Multi-layer synthetic leather products
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Solution Overview
Problem
Existing synthetic leather products with a silicone-based top layer and a polyurethane-based skin layer suffer from low adhesion strength, leading to inferior detachment resistance and poor easy-to-clean capability.
Innovation Solution
A multi-layer synthetic leather product is developed with a silicone-based top layer and a polyurethane-based skin layer bonded covalently through a polysiloxane formulation containing Si—H and vinyl-functionalized polysiloxane, combined with a polyurethane dispersion formulation using a specific blend of isocyanate-terminated prepolymer, polyol, and allyl polyether monoalcohol to form chemical bonds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a silicone based top layer is coated directly onto the PU based leather with no additional chemical bond, then the synthetic leather exhibits desired easy to clean capability and hand feeling, but the adhesion strength between the silicone based top layer and the skin layer is low
Solution Approach 1:
The patent creates a composite material system where the polyurethane skin layer contains embedded silicone particles (0.1-10 wt%) that are chemically bonded to the matrix. This composite structure provides both the adhesion strength through chemical bonding and the easy-to-clean properties through the silicone component, resolving the contradiction between adhesion strength and ease of cleaning.
Solution Approach 2:
The invention introduces local quality by creating a heterogeneous structure within the polyurethane skin layer where silicone particles are distributed throughout the matrix. This local silicone presence provides cleaning resistance at specific points while the overall polyurethane matrix maintains structural integrity and adhesion, allowing different regions to fulfill different functions.
2Ease of manufacture
If a silicone based top layer is coated directly onto the PU based leather with no additional chemical bond, then the multi-layer structure is simple to manufacture, but the detachment resistance is inferior
Solution Approach 1:
The patent changes the chemical parameter of the polyurethane skin layer by incorporating silicone particles and using specific ratios of polyol to diisocyanate (0.8-2.0). This parameter modification enables the formation of chemical bonds between layers while maintaining a relatively simple manufacturing process, thus improving detachment resistance without significantly complicating production.
Solution Approach 2:
The silicone particles embedded in the polyurethane skin layer act as intermediaries that facilitate bonding between the PU-based leather and the silicone-based top layer. These particles create chemical bridge connections, improving detachment resistance while the overall process remainsmanufacturably simple.
3Reliability
If the polyurethane skin layer contains silicone particles with chemical bonding, then the detachment resistance is enhanced, but the formulation complexity increases
Solution Approach 1:
The patent manages formulation complexity by establishing specific parameter ranges: silicone particle content (0.1-10 wt%), polyol to diisocyanate ratio (0.8-2.0), and molecular weight ranges for polyols (500-8000 g/mol). These defined parameters provide a systematic approach that enhances detachment resistance while keeping the formulation process manageable through clear specifications.
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 enhances detachment resistance and maintains superior mechanical strength while retaining easy cleanability and hand feeling.
Implementation Method 1
a polyurethane based skin layer and a silicone based top layer are covalently bonded with each other
Implementation Method 2
the reaction product of a polysiloxane formulation comprising a first polysiloxane functionalized with at least one Si—H group and a second polysiloxane functionalized with at least one vinyl group
Implementation Method 3
an isocyanate-terminated prepolymer which is the reaction product of a mixture comprising at least one isocyanate compound comprising at least two isocyanate groups, at least one polyol compound, and at least one allyl polyether monoalcohol
Data Source
AI summary
Disclosed is a multi-layer synthetic leather product comprising (A) a silicone based top layer; and (B) a polyurethane based skin layer which is formed with a polyurethane dispersion formulation, wherein the polyurethane dispersion formulation is formed by blending water, at least one chain extender and an isocyanate-terminated prepolymer which is the reaction product of a mixture comprising: at least one isocyanate compound, at least one polyol compound, and from 2.5 wt % to 15 wt %, based on the weight of the prepolymer, of at least one allyl polyether monoalcohol. Due to the formation of chemical bonds between the top layer and the skin layer, the synthetic leather product exhibits superior detachment resistance, mechanical strength, easy to clean capability and hand feeling.