JPWO2009119752A1 - Solventless polyurethaneurea foam sheet, method for producing the same, and synthetic leather - Google Patents

Abstract

A prepolymer (A) obtained by reacting a diisocyanate compound with a polyol having a molecular weight of 500 to 3000, a crosslinking agent (B) comprising a polyol having an average number of hydroxyl groups of 2 to 4, and water (C), The content of the isocyanate group is 7.0 to 12.0% by mass, and when the (A) and (B) are mixed, the residual amount of the isocyanate group is 2.0 to 5.0% by mass, (A), ( The residual amount of isocyanate groups when B) and (C) are mixed is 0.01 to 0.5% by mass, and the number average of all polyols when the polyol (A) and the polyol (B) are mixed Solventless polyurethaneurea foam sheet obtained by foaming air or inert gas into a solventless urethane resin composition having a molecular weight of 600 or more, then forming into a sheet shape, and heat-curing, and a method for producing the same common Synthetic leather with a sheet to.

Description

  The present invention relates to a solventless polyurethaneurea foam sheet, a method for producing the same, and a synthetic leather provided with the solventless polyurethaneurea foam sheet.

  Synthetic leather and artificial leather are used as substitutes for natural leather. As one of such leathers, for example, a polyurethane urea foam sheet obtained by reacting and solidifying a urethane prepolymer having an isocyanate group at the terminal in a humidified / heated atmosphere and a fiber base material, Furthermore, what laminated | stacked the skin layer which consists of polyurethane on it is known.

  And as such a polyurethane urea foam sheet, there exists a thing described in Unexamined-Japanese-Patent No. 11-60768 (reference 1), for example. However, in the case of producing a polyurethaneurea foam sheet as described in Reference 1, since a urethane resin composition containing an organic solvent is used, removal of the organic solvent discharged in the processing step by adsorbent treatment And detoxification by combustion treatment is necessary, and the economic cost has been a great burden.

  On the other hand, JP-A-2003-306526 (Reference 2) discloses a moisture-curable hot-melt urethane resin composition that does not contain an organic solvent. However, when the resin composition as described in Document 2 is used, the resin composition does not have fluidity at room temperature, and thus it is necessary to heat and melt the resin composition. Therefore, a method for producing a polyurethaneurea foam sheet using such a resin composition is not necessarily a sufficient method in terms of productivity.

  In addition, a method using an emulsion or an aqueous urethane resin coating material as a material for the polyurethaneurea foam sheet is also being studied. However, in such a method, it is difficult to form a laminated structure and a drying speed is increased. There was a problem in that it was insufficient.

  The present invention has been made in view of the above-mentioned problems of the prior art, and in a method for producing a polyurethaneurea foam sheet using a solvent-free urethane resin composition, it is good at the time of mixing raw materials without heating and melting. By using a solvent-free urethane resin composition having fluidity, a method for producing a polyurethane urea foam sheet capable of efficiently producing a polyurethane urea foam sheet having sufficient elongation and strength, and a method for producing the same An object of the present invention is to provide a polyurethane urea foam sheet and a synthetic leather comprising the same.

  As a result of intensive studies to achieve the above object, the present inventors have found that a prepolymer having a high isocyanate group content, a cross-linking in a method for producing a polyurethaneurea foam sheet using a solventless urethane resin composition Polyurethane urea foam sheet having a sufficiently uniform foam structure and sufficient elongation and strength by using a solvent-free urethane resin composition in which an agent and water are blended so as to satisfy specific conditions. Has been found to be able to be produced efficiently, and the present invention has been completed.

The method for producing a solventless polyurethaneurea foam sheet according to the present invention comprises: a prepolymer (A) obtained by reacting a diisocyanate compound with a polyol having a molecular weight of 500 to 3000; an average number of hydroxyl groups of 2 to 4; Containing the crosslinking agent (B) and water (C), the following conditions:
The isocyanate group content in the prepolymer (A) is 7.0 to 12.0% by mass,
When the content of the cross-linking agent (B) is a mixture of the prepolymer (A) and the cross-linking agent (B), the residual amount of isocyanate groups in the prepolymer (A) is 2.0 to 5.0. The amount is in the range of mass%,
When the content of the water (C) is a mixture of the prepolymer (A), the cross-linking agent (B) and the water (C), the residual amount of isocyanate groups in the prepolymer (A) is 0.00. In an amount ranging from 01 to 0.5% by weight, and
The number average molecular weight of all the polyols when the polyol which is one of the raw materials of the prepolymer (A) and the polyol in the crosslinking agent (B) are mixed is 600 or more.
Preparing a solventless urethane resin composition that satisfies
A step of obtaining a foamed urethane resin composition by foaming air or an inert gas into the solventless urethane resin composition;
Molding the foamed urethane resin composition into a sheet, heating and curing to obtain a solventless polyurethaneurea foam sheet; and
Including a method.

  Moreover, in the manufacturing method of the solvent-free polyurethane urea foam sheet of the present invention, the crosslinking agent (B) is a crosslinking agent composed of a polyol having an average number of hydroxyl groups of 2 to 4 and a molecular weight of 60 to 3000. It is preferable that

  Furthermore, in the method for producing a solventless polyurethaneurea foam sheet of the present invention, the content of the water (C) is 0.2 to 1.5 parts by mass with respect to 100 parts by mass of the prepolymer (A). It is preferable that

  Moreover, in the manufacturing method of the solventless type polyurethane urea foam sheet of this invention, it is preferable that the viscosity in 25 degreeC of the said prepolymer (A) is 4000-30000 mPa * s.

Furthermore, in the method for producing the solventless polyurethane urea foam sheet of the present invention, in the step of obtaining the foamed urethane resin composition, the volume at a temperature of 25 ° C. with respect to 100 parts by mass of the solventless urethane resin composition. Is preferably bubbled with 5-30 cm ³ of air or inert gas.

The solventless polyurethaneurea foam sheet of the present invention comprises a prepolymer (A) obtained by reacting a diisocyanate compound with a polyol having a molecular weight of 500 to 3000, an average number of hydroxyl groups of 2 to 4, and the polyol. A crosslinking agent (B) and water (C) are contained, and the following conditions:
The isocyanate group content in the prepolymer (A) is 7.0 to 12.0% by mass,
When the content of the cross-linking agent (B) is a mixture of the prepolymer (A) and the cross-linking agent (B), the residual amount of isocyanate groups in the prepolymer (A) is 2.0 to 5.0. The amount is in the range of mass%,
When the content of the water (C) is a mixture of the prepolymer (A), the cross-linking agent (B) and the water (C), the residual amount of isocyanate groups in the prepolymer (A) is 0.00. In an amount ranging from 01 to 0.5% by weight, and
The number average molecular weight of all the polyols when the polyol which is one of the raw materials of the prepolymer (A) and the polyol in the crosslinking agent (B) are mixed is 600 or more.
Prepare a solventless urethane resin composition that satisfies
The solvent-free urethane resin composition is foamed with air or an inert gas, and then molded into a sheet and heated and cured.

  In the solventless polyurethaneurea foam sheet of the present invention, the crosslinking agent (B) is a crosslinking agent comprising a polyol having an average number of hydroxyl groups of 2 to 4 and a molecular weight of 60 to 3000. Is preferred.

  Furthermore, in the solventless polyurethaneurea foam sheet of the present invention, the content of the water (C) is 0.2 to 1.5 parts by mass with respect to 100 parts by mass of the prepolymer (A). Is preferred.

  The synthetic leather of the present invention comprises the solventless polyurethane urea foam sheet of the present invention.

  According to the present invention, in a method for producing a polyurethaneurea foam sheet using a solventless urethane resin composition, a solventless urethane resin composition having good fluidity at the time of mixing raw materials without heating and melting is used. A method for producing a polyurethane urea foam sheet capable of efficiently producing a polyurethane urea foam sheet having sufficient elongation and strength, and a polyurethane urea foam sheet obtained by the production method and a synthetic leather comprising the same Can be provided.

  Hereinafter, the present invention will be described in detail with reference to preferred embodiments thereof.

First, a method for producing the solventless polyurethaneurea foam sheet of the present invention will be described. The method for producing a solventless polyurethaneurea foam sheet according to the present invention comprises: a prepolymer (A) obtained by reacting a diisocyanate compound with a polyol having a molecular weight of 500 to 3000; an average number of hydroxyl groups of 2 to 4; Containing the crosslinking agent (B) and water (C), and the following conditions:
The isocyanate group content in the prepolymer (A) is 7.0 to 12.0% by mass,
When the content of the cross-linking agent (B) is a mixture of the prepolymer (A) and the cross-linking agent (B), the residual amount of isocyanate groups in the prepolymer (A) is 2.0 to 5.0. The amount is in the range of mass%,
When the content of the water (C) is a mixture of the prepolymer (A), the cross-linking agent (B) and the water (C), the residual amount of isocyanate groups in the prepolymer (A) is 0.00. In an amount ranging from 01 to 0.5% by weight, and
The number average molecular weight of all the polyols when the polyol which is one of the raw materials of the prepolymer (A) and the polyol in the crosslinking agent (B) are mixed is 600 or more.
Preparing a solventless urethane resin composition that satisfies
A step of obtaining a foamed urethane resin composition by foaming air or an inert gas into the solventless urethane resin composition;
Molding the foamed urethane resin composition into a sheet, heating and curing to obtain a solventless polyurethaneurea foam sheet; and
Including a method.

  First, the solventless urethane resin composition used in the method for producing a solventless polyurethaneurea foam sheet of the present invention will be described. The solventless urethane resin composition according to the present invention comprises a prepolymer (A) obtained by reacting a diisocyanate compound with a polyol having a molecular weight of 500 to 3000, a cross-linking agent having an average number of hydroxyl groups of 2 to 4 and comprising a polyol. (B) and water (C) are contained.

  The prepolymer (A) according to the present invention is obtained by reacting a diisocyanate compound with a polyol having a molecular weight of 500 to 3000. And in this invention, it is required that content (NCO group content) of the isocyanate group in such a prepolymer (A) is the range of 7.0-12.0 mass%. If the NCO group content is less than 7.0% by mass, the resulting solventless urethane resin composition is too viscous to produce a polyurethaneurea foam sheet efficiently. When the content exceeds 0% by mass, the viscosity of the resulting solventless urethane resin composition is too low, so that a polyurethaneurea foam sheet cannot be efficiently produced.

Examples of the diisocyanate compound used to obtain such a prepolymer (A) include 4,4′-diphenylmethane diisocyanate (hereinafter sometimes referred to as “MDI”), toluene diisocyanate (hereinafter sometimes referred to as “TDI”), and isophorone. Diisocyanate (hereinafter sometimes referred to as “IPDI”), norbornane diisocyanate (hereinafter sometimes referred to as “NBDI”), xylene diisocyanate (hereinafter sometimes referred to as “XDI”), hexamethylene diisocyanate (hereinafter sometimes referred to as “HDI”), 4, 4'-dicyclohexylmethane diisocyanate (hereinafter sometimes referred to as “H ₁₂ MDI”) and o-tridin diisocyanate (hereinafter sometimes referred to as “TODI”). Among these, MDI is preferable from the viewpoint of being economically preferable and having excellent physical properties. Moreover, these diisocyanate compounds may be used individually by 1 type, or may mix and use 2 or more types.

  Moreover, the polyol used in order to obtain such a prepolymer (A) is a polyol of molecular weight 500-3000 (preferably molecular weight 1000-2000). Examples of such polyols include long-chain glycols such as polyoxyethylene glycol, polyoxypropylene glycol, polyoxytetramethylene glycol, and polyoxypropylene / oxymethylene glycol. Such polyols may be used alone or in combination of two or more.

  The crosslinking agent (B) according to the present invention is a crosslinking agent having an average number of hydroxyl groups of 2 to 4 and comprising a polyol. If the average number of hydroxyl groups of the cross-linking agent is less than 2, the resulting urethane resin composition cannot be sufficiently high molecular weight. On the other hand, if it exceeds 4, the cross-linking density is too high, so that the resulting polyurethane urea foam sheet is obtained. The elasticity of the resin becomes too high, which is undesirable when used for synthetic leather. And as such a crosslinking agent, the crosslinking agent which consists of a group which consists of a polyol of molecular weight 60-10000 (more preferably molecular weight 60-3000) is mentioned. Such crosslinking agents may be used alone or in combination of two or more.

Thus, as a polyol used as a crosslinking agent, in addition to a glycol having 2 hydroxyl groups in one molecule, a compound having 3 or more hydroxyl groups in one molecule may be used. As a compound having three or more hydroxyl groups in one molecule, the following general formula (1):
R ¹ (R ² OH) _n (1)
The compound represented by these is mentioned. In the general formula (1), n represents an integer of 3 or more. R ¹ represents an alkylene group, R ³ C = group, (R ³ represents an organic group) or the like, and R ² represents an alkylene group, an oxyalkylene group or the like. As the compound represented by the general formula (1), it is preferable to use a compound having a hydroxyl number of 3 or more (preferably 3 to 6) and a molecular weight of 100 to 10,000. Furthermore, examples of the compound represented by the general formula (1) include active hydrogen-containing compounds such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, trimethylolpropane, and glycerin, and alkylenes such as propylene oxide and ethylene oxide. Examples thereof include polyoxyalkylene polyols obtained by addition polymerization of oxide or tetrahydrofuran.

  Further, as the glycol having 2 hydroxyl groups, those having a molecular weight of 60 to 3000 are preferably used. For example, ethylene glycol, 1,3- or 1,2-propylene glycol, 1,4- or 1,3- or 2,3-butylene glycol, 1,6-hexane glycol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, 2,2-dimethyl-1,3-propanediol, cyclohexane Dimethanol, 1,4-bis- (hydroxymethyl) -cyclohexane, 2-methyl-1,3-propanediol, 3-methyl-1,5-pentanediol, 2,2,4-trimethyl- 1,3-pentanediol, 2-butyl-2-ethyl-1,3-propanediol, diethylene glycol, dipropylene glycol, tri Short chain glycols such as tylene glycol, tripropylene glycol, dibutylene glycol; polyoxyethylene glycol, polyoxypropylene glycol, polyoxytetramethylene glycol, polyoxypropylene / oxymethylene glycol, polyethylene glycol adipate, polybutylene glycol adipate, poly Examples include long-chain glycols such as neopentyl glycol adipate, polybutylene / hexylene glycol adipate, polycaprolactone, poly-3-methylpentanediol adipate, poly-β-methylvalerolactone, and dimer acid diol.

The content of such a crosslinking agent (B) is the residual amount of isocyanate groups (NCO group residual amount) in the prepolymer (A) when the prepolymer (A) and the crosslinking agent (B) are mixed. It is necessary that the amount be in the range of 2.0 to 5.0% by mass. When the content of the crosslinking agent (B) is such that the NCO group residual amount is less than 2.0% by mass, the resulting polyurethane urea foam sheet has insufficient elongation and strength, while 5.0% by mass is obtained. If the amount exceeds this, the generation of CO ₂ will be excessive, the smoothness of the surface of the resulting polyurethaneurea foam sheet will be remarkably impaired, and the strength will be high, but a flexible foam sheet cannot be obtained. Moreover, from the viewpoint of improving the thermoplasticity of the resulting polyurethaneurea foam sheet and improving the heat embossing property, the content of the crosslinking agent (B) is such that the NCO group residual amount is 2.0 to 2.5 mass. The amount is preferably in the range of%. From the viewpoint of improving the heat resistance and strength of the resulting polyurethaneurea foam sheet, the content of the crosslinking agent (B) is such that the NCO group residual amount is 2.5 to 5.0% by mass (more preferably It is preferable that it is the quantity used as the range of 3.0-4.5 mass%.

  Moreover, in this invention, the number average molecular weight of all the polyols when the polyol which is one of the raw materials of the said prepolymer (A) and the polyol in the said crosslinking agent (B) are mixed is 600 or more. is required. When the number average molecular weight of the polyol is less than 600, the resulting polyurethane urea foam sheet has insufficient elongation and tensile strength.

The solventless urethane resin composition according to the present invention contains water (C) in addition to the prepolymer (A) and the crosslinking agent (B). And content of such water (C) is the residual of the isocyanate group in the said prepolymer (A) at the time of mixing the said prepolymer (A), the said crosslinking agent (B), and the said water (C). It is necessary that the amount be in the range of 0.01 to 0.5% by mass. When the content of water (C) is such that the NCO group residual amount is less than 0.01% by mass, the generation of CO ₂ becomes excessive, and the peel strength and wear resistance of the resulting polyurethaneurea foam sheet decrease. On the other hand, if the amount exceeds 5.0% by mass, the generation of CO ₂ necessary for foaming is remarkably suppressed, and the resulting polyurethane urea foam sheet becomes hard and unfavorable when used for synthetic leather or the like. . Moreover, it is preferable that content of such water (C) is 0.2-1.5 mass parts with respect to 100 mass parts of said prepolymers (A), 0.5-1.0 mass part It is more preferable that If the content of water (C) is less than the lower limit, it tends to be difficult to form a uniform foam layer. On the other hand, if the content exceeds the upper limit, not only the physical properties are lowered, but the cells of the foam layer are coarsened. It tends to impair smoothness and make it difficult to form a foam layer having a uniform thickness.

  In addition, the solventless urethane resin composition according to the present invention may further contain a catalyst and a foam stabilizer as necessary. Examples of such catalysts include organometallic catalysts such as dibutyltin dilaurate, tin octylate, dibutyltin oxide, bismuth octylate, zinc octylate, aluminum octylate; N, N, N ″, N ″ -tetramethylhexa Methylenediamine, N, N, N ′, N ″, N ″ -pentamethyldiethylenetriamine, N-methylmorpholine, N, N ′, N ″ -tris (3-dimethylaminopropyl) hexahydro-s-triazine, 1,8 -Phenol salts, octylates, formates or p-toluenesulfonates of diazabicyclo (5,4,0) -undecene-7, 1,8-diazabicyclo (5,4,0) -undecene-7 These catalysts may be used alone or in combination of two or more, but the amine catalyst may be used. When used alone, it is difficult to achieve the strength required for synthetic leather, so it is preferable to use it together with an organometallic catalyst, although the amount of such a catalyst added is not particularly limited, but the prepolymer (A) 100 mass It is preferable that it is 0.001-0.2 mass part with respect to a part.

  Examples of the foam stabilizer include propylene oxide / ethylene oxide-added silicone oil, for example, trade names SF2969, PRX607, SF2964, SRX274C, SF2961, SF2962, SF2965, SF2908, BY10-123 manufactured by Toray Dow Corning Silicone Co., Ltd. SF2904, SRX294A, BY10-124, SF2935F, SF2945F, SF2944F, SF2936F, SH193, SH192H, SH192, SF2909, SH194, SH190, SRX290A, SRX298, Z11, S11, Z11, Z11 SZ1162, L3601, L5309, L5366, SZ1306, Z1311, SZ1313, SZ1342, L5340, L5420, SZ1605, SZ1627, SZ1642, SZ1649, SZ1671, SZ1675, SZ1923, and the like.

  The solvent-free urethane resin composition according to the present invention includes a pigment, an antifungal agent, an ultraviolet absorber, an antiblocking agent, a hydrolysis inhibitor, a fragrance, a dye, an inorganic filler, an antibacterial agent, and the like as necessary. The polyurethane urea foam sheet obtained may further be contained within a range not impairing the physical properties.

  The solventless urethane resin composition according to the present invention is substantially free of organic solvent, but a trace amount of organic solvent remains in such solventless urethane resin composition. Even in this case, the residual organic solvent content is preferably 400 ppm or less. Moreover, it is preferable that such a solventless type urethane resin composition does not contain what is designated as a volatile organic compound among organic solvents.

  As mentioned above, although the solventless type urethane resin composition used for the manufacturing method of the solventless type polyurethaneurea foam sheet of this invention was demonstrated, hereafter, the manufacturing method of the solventless type polyurethaneurea foam sheet of this invention is demonstrated.

  The method for producing a solventless polyurethaneurea foam sheet according to the present invention includes a step of preparing the solventless urethane resin composition (first step), and air or an inert gas in the solventless urethane resin composition. A step of obtaining a foamed urethane resin composition by foaming (second step), and forming the foamed urethane resin composition into a sheet shape and heating and curing it to form a solventless polyurethane urea foam sheet (Step 3).

  In the first step, the solventless urethane resin composition is prepared. The solventless urethane resin composition can be obtained by appropriately mixing the prepolymer (A), the crosslinking agent (B) and the water (C) by a known method. The viscosity of the prepolymer (A) at a temperature of 25 ° C. is preferably 4000 to 30000 mPa · s, and more preferably 5000 to 12000 mPa · s. When the viscosity is less than 4000 mPa · s, since the viscosity is low and the bubbles disappear, it is difficult not only to make the solvent-free urethane resin composition contain sufficient bubbles, but also repellency tends to occur. is there. On the other hand, if the viscosity exceeds 30000 mPa · s, the resin having a high initial viscosity is less likely to change the shape of the mixed bubbles, so that the uniformity of the bubble (cell) shape in the obtained polyurethaneurea foam sheet decreases. There is a tendency.

In the second step, the solventless urethane resin composition is bubbled with air or an inert gas to obtain a foamed urethane resin composition. As described above, as a method of foaming air or an inert gas into the solventless urethane resin composition, a method of mixing air or an inert gas into the solventless urethane resin composition using a known mixer as appropriate. Can be adopted. The amount of air or inert gas in the foamed urethane resin composition is such that the volume at a temperature of 25 ° C. is 5 to ³⁰ cm ³ with respect to 100 parts by mass of the solventless urethane resin composition. The amount is preferably 10 to 20 cm ³ . If the amount of bubbles is less than the lower limit, the resulting polyurethane urea foam sheet tends to be rough, and the cells tend to be large.On the other hand, if the upper limit is exceeded, the cells tend to be fine and uniform. There exists a tendency for the intensity | strength of the polyurethane urea foam sheet obtained to fall. Moreover, as air or an inert gas, it is preferable to use the thing whose absolute humidity in temperature 25 degreeC is 5 g / m < ³ > or less from a viewpoint of obtaining the stable foam. In the present invention, the foamed urethane resin composition is heated by the synergistic effect of the expansion of air or inert gas in the foamed urethane resin composition and the generation of carbon dioxide by the reaction of moisture and isocyanate. It is presumed that the polyurethane urea foam sheet having a sufficiently uniform foamed structure can be obtained because the bubbles (cells) formed upon curing are uniform.

  In the third step, the foamed urethane resin composition is formed into a sheet shape, heated and cured to obtain a solvent-free polyurethane urea foam sheet. Examples of a method for forming the foamed urethane resin composition into a sheet include a method of applying the foamed urethane resin composition on a release substrate. As a coating method, a method using a doctor knife coater, a comma coater, a die coater or the like can be employed. Such a release substrate is not particularly limited as long as it is commercially available for producing synthetic leather, such as a patterned release paper, and any substrate can be used. Moreover, when apply | coating the said foam containing urethane resin composition, it is preferable to cool the said foam containing urethane resin composition (for example, temperature shall be 30 degrees C or less), and extending pot life in this way. Can do. Furthermore, the coating amount of the foamed urethane resin composition is not particularly limited, but it is preferable that the thickness of the resulting polyurethane urea foam sheet is in the range of 0.15 to 0.60 mm. Moreover, it is preferable to perform reaction which hardens the foamed urethane-resin composition after shaping | molding, for example in the temperature of 80-130 degreeC atmosphere.

  Next, the solventless polyurethane urea foam sheet of the present invention will be described. The solventless polyurethaneurea foam sheet of the present invention is obtained by the above-described method for producing a solventless polyurethaneurea foam sheet of the present invention.

The solventless polyurethaneurea foam sheet of the present invention preferably satisfies the following conditions.
(I) The glass transition point is −15 ° C. or lower (more preferably −20 ° C. or lower).
(Ii) Tensile strength [(measured value of tensile strength) / (measured value of density)] in an unfoamed state is 4 MPa or more (more preferably 6 MPa or more).
(Iii) The elongation is 200% or more (more preferably 300% or more).
(Iv) The loss tangent is 0.35 or more (more preferably 0.45 or more).
(V) 100% modulus [(measured value of 100% modulus) / (measured value of density)] in an unfoamed state is 4 MPa or less (more preferably 3 MPa or less).
Any material that satisfies all these physical properties can be suitably used as a material for synthetic leather that requires strength (for example, synthetic leather used for vehicle seats, etc.). In addition, even if it does not satisfy some of these physical properties, it can be used as a material for synthetic leather that does not require strength (for example, synthetic leather used for doors). These physical properties can be measured by the methods described in the examples described later.

  Further, the thickness of the solventless polyurethaneurea foam sheet of the present invention is not particularly limited because it varies depending on the use, but when used as a synthetic leather material, it is generally about 0.15 to 0.60 mm. is there. Further, the amount of the volatile organic compound in such a solventless polyurethaneurea foam sheet is preferably 400 ppm or less.

  Such a solventless polyurethaneurea foam sheet of the present invention is particularly useful as a material for synthetic leather, but is also useful as a material for synthetic resin sheets, carpets, soundproof flooring, and the like.

  Next, the synthetic leather of the present invention will be described. That is, the synthetic leather of the present invention includes the solventless polyurethane urea foam sheet. Such synthetic leather comprises at least a fiber base fabric base material and the solventless polyurethaneurea foam sheet.

  As such a fiber base material, any fiber base material that has been conventionally used as a fiber base material for synthetic leather may be used. Examples thereof include an ultrafine fiber nonwoven fabric, a nonwoven fabric, a woven fabric, and a knitted fabric. Moreover, such a fiber base fabric base material may have one side or both sides raised.

  Moreover, the skin layer which has a polyurethane as a main component may be laminated | stacked on the surface of the said solventless type polyurethane urea foam sheet in such a synthetic leather like the conventional synthetic leather. As this skin layer, those manufactured and sold for use as a synthetic leather skin resin can be used as appropriate, and although not particularly limited, a solventless type polyurethane urea foam sheet of the present invention is of a solventless type. It is preferable to use a polyurethane resin. The thickness of the skin layer polyurethane resin is preferably in the range of about 10 to 50 μm. Further, a protective layer may be provided on the skin layer.

  The method for producing such synthetic leather is not particularly limited, and a known method for producing synthetic leather can be employed. And as such a method, the method of laminating | stacking the said solvent-free type polyurethane urea foam sheet | seat using an adhesive agent on the said fiber base fabric base material, for example is mentioned.

  The adhesive used for adhering the solventless polyurethaneurea foam sheet and the fiber base fabric base material may be one used for adhesion to the base fabric base material for the production of synthetic leather. Although it is not particularly limited, it is preferable to use a solventless resin.

  In the method of obtaining synthetic leather in this way, for example, a skin layer is coated on a release paper, the solventless polyurethaneurea foam sheet is formed on the skin layer, and the solventless polyurethaneurea is formed. A method may be employed in which an adhesive layer is provided on the foam sheet, the release paper is peeled off after being adhered to the fiber base fabric substrate, and a protective layer is provided on the skin layer as necessary. Alternatively, each layer may be created separately and laminated and integrated with an adhesive.

  EXAMPLES Hereinafter, although this invention is demonstrated more concretely based on an Example and a comparative example, this invention is not limited to a following example.

Example 1
First, 447 parts by mass of polytetramethylene glycol (number average molecular weight: 1000), 341 parts by mass of MDI, and 12 parts by mass of Irganox 245 were charged into a four-necked separable flask (capacity 1 L), and then a temperature of 25 The prepolymer (A-1) was obtained by reacting for 3 hours while passing nitrogen gas at -85 ° C under normal pressure. The NCO group content in the obtained prepolymer (A-1) was 9.5% by mass.

  Next, 48.34 parts by mass of a glycerin-based propylene oxide ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3), polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) 41.44 parts by mass, 1,3-butanediol (average molecular weight: 90.12, hydroxyl number: 2) 5.54 parts by mass, catalyst (dibutyltin dilaurate and N, N, N ′, N Then, 0.09 part by mass of '-tetramethyl-1,6-hexamethylenediamine) and 3.11 parts by mass of SH190 were charged and then mixed to obtain a crosslinking agent mixture (B-1).

  And with respect to 100 mass parts of prepolymers (A-1), 45.93 mass parts of crosslinking agent liquid mixture (B-1) and 0.92 mass parts of water (C) are mixed, and a solvent-free urethane resin composition. I got a thing. In addition, the NCO group residual amount in the prepolymer (A-1) in the mixture of 100 parts by mass of the prepolymer (A-1) and 45.93 parts by mass of the cross-linking agent mixed solution (B-1) is calculated as 3. In addition to 100 parts by mass of the prepolymer (A-1), 45.93 parts by mass of the cross-linking agent mixed solution (B-1), and 0.92 parts by mass of water (C). The residual amount of NCO groups in the prepolymer (A-1) is calculated to be 0.5% by mass.

Next, the obtained solvent-free urethane resin composition was stirred with a four-blade stirrer under the conditions of a stirring speed of 3000 rpm and a stirring time of 60 seconds to mix dry air, and the density was 0.8 to 0.9 g / A coating composition (foamed urethane resin composition) in the range of cm ³ was obtained. Thereafter, the coating composition was applied on a release paper so as to have a thickness of 0.3 mm, and then cured at a temperature of 110 ° C. to obtain a polyurethaneurea foam sheet. The coating composition was applied under the conditions of a temperature of 20 to 30 ° C. and an absolute humidity of 5 g / m ³ or less.

(Example 2)
First, in a four-necked separable flask, 500 parts by mass of polytetramethylene glycol (number average molecular weight: 1000), 291 parts by mass of MDI, and 9 parts by mass of Irganox 245 were charged, and then the temperature was 25 to 85 ° C. The mixture was reacted for 3 hours while passing nitrogen gas under normal pressure to obtain a prepolymer (A-2). The NCO group content in the obtained prepolymer (A-2) was 7% by mass.

  Next, in a beaker, 75.61 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and 10 polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) were added. 80 parts by weight, 8.66 parts by weight of 1,3-butanediol (average molecular weight: 90.12, number of hydroxyl groups: 2), catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl) -1,6-hexamethylenediamine) and 0.13 parts by mass of SH190 and 4.8 parts by mass of SH190 were added and mixed to obtain a cross-linking agent mixture (B-2).

  And it is the same as Example 1 except having mixed 25.69 mass parts of crosslinking agent mixed liquid (B-2) and 0.79 mass parts of water (C) with respect to 100 mass parts of prepolymers (A-2). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. In addition, the NCO group residual amount in the prepolymer (A-2) in the mixture of 100 parts by mass of the prepolymer (A-2) and 25.69 parts by mass of the cross-linking agent mixed solution (B-2) is calculated as 3. In addition to 100 parts by mass of the prepolymer (A-2), 25.69 parts by mass of the crosslinking agent mixed solution (B-2), and 0.79 parts by mass of water (C). The residual amount of NCO groups in the prepolymer (A-2) is 0.5% by mass in calculation.

(Example 3)
First, 403 parts by mass of polytetramethylene glycol (number average molecular weight: 1000), 384 parts by mass of MDI, and 13 parts by mass of Irganox 245 are charged into a four-necked separable flask, and then a temperature of 25 to 85 ° C. The mixture was reacted for 3 hours while passing nitrogen gas under normal pressure to obtain a prepolymer (A-3). NCO group content in the obtained prepolymer (A-3) was 12 mass%.

  Next, 38.87 parts by mass of glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) are 54 in a beaker. .14 parts by mass, 1,3-butanediol (average molecular weight: 90.12, hydroxyl number: 2) 4.45 parts by mass, catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl -1,6-hexamethylenediamine) and 0.07 parts by mass of SH190 and 2.47 parts by mass of SH190 were added and mixed to obtain a cross-linking agent mixture (B-3).

  And it is the same as Example 1 except mixing 65.98 mass parts of crosslinking agent liquid mixture (B-3), and 1.04 mass parts of water (C) with respect to 100 mass parts of prepolymers (A-3). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. In addition, the NCO group residual amount in the prepolymer (A-3) in the mixture of 100 parts by mass of the prepolymer (A-3) and 65.98 parts by mass of the crosslinking agent mixed solution (B-3) is calculated as 3. 0.5 mass%, and in which 100 parts by mass of the prepolymer (A-3), 65.98 parts by mass of the crosslinking agent mixed solution (B-3) and 1.04 parts by mass of water (C) are mixed. The residual amount of NCO groups in the prepolymer (A-3) is calculated to be 0.5% by mass.

Example 4
First, 69.42 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) are added to a beaker. 96 parts by mass, 1,3-butanediol (average molecular weight: 90.12, number of hydroxyl groups: 2) 20.55 parts by mass, catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl- 1,4-hexamethylenediamine) and 0.13 parts by mass of SH190 were charged and then mixed to obtain a crosslinking agent mixture (B-4).

  And, with respect to 100 parts by mass of the prepolymer (A-1) used in Example 1, 24.79 parts by mass of the crosslinking agent mixed solution (B-4) and 0.79 parts by mass of water (C) were mixed. Were the same as in Example 1 to obtain a solventless urethane resin composition and a polyurethaneurea foam sheet. In addition, the NCO group residual amount in the prepolymer (A-1) in a mixture of 100 parts by mass of the prepolymer (A-1) and 24.79 parts by mass of the cross-linking agent mixed solution (B-4) is calculated as 3. In addition to 100 parts by mass of the prepolymer (A-1), 24.79 parts by mass of the cross-linking agent mixed solution (B-4) and 0.79 parts by mass of water (C). The residual amount of NCO groups in the prepolymer (A-1) is calculated to be 0.5% by mass.

(Example 5)
First, 504 parts by mass of polytetramethylene glycol (number average molecular weight: 3000), 280 parts by mass of MDI, and 15 parts by mass of Irganox 245 are charged into a four-necked separable flask. The mixture was reacted for 3 hours while passing nitrogen gas under pressure to obtain a prepolymer (A-4). The NCO group content in the obtained prepolymer (A-4) was 10% by mass.

  Next, in a beaker, 14.72 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and polytetramethylene glycol (number average molecular weight: 3000, hydroxyl number: 2) 82 .30 parts by mass, 1,3-butanediol (average molecular weight: 90.12, hydroxyl number: 2) 0.92 parts by mass, catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl -1,6-hexamethylenediamine) and 2.00 parts by mass of SH190 were mixed and then mixed to obtain a crosslinking agent mixture (B-5).

  And it is the same as that of Example 1 except having mixed 95.71 mass parts of crosslinking agent liquid mixture (B-5) and 1.23 mass parts of water (C) with respect to 100 mass parts of prepolymers (A-4). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. In addition, the NCO group residual amount in the prepolymer (A-4) in the mixture of 100 parts by mass of the prepolymer (A-4) and 95.71 parts by mass of the cross-linking agent mixed solution (B-5) is calculated as 3. In addition to 100 parts by mass of the prepolymer (A-4), 95.71 parts by mass of the crosslinking agent mixed solution (B-5) and 1.23 parts by mass of water (C) The residual amount of NCO groups in the prepolymer (A-4) is calculated to be 0.5% by mass.

(Example 6)
First, 41.21 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) in a beaker 51 parts by mass, 4.73 parts by mass of 1,3-butanediol (average molecular weight: 90.12, number of hydroxyl groups: 2), catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl- 1,6-hexamethylenediamine) and 0.049 parts by mass of SH190 and 2.49 parts by mass of SH190 were added and mixed to obtain a crosslinking agent mixture (B-6).

  And, with respect to 100 parts by mass of the prepolymer (A-1) used in Example 1, 64.92 parts by mass of the crosslinking agent mixed solution (B-6) and 0.52 parts by mass of water (C) were mixed. Were the same as in Example 1 to obtain a solventless urethane resin composition and a polyurethaneurea foam sheet. In addition, the NCO group residual amount in the prepolymer (A-1) in a mixture of 100 parts by mass of the prepolymer (A-1) and 64.92 parts by mass of the crosslinking agent mixed solution (B-6) is calculated as 2. 0.0 mass%, and in which 100 parts by mass of the prepolymer (A-1), 64.92 parts by mass of the crosslinking agent mixed solution (B-6) and 0.52 parts by mass of water (C) are mixed. The residual amount of NCO groups in the prepolymer (A-1) is calculated to be 0.5% by mass.

(Example 7)
First, 63.45 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and 24% polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) in a beaker. 93 parts by mass, 7.27 parts by mass of 1,3-butanediol (average molecular weight: 90.12, number of hydroxyl groups: 2), catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl- 1,2-hexamethylenediamine) and 0.124 parts by mass of SH190 and 4.24 parts by mass of SH190 were added and mixed to obtain a crosslinking agent mixture (B-7).

  And, with respect to 100 parts by mass of the prepolymer (A-1) used in Example 1, 30.10 parts by mass of the crosslinking agent mixed solution (B-7) and 1.23 parts by mass of water (C) were mixed. Were the same as in Example 1 to obtain a solventless urethane resin composition and a polyurethaneurea foam sheet. In addition, the NCO group residual amount in the prepolymer (A-1) in the mixture of 100 parts by mass of the prepolymer (A-1) and 30.10 parts by mass of the crosslinking agent mixed solution (B-7) is calculated to be 5 0.0 mass%, and in which 100 parts by mass of the prepolymer (A-1), 30.10 parts by mass of the crosslinking agent mixture (B-7) and 1.23 parts by mass of water (C) are mixed. The residual amount of NCO groups in the prepolymer (A-1) is calculated to be 0.5% by mass.

(Example 8)
First, 436 parts by mass of polytetramethylene glycol (number average molecular weight: 850), 351 parts by mass of MDI, and 12 parts by mass of Irganox 245 are charged into a four-necked separable flask, and then a temperature of 25 to 85 ° C. The mixture was reacted for 3 hours while passing nitrogen gas under normal pressure to obtain a prepolymer (A-5). The NCO group content in the obtained prepolymer (A-5) was 9.5% by mass.

  Next, in a beaker, 50.46 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) 44 .42 parts by mass, 1.27 parts by mass of 1,3-butanediol (average molecular weight: 90.12, number of hydroxyl groups: 2), catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl) -1,6-hexamethylenediamine) and 0.077 parts by mass of SH190 and 2.77 parts by mass of SH190 were added and mixed to obtain a cross-linking agent mixture (B-8).

  And it is the same as that of Example 1 except having mixed 54.78 mass parts of crosslinking agent mixed liquid (B-8) and 0.79 mass parts of water (C) with respect to 100 mass parts of prepolymers (A-5). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. In addition, the NCO group residual amount in the prepolymer (A-5) in the mixture of 100 parts by mass of the prepolymer (A-5) and 54.78 parts by mass of the cross-linking agent mixed solution (B-8) is calculated as 3. In which 100 parts by mass of the prepolymer (A-5), 54.78 parts by mass of the crosslinking agent mixed solution (B-8) and 0.97 parts by mass of water (C) are mixed. The residual amount of NCO groups in the prepolymer (A-5) is 0.5% by mass in calculation.

Example 9
First, 504 parts by mass of polytetramethylene glycol (number average molecular weight: 2000), 287 parts by mass of MDI, and 9 parts by mass of Irganox 245 were charged into a four-necked separable flask, and then the temperature was 25 to 85 ° C. The mixture was reacted for 3 hours while passing nitrogen gas under normal pressure to obtain a prepolymer (A-6). The NCO group content in the obtained prepolymer (A-6) was 9.5% by mass.

  Next, 23.32 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and 73 polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) were added to a beaker. .28 parts by mass, 1,3-butanediol (average molecular weight: 90.12, hydroxyl number: 2) 1.06 parts by mass, catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl -1,6-hexamethylenediamine) and 0.028 parts by mass of SH190 and 2.28 parts by mass of SH190 were mixed and mixed to obtain a cross-linking agent mixture (B-9).

  And it is the same as that of Example 1 except mixing 75.13 mass parts of crosslinking agent liquid mixture (B-9) and 1.1 mass parts of water (C) with respect to 100 mass parts of prepolymers (A-6). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. In addition, the NCO group residual amount in the prepolymer (A-6) in a mixture of 100 parts by mass of the prepolymer (A-6) and 75.13 parts by mass of the cross-linking agent mixed solution (B-9) is calculated as 3. 0.5 mass%, and a mixture of 100 parts by mass of the prepolymer (A-6), 75.13 parts by mass of the crosslinking agent mixture (B-9) and 1.1 parts by mass of water (C). The residual amount of NCO groups in the prepolymer (A-6) is calculated to be 0.5% by mass.

(Example 10)
First, 498 parts by mass of polytetramethylene glycol (number average molecular weight: 1000), 290 parts by mass of NBDI, and 12 parts by mass of Irganox 245 are charged into a four-neck separable flask, and then a temperature of 25 to 85 ° C. The mixture was reacted for 3 hours while passing nitrogen gas under normal pressure to obtain a prepolymer (A-7). The NCO group content in the obtained prepolymer (A-7) was 9.5% by mass.

  Next, in a beaker, 49.06 parts by mass of glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) 42 0.05 parts by mass, 1,3-butanediol (average molecular weight: 90.12, hydroxyl number: 2), 5.62 parts by mass, catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl) -1,6-hexamethylenediamine) and 0.11 part by mass of SH190 and 3.11 parts by mass of SH190 were mixed and mixed to obtain a cross-linking agent mixture (B-1).

  And it is the same as that of Example 1 except having mixed 45.96 mass parts of crosslinking agent liquid mixture (B-10), and 0.91 mass part of water (C) with respect to 100 mass parts of prepolymers (A-7). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. In addition, the NCO group residual amount in the prepolymer (A-7) in a mixture of 100 parts by mass of the prepolymer (A-7) and 45.96 parts by mass of the cross-linking agent mixed solution (B-10) is calculated as 3 Prepolymer (A-7) 100 parts by mass, crosslinker mixed solution (B-10) 45.96 parts by mass and water (C) 0.91 parts by mass The residual amount of NCO group in (A-7) is 0.5% by mass in calculation.

(Comparative Example 1)
First, 516 parts by mass of polytetramethylene glycol (number average molecular weight: 1000), 274 parts by mass of MDI, and 10 parts by mass of Irganox 245 are charged into a four-necked separable flask, and then a temperature of 25 to 85 ° C. The mixture was reacted for 3 hours while passing nitrogen gas under normal pressure to obtain a prepolymer (A-8). The NCO group content in the obtained prepolymer (A-8) was 6.0% by mass.

  Next, 69.65 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and 24 polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) were added to a beaker. .87 parts by mass, 1,3-butanediol (average molecular weight: 90.12, hydroxyl number: 2) 1.23 parts by mass, catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl -1,6-hexamethylenediamine) and 0.13 parts by mass of SH190 and 4.13 parts by mass of SH190 were mixed and mixed to obtain a crosslinking agent mixture (B-11).

  And it is the same as Example 1 except having mixed 31.08 mass parts of crosslinking agent mixed liquid (B-11) and 0.83 mass parts of water (C) with respect to 100 mass parts of prepolymers (A-8). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. In addition, the NCO group residual amount in the prepolymer (A-8) in a mixture of 100 parts by mass of the prepolymer (A-8) and 31.08 parts by mass of the cross-linking agent mixed solution (B-11) is calculated as 3. Prepolymer (A-8) 100 parts by mass, crosslinker mixed solution (B-11) 31.08 parts by mass and water (C) 0.83 parts by mass The residual amount of NCO group in (A-8) is 0.5% by mass in calculation.

(Comparative Example 2)
First, in a four-neck separable flask, 380 parts by mass of polytetramethylene glycol (number average molecular weight: 1000), 406 parts by mass of MDI, and 14 parts by mass of Irganox 245 were charged, and then the temperature was 25 to 85 ° C. The mixture was reacted for 3 hours while passing nitrogen gas under normal pressure to obtain a prepolymer (A-9). The NCO group content in the obtained prepolymer (A-9) was 13% by mass.

  Next, 36.35 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and 57 polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) were added to a beaker. .12 parts by mass, 1.16 parts by mass of 1,3-butanediol (average molecular weight: 90.12, number of hydroxyl groups: 2), catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl) -1,6-hexamethylenediamine) and 0.031 parts by mass of SH190 and 2.31 parts by mass of SH190 were mixed to obtain a cross-linking agent mixture (B-12).

  And Example 1 except mixing 73.94 mass parts of crosslinking agent liquid mixture (B-12) and 1.10 mass parts of water (C) with respect to 100 mass parts of prepolymers (A-9). In the same manner as above, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. In addition, the NCO group residual amount in the prepolymer (A-9) in the mixture of 100 parts by mass of the prepolymer (A-9) and 73.94 parts by mass of the cross-linking agent mixed solution (B-12) is calculated as 3. Prepolymer (A-9) 100 parts by weight, crosslinker mixed solution (B-12) 73.94 parts by weight and water (C) 1.1 parts by weight The residual amount of NCO group in (A-9) is 0.5% by mass in calculation.

(Comparative Example 3)
First, 58.10 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) in a beaker are 10. 37 parts by mass, 26.87 parts by mass of 1,3-butanediol (average molecular weight: 90.12, number of hydroxyl groups: 2), catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl- 1,2-hexamethylenediamine) and 0.14 parts by mass of SH190 and 4.54 parts by mass of SH190 were added and mixed to obtain a cross-linking agent mixture (B-13).

  And, with respect to 100 parts by mass of the prepolymer (A-3) used in Example 3, 27.56 parts by mass of the crosslinking agent mixture (B-13) and 0.80 parts by mass of water (C) were mixed. Were similar to Example 3 to obtain a solventless urethane resin composition and a polyurethaneurea foam sheet. In addition, NCO group residual amount in prepolymer (A-3) in what mixed 100 mass parts of prepolymer (A-3) and 27.56 mass parts of crosslinking agent mixed liquid (B-13) was 3.5. And a prepolymer in which 100 parts by mass of the prepolymer (A-3), 27.56 parts by mass of the crosslinking agent mixed solution (B-13) and 0.8 part by mass of water (C) are mixed. The remaining amount of NCO group in (A-3) is 0.5% by mass in calculation.

(Comparative Example 4)
First, 39.48 parts by mass of a glycerin-based propylene oxide / ethylene oxide adduct (hydroxyl value: 24, hydroxyl number: 3) and polytetramethylene glycol (number average molecular weight: 1000, hydroxyl number: 2) 53. 58 parts by mass, 4.5 parts by mass of 1,3-butanediol (average molecular weight: 90.12, number of hydroxyl groups: 2), catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl- 1,6-Hexamethylenediamine) and 0.035 parts by mass of SH190 and 2.35 parts by mass of SH190 were added and mixed to obtain a crosslinking agent mixture (B-14).

  And, with respect to 100 parts by mass of the prepolymer (A-1) used in Example 1, 71.64 parts by mass of the crosslinking agent mixed solution (B-14) and 0.36 parts by mass of water (C) were mixed. Were the same as in Example 1 to obtain a solventless urethane resin composition and a polyurethaneurea foam sheet. In addition, the NCO group residual amount in the prepolymer (A-1) in the mixture of 100 parts by mass of the prepolymer (A-1) and 71.64 parts by mass of the crosslinking agent mixed solution (B-14) is calculated as 1. Prepolymer (A-1) 100 parts by mass, crosslinker mixed solution (B-14) 71.64 parts by mass and water (C) 0.36 parts by mass The residual amount of NCO group in (A-1) is 0.5% by mass in calculation.

(Comparative Example 5)
A four-necked separable flask is charged with 283 parts by mass of polytetramethylene glycol (number average molecular weight: 250), 505 parts by mass of MDI, and 12 parts by mass of Irganox 245, and then at a temperature of 25 to 85 ° C under normal pressure. The mixture was reacted for 3 hours while passing nitrogen gas through to obtain a prepolymer (A-10). The NCO group content in the obtained prepolymer (A-10) was 9.5% by mass. Moreover, since the obtained prepolymer (A-10) is solid at normal temperature and cannot obtain fluidity even when heated at a temperature of 80 ° C. for 8 hours, a solventless urethane resin composition is prepared. I couldn't.

(Comparative Example 6)
Except not adding water (C) when mixing 45.93 mass parts of crosslinking agent mixed liquid (B-1) with respect to 100 mass parts of prepolymer (A-1) used in Example 1. In the same manner as in Example 1, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. In addition, the NCO group residual amount in the prepolymer (A-1) in the mixture of 100 parts by mass of the prepolymer (A-1) and 45.93 parts by mass of the cross-linking agent mixed solution (B-1) is calculated as 3. .5% by mass.

(Comparative Example 7)
Implemented except that 45.93 parts by mass of the crosslinking agent mixed solution (B-1) and 1.84 parts by mass of water (C) were mixed with 100 parts by mass of the prepolymer (A-1) used in Example 1. In the same manner as in Example 1, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. In addition, the NCO group residual amount in the prepolymer (A-1) in the mixture of 100 parts by mass of the prepolymer (A-1) and 45.93 parts by mass of the cross-linking agent mixed solution (B-1) is calculated as 3. In addition to 100 parts by mass of the prepolymer (A-1), 45.93 parts by mass of the cross-linking agent mixed solution (B-1) and 1.84 parts by mass of water (C). The NCO group residual amount in the prepolymer (A-1) is less than 0.01% by mass in calculation, and the water content in the solventless urethane resin composition is excessive.

<Evaluation of productivity of polyurethane urea foam sheet>
The productivity (foaming state, workability) of the polyurethaneurea foam sheets obtained in Examples 1 to 10 and Comparative Examples 1 to 7 was evaluated by the following methods. The obtained results are shown in Table 1. Moreover, the kind of isocyanate of prepolymer (A) used in Examples 1-10 and Comparative Examples 1-7, the molecular weight of a polyol, the number average molecular weight of a crosslinking agent (B), and the prepolymer of water (C) ( A) The content with respect to 100 parts by mass is shown in Table 1. Furthermore, in the solvent-free urethane resin compositions obtained in Examples 1 to 10 and Comparative Examples 1 to 7, the viscosity at a temperature of 25 ° C., the NCO group content in the prepolymer (A), the prepolymer (A) and NCO group residual amount in the prepolymer (A) in the mixture of the crosslinking agent (B), prepolymer (A) in the mixture of the prepolymer (A), the crosslinking agent (B) and water (C) Table 1 shows the residual amount of NCO groups in the solvent and the number average molecular weights of all polyols.

(I) Method for evaluating foamed state of polyurethaneurea foam sheet The foamed state of the obtained polyurethaneurea foam sheet was evaluated based on the following criteria.
A: Smooth and uniform foaming.
B: Almost uniform foaming.
C: It is not uniform foaming.
D: The foam sheet is not sufficiently foamed, or the foam sheet has insufficient strength due to excessive foaming.

(Ii) Method for evaluating workability in a method for producing a polyurethaneurea foam sheet Workability in a method for producing a polyurethaneurea foam sheet was evaluated based on the following criteria.
A: Viscosity is good, blending and coating are not hindered, and air bubbles are good.
B: There is no problem in blending and coating.
C: Viscosity is not suitable, and there is some influence on the formulation and coating.
D: Viscosity is too high and there is a problem in blending and coating, or the viscosity is too low and bubbles are removed.

  As apparent from the results shown in Table 1, according to the method for producing a solventless polyurethaneurea foam sheet of the present invention (Examples 1 to 10), a sufficiently uniform polyurethaneurea foam sheet was obtained. It was confirmed that it can be produced efficiently.

<Evaluation of physical properties of polyurethane urea foam sheet>
About the polyurethane urea foam sheets obtained in Examples 1 to 10 and Comparative Examples 1 to 4 and 6 to 7, the physical properties of the polyurethane urea foam sheets [thickness, density, 100% modulus (100% M) by the following method , 200% modulus (200% M), 300% modulus (300% M), elongation (EB), tensile strength (TSB), loss tangent (tan δ), glass transition point (Tg)]. The obtained results are shown in Table 2. Moreover, about the measured value of 100% modulus and tensile strength, the numerical value which divided those measured values by the measured value of density was computed. The obtained results are shown in Table 2.

(I) Measuring method of thickness and density The thickness of the sample was measured using a Digimatic indicator (ID-C112 manufactured by Mitutoyo Corporation). Then, the vertical and horizontal dimensions and mass of the sample were measured, the volume was calculated from the result, and the mass divided by the volume was taken as the density of the sample.

(Ii) Measuring method of 100 to 300% modulus Using a tensile tester (Tensilon manufactured by A & D), the sample was measured for 100 to 300% modulus, elongation, and tensile strength. The modulus means a value (unit: MPa) obtained by dividing the load when a specific elongation is given to the sample by the cross-sectional area before the test, and 100% modulus indicates a value when the elongation is 100%, 300% The modulus is a value at an elongation of 300%. Elongation refers to the percentage (%) divided by the length of elongation when the test breaks in the tensile test. Tensile strength refers to the tensile test with which the sample can withstand even greater loads beyond the yield point and yield strength. And the value (unit: MPa) obtained by dividing the maximum load at that time by the cross-sectional area before the test.

(Iii) Measuring method of elongation and tensile strength Using a tensile testing machine (manufactured by Shimadzu Corporation, product name “Autograph”), the elongation and tensile strength of the sample were measured. In addition, elongation means the percentage (%) which divided the length of the sample when the sample broke in the tensile test by the length before the test. Further, the tensile strength is a value (unit: MPa) obtained by dividing the maximum load at that time by the cross-sectional area before the test, assuming that the sample exceeded the yield point and yield strength in the tensile test and withstood a larger load.

(Iv) Measuring method of loss tangent and glass transition point The loss tangent and glass transition point of the sample were measured using a dynamic viscoelasticity measuring apparatus (manufactured by Rheometrics). That is, using a dynamic viscoelasticity measuring apparatus, the storage elastic modulus (E ′), loss elastic modulus (E ″), and loss tangent [tan δ = (E ′) of the sample at a heating rate of 5 ° C./min and a frequency of 10 Hz. '/ E')] is measured, and from the measurement results, the maximum values of the loss modulus (E '') and loss tangent (tan δ) are analyzed, and the maximum value of loss tangent (tan δ) is determined as the loss tangent ( tan δ), and the temperature at which the loss tangent (tan δ) is the maximum is the glass transition point (Tg).

  As is apparent from the results shown in Table 2, the solventless polyurethaneurea foam sheets (Examples 1 to 10) obtained by the production method of the present invention have sufficient physical properties as polyurethaneurea foam sheets used for synthetic leather. It was confirmed to have On the other hand, the polyurethane urea foam sheet obtained in Comparative Example 3 had a low measured value of elongation and a high glass transition point. Therefore, it was confirmed that the polyurethaneurea foam sheet obtained in Comparative Example 3 was insufficient in elongation and inferior in heat resistance. Moreover, it was confirmed that the polyurethane urea foam sheet obtained in Comparative Example 4 has low measured values of elongation and tensile strength and is insufficient in elongation and strength.

  As described above, according to the present invention, a polyurethane urea foam sheet having sufficient elongation and strength can be obtained by using a solventless urethane resin composition having good fluidity at the time of mixing raw materials without being heated and melted. It is possible to provide a method for producing a polyurethaneurea foam sheet that can be produced efficiently, and a polyurethaneurea foam sheet obtained by the production method.

  Therefore, the method for producing a polyurethaneurea foam sheet of the present invention is useful as a technique for producing a polyurethaneurea foam sheet that can be suitably used particularly as a material for synthetic leather.

Claims (9)

A prepolymer (A) obtained by reacting a diisocyanate compound with a polyol having a molecular weight of 500 to 3000, a crosslinking agent (B) having an average number of hydroxyl groups of 2 to 4 and comprising a polyol, and water (C). The following conditions:
The isocyanate group content in the prepolymer (A) is 7.0 to 12.0% by mass,
When the content of the cross-linking agent (B) is a mixture of the prepolymer (A) and the cross-linking agent (B), the residual amount of isocyanate groups in the prepolymer (A) is 2.0 to 5.0. The amount is in the range of mass%,
When the content of the water (C) is a mixture of the prepolymer (A), the cross-linking agent (B) and the water (C), the residual amount of isocyanate groups in the prepolymer (A) is 0.00. In an amount ranging from 01 to 0.5% by weight, and
The number average molecular weight of all the polyols when the polyol which is one of the raw materials of the prepolymer (A) and the polyol in the crosslinking agent (B) are mixed is 600 or more.
Prepare a solventless urethane resin composition that satisfies
A solvent-free polyurethane-urea foam sheet obtained by foaming the solvent-free urethane resin composition with air or an inert gas, and then forming the sheet and heating and curing it. The solventless polyurethaneurea foam sheet according to claim 1, wherein the crosslinking agent (B) is a crosslinking agent comprising a polyol having an average number of hydroxyl groups of 2 to 4 and a molecular weight of 60 to 3000. The solvent-free polyurethane urea foam sheet according to claim 1, wherein the content of water (C) is 0.2 to 1.5 parts by mass with respect to 100 parts by mass of the prepolymer (A). A prepolymer (A) obtained by reacting a diisocyanate compound with a polyol having a molecular weight of 500 to 3000, a crosslinking agent (B) having an average number of hydroxyl groups of 2 to 4 and comprising a polyol, and water (C). The following conditions:
The isocyanate group content in the prepolymer (A) is 7.0 to 12.0% by mass,
When the content of the cross-linking agent (B) is a mixture of the prepolymer (A) and the cross-linking agent (B), the residual amount of isocyanate groups in the prepolymer (A) is 2.0 to 5.0. The amount is in the range of mass%,
When the content of the water (C) is a mixture of the prepolymer (A), the cross-linking agent (B) and the water (C), the residual amount of isocyanate groups in the prepolymer (A) is 0.00. In an amount ranging from 01 to 0.5% by weight, and
The number average molecular weight of all the polyols when the polyol which is one of the raw materials of the prepolymer (A) and the polyol in the crosslinking agent (B) are mixed is 600 or more.
Preparing a solventless urethane resin composition that satisfies
A step of obtaining a foamed urethane resin composition by foaming air or an inert gas into the solventless urethane resin composition;
Molding the foamed urethane resin composition into a sheet, heating and curing to obtain a solventless polyurethaneurea foam sheet; and
A process for producing a solventless polyurethaneurea foam sheet. The method for producing a solventless polyurethaneurea foam sheet according to claim 4, wherein the crosslinking agent (B) is a crosslinking agent comprising a polyol having an average number of hydroxyl groups of 2 to 4 and a molecular weight of 60 to 3000. The solvent-free polyurethaneurea foam sheet according to claim 4, wherein the content of water (C) is 0.2 to 1.5 parts by mass with respect to 100 parts by mass of the prepolymer (A). Method. The manufacturing method of the solventless type polyurethane urea foam sheet of Claim 4 whose viscosity in the temperature of 25 degreeC of the said prepolymer (A) is 4000-30000 mPa * s. 5. In the step of obtaining the foamed urethane resin composition, air or an inert gas having a volume of 5 to ³⁰ cm ^{3 at} a temperature of 25 ° C. is foamed with respect to 100 parts by mass of the solventless urethane resin composition. A process for producing a solventless polyurethaneurea foam sheet according to claim 1. A synthetic leather comprising the solventless polyurethaneurea foam sheet according to any one of claims 1 to 3.