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Sheet-like article, and method for producing same

Inactive Publication Date: 2017-06-29
TORAY IND INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent text describes a new technique for producing a sheet material with a soft texture and good touch using a special type of polyurethane resin. This resin is applied to a fibrous substrate and has a microphase-separated structure including hard and soft segments. The resulting sheet material has a uniform nap length, comparable to man-made leathers made with organic-solvent-based polyurethane, and a soft and excellent touch with high rubber-like feel. Additionally, this eco-friendly production process uses an aqueous dispersed type resin and achieves a highly desirable result.

Problems solved by technology

Organic solvents, however, are generally very harmful to health and environment, and thus there is a strong need for methods for producing a sheet material using no organic solvent.
However, sheet materials obtained by impregnating a fibrous substrate with an aqueous dispersed type polyurethane resin and coagulating the polyurethane resin tend to have a hard touch.
As a result, the fibrous substrate and the polyurethane resin adhere closely to each other to firmly hold entangled portions of fibers, which results in a hard touch.

Method used

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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  • Sheet-like article, and method for producing same
  • Sheet-like article, and method for producing same

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0183]Polyethylene terephthalate copolymerized with 8 mol % 5-sodium sulfoisophthalate was used as a sea component, and polyethylene terephthalate was used as an island component. The sea component and the island component were conjugated in a ratio of 20% by mass to 80% by mass to give sea-island type conjugated fibers having 16 islands per filament and an average fiber diameter of 20 μm. The sea-island type conjugated fibers obtained were cut into staple fibers 51 mm in length and passed through a card and a crosslapper to form a fiber web. The fiber web was processed into a nonwoven fabric by needle punching.

[0184]The nonwoven fabric thus obtained was shrunk by dipping in hot water at 97° C. for 5 minutes, and dried at 100° C. for 10 minutes. The resulting nonwoven fabric was then provided with an aqueous solution of a PVA (NM-14 available from Nippon Synthetic Chemical Industry), having a degree of saponification of 99% and a degree of polymerization of 1,400, the aqueous soluti...

example 2

[0186]The same procedure as in Example 1 was repeated except that the sheet substrate was impregnated with a dispersion of the polyurethane resin composition B adjusted to have a solids concentration of 20%, an active ingredient of a blocked isocyanate (“Erastron” [registered trademark] BN-77 available from Dai-ichi Kogyo Seiyaku) in an amount of 6% based on solid polyurethane, and magnesium sulfate in an amount of 0.3 part by mass based on solid polyurethane, thereby obtaining a man-made leather with a unit weight of 222 g / m2. The man-made leather obtained had a good appearance and a touch without a paper-like feel. From the man-made leather, the polyurethane resin was collected and observed under an AFM. The parameter A was 4.2, and the polyurethane resin had a microphase-separated structure with HS domains and SS domains finely dispersed. In the microphase-separated structure observed, spherical HS domains mainly having a size of 100 nm or smaller were dispersed in uniform SS dom...

example 3

[0187]The same procedure as in Example 1 was repeated except that the sheet substrate was impregnated with a dispersion of the polyurethane resin composition C adjusted to have a solids concentration of 20%, an active ingredient of a carbodiimide crosslinking agent (“Carbodilite” [registered trademark] V02-L2 available from Nisshinbo Chemical) in an amount of 6% by mass based on solid polyurethane, and magnesium sulfate in an amount of 0.4 part by mass based on solid polyurethane, thereby obtaining a man-made leather with a unit weight of 252 g / m2. The man-made leather obtained had a good appearance and a touch without a paper-like feel. From the man-made leather, the polyurethane was collected and observed under an AFM. The parameter A was 2.2, and the polyurethane resin had a microphase-separated structure with HS domains and SS domains finely dispersed. In the microphase-separated structure observed, spherical HS domains mainly having a size of 100 nm or smaller were dispersed in...

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Abstract

A sheet material includes a fibrous substrate made of microfibers and a hydrophilic-group-containing resin applied to the fibrous substrate. The hydrophilic-group-containing resin has a microphase-separated structure that satisfies Condition I: In a phase image obtained by observing an area of 1 μm2 in a cross-section of the hydrophilic-group-containing resin applied to the fibrous substrate by phase imaging using an atomic force microscope (AFM), a standard deviation of a mode of brightness distribution of areas of 0.2 μm2 in the area of 1 μm2 is from 0 to 10. Provided are a sheet material that is produced through an eco-conscious production process and yet has such uniformity that is comparable to those of man-made leathers produced using organic-solvent-based polyurethanes, an elegant surface appearance, and a good touch, and a method for producing such a sheet material.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This is the U.S. National Phase application of PCT International Application No. PCT / JP2015 / 051620, filed Jan. 22, 2015, and claims priority to Japanese Patent Application No. 2014-015350, filed Jan. 30, 2014, the disclosures of each of these applications being incorporated herein by reference in their entireties for all purposes.FIELD OF THE INVENTION[0002]The present invention relates to eco-conscious sheet materials produced by a process using no organic solvent and methods for producing such sheet materials, and more particularly to a sheet material having a good surface appearance and touch and a method for producing such a sheet material.BACKGROUND OF THE INVENTION[0003]Sheet materials composed mainly of fibrous substrates and polyurethane resins, the fibrous substrates being made of fabrics such as nonwoven fabrics, have excellent features that natural leathers do not have, and have been widely used in various applications such as ...

Claims

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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Application Information

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IPC IPC(8): D06N3/00D06N3/14
CPCD06N3/0004D06N3/0036D06N3/147D06N3/14C08G18/0823C08G18/4854C08G18/6659C08G18/6692C08G18/758C08G18/7621C08G18/7671C08G18/791C08G18/797C08G18/80C08G18/44C08G18/12C08G18/3228C08G18/3234
Inventor MURAHARA, HISASHINAKAI, SHUNICHIROMATSUZAKI, YUKIHIRONISHIMURA, MAKOTO
Owner TORAY IND INC
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