Stain-proof structure and production method thereof
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Solution Overview
Problem
Synthetic leather surfaces are prone to dirt and graffiti, leading to shortened service life and environmental impact, as existing fouling-proof structures lack an alcohol-resistant basal layer, causing them to deteriorate quickly when exposed to solvents.
Innovation Solution
A fouling-proof structure comprising an alcohol-resistant layer and a water-based fouling-proof layer, where the alcohol-resistant layer is formed by curing a combination of polyurethane resin, water, and additives, and the water-based fouling-proof layer includes polyurethane resin, polymerized siloxanes, water-based PTFE, and silicone oil, applied using a spraying-coating process to ensure strong bonding and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional fouling-proof layer is applied on synthetic leather surface, then dirt and graffiti prevention is improved, but the structure deteriorates quickly when exposed to solvents or detergents
Solution Approach 1:
The protective structure is divided into two distinct layers: an alcohol-resistant basal layer and a water-based fouling-proof layer. This segmentation allows each layer to perform its specialized function - the basal layer provides solvent resistance while the top layer provides fouling prevention, resolving the contradiction between dirt prevention and solvent resistance.
Solution Approach 2:
The invention uses composite material structure combining alcohol-resistant polyurethane resin in the basal layer with water-based fouling-proof coating containing PTFE and silicone oil in the top layer. This composite approach integrates the advantages of different materials to achieve both solvent resistance and effective fouling prevention simultaneously.
2Ease of operation
If existing fouling-proof structures are used, then cleaning function is improved, but service life is shortened due to lack of alcohol-resistant basal layer
Solution Approach 1:
The alcohol-resistant basal layer is applied in advance before the fouling-proof layer, creating a durable foundation that prevents subsequent deterioration. This preliminary protective action ensures the structure maintains its integrity and service life while providing effective cleaning functionality.
Solution Approach 2:
By separating the protective function into two layers - basal layer for long-term durability and top layer for cleaning functionality - the invention resolves the contradiction between ease of cleaning and extended service life.
3Ease of manufacture
If single-layer fouling-proof coating is applied, then manufacturing process is simple, but performance deteriorates when exposed to repeated alcohol solutions
Solution Approach 1:
The manufacturing process is segmented into two coating steps: first applying the alcohol-resistant basal layer, then applying the water-based fouling-proof layer. This segmentation maintains manufacturing simplicity while dramatically improving reliability under repeated alcohol exposure through the protective basal layer.
Solution Approach 2:
The composite coating structure combines alcohol-resistant polyurethane resin with water-based fouling-proof materials, creating a multi-functional protective layer that maintains performance under repeated alcohol exposure while remaining manufacturable through standard coating processes.
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 structure effectively prevents dirt and graffiti, extending the service life of synthetic leather products, reducing environmental impact, and allowing easy removal of stains with dry cloths or commercial detergents, maintaining performance even after repeated exposure to alcohol solutions or detergents.
Implementation Method 1
the alcohol-resistant layer is formed by curing an alcohol-resistant combination, and the water-based fouling-proof layer is formed by curing a water-based fouling-proof combination
Implementation Method 2
the water-based fouling-proof combination comprises polyurethane resin, water, polymerized siloxanes, water-based PTFE and silicone oil
Data Source
Figure 1~2
AI summary
A fouling-proof structure (10) is applicable to synthetic leather or fabric and it includes an alcohol-resistant layer (12); and a water-based fouling-proof layer (13) disposed on the alcohol-resistant layer (12), wherein the alcohol-resistant layer (12) is formed by curing an alcohol-resistant combination, and the alcohol-resistant combination comprises polyurethane resin, wherein the water-based fouling-proof layer (13) is formed by curing a water-based fouling-proof combination, and the water-based fouling-proof combination comprises polyurethane resin, water, polymerized siloxanes, water-based PTFE and silicone oil. A method of producing aforementioned fouling-proof structure (10).