Grained artificial leather
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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 a fiber-entangled body of ultrafine fibers with 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 fatty acid ester plasticizer, 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 blended to achieve high flame retardancy, then flame retardancy is improved, but toxic halogen gas is generated during burning
Solution Approach 1:
The patent changes the chemical composition parameters by replacing halogen-based flame retardants with phosphorous-based flame retardant particles (2.5 to 6 mass% in terms of phosphorus atoms) and metal hydroxide-based flame retardant particles (1 to 6 mass% in terms of hydroxyl groups). This substitution maintains flame retardancy while eliminating toxic halogen gas generation during combustion
Solution Approach 2:
The patent uses readily available phosphorous-based and metal hydroxide-based flame retardant particles that decompose into non-toxic substances during burning, replacing expensive and environmentally harmful halogen-based alternatives. These flame retardants provide effective fire protection without generating persistent toxic emissions
2Object-generated harmful factors
If non-halogen-based flame retardants are used to achieve high flame retardancy, then toxic gas generation is reduced, but suppleness and fullness are impaired
Solution Approach 1:
The patent applies local quality by using ultrafine fibers (average fineness of 0.9 dtex or less) as the base material, which provides inherent flexibility and fullness. The flame retardant particles are distributed within this flexible fiber structure, allowing the material to maintain its supple characteristics while achieving high flame retardancy through the synergistic effect of the fiber structure and flame retardant composition
Solution Approach 2:
The patent creates a composite material system combining ultrafine fibers, phosphorous-based flame retardant particles, metal hydroxide-based flame retardant particles, and elastic polymer. This composite structure achieves both flame retardancy and flexibility by integrating multiple materials with complementary properties, where the ultrafine fiber matrix provides suppleness and the flame retardant particles provide fire protection
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 optimizes the elastic polymer content ratio to 3 to 50 mass% of the total weight of ultrafine fibers and elastic polymer. This controlled parameter range fills voids to achieve fullness while preventing excessive resin content that would cause rubber-like rigidity. The patent also controls the fiber entanglement density and uses ultrafine fibers to maintain flexibility despite increased polymer content
Solution Approach 2:
The patent utilizes a fiber-entangled body structure that maintains a controlled porous network. This porous structure allows the material to retain flexibility and natural leather-like texture by preventing complete void elimination, while still achieving sufficient fullness through optimized elastic polymer distribution within the fiber matrix
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 solution enables grain-finished artificial leather to possess high flame retardancy, self-extinguishing properties, low smoke generation, and flexible texture, suitable for applications in public transport and building interiors, while maintaining suppleness and fullness.
Implementation Method 1
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 wherein the artificial leather base material contains a fatty acid ester as the 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
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.