Bi-component, solvent-free polyurethane composition for producing imitation leathers, by spray application
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Solution Overview
Problem
Existing methods for producing polyurethane-based imitation leather involve high energy consumption due to solvent evaporation and leave harmful residues, necessitating a solvent-free and residue-free production process.
Innovation Solution
A two-component polyurethane composition is formulated with a specific catalytic mixture and foam stabilizing agent, allowing for uniform thickness without mechanical leveling, using spray technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent casting method is used to produce polyurethane imitation leather, then the production process is simple, but high energy consumption is required for solvent evaporation and harmful solvent residues remain on the final product
Solution Approach 1:
The invention extracts and eliminates the solvent component from the traditional solvent casting process. By using a solvent-free polyurethane composition, the harmful evaporation step is completely removed, thereby eliminating the associated energy consumption and environmental pollution while maintaining the simplicity of the casting method.
Solution Approach 2:
The invention changes the physical and chemical parameters of the polyurethane composition by formulating a solvent-free system. This parameter change allows the material to be applied and cured without the intermediate evaporation step, directly resolving the energy consumption issue while preserving process simplicity.
2Ease of manufacture
If solvent casting method is used to produce polyurethane imitation leather, then the production process is simple, but harmful solvent residues remain on the final product
Solution Approach 1:
The invention extracts and eliminates the solvent component from the traditional solvent casting process. By using a solvent-free polyurethane composition, the harmful evaporation step is completely removed, thereby eliminating the associated energy consumption and environmental pollution while maintaining the simplicity of the casting method.
Solution Approach 2:
The invention converts the potential harm of solvent use into a benefit by completely eliminating solvents from the formulation. The solvent-free composition achieves both environmental safety and process simplicity, turning what was previously a harmful necessity into an unnecessary element that is entirely removed.
3Object-generated harmful factors
If bi-component solvent-free polyurethane composition is used with spray technology, then solvent residues are eliminated and energy consumption is reduced, but uniform thickness requires mechanical leveling operations
Solution Approach 1:
The invention changes the chemical parameters of the bi-component composition, specifically the viscosity and reactivity ratios of the polyol and isocyanate components. By optimizing these parameters, the composition achieves self-leveling properties during spray application, eliminating the need for subsequent mechanical leveling operations while maintaining the benefits of being solvent-free.
Solution Approach 2:
The invention incorporates preliminary action by formulating the composition with specific catalysts and stabilizers that promote uniform expansion and self-leveling during the spray application process itself. This preliminary chemical action ensures uniform thickness is achieved during application, preventing the need for later mechanical correction.
4Loss of energy
If bi-component solvent-free polyurethane composition is used with spray technology, then solvent residues are eliminated and energy consumption is reduced, but uniform thickness requires mechanical leveling operations
Solution Approach 1:
The invention changes the chemical parameters of the bi-component composition, specifically the viscosity and reactivity ratios of the polyol and isocyanate components. By optimizing these parameters, the composition achieves self-leveling properties during spray application, eliminating the need for subsequent mechanical leveling operations while maintaining the benefits of being solvent-free.
Solution Approach 2:
The invention incorporates preliminary action by formulating the composition with specific catalysts and stabilizers that promote uniform expansion and self-leveling during the spray application process itself. This preliminary chemical action ensures uniform thickness is achieved during application, preventing the need for later mechanical correction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves a uniform polyurethane coating with reduced energy consumption and no solvent residues, maintaining excellent mechanical properties.
Implementation Method 1
mixing and reacting in situ, applying the mixture to the substrate by means of spray technology
Implementation Method 2
expanded microcellular polyurethane foam
Data Source
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AI summary
Process for the production of artificial leather comprising the spray application of a layer of polyurethane foam obtained by mixing and spraying a two-component, solvent-free polyurethane composition, comprising: a component A comprising a polyester-based polyol and/or a polyester-polyester hybrid and/or a polycarbonate polyol and/or polybutadiene polyol (unsaturated or hydrogenated) or a mixture of two or more of these, a blowing agent, a catalyst and optionally a chain extender agent or a foam stabilizing agent, and an isocyanate component B comprising an isocyanate or a mixture of isocyanates (based on MDI and its derivatives) and a polymeric or prepolymer polyol selected from a polyester polyol and/or a polyester-polyether hybrid and/or a polycaprolactone polyol and/or polycarbonate polyol and/or polybutadiene polyol (unsaturated or hydrogenated) or a mixture of two or more of these, and optionally a short-chain di- or poly-functional alcohol and/or an anti-hydrolysis agent, and wherein the catalyst included in component A comprises a mixture of a gel catalyst and a blow catalyst.