Curable composition and synthetic leather
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Solution Overview
Problem
Conventional synthetic leather lacks sufficient sweat resistance and durability, particularly in applications requiring high durability, and often requires the use of large amounts of organic solvents, leading to environmental concerns.
Innovation Solution
A curable composition comprising specific ratios of polycarbonate polyols, polyether polyols, and polyester polyols, along with polyisocyanates, is used to create synthetic leather with improved flexibility, chemical resistance, and heat resistance, while reducing the need for organic solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional polyurethane resin solutions are used to make synthetic leather, then flexibility and feeling are excellent, but durability is poor due to decomposition by sweat and hydrolysis
Solution Approach 1:
The patent changes the chemical composition parameters of the polyol component by using specific ratios of polycarbonate diol (50-90 mass%), polyester diol (5-30 mass%), and polyether diol (5-30 mass%). This parameter optimization resolves the contradiction by achieving both flexibility (from polyether diol) and durability/hydrolysis resistance (from polycarbonate and polyester diols).
Solution Approach 2:
The patent creates a composite polyol system combining multiple types of diols (polycarbonate, polyester, polyether) in specific proportions. This composite approach allows the synthetic leather to simultaneously achieve flexibility from polyether components and durability from polycarbonate and polyester components, resolving the contradiction between ease of operation and reliability.
2Ease of manufacture
If large amounts of organic solvent are used in polyurethane polymerization, then processing is easier, but environmental load increases
Solution Approach 1:
The patent extracts and eliminates organic solvents from the polyurethane polymerization system, using instead a solvent-free or water-based formulation. This allows the manufacturing process to proceed without harmful organic solvents, resolving the contradiction between ease of manufacture and environmental load by removing the harmful element entirely.
Solution Approach 2:
The patent replaces expensive and environmentally harmful organic solvents with cheaper, environmentally benign alternatives (water or no solvent). This substitution maintains processing ease while eliminating environmental load, effectively resolving the contradiction through material substitution.
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 composition provides synthetic leather with favorable low-temperature characteristics, excellent balance of physical properties, and reduced solvent usage, enhancing durability and environmental sustainability.
Implementation Method 1
a curable composition including a polycarbonate polyol (a), a polycarbonate polyol (b), a polyether polyol (c), a polyester polyol (d), and a polyisocyanate (e)... an isocyanate group-terminated prepolymer (f) including a unit derived from at least one polyol selected from the group consisting of a polycarbonate polyol (a), a polycarbonate polyol (b), a polyether polyol (c), and a polyester polyol (d), and a unit derived from a polyisocyanate (e)
Implementation Method 2
the curable composition... is cured to thereby... form a polyurethane
Data Source
Figure 1~2
AI summary
To provide a curable composition capable of providing synthetic leather having favorable low-temperature characteristics and having excellent balance of physical properties including flexibility (texture), chemical resistance and heat resistance, and synthetic leather. A curable composition including a component (a): a polycarbonate polyol having a hydroxyl value of 40 to 75 mgKOH/g, a component (b): a polycarbonate polyol having a hydroxyl value of 100 to 280 mgKOH/g, a component (c): a polyether polyol, a component (d): a polyester polyol, and a component (e): a polyisocyanate having an average number of functional groups per molecule, of 2 to 6, in which a total amount of the component (a) and the component (b) is 30% by mass to 70% by mass based on a total amount of all the polyol components in the composition.