Flame retardant polyurethane resin composition and synthetic artificial leather using same
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Solution Overview
Problem
Existing polyurethane resins used in automobile seat materials face challenges with bleeding of flame retardants, loss of flexibility, and increased hardness when using conventional flame retardants, which are not suitable for high flexibility requirements.
Innovation Solution
A modified isocyanurate-type polyisocyanate compound with a specific number of isocyanate groups is used, combined with a polyol component, to create a flame-retardant polyurethane resin composition that maintains flexibility and reduces the need for additional flame retardants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid flame retardant is blended into polyurethane resin, then flame retardancy is improved, but bleeding occurs and flexibility deteriorates
Solution Approach 1:
The invention changes the physical state parameter of the flame retardant from liquid to solid form through chemical reaction (polymerization), eliminating bleeding while maintaining flame retardancy. The modified isocyanurate-type polyisocyanate compound reacts to form a solid integrated structure within the polyurethane resin matrix.
Solution Approach 2:
The invention converts the harmful bleeding effect into a beneficial solid-integrated structure. By using modified isocyanurate-type polyisocyanate that forms solid flame retardant structures through chemical bonding, the harmful oozing out is transformed into a stable, non-migrating flame retardant system that maintains flexibility.
2Object-generated harmful factors
If solid flame retardant is blended into polyurethane resin, then bleeding is prevented, but hardness increases and flexibility is lost
Solution Approach 1:
The invention creates a composite material system where modified isocyanurate-type polyisocyanate forms an integrated solid structure within the polyurethane resin matrix. This composite approach maintains the flexibility of the base resin while incorporating flame retardant properties without the brittleness associated with simple solid flame retardant blends.
Solution Approach 2:
The invention merges the flame retardant function with the polyurethane resin structure itself. The modified isocyanurate-type polyisocyanate becomes part of the resin matrix through chemical bonding, creating a unified material that simultaneously provides flexibility and fire resistance rather than combining separate components that conflict in properties.
3Reliability
If large amount of flame retardant is blended, then flame retardancy is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The polyurethane resin system provides its own flame retardancy through the modified isocyanurate-type polyisocyanate component. The resin essentially self-retards flame through its inherent chemical structure, eliminating the need for large amounts of separate flame retardant additives and the complex mixing and distribution processes required.
4Reliability
If polyfunctional isocyanate components such as isocyanurates are used, then flame retardancy is improved, but hardness increases making it unsuitable for flexible applications
Solution Approach 1:
The invention modifies the isocyanurate structure by controlling the isocyanate group content to a specific range (1.7-2.3 average number of isocyanate groups per molecule). This parameter adjustment allows the material to maintain flame retardancy through the isocyanurate ring structure while preventing excessive crosslinking that would cause hardness and brittleness.
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 composition achieves high flame retardancy with reduced bleeding and maintains flexibility, suitable for automobile seat materials, while also being environmentally friendly with a high biomass ratio.
Implementation Method 1
a reaction product of polyurethane resin raw material components containing a polyisocyanate component and a polyol component
Data Source
AI summary
[Problem] The present invention addresses the problem of providing: a polyurethane resin composition which has excellent flame retardancy and flexibility, while being reduced in the amount of an added flame retardant; and a synthetic artificial leather which is formed of this polyurethane resin composition. [Solution] A polyurethane resin composition which contains a flame retardant and a reaction product of a polyurethane resin starting material component containing a polyisocyanate compound and a polyol compound, wherein a modified isocyanurate type polyisocyanate component having an average of 1.7 to 2.3 isocyanate groups is used as the polyisocyanate compound. A synthetic artificial leather which is obtained by forming, on a supporting body such as a fiber fabric, a surface skin layer with use of the thus-obtained flame retardant polyurethane resin composition.