Patent Description:
Moisture-permeable waterproof functional clothing having both moisture permeability and waterproofness is a material having a structure that has a moisture permeable film bonded onto a cloth using an adhesive, and, as the adhesive, in view of excellent adhesion with both the moisture permeable film and the cloth, an urethane adhesive is generally used. Further, recently, there are solvent emission regulations and residual solvent regulations worldwide, and thus, among the urethane adhesives, a moisture-curable polyurethane resin composition which is of a solventless type is gradually increased in the amount of the composition used (see, for example, PTL <NUM>).

Meanwhile, the cloth used in the clothing is reduced in denier and improved in water repellency to further improve the function, and consequently, a problem of poor adhesion of such a cloth with an adhesive is pointed out, and the moisture-curable polyurethane resin composition currently used has not yet exhibited high adhesion, particularly with a super-water-repellent cloth.

Further, marine plastic pollution problems have drawn attention recently, and accordingly, biobased resins aimed at getting rid of the fossil fuel resources have increasingly attracted attention, and the moisture-curable polyurethane resin composition is no exception.

<CIT> describes a low-molecular-weight polyester resin which can elasticize a resin suitably and can be used for various purposes and various resins obtained by using the resin. The polyester resin is obtained by polymerizing a monomer composition containing <NUM> to <NUM> weight % of a linear dicarboxylic acid and/or diol having at least <NUM> carbon atoms (I), <NUM> to <NUM> weight % of a branched dicarboxylic acid and/or diol having at least <NUM> carbon atoms (II-<NUM>) and/or <NUM> to <NUM> weight % of at least one polyfunctional monomer (II-<NUM>) selected from the group consisting of polyols, polycarboxylic acids and hydroxycarboxylic acids having <NUM> or more functional groups respectively and which has the number average molecular weight of <NUM> to <NUM> and is amorphous.

<CIT> describes a moisture curable hotmelt adhesive composition comprising at least one polyurethane prepolymer obtained from the reaction of a) at least one polyether; b) at least one (meth)acrylic resin; c) at least one crystalline polyester; d) at least one amorphous polyester; e) at least one isocyanate compound; in a presence of a catalyst, wherein at least one of said polyether, crystalline polyester and amorphous polyester is partially or completely bio-based material.

<CIT> relates to the problem to provide, using biomass-derived raw materials, a moisture-curable polyurethane resin composition which is excellent in terms of adhesion to fabric (in particular, water-repellent fabric) and film strength. As a solution to the problem, the document describes a moisture-curable polyurethane hot-melt resin composition characterized by including a urethane prepolymer (i) having isocyanate groups which is a product of reaction between polyols (A) and a polyisocyanate (B), the polyols (A) comprising a polyester polyol (a1) obtained from a biomass-derived polybasic acid (x) and a biomass-derived glycol (y) as raw materials and other polyester polyol(s) (a2). The document further describes an adhesive characterized by comprising the moisture-curable polyurethane hot-melt resin composition.

Further technical background is described in <NPL>, and <NPL>.

A task to be achieved by the present invention is to provide the use of a moisture-curable polyurethane hot-melt resin composition which uses a biomass raw material, and which has excellent adhesion with a cloth (particularly, a water-repellent cloth) as an adhesive for producing moisture-permeable waterproof functional clothing.

As a solution to the above problem, the invention provides the use according to claim <NUM>.

The moisture-curable polyurethane resin composition used according to the invention uses a biomass raw material, and thus is an environment-friendly material. Further, the moisture-curable polyurethane resin composition used according to the invention has excellent adhesion with various types of cloths, and has excellent adhesion even with a water-repellent cloth.

The moisture-curable polyurethane hot-melt resin composition used in the present invention contains an urethane prepolymer (i) having an isocyanate group, which is a reaction product of a polyol (A) comprising a specific polyester polyol, and a polyisocyanate (B).

It is necessary that the polyol (A) comprise a polyester polyol (a1) which uses a polybasic acid (x) derived from biomass and a glycol (y) derived from biomass as raw materials.

As the biomass-derived polybasic acid (x), sebacic acid and/or succinic acid is used. These compounds may be used individually or in combination.

As the above-mentioned sebacic acid, for example, there can be used sebacic acid which is obtained by subjecting a vegetable fat or oil, such as castor oil, to known cleavage reaction using caustic alkali. As the above-mentioned succinic acid, for example, there can be used succinic acid which is obtained by subjecting corn, sugarcane, casaba, sago palm, or the like to fermentation by a known method.

With respect to the biomass-derived polybasic acid (x), among those mentioned above, from the viewpoint of obtaining even more excellent adhesion with a cloth, sebacic acid is more preferred.

As the biomass-derived glycol (y), <NUM>,<NUM>-propanediol and/or <NUM>,<NUM>-butanediol is used. These compounds may be used individually or in combination.

As the above-mentioned <NUM>,<NUM>-propanediol, for example, there can be used <NUM>,<NUM>-propanediol which is obtained by forming <NUM>-hydroxypropionaldehyde from glycerol, glucose, or another saccharide by a known fermentation method and then converting it to <NUM>,<NUM>-propanediol; or which is directly obtained from glucose or another saccharide by a fermentation method.

As the above-mentioned <NUM>,<NUM>-butanediol, for example, there can be used <NUM>,<NUM>-butanediol which is obtained from glucose by a known fermentation method; which is obtained from <NUM>,<NUM>-butadiene obtained by a fermentation method; or which is obtained by hydrogenating succinic acid using a reducing catalyst.

With respect to the biomass-derived glycol (y), among those mentioned above, from the viewpoint of obtaining even more excellent adhesion with a cloth, <NUM>,<NUM>-propanediol is more preferred.

The polyester polyol (a1) uses the biomass-derived polybasic acid (x) and the biomass-derived glycol (y) as essential raw materials, but another polybasic acid and/or another glycol may be used in such an amount that the effects of the present invention are not sacrificed.

From the viewpoint of obtaining even more excellent mechanical strength and even more excellent adhesion with a cloth, the polyester polyol (a1) preferably has a number average molecular weight in the range of from <NUM> to <NUM>,<NUM>, more preferably in the range of from <NUM> to <NUM>,<NUM>, further preferably in the range of from <NUM> to <NUM>,<NUM>. The number average molecular weight of the polyester polyol (a1) indicates a value measured by a gel permeation chromatography (GPC) method.

The polyol (A) contains the polyester polyol (a1) as an essential component, but may contain an additional polyol if necessary. The content of the polyester polyol (a1) in the polyol (A) is preferably <NUM>% by mass or more, more preferably <NUM>% by mass or more, further preferably <NUM>% by mass or more.

As the above-mentioned additional polyol, for example, there can be used polyester polyol other than the polyester polyol (a1), polycarbonate polyol, polyether polyol, polybutadiene polyol, or polyacryl polyol. These polyols may be used individually or in combination.

The number average molecular weight of the additional polyol is, for example, in the range of from <NUM> to <NUM>,<NUM>. The number average molecular weight of the additional polyol indicates a value measured by a gel permeation chromatography (GPC) method.

As the polyisocyanate (B), there can be used an aromatic polyisocyanate, such as polymethylene polyphenyl polyisocyanate, diphenylmethane diisocyanate, carbodiimide-modified diphenylmethane diisocyanate isocyanate, xylylene diisocyanate, phenylene diisocyanate, tolylene diisocyanate, or naphthalene diisocyanate; an aliphatic or alicyclic polyisocyanate, such as hexamethylene diisocyanate, cyclohexane diisocyanate, isophorone diisocyanate, dicyclohexylmethane diisocyanate, or tetramethylxylylene diisocyanate, or the like. These polyisocyanates may be used individually or in combination. Of these, from the viewpoint of obtaining even more excellent reactivity and even more excellent adhesion with a cloth, an aromatic polyisocyanate is preferably used, and diphenylmethane diisocyanate is more preferably used.

The amount of the polyisocyanate (B) used is preferably in the range of from <NUM> to <NUM>% by mass, more preferably in the range of from <NUM> to <NUM>% by mass, based on the total mass of the raw materials constituting the urethane prepolymer (i).

The hot-melt urethane prepolymer (i) is obtained by reacting the polyol (A) and the polyisocyanate (B), and has an isocyanate group which is capable of reacting with water present in air or the substrate to which the moisture-curable polyurethane hot-melt resin composition is applied to form a crosslinked structure.

With respect to the method for producing the hot-melt urethane prepolymer (i), for example, the hot-melt urethane prepolymer (i) can be produced by a method in which the polyisocyanate (B) is placed in a reaction vessel containing the polyol (A) and reacted under conditions such that the amount of the isocyanate group of the polyisocyanate (B) is excessively larger than the amount of the hydroxyl group of the polyol (A).

In producing the hot-melt urethane prepolymer (i), from the viewpoint of obtaining even more excellent adhesion, the equivalent ratio of the isocyanate group of the polyisocyanate (B) to the hydroxyl group of the polyol (A) (isocyanate group/hydroxyl group) is preferably in the range of from <NUM> to <NUM>, more preferably in the range of from <NUM> to <NUM>.

With respect to the hot-melt urethane prepolymer (i) obtained by the above-mentioned method, from the viewpoint of obtaining even more excellent adhesion, the hot-melt urethane prepolymer (i) preferably has an isocyanate group content (hereinafter, referred to simply as "NCO%") in the range of from <NUM> to <NUM>, more preferably in the range of from <NUM> to <NUM>. The NCO% of the hot-melt urethane prepolymer (i) indicates a value measured by a potentiometric titration method in accordance with JIS K1603-<NUM>:<NUM>.

The moisture-curable polyurethane hot-melt resin composition used in the invention contains the urethane prepolymer (i) as an essential component, but may use an additional additive if necessary.

With respect to the additional additive, for example, there can be used a light stabilizer, a curing catalyst, a tackifier, a plasticizer, a stabilizer, a filler, a dye, a pigment, a fluorescent brightener, a silane coupling agent, a wax, a thermoplastic resin, and the like. These additives may be used individually or in combination.

The moisture-curable polyurethane resin composition used according to the invention preferably has a biomass degree of <NUM>% or more, more preferably <NUM>% or more. The biomass degree of the moisture-curable polyurethane hot-melt resin composition indicates a ratio of the total weight of the biomass-derived raw materials used when producing the moisture-curable polyurethane hot-melt resin composition to the whole weight of the moisture-curable polyurethane hot-melt resin composition.

As mentioned above, the moisture-curable polyurethane hot-melt resin composition used according to the invention uses a biomass raw material, and thus is an environment-friendly material. Further, the moisture-curable polyurethane resin composition used according to the invention has excellent adhesion with various types of cloths, and has excellent adhesion even with a water-repellent cloth. Therefore, the moisture-curable polyurethane hot-melt resin composition is especially advantageously used as an adhesive for producing moisture-permeable waterproof functional clothing.

Next, a multilayer body that can be obtained by the use of the present invention is described.

The multilayer body has at least a cloth (i) and a cured product of the moisture-curable polyurethane hot-melt resin composition.

As the cloth (i), for example, there can be used a fiber substrate, such as nonwoven fabric, woven fabric, or knitted fabric, each formed from a polyester fiber, a polyethylene fiber, a nylon fiber, an acrylic fiber, a polyurethane fiber, an acetate fiber, a rayon fiber, a polylactate fiber, cotton, linen, silk, wool, a glass fiber, a carbon fiber, a mixed fiber thereof, or the like; the above-mentioned nonwoven fabric which is impregnated with a resin, such as a polyurethane resin; the above-mentioned nonwoven fabric which has further formed thereon a porous layer; a resin substrate, or the like.

Further, with respect to the cloth (i), the composition used according to the invention exhibits excellent adhesion even with the above-mentioned cloth which has been subjected to water repellency treatment (hereinafter, referred to simply as "water-repellent cloth"). In the invention, with respect to the water-repellent cloth, the "water repellency" indicates a cloth having a surface free energy of <NUM> mJ/m<NUM> or less, as obtained from the calculation shown below.

A contact angle of a measurement liquid (water and diiodomethane) on the cloth (i) was measured using a contact angle meter ("DM500", manufactured by Kyowa Interface Science Co. Based on the result of the measurement, a surface free energy of the cloth (i) was calculated using the following formula (<NUM>).

As a method for applying the moisture-curable polyurethane hot-melt resin composition, for example, there can be mentioned a method using a roll coater, a knife coater, a spray coater, a gravure roll coater, a comma coater, a T-die coater, an applicator, a dispenser, or the like.

The moisture-curable polyurethane hot-melt resin composition is applied, and then can be dried and matured by a known method.

The cured product of the moisture-curable urethane hot-melt resin composition has a thickness, for example, in the range of from <NUM> to <NUM>.

The moisture-curable polyurethane hot-melt resin composition is used as an adhesive for moisture-permeable waterproof functional clothing, and it is preferred that the moisture-curable polyurethane hot-melt resin composition is intermittently applied by means of a gravure roll coater or a dispenser and the cloth (i) and a known moisture permeable film are put on one another. In this case, the cured product of the moisture-curable polyurethane hot-melt resin composition has a thickness, for example, in the range of from <NUM> to <NUM>.

Hereinbelow, the present invention will be described in more detail with reference to the following Examples.

Into a four-necked flask equipped with a thermometer, a stirrer, an inert gas introducing inlet, and a reflux condenser was charged <NUM> parts by mass of a biomass polyester polyol (reaction product of sebacic acid ("Sebacic Acid", manufactured by Hokoku Corporation) and <NUM>,<NUM>-propanediol ("SUSTERRA Propanediol", manufactured by Dupont, Inc. ); number average molecular weight: <NUM>,<NUM>; hereinafter, referred to simply as "BioPEs (<NUM>)"), and the BioPEs (<NUM>) was dehydrated by vacuum drying at <NUM> until the water content became <NUM>% by mass or less. Subsequently, after cooling to <NUM>, <NUM> parts by mass of diphenylmethane diisocyanate (hereinafter, abbreviated to "MDI") was added, and the resultant mixture was increased in temperature to <NUM> and subjected to reaction for <NUM> hours until the isocyanate group content became constant, obtaining a moisture-curable polyurethane hot-melt resin composition.

A moisture-curable polyurethane hot-melt resin composition was obtained in substantially the same manner as in Example <NUM> except that, instead of the BioPEs (<NUM>), a biomass polyester polyol (reaction product of sebacic acid ("Sebacic Acid", manufactured by Hokoku Corporation) and <NUM>,<NUM>-butanediol ("Bio-BDO", manufactured by Jenomatica, Inc. ); number average molecular weight: <NUM>,<NUM>; hereinafter, referred to simply as "BioPEs (<NUM>)") was used.

A moisture-curable polyurethane hot-melt resin composition was obtained in substantially the same manner as in Example <NUM> except that, instead of the BioPEs (<NUM>), a biomass polyester polyol (reaction product of succinic acid ("Succinic Acid", manufactured by SUCCINITY GmbH) and <NUM>,<NUM>-propanediol ("SUSTERRA Propanediol", manufactured by Dupont, Inc. ); number average molecular weight: <NUM>,<NUM>; hereinafter, referred to simply as "BioPEs (<NUM>)") was used.

Into a four-necked flask equipped with a thermometer, a stirrer, an inert gas introducing inlet, and a reflux condenser were charged <NUM> parts by mass of a polyester polyol (reaction product of phthalic anhydride and <NUM>,<NUM>-hexanediol (which are of a petroleum type); number average molecular weight: <NUM>,<NUM>; hereinafter, referred to simply as "RPEs (<NUM>)") and a polyester polyol (reaction product of phthalic anhydride, terephthalic acid, adipic acid, and ethylene glycol (which are of a petroleum type); number average molecular weight: <NUM>,<NUM>; hereinafter, referred to simply as "RPEs (<NUM>)"), and the resultant mixture was dehydrated by vacuum drying at <NUM> until the water content became <NUM>% by mass or less. Subsequently, after cooling to <NUM>, <NUM> parts by mass of MDI was added, and the resultant mixture was increased in temperature to <NUM> and subjected to reaction for <NUM> hours until the isocyanate group content became constant, obtaining a moisture-curable polyurethane hot-melt resin composition.

The number average molecular weight of the polyol used in the Examples and Comparative Example is a value as measured by a gel permeation chromatography (GPC) method under the conditions shown below.

The moisture-curable polyurethane hot-melt resin compositions obtained in the Examples and Comparative Example were individually melted at <NUM>, and then applied onto a moisture permeable film ("VENTEX", manufactured by Kahei Co. ) using a gravure roll coater (<NUM>/inch; <NUM> depth; coating weight: <NUM>/m<NUM>), and put on each of the three types of cloths shown below, and allowed to stand in an atmosphere at a temperature of <NUM> and at a humidity of <NUM>% for <NUM> days to obtain a processed cloth.

The obtained processed cloth was cut into a piece with a width of <NUM> inch, and, using "Autograph AG-<NUM>", manufactured by Shimadzu Corporation, a peel strength (N/inch) of the moisture permeable film and the cloth was measured.

The abbreviations shown in Table <NUM> are as follows.

It was found that the moisture-curable polyurethane hot-melt resin composition used according to the present invention has a high biomass degree and excellent adhesion with a cloth. Particularly, it was found that the moisture-curable polyurethane hot-melt resin composition used according to the present invention has excellent adhesion even with a water-repellent cloth and a super-water-repellent cloth.

Claim 1:
Use of a moisture-curable polyurethane hot-melt resin composition containing an urethane prepolymer (i) having an isocyanate group, which is a reaction product of a polyol (A) and a polyisocyanate (B), the polyol (A) comprising a polyester polyol (a1) which uses a polybasic acid (x) derived from biomass and a glycol (y) derived from biomass as raw materials
as an adhesive for producing moisture-permeable waterproof functional clothing,
wherein the biomass-derived polybasic acid (x) is sebacic acid and/or succinic acid, and
wherein the biomass-derived glycol (y) is <NUM>,<NUM>-propanediol and/or <NUM>,<NUM>-butanediol.