JP6501136B1 - 合成皮革の製造方法 - Google Patents
合成皮革の製造方法 Download PDFInfo
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- JP6501136B1 JP6501136B1 JP2018563652A JP2018563652A JP6501136B1 JP 6501136 B1 JP6501136 B1 JP 6501136B1 JP 2018563652 A JP2018563652 A JP 2018563652A JP 2018563652 A JP2018563652 A JP 2018563652A JP 6501136 B1 JP6501136 B1 JP 6501136B1
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- Prior art keywords
- urethane resin
- aqueous
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- thickener
- parts
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Abstract
Description
温度計、窒素ガス、導入管、及び撹拌機を備えた窒素置換された容器中で、ポリテトラメチレンエーテルグリコール(数平均分子量;2000)500質量部、2,2’−ジメチロールプロピオン酸(以下「DMPA」と略記する。)25質量部、ジシクロヘキシルメタンジイソシアネート(以下「H12MDI」と略記する。)128質量部、及びメチルエチルケトン620質量部の存在下、反応物の規定のNCO%に達する時点まで70℃で反応させることによって、末端にイソシアネート基を有するウレタンプレポリマーのメチルエチルケトン溶液を得た。
次いで、前記ウレタンプレポリマーの有機溶剤溶液に、中和剤としてトリエチルアミン23質量部加えて攪拌し、更に水830質量部加え撹拌することにより、前記ウレタンプレポリマーが水に分散した乳化液を得た。
得られた乳化液とヒドラジン2.6質量部を含む鎖伸長剤水溶液3.2質量部とを混合し鎖伸長反応することによってウレタン樹脂(A−1)の水分散体を得た。次いで、この水分散体を脱溶剤することにより、不揮発分;30質量%の水性ウレタン樹脂組成物(X−1)を得た。
温度計、窒素ガス、導入管、及び撹拌機を備えた窒素置換された容器中で、ポリカーボネートジオール(宇部興産株式会社製「エタナコールUH−200」、数平均分子量;2000)250質量部、DMPA18質量部、H12MDI90質量部、及びメチルエチルケトン236質量部の存在下、反応物の規定のNCO%に達する時点まで70℃で反応させることによって、末端にイソシアネート基を有するウレタンプレポリマーのメチルエチルケトン溶液を得た。
次いで、前記ウレタンプレポリマーの有機溶剤溶液に、中和剤としてトリエチルアミン16質量部加えて攪拌し、更に水797質量部加え撹拌することにより、前記ウレタンプレポリマーが水に分散した乳化液を得た。
得られた乳化液とヒドラジン5.0質量部を含む鎖伸長剤水溶液6.3質量部とを混合し鎖伸長反応することによってウレタン樹脂(A−2)の水分散体を得た。次いで、この水分散体を脱溶剤することにより、不揮発分;35質量%の水性ウレタン樹脂組成物(X−2)を得た。
温度計、窒素ガス、導入管、及び撹拌機を備えた窒素置換された容器中で、1,6−ヘキサンジオール(以下「HG」と略記する。)155質量部、ネオペンチルグリコール137質量部、アジピン酸424質量部添加し、120℃でそれらを溶融した。次いで、撹拌しながら3時間〜4時間かけて220℃へ昇温し5時間保持した後、150℃まで冷却した後、DMPAを88質量部添加し、150℃で撹拌しながら5時間〜10時間保持した後、メチルエチルケトン300質量部添加することによって、不揮発分70量%のカルボキシル基を有するポリエステルポリオールのメチルエチルケトン溶液(X−3−a)を調製した。
温度計、窒素ガス、導入管、及び撹拌機を備えた窒素置換された容器中で、上記カルボキシル基を有するポリエステルポリオール(X−3−a)のメチルエチルケトン溶液198質量部、ポリエステルポリオール(DIC株式会社製「クリスボンCMA−654」、数平均分子量;1,500)160質量部、HG19質量部、トリレンジイソシアネート75質量部、及びメチルエチルケトン152質量部の存在下、反応物の規定のNCO%に達する時点まで70℃で反応させることによって、末端にイソシアネート基を有するウレタンプレポリマーのメチルエチルケトン溶液を得た。
次いで、ウレタンプレポリマーの有機溶剤溶液に、中和剤としてトリエチルアミン17.2質量部加えて攪拌し、更に水を653質量部、ピペラジン7.7質量部を加え混合し鎖伸長反応することによってウレタン樹脂(A−3)の水分散体を得た。次いで、この水分散体を脱溶剤することにより、不揮発分;40質量%の水性ウレタン樹脂組成物(X−3)を得た。
温度計、窒素ガス、導入管、及び撹拌機を備えた窒素置換された容器中で、ポリテトラメチレングリコール(三菱化学株式会社製、数平均分子量:2,000)1,000質量部、日油株式会社製「ユニルーブ75DE−60」(ポリオキシエチレンオキシプロピレングリコール、ポリオキシエチレン構造/ポリオキシプロピレン構造(質量割合)=75/25、数平均分子量:約3,000)50質量部、日油株式会社製「ユニルーブ75MB−900」(ポリオキシエチレンオキシプロピレングリコールモノブチルエーテル、ポリオキシエチレン構造/ポリオキシプロピレン構造(質量割合)=75/25、数平均分子量約3,400)50質量部、H12MDI183質量部、及びメチルエチルケトン1,283質量部の存在下、反応物の規定のNCO%に達する時点まで70℃で反応させることによって、末端にイソシアネート基を有するウレタンプレポリマーのメチルエチルケトン溶液を得た。
次いで、ウレタンプレポリマーの有機溶剤溶液に、水を2,566質量部加え撹拌することにより、水性ウレタン樹脂の水分散体を得た。得られた乳化液と、ピペラジン13.5質量部を含む鎖伸長剤水溶液135質量部とを混合し鎖伸長反応することによってウレタン樹脂(A’−1)の水分散体を得た。次いで、この水分散体を脱溶剤することにより、不揮発分;40質量%の水性ウレタン樹脂組成物(X’−1)を得た。
DIC株式会社製水系ウレタン樹脂「ハイドラン WLS−250」100質量部に、DIC株式会社製顔料「DILAC BLACK HS−9533」を10質量部を混合し、コンマコーターを使用して、離型紙上に塗布量がwet換算で100g/m2となるように塗布した。その後、70℃で2分間、及び120℃で2分間乾燥させて、厚さ30μmの表皮層を作製した。
これとは別に、水性ウレタン樹脂組成物(X−1)100質量部に、水で10質量%に希釈したカルボキシメチルセルロース(第一工業製薬株式会社製「セロゲンWS−C」、以下「CMC」と略記する。)6.3質量部をメカニカルミキサーにて800rpmで10分間撹拌し、次いで遠心脱泡器を使用して脱泡させて配合液を作製した。前記配合液(増粘剤を含む水性ウレタン樹脂組成物)の粘度は、2,600mPa・sであった。
これをポリエステル繊維の不織布上に、ナイフコートを使用して配合液を塗布し、次いで、5質量%の硝酸カルシウム水溶液中に3分間浸漬させて配合液を凝固させた。その後、凝固物を5時間流水に浸し、余分な凝固剤を洗浄除去した。次いで、この凝固物を70℃で20分間、及び120℃で20分間乾燥することによって乾燥し、繊維基材と多孔構造を有するウレタン樹脂層の積層体を得、前記表皮層と貼り合わせることによって、合成皮革を得た。
用いる水性ウレタン樹脂組成物の種類、増粘剤(B)の種類、及び量を表1〜3に示す通りに変更した以外は、実施例1と同様にして合成皮革を作製した。
なお、実施例6及び7は参考例である。
調整例で使用したポリオールの数平均分子量は、ゲル・パーミエーション・クロマトグラフィー(GPC)法により、下記の条件で測定した値を示す。
カラム:東ソー株式会社製の下記のカラムを直列に接続して使用した。
「TSKgel G5000」(7.8mmI.D.×30cm)×1本
「TSKgel G4000」(7.8mmI.D.×30cm)×1本
「TSKgel G3000」(7.8mmI.D.×30cm)×1本
「TSKgel G2000」(7.8mmI.D.×30cm)×1本
検出器:RI(示差屈折計)
カラム温度:40℃
溶離液:テトラヒドロフラン(THF)
流速:1.0mL/分
注入量:100μL(試料濃度0.4質量%のテトラヒドロフラン溶液)
標準試料:下記の標準ポリスチレンを用いて検量線を作成した。
東ソー株式会社製「TSKgel 標準ポリスチレン A−500」
東ソー株式会社製「TSKgel 標準ポリスチレン A−1000」
東ソー株式会社製「TSKgel 標準ポリスチレン A−2500」
東ソー株式会社製「TSKgel 標準ポリスチレン A−5000」
東ソー株式会社製「TSKgel 標準ポリスチレン F−1」
東ソー株式会社製「TSKgel 標準ポリスチレン F−2」
東ソー株式会社製「TSKgel 標準ポリスチレン F−4」
東ソー株式会社製「TSKgel 標準ポリスチレン F−10」
東ソー株式会社製「TSKgel 標準ポリスチレン F−20」
東ソー株式会社製「TSKgel 標準ポリスチレン F−40」
東ソー株式会社製「TSKgel 標準ポリスチレン F−80」
東ソー株式会社製「TSKgel 標準ポリスチレン F−128」
東ソー株式会社製「TSKgel 標準ポリスチレン F−288」
東ソー株式会社製「TSKgel 標準ポリスチレン F−550」
調製例にて得た水性ウレタン樹脂組成物をレーザー回折/散乱式粒度分布測定装置(株式会社堀場製作所製「LA−910」)を使用して、分散液として水を使用し、相対屈折率=1.10、粒子径基準が面積の時の平均粒子径を測定した。
調整例にて得た水性ウレタン樹脂組成物を乾燥し、乾燥固化した樹脂粒子の0.05g〜0.5gを、300mL三角フラスコに秤量し、次いで、テトラヒドロフランとイオン交換水との質量割合[テトラヒドロフラン/イオン交換水]が80/20の混合溶媒約80mLを加えそれらの混合液を得た。
次いで、前記混合液にフェノールフタレイン指示薬を混合した後、あらかじめ標定された0.1mol/Lの水酸化カリウム水溶液で滴定し、滴定に用いた水酸化カリウム水溶液の量から下記計算式(2)に従い、水性ウレタン樹脂(A)の酸価(mgKOH/g)を求めた。
計算式 A=(B×f×5.611)/S (2)
式中、Aは樹脂の固形分酸価(mgKOH/g)、Bは滴定に用いた0.1mol/L水酸化カリウム水溶液の量(mL)、fは0.1mol/L水酸化カリウム水溶液のファクター、Sは樹脂粒子の質量(g)、5.611は水酸化カリウムの式量(56.11/10)である。
実施例及び比較例で得られた合成皮革において、表皮層を形成する前のウレタン樹脂層を、日立ハイテクテクノロジー株式会社製走査型電子顕微鏡「SU3500」(倍率:2,000倍)を使用して観察し、以下のように評価した。
「A」;電子顕微鏡写真のウレタン樹脂層の断面図において、縦長状のセルが多数確認される。
「B」;電子顕微鏡写真のウレタン樹脂層の断面図において、孔が多数確認される。 「C」;上記以外のもの。
実施例及び比較例で得られた合成皮革を手で触った際の感触により以下のように評価した。なお、樹脂が凝固せず風合いの評価ができなかったものは「−」と評価した。
「A」;張り腰感、充実感ともに優れている。
「B」;張り腰感、充実感が感じられる。
「C」;張り腰感、充実感がやや劣る。
「D」;張り腰感、充実感が全く感じられない。
・「ALA」:Borcher社製「Borch Gel ALA」、ポリアクリル酸のナトリウム塩
・「MC」:メチルセルロース
・「L75N」:Borchers社「Borch Gel L75N」(1,6−ヘキサンジイソシアネート、数平均分子量が3,000のポリエチレングリコール及び数平均分子量が6,000のポリエチレングリコールの反応物と、ポリオキシエチレンジスチレン化フェニルエーテルと、アセチレングリコールと、水(含有率:50質量%)とを含むもの、オキシエチレン基の含有量:1.6×10−2mol/g)
・「T10」:DIC株式会社製「アシスター T10」(1,6−ヘキサンジイソシアネート及び数平均分子量が6,000のポリエチレングリコールの反応物と、ポリオキシエチレンジスチレン化フェニルエーテルと、水(含有率:75質量%)とを含むもの、オキシエチレン基の含有量:2.1×10−2mol/g)
Claims (2)
- 酸価が0.01mgKOH/g以上の水性ウレタン樹脂(A)を含む水性ウレタン樹脂組成物に、
オキシエチレン基の含有量が2×10−2mol/g以下のアクリル増粘剤、又は、カルボキシメチルセルロース(B)を、
前記水性ウレタン樹脂(A)100質量部に対して0.01〜30質量部の範囲で加えて増粘させた液を得た後、
増粘させた液を基材に塗布し、金属塩(c−1)を水で希釈した凝固浴(C)で凝固する
ものであり、前記水性ウレタン樹脂(A)の凝固の際に、加熱工程を経ないことを特徴とする合成皮革の製造方法。 - 前記金属塩(c−1)が、硝酸カルシウムである請求項1又は2記載の合成皮革の製造方法。
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