Non-solvent 2K polyurethane artificial leather composition, artificial leather prepared with same and preparation method thereof
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Solution Overview
Problem
Current solvent-based polyurethane (PU) artificial leather manufacturing processes face environmental concerns due to volatile organic solvents, high costs, and complexity in controlling the foaming reaction, which necessitates the development of an environmentally friendly and cost-effective alternative.
Innovation Solution
A non-solvent two-component polyurethane artificial leather composition using an encapsulated foaming agent that eliminates the need for isocyanate consumption in bubbling and stabilizers, allowing for controlled foaming without affecting polyurethane chain formation, resulting in a more stable and cost-effective production method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If moisture foaming technology is used to generate CO2 for bubbling, then foaming is achieved, but isocyanate raw material is consumed increasing manufacture cost
Solution Approach 1:
The patent extracts the foaming function from the isocyanate-water reaction system by introducing a dedicated encapsulated foaming agent. This separates the foaming mechanism from the polyurethane formation mechanism, allowing bubbles to be generated without consuming isocyanate raw materials that would otherwise be used for both purposes.
Solution Approach 2:
The encapsulated foaming agent acts as an intermediary substance that enables bubble generation through a different chemical pathway. The foaming agent contains a core phase that reacts to produce gas bubbles, while the shell phase controls the reaction timing and protects the system from direct isocyanate-water reactions.
2Ease of manufacture
If moisture foaming technology is used, then bubbles are generated, but additional surfactants are needed to stabilize bubbles increasing manufacture cost
Solution Approach 1:
The patent combines the foaming agent functionality with the polyol component of the polyurethane system. The encapsulated foaming agent is integrated into the polyol mixture, merging the bubble generation function with the existing polyol formulation and eliminating the need for separate surfactant additions.
Solution Approach 2:
The polyol component serves multiple functions: it acts as both a reactant for polyurethane formation and as a carrier for the encapsulated foaming agent. This multi-functionality reduces the total number of additives required in the system.
3Ease of manufacture
If water is used as foaming agent, then CO2 is generated for bubbling, but reaction control becomes difficult increasing process complexity
Solution Approach 1:
The foaming agent is pre-encapsulated in a controlled structure before being introduced to the reaction system. The encapsulation shell is designed to maintain integrity during mixing and application, and only breaks down under specific conditions (heat, mechanical stress) to release the core phase for controlled gas generation.
Solution Approach 2:
The patent controls the foaming process by changing physical parameters such as temperature and mechanical stress rather than controlling chemical reaction rates. The encapsulated structure responds predictably to these parameter changes, providing easier process control compared to managing chemical reaction kinetics.
4Ease of manufacture
If volatile organic solvents are used in PU artificial leather manufacturing, then processing is facilitated, but environmental pollution increases
Solution Approach 1:
The patent changes the fundamental parameter of the system from solvent-based to non-solvent-based processing. By using a moisture-curing or water-free polyurethane system with encapsulated foaming, the process eliminates volatile organic solvent emissions while maintaining processing capability through alternative mechanisms.
Solution Approach 2:
The encapsulated foaming agent is designed as a single-use component that is consumed during the foaming process. This disposable approach eliminates the need for solvent recovery and recycling systems, simplifying the process and reducing environmental impact.
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 achieves mild bubble generation, improved hand feeling, and reduced manufacturing costs while eliminating the use of volatile solvents, thereby enhancing the environmental sustainability and performance of the polyurethane leather product.
Implementation Method 1
an encapsulated foaming agent comprising at least one foaming core phase encapsulated within an outer shell
Implementation Method 2
reacting at least one polyisocyanate compound with at least one first polyol to form a polyurethane-prepolymer
Data Source
AI summary
A non-solvent two-component polyurethane artificial leather composition is provided. The polyurethane composition comprises (A) a polyurethane-prepolymer component, comprising one or more polyurethane-prepolymers prepared by reacting at least one polyisocyanate compound with at least one first polyol, wherein the polyurethane-prepolymer comprises at least two free isocyanate groups; and (B) a polyol component, comprising at least one second polyol; wherein the polyol component further comprises an encapsulated foaming agent comprising at least one foaming core phase encapsulated within an outer shell. The polyurethane leather product derived from the polyurethane composition exhibits enhanced stability, mild bubble generation and improved cost effectiveness. A polyurethane leather product prepared with said composition and the method for preparing the same are also provided.