Grain-Finished Artificial Leather With Halogen-Free Flame Retardancy
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Solution Overview
Problem
Grain-finished artificial leather with a fiber-entangled body of ultrafine fibers faces challenges in achieving high flame retardancy without using halogen-based flame retardants, which compromises its suppleness and fullness.
Innovation Solution
Incorporating 3 to 50 mass % of a first elastic polymer, 2.5 to 6 mass % of phosphorous-based flame retardant particles, and 1 to 6 mass % of a plasticizer into the artificial leather base material, along with a resin layer containing 0 to 8 mass % of phosphorous-based or metal hydroxide flame retardant particles, to achieve both high flame retardancy and excellent texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-based flame retardants are used to achieve high flame retardancy, then flame retardancy is improved, but toxic halogen gas is generated during burning
Solution Approach 1:
The patent replaces halogen-based flame retardants with phosphorous-based flame retardants that contain phosphorus atoms. These phosphorous-based flame retardants provide equivalent or superior flame retardancy while eliminating the generation of toxic halogen gases during burning, thus converting a harmful material into a beneficial one.
2Reliability
If phosphorous-based flame retardant particles are incorporated into the artificial leather base material, then flame retardancy is improved, but suppleness and fullness deteriorate
Solution Approach 1:
The patent specifies that phosphorous-based flame retardant particles with an average particle size of 1 to 10 μm are incorporated into the artificial leather base material at a controlled content of 2.5 to 6 mass %. This localized control of particle size and distribution allows the flame retardant to function effectively while minimizing its impact on the overall suppleness and fullness of the material.
Solution Approach 2:
The patent optimizes the particle size parameter of the phosphorous-based flame retardant to 1 to 10 μm and controls its content parameter at 2.5 to 6 mass %. By adjusting these parameters, the flame retardant provides effective protection while maintaining the suppleness and fullness characteristics of the artificial leather.
3Shape
If the content ratio of elastic polymer is increased to decrease voids, then fullness is improved, but resilience increases resulting in rubber-like rigid texture
Solution Approach 1:
The patent specifies that the elastic polymer content in the artificial leather base material should be 3 to 50 mass %. By controlling the elastic polymer content within this range and using phosphorous-based flame retardant particles with 1 to 10 μm average particle size, the patent achieves a balance between fullness and flexible texture, avoiding the rubber-like rigid texture that occurs with excessive elastic polymer.
Data Source
AI summary
Disclosed is a grain-finished artificial leather including: an artificial leather base material; and a resin layer stacked on at least one surface of the artificial leather base material, wherein the artificial leather base material contains: a fiber-entangled body of ultrafine fibers; 3 to 50 mass % of a first elastic polymer; 2.5 to 6 mass %, in terms of phosphorus atoms, of first phosphorous-based flame retardant particles having an average particle size of 1 to 10 μm; and 1 to 6 mass % of a plasticizer, and the resin layer contains: a second elastic polymer; and a total content, in terms of phosphorus atoms or in terms of hydroxyl groups, of 0 to 8 mass % of flame retardant particles having an average particle size of 1 to 10 μm and being at least one selected from the group consisting of second phosphorous-based flame retardant particles and first metal hydroxide particles.