Coated substrates and polymer dispersions suitable for use in making the same

• US 8,431,648 B2
• Filed: 01/17/2011
• Issued: 04/30/2013
• Est. Priority Date: 03/31/2006
• Status: Active Grant

• Current Assignee: Milliken & Company
• Original Assignee: Milliken & Company
• Inventors: Xia, Jusong, Zhou, Zhaolin, Vogt, Kirkland W., Harris, Philip G.
• Primary Examiner(s): Salvatore, Lynda
• Application Number:
  US13/007,702
• Publication Number:
  US 20110111657A1
• Time in Patent Office: 834 Days
• Field of Search: 524/591
• US Class Current: 524/591
• CPC Class Codes: C08G 18/0823 containing carboxylate salt groups or groups forming them
• CPC Class Codes: C08G 18/12 using two or more compounds having active hydrogen in the first polymerisation step
• CPC Class Codes: C08G 18/302 Water
• CPC Class Codes: C08G 18/3228 acyclic
• CPC Class Codes: C08G 18/348 Hydroxycarboxylic acids
• CPC Class Codes: C08G 18/4277 Caprolactone and/or substituted caprolactone
• CPC Class Codes: C08G 18/664 with compounds of group C08G18/3203
• CPC Class Codes: C08G 18/758 containing two or more cycloaliphatic rings
• CPC Class Codes: C08G 18/7671 containing only one alkylene bisphenyl group
• CPC Class Codes: C08G 2150/60 Compositions for foaming; Foamed or intumescent coatings
• CPC Class Codes: C09B 67/0013 with polymeric coatings
• CPC Class Codes: C09B 67/009 polymeric dispersing agent
• CPC Class Codes: C09B 69/10 Polymeric dyes; Reaction products of dyes with monomers or with macromolecular compounds addition products of alkylene oxide to dyes, C09B69/00; dyeing with polymeric dyes D06P1/0056
• CPC Class Codes: D06N 2209/0823 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: D06N 2211/28 Artificial leather
• CPC Class Codes: D06N 3/0056 characterised by the compounding ingredients of the macro-molecular coating D06N3/005 takes precedence
• CPC Class Codes: D06N 3/0097 Release surface, e.g. separation sheets; Silicone papers
• CPC Class Codes: D06N 3/14 with polyurethanes
• CPC Class Codes: D06N 3/145 two or more layers of polyurethanes
• CPC Class Codes: Y10T 428/24512 Polyurethane
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31558 : Next to animal skin or membrane
• CPC Class Codes: Y10T 442/20 : Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer

Abstract

A coated substrate comprises a substrate and a coating on at least one surface of the substrate. The coating comprises a prepolymer, polymer, or resin produced, for example, by the reaction of (i) an isocyanate (e.g., a polyisocyanate), (ii) an active hydrogen-terminated colorant, and optionally (iii) at least one reactant selected from the group consisting of chain extenders, polyols, internal surfactants, and combinations thereof. Polymer dispersions suitable for use in making such coated substrates comprise such a prepolymer, polymer, or resin.

Claims

1. A dispersion comprising:

(a) an aqueous continuous phase, and

(b) a discontinuous phase comprising a polyurethane polymer or polyurethane polymer segment that is the product of the reaction of a reactant mixture comprising;

(i) a polyisocyanate,

(ii) an internal surfactant, and

(iii) an active hydrogen-terminated colorant, the active hydrogen-terminated colorant being selected from the group consisting of colorants conforming to the structure of Formula (IV), (V), (VI), (VII), or (VIII) below

2. The dispersion of claim 1, wherein reactant mixture further comprises at least one reactant selected from the group consisting of chain extenders, polyols, and combinations thereof.

3. The dispersion of claim 1, wherein the active hydrogen-terminated colorant comprises about 25 to about 75% of the weight of the reactant mixture.

4. The dispersion of claim 1, wherein the discontinuous phase comprises the product of the reaction of the polyurethane polymer or polyurethane polymer segment and a neutralizing agent.

5. The dispersion of claim 1, wherein the discontinuous phase comprises the product of the reaction of the polyurethane polymer or polyurethane polymer segment, a neutralizing agent, and a chain extender.

6. The dispersion of claim 1, wherein the dispersion has a weight, and the discontinuous phase comprises about 5 to about 50% of the dispersion, based on the weight of the dispersion.

7. A dispersion comprising:

(a) an aqueous continuous phase, and

(b) a discontinuous phase comprising a polyurethane polymer or polyurethane polymer segment produced by a process comprising the steps of;

(i) reacting a polyisocyanate with an active hydrogen-terminated colorant to produce a polymer intermediate, and

(ii) reacting the polymer intermediate produced in step (i) with an internal surfactant to produce the polyurethane polymer or polyurethane polymer segment;

wherein the active hydrogen-terminated colorant is selected from the group consisting of colorants conforming to the structure of Formula (IV), (V), (VI), (VII), or (VIII) below

8. The dispersion of claim 7, wherein the discontinuous phase comprises the product of the reaction of the polyurethane polymer or polyurethane polymer segment and a neutralizing agent.

9. The dispersion of claim 7, wherein the discontinuous phase comprises the product of the reaction of the polyurethane polymer or polyurethane polymer segment, a neutralizing agent, and a chain extender.

10. The dispersion of claim 7, wherein the polyisocyanate, the active hydrogen-terminated colorant, and the internal surfactant have a combined total weight, and the active hydrogen-terminated colorant comprises about 25 to about 75% of said total weight.

11. The dispersion of claim 7, wherein the dispersion has a weight, and the discontinuous phase comprises about 5 to about 50% of the dispersion, based on the weight of the dispersion.