Ultra-Light Polyurethane Leather Composition for Uniform Porous Cells
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Solution Overview
Problem
Existing artificial leather materials face issues with non-uniform porous cell formation, thermal deformation, and high volatile organic compounds (VOC) emissions, which affect their quality and safety for use in vehicles and home furniture.
Innovation Solution
An ultra-light polyurethane artificial leather composition is developed, comprising a one-component type blocked polyurethane high solid resin, capsule-type hollow microspheres, a curing agent, and a high solid type toner, which minimizes VOC emissions and enhances tensile strength, softness, and thermal resistance by forming a uniform air layer and porous cell structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If organic solvent-type polyurethane and olefin-based artificial leather are used, then manufacturing ease is improved, but VOC emissions increase causing harm to human body and work environment
Solution Approach 1:
The patent changes the chemical composition parameters by using water-based polyurethane resin instead of organic solvent-type resin, fundamentally altering the solvent system to eliminate VOC emissions while maintaining manufacturing processability through optimized resin formulation and curing conditions
Solution Approach 2:
The patent converts the previously harmful organic solvents into beneficial water-based systems, where water serves as the solvent without causing VOC pollution, and the curing process that previously required solvent evaporation is replaced by water evaporation and chemical crosslinking that produces no harmful emissions
2Strength
If porous cell structure is formed in artificial leather, then softness and lightness are improved, but uniform distribution of air layer and porous cells deteriorates leading to non-uniform structure
Solution Approach 1:
The patent introduces a blowing agent as an intermediary substance that uniformly distributes throughout the polyurethane resin matrix and generates gas bubbles during curing, creating uniformly distributed porous cells. The blowing agent acts as a mediator that transforms the homogeneous resin into a uniformly porous structure without direct mechanical intervention
Solution Approach 2:
The patent utilizes phase transition of the blowing agent during the curing process, where the blowing agent transitions from liquid to gas phase, generating uniform bubbles throughout the resin. This phase change occurs at controlled temperatures, ensuring uniform porous cell formation throughout the artificial leather structure
3Weight of moving object
If artificial leather is made lightweight with air layer and porous cells, then weight is reduced, but thermal deformation resistance deteriorates
Solution Approach 1:
The patent creates a composite structure combining polyurethane resin with a foam layer containing uniformly distributed porous cells and air layers. This composite architecture provides both lightweight properties from the air pockets and thermal stability from the polyurethane matrix, achieving synergistic performance that neither component could provide alone
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 reduces VOC emissions, improves physical properties such as tensile strength and softness, and prevents thermal deformation, making the artificial leather suitable for use in vehicles and home furniture while maintaining a lightweight and durable structure.
Implementation Method 1
a capsule-type microsphere of 1 to 10 parts per weight... a microsphere in which a shell made of a thermoplastic resin having the softening temperature of 170° C. to 220° C. is filled with hydrocarbon having a low boiling point of less than 170° C.
Implementation Method 2
an one-component type blocked polyurethane high solid resin of 100 parts per weight... a curing agent of 1 to 10 parts per weight
Data Source
AI summary
An ultra-light polyurethane artificial leather composition comprises a one-component type blocked polyurethane high solid resin of 100 parts per weight, a capsule-type hollow microsphere of 1 to 10 parts per weight, a curing agent of 1 to 10 parts per weight, and a high solid type toner of 1 to 20 parts per weight.