Sheet material and method for producing same

Patent metadata

Field	Value
Publication number	US-12338575-B2
Application number	US-202017784749-A
Country	US
Kind code	B2
Filing date	Dec 10, 2020
Priority date	Dec 20, 2019
Publication date	Jun 24, 2025
Grant date	Jun 24, 2025

Abstract

The sheet material according to the present invention has a polymer elastic body and a fibrous base material comprising ultrafine fibers, wherein the average single fiber diameter of the ultrafine fibers is 0.1 μm to 10.0 μm, the polymer elastic body has a hydrophilic group and an N-acylurea bond and/or an isourea bond, and the following conditions are satisfied: the longitudinal stiffness, in accordance with method A (45° cantilever method) in the text of “8.21 Stiffness” of JIS L 1096:2010 “Testing Methods for Woven and Knitted Fabrics”, is 40 mm to 140 mm; and after immersion for 24 hours in N,N-dimethylformamide, the following are obtained in wear testing using a pressing load of 12.0 kPa and 20,000 friction cycles in accordance with method E (Martindale method) in the text of “8.19 Wear Strength and Friction Discoloration” of JIS L 1096:2010 “Testing Methods for Woven and Knitted Fabrics”: a grade of at least 4 and a wear loss of not more than 25 mg.

First claim

The invention claimed is:

1. A sheet material comprising:
a fibrous base material made of ultrafine fibers;
a chain extender, and
an elastomer,
wherein an average single-fiber diameter of the ultrafine fibers is 0.1 μm or more and 10.0 μm or less,
wherein the chain extender comprises water, a low-molecular weight diol, an alicyclic diol, an aromatic diol, an aliphatic diamine, an alicyclic diamine, an aromatic diamine, an aroaliphatic diamine, an alkanolamine, hydrazine, a dihydrazide, or a mixture thereof;
the elastomer has a hydrophilic group and an N-acylurea bond and/or an isourea bond, and
the following condition 1 and condition 2 are satisfied:
condition 1: A longitudinal stiffness, in accordance with method A (45° cantilever method) in the text of “8.21 Stiffness” of JIS L 1096:2010 “Testing Methods for Woven and Knitted Fabrics”, is 40 mm or more and 140 mm or less; and
condition 2: After immersion for 24 hours in N,N-dimethylformamide, the following are obtained in wear testing using a pressing load of 12.0 kPa and 20,000 friction cycles in accordance with method E (Martindale method) in the text of “8.19 Wear Strength and Friction Discoloration” of JIS L 1096:2010 “Testing Methods for Woven and Knitted Fabrics”: a grade of at least 4 and a wear loss of not more than 25 mg.

2. The sheet material according to claim 1 , wherein the elastomer includes two types of an elastomer A and an elastomer B different from the elastomer A.

3. The sheet material according to claim 1 , wherein a wet tensile strength of the sheet material is 75% or more of a dry tensile strength of the sheet material.

4. The sheet material according to claim 1 , wherein a wet tensile elongation of the sheet material is 100% or more of a dry tensile elongation of the sheet material.

5. The sheet material according to claim 1 , wherein the sheet material further satisfies the following condition 3:
condition 3: The sheet material has an L value retention of 90% or more and 100% or less when a nap raising surface of the sheet material is placed on a hot plate heated to 150° C. and pressed at a pressing load of 2.5 kPa for 10 seconds.

6. The sheet material according to claim 1 , wherein the sheet material further satisfies the following condition 4:
condition 4: In a washing test according to the ISO 6330 C4N method, when the washing test of one sheet of the sheet material is performed, and fiber fragments attached to a collecting bag attached to a drain hose after the test is collected using a membrane filter, an amount of the fiber fragment is 10.0 (mg/sheet material 100 cm 2 ) or less.

7. A method for producing a sheet material according to claim 1 , comprising the following steps (1) to (3) in this order:
(1) A first elastomer precursor impregnation step of forming an elastomer by impregnating a fibrous base material made of ultrafine fiber-generating fibers with an aqueous dispersion containing an elastomer precursor having a hydrophilic group, a monovalent cation-containing inorganic salt, and a crosslinker, and then subjecting the fibrous base material impregnated with the aqueous dispersion to a heat drying treatment at a temperature of 100° C. or higher and 180° C. or lower, wherein a content of the monovalent cation-containing inorganic salt in the aqueous dispersion is 10 parts by mass or more and 100 parts by mass or less with respect to 100 parts by mass of the elastomer precursor;
(2) An ultrafine fiber generating step of generating ultrafine fibers from the ultrafine fiber-generating fibers to form a fibrous base material made of the ultrafine fibers; and
(3) A second elastomer precursor impregnation step of further forming an elastomer by impregnating a fibrous base material made of the ultrafine fibers with an aqueous dispersion containing an elastomer precursor having a hydrophilic group, a monovalent cation-containing inorganic salt, and a crosslinker, and then subjecting the fibrous base material impregnated with the aqueous dispersion to a heat drying treatment at a temperature of 100° C. or higher and 180° C. or lower, wherein a content of the monovalent cation-containing inorganic salt in the aqueous dispersion is 10 parts by mass or more and 100 parts by mass or less with respect to 100 parts by mass of the elastomer precursor.

8. The method for producing a sheet material according to claim 7 , wherein the elastomer precursor used in the first elastomer precursor impregnation step and the elastomer precursor used in the second elastomer precursor impregnation step are the same elastomer precursor.

9. The method for producing a sheet material according to claim 7 , wherein the elastomer precursor contains polyether diol and/or polycarbonate diol.

10. The method for producing a sheet material according to claim 7 , wherein the elastomer precursor used in the first elastomer precursor impregnation step is an elastomer precursor A, and the elastomer precursor used in the second elastomer precursor impregnation step is an elastomer precursor B different from the elastomer precursor A.

11. The method for producing a sheet material according to claim 10 , wherein the elastomer precursor A contains polyether diol as a constituent.

12. The method for producing a sheet material according to claim 10 , wherein the elastomer precursor B contains polycarbonate diol as a constituent.

13. The method for producing a sheet material according to claim 7 , wherein the crosslinker is a carbodiimide-based crosslinker and/or a blocked isocyanate crosslinker.

14. The method for producing a sheet material according to claim 7 , wherein the monovalent cation-containing inorganic salt is sodium chloride and/or sodium sulfate.

15. The sheet material of claim 1 , wherein:
the low-molecular-weight diol comprises ethylene glycol, propylene glycol, 1,3-butylene glycol, 1,4-butanediol, 1,6-hexanediol, diethylene glycol, or neopentyl glycol;
the alicyclic diol comprises 1,4-bis(hydroxymethyl)cyclohexane;
the aromatic diol comprises 1,4-bis(hydroxyethyl)benzene;
the aliphatic diamine comprises ethylenediamine;
the alicyclic diamine comprises isophorondiamine;
the aromatic diamine comprises 4-4-diaminodiphenylmethane;
the aroaliphatic diamine comprises xylenediamine;
the alkanolamine comprises ethanolamine; and,
the dihydrazide comprises adipic acid dihydrazide.

Assignees

• Toray Industries

Inventors

• Ishii Koki
• Shikuri Ryuji
• Shibano Takuya

Classifications

• D06N2211/267

  Aircraft · CPC title

• D06N2211/265

  Trains · CPC title

• D06N2211/263

  Cars · CPC title

• D06N2211/14

  Furniture, upholstery · CPC title

• D06N2211/10

  Clothing · CPC title