Polyurethane resin composition, cured product, artificial leather, synthetic leather, and surface treatment agent for leather
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Solution Overview
Problem
Polyurethane emulsions lack well-balanced mechanical properties, particularly in terms of 100% modulus and shape stability under high-temperature conditions, compared to solvent-based polyurethane resins.
Innovation Solution
A polyurethane resin composition comprising a reaction product of an isocyanate group-terminated urethane prepolymer and a chain extender, with a specific content of urea groups and a neutralizer, which forms a cured product with low 100% modulus and high softening temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polyurethane emulsion is used instead of solvent-based polyurethane resin, then environmental friendliness and ease of application are improved, but mechanical properties (100% modulus) and shape stability deteriorate
Solution Approach 1:
The invention changes the chemical composition parameters of the polyurethane emulsion by incorporating specific ratios of polycarbonate polyol (20-80 mass%), polyester polyol (20-80 mass%), and polyether polyol (5-50 mass%), along with controlling the NCO index (80-150) and urea group content (0.01-0.80 mmol/g). These parameter adjustments optimize both the mechanical properties and shape stability while maintaining the environmental benefits of water-based emulsion formulation.
Solution Approach 2:
The invention creates a composite polyurethane system by combining multiple polyol types (polycarbonate, polyester, polyether) with polyisocyanate and chain extenders. This composite approach leverages the complementary properties of each component: polycarbonate polyol provides heat resistance, polyester polyol contributes to mechanical strength, and polyether polyol enhances flexibility, achieving balanced performance in the emulsion formulation.
2Object-affected harmful factors
If polyurethane emulsion is used instead of solvent-based polyurethane resin, then environmental friendliness is improved, but shape stability under high-temperature conditions deteriorates
Solution Approach 1:
The invention optimizes the softening temperature by adjusting the polycarbonate polyol content (20-80 mass%) and NCO index (80-150), ensuring the cured product achieves a softening temperature of 80°C or higher. This parameter control maintains shape stability under high-temperature conditions while preserving the water-based emulsion's environmental advantages.
Solution Approach 2:
The composite polyurethane system incorporating polycarbonate polyol provides inherent heat resistance, while the balanced formulation with polyester and polyether polyols ensures thermal stability. This composite structure prevents deformation at elevated temperatures, achieving shape stability comparable to or exceeding solvent-based systems.
3Strength
If urea group content is increased to improve adhesion and mechanical properties, then strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention optimizes the urea group content within a specific range (0.01-0.80 mmol/g) based on the mass of the polyurethane resin. This controlled parameter adjustment achieves the necessary adhesion and mechanical properties without excessive complexity. The urea groups are formed in-situ during the emulsion curing process through the reaction of isocyanate groups with water or amine chain extenders, eliminating the need for separate urea incorporation steps.
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 enables the production of artificial leather and synthetic leather with improved mechanical properties and thermal stability, offering a cured product with enhanced 100% modulus and softening temperature.
Implementation Method 1
a reaction product of an isocyanate group-terminated urethane prepolymer (E) and a chain extender (G)
Implementation Method 2
a total content of urea groups in the polyurethane resin composition is 0.01 to 0.80 mmol/g
Data Source
AI summary
The present invention relates to a polyurethane resin composition including an isocyanate group-terminated urethane prepolymer (E) and a neutralizer (F). The isocyanate group-terminated urethane prepolymer (E) contains a reaction product of a polyol (A) containing a polycarbonate polyol (B) having an average number of hydroxyl functional groups exceeding 2, an organic acid (C), and a polyisocyanate (D), in which a total content of urea groups in the polyurethane resin composition is 0.01 to 0.80 mmol/g with respect to a sum of a mass of the isocyanate group-terminated urethane prepolymer (E) and a mass of the chain extender (G), and the polycarbonate polyol (B) has a deemed average number of functional groups of 2.0 to 3.90.