A method of manufacturing synthetic leather

Abstract

The application relates to the technical field of synthetic leather and discloses a manufacturing method of synthetic leather, which comprises the following steps: step one, preparing raw materials: the raw materials comprise 30% of polyvinyl chloride, 30% of polyurethane, 30% of polyester fiber and 10% of rubber; step two, after the raw materials in step one are mixed and stacked, the raw materials are placed into a fumigator, and incense raw materials are used for fumigation; step three, the raw materials after fumigation are added into a mixing machine, mixed with additives, and melted into a composition after heating; step four, making a backing: a fiber cloth, a textile and carbon fiber are crushed and added into polyethylene and stirred and mixed until uniform, and then the mixed materials are pressed into the shape of the backing through a hot press; step five, the backing material is bonded with the coating composition through hot pressing or cold pressing, the mixed materials are pressed through a calendering machine, and synthetic leather is formed; and step six, the synthetic leather is sent into an oven for drying and curing, and the synthetic leather is additionally subjected to finishing treatment.

Description

Technical Field

[0001] This invention relates to the field of synthetic leather technology, specifically to a method for manufacturing synthetic leather. Background Technology

[0002] Synthetic leather is a man-made alternative to leather that can be used to make a variety of products, such as clothing, shoes, and furniture. Synthetic leather is typically made from synthetic fibers (such as polyurethane) or fiber-based materials, and then surface-treated to give it a similar appearance and texture to genuine leather.

[0003] Synthetic leather is typically formed as a laminate consisting of a base fabric, an intermediate layer, and an outer layer. Its manufacturing process generally involves: creating the outer layer on release paper, forming the intermediate layer on top of it, and then bonding the intermediate layer to the base fabric using an adhesive. Existing technology, such as Chinese Patent Publication No. CN 114277581A, describes a synthetic leather and its preparation method.

[0004] This technical solution utilizes styrene-terminated copolymers (SBCs) as environmentally friendly polymer raw materials with excellent physical properties. These copolymers can be modified using superior physical and chemical methods to meet the needs of various applications, making them the optimal replacement material for PVC. Furthermore, this invention allows for secondary processing of styrene-terminated copolymer (SBC) materials, maximizing their utilization rate and achieving waste recycling. This solves the problem of material waste and is beneficial to environmental protection.

[0005] However, since synthetic leather currently requires the use of various chemical materials, these chemical materials have a pungent odor, resulting in a poor user experience. At the same time, the durability and toughness of synthetic leather mainly rely on the backing, which is usually made of synthetic fibers or other textiles. After prolonged use, the backing will become fluffy and rotten, causing the synthetic leather to become brittle and age. Summary of the Invention

[0006] (a) Technical problems to be solved

[0007] To address the shortcomings of existing technologies, this invention provides a method for manufacturing synthetic leather, which has the advantages of being more resilient and less prone to rotting, and does not have a pungent odor that affects its use, thus solving the problems mentioned above.

[0008] (II) Technical Solution

[0009] To achieve the above objectives, the present invention provides the following technical solution: a method for manufacturing synthetic leather, wherein the synthetic leather is soft and odorless, comprising the following steps:

[0010] Step 1: Prepare raw materials: The raw materials include 30% polyvinyl chloride, 30% polyurethane, 30% polyester fiber and 10% rubber;

[0011] Step 2: After mixing and piling the raw materials from Step 1, put them into the fumigator and use aromatherapy ingredients for fumigation;

[0012] Step 3: Add the fumigated raw materials to the mixer, mix with the additives, and heat to melt into a composition;

[0013] Step 4: Making the backing: Crush the fiber cloth, textiles and carbon fiber and add polyethylene and stir until uniform. Then press the mixture into shape using a hot press.

[0014] Step 5: The backing material is bonded to the coated composition by hot or cold pressing. The mixed material is then pressed by a calendering machine to form synthetic leather.

[0015] Step Six: The synthetic leather is placed in an oven for drying and curing, while additional finishing treatments are applied.

[0016] Preferably, the polyvinyl chloride is in granular form with a diameter of 4mm-7mm, the polyester fiber has a diameter of 10μm-20μm, the polyester fiber is in 10cm segments, the rubber is in granular form with a particle diameter of 4mm-6mm, and the rubber is one or a mixture of acrylate rubber and styrene-butadiene rubber.

[0017] Through the above technical solutions, the diversity of synthetic leather materials in terms of appearance and texture can be achieved by combining different raw materials. The different properties and textures of polyvinyl chloride, polyester fiber, and rubber can be combined to create various styles of synthetic leather. Polyvinyl chloride, polyester fiber, and rubber materials all have high durability and strength, giving synthetic leather better wear resistance, scratch resistance, and durability, allowing it to maintain its appearance and performance for a long time. These materials have good plasticity and deformability during the manufacturing process, and can be processed into complex shapes and textures through processes such as hot pressing and calendering, making synthetic leather more flexible and diverse in design and production. Compared with natural leather, synthetic leather is easier to clean and maintain. Its surface can resist liquid penetration, and it is easier to remove stains and dirt. This can reduce the demand for animal leather and reduce environmental problems related to the livestock industry, making it more environmentally friendly.

[0018] Preferably, the fumigation in step two includes the following steps:

[0019] S1.1. Prepare the fumigator: Prepare the fumigator and ensure it is clean, odorless, and free of bacteria and microorganisms. Make sure the liquid container inside the fumigator is filled with one-third of its total capacity of water, and set the heating element to a temperature of 100℃-120℃.

[0020] S1.2 Add fragrance: Add the required fragrance or flavoring to the liquid container of the fumigator. Adjust the amount added according to the strength of the fragrance used. The ratio is 3 ml to 5 ml of fragrance per kilogram of raw material.

[0021] S1.3 Start the fumigator: Turn on the fumigator and start it to heat up and generate steam. Wait for the temperature of the fumigator to reach 100°C and ensure that the steam is fully generated.

[0022] S1.4 Fumigation Material: Place the prepared raw materials in a container connected to the fumigator, ensuring that the raw materials come into contact with the steam so that the fragrance can penetrate into them;

[0023] S1.5 Waiting for the flavor to penetrate: Expose the materials in the fumigator for 10 minutes to allow the flavor to fully penetrate and infuse. The time should be adjusted according to the type and size of the materials, with an additional 10 minutes of waiting time for every 100kg of raw materials.

[0024] S1.6 Inspection and Storage: After fumigation, check the taste and flavor of the material. If a stronger aroma is needed, the fumigation process can be repeated. After completion, store the material in a sealed container to maintain its flavor.

[0025] Through the above technical solutions, some raw materials may have pungent or unpleasant odors. Fragrances are used to neutralize or mask these odors, thereby improving the smell of synthetic leather products and making them more pleasant and attractive. By using fragrances to provide the desired aroma to synthetic leather products, different types of fragrances, such as fruit fragrances, floral fragrances, wood fragrances, food fragrances, and green leaf fragrances, can be used to give synthetic leather a variety of different aromas, increasing its attractiveness and personality.

[0026] Preferably, the fragrances in S1.2 include fruit fragrances, floral fragrances, wood fragrances, food fragrances, and green leaf fragrances. The fruit fragrances include lemon fragrance, orange fragrance, strawberry fragrance, and blueberry fragrance. The floral fragrances include rose, jasmine, lavender, and rosemary. The wood fragrances include sandalwood, cedar, and cinnamon. The food fragrances include chocolate, coffee, and vanilla. The green leaf fragrances include mint, rosemary, and peppermint.

[0027] By employing the aforementioned technical solutions and using different types of fragrances, such as lemon, orange, strawberry, blueberry, rose, jasmine, lavender, rosemary, sandalwood, cedarwood, cinnamon, chocolate, coffee, vanilla, and mint, synthetic leather can be endowed with diverse aroma characteristics. This provides a wide range of product options and meets consumers' needs for different scents.

[0028] Preferably, the backing preparation method in step four includes the following steps:

[0029] S2.1 Selection of backing material: Backing materials include fiber cloth, textiles and carbon fiber;

[0030] S2.2 Cleaning the backing material: Place the fiber cloth and textiles into the cleaning tank and rinse them to ensure that the backing material is free of dust or dirt.

[0031] S2.3. Shred the fiber cloth and textiles and add carbon fiber, stirring until evenly mixed;

[0032] S2.4 Add polyethylene to the fiber cloth, textile and carbon fiber mixture and continue stirring;

[0033] S2.5. Use a calender to calender the clumps of mixed materials into sheets to complete the backing material production.

[0034] By selecting different types of backing materials, such as fiber cloth, textiles, and carbon fiber, different properties and performances can be obtained through the above technical solutions. Fiber cloth and textiles generally have good softness and flexibility, while carbon fiber has high strength and wear resistance. Carbon fiber is a high-strength, high-modulus material with better strength and stiffness than traditional fiber materials. Adding carbon fiber to the backing material can enhance the overall structural strength and rigidity, improve the durability and load-bearing capacity of the backing material. Carbon fiber is lighter than traditional materials and has a lower density. By using carbon fiber in the backing material, the overall weight of the product can be reduced, improving the product's lightness and comfort. Carbon fiber has excellent wear resistance. Adding carbon fiber to the backing material can improve the material's wear resistance and extend the product's service life, especially for products that require frequent friction and wear, such as footwear and car seats. Carbon fiber has good thermal stability and can maintain its structural stability in high-temperature environments. This gives the backing material good performance and stability under high-temperature conditions, making it suitable for applications in high-temperature processes or environments.

[0035] Preferably, the fiber cloth, textile and carbon fiber each account for 40% of the total composition, 40% of the total composition, and 20% of the total composition, respectively.

[0036] The above technical solution improves the stability and processability of the mixed material by adding polyethylene. Polyethylene has good adhesion and plasticity, which makes the backing material stronger and more malleable, and easier to process and manufacture.

[0037] Preferably, the stirring rate of the fiber cloth and textile in S1.3 is 80 / prm-110 / prm.

[0038] By using the above technical solution, limiting the processing stirring rate to 80 / rpm-110 / rpm avoids excessively high rotation speeds that could cause misalignment of the fiber cloth. Shredding and mixing the fiber cloth, textiles, and carbon fibers achieves a uniform distribution of the materials. This ensures that the various components in the mixed material are fully combined and integrated, improving product consistency and performance.

[0039] Preferably, the stirring time of the S1.3 fiber cloth and textile is 6 min to 13 min.

[0040] Preferably, the additives in step three include plasticizers, stabilizers, and softeners.

[0041] Preferably, the plasticizer includes dioctyl phthalate, polyglycerol fatty acid ester and polyester, the light stabilizer includes phenol ketone, benzotriazole and dihydroxyphenyltriazole, and the softener includes polysiloxane and silicone rubber.

[0042] Compared with the prior art, the present invention provides a method for manufacturing synthetic leather, which has the following beneficial effects:

[0043] 1. This invention provides the desired aroma to synthetic leather products through fragrances. By using different types of fragrances, such as fruit fragrances, floral fragrances, wood fragrances, food fragrances, and green leaf fragrances, synthetic leather can be endowed with various different aromas, increasing its attractiveness and individuality, and achieving the beneficial effect of making synthetic leather more resilient and less prone to decay.

[0044] 2. This invention achieves different properties and performances by selecting different types of backing materials, such as fiber cloth, textiles, and carbon fiber. Fiber cloth and textiles typically have good softness and flexibility, while carbon fiber has high strength and wear resistance. Carbon fiber is a high-strength, high-modulus material with better strength and stiffness than traditional fiber materials. Adding carbon fiber to the backing material can enhance the overall structural strength and rigidity, improve the durability and load-bearing capacity of the backing material. Carbon fiber is lighter and has a lower density than traditional materials. By using carbon fiber in the backing material, the overall weight of the product can be reduced, improving its portability and comfort. Carbon fiber has excellent wear resistance. Adding carbon fiber to the backing material can improve the material's wear resistance, extend the product's service life, and achieve the beneficial effect of synthetic leather not having a pungent odor that affects its use. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of the process of the present invention. Detailed Implementation

[0046] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0047] Please see Figure 1 A method for manufacturing synthetic leather, the synthetic leather being soft and odorless, includes the following steps:

[0048] Step 1: Prepare raw materials: The raw materials include 30% polyvinyl chloride, 30% polyurethane, 30% polyester fiber and 10% rubber.

[0049] Step 2: After mixing and piling the raw materials from Step 1, put them into the fumigator and use aromatherapy ingredients for fumigation;

[0050] Step 3: Add the fumigated raw materials to the mixer, mix with the additives, and heat to melt into a composition;

[0051] Step 4: Making the backing: Crush the fiber cloth, textiles and carbon fiber and add polyethylene and stir until uniform. Then press the mixture into shape using a hot press.

[0052] Step 5: The backing material is bonded to the coated composition by hot or cold pressing. The mixed material is then pressed by a calendering machine to form synthetic leather.

[0053] Step Six: The synthetic leather is placed in an oven for drying and curing, while additional finishing treatments are applied.

[0054] Specifically, polyvinyl chloride (PVC) is in granular form with a diameter of 4mm-7mm, polyester fiber has a diameter of 10μm-20μm, with each polyester fiber segment measuring 10cm. Rubber is also in granular form with a particle diameter of 4mm-6mm. The rubber is one or a mixture of acrylic rubber and styrene-butadiene rubber. The advantage is that by combining different raw materials, the diversity of appearance and texture of synthetic leather materials can be achieved. The different properties and textures of PVC, polyester fiber, and rubber can be combined to create various styles of synthetic leather. All three materials possess high... Durability and strength give synthetic leather better abrasion resistance, scratch resistance, and durability, allowing it to maintain its appearance and performance for a longer period. These materials have good plasticity and deformability during the manufacturing process, and can be processed into complex shapes and textures through processes such as hot pressing and calendering. This makes synthetic leather more flexible and diverse in design and production. Compared to natural leather, synthetic leather is easier to clean and maintain. Its surface can resist liquid penetration, and it is easier to remove stains and dirt. It can reduce the demand for animal leather and reduce environmental problems related to the livestock industry, making it more environmentally friendly.

[0055] Specifically, step two, fumigation, includes the following steps:

[0056] S1.1. Prepare the fumigator: Prepare the fumigator and ensure it is clean, odorless, and free of bacteria and microorganisms. Make sure the liquid container inside the fumigator is filled with one-third of its total capacity of water, and set the heating element to a temperature of 100℃-120℃.

[0057] S1.2 Add fragrance: Add the required fragrance or flavoring to the liquid container of the fumigator. Adjust the amount added according to the strength of the fragrance used. The ratio is 3 ml to 5 ml of fragrance per kilogram of raw material.

[0058] S1.3 Start the fumigator: Turn on the fumigator and start it to heat up and generate steam. Wait for the temperature of the fumigator to reach 100°C and ensure that the steam is fully generated.

[0059] S1.4 Fumigation Material: Place the prepared raw materials in a container connected to the fumigator, ensuring that the raw materials come into contact with the steam so that the fragrance can penetrate into them;

[0060] S1.5 Waiting for the flavor to penetrate: Expose the materials in the fumigator for 10 minutes to allow the flavor to fully penetrate and infuse. The time should be adjusted according to the type and size of the materials, with an additional 10 minutes of waiting time for every 100kg of raw materials.

[0061] S1.6 Inspection and Storage: After fumigation, check the taste and flavor penetration of the material. If a stronger aroma is needed, the fumigation process can be repeated. After completion, store the material in a sealed container to maintain its flavor penetration effect. The advantage is that some raw materials may have pungent or unpleasant odors. Fragrances are used to neutralize or mask these odors, thereby improving the smell of synthetic leather products and making them more pleasant and attractive. Fragrances provide the desired aroma to synthetic leather products. Using different types of fragrances, such as fruit fragrances, floral fragrances, wood fragrances, food fragrances, and green leaf fragrances, synthetic leather can be given a variety of different aromas, increasing its attractiveness and personality.

[0062] Specifically, the fragrances in S1.2 include fruit fragrances, floral fragrances, wood fragrances, food fragrances, and green fragrances. Fruit fragrances include lemon, orange, strawberry, and blueberry; floral fragrances include rose, jasmine, lavender, and rosemary; wood fragrances include sandalwood, cedar, and cinnamon; food fragrances include chocolate, coffee, and vanilla; and green fragrances include peppermint, rosemary, and mint. The advantage is that by using different types of fragrances, such as lemon, orange, strawberry, blueberry, rose, jasmine, lavender, rosemary, sandalwood, cedar, cinnamon, chocolate, coffee, vanilla, and mint, different aroma characteristics can be imparted to synthetic leather. This provides a wide range of product choices and meets consumers' needs for different scents.

[0063] Specifically, the backing preparation method in step four includes the following steps:

[0064] S2.1 Selection of backing material: Backing materials include fiber cloth, textiles and carbon fiber;

[0065] S2.2 Cleaning the backing material: Place the fiber cloth and textiles into the cleaning tank and rinse them to ensure that the backing material is free of dust or dirt.

[0066] S2.3. Shred the fiber cloth and textiles and add carbon fiber, stirring until evenly mixed;

[0067] S2.4 Add polyethylene to the fiber cloth, textile and carbon fiber mixture and continue stirring;

[0068] S2.5. Use a calender to calender the clumps of mixed materials into sheets to complete the backing material production.

[0069] The advantages are that by selecting different types of backing materials, such as fiber cloth, textiles, and carbon fiber, different properties and performances can be obtained. Fiber cloth and textiles generally have better softness and flexibility, while carbon fiber has higher strength and abrasion resistance. Carbon fiber is a high-strength, high-modulus material with better strength and stiffness than traditional fiber materials. Adding carbon fiber to the backing material can enhance the overall structural strength and rigidity, improve the durability and load-bearing capacity of the backing material. Carbon fiber is lighter than traditional materials and has a lower density. By using carbon fiber in the backing material, the overall weight of the product can be reduced, improving the product's lightness and comfort. Carbon fiber has excellent abrasion resistance. Adding carbon fiber to the backing material can improve the material's abrasion resistance and extend the product's service life, especially for products that require frequent friction and wear, such as footwear and car seats. Carbon fiber has good thermal stability and can maintain its structural stability in high-temperature environments. This gives the backing material good performance and stability under high-temperature conditions, making it suitable for applications in high-temperature processes or environments.

[0070] Specifically, the proportions of fiber cloth, textiles, and carbon fiber are 40%, 40%, and 20%, respectively.

[0071] The advantage is that adding polyethylene to the blend improves its stability and processability. Polyethylene has good adhesion and plasticity, which makes the backing material stronger and more malleable, and easier to process and manufacture.

[0072] Specifically, the stirring rate of the fiber cloth and textile in S1.3 is 80 / prm-110 / prm.

[0073] The advantage is that by limiting the processing stirring rate to 80-110 revolutions per minute, excessively high rotation speeds can prevent the fiber cloth from becoming misaligned. Shredding and mixing the fiber cloth, textiles, and carbon fibers ensures a uniform distribution of the materials. This guarantees that the various components in the mixture are fully combined and integrated, improving product consistency and performance.

[0074] Specifically, the mixing time for S1.3 fiber cloth and textiles is 6-13 minutes.

[0075] Specifically, the additives in step three include plasticizers, stabilizers, and softeners.

[0076] Specifically, plasticizers include dioctyl phthalate, polyglycerol fatty acid esters and polyesters; light stabilizers include phenolic ketones, benzotriazoles and dihydroxyphenyltriazoles; and softeners include polysiloxanes and silicone rubber.

[0077] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing synthetic leather, characterized in that, The synthetic leather is soft and odorless, and includes the following steps: Step 1: Prepare raw materials: The raw materials include 30% polyvinyl chloride, 30% polyurethane, 30% polyester fiber and 10% rubber. Step 2: After mixing and piling the raw materials from Step 1, put them into the fumigator and use aromatherapy ingredients for fumigation; Step 3: Add the fumigated raw materials to the mixer, mix with the additives, and heat to melt into a composition; Step 4: Making the backing: Crush the fiber cloth, textiles and carbon fiber and add polyethylene and stir until uniform. Then press the mixture into shape using a hot press. Step 5: The backing material is bonded with a coating compound by hot or cold pressing, and the mixed material is pressed by a calendering machine to form synthetic leather; Step Six: The synthetic leather is placed in an oven for drying and curing, while additional finishing treatments are applied to the synthetic leather. The fiber cloth, textile, and carbon fiber each account for 40%, 40%, and 20%, respectively. The additives in step three include plasticizers, light stabilizers, and softeners; The plasticizers include dioctyl phthalate, polyglycerol fatty acid esters, and polyesters; the light stabilizers include phenol ketones, benzotriazoles, and dihydroxyphenyltriazoles; and the softeners include polysiloxanes and silicone rubber. The polyvinyl chloride is in granular form with a diameter of 4mm-7mm, the polyester fiber has a diameter of 10μm-20μm, the polyester fiber is in 10cm segments, the rubber is in granular form with a particle diameter of 4mm-6mm, and the rubber is one or a mixture of acrylate rubber and styrene-butadiene rubber. The fumigation in step two includes the following steps: S1.

1. Prepare the fumigator: Prepare the fumigator and ensure it is clean, odorless, and free of bacteria and microorganisms. Make sure the liquid container inside the fumigator is filled with one-third of its total capacity of water, and set the heating element to 100℃-120℃. S1.2 Add fragrance: Add the required fragrance to the liquid container of the fumigator. Adjust the amount added according to the strength of the fragrance used. The ratio is 3 ml to 5 ml of fragrance per kilogram of raw materials. S1.3 Start the fumigator: Turn on the fumigator and start it to heat up and generate steam. Wait for the temperature of the fumigator to reach 100°C and ensure that the steam is fully generated. S1.4 Fumigation of raw materials: Place the prepared raw materials in a container connected to the fumigator, ensuring that the raw materials come into contact with the steam so that the fragrance can penetrate into them; S1.5 Waiting for the flavor to infuse: Expose the raw materials in the fumigator for 10 minutes to allow the flavor to fully penetrate and infuse. The time should be adjusted according to the type and size of the raw materials, with an additional 10 minutes of waiting time for every 100kg of raw materials. S1.6 Inspection and Storage: After fumigation, check the taste and flavor of the raw materials. If a stronger aroma is required, the fumigation process can be repeated. After completion, store the raw materials in a sealed container to maintain their flavor. The fragrances in S1.2 include fruit fragrances, floral fragrances, wood fragrances, food fragrances, and green leaf fragrances. The fruit fragrances include lemon fragrance, orange fragrance, strawberry fragrance, and blueberry fragrance. The floral fragrances include rose, jasmine, lavender, and rosemary. The wood fragrances include sandalwood, cedar, and cinnamon. The food fragrances include chocolate, coffee, and vanilla. The green leaf fragrances include rosemary and mint. The backing preparation method in step four includes the following steps: S2.1 Selection of backing material: Backing materials include fiber cloth, textiles and carbon fiber; S2.2 Cleaning the backing material: Place the fiber cloth and textiles into the cleaning tank and rinse them to ensure that the backing material is free of dust or dirt. S2.

3. Shred the fiber cloth and textiles and add carbon fiber, stirring until evenly mixed; S2.4 Add polyethylene to the fiber cloth, textile and carbon fiber mixture and continue stirring; S2.

5. Use a calender to calender the clumps of mixed materials into sheets to complete the backing material production; The stirring rate of the fiber cloth and textile in S2.3 is 80 / prm-110 / prm; The mixing time for the S2.3 fiber cloth and textile is 6 min to 13 min.

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