Polyurethane prepolymer composition, laminate and preparation process and use thereof
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing polyurethane synthetic leather production methods require high temperature curing, leading to high energy consumption and result in products with insufficient peel strength, flexing endurance, and embossing properties, while lacking the ability to embed logos effectively.
Innovation Solution
A one-component polyurethane prepolymer composition is developed, comprising specific amounts of isocyanate groups and polyol components, which can be cured at lower temperatures (45-90°C) using moisture, without the need for high temperature heating, and includes a catalyst, filler, and optional additives to enhance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature curing (80-130°C) is used to produce solvent-free polyurethane foam sheet, then the curing performance is improved, but the energy consumption increases and the embossing property deteriorates
Solution Approach 1:
The invention changes the curing temperature parameter from conventional high temperature (80-130°C) to low temperature (45-90°C) range. This is achieved by optimizing the isocyanate index (105-115) and using specific catalyst systems that enable effective curing at lower temperatures, thereby reducing energy consumption while maintaining good curing performance and improving embossing properties.
Solution Approach 2:
The invention applies different functional components in specific proportions to achieve localized optimization: using polyols with specific OH values (20-400 mg KOH/g) and molecular weights (500-10000), combined with isocyanates at controlled indices, creates a composition that cures effectively at low temperature while maintaining the foam structure suitable for embossing.
2Reliability
If high temperature curing (80-130°C) is used to produce solvent-free polyurethane foam sheet, then the curing performance is improved, but the peel strength and flexing endurance are insufficient
Solution Approach 1:
The invention optimizes the isocyanate index to a higher range (105-115) compared to conventional formulations, which promotes better crosslinking density and network formation during curing. This enhanced crosslinking structure improves peel strength and flexing endurance while the low curing temperature (45-90°C) prevents degradation of these mechanical properties.
Solution Approach 2:
The invention uses a composite polyol system combining different types of polyols (polyether polyol and polyester polyol) with specific molecular weights and OH values. This composite approach creates a more robust polyurethane network that exhibits superior peel strength and flexing endurance compared to single polyol systems.
3Ease of manufacture
If conventional polyurethane composition is used, then the production process is simple, but the logo embedding property is insufficient
Solution Approach 1:
The invention adjusts the curing temperature parameter to a lower range (45-90°C) which maintains the polyurethane composition in a more pliable state during curing. This extended working window allows logo embedding processes to be performed effectively without requiring complex high-temperature equipment, thus maintaining production simplicity while improving logo embedding quality.
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 achieves improved embossing properties, peel strength, and flexing endurance, allowing for effective logo embedding, while reducing energy consumption through lower curing temperatures.
Implementation Method 1
The polyurethane prepolymer composition is a one-component system, whose curing involves water or moisture and do not need to be mixed with a polyol composition
Data Source
AI summary
Disclosed herein is a polyurethane prepolymer composition, including a reaction product of an isocyanate component and a polyol component, where the reaction product includes isocyanate groups at an amount of from 5.0 to 13.0 wt %, based on the total weight of the isocyanate component and the polyol component, and the polyol component has a functionality in a range of from 1.5 to 3.0. Further disclosed herein is a laminate including the polyurethane prepolymer composition. Additionally disclosed herein are a process of preparing the polyurethane prepolymer composition, the laminate, and a method of using the laminate.