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Textile Light | First Prize Of Textile Science And Technology Progress: New Generation PU Coating Technology Leads Green Transformation Of New Energy Vehicle Leather
On November 12, the Science and Technology Award Conference of China Textile Industry Federation was held in the Great Hall of the People in Beijing to commend the 2024 Science and Technology Award of China Textile Industry Federation. Qi Dongming, Deputy Director of the Modern Textile Technology Innovation Center and Professor of the School of Textile Science and Engineering (International Silk College) of Zhejiang University of Technology, as the first person to complete the project, won the first prize of the Science and Technology Progress Award for the "New Technology and Industrialization of Reactive Polyurethane Coating Processing for Automotive Ultra Fiber Leather" project.
The new energy vehicle leather is based on superfine fiber base cloth and endowed with flame retardant, antibacterial, mildew resistant, sun resistant, easy decontamination and other characteristics through polyurethane based (PU) functional coating, and needs to maintain high physical properties, lightweight and comfort for a long time. It is one of the most challenging subdivision technology tracks in coating processing. The project was jointly completed by the team of Professor Qi Dongming, deputy director of Zhejiang University of Technology and Zhejiang Modern Textile Technology Innovation Center, and the team of Zhejiang Hexin Holding Co., Ltd. Aiming at the problems of high energy consumption, high pollution and solvent residue in the production and processing process and products of traditional automotive leather, the project has taken five years to jointly tackle key problems from the three levels of principle mechanism, process technology and production equipment, and has mastered the new generation of PU coating processing technology. The overall technology of the project has reached the international advanced level, among which the PU prepolymer tubular mixing reactor and high-speed blending high-precision spray coating technology have reached the international advanced level. Through the deep integration of industry, learning and research, and collaborative innovation, Zhejiang Hexin Holding Co., Ltd. has established three green manufacturing directions, namely, reactive PU resin green low-carbon synthesis, superfine fiber green low-carbon spinning, and microfiber synthetic leather green low-carbon preparation, and has exported a number of high-end products with high physical properties and lightweight for the interior of new energy vehicles.
Analyze reaction mechanism and guide technical route
Aiming at the problem of high energy consumption and high pollution of traditional PU coating processing technology, the team visited and investigated the enterprises, and innovatively put forward the concept of "reactive PU". In the absence of medium, how to effectively adjust the viscosity of the system to control the reaction rate is the key to mastering the preparation technology of reactive PU coating. By dynamically tracking the structural evolution process of reactive PU coating, the team proposed a three-stage theory of "chain extension - gelation - phase separation" for simultaneous polymerization/forming of reactive PU coating, which filled the gap in reactive PU reaction mechanism, mastered the control methods of prepolymer viscosity and reaction rate, and realized a new technical route of short process production of simultaneous polymerization/forming without media.
R&D of new process and stage control process
Reactive PU has the characteristics of simultaneous polymerization/molding, so there is a problem of low reaction controllability in the process, resulting in poor physical properties of the final product. The team proposed a new process of polymerization/molding rate control and physical property improvement for the time temperature co domain constraints under the high speed polymerization/molding synchronization without media: developed a tubular mixed prepolymerization technology and reactor to control the polymerization degree of prepolymer; The substitution strategy of crosslinking system was proposed to optimize the number and distribution of physical crosslinking points and improve the physical properties of PU; The biaxial stretching ripening process was developed, and the distribution of micro phase structure was optimized with the aid of biaxial stretching, taking advantage of the fact that the PU coating was still in the curing stage. Zhejiang Hexin Holding Co., Ltd. has developed a series of high-quality products to achieve a perfect balance between functional design and environmental protection.
Develop complete sets of equipment and improve the industrial level
Facing the synchronous characteristics of reactive PU polymerization/molding and the actual high speed production characteristics, the team created a complete set of new production equipment based on the new process of phased regulation: developed a "chain expanding inhibiting gel" type blend injection system matching the "chain expanding" tubular hybrid prepolymerization technology, which solved the problem of gelation advance caused by the heat of PU self polymerization; A turnback gradient temperature controlled "ripening" system suitable for "gelation" reversible crosslinking was developed; A closed-loop control production system with precise and synchronous coordination of tension and speed adapted to the phase of "phase separation" has been developed to improve the overall uniformity.
The project has been granted 14 invention patents (including 1 U.S. patent), 6 utility model patents (including 1 Japanese patent), and formulated 1 national standard, 2 industrial standards, and 5 group standards, forming an intellectual property and standard system for reactive PU microfiber leather coating processing. Professor Qi Dongming's team and the team of Zhejiang Hexin Holding Co., Ltd. jointly built 10 production demonstration lines of reactive PU for automotive microfiber leather, forming a production capacity of 24 million meters per year, developed a series of high-end automotive products such as flame retardant and self-cleaning products, broke the international technology monopoly, and increased sales by 1.29 billion yuan and profits by 200 million yuan in the past three years.
The carbon footprint of the product has been tested and evaluated by a third party, and the energy consumption and CO2 emissions of each 1kg reactive PU coating synthesized and coated are 37% and 45% lower than those of traditional solvent based PU. The economic, social and environmental benefits are significant, which will help China's automotive microfiber leather coating processing technology to move from following the trend to leading the world.
(Source: Ministry of Science and Technology of China Textile Federation)
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