Fouling-proof structure
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Solution Overview
Problem
Synthetic leather surfaces are prone to dirt and graffiti, leading to unattractive appearances, shortened service life, and environmental burdens due to the lack of effective fouling-proof structures that can withstand cleaning with solvents.
Innovation Solution
A fouling-proof structure comprising an alcohol-resistant layer and a water-based fouling-proof layer, where the alcohol-resistant layer is formed by curing a combination of polyurethane resin, wetting agents, and crosslinkers, and the water-based fouling-proof layer includes polyurethane resin, polymerized siloxanes, PTFE, and silicone oil, applied through a spraying-coating process to ensure strong bonding and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional fouling-proof structure is applied to synthetic leather, then the surface becomes resistant to dirt and graffiti, but the structure cannot withstand cleaning with solvents like alcohol, leading to damage and loss of fouling-proof performance
Solution Approach 1:
The protective coating is divided into two distinct layers: an alcohol-resistant base layer containing polyurethane resin and crosslinkers that provide solvent resistance, and a water-based fouling-proof top layer containing PTFE and silicone oil that provides dirt and graffiti resistance. This segmentation allows each layer to specialize in one function without compromising the other.
Solution Approach 2:
The invention uses composite material composition in both layers. The base layer combines polyurethane resin with crosslinkers (polycarbodiimide or melamine) to create a chemically resistant network. The top layer combines water-based PTFE, silicone oil, and polyurethane resin to create a fouling-proof surface that is also alcohol-resistant due to the underlying base layer.
2Reliability
If a water-based fouling-proof layer is applied alone, then the surface gains resistance to dirt and graffiti, but the bonding between the fouling-proof layer and the substrate is weak, causing the layer to detach when wiped with solvents
Solution Approach 1:
The alcohol-resistant base layer acts as an intermediary between the water-based fouling-proof top layer and the synthetic leather substrate. This base layer provides strong chemical bonding to the substrate while also serving as a stable foundation for the top layer, preventing detachment when solvents are applied.
Solution Approach 2:
The alcohol-resistant base layer is applied and cured first before applying the water-based fouling-proof top layer. This preliminary action ensures that the bonding interface is already established and stabilized before the top layer is added, preventing subsequent detachment issues.
3Ease of operation
If the synthetic leather surface is cleaned with solvents to remove stains, then the stains are removed, but the fouling-proof structure is damaged and service life is shortened
Solution Approach 1:
The invention changes the chemical resistance parameters of the protective coating by incorporating crosslinking agents that create a solvent-resistant network structure. This allows the coating to withstand alcohol and other solvents used in cleaning without degrading, thereby extending service life while maintaining cleanability.
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 structure effectively prevents staining from common substances like ballpoint pens and allows easy removal of stains with dry cloths or detergents, extending the service life of synthetic leather products and reducing environmental impact.
Implementation Method 1
the alcohol-resistant layer is formed by curing an alcohol-resistant combination, and the alcohol-resistant combination comprises polyurethane resin
Implementation Method 2
the alcohol-resistant combination comprises 0.01-2 weight percent of matting agent
Implementation Method 3
the water-based fouling-proof combination comprises polyurethane resin, water, polymerized siloxanes, water-based PTFE and silicone oil
Data Source
AI summary
A fouling-proof structure is applicable to synthetic leather or fabric and it includes an alcohol-resistant layer; and a water-based fouling-proof layer disposed on the alcohol-resistant layer, wherein the alcohol-resistant layer is formed by curing an alcohol-resistant combination, and the alcohol-resistant combination comprises polyurethane resin, wherein the water-based fouling-proof layer is formed by curing a water-based fouling-proof combination, and the water-based fouling-proof combination comprises polyurethane resin, water, polymerized siloxanes, water-based PTFE and silicone oil.