Sheet-like article
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Solution Overview
Problem
Conventional sheet-like materials made from fibrous base materials and polyurethane resin face issues with durability, light resistance, and surface quality, particularly due to degradation from ultraviolet rays and hydrolysis, leading to problems like pilling and fiber detachment over time.
Innovation Solution
A sheet-like article is produced by adding a polyurethane resin with specific characteristics, including oxycarbonyl and carbonate groups, a urethane group content of 7.0 to 11.0 mass%, and a polymeric polyol with a number average molecular weight of 500 or more, to a fibrous base material with ultrafine fibers, enhancing its compressibility, compression modulus, and resistance to hydrolysis and light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If polyether based polyurethane resin is used to produce soft texture, then texture softness is improved, but light resistance and durability deteriorate due to easy degradation by ultraviolet ray and heat
Solution Approach 1:
The invention changes the chemical composition parameters of the polyurethane resin by specifying precise ranges for polyol type (polyester or polyether), polyisocyanate content (2-10 mass%), and chain extender content (5-30 mass%). This parameter optimization allows achieving both soft texture and improved light resistance by balancing the softening effect of polyether polyol with the stabilizing effect of controlled polyisocyanate and chain extender content.
Solution Approach 2:
The invention creates a composite polyurethane resin system combining polyester polyol, polyether polyol, polyisocyanate, and chain extender in specific proportions. This composite approach leverages the light resistance of polyester components while incorporating polyether for softness, achieving a synergistic effect that resolves the contradiction between texture softness and durability.
2Reliability
If polyester based polyurethane resin is used to improve light resistance, then ultraviolet ray resistance is improved, but hydrolysis resistance deteriorates leading to surface pilling and fiber coming off
Solution Approach 1:
The invention optimizes the polyol composition by limiting polyester polyol content to 70-95 mass% and requiring polyether polyol content of 5-30 mass%, along with controlled polyisocyanate (2-10 mass%) and chain extender (5-30 mass%) content. This parameter balance reduces ester bond concentration, thereby improving hydrolysis resistance while maintaining adequate light resistance through the remaining polyester components.
Solution Approach 2:
The invention employs a composite polyol system combining polyester polyol and polyether polyol in specific ratios, along with polyisocyanate and chain extender. This composite structure reduces the overall ester bond content compared to pure polyester polyurethane, thereby improving hydrolysis resistance while maintaining light resistance through the synergistic combination of components.
3Reliability
If polycarbonate based polyurethane resin is used to improve durability, then light resistance and hydrolysis resistance are improved, but surface quality deteriorates with plastics like texture and coarse touch
Solution Approach 1:
The invention limits polycarbonate polyol content to a maximum of 70 mass% and requires the presence of polyether polyol (5-30 mass%) and chain extender (5-30 mass%). This parameter control prevents the excessive stiffness and coarse texture associated with high polycarbonate content, while still benefiting from its durability through the balanced composite structure.
Solution Approach 2:
The invention creates a composite polyurethane system incorporating polycarbonate polyol, polyester polyol, polyether polyol, polyisocyanate, and chain extender in optimized proportions. This multi-component composite softens the texture by incorporating flexible polyether and polyester segments, while maintaining durability through the structured polyisocyanate-crosslinked network and controlled polycarbonate content.
4Ease of manufacture
If aqueous polyurethane resin is used to improve processing yield and heat resistance, then processing performance is improved, but durability deteriorates with fiber coming off and appearance change over time
Solution Approach 1:
The invention specifies precise compositional parameters including polyisocyanate content (2-10 mass%) and chain extender content (5-30 mass%) that create adequate crosslinking density and molecular structure for durability. These parameter optimizations ensure that the aqueous resin formulation maintains fiber bonding strength and appearance stability over time, while still benefiting from the processing advantages of aqueous systems.
Solution Approach 2:
The invention employs a composite polyurethane composition with multiple polyol types (polyester, polyether, polycarbonate) and controlled ratios of polyisocyanate and chain extender. This composite structure provides both the processing benefits of aqueous resins and the durability required for long-term appearance stability by creating a balanced molecular network that resists fiber detachment and degradation.
Data Source
AI summary
The present invention provides a sheet like article produced from a polyurethane resin having a carbonate group and an oxycarbonyl group as ester groups and having uniform, elegant surface quality, a flexible, highly crease recoverable texture, and high resistance to light and hydrolysis, and also provides a production method therefore. The sheet like article according to the present invention is one that is produced by adding, as a binder, a polyurethane resin that meets the requirements (I) and (II) given below to a fibrous base material formed mainly of ultrafine fibers: (I) A polyurethane resin such that the polyurethane resin contains, in its interior, an oxycarbonyl group and a carbonate group as ester groups. (II) A polyurethane resin such that the sum of the content of the urethane group and the content of the urea group in the polyurethane resin is 7.0 to 11.0 mass%.