CN109689718A - 用于微纤维非编织合成皮革应用的耐化学pud和方法 - Google Patents

用于微纤维非编织合成皮革应用的耐化学pud和方法 Download PDF

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CN109689718A
CN109689718A CN201680088989.3A CN201680088989A CN109689718A CN 109689718 A CN109689718 A CN 109689718A CN 201680088989 A CN201680088989 A CN 201680088989A CN 109689718 A CN109689718 A CN 109689718A
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microfibre
polyester
dispersion liquid
urethane prepolymer
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何超
章翼
曲朝晖
张朝
邰向阳
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Dow Global Technologies LLC
Rohm and Haas Co
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Abstract

本发明提供一种聚氨基甲酸酯分散液,其包括聚氨基甲酸酯预聚物和离子表面活性剂。其另外提供一种微纤维非编织合成皮革,其包括微纤维非编织物和所述聚氨基甲酸酯分散液。其另外提供一种制备所述微纤维非编织合成皮革的方法,其包括将浸没的微纤维非编织物浸没至所述聚氨基甲酸酯分散液中的步骤。

Description

用于微纤维非编织合成皮革应用的耐化学PUD和方法
技术领域
本发明涉及新颖的耐化学聚氨基甲酸酯分散液,其在微纤维非编织合成皮革制备中的应用以及应用方法。
背景技术
微纤维非编织合成皮革为人造皮革中真皮的原纤维样结构的最佳模拟物。随着微纤维非编织合成皮革的市场增长,这一领域中的研究热点显著增加。微纤维非编织合成皮革通常通过用如二甲基甲酰胺(DMF)聚氨基甲酸酯树脂的基于溶剂的黏着剂浸没非编织物来黏合材料并且赋予其与真皮类似的机械特性和手感来制备。这些溶剂在制造和制造后期间蒸发,导致制造工作人员、合成皮革的最终使用者以及环境的可能的健康问题。随着研究的发展,使用不含溶剂或水性聚氨基甲酸酯分散液代替典型的基于溶剂的聚氨基甲酸酯树脂。聚氨基甲酸酯分散液为聚氨基甲酸酯粒子于水中的水性乳液,其具有高固体含量、小粒径以及长期稳定性(高达六个月或更久)。然而,典型聚氨基甲酸酯分散液不能经受微纤维非编织合成皮革制备中的极严格后续甲苯/碱性溶解工艺,即不可避免的高温或与甲苯/碱溶液接触。
因此,仍需要一种新颖聚氨基甲酸酯分散液来应用于微纤维非编织合成皮革制备中。特定来说,新颖聚氨基甲酸酯分散液应耐化学试剂,尤其耐甲苯和碱。
本发明提供聚氨基甲酸酯分散液,其包括聚氨基甲酸酯预聚物和离子表面活性剂。聚氨基甲酸酯预聚物包括以聚氨基甲酸酯预聚物的总干重计25干重%至40干重%单体芳香族二异氰酸酯和20干重%至85干重%聚醚多元醇作为聚合单元。聚氨基甲酸酯预聚物的异氰酸酯含量(“NCO%”)为3%至10%。
本发明另外提供微纤维非编织合成皮革,其包括微纤维非编织物和聚氨基甲酸酯分散液。
本发明另外提供制备微纤维非编织合成皮革的方法,其包括将微纤维非编织物浸没至聚氨基甲酸酯分散液中的步骤。
具体实施方式
本发明的聚氨基甲酸酯分散液通过借助于离子表面活性剂将聚氨基甲酸酯预聚物分散至水中来制备。
聚氨基甲酸酯预聚物包括以聚氨基甲酸酯预聚物的总干重计25干重%至40干重%,或28干重%至35干重%,以及高于28干重%或28干重%至32干重%的单体芳香族二异氰酸酯和20干重%至85干重%或25干重%至80干重%,或30干重%至75干重%聚醚多元醇作为聚合单元。
任选地,聚氨基甲酸酯预聚物另外包括以聚氨基甲酸酯预聚物的总干重计0.1干重%至30干重%,或18干重%至28干重%,或20干重%至25干重%聚酯多元醇作为聚合单元。
单体芳香族二异氰酸酯或分子量Mw低于500g/mol,或低于300g/mol以及高于或低于275g/mol。
在一些实施例中,单体芳香族二异氰酸酯选自亚甲基二苯基二异氰酸酯(MDI)、甲苯二异氰酸酯(TDI)和其组合。一般可以使用具有任何通常可用的异构体分布的TDI。最常用的TDI具有80%2,4-异构体和20%2,6-异构体的异构体分布。还可以使用具有其它异构体分布的TDI。当MDI用于制备聚氨基甲酸酯预聚物时,可以使用纯4,4'-MDI,或MDI异构体的任何组合。在一些实施例中,使用纯4,4'-MDI和4,4'-MDI与其它MDI异构体的任何组合。当使用4,4'-MDI与其它MDI异构体的组合时,4,4'-MDI于组合中的优选浓度为全部MDI异构体的25%至75%。
聚醚多元醇为环氧乙烷、环氧丙烷、四氢呋喃和环氧丁烷的加成聚合产物和接枝产物、多元醇的缩合产物和其任何组合。聚醚多元醇的适合实例包含(但不限于)聚丙二醇(PPG)、聚乙二醇(PEG)、聚丁二醇、聚四亚甲基醚二醇(PTMEG)和其任何组合。在一些实施例中,聚醚多元醇为PEG与选自上述加成聚合和接枝产物和缩合产物的至少一种另一聚醚多元醇的组合。在一些实施例中,聚醚多元醇为PEG与PPG、聚丁二醇和PTMEG中的至少一个的组合。
聚酯多元醇是二醇与二羧酸和其衍生物的缩合产物或其衍生物。
二醇的适合实例包含(但不限于)乙二醇、丁二醇、二乙二醇、三乙二醇、聚烷二醇(如聚乙二醇)、1,2-丙二醇、1,3-丙二醇、2-甲基-1,3-丙二醇、1,3-丁二醇、1,4-丁二醇、1,6-己二醇、新戊二醇、3-甲基-1,5-戊二醇和其任何组合。为了实现多元醇官能度大于2,还可以使用三醇和/或四醇。这类三醇的适合实例包含(但不限于)三羟甲基丙烷和丙三醇。这类四醇的适合实例包含(但不限于)赤藻糖醇和季戊四醇。
二羧酸选自芳香族酸、脂肪族酸和其组合。芳香族酸的适合实例包含(但不限于)邻苯二甲酸、间苯二甲酸和对苯二甲酸;而脂肪族酸的适合实例包含(但不限于)己二酸、壬二酸、癸二酸、戊二酸、四氯邻苯二甲酸、顺丁烯二酸、反丁烯二酸、衣康酸、丙二酸、辛二酸、2-甲基丁二酸、3,3-二乙基戊二酸以及2,2-二甲基丁二酸。同样可使用这些酸的酸酐。对于本发明,酸酐因此由术语“酸”的表述涵盖。在一些实施例中,脂肪族酸和芳香族酸是饱和的,并且分别是己二酸和间苯二甲酸。如苯甲酸和己烷羧酸的单羧酸应减至最少或排除。
聚酯多元醇还可以通过内酯与二醇、三醇和/或四醇的加成聚合来制备。内酯的适合实例包含(但不限于)己内酯、γ-丁内酯和戊内酯。二醇的适合实例包含(但不限于)乙二醇、丁二醇、二乙二醇、三乙二醇、聚烷二醇(如聚乙二醇)、1,2-丙二醇、1,3-丙二醇、2-甲基-1,3-丙二醇、1,3-丁二醇、1,4-丁二醇、1,6-己二醇、新戊二醇、3-甲基-1,5-戊二醇和其任何组合。三醇的适合实例包含(但不限于)三羟甲基丙烷和丙三醇。四醇的适合实例包含赤藻糖醇和季戊四醇。
聚醚多元醇和聚酯多元醇各自的分子量Mw为400至4000g/mol,或750至3500g/mol,或800至3000g/mol。聚醚多元醇和聚酯多元醇各自的官能度为1.8至4,或1.9至3,或2至2.5。
聚氨基甲酸酯预聚物的制备为所属领域的普通技术人员已知的任何方式,并且包含缩聚。聚氨基甲酸酯预聚物调配物公开内容的化学计量使得二异氰酸酯过量存在,并且聚氨基甲酸酯预聚物经NCO基团封端。在一些实施例中,聚氨基甲酸酯预聚物的异氰酸酯含量(也称为NCO%,如通过ASTM D2572所测量)为3%至10%,或4%至9%,或5%至8%。
有机溶剂优选不用于制备聚氨基甲酸酯预聚物。
在制备本发明的聚氨基甲酸酯分散液的实践中,离子表面活性剂可以在水添加之前引入至聚氨基甲酸酯预聚物中,但表面活性剂在聚氨基甲酸酯预聚物添加之前引入水中并没有超出本发明的范围。
以聚氨基甲酸酯分散液的总干重计,离子表面活性剂为0.5干重%至10干重%,或1干重%至8干重%,或1.5干重%至6干重%。
离子表面活性剂可以是阴离子型。阴离子表面活性剂的适合实例包含(但不限于)磺酸盐、磷酸盐、羧酸盐和其任何组合。在一些实施例中,阴离子表面活性剂为磺酸盐,如十二烷基苯磺酸钠、十二烷基磺酸钠、十二烷基二苯醚二磺酸钠、正癸基二苯醚二磺酸钠、十二烷基苯磺酸异丙胺和己基二苯醚二磺酸钠。在一些实施例中,阴离子表面活性剂为十二烷基苯磺酸钠。
当制备聚氨基甲酸酯分散液时,预聚物可以通过单独的水延长或可以使用增链剂,如所属领域中已知的增链剂或随后发现的增链剂延长。当使用时,增链剂可以是任何异氰酸酯反应性多元胺或具有另一异氰酸酯反应性基团并且分子量是60至450g/mol的胺。增链剂的适合实例包含(但不限于)乙二胺(EDA)、1,2-和1,3-二氨基丙烷、1,4-二氨基丁烷、1,6-二氨基己烷、异佛尔酮二胺、胺化聚醚二醇、哌嗪、氨基乙基乙醇胺(AEEA)、乙醇胺和其任何组合。在一些实施例中,以聚氨基甲酸酯分散液的总干重计,增链剂为0.1干重%至8干重%,或0.2干重%至6干重%,或0.5干重%至5干重%。
在一些实施例中,聚氨基甲酸酯分散液另外包括一种或多种选自以下组成的组的已知或随后发现的添加剂:水、流变改质剂、填充剂、阻燃剂、颜料、流动添加剂、手感添加剂、抗氧化剂、抗UV添加剂和其两个或更多个的组合。
微纤维非编织合成皮革为用如聚氨基甲酸酯的聚合物浸没的微纤维非编织物,上面随后可以具有聚合物涂料。
在一个实施例中,微纤维非编织物用本发明的聚氨基甲酸酯分散液直接浸没产生微纤维非编织合成皮革。微纤维非编织物包括纤维,如“海岛”型纤维。纤维的“海”组分可以溶解,导致具有小尺寸的超细纤维束。获得的织物具有软和柔韧的感觉。本发明的聚氨基甲酸酯分散液可以抵抗从海岛型纤维溶解“海”组分时遭遇的条件。
制造微纤维非编织物的方法包含所属领域中已知或随后发现的方法。通常,通过将两种聚合物馈入纺丝头使得“海”组分包围其它“岛”长丝组分来制备具有两种组分的“海岛”型纤维,即纺丝两种组分的纤维。“海”组分通常可溶于有机溶剂,如甲苯或碱溶液中。“海”组分可以包括聚乙烯(PE)或聚对苯二甲酸乙二酯(PET),并且“岛”组分通常不溶并且可以包括聚酰胺(PA)。
用于两种组分纤维纺丝的“岛”组分与“海”组分之间的重量比可以介于20:80与80:20之间。在一些实施例中,组分的重量比为50:50。
聚氨基甲酸酯分散液可以具有聚氨基甲酸酯粒子的任何适合固体负载量。在一些实施例中,以总分散液重量计,固体负载量为1重量%至50重量%固体,以促进浸没至非编织物中。
聚氨基甲酸酯分散液还可以含有流变改质剂,如增稠剂,以增加凝固之前分散液在非编织物中的滞留。可使用任何适合流变改质剂,如所属领域中已知和随后发现的流变改质剂。在一些实施例中,流变改质剂是不导致分散液变得不稳定的流变改质剂。流变改质剂的适合实例包含(但不限于)甲基纤维素醚、碱性可膨胀增稠剂(例如钠或铵中和的丙烯酸聚合物)、疏水性改质的碱性可膨胀增稠剂(例如疏水性改质的丙烯酸共聚物)和缔合型增稠剂(例如疏水性改质的基于环氧乙烷的氨基甲酸酯嵌段共聚物)。增稠剂的量可以是任何适用量,并且以聚氨基甲酸酯分散液的总重量计通常为0.1重量%至5重量%。在一些实施例中,增稠剂的量为0.3%至2%,而聚氨基甲酸酯分散液的黏度在室温下控制为1000至12000mPa.s,如通过BROOKFIELDTM LV-T黏度计使用转轴3在速度6下所测量。
如所属领域中已知和随后发现的其它添加剂也可以添加至聚氨基甲酸酯分散液中以赋予浸没的微纤维非编织合成皮革所需特征,如提高的柔软度或改良的紫外线稳定性。
聚氨基甲酸酯分散液通过所属领域已知或随后发现的任何适合方法浸没,包含浸渍、喷洒或刀片刮抹。浸没之后,浸没的微纤维非编织物可以去除过量分散液或水,在微纤维非编织物内留下所需量的分散液。通常,这可以通过使浸没的纺织物穿过橡胶辊来实现,其中一般聚氨基甲酸酯浸没的量(加入量)为以干重计200至1200g/m2。浸没的微纤维非编织物随后在100至130℃的温度下在烘箱中干燥持续5至20分钟,形成浸没的衬底织物。接着,使织物进行甲苯或碱性溶解工艺,去除微纤维的“海”组分,形成微纤维非编织合成皮革衬底。
实例
实例中所用的相关原料在表1中详述。
表1:原料
II.工艺
1.耐甲苯性评估
将4g下文所述的各聚氨基甲酸酯分散液(35重量%)添加至直径为9.5cm的盘中并且保持24至48小时来蒸发水。去除水之后,盘在130℃下烘烤20分钟。聚氨基甲酸酯分散液膜接着切割且称重(重量一(克)),接着在130℃下置于回流甲苯中以供溶解。在3小时溶解中,在130℃下干燥剩余的膜持续20分钟,接着称重(重量二(克))。将重量二除以重量一来计算剩余(%)。
2.耐碱性评估
将4g下文所述的各聚氨基甲酸酯分散液(35重量%)添加至直径为9.5cm的盘中并且保持24至48小时来蒸发水。去除水之后,盘在130℃下烘烤20分钟。聚氨基甲酸酯分散液膜接着切割且称重(重量一(克)),接着在130℃下置于回流NaOH(10重量%)中以供溶解。在3小时溶解中,在130℃下干燥剩余的膜持续20分钟,接着称重(重量二(克))。将重量二除以重量一来计算剩余(%)。
3.微纤维非编织合成皮革的耐甲苯评估
将微纤维非编织物称重(重量一(克))接着浸没于聚氨基甲酸酯分散液(25重量%)中持续10秒,随后用间隙控制辊挤压浸没的微纤维非编织物。此后,浸没的微纤维非编织物在90℃烘箱中干燥10分钟,接着在150℃下干燥20分钟,接着称重(重量二(克))。将干燥的微纤维非编织物浸渍于回流甲苯(约130℃)中持续约3小时,在130℃下干燥20分钟,接着称重(重量三(克))。根据以下等式计算剩余:(重量三-重量一/2)/(重量二-重量一)。每种样品进行两次测试。
III.实例
1.说明性实例1(IE1)
添加680g VORANOLTM 9287聚醚多元醇和20g CARBOWAXTM甲氧基聚乙二醇并且在装备有机械分散搅拌器、滴液漏斗和气体引入管的5000ml圆形三颈玻璃烧瓶中混合。混合物在氮气流下隔夜,接着在130℃下加热1小时以去除水。
在氮气流下将300g二异氰酸二苯基甲酯和0.042g苯甲酰氯添加至装备有机械分散搅拌器、滴液漏斗和气体引入管的500ml圆底三颈玻璃烧瓶,并且加热至80℃。将上文所制备的干燥混合物添加至500ml烧瓶且在80℃下反应4小时,接着冷却至室温来制备预聚物。
将270g预聚物和35.7g RHODACALTM DS-4十二烷基苯磺酸钠添加至1L塑料烧杯中且在3000rpm下用机械分散搅拌器搅拌。接着将152g冰水缓慢倒入烧杯中且在400-500rpm下搅拌。接着向烧杯添加66g氨基乙基乙醇胺。接着将混合物保持一周进行脱气。所得产物为说明性聚氨基甲酸酯分散液实例1(IE1)。
2.说明性实例2(IE2)
根据制备说明性聚氨基甲酸酯分散液实例1(IE1)的相同程序,但使用不同增链剂乙二胺来制备说明性聚氨基甲酸酯分散液实例2(IE2)。
3.比较例1(CE1)
根据与制备说明性聚氨基甲酸酯分散液实例1(IE1)相同的程序,但使用不同异氰酸酯,266.4g相同浓度的异佛尔酮二异氰酸酯来制备聚氨基甲酸酯分散液比较例1(CE1)。
4.比较例2(CE2)
聚氨基甲酸酯分散液比较例2(CE2)为IMPRANILTM DL 1380基于脂肪族异氰酸酯的聚氨基甲酸酯分散液,其可购自拜耳公司(Bayer Company)。
5.比较例3和4(CE3和CE4)
根据与制备说明性聚氨基甲酸酯分散液实例1(IE1)相同的程序,但使用154g二异氰酸二苯基甲酯和不同增链剂来制备聚氨基甲酸酯分散液比较例3和4(CE3和CE4)。
各聚氨基甲酸酯分散液实例的具体组分显示于表2中。
表2:实例组成物
IV.结果
表3:耐甲苯性
重量一(g) 重量二(g) 剩余(%)
IE1 0.4488 0.4384 97.7
IE2 0.4696 0.4581 97.5
CE1 0.4864 0 0
CE2 0.6237 0 0
CE3 0.4671 0 0
CE4 0.4700 0.0865 18.4
表4:耐碱性
重量一(g) 重量二(g) 剩余(%)
IE1 0.5589 0.5587 100.0
CE1 0.4082 0.3502 85.8
CE2 0.7177 0.7036 98.0
表5:微纤维非编织合成皮革的耐甲苯性
如表3至5中所示,仅专门设计的聚氨基甲酸酯分散液,即经特定浓度的单体芳香族二异氰酸酯制备的聚氨基甲酸酯分散液,可实现本发明的目标。

Claims (11)

1.一种聚氨基甲酸酯分散液,包括:
聚氨基甲酸酯预聚物,其包括以所述聚氨基甲酸酯预聚物的总干重计25干重%至40干重%单体芳香族二异氰酸酯和20干重%至85干重%聚醚多元醇作为聚合单元;以及
离子表面活性剂。
2.根据权利要求1所述的聚氨基甲酸酯分散液,其中所述聚氨基甲酸酯预聚物另外包括以所述聚氨基甲酸酯预聚物的总干重计0.1干重%至30干重%聚酯多元醇作为聚合单元。
3.根据权利要求1所述的聚氨基甲酸酯分散液,其中所述聚氨基甲酸酯预聚物的NCO%为3%至10%。
4.根据权利要求1所述的聚氨基甲酸酯分散液,其中有机溶剂不用于制备所述聚氨基甲酸酯预聚物。
5.一种微纤维非编织合成皮革,包括微纤维非编织物和聚氨基甲酸酯分散液,其中所述聚氨基甲酸酯分散液包括聚氨基甲酸酯预聚物和离子表面活性剂,其中所述聚氨基甲酸酯预聚物包括以所述聚氨基甲酸酯预聚物的总干重计25干重%至40干重%单体芳香族二异氰酸酯和20干重%至85干重%聚醚多元醇作为聚合单元。
6.根据权利要求5所述的微纤维非编织合成皮革,其中所述聚氨基甲酸酯预聚物另外包括以所述聚氨基甲酸酯预聚物的总干重计0.1干重%至30干重%聚酯多元醇作为聚合单元。
7.根据权利要求5所述的微纤维非编织合成皮革,其中所述聚氨基甲酸酯预聚物的异氰酸酯含量以所述聚氨基甲酸酯预聚物的重量计为3重量%至10重量%。
8.根据权利要求5所述的微纤维非编织合成皮革,其中有机溶剂不用于制备所述聚氨基甲酸酯预聚物。
9.一种制备微纤维非编织合成皮革的方法,其中其包括将微纤维非编织物浸没至根据权利要求1所述的聚氨基甲酸酯分散液中的步骤。
10.根据权利要求9所述的制备微纤维非编织合成皮革的方法,其中其另外包括对浸没的微纤维非编织物进行甲苯溶解法的步骤。
11.根据权利要求9所述的制备微纤维非编织合成皮革的方法,其中其另外包括对所述浸没的微纤维非编织物进行碱性溶解法的步骤。
CN201680088989.3A 2016-09-09 2016-09-09 用于微纤维非编织合成皮革应用的耐化学pud和方法 Pending CN109689718A (zh)

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