Waterproof moisture-permeable composite film and waterproof moisture-permeable fabric having the same

Abstract

To provide a waterproof moisture-permeable composite film capable of reconciling sufficient water resistance, moisture permeability and durability without using an organic fluorine compound, and a waterproof moisture-permeable fabric having the waterproof moisture-permeable composite film.SOLUTION: In the waterproof moisture-permeable composite film 1A, a non-porous urethane layer 3 which is a non-porous resin layer is laminated on one surface of a porous urethane layer 2 which is a porous resin layer not containing an organic fluorine compound, and the non-porous urethane layer 3 partially covers the surface of the porous urethane layer 2. In the waterproof moisture-permeable fabric, a nonporous urethane layer 3 which is a nonporous resin layer is laminated on one surface of a porous urethane layer 2 which is a porous resin layer containing no organic fluorine compound, and the nonporous urethane layer 3 has a waterproof moisture-permeable composite film partially covering the surface of the porous urethane layer 2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a waterproof, breathable composite membrane having both waterproofness and breathability, and a waterproof, breathable fabric having a waterproof, breathable composite membrane. [Background technology]

[0002] Conventionally, waterproof and breathable composite membranes having both waterproofness and breathability have been used in sportswear, rainwear, etc. As such a waterproof and breathable composite membrane, the waterproof and breathable composite membrane shown in Patent Document 1 is known.

[0003] In the waterproof and breathable composite membrane of Patent Document 1, the porous hydrophobic urethane contains an organic fluorine compound (PFAS) that provides water and oil repellency.

[0004] The porous hydrophobic urethane is moisture permeable.

[0005] In addition, the hydrophobicity of the porous hydrophobic urethane can be further improved by including an organic fluorine compound, which makes it more difficult for water to penetrate into the pores of the porous hydrophobic urethane, thereby improving waterproofing.

[0006] Furthermore, the inclusion of an organic fluorine compound in the porous hydrophobic urethane allows it to repel water containing surfactants, thereby suppressing the residue of surfactants in the porous hydrophobic urethane when rinsing after washing, and improving the durability of the porous hydrophobic urethane in maintaining its waterproof properties after washing. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 03-027184 Summary of the Invention [Problem to be solved by the invention]

[0008] However, the water- and oil-repellent film action on the surface of porous hydrophobic urethane is achieved by using organic fluorine compounds.

[0009] As restrictions on the use of organic fluorine compounds become more stringent in the future, there is a problem that it will be difficult to simultaneously achieve sufficient water resistance, breathability, and durability in waterproof and breathable composite membranes and waterproof and breathable fabrics having waterproof and breathable composite membranes.

[0010] Therefore, an object of the present invention is to provide a waterproof, breathable composite membrane and a waterproof, breathable fabric having a waterproof, breathable composite membrane that simultaneously achieves sufficient water resistance, breathability, and durability without using an organic fluorine compound. [Means for solving the problem]

[0011] The waterproof and moisture-permeable composite membrane of claim 1 has a non-porous resin layer laminated on a porous resin layer that does not contain an organic fluorine compound.

[0012] According to the waterproof and moisture-permeable composite membrane of claim 1, even if the porous resin layer that does not contain an organic fluorine compound does not have water or oil repellency, the nonporous resin layer can prevent water from penetrating into the pores of the porous resin layer. Furthermore, the nonporous resin layer can prevent surfactants from penetrating into the pores of the porous resin layer during washing. Both the porous resin layer and the nonporous resin layer have moisture permeability.

[0013] A waterproof and moisture-permeable composite membrane according to claim 2 of the present invention is the waterproof and moisture-permeable composite membrane according to claim 1, in which the non-porous resin layer partially covers the surface of the porous resin layer.

[0014] According to the waterproof and breathable composite membrane of claim 2, in addition to the same effects as those of claim 1, the non-porous resin layer partially covers the surface of the porous resin layer, thereby achieving optimal water resistance, breathability, and durability.

[0015] The waterproof and moisture-permeable composite membrane of claim 3 of the present invention is the waterproof and moisture-permeable composite membrane of claim 2, wherein the coverage of the non-porous resin layer on the surface of the porous resin layer is in the range of 20% to 90%.

[0016] According to the waterproof and breathable composite membrane of claim 3, in addition to the same effects as those of claim 2, it is possible to achieve more optimal water resistance, breathability, and durability all at the same time.

[0017] The waterproof and moisture-permeable composite membrane of claim 4 of the present invention is the waterproof and moisture-permeable composite membrane of claim 2, wherein the Gurley air resistance according to JIS L 1096 B method (Gurley method) is in the range of 200 seconds to 1000 seconds.

[0018] According to the waterproof and breathable composite film of claim 4, in addition to the same effects as those of claim 2, it is possible to achieve more optimal water resistance, breathability, and durability all at the same time.

[0019] A waterproof and breathable fabric according to a fifth aspect of the present invention comprises the waterproof and breathable composite membrane according to any one of the first to fourth aspects.

[0020] The waterproof and breathable fabric of claim 5 has the same effects as any of claims 1 to 4. [Effects of the Invention]

[0021] The waterproof and breathable composite membrane of the present invention and the waterproof and breathable fabric having the waterproof and breathable composite membrane can simultaneously achieve sufficient water resistance, breathability, and durability without using any organic fluorine compounds. [Brief explanation of the drawings]

[0022] [Figure 1] 1 is a schematic cross-sectional view of a waterproof, moisture-permeable composite membrane 1A of a first embodiment. [Figure 2] FIG. 1 is a schematic cross-sectional view of a waterproof, moisture-permeable composite membrane 1B of a second embodiment. [Figure 3] FIG. 10 is a schematic cross-sectional view of a waterproof, breathable fabric having a waterproof, breathable composite membrane of a third embodiment. [Figure 4]FIG. 10 is a schematic cross-sectional view of a waterproof, breathable fabric having a waterproof, breathable composite membrane according to a fourth embodiment. [Figure 5] FIG. 10 is a schematic cross-sectional view of a waterproof, breathable fabric having a waterproof, breathable composite membrane of a fifth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0023] A waterproof, moisture-permeable composite membrane 1A according to a first embodiment of the present invention will be described with reference to Fig. 1. The waterproof, moisture-permeable composite membrane 1A has a non-porous urethane layer 3, which is a non-porous resin layer, laminated on one surface of a porous urethane layer 2, which is a porous resin layer that does not contain organic fluorine compounds. In the cross-sectional schematic diagram of Fig. 1, the waterproof, moisture-permeable composite membrane 1A is shown enlarged to facilitate understanding of the structure, but in reality, the porous urethane layer 2 has a thickness similar to that of a sheet or film, and the spacing between dots that will become the non-porous urethane layer 3 (described below) is several tens to several hundreds of micrometers.

[0024] The porous urethane layer 2 is porous and does not contain any organic fluorine compounds.

[0025] In the first embodiment, the non-porous urethane layer 3 is made of hydrophobic urethane.

[0026] In the waterproof, moisture-permeable composite membrane 1A, the non-porous urethane layer 3 partially covers the surface of the porous urethane layer 2.

[0027] When the waterproof and moisture-permeable composite membrane 1A is washed, in order for water containing a surfactant to penetrate into the pores of the porous urethane layer 2, an equal volume of air must be released from the porous urethane layer 2.

[0028] By partially covering the surface of the porous urethane layer 2 with the non-porous urethane layer 3, it becomes difficult for air to escape from the porous urethane layer 2. The difficulty in escaping air from the porous urethane layer 2 makes it possible to prevent water containing a surfactant from penetrating into the porous urethane layer 2 during washing.

[0029] Although the difficulty of air escaping from the porous urethane layer 2 may result in a decrease in the Gurley air resistance and moisture permeability described below, sufficient Gurley air resistance and moisture permeability can be ensured depending on the conditions for partially covering the surface of the porous urethane layer 2 with the nonporous urethane layer 3.

[0030] Furthermore, the air tightness of the porous urethane layer 2 also contributes to improving the water pressure resistance, which will be described later.

[0031] The coverage of the non-porous urethane layer 3 on the surface of the porous urethane layer 2 is in the range of 20% to 90%.

[0032] One example of a method for laminating the non-porous urethane layer 3 so as to partially cover the surface of the porous urethane layer 2 is gravure dot printing.

[0033] The minimum spacing between adjacent dots of non-porous urethane formed by gravure dot printing is preferably less than 200 μm, and more preferably less than 10 μm.

[0034] The waterproof and moisture-permeable composite membrane 1A of this embodiment achieves a Gurley air resistance according to JIS L 1096 B method (Gurley method) within the range of 200 seconds to 1000 seconds.

[0035] The waterproof and breathable composite membrane 1A of this embodiment achieves a breathability of 10,000 g / m 2 ·24 h or more according to the initial JIS L 1099A-1 method.

[0036] The waterproof and breathable composite membrane 1A of this embodiment achieves an initial water pressure resistance of 20,000 mmH2O or more. The water pressure resistance was measured based on JIS L 1092B. To prevent the measurement sample from swelling and breaking due to water pressure, the measurement was performed by placing two pieces of 70-mesh, 0.15 mm-thick polyester mesh on the measurement sample as a pad.

[0037] The waterproof and breathable composite membrane 1A of this embodiment achieves a water pressure resistance of 10,000 mmH2O or more after a sample is washed 20 times by hanging and drying according to JIS L 1930 C4M method.

[0038] A waterproof, moisture-permeable composite membrane 1B according to a second embodiment of the present invention will be described with reference to FIG.

[0039] The waterproof moisture-permeable composite membrane 1B has non-porous urethane layers 3, which are non-porous resin layers, laminated on both surfaces of a porous urethane layer 2, which is a porous resin layer that does not contain an organic fluorine compound.

[0040] The waterproof and breathable composite membrane 1B of this embodiment has the same Gurley air resistance according to JIS L 1096 B method (Gurley method), the initial breathability according to JIS L 1099A-1 method, the initial water pressure resistance, and the water pressure resistance after 20 washes by line drying according to JIS L 1930 C4M method, as the waterproof and breathable composite membrane 1A of the first embodiment.

[0041] A waterproof, breathable fabric 10A having a waterproof, breathable composite membrane 1A according to a third embodiment of the present invention will be described with reference to FIG.

[0042] The waterproof and breathable fabric 10A has a surface 4 attached via an adhesive 6 to the surface of the porous urethane layer 2 on which the non-porous urethane layer 3 is not laminated in the waterproof and breathable composite membrane 1A of the first embodiment.

[0043] The waterproof and breathable fabric 10A of this embodiment has a Gurley air resistance according to JIS L 1096 B method (Gurley method) within the range of 200 seconds to 1000 seconds.

[0044] The waterproof and breathable fabric 10A of this embodiment achieves a moisture permeability of 10,000 g / m 2 ·24 h or more according to the initial JIS L 1099A-1 method.

[0045] The waterproof and breathable fabric 10A of this embodiment achieves an initial water pressure resistance of 20,000 mmH2O or more. The water pressure resistance was measured under the same conditions as those for the waterproof and breathable composite membrane 1A of the first embodiment.

[0046] The waterproof and breathable fabric 10A of this embodiment achieves a water pressure resistance of 10,000 mmH2O or more after a sample is washed 20 times by line drying according to JIS L 1930 C4M method.

[0047] A waterproof, breathable fabric 10B having a waterproof, breathable composite membrane 1A according to a fourth embodiment of the present invention will be described with reference to FIG.

[0048] The waterproof and breathable fabric 10B is the waterproof and breathable composite membrane 1A of the first embodiment, in which an outer fabric 4 is attached via an adhesive to the surface of the porous urethane layer 2 on which the nonporous urethane layer 3 is not laminated, and a lining 5 is attached via an adhesive to the surface of the porous urethane layer 2 on which the nonporous urethane layer 3 is laminated.

[0049] The waterproof and breathable fabric 10B of this embodiment has the same Gurley air resistance according to JIS L 1096 B method (Gurley method), the initial breathability according to JIS L 1099A-1 method, the initial water pressure resistance, and the water pressure resistance after 20 washes by line drying according to JIS L 1930 C4M method, which are the same as those of the waterproof and breathable fabric 10A of the third embodiment.

[0050] A waterproof, breathable fabric 10C having a waterproof, breathable composite membrane 1B according to a fifth embodiment of the present invention will be described with reference to FIG.

[0051] The waterproof and breathable fabric 10C is a waterproof and breathable composite membrane 1 of the second embodiment, in which an outer fabric 4 is attached via an adhesive to one surface of the porous urethane layer 2 on which the non-porous urethane layer 3 is laminated, and a lining 5 is attached via an adhesive to the other surface of the porous urethane layer 2 on which the non-porous urethane layer 3 is laminated.

[0052] The waterproof and breathable fabric 10C of this embodiment has the same Gurley air resistance according to JIS L 1096 B method (Gurley method), the initial breathability according to JIS L 1099A-1 method, the initial water pressure resistance, and the water pressure resistance after 20 washes by line drying according to JIS L 1930 C4M method, which are the same as those of the waterproof and breathable fabric 10A of the third embodiment.

[0053] In the first embodiment, the porous resin layer not containing an organic fluorine compound is a porous urethane layer, but the present invention is not limited to this. The porous resin layer may be a material not containing an organic fluorine compound, such as a commercially available stretched porous polyolefin film, an electrospun porous film made from various materials, or "Microporous Urethane Film Non-Fluorine Polycarbonate FGX" manufactured by Tech One Co., Ltd., which has a moisture permeability of 10,000 g / m² 24 h or more and an initial water pressure resistance of 10,000 mmH2O or more according to the initial JIS L 1099A-1 method.

[0054] In the first embodiment, the nonporous urethane layer 3, which is a nonporous resin layer, is described as being made of hydrophobic urethane, but this is not limited thereto. The nonporous urethane layer 3, which is a nonporous resin layer, is laminated so as to partially cover the surface of the porous urethane layer 2, thereby forming a non-continuous film. Therefore, water vapor can pass through the voids formed in the nonporous resin layer. Therefore, the nonporous resin layer itself does not need to be moisture permeable, and its hydrophilicity or hydrophobicity can be selected as desired depending on the desired performance. The coating liquid used to form the nonporous resin layer may be in any form, such as a hot melt, an organic solvent solution, a water-based emulsion, or an aqueous resin solution. Additionally, an antiblocking agent such as silica, a water-repellent material not containing an organic fluorine compound, a colorant, a crosslinking agent, a leveling agent, a defoaming agent, a thickener, an ultraviolet absorber, an antioxidant, etc. may be optionally mixed and used.

[0055] In the first embodiment, gravure dot printing was described as an example of a method for laminating the non-porous urethane layer 3 so as to partially cover the surface of the porous urethane layer 2, but the method is not limited to this. Other methods, such as gravure diagonal printing, may also be used to laminate the non-porous urethane layer 3 so as to partially cover the surface of the porous urethane layer 2. When gravure diagonal printing is used, the minimum distance between adjacent diagonal lines of non-porous urethane is preferably less than 200 μm, and more preferably less than 30 μm.

[0056] The non-porous urethane layer 3 in the first and second embodiments may be an adhesive made of urethane resin, assuming that it will be used in the waterproof and breathable fabrics of the third, fourth, and fifth embodiments. The adhesive made of urethane resin is a non-porous resin.

[0057] In the waterproof and breathable composite membranes of the third to fifth embodiments, the method for adhering the waterproof and breathable composite membrane to the outer and / or inner fabrics can be any known technique and is not particularly limited. Examples of known adhesives that can be used include urethane resins, acrylic resins, vinyl acetate resins, and epoxy resins. The applied adhesive may be in any form, such as a hot melt, an organic solvent solution, a water-based emulsion, or an aqueous resin solution. The adhesive may also be optionally mixed with an antiblocking agent such as silica, a water-repellent material not containing an organic fluorine compound, a colorant, a crosslinking agent, a leveling agent, a defoaming agent, a thickener, an ultraviolet absorber, an antioxidant, and the like. [Explanation of symbols]

[0058] 1A waterproof and breathable composite membrane 1B Waterproof and breathable composite membrane 2 Porous urethane layer 3 Non-porous urethane layer 4 Outer fabric 5. Lining 10A waterproof and breathable fabric 10B waterproof and breathable fabric 10C waterproof and breathable fabric

Claims

1. A waterproof and moisture-permeable composite membrane characterized in that a non-porous resin layer is laminated on a porous resin layer that does not contain an organic fluorine compound.

2. 2. The waterproof and moisture-permeable composite membrane according to claim 1, wherein the non-porous resin layer partially covers the surface of the porous resin layer.

3. 3. The waterproof and moisture-permeable composite membrane according to claim 2, wherein the coverage of the non-porous resin layer on the surface of the porous resin layer is in the range of 20% to 90%.

4. 3. The waterproof and breathable composite membrane according to claim 2, wherein the Gurley air resistance according to JIS L 1096 B method (Gurley method) is in the range of 200 seconds to 1000 seconds.

5. A waterproof and breathable fabric comprising the waterproof and breathable composite membrane according to any one of claims 1 to 4.

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