Microfiber PU Artificial Leather With Integrated Flame Retardants

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Solution Overview

Problem

Current methods for flame retardant artificial leather, particularly those using bromine-based flame retardants, are toxic and face regulatory restrictions, while surface-coating methods with polymer resins result in hard texture and poor appearance due to excessive flame retardant usage, and existing methods fail to provide sufficient flame retardancy without additional processes.

Innovation Solution

Incorporating aluminum hydroxide as a flame retardant in a polyurethane resin impregnated in a microfiber nonwoven fabric and using a phosphorous-based flame retardant, such as bis-amide phosphate, in an adhesive layer with a surface coating to enhance flame retardancy, while controlling the content of each to avoid quality issues and regulatory concerns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bromine-based flame retardant is used in polyurethane resin, then flame retardancy is improved, but toxicity increases and regulatory restrictions are imposed

Engineering Contradiction:

Improveflame retardancyVSAvoidtoxicity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameter by replacing bromine-based flame retardant with aluminum hydroxide-based flame retardant in the polyurethane resin. This substitution maintains flame retardancy while eliminating toxicity issues, directly resolving the contradiction between reliability and harmful factors.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite approach by combining aluminum hydroxide with polyurethane resin to create a flame-retardant composite material. This composite maintains the desired flame retardancy properties while avoiding the toxic effects of bromine-based alternatives.

Inventive Principle:

Principle #40Composite materials

2Reliability

If large quantities of flame retardant are used in surface coating, then flame retardancy is improved, but texture becomes hard and appearance deteriorates

Engineering Contradiction:

Improveflame retardancyVSAvoidtexture softness

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent extracts the flame retardant function from the surface coating layer and relocates it to the polyurethane resin impregnated in the nonwoven fabric. This allows the surface coating to focus on providing soft texture and good appearance while the flame retardancy is achieved through the aluminum hydroxide-containing polyurethane resin, thus resolving the contradiction between flame retardancy and texture quality.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If additional flame retarding process is applied to PU artificial leather, then flame retardancy is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveflame retardancyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the flame retardant function with the polyurethane resin itself by incorporating aluminum hydroxide into the resin formulation. This integration allows the flame retardancy to be achieved during the existing impregnation process without requiring separate additional flame retarding steps, thus resolving the contradiction between reliability and device complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 effectively enhances flame retardancy of PU artificial leather, ensuring compliance with future regulations by replacing toxic bromine-based retardants and maintaining the soft texture and appearance, with aluminum hydroxide and phosphorous-based additives providing excellent combustion resistance without the need for additional flame retarding processes.

Implementation Method 1

aluminum hydroxide in a polyurethane resin impregnated in a microfiber nonwoven fabric as a flame retardant for enhancing flame retardancy

Methodology Applied

Scientific EffectThermal decomposition: Decomposition (biological)

Implementation Method 2

aluminum hydroxide in a polyurethane resin impregnated in a microfiber nonwoven fabric as a flame retardant for enhancing flame retardancy

Methodology Applied

Scientific EffectEndothermic reaction: Endothermic Reaction

Implementation Method 3

a phosphorous-based flame retardant in an adhesive with a surface coating layer

Methodology Applied

Scientific EffectCharring:

Data Source

PatentUS10640646B2Flame retardant polyurethane artificial leather and method for manufacturing the same

Publication Date: 2020.05.05 HYUNDAI MOTOR CO LTD

AI summary

Provided herein is a flame retardant polyurethane (PU) artificial leather and a method for manufacturing the flame retardant polyurethane (PU) artificial leather, wherein the method may include preparing a microfiber nonwoven fabric material, consecutively forming a polyurethane coating layer and an adhesive layer on one surface of a release paper, and combining the nonwoven fabric material and the release paper.