Aqueous-dispersion type polycarbonate-based polyurethane resin composition, textile product treated with same, and process for producing aqueous-dispersion type polycarbonate-based polyurethane resin composition
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Solution Overview
Problem
Conventional water-dispersible polycarbonate-based polyurethane resin compositions used for fiber products often result in hard, paper-like textures with low resilient feel, and face challenges in balancing softness and durability, especially during dyeing treatments.
Innovation Solution
A water-dispersible polycarbonate-based polyurethane resin composition is developed using a decanediol-derived polycarbonate diol and a polyvalent alcohol with hydroxyl groups, combined with a polyether-based polyol, and chain extended with a polyamine compound, to achieve a soft texture and resilient feel, while maintaining these properties after dyeing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polycarbonate-based polyol is used as the main component of polyols, then excellent strength, light resistance, heat resistance, hydrolysis resistance, and oil resistance are achieved, but the texture of the fiber product becomes very hard and paper-like with low resilient feel
Solution Approach 1:
The patent uses a composite polyol system combining polycarbonate-based polyol (providing durability and resistance properties) with polyester-based polyol (providing softness and flexibility). This composite approach allows the fiber product to simultaneously achieve excellent strength and heat/hydrolysis resistance from the polycarbonate component while maintaining soft texture and resilient feel from the polyester component.
Solution Approach 2:
The patent specifies precise parameter ranges for the polyol components: polycarbonate-based polyol with number average molecular weight of 1,000-5,000 and hydroxyl value of 20-80 mg KOH/g, and polyester-based polyol with number average molecular weight of 1,000-3,000 and hydroxyl value of 30-100 mg KOH/g. By controlling these parameters within specific ranges, the invention optimizes the balance between durability properties and texture softness.
2Ease of operation
If at least two polyisocyanates are used to achieve soft texture and resilient feel, then the texture properties are improved, but the management becomes complicated and stable production becomes difficult due to difficulty in controlling the reaction
Solution Approach 1:
The patent extracts and isolates the essential functional requirements into a single polyisocyanate component with specific characteristics (isophorone diisocyanate, hexamethylene diisocyanate, or tolylene diisocyanate). Instead of using multiple polyisocyanates as in PTL 1, the invention identifies that one carefully selected polyisocyanate with appropriate reactivity and molecular structure can provide both soft texture and resilient feel while simplifying production management and reaction control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition provides fiber products with a soft texture and resilient feel, ensuring dyeing durability by preventing resin fracture or detachment, even under heat or crumpling forces, thus offering improved film formability and resistance.
Implementation Method 1
a urethane prepolymer having an isocyanate group at a terminal and being a reaction product of polyols with a polyisocyanate
Implementation Method 2
obtained by chain extension of a urethane prepolymer with a polyamine compound
Implementation Method 3
neither fracture nor detachment of the resin due to heat or a force of crumpling or the like occurs even when the obtained fiber product is subjected to a dyeing treatment
Data Source
AI summary
A water-dispersible polycarbonate-based polyurethane resin composition obtained by chain extension of a urethane prepolymer with a polyamine compound, wherein the urethane prepolymer has an isocyanate group at a terminal and is a reaction product of polyols comprising a polycarbonate diol containing a structural unit derived from 1,10-decanediol and a polyvalent alcohol containing only hydroxyl groups as functional groups and having a molecular weight of 400 or lower with an organic polyisocyanate, and the polyamine compound contains two or more amino groups of at least one type selected from the group consisting of primary amino groups and secondary amino groups in a single molecule.