Fouling-proof structure

Abstract

A fouling-proof structure is applicable to synthetic leather or fabric and it includes an alcohol-resistant layer; and a water-based fouling-proof layer disposed on the alcohol-resistant layer, wherein the alcohol-resistant layer is formed by curing an alcohol-resistant combination, and the alcohol-resistant combination comprises polyurethane resin, wherein the water-based fouling-proof layer is formed by curing a water-based fouling-proof combination, and the water-based fouling-proof combination comprises polyurethane resin, water, polymerized siloxanes, water-based PTFE and silicone oil.

Claims

1. A fouling-proof structure, comprising: an alcohol-resistant layer; and a water-based fouling-proof layer disposed on the alcohol-resistant layer, wherein the alcohol-resistant layer is formed by curing an alcohol-resistant combination by drying the alcohol-resistant combination at 90-120° C. for one to five minutes, and wherein the water-based fouling-proof layer is formed by curing a water-based fouling-proof combination by drying the water-based fouling-proof combination above 140° C. for one to five minutes, wherein the alcohol-resistant combination comprises: 30-50 weight percent of polyether and polyester aliphatic water-based polyurethane resin; 0.5-3 weight percent of wetting agent; 1-2 weight percent of aziridine crosslinker; 0.7-2.1 weight percent of polycarbodiimide crosslinker; and 41.9-67.8 weight percent of water; wherein the water-based fouling-proof combination comprises: 6.6-28.9 weight percent of polyether and polyester aliphatic and hydrolysis-resistant water-based PU resin; 43.6-58.5 weight percent of water; 12-15.3 weight percent of polymerized siloxanes; 1-2 weight percent of water-based polytetrafluoroethylene; and 1.4-2.0 weight percent of silicone oil.

2. The fouling-proof structure of claim 1, wherein the water-based fouling-proof combination further comprises: 0.1-3 weight percent of isocyanate crosslinker; 0.1-3 weight percent of tackifier; 0.1-3 weight percent of wetting agent; 0.01-3 weight percent of antifoaming agent; 5-15 weight percent of leather slipping agent; and 0.01-1 weight percent of matting agent.

3. The fouling-proof structure of claim 1, wherein the fouling-proof structure is disposed on a substrate, and the alcohol-resistant layer is disposed between the water-based fouling-proof layer and the substrate, the substrate being made of fabric, polyurethane, polyvinyl chloride, thermoplastic polyurethane, thermoplastic olefin, thermoplastic vulcanizate, thermoplastic styrene, thermoplastic polyether ester elastomer or thermoplastic polyamide.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In order to clarify the description, the thickness and size of each layer shown in the drawings are enlarged, omitted or schematically depicted. The drawings are not drawn to scale.

(2) FIG. 1 is a scheme of a fouling-proof structure and a substrate according to embodiment 1 of the present disclosure.

(3) FIG. 2 is a picture of the fouling-proof structure and the substrate according to embodiment 1 of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

(4) To well understand the purpose, characteristics, and effects of this present disclosure, embodiments together with the detailed descriptions and the attached tables of the present disclosure are provided.

Embodiment 1-1

(5) Referring to FIG. 1, a fouling-proof structure 10 in embodiment 1 comprises an alcohol-resistant layer 12 and a water-based fouling-proof layer 13 disposed on the alcohol-resistant layer 12. In this embodiment, the fouling-proof structure 10 is disposed on a substrate 20. The alcohol-resistant layer 12 is disposed between the water-based fouling-proof layer 13 and the substrate 20.

(6) In this embodiment, the substrate 20 is water-based PU synthetic leather, but the present disclosure is not limited thereto. In a variant embodiment, the substrate is fabric, polyurethane (PU) leather, water-based PU leather, polyvinyl chloride (PVC) leather, semi PU/PVC leather, thermoplastic polyurethane (TPU) leather, thermoplastic olefin (TPO), thermoplastic vulcanizate (TPV), thermoplastic styrene (TPS), thermoplastic polyether ester elastomer (TPEE), thermoplastic polyamide (TPA), or a combination thereof.

(7) The process of producing the fouling-proof structure 10 in this embodiment is as follows: a) coating an alcohol-resistant combination on the substrate 20 and drying the alcohol-resistant combination at 90-120° C. for one to five minutes to form the alcohol-resistant layer 12; b) coating a water-based fouling-proof combination on the alcohol-resistant layer 12 and drying the water-based fouling-proof combination above 140° C. for one to five minutes to form the water-based fouling-proof layer 13.

(8) The drying temperature and duration in step a) and step b) only serve exemplary purposes and thus must not be interpreted in such a manner to be restrictive of the scope of the present disclosure. Hence, persons skilled in the art can appropriately adjust the drying temperature and duration in step a) and step b) as needed without departing from the scope of the claims of the present disclosure. In a variant embodiment, the drying in step b) takes place at 140-145° C.

(9) In this embodiment, the alcohol-resistant combination and water-based fouling-proof combination are coated by means of spraying-coating, but the present disclosure is not limited thereto; hence, persons skilled in the art can select an appropriate method of coating as needed. According to the present disclosure, the means of coating for use in the method of producing a fouling-proof structure includes but is not limited to: spraying-coating, soaking-coating, showering-coating, painting-coating, rotating-coating, vacuum-coating, rolling-coating and direct coating.

(10) In this embodiment, the alcohol-resistant layer 12 is formed by curing an alcohol-resistant combination A. The constituents of the alcohol-resistant combination A are enumerated in Table 1 below.

(11) TABLE-US-00001 TABLE 1 weight percent alcohol- alcohol- alcohol- resistant resistant resistant combi- combi- combi- constituent nation A nation B nation C aliphatic water-based PU resin 30 42 50 (polyether & polyester type) (model number: F-363, purchased from Chain Chemical Co., Ltd.) wetting agent (model number: 0.5 1.5 3 OFX-5211, purchased from Guang zhou HT-Chemical Co., Ltd.) aziridine crosslinker (model 1 1.5 2 number: PZ-33, purchased from PolyAziridine LLC) antifoaming agent (model number: 0 0.5 1 A5757, purchased from Sigma- Aldrich) polycarbodiimide crosslinker 0.7 1.4 2.1 (model number: V-02-L2, purchased from An Fong Development Co., Ltd.) water 67.8 53.1 41.9

(12) In this embodiment, the water-based fouling-proof layer 13 is formed by curing the water-based fouling-proof combination A. The constituents of the water-based fouling-proof combination A are enumerated in Table 2 below.

(13) TABLE-US-00002 TABLE 2 weight percent water- water- water- based based based fouling- fouling- fouling- proof proof proof combi- combi- combi- constituent nation A nation B nation C aliphatic & hydrolysis-resistant 6.6 19.4 28.9 water-based PU resin (polyether & polyester type) (model number: JW-25A-2, purchased from Jiuh Yi Chemical Industrial Co. Ltd.) isocyanate crosslinker (model 0.6 1.9 2.9 number: EC-385, purchased from SiwoChem) water 58.5 50.2 43.6 polymerized siloxanes (model 15.3 13.4 12 number: PA-8316, purchased from Guang zhou HT-Chemical Co., Ltd.) water-based 2 1.1 1 polytetrafluoroethylene (PTFE) (model number: Teflon ™ PTFE, purchased from Dupont Chemours) silicone oil (model number: 2.0 1.7 1.4 85409-IL, purchased from Sigma- Aldrich) tackifier (model number: CA- 0.5 0.4 0.3 909, purchased from Xuanning Chemical Technology) wetting agent (model number: 0.3 0.2 0.2 OFX-5211, purchased from Guang zhou HT-Chemical Co., Ltd.) antifoaming agent (model number: 0.1 0.1 0.1 A5757, purchased from Sigma- Aldrich leather slipping agent (model 13.1 11.1 9.6 number: AQUADERM ADDITIVE GF, purchased from Lanxess (Changzhou) Co., Ltd.) matting powder (model number: 1 0.5 0 ACEMATT ® TS-100, purchased from EVONIK)

(14) The product model numbers, suppliers, and weight percents of the constituents enumerated in Table 1 and Table 2 only serve exemplary purposes but must not be interpreted in such a manner to be restrictive of the scope of the present disclosure. Hence, persons skilled in the art can select appropriate product model numbers and suppliers of the constituents and adjust appropriate weight percents as needed without departing from the scope of the claims of the present disclosure. In this embodiment, for exemplary purposes, matting powder is used as the matting agent, but the present disclosure is not limited thereto, and thus it is feasible to use any other types (for example, liquid) of matting agent. In a variant embodiment, the alcohol-resistant combination does not include any wetting agent, aziridine crosslinker and antifoaming agent. In a variant embodiment, the water-based fouling-proof combination does not include any antifoaming agent and matting agent.

(15) FIG. 2 is a picture taken of the fouling-proof structure 10 and the substrate 20 according to embodiment 1 of the present disclosure. The picture shows four layers arranged from top to bottom as follows: (a) a top layer is the fouling-proof structure 10 which comprises the alcohol-resistant layer 12 and the water-based fouling-proof layer 13; the substrate 20 includes: (b) a surface layer which comprises the surface of water-based PU; (c) a middle layer which comprises water-based PU foam; and (d) fabric.

Embodiment 1-2

(16) When it comes to the fouling-proof structure and the process of producing the same, embodiment 1-2 differs from embodiment 1-1 as follows: in embodiment 1-2, the alcohol-resistant layer is formed by curing an alcohol-resistant combination B, and the constituents of the alcohol-resistant combination B are enumerated in Table 1; and the water-based fouling-proof layer is formed by curing the water-based fouling-proof combination B, and the constituents of the water-based fouling-proof combination B are enumerated in Table 2 above.

Embodiment 1-3

(17) When it comes to the fouling-proof structure and the process of producing the same, embodiment 1-3 differs from embodiment 1-1 as follows: in embodiment 1-3, the alcohol-resistant layer is formed by curing an alcohol-resistant combination C; the constituents of the alcohol-resistant combination C are enumerated in Table 1 above; and the water-based fouling-proof layer is formed by curing the water-based fouling-proof combination C, and the constituents of the water-based fouling-proof combination C are enumerated in Table 2 above.

Embodiment 2-1

(18) The fouling-proof structure in embodiment 2-1 comprises: an alcohol-resistant layer; and a water-based fouling-proof layer disposed on the alcohol-resistant layer. In this embodiment, the fouling-proof structure is disposed on a substrate, and the alcohol-resistant layer is disposed between the water-based fouling-proof layer and the substrate.

(19) In this embodiment, the substrate is solvent-based PU synthetic leather, but the present disclosure is not limited thereto. In a variant embodiment, the substrate is fabric, polyurethane (PU) leather, water-based PU leather, polyvinyl chloride (PVC) leather, semi PU/PVC leather, thermoplastic polyurethane (TPU) leather, thermoplastic olefin (TPO), thermoplastic vulcanizate (TPV), thermoplastic styrene (TPS), thermoplastic polyether ester elastomer (TPEE), thermoplastic polyamide (TPA), or a combination thereof.

(20) The process flow of producing the fouling-proof structure in this embodiment comprises the steps as follows: a) coating an alcohol-resistant combination on a substrate and then drying the alcohol-resistant combination at 90-130° C. for one to five minutes to form an alcohol-resistant layer; and b) coating a water-based fouling-proof combination on the alcohol-resistant layer and then drying the water-based fouling-proof combination above 140° C. for one to five minutes to form a water-based fouling-proof layer.

(21) The drying temperatures and durations in step a) and step b) only serve exemplary purposes but must not be interpreted in such a manner to be restrictive of the scope of the present disclosure. Persons skilled in the art can appropriately adjust the drying temperatures and durations in step a) and step b) as needed without departing from the scope of the claims of the present disclosure. In a variant embodiment, the drying in step b) takes place at 140-145° C.

(22) In this embodiment, the alcohol-resistant combination and water-based fouling-proof combination are coated by spraying-coating, but the present disclosure is not limited thereto, and thus persons skilled in the art may choose an appropriate way of coating as needed. The way of coating for use in the method of producing a fouling-proof structure according to the present disclosure includes, but is not limited to, spraying-coating, soaking-coating, showering-coating, painting-coating, rotating-coating, vacuum-coating, rolling-coating and direct coating.

(23) In this embodiment, the alcohol-resistant layer is formed by curing an alcohol-resistant combination D, and the constituents of the alcohol-resistant combination D are enumerated in Table 3 below.

(24) TABLE-US-00003 TABLE 3 weight percent alcohol- alcohol- alcohol- resistant resistant resistant combi- combi- combi- constituent nation D nation E nation F hydrolysis-resistant & yellowing- 76 82 88 resistant PU resin (polyether type) (model number: SC-8200G, purchased from Guangzhou Songjeong Chemical Co., Ltd.) two-component crosslinker 11 8.2 5.3 (melamine type) (model number: SH-82, purchased from Guangzhou Songjeong Chemical Co., Ltd.) matting powder (model number: 1.5 1.6 1.8 ACEMATT ® TS-100, purchased from EVONIK) two-component chemical promoter 11.5 8.2 4.9 (model number: SE-82, purchased from Guangzhou Songjeong Chemical Co., Ltd.)

(25) In this embodiment, the water-based fouling-proof layer is formed by curing the water-based fouling-proof combination D, and the constituents of the water-based fouling-proof combination D are enumerated in Table 4 below.

(26) TABLE-US-00004 TABLE 4 weight percent water- water- water- based based based fouling- fouling- fouling- proof proof proof combi- combi- combi- constituent nation D nation E nation F aliphatic & hydrolysis-resistant, 6.6 19.4 28.9 water-based PU resin (polyether & polyester type) (model number: JW-25A-2, purchased from Jiuh Yi Chemical Industrial Co. Ltd.) isocyanate crosslinker (model 0.6 1.9 2.9 number: EC-385, purchased from SiwoChem) water 58.5 50.2 43.6 polymerized siloxanes (model 15.3 13.4 12 number: PA-8316, purchased from Guang zhou HT-Chemical Co., Ltd.) water-based 2 1.1 1 polytetrafluoroethylene (PTFE) (model number: Teflon ™ PTFE, purchased from Dupont Chemours) silicone oil (model number: 2.0 1.7 1.4 85409-IL, purchased from Sigma- Aldrich) tackifier (model number: CA- 0.5 0.4 0.3 909, purchased from Xuanning Chemical Technology) wetting agent (model number: 0.3 0.2 0.2 OFX-5211, purchased from Guang zhou HT-Chemical Co., Ltd.) antifoaming agent (model number: 0.1 0.1 0.1 A5757, purchased from Sigma- Aldrich) leather slipping agent (model 13.1 11.1 9.6 number: AQUADERM ADDITIVE GF, purchased from Lanxess (Changzhou) Co., Ltd.) matting powder (model number: 1 0.5 0 ACEMATT ® TS-100, purchased from EVONIK)

(27) The product model numbers, suppliers, and weight percents of the constituents enumerated in Table 3 and Table 4 only serve exemplary purposes but must not be interpreted in such a manner to be restrictive of the scope of the present disclosure. Persons skilled in the art can select appropriate product model numbers and suppliers of the constituents and adjust appropriate weight percents as needed without departing from the scope of the claims of the present disclosure. In this embodiment, matting powder is used as the matting agent for exemplary purposes, but the present disclosure is not limited thereto, and thus it is feasible to use any other types (for example, liquid) of matting agent. In a variant embodiment, the alcohol-resistant combination does not include any matting agent. In a variant embodiment, the water-based fouling-proof combination does not include any antifoaming agent and matting agent.

Embodiment 2-2

(28) When it comes to the fouling-proof structure and the process of producing the same, embodiment 2-2 differs from embodiment 2-1 as follows: in embodiment 2-2, the alcohol-resistant layer is formed by curing an alcohol-resistant combination E, and the constituents of the alcohol-resistant combination E are enumerated in Table 3 above; and the water-based fouling-proof layer is formed by curing the water-based fouling-proof combination E, and the constituents of the water-based fouling-proof combination E are enumerated in Table 4 above.

Embodiment 2-3

(29) When it comes to the fouling-proof structure and the process of producing the same, embodiment 2-3 differs from embodiment 2-1 as follows: in embodiment 2-3, the alcohol-resistant layer is formed by curing an alcohol-resistant combination F, and the constituents of the alcohol-resistant combination F are enumerated in Table 3 above; and the water-based fouling-proof layer is formed by curing the water-based fouling-proof combination F, and the constituents of the water-based fouling-proof combination F are enumerated in Table 4 above.

(30) Test

(31) A test is performed on the fouling-proof structure of embodiments 1-1 through 1-3 and 2-1 through 2-3. First, the ability of the fouling-proof structure of embodiments 1-1 through 1-3 and 2-1 through 2-3 is testified by specific staining agents. Next, after a specific period of time has passed, the contaminated fouling-proof structure is wiped. After that, remnants of stains are assessed in terms of their extent, and the result of the assessment is shown in Table 5 below.

(32) TABLE-US-00005 TABLE 5 stain dwell time within 3 minutes 3 hours later 24 hours later preclean- preclean- preclean- wipe wipe wipe staining agents, with dry 95% with dry 95% with dry 95% (class) cloth ethanol* cloth ethanol* cloth ethanol* Embodiment 1-1 denim dye 5 5 5 5 5 5 (color migration) hotel ballpoint pen 5 5 5 5 5 5 marker 5 5 5 5 4 4.5 black tea 5 5 5 5 5 5 coffee 5 5 5 5 5 5 ketchup 5 5 5 5 5 5 mustard 5 5 5 5 4 4.5 Coca-Cola 5 5 5 5 5 5 soy sauce 5 5 5 5 5 5 Embodiment 1-2 denim dye 5 5 5 5 5 5 (color migration) hotel ballpoint pen 5 5 5 5 5 5 marker 5 5 5 5 4.5 5 black tea 5 5 5 5 5 5 coffee 5 5 5 5 5 5 ketchup 5 5 5 5 5 5 mustard 5 5 5 5 4.5 5 Coca-Cola 5 5 5 5 5 5 soy sauce 5 5 5 5 5 5 Embodiment 1-3 denim dye 5 5 5 5 5 5 (color migration) hotel ballpoint pen 5 5 5 5 5 5 marker 5 5 4.5 5 3.5 4 black tea 5 5 5 5 5 5 coffee 5 5 5 5 5 5 ketchup 5 5 5 5 5 5 mustard 5 5 4.5 5 3.5 4 Coca-Cola 5 5 5 5 5 5 soy sauce 5 5 5 5 5 5 Embodiment 2-1 denim dye 5 5 5 5 5 5 (color migration) hotel ballpoint pen 5 5 5 5 5 5 marker 5 5 5 5 4 4.5 black tea 5 5 5 5 5 5 coffee 5 5 5 5 5 5 ketchup 5 5 5 5 5 5 mustard 5 5 5 5 4 4.5 Coca-Cola 5 5 5 5 5 5 soy sauce 5 5 5 5 5 5 Embodiment 2-2 denim dye 5 5 5 5 5 5 (color migration) hotel ballpoint pen 5 5 5 5 5 5 marker 5 5 5 5 4.5 5 black tea 5 5 5 5 5 5 coffee 5 5 5 5 5 5 ketchup 5 5 5 5 5 5 mustard 5 5 5 5 4.5 5 Coca-Cola 5 5 5 5 5 5 soy sauce 5 5 5 5 5 5 Embodiment 2-3 denim dye 5 5 5 5 5 5 (color migration) hotel ballpoint pen 5 5 5 5 5 5 marker 5 5 4.5 5 3.5 4 black tea 5 5 5 5 5 5 coffee 5 5 5 5 5 5 ketchup 5 5 5 5 5 5 mustard 5 5 4.5 5 3.5 4 Coca-Cola 5 5 5 5 5 5 soy sauce 5 5 5 5 5 5 *wipe with dry cloth and then with 95% ethanol

(33) Rating system:

(34) Class 5 No evidence of stain present

(35) Class 4 Slight evidence of stain present

(36) Class 3 Noticeable evidence of stain present

(37) Class 2 Considerable evidence of stain present

(38) Class 1 Excessive evidence of stain present

(39) In Table 5, the cardinal number of the class assessment is 0.5. For example, 4.5 indicates that the fouling-proof class stands between class 4 and class 5. After being wiped with 95% ethanol, the fouling-proof structure contaminated by the staining agents enumerated in Table 5 has either no evidence or slight evidence of stain present. Hence, the fouling-proof structure of the present disclosure is capable of performing stain resistibility.

(40) The main differences in synthetic leather processing between the fouling-proof structure of the present disclosure and a conventional fouling-proof material disclosed in the prior art are as follows: 1. Most of the commercial fouling-proof materials suitable for synthetic leather processing are solvent-based two-component resin. Their constituents include organic solvents, and thus they are confronted by the volatilization of volatile organic compounds (VOC). 2. Commercial fouling-proof materials suitable for use with leather are high-modulus resins. By contrast, the water-based PU used in the fouling-proof structure of the present disclosure is low-modulus resin. The issue of the ability of flex, which occurs in soft leather processing, is typical in the commercial fouling-proof materials but not in the fouling-proof structure of the present disclosure. 3. The ballpoint pen is hard to write on the synthetic leather coated with the fouling-proof material of the present disclosure. Even if it can do so, the stain can be wiped off easily. By contrast, the ballpoint pen can write on the synthetic leather coated with commercial fouling-proof materials easily, and the stain should wipe with detergent in three hours (better not more than 24 hours). Otherwise, the stain cannot be removed anymore. 4. There exists the issue of denim dye migration in commercial water-based fouling-proof material. 5. Commercial fouling-proof materials are not always suitable for all kinds of synthetic leather finishing. 6. The fouling-proof structure of the present disclosure comprises a water-based fouling-proof layer and an alcohol-resistant layer which are coupled together to form a stronger protective layer. Hence, until the fouling-proof structure of the present disclosure is wiped repeatedly with alcohol solution at least 30 times, its fouling-proof structure starts to decay.

(41) The fouling-proof structure of the present disclosure has advantages as follows: 1. The main residues, water-based PU resin in the process of the fouling-proof structures can be reused. 2. The fouling-proof structure of the present disclosure is odorless, non-toxic, free of VOC, environment-friendly, and thus conducive to environmental protection. 3. The fouling-proof structure of the present disclosure is still high yellowing-resistant and free of burnt smell after high-temperature embossing process.

(42) While the present disclosure has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope and spirit of the present disclosure set forth in the claims.