分散在水中的同时,在含有主链中的羧酸基团(来自二醇化合物)和链端的异氰酸酯基团的稀释的预聚物被中和并且扩链。
2)可以加入溶剂并与其它成分如多元醇、多异氰酸酯和二醇化合物混合以在溶液中制备预聚物,然后在溶液中含有主链中的羧酸基团和链端的异氰酸酯基团的所述预聚物分散在水中并同时被中和并扩链。
3)溶剂可以在分散之前与二醇化合物的中和盐和中和剂一起加入,并与多元醇和多异氰酸酯混合,以制备预聚物。
4)溶剂可以与TEA混合,然后在分散之前加入到形成的预聚物中。
5)可以加入溶剂并与多元醇混合,然后在分散之前向溶液中的中和的预聚物中依次加入二醇化合物和中和剂,然后加入多异氰酸酯。
6)也可以从分散体中除去溶剂,特别是在丙酮法的情况下。
衍生自聚氨酯分散体的涂料、分散体、膜或成形制品可以是染色的或着色的,并且还可以用作设计元件。
用于施用一些实施例的聚氨酯脲组合物的方法和手段包括但不限于:辊涂(包括逆辊涂布);使用金属工具或刀片(例如,将分散体倾倒在基底上,然后通过使用金属工具例如刀片将分散体散布在基底上而将分散体铸造成均匀的厚度);喷雾(例如,使用泵喷雾瓶);浸泡;涂漆;印刷;冲压;并且浸渍制品。这些方法可用于将分散体直接施用到基底上而不需要另外的粘合剂材料,并且如果需要额外的/更重的层,则可以重复。分散体可以施用于任何基底,包括模具或织物。织物可以包括用于涂布、粘结、层压和粘合目的,由合成、天然或合成/天然共混材料制成的针织物、纺织物或非织造物。
在加工期间(例如,通过空气干燥或使用烘箱),可以通过干燥除去分散体中的水。制品可以在任何合适的条件下固化。这可以包括高达约200℃的温度,例如约140℃至约200℃下持续包括约90秒至约120秒的任何合适的时间。
膜、溶液和分散体的厚度可以根据应用而变化。在成型制品的情况下,每层膜的最终厚度可以例如为约0.1密耳至约250密耳,例如约0.5密耳至约25密耳,包括约1密耳至约6密耳(1密耳=千分之一英寸)。合适厚度的其它实例包括约0.5密耳至约12密耳,约0.5至约10密耳和约1.5密耳至约9密耳。
可以以通过单位面积上的分散体的重量描述的任何合适的量将水性分散体施用到基底或模具上。所用的量可以例如为约2.5g/m2至约6.40kg/m2,例如约12.7-约635g/m2,包括约25.4-约152.4g/m2
用于制备制品的方法可以包括首先提供施用有表面活性剂或润湿剂的合适的基底或模具。这之后是添加可通过任何合适的方法添加的纤维阵列。美国专利3,917,883描述了一种用于将纤维阵列提供到模具表面上的合适方法。这可以通过静电手段实现,使得纤维由于静电场的影响而相对于模具或基底基本垂直地定向。这些纤维可以以任何所需的方式提供。这可以包括基本均匀的分布或图案。当以这种方式取向时,纤维的端部可以延伸超出制品中固化/干燥的分散体的表面。
聚氨酯分散体可以通过任何合适的方法例如喷雾、涂漆、涂布等来添加。可以添加纤维或聚氨酯分散体的另外的层,随后是最后一层纤维阵列。可以包括任何合适数量的层,例如1至50层,这取决于所需的厚度和其它性质。
或者,纤维可以以另一种方式与分散体组合。这可以包括分散体与纤维的组合以提供可以成型的制品。它们的纤维也可制备成包括分散体的非织造织物,例如纺粘或熔融粘结织物。在制备中,纤维/分散体组合可以施用到基底例如带/输送带。
可以使用分散体和成形制品生产的终制品包括但不限于:服装,其包括任何类型的衣服或布料制品;针织手套;室内装饰品;发饰;床单;地毯和地毯背衬;输送带;医疗应用,如拉伸绷带;个人护理用品,包括失禁和女性卫生用品;和鞋类。
可以使用落入本发明范围内的分散体和成型制品生产的服装或衣服的实例包括但不限于:贴身衣、胸罩、内裤、内衣、泳装、成型裤、吊带裤、靴袜、睡衣、围裙、潜水衣、领带、毛巾、太空服、制服、帽子、衣帽带、汗带、皮带、运动服、外衣、雨衣、寒冷天气夹克、裤子、衬衫、裙子、短衫、男士和女士上衣、毛衣、胸衣、背心、短衬裤、袜子、膝盖高、连衣裙、短衫、围裙、无尾礼服、阿拉伯袍子(bisht)、黑纱袍(abaya)、头巾(hijab)、长袍(jilbab)、白袍(thoub)、罩袍(burka)、披风、服饰、潜水服、褶裥短裙(kilt)、和服、球衣(jerseys)、法衣、防护服、纱丽、布裙、裙子、鞋罩(spats)、面纱(stola)、套装、束身衣、宽外袍、紧身裤、毛巾、制服、面罩、潜水衣、医用压缩服装、绷带、西服衬里、腰带及其中的所有部件。
本发明的另一方面是包含成形制品和基底的制品,其中成形制品和基底附接以形成层压体,由此弹性层压体的摩擦系数大于单独基底的摩擦系数。其实例是具有包含水性聚氨酯分散体的涂层或膜的腰带,其防止衣服从另一衣服(诸如女衬衫或衬衫)的滑脱,或者防止腰带在衣服穿着者的皮肤上滑脱。
本发明的另一方面是包含聚氨酯脲组合物和基底的制品,其中成形制品的模量沿制品的长度或者宽度变化。例如,基底(如织物)可以用两英尺(61cm)的聚氨酯脲组合物(如一英寸(2.5 cm)宽的胶带)处理。可以通过沿着一英寸宽的胶带的长度涂布三个两英寸(5cm)×一英寸的片段以形成复合结构来施用附加的粘合剂层。
由水性聚氨酯分散体形成的制品可以具有以下性质:
- 在约0至10%,例如约0至5%,典型地约0至约3%的伸长率下定型,
-伸长率为约400至约800%
-韧度为约0.5至约3Mpa,
-透气率为至少约0至约0.5cfm或更高,和
-在24小时内至少约0至约500g/m2,包括在24小时内约50至约1000g/m2或在24小时内约100至约500g/m2的水蒸汽渗透率。湿气透过率可根据ASTM标准E 96-00“材料的水蒸气透过的标准测试方法(Standard Test Methods for Water Vapor Transmission ofMaterials)”进行测试。
尽管已经描述了目前被认为是本发明的优选实施例的内容,但是本领域技术人员将认识到,在不脱离本发明的精神的情况下,可以对其进行改变和修改,包括落入本发明的真实范围内的所有这样的改变和修改。

Claims (11)

1.一种制品,其包含聚氨酯组合物和纤维阵列,其中所述纤维阵列嵌入所述聚氨酯组合物中,使得所述纤维的一部分延伸超出所述成型制品的内表面和所述成型制品的外表面。
2.根据权利要求1所述的制品,其在24小时或更长时间内具有约100g/m2的水蒸气输送。
3.根据权利要求1所述的制品,其中所述聚氨酯组合物由聚氨酯分散体形成。
4.根据权利要求1所述的制品,其中所述制品是成型的。
5.一种用于制备制品的方法,其包含:
(a)提供具有制品接触表面的基底,其中所述制品接触表面包括表面活性剂或润湿剂;
(b)将内部纤维阵列施用到所述制品接触表面;
(c)将聚氨酯分散体施用到所述纤维阵列;
(d)将外部纤维阵列施用到所述分散体;
(e)干燥所述制品;
(f)从所述基底移出所述制品。
6.根据权利要求5所述的方法,其中所述基底是模具。
7.根据权利要求5所述的方法,其还包括在施用所述外部纤维阵列之前施用多于一个的附加的聚氨酯分散体层。
8.根据权利要求7所述的方法,其还包括在添加一个或多个附加的聚氨酯分散体层之前施用一个或多个附加的纤维阵列。
9.根据权利要求5所述的方法,其中所述聚氨酯分散体包含聚氨酯脲。
10.根据权利要求5所述的方法,其中所述内部纤维阵列和所述外部纤维阵列嵌入聚氨酯分散体层中并且部分地延伸超出所述制品的内表面和外表面。
11.根据权利要求5所述的方法,其中所述制品选自由服装、袖套、绷带和手套组成的群组。
CN201580030966.2A 2014-06-11 2015-06-10 包括水性聚氨酯组合物的分散体和膜 Pending CN106795693A (zh)

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