Artificial Sueded Leather Coating for Halogen-Free Flame Retardance
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Solution Overview
Problem
Conventional artificial sueded leathers face challenges in achieving high flame retardance without using halogenated substances, which can generate toxic gases during burning, and often result in water spots, reduced surface quality, and decreased durability due to the incorporation of flame retardants.
Innovation Solution
A thermoplastic synthetic fiber cloth with a raised or napped surface, impregnated with a polyurethane resin and treated with a non-halogenated flame retardant containing phosphate compounds, vinyl-group-containing resins, and water-insoluble thickeners, applied to one face to enhance flame retardance and prevent water spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogenated flame retardant substances are used to achieve high flame retardance, then flame retardant properties are improved, but toxic gases are generated during burning
Solution Approach 1:
The invention changes the chemical composition parameters of the flame retardant from halogenated substances to non-halogenated phosphate ester compounds, specifically using phosphorus-containing compounds that do not generate toxic halogen gases during combustion while maintaining effective flame retardant properties
Solution Approach 2:
The invention converts the potentially harmful effect of flame retardants generating toxic gases into a beneficial outcome by selecting phosphate ester compounds that produce harmless combustion products, thereby eliminating the harmful effect while preserving the flame retardant function
2Reliability
If flame retardant compounds are applied to the surface of artificial sueded leather, then flame retardant properties are improved, but water spots appear on the surface
Solution Approach 1:
The invention changes the solubility parameter of the flame retardant compound by selecting water-insoluble phosphate ester compounds, which prevents the formation of water spots on the leather surface while maintaining effective flame retardant properties
Solution Approach 2:
The invention introduces a resin component as an intermediary carrier that bonds the flame retardant compound to the leather surface, creating a stable coating that prevents water penetration and spot formation while delivering the flame retardant effect
3Reliability
If flame retardant is included in the polyurethane elastomer, then flame retardant properties are improved, but the degree of polymerization decreases over time
Solution Approach 1:
The invention segments the flame retardant function from the polyurethane elastomer matrix by applying the flame retardant compound as a separate coating layer on the leather surface, thereby preventing the flame retardant from interfering with the polymerization and long-term stability of the elastomer
Solution Approach 2:
The invention uses a resin as an intermediary carrier that separates the flame retardant compound from direct contact with the polyurethane elastomer, allowing the elastomer to maintain its polymerization degree and structural integrity while the resin-coated flame retardant provides the protective function
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 provides excellent flame retardance, light resistance, and abrasion resistance while avoiding water spots and the use of halogenated chemicals, maintaining the texture and appearance of the artificial sueded leather.
Implementation Method 1
phosphate compound A... capable of forming a carbonization skeleton in burning
Implementation Method 2
water-insoluble thickener D... exhibits no water spot
Data Source
AI summary
It is intended to provide a novel artificial sueded leather having flame retardance, which is excellent inflame retardance, light resistance and abrasion resistance, suffers from no water spot and is free from any halogenated chemical (i.e., one having been treated with a so-called non-halogenated flame retardant), and a method of producing the same. The above artificial sueded leather comprises a thermoplastic synthetic fiber cloth made of a woven fabric, a knitted web or a nonwoven fabric, which has a raised-fiber or napped-fiber surface and has been impregnated with a polyurethane resin, and a flame retardant which contains at least a phosphate compound A having a solubility in water of 1% or less, a vinyl group-containing resin C capable of forming a carbonization skeleton in burning and a water-insoluble thickener D and is imparted to one face of the thermoplastic synthetic fiber cloth. A method of producing the artificial sueded leather as described above comprises imparting an flame retardant, which contains at least a phosphate compound A having a solubility in water of 1% or less, a vinyl group-containing resin C capable of forming a carbonization skeleton in burning and a water-insoluble thickener D, to one face of a thermoplastic synthetic fiber cloth made of a woven fabric, a knitted web or a nonwoven fabric which has a raised-fiber or napped-fiber surface and has been impregnated with a polyurethane resin.