[Technical Field]
[0001] The present invention relates to a suede type artificial leather having antifouling
properties, and more particularly to a simple method of preparing an artificial leather
impregnated with a modified polyurethane having an antifouling property, which the
addition of an additive having an antifouling function is not needful.
[Background Art]
[0002] Artificial leather is prepared by impregnating a polymer elastomer in a nonwoven
fabric formed by three-dimensionally interlacing ultrafine fibers. The artificial
leather has a smooth texture and unique appearance which is similar to natural leather
and is widely used in various fields such as shoes, clothes, gloves, miscellaneous
goods, furniture and automobile interior materials.
[0003] Artificial leather requires various characteristics according to its use. For example,
the properties required for artificial leather for clothing include high durability,
high sensitivity, excellent dyeability which can be stained with various colors and
concentrations and high fastness.
[0004] In order to improve the durability among these demand characteristics, artificial
leather is required to be provided with an antifouling function including a water-repellent
and oil-repellent function for inhibiting the occurrence of fouling even after a long-term
use.
[0005] To provide an antifouling property to artificial leather, a fluorine-based or silicone-based
surfactant can be mixed with polyurethane and a mixture can be impregnated in a nonwoven
fabric, thereby arranging a fluorine chain or a silicone chain on the surface of the
artificial leather. The occurrence of fouling can be suppressed from the outside of
the artificial leather accordingly.
[0006] However, fluorine-based or silicone-based surfactants are generally inactive additives,
and in case that they are mixed with polyurethane, there is a problem that they are
not chemically bonded to each other, thus they are free to move in the urethane molecular
structure and as a result, transition of the surfactants to the surface of artificial
leather occurs causing a surface change with the passage of time thereof.
[0007] Korean Patent No. 0969839 discloses a modified urethane to which fluorine is bonded and a method of preparing
leathery sheet object using the modified urethane without the addition of a fluorine-based
compound.
[0008] According to the patent, a urethane compound modified with fluorine-containing side
chain in which
- (i) 3 to 12 fluorine-containing side chains having a molecular weight of 200 to 1,000
are bonded to a urethane bond-containing compound having a molecular weight of 500
to 5,000
- (ii) the fluorine content is 20 to 60 weight% in terms of fluorine atoms, and
- (iii) containing 6 to 36 urethane bonds per a molecule,
improves water repellency and water resistance at the cut cross section of the leathery
sheet object, are disclosed.
[0009] However, according to the patent, the urethane compound modified with fluorine-containing
side chain is used together with polyurethane which is an elastomer constituting the
treatment liquid of a leathery sheet object, and exhibits an effect as a water-repellent
agent as an additive.
[0010] On the other hand, the development of providing an antifouling effect by an elastomer
impregnated in artificial leather without adding an antifouling additive is progressing.
[Disclosure]
[Technical Problem]
[0011] To solve the above problems, an object of the present invention is to provide artificial
leather impregnated with a novel modified polyurethane, having an antifouling property
without adding an additive having an antifouling property.
[Technical Solution]
[0012] To achieve the object of the present invention, an aspect of the present invention
provides a suede type artificial leather having antifouling property in which a polymeric
elastomer is impregnated in a nonwoven fabric formed by three-dimensionally interlacing
ultrafine fibers and raising is formed, wherein the polymeric elastomer is a fluorine-containing
modified polyurethane, and the fluorine-containing modified polyurethane is a product
obtained by a polymerization reaction between a urethane prepolymer having isocyanate
groups at terminals, obtained by reacting a diol and a diisocyanate, and a fluorinated
carbon compound having hydroxy functional groups at both terminals, and has a weight
average molecular weight (Mw) of 500,000 to 800,000.
[0013] The present invention also provides a method of preparing a suede type artificial
leather having antifouling property in which a polymeric elastomer is impregnated
in a nonwoven fabric formed by three-dimensionally interlacing ultrafine fibers and
raising is formed, wherein the polymeric elastomer is a fluorine-containing modified
polyurethane, and the fluorine-containing modified polyurethane is prepared by a method
comprising: preparing a urethane prepolymer having a weight average molecular weight
(Mw) of 400,000 to 700,000 by reacting a diol and a diisocyanate; and preparing a
polymerization product having a weight average molecular weight (Mw) of 500,000 to
800,000 by reacting the prepolymer and a fluorinated carbon compound having hydroxy
functional groups at both terminals.
[Advantageous Effects]
[0014] According to the present invention, artificial leather impregnated with a fluorine-containing
modified polyurethane elastomer having antifouling property also exhibits excellent
water repellency in addition to the antifouling property.
[0015] In addition, the artificial leather of the present invention can decrease the surface
change with the passage of time, as compared with artificial leather produced by separately
adding a fluorine-containing surfactant having the large occurrence of surface change
with the passage of time due to the migration of the surfactant.
[0016] Further, since the separate addition of the fluorine-based surfactant is not required,
the manufacture method can be simplified.
[Description of Drawings]
[0017]
Figure 1 illustrates a polymerization reaction scheme of a fluorine-containing modified
polyurethane according to an embodiment of the present invention.
Figure 2 shows a drawing of an apparatus for evaluating water repellency of the artificial
leather.
Figure 3 is a rating criterion for the water repellency evaluation.
[Best Mode]
[0018] The present invention relates to a suede type artificial leather having antifouling
property in which a polymeric elastomer is impregnated in a nonwoven fabric formed
by three-dimensionally interlacing ultrafine fibers and raising is formed, wherein
the polymeric elastomer is a fluorine-containing modified polyurethane.
[0019] The fluorine-containing modified polyurethane is a product obtained by a polymerization
reaction between a urethane prepolymer having isocyanate groups at terminals and a
weight average molecular weight (Mw) of 400,000 to 700,000, obtained by reacting a
diol and a diisocyanate, and a fluorinated carbon compound having hydroxy functional
groups at both terminals, and has a weight average molecular weight (Mw) of 500,000
to 800,000.
[0020] The diol may be used alone or in combination with diols such as 1,3-propanediol,
1,4-butanediol, 1,6-hexanediol, ethylene glycol, diethylene glycol, polyethylene glycol,
polypropylene glycol or polytetramethylene glycol.
[0021] The diisocyanate may be 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate,
1,12-dodecamethylene diisocyanate, cyclohexane-1,3- to 1,4-diisocyanate, 1-isocyanate-3-isocyanatemethyl-3,5,5-trimethylcyclohexane(isophorone
diisocyanate), bis-(4-isocyanatecyclohexyl) methane(hydrogenated MDI), 2- to 4-isocyanatecyclohexyl-2-isocyanatecyclohexylmethane,
1,3- to 1,4-tetramethylxylene diisocyanate, 2,4-to 2,6-diisocyanate toluene, 2,2-2,4-
to 4,4'-diphenylmethane diisocyanate , 1,5-naphthalene diisocyanate, xylene diisocyanate
or diphenyl-4,4-diisocyanate, and the like, but are not limited thereto.
[0022] In the present invention, when the diol is reacted with the diisocyanate, the proportion
to be reacted needs an excess amount of all NCO groups rather than all OH groups.
By adjusting the ratio of the diol and the diisocyanate to react as such, the resulting
urethane prepolymer may have an isocyanate group terminal in side chains thereof.
[0023] At this time, the molar ratio of the diol and the diisocyanate is preferably 1:1.2
to 1:1.4 because the fluorine-containing modified polyurethane having the weight average
molecular weight range of the present invention can be produced.
[0024] When the molar ratio is less than 1:1.2, a side reaction occurs due to moisture or
active hydrogen, etc. in the air, or the isocyanate reacts with each other to manifest
a property of isocyanate for forming a trimer and to decrease the polymerization efficiency
due to the increase of inactive NCO. When the molar ratio is more than 1:1.4, the
excess of NCO groups causes an insufficient OH group so that it is difficult to raise
the degree of polymerization.
[0025] In order to ensure the mechanical properties required in case that the fluorine-containing
modified polyurethane of the present invention is applied to artificial leather, it
is necessary to increase the polymerization molecular weight to an appropriate level
easily and to do so, a urethane prepolymer can be prepared first.
[0026] If the weight average molecular weight (Mw) of the urethane prepolymer is less than
400,000, the molecular weight of the fluorine-containing modified polyurethane is
lowered, and the mechanical properties such as tear strength, etc. and the chemical
properties such as thermal stability and hydrolysis resistance, etc. are lowered.
If it exceeds 700,000, the gelation phenomenon may occur in the production of the
fluorine-containing modified polyurethane, and the viscosity of the fluorine-containing
modified polyurethane may be high to reduce the workability in blending of an elastomer
impregnation solution, and the resulting fluorine-containing modified polyurethane
may be hardened, which may deteriorate the sensual quality in artificial leather.
[0027] The fluorinated carbon compound having hydroxy functional groups at both terminals
is represented by the following Chemical Formula 1, has 8 to 14 fluorine groups bonded
to one side chain and fluorine content of 50 to 70mol% in one functional group and
is an ether diol having hydroxy functional groups at both terminals.
[Chemical Formula 1] HO-CH
2-CF
2-O- (CF
2CF
2O) m- (CF
2O) n-CF
2-CH
2-OH
[0028] The fluorine-containing modified polyurethane obtained by reacting the ether diol
of the Chemical Formula 1 with the urethane prepolymer can provide water-repellent
and oil-repellent functions because the fluorine which is present as the diatomic
molecule in the element state, in the side chain of the urethane polymer is bonded
to prevent that the modified polyurethane is bonded to other atoms or molecules. Thus,
by the fluorine-containing modified polyurethane of the present invention, the artificial
leather can be suppressed deposition of an external contaminant and easily removed
contaminants on the coated surface.
[0029] A commercialized product of a fluorinated carbon compound having hydroxy functional
groups at both terminals is Solvay's FLUOROLINK.
[0030] The polymerization of the fluorine-containing modified polyurethane of the present
invention can be carried out through the addition-polymerization by adding dropwise
the fluorinated carbon compound having hydroxy functional groups at both terminals
to the urethane prepolymer until the desirable molecular weight is reached. At this
time, the addition amount of the fluorinated carbon compound corresponds to the moles
of excess isocyanate in preparing the urethane prepolymer.
[0031] When a fluorinated carbon compound having hydroxy functional groups at both terminals
is added at a time, the fluorinated carbon compound is partially bound to the urethane
prepolymer, so that the dispersion of the fluorine groups in the fluorine-containing
modified polyurethane becomes insufficient and as a result it is difficult to develop
the uniform antifouling performance. Therefore, it is preferable to slowly add dropwise.
[0032] The fluorine-containing modified polyurethane of the present invention is polymerized
by the above-mentioned method and is characterized by having a weight average molecular
weight (Mw) of 500,000 to 800,000. If the weight average molecular weight (Mw) is
less than 500,000, the mechanical strength such as tear strength, etc. and chemical
properties such as thermal stability, hydrolysis resistance, and the like in artificial
leather may be reduced. When the weight average molecular weight (Mw) is more than
800,000, the viscosity of the fluorine-containing modified polyurethane may be high
to reduce the workability in blending of an elastomer impregnation solution, and the
resulting fluorine-containing modified polyurethane may be hardened, which may deteriorate
the sensual quality in artificial leather.
[0033] It is preferable that the fluorine-containing modified polyurethane of the present
invention has a fluorine content of 5 to 20mol%. When the content is less than 5mol%,
the antifouling performance is insufficient, and when the content is more than 20mol%,
the water repellency is too strong so that the fluorine-containing modified polyurethane
cannot undergo the substitution solidification in the manufacturing process of the
artificial leather.
[0034] An example of the synthesis reaction of the fluorine-containing modified polyurethane
described above can be represented by the following reaction:

[0035] Here, R and R' are each independently an alkyl group.
[0036] Generally, artificial leather can be prepared by immersing a nonwoven fabric formed
by three-dimensionally interlacing ultrafine fibers in an impregnating liquid comprising
a polymeric elastomer such as polyurethane, impregnating the polymeric elastomer to
solidify the elastomer in the nonwoven fabric, raising by grinding and dyeing.
[0037] In the present invention, the fluorine-containing modified polyurethane of the present
invention can be used as a polymeric elastomer of the impregnating liquid. The fluorine-containing
modified polyurethane may be used as an impregnating liquid by diluting it in dimethyl
formamide of 100 to 200wt% in respect of the weight of the fluorine-containing modified
polyurethane.
[0038] The present invention will be described more fully hereinafter with reference to
the accompanying drawings, in which exemplary embodiments of the invention are shown.
[Preparation Example 1]
[0039] Polytetramethylene glycol (Mw: 1,500-2,500) of 0.45mol, ethylene glycol of 0.47mol
and 1,4-butanediol of 0.08mol were subjected to addition polymerization with 1.2mol
of 4,4'-diphenylmethane diisocyanate, and the produced polymerization product was
diluted and dissolved in dimethylformamide so as to be a total solid content of 40%
by weight to prepare an NCO-terminated polyurethane prepolymer having a weight average
molecular weight (Mw) of 700,000.
[0040] The prepared prepolymer was subjected to addition polymerization with 0.2mol of a
fluorinated carbon compound having hydroxy functional groups at both terminals in
a side chain (trade name: FLUOROLINK D10-H, manufactured by Solvay, Mw: 1,400) and
the produced polymerization product was diluted and dissolved in dimethylformamide
so as to be a total solid content of 30% by weight to prepare a fluorine-containing
modified polyurethane having a weight average molecular weight (Mw) of 800,000.
[Preparation Example 2]
[0041] Polytetramethylene glycol (Mw: 1,500-2,500) of 0.45mol, ethylene glycol of 0.47mol
and 1,4-butanediol of 0.08mol were subjected to addition polymerization with 1.3mol
of 4,4'-diphenylmethane diisocyanate, and the produced polymerization product was
diluted and dissolved in dimethylformamide so as to be a total solid content of 40%
by weight to prepare an NCO-terminated polyurethane prepolymer having a weight average
molecular weight (Mw) of 600,000.
[0042] The prepared prepolymer was subjected to addition polymerization with 0.3mol of a
fluorinated carbon compound having hydroxy functional groups at both terminals in
a side chain (trade name: FLUOROLINK D10-H, manufactured by Solvay, Mw: 1,400) and
the produced polymerization product was diluted and dissolved in dimethylformamide
so as to be a total solid content of 30% by weight to prepare a fluorine-containing
modified polyurethane having a weight average molecular weight (Mw) of 700,000.
[Preparation Example 3]
[0043] Polytetramethylene glycol (Mw: 1,500-2,500) of 0.45mol, ethylene glycol of 0.47mol
and 1,4-butanediol of 0.08mol were subjected to addition polymerization with 1.4mol
of 4,4'-diphenylmethane diisocyanate, and the produced polymerization product was
diluted and dissolved in dimethylformamide so as to be a total solid content of 40%
by weight to prepare an NCO-terminated polyurethane prepolymer having a weight average
molecular weight (Mw) of 400,000.
[0044] The prepared prepolymer was subjected to addition polymerization with 0.4mol of a
fluorinated carbon compound having hydroxy functional groups at both terminals in
a side chain and the produced polymerization product was diluted and dissolved in
dimethylformamide so as to be a total solid content of 30% by weight to prepare a
fluorine-containing modified polyurethane having a weight average molecular weight
(Mw) of 500,000.
[Preparation Example 4]
[0045] Polytetramethylene glycol (Mw: 1,500-2,500) of 0.45mol, ethylene glycol of 0.47mol
and 1,4-butanediol of 0.08mol were subjected to addition polymerization with 1.0mol
of 4,4'-diphenylmethane diisocyanate, and the produced polymerization product was
diluted and dissolved in dimethylformamide so as to be a total solid content of 70%
by weight to prepare a reaction-terminated polyurethane having a weight average molecular
weight (Mw) of 700,000.
[Preparation Example 5]
[0046] Polytetramethylene glycol (Mw: 1,500-2,500) of 0.45mol, ethylene glycol of 0.47mol
and 1,4-butanediol of 0.08mol were subjected to addition polymerization with 1.7mol
of 4,4'-diphenylmethane diisocyanate, and the produced polymerization product was
diluted and dissolved in dimethylformamide so as to be a total solid content of 40%
by weight to prepare an NCO-terminated polyurethane prepolymer having a weight average
molecular weight (Mw) of 350,000.
[0047] The prepared prepolymer was subjected to addition polymerization with 0.7mol of a
fluorinated carbon compound having hydroxy functional groups at both terminals in
a side chain and the produced polymerization product was diluted and dissolved in
dimethylformamide so as to be a total solid content of 30% by weight to prepare a
fluorine-containing modified polyurethane having a weight average molecular weight
(Mw) of 450,000.
[Preparation Example 6]
[0048] Polytetramethylene glycol (Mw: 1,500-2,500) of 0.45mol, ethylene glycol of 0.47mol
and 1,4-butanediol of 0.08mol were subjected to addition polymerization with 1.0mol
of 4,4'-diphenylmethane diisocyanate, and the produced polymerization product was
diluted and dissolved in dimethylformamide so as to be a total solid content of 70%
by weight to prepare a reaction-terminated polyurethane having a weight average molecular
weight (Mw) of 700,000.
[Example 1]
[0049] The fluorine-containing modified polyurethane of the Preparation Example 1 was diluted
with 150% by weight of dimethylformamide in respect of the weight of the polyurethane
to prepare an impregnating liquid.
[0050] The nonwoven fabric in which the polyester fibers (0.3 denier, fiber length: 51 mm)
was entangled was immersed in the impregnation solution, taken out and carried out
coagulating process in an aqueous solution diluted with 20% by weight of dimethylformamide
to form the fluorine-containing modified polyurethane elastomer impregnated nonwoven
fabric in which a fine porous layer was formed in the fiber structure.
[0051] Thereafter, a suede type artificial leather was produced by raising finishing on
the surface of the elastomer impregnated nonwoven fabric.
[Example 2]
[0052] A suede type artificial leather was produced in the same manner as in Example 1,
except that the fluorine-containing modified polyurethane of Preparation Example 2
was used to prepare an impregnation solution.
[Example 3]
[0053] A suede type artificial leather was produced in the same manner as in Example 1,
except that the fluorine-containing modified polyurethane of Preparation Example 3
was used to prepare an impregnation solution.
[Comparative Example 1]
[0054] A suede type artificial leather was produced in the same manner as in Example 1,
except that the fluorine-containing modified polyurethane of Preparation Example 4
was used to prepare an impregnation solution.
[Comparative Example 2]
[0055] A suede type artificial leather was produced in the same manner as in Example 1,
except that the fluorine-containing modified polyurethane of Preparation Example 5
was used to prepare an impregnation solution.
[Comparative Example 3]
[0056] A suede type artificial leather was produced in the same manner as in Example 1,
except that the reaction-terminated polyurethane of Preparation Example 6 is diluted
with a mixture of 150% by weight of dimethylformamide and 0.5% of a fluorine-based
surfactant (trade name FC-4430, 3M) with respect of the weight of the polyurethane,
to prepare an impregnation solution.
[0057] The weight average molecular weights (Mw) of the polymer prepared in the above Examples
and Comparative Examples were measured using gel permeation chromatography (GPC) (RI-8000,
manufactured by Tosoh Corporation) passing through the column connected TSKgel super
HM-L, TSKgel super HM-M and TSKgel super HM-N (tosoh) in series with tetrahydrofuran
(flow rate: 1 mL/min) as a mobile phase and the column oven at temperature of 40°C.
[0058] The raw material composition ratio for the polymerization in the above Preparation
Examples and the weight average molecular weight of the polymerization product are
shown in the following Table 1.
[Table 1]
| |
Preparation Example 1 |
Preparation Example 2 |
Preparation Example 3 |
Preparation Example 4 |
Preparation Example 5 |
Preparation Example 6 |
| diol |
1 mol |
1 mol |
1 mol |
1 mol |
1 mol |
1 mol |
| Diisocyanate |
1.2 mol |
1.3 mol |
1.4 mol |
1 mol |
1.7 mol |
1 mol |
| prepolymer |
700,000 |
600,000 |
400,000 |
700,000 |
350,000 |
700,000 |
| FLUOROLINK D10-H |
0.2 mol |
0.3 mol |
0.4 mol |
- |
0.7 mol |
- |
| Fluorine-containing modified polyurethane |
800,000 |
700,000 |
500,000 |
- |
450,000 |
- |
| surfactant (FC-4430) |
- |
- |
- |
- |
- |
0.5% |
| The value of the surfactant is that in elastomer impregnation solution. |
[0059] The properties of the artificial leather prepared in the above Examples and Comparative
Examples were evaluated according to the following antifouling property evaluation
method, and the results are shown in Table 2 below.
Evaluation method of antifouling property
[0060] An artificial leather sample was cut into a size of 5x15cm and placed in a rubbing
fastness tester (model name DL-2007) and a test fabric (product name: IEC carbon black/mineral
oil, manufactured by EMPA) was placed on the surface of the fouled sample and rubbed
by 10 times reciprocating motion, and the fouled sample was visually compared to give
a fouling degree.
(Standard of fouling grade,
[0061] 5: no visible fouling, 4: slightly visible but almost inconspicuous fouling, 3: slightly
fouled and visible, 2: slightly severe fouling, 1: significant fouling)
Water repellency evaluation method
[0062] The artificial leather sample was fixed (diameter 10cm) as shown in Figure 2 and
then tilted at an angle of 45°. Then, 100ml of water was injected into the spray-type
funnel located at the upper part, and the degree of distribution of the water droplets
on the surface of the sample after the completion of the spraying was observed to
give a rating according to Figure 3.
[Table 2]
| |
Example 1 |
Example 2 |
Example 3 |
Comparative Example 1 |
Comparative Example 2 |
Comparative Example 3 |
| Fouling grade |
3.5 |
3.5 |
3.5 |
2.0 |
2.5 |
3.5 |
| Water repellency rating |
3.5 |
4.0 |
4.5 |
2.5 |
3.0 |
2.5 |
[0063] As shown in the above Table 2, it can be confirmed that, the artificial leather of
the Example according to the present invention, in which the fluorine-containing modified
polyurethane is impregnated as an elastomer has the same antifouling performance as
the artificial leather (Comparative Example 3) in which the fluorine-containing surfactant
was separately added, and exhibits improved water repellency at the same time.
[0064] The artificial leather according to the present invention is an artificial leather
in which a fluorine-containing modified polyurethane having an antifouling property
is impregnated. The fluorine-containing surfactant does not need separately for the
antifouling property during the production of artificial leather so that productivity
increase is possible. The artificial leather according to the present invention exhibits
an excellent antifouling performance that suppresses the surface change with the passage
of time of the artificial leather caused by using a fluorine-containing surfactant,
thereby improving the appearance quality of the artificial leather.
[0065] Although the present invention has been described in detail with reference to the
specific features, it will be apparent to those skilled in the art that this description
is only for a preferred embodiment and does not limit the scope of the present invention.
Thus, the substantial scope of the present invention will be defined by the appended
claims and equivalents thereof.