WO2009119752A1 - 無溶剤型ポリウレタンウレア発泡体シート及びその製造方法並びに合成皮革 - Google Patents
無溶剤型ポリウレタンウレア発泡体シート及びその製造方法並びに合成皮革 Download PDFInfo
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- WO2009119752A1 WO2009119752A1 PCT/JP2009/056151 JP2009056151W WO2009119752A1 WO 2009119752 A1 WO2009119752 A1 WO 2009119752A1 JP 2009056151 W JP2009056151 W JP 2009056151W WO 2009119752 A1 WO2009119752 A1 WO 2009119752A1
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- prepolymer
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- foam sheet
- solventless
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Classifications
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
- D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/08—Processes
- C08G18/10—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/40—High-molecular-weight compounds
- C08G18/48—Polyethers
- C08G18/4854—Polyethers containing oxyalkylene groups having four carbon atoms in the alkylene group
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0008—Foam properties flexible
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0083—Foam properties prepared using water as the sole blowing agent
Definitions
- the present invention relates to a solventless polyurethane urea foam sheet, a method for producing the same, and a synthetic leather provided with the solventless polyurethane urea foam sheet.
- Synthetic leather and artificial leather are used as substitutes for natural leather.
- 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
- Japanese Patent Application Laid-Open No. 2003-306526 discloses a moisture-curable hot-melt urethane resin composition that does not contain an organic solvent.
- the resin composition as described in Document 2 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.
- 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.
- a solvent-free urethane resin composition having fluidity 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.
- 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
- a solvent-free urethane resin composition in which an agent and water are blended so as to satisfy specific conditions.
- the process for producing a 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 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
- the content of the crosslinking agent (B) is such that the residual amount of isocyanate groups in the prepolymer (A) when the prepolymer (A) and the crosslinking agent (B) are mixed 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.
- 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. It is preferable that
- 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
- the viscosity of the prepolymer (A) at a temperature of 25 ° C. is preferably 4000 to 30000 mPa ⁇ s.
- 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
- the content of the crosslinking agent (B) is such that the residual amount of isocyanate groups in the prepolymer (A) when the prepolymer (A) and the crosslinking agent (B) are mixed 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.
- the solvent-free urethane resin composition is foamed with air or an inert gas, and then molded into a sheet and heated and cured.
- 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.
- 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). Is preferred.
- the synthetic leather of the present invention is provided with the solventless polyurethane urea foam sheet of the present invention.
- 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.
- the process for producing a 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 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
- the content of the crosslinking agent (B) is such that the residual amount of isocyanate groups in the prepolymer (A) when the prepolymer (A) and the crosslinking agent (B) are mixed 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.
- the solventless urethane resin composition used in the method for producing the solventless polyurethaneurea foam sheet of the present invention includes a prepolymer (A) obtained by reacting a diisocyanate compound with a polyol having a molecular weight of 500 to 3000, a crosslinking 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.
- the content of isocyanate groups (NCO group content) in such a prepolymer (A) needs to be in the range of 7.0 to 12.0% by 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.
- diisocyanate compound used for obtaining such a prepolymer (A) examples include 4,4′-diphenylmethane diisocyanate (hereinafter sometimes referred to as “MDI”), toluene diisocyanate (hereinafter sometimes referred to as “TDI”), isophorone, and the like.
- MDI 4,4′-diphenylmethane diisocyanate
- TDI toluene diisocyanate
- isophorone isophorone
- IPDI Diisocyanate
- NBDI norbornane diisocyanate
- XDI xylene diisocyanate
- HDI hexamethylene diisocyanate
- H 12 MDI 4, 4′-dicyclohexylmethane diisocyanate
- TODI o-tridin diisocyanate
- MDI is preferable from the viewpoint of being economically preferable and having excellent physical properties.
- these diisocyanate compounds may be used individually by 1 type, or may mix and use 2 or more types.
- the polyol used for obtaining such a prepolymer (A) is a polyol having a molecular weight of 500 to 3000 (preferably a molecular weight of 1000 to 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) 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.
- Examples of such a cross-linking agent include a cross-linking agent consisting of a polyol having a molecular weight of 60 to 10,000 (more preferably, a molecular weight of 60 to 3000). Such crosslinking agents may be used alone or in combination of two or more.
- a compound having 3 or more hydroxyl groups in one molecule may be used as a polyol used as a crosslinking agent.
- 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.
- n represents an integer of 3 or more.
- R 1 represents an alkylene group
- R 3 C group
- R 3 represents an organic group
- R 2 represents an alkylene group, an oxyalkylene group or the like.
- 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.
- 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.
- glycol having 2 hydroxyl groups those having a molecular weight of 60 to 3000 are preferably used.
- 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. Is required to be in the range of 2.0 to 5.0% by mass.
- 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.
- 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%.
- 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 The amount is preferably in the range of 3.0 to 4.5% by mass.
- 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.
- 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.
- the content of such water (C) is preferably 0.2 to 1.5 parts by mass, and 0.5 to 1.0 parts by mass with respect to 100 parts by mass of the prepolymer (A). 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.
- the solventless urethane resin composition according to the present invention may further contain a catalyst and a foam stabilizer as necessary.
- catalysts include dibutyltin dilaurate, tin octylate, dibutyltin oxide, bismuth octylate, zinc octylate, aluminum octylate, and the like; 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-
- the amount of such a catalyst added is not particularly limited, but the prepolymer (A) 100 mass
- the amount is preferably 0.001 to 0.2 parts by mass with respect to parts.
- foam stabilizer examples 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.
- SRX290A BY10-124, SF2935F, SF2945F, SF2944F, SF2936F, SH193, SH192H, SH192, SF2909, SH194, SH190, SRX290A, SRX298, Z11, Z11, Z11 SZ1162, L3601, L5309, L5366, SZ1306 SZ1311, 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.
- 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.
- 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 from 4000 to 30000 mPa ⁇ s, more preferably from 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.
- 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.
- the solventless urethane resin composition is bubbled with air or an inert gas to obtain a foamed urethane resin composition.
- 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 .
- 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
- 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.
- the foamed urethane resin composition is formed into a sheet shape, heated and cured to obtain a solventless polyurethane urea foam sheet.
- 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.
- a coating method a method using a doctor knife coater, a comma coater, a die coater or the like can be employed.
- 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.
- 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 be in the range of 0.15 to 0.60 mm.
- the reaction for curing the foamed urethane resin composition after molding is preferably performed in an atmosphere at a temperature of 80 to 130 ° C., for example.
- the solventless polyurethane urea 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.
- the glass transition point is ⁇ 15 ° C. or lower (more preferably ⁇ 20 ° C. or lower).
- 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).
- the elongation is 200% or more (more preferably 300% or more).
- 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.
- the thickness of the solventless polyurethaneurea foam sheet of the present invention is not particularly limited because it varies depending on the application, but is generally about 0.15 to 0.60 mm when used as a synthetic leather material. 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.
- 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.
- any fiber base material conventionally used as a synthetic leather fiber base material may be used, and examples thereof include an ultrafine fiber nonwoven fabric, a nonwoven fabric, a woven fabric, and a knitted fabric.
- a fiber base fabric base material may have one side or both sides raised.
- a skin layer mainly composed of polyurethane may be laminated on the surface of the solventless polyurethaneurea foam sheet as in the case of conventional synthetic leather.
- 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 ⁇ m.
- 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
- 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.
- 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.
- each layer may be created separately and laminated and integrated with an adhesive.
- 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 reaction was allowed to proceed for 3 hours while passing nitrogen gas at ⁇ 85 ° C. under normal pressure to obtain Prepolymer (A-1). The resulting prepolymer (A-1) had an NCO group content of 9.5% by mass.
- a solvent-free urethane resin composition was prepared by mixing 45.93 parts by mass of the cross-linking agent mixed solution (B-1) and 0.92 parts by mass of water (C) with respect to 100 parts by mass of the prepolymer (A-1). I got a thing. Note that the residual amount of NCO groups in the prepolymer (A-1) in a mixture of 100 parts by weight of the prepolymer (A-1) and 45.93 parts by weight of the cross-linking agent mixed solution (B-1) was calculated to be 3 In which 100 parts by mass of the prepolymer (A-1), 45.93 parts by mass of the crosslinking agent mixed solution (B-1) and 0.92 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.
- 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, and mixed with dry air.
- the density was 0.8 to 0.9 g /
- a coating composition (foamed urethane resin composition) in the range of cm 3 was obtained.
- 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, 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 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-2). The obtained prepolymer (A-2) had an NCO group content of 7% by mass.
- Example 2 The same as Example 1 except that 100 parts by mass of the prepolymer (A-2) was mixed with 25.69 parts by mass of the crosslinking agent mixed solution (B-2) and 0.79 parts by mass of water (C). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. Note that the residual amount of NCO groups in the prepolymer (A-2) in a mixture of 100 parts by weight of the prepolymer (A-2) and 25.69 parts by weight of the cross-linking agent mixed solution (B-2) was calculated to be 3 In addition, 100 parts by mass of the prepolymer (A-2), 25.69 parts by mass of the crosslinking agent mixture (B-2) and 0.79 parts by mass of water (C) are mixed. The residual amount of NCO groups in the prepolymer (A-2) is calculated to be 0.5% by mass.
- 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 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-3). The resulting prepolymer (A-3) had an NCO group content of 12% by mass.
- Example 2 The same procedure as in Example 1 was conducted except that 65.98 parts by mass of the crosslinking agent mixed solution (B-3) and 1.04 parts by mass of water (C) were mixed with 100 parts by mass of the prepolymer (A-3). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained.
- the residual amount of NCO groups in the prepolymer (A-3) in a mixture of 100 parts by mass of the prepolymer (A-3) and 65.98 parts by mass of the cross-linking agent mixed solution (B-3) was calculated to be 3 In which 100 parts by mass of the prepolymer (A-3), 65.98 parts by mass of the crosslinking agent mixture (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, 20.55 parts by mass of 1,3-butanediol (average molecular weight: 90.12, hydroxyl number: 2), catalyst (dibutyltin dilaurate and N, N, N ′, N′-tetramethyl- 1,4-hexamethylenediamine) and 0.13 part by weight of SH190 were added and then mixed to obtain a crosslinking agent mixture (B-4).
- a crosslinking agent mixture B-4
- the residual amount of NCO groups 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) was calculated to be 3 In which 100 parts by weight of the prepolymer (A-1), 24.79 parts by weight of the crosslinking agent mixed solution (B-4) and 0.79 parts by weight 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 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 resulting prepolymer (A-4) had an NCO group content of 10% by mass.
- Example 2 The same procedure as in Example 1 was conducted except that 95.71 parts by mass of the crosslinking agent mixed solution (B-5) and 1.23 parts by mass of water (C) were mixed with 100 parts by mass of the prepolymer (A-4). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained.
- the residual amount of NCO groups in the prepolymer (A-4) in a 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) was calculated to be 3 In which 100 parts by mass of the prepolymer (A-4), 95.71 parts by mass of the crosslinking agent mixture (B-5) and 1.23 parts by mass of water (C) are mixed.
- 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 2.49 parts by weight of SH190 were charged and mixed to obtain a crosslinking agent mixture (B-6).
- a crosslinking agent mixture B-6.
- 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.
- Example 1 100 parts by mass of the prepolymer (A-1) used in Example 1 was mixed with 30.10 parts by mass of the crosslinking agent mixture (B-7) and 1.23 parts by mass of water (C). Were the same as in Example 1 to obtain a solventless urethane resin composition and a polyurethaneurea foam sheet.
- the residual amount of NCO groups in the prepolymer (A-1) in a mixture of 100 parts by weight of the prepolymer (A-1) and 30.10 parts by weight of the cross-linking agent mixed solution (B-7) was calculated to be 5 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 were charged into a four-necked separable flask. 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.
- Example 2 The same procedure as in Example 1 was conducted except that 54.78 parts by mass of the crosslinking agent mixed solution (B-8) and 0.79 parts by mass of water (C) were mixed with 100 parts by mass of the prepolymer (A-5). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained.
- the residual amount of NCO groups in the prepolymer (A-5) in a 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) was calculated to be 3 In which 100 parts by weight of the prepolymer (A-5), 54.78 parts by weight of the crosslinking agent mixed solution (B-8) and 0.97 parts by weight 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. The mixture was reacted for 3 hours while passing nitrogen gas under normal pressure to obtain a prepolymer (A-6). The resulting prepolymer (A-6) had an NCO group content of 9.5% by mass.
- Example 2 The same as Example 1 except that 100 parts by mass of the prepolymer (A-6) was mixed with 75.13 parts by mass of the crosslinking agent mixed solution (B-9) and 1.1 parts by mass of water (C). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained.
- the amount of residual NCO groups in the prepolymer (A-6) in a mixture of 100 parts by weight of the prepolymer (A-6) and 75.13 parts by weight of the cross-linking agent mixed solution (B-9) was calculated to be 3 0.5 mass%, and in which 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) were mixed.
- 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-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-7). The resulting prepolymer (A-7) had an NCO group content of 9.5% by mass.
- Example 2 The same procedure as in Example 1 was conducted except that 45.96 parts by mass of the crosslinking agent mixed solution (B-10) and 0.91 parts by mass of water (C) were mixed with 100 parts by mass of the prepolymer (A-7). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained.
- the residual amount of NCO groups 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 crosslinking agent mixed solution (B-10) was calculated to be 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.
- Example 2 The same procedure as in Example 1 was conducted except that 31.08 parts by mass of the crosslinking agent mixed solution (B-11) and 0.83 parts by mass of water (C) were mixed with 100 parts by mass of the prepolymer (A-8). Thus, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained.
- the residual amount of NCO groups 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 crosslinking agent mixed solution (B-11) was calculated to be 3 Prepolymer (A-8) in which 100 parts by mass of the prepolymer (A-8), 31.08 parts by mass of the crosslinking agent mixed solution (B-11) and 0.83 parts by mass of water (C) are mixed.
- the residual amount of NCO group in (A-8) is 0.5% by mass in calculation.
- Example 1 except that 73.94 parts by mass of the crosslinking agent mixed solution (B-12) and 1.10 parts by mass of water (C) were mixed with 100 parts by mass of the prepolymer (A-9).
- a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained.
- the residual amount of NCO groups in the prepolymer (A-9) in a 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) was calculated to be 3 Prepolymer (A-9) 100 parts by mass, crosslinker mixed solution (B-12) 73.94 parts by mass and water (C) 1.1 parts by mass
- the residual amount of NCO group in (A-9) is 0.5% by mass in calculation.
- Example 3 100 parts by mass of the prepolymer (A-3) used in Example 3 was mixed with 27.56 parts by mass of the crosslinking agent mixed solution (B-13) and 0.80 parts by mass of water (C). Were similar to Example 3 to obtain a solventless urethane resin composition and a polyurethaneurea foam sheet.
- the residual amount of NCO groups in the prepolymer (A-3) in a mixture of 100 parts by mass of the prepolymer (A-3) and 27.56 parts by mass of the crosslinking agent mixed solution (B-13) was 3.5.
- Example 6 Comparative Example 6 Except that 100 parts by mass of the prepolymer (A-1) used in Example 1 was mixed with 45.93 parts by mass of the crosslinking agent mixed solution (B-1), water (C) was not added. In the same manner as in Example 1, a solventless urethane resin composition and a polyurethaneurea foam sheet were obtained. Note that the residual amount of NCO groups in the prepolymer (A-1) in a mixture of 100 parts by weight of the prepolymer (A-1) and 45.93 parts by weight of the cross-linking agent mixed solution (B-1) was calculated to be 3 .5% by mass.
- the residual amount of NCO groups in the prepolymer (A-1) in a mixture of 100 parts by weight of the prepolymer (A-1) and 45.93 parts by weight of the cross-linking agent mixed solution (B-1) was calculated to be 3 In which 100 parts by weight of the prepolymer (A-1), 45.93 parts by weight of the cross-linking agent mixed solution (B-1) and 1.84 parts by weight of water (C) are mixed.
- the residual amount of NCO groups in the prepolymer (A-1) is calculated to be less than 0.01% by mass, and the water content in the solventless urethane resin composition is excessive.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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 as a material for synthetic leather.
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Abstract
Description
前記プレポリマー(A)中のイソシアネート基の含有量が7.0~12.0質量%であり、
前記架橋剤(B)の含有量が、前記プレポリマー(A)及び前記架橋剤(B)を混合した場合における前記プレポリマー(A)中のイソシアネート基の残存量が2.0~5.0質量%の範囲となる量であり、
前記水(C)の含有量が、前記プレポリマー(A)、前記架橋剤(B)及び前記水(C)を混合した場合における前記プレポリマー(A)中のイソシアネート基の残存量が0.01~0.5質量%の範囲となる量であり、且つ、
前記プレポリマー(A)の原料の一つであるポリオールと前記架橋剤(B)中のポリオールとを混合した場合における全てのポリオールの数平均分子量が600以上である、
を満たす無溶剤型ウレタン樹脂組成物を準備する工程と、
前記無溶剤型ウレタン樹脂組成物に空気又は不活性ガスを含泡せしめて含泡ウレタン樹脂組成物を得る工程と、
前記含泡ウレタン樹脂組成物をシート状に成形し、加熱して硬化させて無溶剤型ポリウレタンウレア発泡体シートを得る工程と、
を含む、方法である。
前記プレポリマー(A)中のイソシアネート基の含有量が7.0~12.0質量%であり、
前記架橋剤(B)の含有量が、前記プレポリマー(A)及び前記架橋剤(B)を混合した場合における前記プレポリマー(A)中のイソシアネート基の残存量が2.0~5.0質量%の範囲となる量であり、
前記水(C)の含有量が、前記プレポリマー(A)、前記架橋剤(B)及び前記水(C)を混合した場合における前記プレポリマー(A)中のイソシアネート基の残存量が0.01~0.5質量%の範囲となる量であり、且つ、
前記プレポリマー(A)の原料の一つであるポリオールと前記架橋剤(B)中のポリオールとを混合した場合における全てのポリオールの数平均分子量が600以上である、
を満たす無溶剤型ウレタン樹脂組成物を準備し、
前記無溶剤型ウレタン樹脂組成物に空気又は不活性ガスを含泡せしめた後に、シート状に成形し、加熱して硬化させてなる、ものである。
前記プレポリマー(A)中のイソシアネート基の含有量が7.0~12.0質量%であり、
前記架橋剤(B)の含有量が、前記プレポリマー(A)及び前記架橋剤(B)を混合した場合における前記プレポリマー(A)中のイソシアネート基の残存量が2.0~5.0質量%の範囲となる量であり、
前記水(C)の含有量が、前記プレポリマー(A)、前記架橋剤(B)及び前記水(C)を混合した場合における前記プレポリマー(A)中のイソシアネート基の残存量が0.01~0.5質量%の範囲となる量であり、且つ、
前記プレポリマー(A)の原料の一つであるポリオールと前記架橋剤(B)中のポリオールとを混合した場合における全てのポリオールの数平均分子量が600以上である、
を満たす無溶剤型ウレタン樹脂組成物を準備する工程と、
前記無溶剤型ウレタン樹脂組成物に空気又は不活性ガスを含泡せしめて含泡ウレタン樹脂組成物を得る工程と、
前記含泡ウレタン樹脂組成物をシート状に成形し、加熱して硬化させて無溶剤型ポリウレタンウレア発泡体シートを得る工程と、
を含む、方法である。
R1(R2OH)n (1)
で表される化合物が挙げられる。なお、前記一般式(1)において、nは3以上の整数を示す。また、R1は、アルキレン基、R3C=基、(R3は有機基を示す)等を示し、R2は、アルキレン基、オキシアルキレン基等を示す。前記一般式(1)で表される化合物としては、水酸基数が3以上(好ましくは3~6)であり、分子量が100~10000のものを用いることが好ましい。さらに、前記一般式(1)で表される化合物としては、例えば、ポリエチレングリコール、ポリプロピレングリコール、ポリテトラメチレングリコール、トリメチロールプロパン、グリセリン等の活性水素含有化合物に、プロピレンオキサイドやエチレンオキサイド等のアルキレンオキサイド又はテトラヒドロフラン等を付加重合させたポリオキシアルキレンポリオールが挙げられる。
(i)ガラス転移点が-15℃以下(より好ましくは-20℃以下)であること。
(ii)未発泡状態における引張強度〔(引張強度の測定値)/(密度の測定値)〕が4MPa以上(より好ましくは6MPa以上)であること。
(iii)伸びが200%以上(より好ましくは300%以上)であること。
(iv)損失正接が0.35以上(より好ましくは0.45以上)であること。
(v)未発泡状態における100%モジュラス〔(100%モジュラスの測定値)/(密度の測定値)〕が4MPa以下(より好ましくは3MPa以下)であること。
これらの物性を全て満たすものであれば、強度を必要とする合成皮革(例えば、車両用シート等に用いる合成皮革)の材料として好適に使用することができる。なお、これらの物性を一部満たさないものであっても、強度を必要としない合成皮革(例えば、ドアに用いる合成皮革)の材料として使用することができる。なお、これらの物性は、後述する実施例に記載の方法により測定することができる。
先ず、4つ口セパラブルフラスコ(容量1L)に、ポリテトラメチレングリコール(数平均分子量:1000)を447質量部、MDIを341質量部、及びイルガノックス245を12質量部仕込み、その後、温度25~85℃、常圧下で窒素ガスを通じつつ3時間反応せしめて、プレポリマー(A-1)を得た。得られたプレポリマー(A-1)におけるNCO基含有量は9.5質量%であった。
先ず、4つ口セパラブルフラスコに、ポリテトラメチレングリコール(数平均分子量:1000)を500質量部、MDIを291質量部、及びイルガノックス245を9質量部仕込み、その後、温度25~85℃、常圧下で窒素ガスを通じつつ3時間反応せしめて、プレポリマー(A-2)を得た。得られたプレポリマー(A-2)におけるNCO基含有量は7質量%であった。
先ず、4つ口セパラブルフラスコに、ポリテトラメチレングリコール(数平均分子量:1000)を403質量部、MDIを384質量部、及びイルガノックス245を13質量部仕込み、その後、温度25~85℃、常圧下で窒素ガスを通じつつ3時間反応せしめて、プレポリマー(A-3)を得た。得られたプレポリマー(A-3)におけるNCO基含有量は12質量%であった。
先ず、ビーカーに、グリセリンベースプロピレンオキサイドエチレンオキサイド付加体(水酸基価:24、水酸基数:3)を69.42質量部、ポリテトラメチレングリコール(数平均分子量:1000、水酸基数:2)を4.96質量部、1,3-ブタンジオール(平均分子量:90.12、水酸基数:2)を20.55質量部、触媒(ジラウリン酸ジブチル錫及びN,N,N’,N’-テトラメチル-1,6-ヘキサメチレンジアミン)を0.14質量部、及びSH190を4.93質量部仕込んだ後に混合して架橋剤混合液(B-4)を得た。
先ず、4つ口セパラブルフラスコに、ポリテトラメチレングリコール(数平均分子量:3000)を504質量部、MDIを280質量部、イルガノックス245を15質量部仕込み、その後、温度25~85℃、常圧下で窒素ガスを通じつつ3時間反応せしめて、プレポリマー(A-4)を得た。得られたプレポリマー(A-4)におけるNCO基含有量は10質量%であった。
先ず、ビーカーに、グリセリンベースプロピレンオキサイドエチレンオキサイド付加体(水酸基価:24、水酸基数:3)を41.21質量部、ポリテトラメチレングリコール(数平均分子量:1000、水酸基数:2)を51.51質量部、1,3-ブタンジオール(平均分子量:90.12、水酸基数:2)を4.72質量部、触媒(ジラウリン酸ジブチル錫及びN,N,N’,N’-テトラメチル-1,6-ヘキサメチレンジアミン)を0.07質量部、及びSH190を2.49質量部仕込んだ後に混合して架橋剤混合液(B-6)を得た。
先ず、ビーカーに、グリセリンベースプロピレンオキサイドエチレンオキサイド付加体(水酸基価:24、水酸基数:3)を63.45質量部、ポリテトラメチレングリコール(数平均分子量:1000、水酸基数:2)を24.93質量部、1,3-ブタンジオール(平均分子量:90.12、水酸基数:2)を7.27質量部、触媒(ジラウリン酸ジブチル錫及びN,N,N’,N’-テトラメチル-1,6-ヘキサメチレンジアミン)を0.12質量部、及びSH190を4.24質量部仕込んだ後に混合して架橋剤混合液(B-7)を得た。
先ず、4つ口セパラブルフラスコに、ポリテトラメチレングリコール(数平均分子量:850)を436質量部、MDIを351質量部、及びイルガノックス245を12質量部仕込み、その後、温度25~85℃、常圧下で窒素ガスを通じつつ3時間反応せしめて、プレポリマー(A-5)を得た。得られたプレポリマー(A-5)におけるNCO基含有量は9.5質量%であった。
先ず、4つ口セパラブルフラスコに、ポリテトラメチレングリコール(数平均分子量:2000)を504質量部、MDIを287質量部、及びイルガノックス245を9質量部仕込み、その後、温度25~85℃、常圧下で窒素ガスを通じつつ3時間反応せしめて、プレポリマー(A-6)を得た。得られたプレポリマー(A-6)におけるNCO基含有量は9.5質量%であった。
先ず、4つ口セパラブルフラスコに、ポリテトラメチレングリコール(数平均分子量:1000)を498質量部、NBDIを290質量部、及びイルガノックス245を12質量部仕込み、その後、温度25~85℃、常圧下で窒素ガスを通じつつ3時間反応せしめて、プレポリマー(A-7)を得た。得られたプレポリマー(A-7)におけるNCO基含有量は9.5質量%であった。
先ず、4つ口セパラブルフラスコに、ポリテトラメチレングリコール(数平均分子量:1000)を516質量部、MDIを274質量部、及びイルガノックス245を10質量部仕込み、その後、温度25~85℃、常圧下で窒素ガスを通じつつ3時間反応せしめて、プレポリマー(A-8)を得た。得られたプレポリマー(A-8)におけるNCO基含有量は6.0質量%であった。
先ず、4つ口セパラブルフラスコに、ポリテトラメチレングリコール(数平均分子量:1000)を380質量部、MDIを406質量部、及びイルガノックス245を14質量部仕込み、その後、温度25~85℃、常圧下で窒素ガスを通じつつ3時間反応せしめて、プレポリマー(A-9)を得た。得られたプレポリマー(A-9)におけるNCO基含有量は13質量%であった。
先ず、ビーカーに、グリセリンベースプロピレンオキサイドエチレンオキサイド付加体(水酸基価:24、水酸基数:3)を58.10質量部、ポリテトラメチレングリコール(数平均分子量:1000、水酸基数:2)を10.37質量部、1,3-ブタンジオール(平均分子量:90.12、水酸基数:2)を26.87質量部、触媒(ジラウリン酸ジブチル錫及びN,N,N’,N’-テトラメチル-1,6-ヘキサメチレンジアミン)を0.12質量部、及びSH190を4.54質量部仕込んだ後に混合して架橋剤混合液(B-13)を得た。
先ず、ビーカーに、グリセリンベースプロピレンオキサイドエチレンオキサイド付加体(水酸基価:24、水酸基数:3)を39.48質量部、ポリテトラメチレングリコール(数平均分子量:1000、水酸基数:2)を53.58質量部、1,3-ブタンジオール(平均分子量:90.12、水酸基数:2)を4.52質量部、触媒(ジラウリン酸ジブチル錫及びN,N,N’,N’-テトラメチル-1,6-ヘキサメチレンジアミン)を0.06質量部、及びSH190を2.35質量部仕込んだ後に混合して架橋剤混合液(B-14)を得た。
4つ口セパラブルフラスコに、ポリテトラメチレングリコール(数平均分子量:250)を283質量部、MDIを505質量部、及びイルガノックス245を12質量部仕込み、その後、温度25~85℃、常圧下で窒素ガスを通じつつ3時間反応せしめて、プレポリマー(A-10)を得た。得られたプレポリマー(A-10)におけるNCO基含有量は9.5質量%であった。また、得られたプレポリマー(A-10)は、常温で固体であり、温度80℃にて8時間熱しても流動性を得ることが出来ないため、無溶剤型ウレタン樹脂組成物を調製することができなかった。
実施例1で用いたプレポリマー(A-1)100質量部に対し、架橋剤混合液(B-1)45.93質量部を混合する際に水(C)を添加していなかった以外は実施例1と同様にして無溶剤型ウレタン樹脂組成物及びポリウレタンウレア発泡体シートを得た。なお、プレポリマー(A-1)100質量部と架橋剤混合液(B-1)45.93質量部とを混合したものにおけるプレポリマー(A-1)中のNCO基残存量は計算上3.5質量%である。
実施例1で用いたプレポリマー(A-1)100質量部に対し、架橋剤混合液(B-1)45.93質量部、及び水(C)1.84質量部を混合した以外は実施例1と同様にして無溶剤型ウレタン樹脂組成物及びポリウレタンウレア発泡体シートを得た。なお、プレポリマー(A-1)100質量部と架橋剤混合液(B-1)45.93質量部とを混合したものにおけるプレポリマー(A-1)中のNCO基残存量は計算上3.5質量%であり、また、プレポリマー(A-1)100質量部と架橋剤混合液(B-1)45.93質量部と水(C)1.84質量部とを混合したものにおけるプレポリマー(A-1)中のNCO基残存量は計算上0.01質量%未満であり、無溶剤型ウレタン樹脂組成物中の水分が過剰なものである。
実施例1~10及び比較例1~7で得られたポリウレタンウレア発泡体シートの生産性(発泡状態、作業性)を以下の方法により評価した。得られた結果を表1に示す。また、実施例1~10及び比較例1~7において用いた、プレポリマー(A)のイソシアネートの種類及びポリオールの分子量、架橋剤(B)の数平均分子量、並びに水(C)のプレポリマー(A)100質量部に対する含有量を表1に示す。さらに、実施例1~10及び比較例1~7で得られた無溶剤型ウレタン樹脂組成物における、温度25℃の粘度、プレポリマー(A)中のNCO基含有量、プレポリマー(A)と架橋剤(B)とを混合したものにおけるプレポリマー(A)中のNCO基残存量、プレポリマー(A)と架橋剤(B)と水(C)とを混合したものにおけるプレポリマー(A)中のNCO基残存量、並びに全てのポリオールの数平均分子量を表1に示す。
得られたポリウレタンウレア発泡体シートの発泡状態を下記の基準に基づいて評価した。
A:平滑で均一な発泡をしている。
B:ほぼ均一な発泡をしている。
C:均一な発泡ではない。
D:十分に発泡していないか、或いは過剰発泡により発泡体シートの強度が不十分となっている。
ポリウレタンウレア発泡体シートの製造方法における作業性を下記の基準に基づいて評価した。
A:粘度が良好であり、配合及びコーティングに支障がなく、気泡の入り方が良好である。
B:配合及びコーティングに支障がない。
C:粘度が適性でなく、配合及びコーティングに多少影響がある。
D:粘度が高すぎて配合及びコーティングに支障があるか、或いは粘度が低すぎて気泡がぬけてしまう。
実施例1~10及び比較例1~4、6~7で得られたポリウレタンウレア発泡体シートについて、以下の方法によりポリウレタンウレア発泡体シートの物性〔厚み、密度、100%モジュラス(100%M)、200%モジュラス(200%M)、300%モジュラス(300%M)、伸び(EB)、引張強度(TSB)、損失正接(tanδ)、ガラス転移点(Tg)〕を測定した。得られた結果を表2に示す。また、100%モジュラス及び引張強度の測定値については、それらの測定値を密度の測定値で除した数値を算出した。得られた結果を表2に示す。
デジマチックインジケーター(ミツトヨ社製 ID-C112)を用いて試料の厚みを測定した。そして、試料の縦及び横の寸法並びに質量を測定し、その結果から体積を算出し、質量を体積で割ったものを試料の密度とした。
引張試験機(エー・アンド・デイ社製 テンシロン)を用いて、試料の100~300%モジュラス及び伸び、引張強度を測定した。なお、モジュラスとは試料に特定の伸びを与えたときの荷重を試験前の断面積で割った値(単位:MPa)をいい、100%モジュラスとは伸び100%時の値を示し、300%モジュラスとは伸び300%時の値を示す。また伸びとは、引張試験において試験が破断した時の伸びの長さで割った百分率(%)をいい、引張強度とは、引張試験で試料が降伏点、耐力を超えてさらに大きな荷重に耐えたとし、そのときの最大荷重を試験前の断面積で割った値(単位:MPa)をいう。
引張試験機(島津製作所社製、製品名「オートグラフ」)を用いて、試料の伸び及び引張強度を測定した。なお、伸びとは、引張試験において試料が破断した時の試料の長さを試験前の長さで割った百分率(%)をいう。また、引張強度とは、引張試験で試料が降伏点・耐力を超えさらに大きな荷重に耐えたとし、その時の最大荷重を試験前の断面積で割った値(単位:MPa)をいう。
動的粘弾性測定装置(レオメトリック社製)を用いて試料の損失正接、ガラス転移点を測定した。すなわち、動的粘弾性測定装置を用いて、昇温速度5℃/min、周波数10Hzで試料の貯蔵弾性率(E’)、損失弾性率(E’’)及び損失正接〔tanδ = (E’’/E’)〕を測定し、その測定結果から損失弾性率(E’’)及び損失正接(tanδ)の最大値を解析し、損失正接(tanδ)の最大値をここでの損失正接(tanδ)の値とし、損失正接(tanδ)が最大値となる温度をガラス転移点(Tg)とした。
Claims (9)
- ジイソシアネート化合物を分子量500~3000のポリオールと反応させて得られるプレポリマー(A)と、平均水酸基数が2~4であり且つポリオールからなる架橋剤(B)と、水(C)とを含有し、以下の条件:
前記プレポリマー(A)中のイソシアネート基の含有量が7.0~12.0質量%であり、
前記架橋剤(B)の含有量が、前記プレポリマー(A)及び前記架橋剤(B)を混合した場合における前記プレポリマー(A)中のイソシアネート基の残存量が2.0~5.0質量%の範囲となる量であり、
前記水(C)の含有量が、前記プレポリマー(A)、前記架橋剤(B)及び前記水(C)を混合した場合における前記プレポリマー(A)中のイソシアネート基の残存量が0.01~0.5質量%の範囲となる量であり、且つ、
前記プレポリマー(A)の原料の一つであるポリオールと前記架橋剤(B)中のポリオールとを混合した場合における全てのポリオールの数平均分子量が600以上である、
を満たす無溶剤型ウレタン樹脂組成物を準備し、
前記無溶剤型ウレタン樹脂組成物に空気又は不活性ガスを含泡せしめた後に、シート状に成形し、加熱して硬化させてなる、無溶剤型ポリウレタンウレア発泡体シート。 - 前記架橋剤(B)が、平均水酸基数が2~4であり且つ分子量60~3000のポリオールからなる架橋剤である、請求項1に記載の無溶剤型ポリウレタンウレア発泡体シート。
- 前記水(C)の含有量が、前記プレポリマー(A)100質量部に対して0.2~1.5質量部である、請求項1に記載の無溶剤型ポリウレタンウレア発泡体シート。
- ジイソシアネート化合物を分子量500~3000のポリオールと反応させて得られるプレポリマー(A)と、平均水酸基数が2~4であり且つポリオールからなる架橋剤(B)と、水(C)とを含有し、以下の条件:
前記プレポリマー(A)中のイソシアネート基の含有量が7.0~12.0質量%であり、
前記架橋剤(B)の含有量が、前記プレポリマー(A)及び前記架橋剤(B)を混合した場合における前記プレポリマー(A)中のイソシアネート基の残存量が2.0~5.0質量%の範囲となる量であり、
前記水(C)の含有量が、前記プレポリマー(A)、前記架橋剤(B)及び前記水(C)を混合した場合における前記プレポリマー(A)中のイソシアネート基の残存量が0.01~0.5質量%の範囲となる量であり、且つ、
前記プレポリマー(A)の原料の一つであるポリオールと前記架橋剤(B)中のポリオールとを混合した場合における全てのポリオールの数平均分子量が600以上である、
を満たす無溶剤型ウレタン樹脂組成物を準備する工程と、
前記無溶剤型ウレタン樹脂組成物に空気又は不活性ガスを含泡せしめて含泡ウレタン樹脂組成物を得る工程と、
前記含泡ウレタン樹脂組成物をシート状に成形し、加熱して硬化させて無溶剤型ポリウレタンウレア発泡体シートを得る工程と、
を含む、無溶剤型ポリウレタンウレア発泡体シートの製造方法。 - 前記架橋剤(B)が、平均水酸基数が2~4であり且つ分子量60~3000のポリオールからなる架橋剤である、請求項4に記載の無溶剤型ポリウレタンウレア発泡体シートの製造方法。
- 前記水(C)の含有量が、前記プレポリマー(A)100質量部に対して0.2~1.5質量部である、請求項4に記載の無溶剤型ポリウレタンウレア発泡体シートの製造方法。
- 前記プレポリマー(A)の温度25℃における粘度が4000~30000mPa・sである、請求項4に記載の無溶剤型ポリウレタンウレア発泡体シートの製造方法。
- 前記含泡ウレタン樹脂組成物を得る工程において、前記無溶剤型ウレタン樹脂組成物100質量部に対して温度25℃における体積が5~30cm3の空気又は不活性ガスを含泡せしめる、請求項4に記載の無溶剤型ポリウレタンウレア発泡体シートの製造方法。
- 請求項1~3のうちのいずれか一項に記載の無溶剤型ポリウレタンウレア発泡体シートを備える合成皮革。
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KR20130105407A (ko) | 2012-03-13 | 2013-09-25 | 주식회사 덕성 | 폴리우레탄 발포 시트의 제조방법, 폴리우레탄 발포 시트 및 피혁 유사 시트형상물 |
JP2014012820A (ja) * | 2012-06-11 | 2014-01-23 | Tokusei:Kk | ポリウレタン発泡シートの製造方法及びそれを用いた皮革様シート状物 |
WO2017038195A1 (ja) * | 2015-09-02 | 2017-03-09 | Dic株式会社 | 湿気硬化型ホットメルトウレタン組成物、その発泡硬化物の製造方法、合成皮革、及び、その製造方法 |
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JP2003306526A (ja) * | 2002-04-15 | 2003-10-31 | Dainippon Ink & Chem Inc | 無溶剤型湿気硬化性ホットメルトウレタン樹脂組成物、発泡体及びそれを用いたシート構造体 |
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JP6135966B1 (ja) * | 2015-09-02 | 2017-05-31 | Dic株式会社 | 湿気硬化型ホットメルトウレタン組成物、その発泡硬化物の製造方法、合成皮革、及び、その製造方法 |
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Also Published As
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JP5465660B2 (ja) | 2014-04-09 |
JPWO2009119752A1 (ja) | 2011-07-28 |
CN101981077B (zh) | 2013-02-13 |
CN101981077A (zh) | 2011-02-23 |
HK1151308A1 (en) | 2012-01-27 |
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