Flame retardant polyurethane artificial leather and method for manufacturing the same

• US 10,640,646 B2
• Filed: 12/29/2017
• Issued: 05/05/2020
• Est. Priority Date: 02/17/2017
• Status: Active Grant

• Current Assignee: Hyundai Motor Company (Hyundai Motor Group), Kia Motors Corporation (Kia Corp.)
• Original Assignee: Hyundai Motor Company (Hyundai Motor Group)
• Inventors: Hwang, Hye-Na, Hong, Sung-Joon, Kim, Han-Seok, Kim, Kyung-Nam, Cho, Seong-Ho, Cha, Yoon-Jong, An, Sung-Deuk
• Primary Examiner(s): Oyer, Andrew J.
• Application Number:
  US15/858,554
• Publication Number:
  US 20180237637A1
• Time in Patent Office: 858 Days
• CPC Class Codes: C08K 2003/2227 of aluminium
• CPC Class Codes: C08K 3/016 Flame-proofing or flame-retarding additives
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 5/0066 Flame-proofing or flame-retarding additives
• CPC Class Codes: C08K 5/5399 Phosphorus bound to nitrogen
• CPC Class Codes: C08L 2201/02 Flame or fire retardant/resistant
• CPC Class Codes: C08L 75/04 Polyurethanes
• CPC Class Codes: C09D 175/04 Polyurethanes
• CPC Class Codes: C09J 175/04 Polyurethanes

Abstract

Provided herein is a flame retardant polyurethane (PU) artificial leather and a method for manufacturing the flame retardant polyurethane (PU) artificial leather, wherein the method may include preparing a microfiber nonwoven fabric material, consecutively forming a polyurethane coating layer and an adhesive layer on one surface of a release paper, and combining the nonwoven fabric material and the release paper.

Claims

1. A method for manufacturing flame retardant polyurethane (PU) artificial leather comprising:

preparing a microfiber nonwoven fabric material;

consecutively forming a polyurethane coating layer and an adhesive layer on one surface of a release paper; and

combining the nonwoven fabric material and the release paper,

wherein the preparing step of the microfiber nonwoven fabric material comprises impregnating a nonwoven fabric into a polyurethane resin comprising a first flame retardant; and

treating the impregnated nonwoven fabric with an alkali solvent to reduce the weight.

2. The method for manufacturing flame retardant PU artificial leather of claim 1, wherein the polyurethane resin comprises the first flame retardant in greater than or equal to 40 parts per hundred parts of resin (PHR) and less than 50 PHR.

3. The method for manufacturing flame retardant PU artificial leather of claim 2, wherein the first flame retardant is aluminum hydroxide (Al(OH)₃).

4. The method for manufacturing flame retardant PU artificial leather of claim 1, wherein the adhesive layer comprises a second flame retardant in 20 PHR or greater.

5. The method for manufacturing flame retardant PU artificial leather of claim 4, wherein the second flame retardant is a phosphorous-based flame retardant.

6. The method for manufacturing flame retardant PU artificial leather of claim 5, wherein the second flame retardant is a non-soluble flame retardant having phosphorous content of 10% by weight or higher and alkalinity resistance of 60% or higher.

7. The method for manufacturing flame retardant PU artificial leather of claim 6, wherein the second flame retardant is a powder-type flame retardant.

8. The method for manufacturing flame retardant PU artificial leather of claim 5, wherein the second flame retardant is bis-amide phosphate.