JPS5922825B2 - Method for manufacturing breathable coated cloth - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a breathable coated fabric.

Breathable coating fabric is made by forming a microporous polyurethane resin layer on a base fabric such as woven fabric, knitted fabric, non-woven fabric, etc., and ensures air circulation through the micropores formed in the polyurethane resin layer. It is something to do.

When forming such a microporous polyurethane resin layer on a base fabric, a one-component polyurethane resin solution is usually used, the base fabric is coated with the one-component polyurethane resin solution, and the base fabric is immersed in a coagulating liquid. A microporous polyurethane resin layer was formed by eluting the solvent in the solution.

However, according to this method, if a large amount of the one-component polyurethane resin solution is permeated into the base fabric and solidified, the adhesion between the base fabric and the polyurethane resin layer becomes stronger, the peel strength increases, and the durability increases. However, as a result of the polyurethane resin filling the spaces between the fibers of the base fabric, there are disadvantages in that the air permeability is significantly reduced and the feel is deteriorated.

On the other hand, if the permeation of the one-component polyurethane resin solution into the base fabric is reduced in consideration of air permeability and texture, the peel strength will be reduced, resulting in a lack of durability.

For this reason, we applied water-repellent treatment to the base fabric to suppress the penetration of the one-component polyurethane resin solution into the base fabric, and also provided an adhesive layer in an attempt to balance breathability, texture, and peel strength.
JP-A-56-26077). However, since this adhesive layer must not be affected by the solvent of the one-component polyurethane resin solution, it is not possible to use a polyurethane resin that has high adhesion to the fabric body and the polyurethane resin layer, so an acrylic polymer is used. ing.

Therefore, although breathability and texture were ensured, it could not be said that the peel strength was significantly improved. The present invention aims to eliminate these drawbacks.

Specifically, the object of the present invention is to provide a method for producing a breathable coated cloth that has excellent peel strength while ensuring breathability and texture. Previously, the method for producing a breathable coated cloth according to the present invention involves partially applying a two-component polyurethane resin solution to a cloth that has not been subjected to water repellent treatment, drying it,
On the base fabric, which has been aged to form a two-component polyurethane resin layer in a semi-crosslinked state, a powder is mixed that dissolves in the eluate or does not dissolve in the solvent of the urethane resin solution. Applying a liquid polyurethane resin solution, drying, and aging to bring the two-component polyurethane resin layer into a crosslinked state, thereby adhering and integrating the one-component polyurethane resin layer and the fabric body with the two-component polyurethane resin layer, This method is characterized in that it is then subjected to a massaging process and immersed in an eluate. According to the method for producing a breathable coated cloth according to the present invention, after applying a one-component polyurethane resin solution to a cloth body,
Because it is dried to scatter the solvent and subjected to a massaging process,
The powder mixed in the one-component polyurethane resin solution loosens and becomes easily eluted when immersed in the eluent, and the polyurethane resin that penetrates the intersections of the base fabric loosens, making the fabric flexible and allowing ventilation. It has the advantage of having a good texture and texture. Moreover, since cracks also occur in the polyurethane resin layer, air permeability is further improved. In addition, during the process of forming the adhesive layer on the base fabric, a thin film may be formed between the adhesive layers, which may be a factor in inhibiting air permeability. It has the advantage of good breathability. The present invention will be explained in more detail. In the method for manufacturing a coated cloth according to the present invention, first, a one-component polyurethane resin solution mixed with a powder that dissolves in the eluate but does not dissolve in the solvent of the urethane resin solution is applied to the base cloth.

The base fabric used in the present invention may basically be of any material, and may be a woven fabric, a knitted fabric, a non-woven fabric, etc. made of natural fibers or synthetic fibers.

An adhesive layer is provided partially on this cloth body. Here, "partially" means that the adhesive layer is not provided over the entire cloth without any gaps. For example, the adhesive layer is applied and formed in the form of a mesh, a line, a dot, etc. with gaps provided. The base fabric according to the present invention is a base fabric having an adhesive layer of a two-component polyurethane resin layer partially coated with a two-component polyurethane resin solution, dried and aged to a semi-crosslinked state.

This is because, in the next step, when the one-component polyurethane resin solution is dried and solidified, the two-component polyurethane resin layer changes from a semi-crosslinked state to a fully crosslinked state, and as a result, both layers are firmly bonded. When using this base fabric, the degree of crosslinking of the semi-crosslinked two-component polyurethane resin layer is preferably 30 to 70%.

If the degree of crosslinking is less than 30%, it will be affected by the solvent of the one-component polyurethane resin solution applied thereon, and the meaning of providing a partial adhesive layer will be lost; if it exceeds 70%, the adhesive strength will be reduced. This is because they will be inferior. To explain in detail the method for manufacturing the base cloth used in the method for manufacturing the coated cloth according to the present invention, first, a diacidic urethane resin solution is partially applied to a cloth body that has not been subjected to water repellent treatment.

The two-component urethane resin solution is made by adding a crosslinking agent, a catalyst, etc. to a polyurethane prepolymer whose main components are isocyanate and polyol, or the two-component polyurethane resin solution is basically but not limited to.

For example, the isocyanate component of the polyurethane prepolymer includes diphenylmethane-4,4'-diisocyanate, diphenyl-dimethylmethane-4,4'-diisocyanate, phenylene-1,4-diisocyanate, 2,2ζ6,6'-tetramethane, diphenylmethane-4,4'-diisocyanate, diphenyl-4,4-diisocyanate, diphenyl ether-4,4'-
Diisocyanates or derivatives substituted with alkyl, alkoxy or halogen, toluylene-2,4-1 and -2
-6-diisocyanate or commercially available mixtures thereof, 2
・Use one or more of 4-diisopropylphenylene-1,3-diisocyanate, m-xylylene diisocyanate, P-xylylene diisocyanate, and α・α・αζα5-tetramethyl-p-xylylene diisocyanate. As the polyol component, the following types of polyester polyols and polyether polyols can be used. The polyurethane prepolymer may be an isocyanate-terminated prepolymer or a hydroxyl-terminated prepolymer.

Examples of crosslinking agents that can be used include trifunctional or higher functional polyisocyanates or hydroxyl compounds, such as ethylene glycol, propylene glycol, butane-1
・4-diol, hexane-2,5-diol, 2,2
-dimethyl-propane-1,3-diol, hexane-
1,6-diol, 2-methylhexane-1,6-diol, 2,2-dimethylhexane-1,3-diol,
P-bis-hydroxymethyl-cyclohexane, 3-methylpentane-1,4-diol, 2,2-diethyl-propane-1,3-diol, and the like are used.

Further, as a catalyst, a tertiary amine, an organic tin compound, an organic lead compound, etc. are used.

The method of applying the two-component polyurethane resin solution is also not limited, and can be applied in dots using a gravure roll with 70 to 120 meshes, for example.

The coating amount is preferably 10 to 309/wl. 109/
If it is less than 309/a, the adhesive strength with the fabric or the upper polyurethane resin layer will decrease, and on the other hand, if it exceeds 309/a,
The two-component polyurethane resin solution also spills into dotted, linear, net-like gaps (i.e., areas where the two-component polyurethane resin solution is not applied), blocking these gaps and reducing breathability. It is from.

In this way, the cloth coated with the two-component polyurethane resin solution is dried.

Drying is preferably carried out at 7'C to 150C for 30 seconds to 15 minutes. If the temperature is less than 70°C, the solvent will not be sufficiently volatilized and the reaction will not proceed sufficiently in the next ripening process. On the other hand, if the temperature exceeds 150° C., on the contrary, the reaction proceeds too quickly and it is difficult to achieve the desired semi-crosslinked state. Furthermore, if the drying time is less than 30 seconds, the solvent will not volatilize sufficiently, and
This is because if it exceeds 15 minutes, the reaction will proceed too quickly.
The cloth thus dried is aged.

That is, it is brought into a semi-crosslinked state, preferably by leaving it in a temperature range of room temperature to 70°C for up to 48 hours. 70
This is because if the temperature exceeds .degree. C., the reaction proceeds too quickly and it is difficult to obtain a preferable semi-crosslinked state.

Furthermore, if the aging time exceeds 48 hours, the uncrosslinked resin will disappear and the adhesive strength will become poor.

It is preferable to manufacture the base fabric through the series of steps as described above, or to manufacture the base fabric by repeating the above-mentioned series of steps excluding the aging step multiple times.

That is, the coating-drying process may be repeated several times and then aged. In this case, the preferred total coating amount of the two-component polyurethane resin solution is 10 to 309/M2. In this way, by repeating the above-mentioned series of steps excluding the aging step, the amount of resin solution applied per time can be reduced. This is because it is possible to prevent the situation from being buried. Next, in the present invention, a one-component polyurethane resin solution is applied onto the base fabric as described above,
dry.

The urethane polymer in the one-component polyurethane resin solution may be any urethane polymer conventionally used in this type of coated fabric, such as a polyester or polyether urethane polymer. Further, as the solvent, for example, one or more of dimethylformamide, ethyl acetate, methyl ethyl ketone, acetone, toluol, butyl acetate, methyl isobutyl ketone, and xylene can be effectively used.

The powder that is added to this one-component polyurethane resin solution and does not dissolve in the solvent of the urethane resin solution but dissolves in the eluent is added to form fine air holes in the one-component polyurethane resin layer. Ru.

Such powder may be inorganic or organic as long as it satisfies the above conditions. For example, one or more of sodium carbonate, sodium bicarbonate, potassium bicarbonate, sodium chloride, calcium chloride, sodium nitrate, calcium nitrate, sugar, phenol, sulfosalicylic acid, and the like can be used. The amount of this powder added is 10 to 10 parts by weight per 100 parts by weight of one-component polyurethane resin solution.
It is preferable that the amount is 0 parts by weight.

If it is less than 10 parts by weight, very few micropores will be formed, resulting in poor air permeability, and if it exceeds 100 parts by weight, the proportion of pores in the one-component polyurethane resin layer will increase and the film will be damaged. .

The method of applying this one-component polyurethane resin solution onto the base fabric is basically not limited. It can be applied with a doctor knife, roll coater, etc. The coating amount is preferably 1
0 to 2009/a. 10f! If it is less than 2009/wl, the adhesive strength will be poor, and if it is more than 2009/w, the feel and breathability will be poor.

The optimum range is 20 to 1509/M°. After the one-component polyurethane resin solution is applied to the base fabric in this manner, it is dried.

Drying is preferably carried out at 700 to 150°C for 30 seconds or more.

If the temperature is less than 70°C, the solvent will not volatilize sufficiently, and the temperature will exceed 150°C.
Exceeding this will cause deterioration of the polyurethane resin.

After this drying step, ripening is performed.

Aging is preferably carried out at a temperature of room temperature to 150°C by leaving for 72 hours. This is because if the aging temperature exceeds 150°C, the polyurethane resin layer will deteriorate.
Furthermore, even if the product is aged for more than 72 hours, the crosslinking reaction is still completed, which is economically disadvantageous.

In this way, the product having the polyurethane resin layer dried, the solvent almost completely evaporated, and solidified is processed. As mentioned above, this kneading process involves (1) partially separating the powder and the polyurethane resin layer;
(2) loosens the intersections of the fibers of the base fabric and loosens the polyurethane resin that has penetrated the base fabric;
3) Creating cracks in the polyurethane resin layer; and (4) destroying the thin film formed between the adhesive layers, thereby improving air permeability and texture.

By applying this treatment, even if a large amount of polyurethane resin solution penetrates into the base fabric, it is possible to prevent the breathability and texture from being significantly impaired, resulting in a breathable coating with excellent peel strength, breathability, and texture. It can be made of cloth.

The method of massaging is not limited in the present invention.

For example, all the means used for kneading textiles and synthetic leathers, such as hand kneading and mechanical kneading, can be used. According to the present invention, it is possible to further add a step of applying a one-component polyurethane resin solution having the same or somewhat different composition as the one-component polyurethane resin solution described above onto the one-component polyurethane resin layer.

In this case, the coating amount of the first layer is 10 to 809/Trl, and after drying (an aging step may be added), 150
It is preferable to apply a one-component polyurethane resin solution at a coating amount of ~4009/wl. If the coating amount of the one-component polyurethane resin solution for the first layer is less than 109/wl, the adhesive strength will deteriorate, while if it exceeds 809/m'', the texture will be impaired. If the second layer polyurethane resin solution is less than 150f1/Rrl, the strength of the one-component polyurethane resin layer will be insufficient, and on the contrary, 4009/M
This is because if it exceeds 100°, breathability will be impaired.

By providing the second layer in this manner, the feel of the coated cloth is significantly improved.

Next, such a cloth is immersed in an eluent.

The eluent may be water or one or more alcohols such as methanol and ethanol. By immersing the cloth in this way, the mixed powder is eluted together with the solvent in the one-component polyurethane resin solution, and a polyurethane resin layer having micropores is formed. When a second polyurethane resin layer is provided, the first and second
They are integrated by the action of layers or solvents.

Next, according to the present invention, the eluate is optionally subjected to hot air treatment at a temperature of 100'C to 140°C to completely dry the eluate, and further a water repellent is applied at 40 to 509/Tn''. Water repellency can be improved. Fluorine-based water repellents and silicone-based water repellents can be effectively used as water repellents.Furthermore, following the above treatment, water treatment at a temperature of about 150°C for 30 seconds You can also bake for ~2 minutes.

Next, examples of the present invention will be described.

Example 1 A two-component polyurethane resin solution of composition (1) was applied three times to one side of a Tetoron/cotton blend plain woven fabric using a 120 mesh engraving roll.

At this time, the amount of adhesion of the two-component polyurethane resin solution was 219
/a (as a solution). This was dried at 120°C for 5 minutes and further aged at 40°C for 24 hours. Furthermore, a one-component polyurethane resin solution of composition (2) was added on top of this at 409/m
(A), 1709/Rrl (B) was applied as one solution and dried at 100° C. for 7 minutes.

This material was kneaded by hand for 3 minutes at a speed of 10 times/min.
)]. Furthermore, it was washed with warm water at 6°C for 1 hour. This was dried with hot air at 1100C. Add 20 more fluorine-based water repellent to this thing! ), dried at 120° C. for 3 minutes, and then heat-treated with 150 Liquid C for 30 seconds. Composition (1) {1diVv The results were as shown in Table 1 below.

Example 2 A two-component polyurethane resin solution of composition (1) was applied three times to one side of a Tetoron/cotton blend plain woven fabric using a 120-mesh engraving roll.

At this time, the amount of adhesion of the two-component polyurethane resin solution was 219
/Trl (as a solution). This was heated to 120℃ for 5
It was dried for a minute and further aged at 40°C for 24 hours. Furthermore, 40g of one-component polyurethane resin solution of composition (2) is added on top of this.
/Trl(A), 170f! /A (B) One solution was applied and dried at 100° C. for 7 minutes.

This material was kneaded by hand for 3 minutes at a speed of 10 times/min.
)]. Next, 180g/I (as a solution) of the one-component polyurethane resin solution of composition (3) was added using a doctor knife.
applied and immediately coagulated in water at 20 °C for 3 minutes, followed by 6 min.
It was washed with warm water at 0°C for 1 hour. This was dried with hot air at 110°C. This material was further treated with an aqueous solution containing 2% fluorine-based water repellent, dried at 120°C for 3 minutes, and then heated to 150°C.
Heat treatment was performed for 30 seconds. Composition (1) Composition (2) Composition (3) The results were as shown in Table 2.

Claims (1)

[Claims] 1. A two-component polyurethane resin solution is partially applied to a fabric that has not been subjected to water-repellent treatment, dried, and aged to form a two-component polyurethane resin solution in a semi-crosslinked state. A one-component polyurethane resin solution mixed with a powder that dissolves in the eluate but does not dissolve in the solvent of the urethane resin solution is applied onto the base fabric with the polyurethane resin layer, dried, and aged. The one-component polyurethane resin layer and the cloth body are bonded and integrated with the two-component polyurethane resin layer by crosslinking the liquid polyurethane resin layer, and then subjected to a kneading process and immersed in an eluent. A method for producing a breathable coated cloth. 2. The method for producing a breathable coated fabric according to claim 1, wherein the degree of crosslinking of the semi-crosslinked two-component polyurethane resin layer of the base fabric is 30 to 70%. 3. The method for producing a breathable coated cloth according to claim 1 or 2, wherein the amount of the two-component polyurethane resin solution applied to the cloth is 10 to 30 g/m^2. 4. The method for producing a breathable coated fabric according to any one of claims 1 to 3, characterized in that the amount of the one-component polyurethane resin solution applied to the base fabric is 10 to 200 g/m^2. 5. The method for producing a breathable coated cloth according to claim 4, wherein the coating amount is 30 to 150 g/m^2. 6. The breathable coated fabric according to any one of claims 1 to 5, wherein drying to bring the two-component polyurethane resin layer into a semi-crosslinked state is carried out at 70 to 150°C for 30 seconds to 15 minutes. Production method. 7. Aeration according to any one of claims 1 to 6, characterized in that the aging to bring the two-component polyurethane resin layer into a semi-crosslinked state is carried out at a temperature of room temperature to 70° C. and left for up to 48 hours. Method of manufacturing sex-coated cloth. 8 A two-component polyurethane resin solution was partially applied to a valve body that had not been subjected to water-repellent treatment, dried, and aged to form a semi-crosslinked two-component polyurethane resin layer from the two-component polyurethane resin solution. A one-component polyurethane resin solution mixed with powder that dissolves in the eluate but does not dissolve in the solvent of the urethane resin solution is applied onto the base fabric, and then dried and aged to form the two-component polyurethane resin. The resin layer is crosslinked, the one-component polyurethane resin layer and the fabric body are bonded and integrated with the two-component polyurethane resin layer, and then a kneading process is applied. A method for producing a breathable coated cloth, which comprises applying a wet-coagable one-component polyurethane resin solution containing powder that does not dissolve in a solvent, and immersing the cloth in an eluate. 9 The coating amount of the one-component polyurethane resin solution to be bonded and integrated with the two-component polyurethane resin layer is 10 to 80 g.
/m^1, and the coating amount of the one-component polyurethane resin solution applied on this one-component polyurethane resin solution is 1
The method for producing a breathable coated fabric according to claim 8, characterized in that the coating has an air permeability of 50 to 400 g/m^2.