Bio-Based Artificial Leather Composition to Reduce Solvent Emissions
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Solution Overview
Problem
Current methods for manufacturing artificial leather for automobile interiors rely on petroleum-based materials, leading to high greenhouse gas emissions and environmental concerns due to the use of organic solvents, which are difficult to completely remove and result in inadequate adhesive strength and production stability.
Innovation Solution
The development of an eco-friendly artificial leather using a bio urethane-containing skin surface layer, a solvent-free bio urethane adhesive layer, and a bio fiber base layer, where the adhesive layer is formed by polymerizing an isocyanate-based compound with a polyol mixture including a carbonate polyol and biomass-derived components, and the bio fiber base layer consists of a composite spun fiber with biomass-derived polytrimethylene terephthalate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If petroleum-based urethane resin and organic solvents are used in artificial leather manufacturing, then adhesive strength and production stability are improved, but greenhouse gas emissions increase and environmental harm worsens
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive layer by using bio-based polyols (corn, sugarcane, cassava) instead of petroleum-based polyols, and employs solvent-free 100% solid urethane resin. This parameter change maintains adhesive strength while eliminating organic solvent emissions and reducing greenhouse gas footprint.
Solution Approach 2:
The patent creates a composite adhesive system combining bio-based polyols with specific chain extenders (ethylene glycol, 1,3-propanediol, 1,4-butanediol) and crosslinking agents. This composite approach ensures the bio-based adhesive achieves performance comparable to petroleum-based adhesives while being environmentally sustainable.
2Object-generated harmful factors
If aqueous urethane-based adhesive is used to replace organic solvent-containing adhesive, then environmental friendliness is improved, but adhesive strength and durability deteriorate
Solution Approach 1:
The patent transitions from aqueous urethane adhesive to solvent-free 100% solid urethane resin, changing the physical state parameter from liquid (aqueous) to solid. This eliminates water content issues while maintaining environmental friendliness by using bio-based materials, thereby improving adhesive strength and durability.
Solution Approach 2:
The patent extracts and eliminates water from the adhesive system by using solvent-free 100% solid urethane resin instead of aqueous solutions. This removes the moisture-related problems (hydrolysis, poor adhesion) while maintaining the environmental benefits of water-based systems.
3Ease of manufacture
If organic solvents are used in the adhesive layer, then ease of manufacture is improved, but residual solvent removal becomes difficult and production stability worsens
Solution Approach 1:
The patent extracts and eliminates organic solvents from the adhesive system by using solvent-free 100% solid urethane resin. This removes the problematic drying step and eliminates residual solvent issues, while the bio-based materials maintain ease of application through proper formulation.
Solution Approach 2:
The patent utilizes the phase transition properties of solvent-free urethane resin, which melts at specific temperatures to become flowable for application, then solidifies upon cooling to form the adhesive layer. This eliminates solvent evaporation while maintaining manufacturing ease.
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
This approach minimizes the use of organic solvents and harmful components, reducing greenhouse gas emissions and improving durability, adhesive strength, and production stability, while conforming to environmental regulations, suitable for use in eco-friendly vehicles like hydrogen, electric, and hybrid vehicles.
Implementation Method 1
the adhesive layer is formed by polymerizing an isocyanate-based compound with a polyol mixture including a carbonate polyol and biomass-derived components
Implementation Method 2
a solvent-free bio urethane adhesive layer... sequentially stacked
Data Source
AI summary
Provided herein is an eco-friendly artificial leather for an interior of an automobile and a manufacturing method thereof. The eco-friendly product is manufactured using a method that is compatible with various environmental regulations such as reduction of greenhouse gas emissions. The artificial leather includes a bio urethane-containing skin surface layer which uses biomass-derived components extracted from vegetable components, a solvent-free bio urethane adhesive layer, and a bio fiber base layer. The layers are sequentially stacked to minimize the use of organic solvents and components that are harmful to the human body.