Synthetic leather and method for producing the same
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Solution Overview
Problem
Conventional synthetic leather with a resin layer is difficult to wash and prone to stain accumulation over time, with existing anti-stain solutions like fluorine resin causing texture deterioration and reduced effectiveness.
Innovation Solution
A synthetic leather with a substrate, skin layer, and an anti-stain layer containing a silicon-containing compound with a urethane bond, where the fluorine atom to silicon atom ratio is 0.01 or less, utilizing the silicon compound's properties for stain resistance and easy stain removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluorine resin is used to improve anti-stain properties, then stain resistance is improved, but texture deteriorates and anti-stain properties deteriorate over time
Solution Approach 1:
The patent changes the chemical composition parameters of the anti-stain layer by using silicon-containing compounds with specific fluorine-to-silicon atomic ratios (0.01 to 0.1) instead of conventional fluorine resin. This parameter change maintains anti-stain properties while preventing texture deterioration and maintaining stability over time.
Solution Approach 2:
The patent creates a composite material system in the anti-stain layer that combines silicon-containing compounds with specific fluorine content. This composite approach integrates the stain-resistant properties of fluorine with the structural stability of silicon-based compounds, resolving the contradiction between anti-stain performance and texture stability.
2Reliability
If fluorine resin is used to improve anti-stain properties, then stain resistance is improved, but anti-stain properties deteriorate after long period use
Solution Approach 1:
The patent modifies the compositional parameters by introducing silicon-containing compounds as the base resin and controlling fluorine content to specific atomic ratios. This change creates a more stable chemical structure that maintains anti-stain properties over extended periods, preventing the deterioration that occurs with conventional fluorine resin.
Solution Approach 2:
The patent moves away from using pure fluorine resin (which has limited durability) to a silicon-based system with controlled fluorine content. This substitution creates a more durable, long-lasting anti-stain layer that maintains its effectiveness throughout the product's service life.
3Ease of manufacture
If conventional resin layer is used, then ease of manufacture is maintained, but anti-stain properties are poor and stain removal is difficult
Solution Approach 1:
The patent changes the chemical composition of the resin layer by incorporating silicon-containing compounds with specific fluorine-to-silicon atomic ratios. This compositional change provides excellent anti-stain properties while maintaining compatibility with conventional manufacturing processes, ensuring ease of manufacture is preserved.
Data Source
AI summary
A synthetic leather comprising a substrate, a skin layer that is disposed on one main surface of the substrate, and an anti-stain layer that is disposed to cover the skin layer. The anti-stain layer contains a base resin that comprises silicon and a unit derived from a compound that has a urethane bond. In the anti-stain layer, a fluorine atom/silicon atom atomic ratio, which is a proportion of a fluorine atom to the silicon atom, is 0.01 or less. A first color difference ΔE1* between before and after a stain adhesion test performed on the synthetic leather rubbed under a specific condition is 5 or less.