Recyclable resin substrate for artificial leather, artificial leather, and method for manufacturing the same, automobile seat, automobile

Abstract

The present application relates to a kind of recyclable resin base material for artificial leather, recyclable artificial leather and its preparation method, automobile seat, automobile, artificial leather includes the surface treatment agent layer, dense layer and base cloth layer sequentially stacked, the dense layer is made by dense layer preform, the dense layer preform includes main material and other auxiliary agent, the total fraction of main material is 100 parts, including: propylene-based elastomer 40~70 parts, ultra-high melt strength polypropylene 5~15 parts, organic silicon copolymer 20~40 parts;Other auxiliary agent is 5~15 parts;Wherein, the organic silicon copolymer has the silane component with greater than or equal to 90% weight ratio.The artificial leather of the present application can meet the basic mechanical properties of automobile interior, increase softness to improve interior comfort, and is environment-friendly and recyclable.

Description

Technical Field

[0001] This invention relates to the field of artificial leather technology, and more particularly to a recyclable resin substrate for artificial leather, recyclable artificial leather and its preparation method, automobile seats, and automobiles. Background Technology

[0002] Artificial leather, as a substitute for genuine leather, is increasingly widely used, especially as a surface covering material for automotive interiors, such as seats, door panels, armrests, headrests, and soft-touch materials for the center console. Traditional artificial leather is mainly made of polyvinyl chloride (PVC), which, through the use of plasticizers, can reduce material hardness, increase flexibility and low-temperature resistance, basically meeting the general requirements of interior decoration. Moreover, it is inexpensive, hence the widespread use of PVC artificial leather in the market.

[0003] As people's demands for comfort and performance in automotive interiors increase, PVC artificial leather can no longer meet user needs in terms of softness, and the plasticizers in PVC artificial leather are prone to migration, which is also detrimental to health. To meet higher comfort requirements, some interiors use PU artificial leather, which improves softness to some extent. However, PU artificial leather has hydrolysis problems, and the negative effects of hydrolysis affect the product's lifespan. Moreover, PU is generally a thermosetting material, which cannot be recycled by heating and melting, posing a potential negative impact on the environment. Some existing technologies also use TPO artificial leather, such as patent CN112895668B. Its softness is not much different from PU artificial leather and can basically meet the requirements of artificial leather for automotive interiors. However, the thermoplastic nature of this material means that its high-temperature resistance is insufficient. It needs to be cross-linked with peroxides to form a network structure to improve the material's temperature resistance. However, peroxides are not friendly to health and the environment, and the TPV material used in large quantities also limits its recycling application due to its own cross-linking and partial oil filling characteristics.

[0004] Therefore, it is imperative to provide a type of artificial leather that can meet the basic mechanical performance requirements of automotive interiors, increase softness to improve interior comfort, and is environmentally friendly and recyclable. Summary of the Invention

[0005] Based on the above situation, the main objective of this invention is to provide a recyclable resin substrate for artificial leather, recyclable artificial leather and its preparation method, car seats, and automobiles, which can not only meet the basic mechanical properties of automobile interiors, but also increase softness to improve interior comfort, and are environmentally friendly and recyclable.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] A first aspect of the present invention provides a recyclable synthetic leather comprising a surface treatment agent layer, a dense layer, and a base fabric layer stacked sequentially, wherein the dense layer is made of a dense layer preform comprising a main ingredient and other additives.

[0008] The total number of the main material is 100 parts, including: 40-70 parts of propylene-based elastomer, 5-15 parts of ultra-high melt strength polypropylene, and 20-40 parts of organosilicon copolymer.

[0009] The other adjuvants are 5 to 15 parts;

[0010] The organosilicon copolymer contains silane components at a weight ratio greater than or equal to 90%.

[0011] Preferably, the propylene-based elastomer is a propylene-ethylene copolymer with a Shore A hardness in the range of 50A to 70A.

[0012] Preferably, the ultra-high melt strength polypropylene has a melting point of 170℃~190℃.

[0013] Preferably, the other additives include at least one of compatibilizers, stabilizers, lubricants, and color masterbatches.

[0014] Preferably, the material further includes an adhesive layer, wherein the dense layer and the base fabric layer are bonded together by the adhesive layer, and the adhesive layer is a high-temperature resistant hot melt adhesive.

[0015] A second aspect of the present invention provides a method for preparing recyclable artificial leather, comprising the steps of:

[0016] S10: A dense layer is formed using a dense layer preform material via calendering; wherein the dense layer preform material comprises: 40-70 parts of propylene-based elastomer, 5-15 parts of ultra-high melt strength polypropylene, 20-40 parts of organosilicon copolymer, and 5-15 parts of other additives; wherein the organosilicon copolymer has a silane content greater than or equal to 90% by weight; in the film-formed dense layer, the weight ratio of the ultra-high melt strength polypropylene to the total weight of the propylene-based elastomer and the organosilicon copolymer is 0.04-0.25, and the weight ratio of the organosilicon copolymer to the propylene-based elastomer is 0.25-0.75;

[0017] S20: The dense layer is combined with the base fabric layer to obtain a semi-finished product;

[0018] S30: A surface treatment agent is printed on the surface of the semi-finished product to form a surface treatment agent layer, and then embossed to obtain the finished artificial leather product.

[0019] Preferably, in step S10, the dense layer preform is melt-blended in an internal mixer, and then sequentially passed through a two-roll open mill, an extruder for filtration, and a four-roll press to obtain the dense layer; wherein the internal mixer temperature is 190℃~220℃, the open mill temperature is 180℃~200℃, the extruder temperature is 200℃~220℃, and the four-roll temperature is 175℃~230℃.

[0020] A third aspect of the present invention provides a recyclable resin substrate for artificial leather, said resin substrate being made from a resin substrate preform comprising:

[0021] 40-70 parts of propylene-based elastomer, 5-15 parts of ultra-high melt strength polypropylene, 20-40 parts of organosilicon copolymer, and 5-15 parts of other additives;

[0022] The organosilicon copolymer contains silane components at a weight ratio greater than or equal to 90%; in the dense layer of the film, the weight ratio of the ultra-high melt strength polypropylene to the total weight of the propylene-based elastomer and the organosilicon copolymer is 0.04 to 0.25, and the weight ratio of the organosilicon copolymer to the propylene-based elastomer is 0.25 to 0.75.

[0023] A fourth aspect of the present invention provides an automobile seat comprising the artificial leather described in any of the preceding claims or artificial leather obtained by any of the preceding claims preparation methods.

[0024] A fifth aspect of the present invention provides an automobile, including an automobile interior, the automobile interior including the automobile seat, the automobile seat comprising the artificial leather described in any of the preceding claims or the artificial leather obtained by the preparation method described in any of the preceding claims.

[0025] In the artificial leather of this invention, the dense layer, through the use of propylene-based elastomers and organosilicon copolymers, significantly improves its softness, achieving or even exceeding the flexibility of traditional PVC artificial leather. Furthermore, the high silane content greatly improves the low-temperature resistance of the dense layer. Simultaneously, the use of ultra-high melt strength polypropylene gives the dense layer excellent heat resistance, acting as a skeletal structure within the dense layer, providing a strong framework, especially in high-temperature environments. This provides excellent support for maintaining the artificial leather's pattern, avoiding the need for peroxides in traditional TPO artificial leather to address the insufficient high-temperature resistance of materials like TPV, while simultaneously improving the high-temperature resistance of the artificial leather. In summary, the artificial leather of this invention achieves or even surpasses the mechanical properties of traditional PVC, PU, ​​and TPO artificial leather, meeting the requirements for artificial leather in automotive interiors.

[0026] Furthermore, since this invention avoids the potential leaching of small molecules such as plasticizers in traditional PVC dense layers and white oil in TPE materials, it is more health-friendly. Moreover, by using ultra-high melt strength polypropylene, the dense layer can have excellent heat resistance, thereby avoiding the use of peroxides and making the resulting dense layer even healthier.

[0027] Meanwhile, the dense layer does not contain non-environmentally friendly substances such as small molecule plasticizers, so it will not cause water pollution or other problems. Furthermore, the dense layer in this application can be recycled and reused through crushing and granulation. Therefore, the dense layer in this application is more environmentally friendly and has good recyclability. After molding the artificial leather, since the thickness of the surface treatment agent layer is negligible, it can still greatly improve the recyclability and environmental friendliness of the artificial leather compared to artificial leather made from traditional PVC or TPV materials.

[0028] Other beneficial effects of the present invention will be explained in detail through the introduction of specific technical features and technical solutions in specific embodiments. Those skilled in the art should be able to understand the beneficial technical effects brought about by these technical features and technical solutions through the introduction of these technical features and technical solutions. Attached Figure Description

[0029] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. In the drawings:

[0030] Figure 1 A schematic diagram of a preferred embodiment of the recyclable artificial leather provided by the present invention;

[0031] Figure 2 A flowchart illustrating a preferred embodiment of the method for preparing recyclable artificial leather provided by the present invention.

[0032] In the picture:

[0033] 100. Surface treatment agent layer; 200. Dense layer; 300. Base fabric layer. Detailed Implementation

[0034] The present invention is described below based on embodiments, but the present invention is not limited to these embodiments. In the following detailed description of the present invention, some specific details are described in detail, but well-known methods, processes, procedures, and elements are not described in detail in order to avoid obscuring the essence of the present invention.

[0035] Furthermore, those skilled in the art should understand that the accompanying drawings provided herein are for illustrative purposes only and are not necessarily drawn to scale.

[0036] Unless the context explicitly requires it, the words "comprising," "including," and similar terms throughout the specification and claims should be interpreted as encompassing rather than being exclusive or exhaustive; that is, meaning "including but not limited to."

[0037] In the description of this invention, it should be understood that the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, in the description of this invention, unless otherwise stated, "a plurality of" means two or more. The number of parts of each component mentioned herein refers to parts by weight.

[0038] This invention provides a recyclable artificial leather that can be used in various scenarios, such as automotive interiors. Figure 1 As shown, the artificial leather comprises a surface treatment agent layer 100, a dense layer 200, and a base fabric layer 300, which are sequentially stacked. The surface treatment agent layer 100 is made of a surface treatment agent, and the dense layer 200 is made of a dense layer preform. The dense layer preform includes a main material and other additives. The main material comprises 100 parts, including: 40-70 parts of acrylic elastomer, 5-15 parts of ultra-high melt strength polypropylene (HMSPP), and 20-40 parts of silicone copolymer; the other additives comprise 5-15 parts. Specifically, propylene-based elastomers, ultra-high melt strength polypropylene, silicone copolymers, and other additives can be selected according to their respective weight ranges as described above. For example, propylene-based elastomers can be selected in amounts of 40, 50, 60, 65, or 70 parts, ultra-high melt strength polypropylene can be selected in amounts of 5, 7, 10, 12, 13, or 15 parts, silicone copolymers can be selected in amounts of 20, 25, 30, 35, or 40 parts, and other additives can be selected in amounts of 5, 7, 10, 12, 13, or 15 parts.

[0039] Regardless of the specific composition of the propylene-based elastomer, ultra-high melt strength polypropylene (HMSPP), and silicone copolymer, the total weight of these components must be 100 parts. Specifically, the propylene-based elastomer must comprise 40%–70% of the main material, HMSPP 5%–15%, and the silicone copolymer 20%–40%. When the total main material weight is 100 parts, other additives can be selected in quantities of 5–15 parts. Furthermore, the silicone copolymer must contain 90% or more silane by weight, such as 90%, 92%, 93%, 94%, 95%, 96%, or 97%.

[0040] In the artificial leather of this invention, the dense layer 200, through the use of propylene-based elastomer and silicone copolymer, and the setting of the weight ratio of propylene-based elastomer, ultra-high melt strength polypropylene, and silicone copolymer, greatly improves the softness of the dense layer 200. In terms of flexibility, it can reach or even exceed that of traditional PVC artificial leather. It avoids the problem of artificial leather becoming too soft due to an excessively high weight ratio of silicone copolymer, and the reduced dyne value affecting the adhesion of the surface treatment layer. It also avoids the problem of artificial leather feeling too hard due to an excessively high weight ratio of ultra-high melt strength polypropylene. This invention significantly improves the low-temperature resistance of the dense layer through a high content of silane; simultaneously, the use of ultra-high melt strength polypropylene gives the dense layer excellent heat resistance, which can act as a skeletal structure within the dense layer, providing a strong skeleton, especially in high-temperature environments. This provides good support for maintaining the pattern of the artificial leather, thus endowing the artificial leather with high-temperature resistance. In summary, the artificial leather of this invention achieves or even exceeds the mechanical properties of traditional PVC artificial leather, PU artificial leather, and TPO artificial leather, meeting the requirements for artificial leather in automotive interiors.

[0041] Furthermore, the artificial leather of this invention primarily uses propylene-based elastomers and silicone copolymers, which provide excellent flexibility and eliminate the need for additional traditional plasticizers. Therefore, it avoids the potential leaching of small molecules such as large amounts of plasticizers found in the dense layer of traditional PVC and white oils found in TPE materials, making it more health-friendly. Moreover, because ultra-high melt strength polypropylene imparts excellent heat resistance to the artificial leather, it eliminates the need for peroxides, as is required in traditional TPO artificial leather to address the insufficient high-temperature resistance of materials like TPV. This results in a healthier dense layer and the final artificial leather.

[0042] Meanwhile, the dense layer of this invention does not contain non-environmentally friendly substances such as small-molecule plasticizers found in traditional artificial leather, and therefore will not cause water pollution or other problems. Furthermore, the dense layer in this application can be recycled and reused through crushing and granulation, resulting in good recyclability and greater environmental friendliness. In the artificial leather prepared, since the thickness of the surface treatment agent layer is negligible, it can significantly improve recyclability and environmental friendliness compared to artificial leather prepared from traditional PVC or TPV materials.

[0043] In the dense layer preform, the propylene-based elastomer is a propylene-ethylene copolymer with a Shore A hardness between 50A and 70A. Preferably, the propylene-based elastomer has a Shore A hardness of 50A, 55A, 60A, 65A, or 70A to optimize the flexibility of the prepared dense layer 200 and the artificial leather, avoiding both excessively high Shore A hardness leading to a stiff artificial leather and excessively low Shore A hardness leading to a soft artificial leather. Of course, within this range, readily available commercially available propylene-based elastomers can be selected as needed, such as those from ExxonMobil-Vitamax.

[0044] In one embodiment, the ultra-high melt strength polypropylene has a melting point of 170°C to 190°C, such as 170°C, 175°C, 180°C, 185°C, or 190°C. Using ultra-high melt strength polypropylene within this melting point range provides superior heat resistance, thereby better ensuring the skeletal structure in high-temperature environments. Of course, within this range, readily available commercially available ultra-high melt strength polypropylene, such as that from ExxonMobil, can be selected as needed.

[0045] Other additives mentioned above may be added as needed, and may include at least one of compatibilizers, stabilizers, lubricants and color masterbatches, or may include only compatibilizers, stabilizers, lubricants or color masterbatches.

[0046] In the above embodiments, the weight percentage of organosilicon in the surface treatment agent layer 100 is more than 60%, such as 60%, 62%, 64%, 65%, 66%, 68%, 70%, 73%, 75%, 78%, or 80% of the weight of organosilicon. The high weight percentage of organosilicon can increase the flexibility of artificial leather and give the surface of artificial leather a silicone feel, thereby greatly improving the feel of artificial leather.

[0047] Specifically, the surface treatment agent layer 100 is prepared by a surface treatment agent, the main component of which is an organosilicon modified dispersion. In a preferred embodiment, the solid content of the organosilicon modified aqueous dispersion is 30% to 50%, such as 30%, 35%, 40%, 45%, or 50%. By selecting an organosilicon modified aqueous dispersion with this solid content, the organosilicon weight percentage of the film-forming surface treatment agent layer can be better achieved to reach 60% to 70%, and the organosilicon modified aqueous dispersion with this solid content is easy to purchase, which can reduce costs.

[0048] The surface treatment agent also contains a small amount of hollow glass microspheres, which can increase the smoothness of the artificial leather surface and improve the feel of the artificial leather.

[0049] In one embodiment, the surface treatment agent includes: 100 parts of organosilicon-modified aqueous dispersion, 2-8 parts of high molecular weight polydimethylsiloxane raw material, 2-10 parts of hollow glass microspheres, 2-5 parts of crosslinking agent, 0.1-1 parts of leveling agent, 0.1-1 parts of defoamer, and 0.1-2 parts of thickener. In other words, in the surface treatment agent, when the weight of the organosilicon-modified aqueous dispersion is 100 parts, the weight of the high molecular weight polydimethylsiloxane raw material can be 2 parts, 3 parts, 4 parts, 5 parts, 6 parts, 7 parts, or 8 parts, etc.; the weight of the hollow glass microspheres can be 2 parts, 3 parts, 5 parts, 6 parts, 8 parts, 9 parts, or 10 parts, etc.; the weight of the crosslinking agent can be 2 parts, 3 parts, 4 parts, or 5 parts, etc.; the weight of the leveling agent can be 0.1 parts, 0.3 parts, 0.5 parts, 0.7 parts, 0.9 parts, or 1 part, etc.; the weight of the defoamer can be 0.1 parts, 0.3 parts, 0.5 parts, 0.7 parts, 0.9 parts, or 1 part, etc.; and the weight of the thickener can be 0.1 parts, 0.3 parts, 0.5 parts, 0.7 parts, 0.9 parts, 1 part, 1.3 parts, 1.5 parts, 1.7 parts, 1.9 parts, or 2 parts, etc. In this embodiment, the weight percentage of organosilicon in the treated agent layer after film formation reaches 60%, 62%, 64%, 65%, 66%, 68%, 70%, 73%, 75%, 78%, or 80%, etc. Using the formulation of this embodiment, the artificial leather can have a smooth silicone feel, and by using a certain amount of high molecular weight polydimethylsiloxane raw material, the silicone feel and abrasion resistance of the artificial leather can be optimized.

[0050] The high molecular weight polydimethylsiloxane raw material is a mixture, comprising water-based silicone oil and high molecular weight polydimethylsiloxane, wherein the solid content of the mixture is greater than or equal to 80%, and the viscosity is 350,000 cs to 600,000 cs. For example, the solid content of the mixture may be 80, 82, 85, 88, 90, 93, or 95, and the viscosity of the mixture may be 350,000, 380,000, 400,000, 450,000, 500,000, 550,000, or 600,000, etc. The solid content and viscosity can be any combination of the values ​​in the examples above. That is, the solid content and viscosity of the mixture can be any combination of the values ​​in the ranges above. The solids in the mixture are mainly organosilicon components. Using the above solid content and range can increase the content of organosilicon in the surface treatment agent, improve the silicone feel of the prepared artificial leather, and increase the adhesion between the surface treatment agent layer and the dense layer. This makes the distribution of each component in the surface treatment agent more uniform on the surface of the dense layer, and improves the smooth feel of the artificial leather surface.

[0051] In a preferred embodiment, the main component of the hollow glass microspheres is sodium-calcium borosilicate glass, with a particle size of 200 μm to 500 μm and a density of 0.2 g / cc to 0.7 g / cc. For example, the particle sizes of the hollow glass microspheres are 200 μm, 230 μm, 250 μm, 280 μm, 300 μm, 320 μm, 350 μm, 380 μm, 400 μm, 420 μm, 450 μm, 480 μm, or 500 μm, etc., and the densities are 0.2 g / cc, 0.3 g / cc, 0.4 g / cc, 0.5 g / cc, 0.6 g / cc, or 0.7 g / cc, etc. Using hollow glass microspheres within this range allows the surface treatment agent to better encapsulate the microspheres, thereby maintaining the mechanical properties of the formed surface treatment agent layer.

[0052] In the above embodiments, the base fabric layer 300 can be a four-way stretch base fabric with a thickness of 0.6cm to 0.8cm, such as 0.6cm, 0.65cm, 0.7cm, 0.75cm, or 0.8cm, to better increase the flexibility of the artificial leather. Specifically, the base fabric layer 300 can be selected from readily available knitted fabrics within this range as needed.

[0053] The base fabric layer 300 and the dense layer 200 can be directly bonded together by hot pressing. In a preferred embodiment, the artificial leather also includes an adhesive layer, and the dense layer 200 and the base fabric layer 300 are bonded together by the adhesive layer. The adhesive layer is a high-temperature resistant hot melt adhesive, which can be a commercially available high-temperature resistant hot melt adhesive.

[0054] This invention also provides a method for preparing recyclable artificial leather, such as... Figure 2 As shown, the steps include:

[0055] S10: A dense layer 200 is formed using a dense layer preform material by calendering; wherein the composition of the dense layer preform material is as described above;

[0056] S20: Composite the dense layer 200 with the base fabric layer 300 to obtain a semi-finished product;

[0057] S30: A surface treatment agent is printed on the surface of the semi-finished product to form a surface treatment agent layer 100, and then embossed to obtain the finished artificial leather product. Specifically, the surface treatment agent is printed on the side of the dense layer 200 of the semi-finished product facing away from the base fabric 300 to form the surface treatment agent layer 100. The components of the dense layer preform and the surface treatment agent are as described in the previous embodiments, and will not be repeated here.

[0058] Specifically, the dense layer preform and the surface treatment agent can be prepared in advance before steps S10 to S30, or the dense layer preform can be prepared before step S10, and the surface treatment agent can be prepared before or after any step before step S30, such as after step S20 and before step S30.

[0059] In this invention, considering that the components in the dense layer preform are mainly granular solids, it is preferable to use a calendering method to form the dense layer 200. Moreover, by using a calendering method, release paper is not used in the production process, and the recycling of release paper can also be avoided. The production process also has better recyclability and environmental friendliness, thereby increasing the environmental friendliness of artificial leather from the production process.

[0060] In one embodiment, in step S10, the dense layer preform is melt-blended in an internal mixer. The components in the dense layer preform are mixed in the internal mixer according to the above-mentioned weight parts. Then, the mixture is sequentially passed through a two-roll mill, filtered by an extruder, and rolled into a thin sheet by a four-roll mill to obtain a dense layer 200, thereby making the thickness of the dense layer more uniform. The internal mixer temperature is 190℃~220℃, the open mill temperature is 180℃~200℃, the extruder temperature is 200℃~220℃, and the four-roll temperature is 175℃~230℃. For example, the internal mixer temperature can be 190℃, 195℃, 200℃, 205℃, 210℃, 215℃, or 220℃, the open mill temperature can be 180℃, 185℃, 190℃, 195℃, or 200℃, the extruder temperature can be 200℃, 205℃, 210℃, 215℃, or 220℃, and the four-roll temperature can be 175℃, 180℃, 190℃, 200℃, 210℃, 220℃, 225℃, or 230℃.

[0061] In step S20, the base fabric layer 300, the adhesive layer and the dense layer 200 are laminated by a composite roller, and then a semi-finished product is obtained after passing through a cooling roller.

[0062] In step S30, a surface treatment agent is printed onto the surface of the semi-finished product using gravure printing. After drying, a surface treatment agent layer is obtained, followed by high-temperature printing to obtain the finished artificial leather product. Preferably, the drying temperature is 110℃, 115℃, 120℃, 125℃, or 130℃, etc.

[0063] The surface treatment agent can be obtained by mechanical stirring according to the weight parts of each raw material. The mechanical stirring speed is 1000 rpm to 1500 rpm, the stirring time is 40 min to 60 min, and the drying temperature is 110℃ to 130℃. For example, the mechanical stirring speed can be 1000 rpm, 1100 rpm, 1200 rpm, 1300 rpm, 1400 rpm, or 1500 rpm, and the stirring time can be 40 min, 45 min, 50 min, 55 min, or 60 min, etc.

[0064] The present invention also provides a recyclable resin substrate for artificial leather, which can serve as a dense layer of artificial leather. It is made from a resin substrate preform, the composition of which is the same as that of the dense layer preform in any of the foregoing embodiments, and will not be repeated here.

[0065] The present invention also provides a car seat comprising the recyclable artificial leather described in any of the above embodiments. Using such a car seat is more health- and environmentally friendly, and the seat has a better feel, which can enhance the user experience.

[0066] The present invention also provides an automobile, including an automobile interior, such as the automobile seat described above. The automobile interior may also include soft-touch materials for the automobile center console, etc., wherein, regardless of the type of automobile interior, it includes the recyclable artificial leather described in any of the above embodiments.

[0067] Several specific embodiments of the artificial leather of the present invention are given below, along with some comparative examples.

[0068] Example 1

[0069] S10: A dense layer 200 is formed by calendering using a dense layer preform material; wherein the dense layer preform material includes: 60 parts of propylene-based elastomer, 5 parts of ultra-high melt strength polypropylene, 35 parts of organosilicon copolymer, and 10 parts of other additives.

[0070] S20: Composite the dense layer 200 with the base fabric layer 300 to obtain a semi-finished product;

[0071] S30: A surface treatment agent is printed on the surface of the semi-finished product to form a surface treatment agent layer 100, and then embossed to obtain the finished artificial leather product. Specifically, a surface treatment agent is printed on the side of the dense layer 200 of the semi-finished product that is away from the base fabric 300 to form a surface treatment agent layer 100.

[0072] Example 2

[0073] Unlike Example 1, the composition of the dense layer preform is different. In Example 2, the composition of the dense layer preform includes 70 parts of propylene-based elastomer, 5 parts of ultra-high melt strength polypropylene, 25 parts of organosilicon copolymer, and 10 parts of other additives.

[0074] Example 3

[0075] Unlike Example 1, the dense layer preform of Example 3 consists of 60 parts of propylene-based elastomer, 15 parts of ultra-high melt strength polypropylene, 25 parts of organosilicon copolymer, and 10 parts of other additives.

[0076] Comparative Example 1

[0077] Unlike Example 1, the composition of the dense layer preform is different. In Comparative Example 1, the composition of the dense layer preform includes 25 parts of propylene-based elastomer, 5 parts of ultra-high melt strength polypropylene, 70 parts of organosilicon copolymer, and 10 parts of other additives.

[0078] Comparative Example 2

[0079] Unlike Example 1, the composition of the dense layer preform is different. The composition of the dense layer preform in Example 2 is compared, which includes 45 parts of propylene-based elastomer, 30 parts of ultra-high melt strength polypropylene, 25 parts of organosilicon copolymer, and 10 parts of other additives.

[0080] Comparative Example 3

[0081] Comparative Example 3 is a commercially available PVC artificial leather, comprising a surface treatment agent layer, a dense layer, a foaming layer, an adhesive layer, and a base fabric layer stacked sequentially. The main components of the dense layer are PVC resin and phthalic plasticizers, with a weight ratio typically of 100:70 to 100:100. The main components of the foaming layer are PVC resin, phthalic plasticizers, and foaming agents, with a weight ratio typically of 100:70:0.1 to 100:100:5. The main components of the adhesive layer are PVC resin and phthalic plasticizers, with a weight ratio typically of 100:40 to 100:80.

[0082] Performance tests were conducted on the artificial leathers of the above embodiments and comparative examples. The test results are shown in Table 1. The stiffness-softness evaluation was based on GMW. The hardness was tested using method 3390, with higher test values ​​indicating higher hardness. Taber abrasion resistance was evaluated using method GMW3208. The artificial leather from the above examples and comparative examples was cut to the same size and placed on a Taber abrasion tester for testing. Specifically, 1 kg of material was used for 4000 rubs, and the samples were rated, with a maximum rating of 5. Bending resistance was evaluated according to ISO 5402. The artificial leather from the above examples and comparative examples was cut to the same size and placed on a flexural endurance tester at room temperature for testing. Specifically, it was bent 100,000 times, and the samples were rated, with a maximum rating of 5. Low-temperature resistance was evaluated according to ISO 5402. The artificial leather from the above examples and comparative examples was cut to the same size and placed on a flexural endurance tester at -20°C for testing. Specifically, it was bent 30,000 times, and the samples were rated, with a maximum rating of 5.

[0083] Table 1

[0084]

[0085] The test data above show that Examples 1 to 3 exhibit excellent performance in terms of rigidity, abrasion resistance, flexural strength, and low-temperature resistance. Although Comparative Example 1 is softer, its dense layer contains a large proportion of organosilicon copolymer, which has low strength and a relatively low dyne value. This results in decreased adhesion of the surface treatment agent layer and extremely poor abrasion resistance, failing to meet the abrasion resistance requirements. Comparative Example 2 has a large proportion of HMSPP, resulting in a noticeably harder feel, similar to general PVC artificial leather. The increased HMSPP content also enhances the material's rigidity, leading to a sharp decrease in flexural strength. Cracks appear on the surface after bending at room temperature, and the dense layer shows obvious cracking after bending at low temperature. Although Comparative Example 3 has good surface performance in terms of abrasion resistance, flexural strength, and low-temperature resistance, its hardness is too high, and it is less health- and environmentally friendly than Examples 1 to 3.

[0086] It should be noted that the use of step numbers (letters or numbers) to refer to certain specific method steps in this invention is merely for the purpose of convenience and brevity in description, and is by no means intended to restrict the order of these method steps. Those skilled in the art will understand that the order of the relevant method steps should be determined by the technology itself and should not be unduly restricted by the existence of step numbers. Those skilled in the art can determine various permissible and reasonable orderings of steps based on the technology itself.

[0087] It is particularly important to emphasize that the specific numerical selection of the various parameters involved in this invention requires not only a theoretical foundation far exceeding that of those skilled in the art, but also creative experimentation and selection based on the expected design results, supplemented by several arduous trials, before the desired target results can be obtained. The determination of these values ​​cannot be achieved by those skilled in the art without creative effort.

[0088] Those skilled in the art will understand that, without conflict, the above-mentioned preferred solutions can be freely combined and superimposed.

[0089] It should be understood that the above embodiments are merely exemplary and not restrictive. Various obvious or equivalent modifications or substitutions that can be made by those skilled in the art regarding the above details without departing from the basic principles of the present invention will be included within the scope of the claims of the present invention.

Claims

1. A recyclable artificial leather, characterized in that, It comprises a surface treatment agent layer, a dense layer, and a base fabric layer stacked sequentially. The dense layer is made of a dense layer preform, which includes a main ingredient and other additives. The total number of the main material is 100 parts, including: 40-70 parts of propylene-based elastomer, 5-15 parts of ultra-high melt strength polypropylene, and 20-40 parts of organosilicon copolymer. The other adjuvants are 5 to 15 parts; The organosilicon copolymer contains silane components at a weight ratio greater than or equal to 90%.

2. The artificial leather according to claim 1, characterized in that, The propylene-based elastomer is a propylene-ethylene copolymer with a Shore A hardness in the range of 50A to 70A.

3. The artificial leather according to claim 1, characterized by, The ultra-high melt strength polypropylene has a melting point of 170℃~190℃.

4. The artificial leather according to claim 1, characterized by, The other additives include at least one of compatibilizers, stabilizers, lubricants, and color masterbatches.

5. The artificial leather according to claim 1, wherein It also includes an adhesive layer, wherein the dense layer and the base fabric layer are bonded together by the adhesive layer, and the adhesive layer is a high-temperature resistant hot melt adhesive.

6. A method for preparing recyclable artificial leather, characterized in that, Including the following steps: S10: A dense layer is formed using a dense layer preform material via calendering; wherein the dense layer preform material comprises: 40-70 parts of propylene-based elastomer, 5-15 parts of ultra-high melt strength polypropylene, 20-40 parts of organosilicon copolymer, and 5-15 parts of other additives; wherein the organosilicon copolymer has a silane content greater than or equal to 90% by weight; in the film-formed dense layer, the weight ratio of the ultra-high melt strength polypropylene to the total weight of the propylene-based elastomer and the organosilicon copolymer is 0.04-0.25, and the weight ratio of the organosilicon copolymer to the propylene-based elastomer is 0.25-0.75; S20: The dense layer is combined with the base fabric layer to obtain a semi-finished product; S30: A surface treatment agent is printed on the surface of the semi-finished product to form a surface treatment agent layer, and then embossed to obtain the finished artificial leather product.

7. The preparation method according to claim 6, characterized in that, In step S10, the dense layer preform is melt-blended in an internal mixer, and then sequentially passed through a two-roll mill, an extruder for filtration, and a four-roll mill for thinning to obtain the dense layer; wherein the internal mixer temperature is 190℃~220℃, the two-roll mill temperature is 180℃~200℃, the extruder temperature is 200℃~220℃, and the four-roll temperature is 175℃~230℃.

8. A recyclable resin substrate for artificial leather, characterized by, The resin substrate is made from a resin substrate preform, which includes the main material and other additives. The total number of the main material is 100 parts, including: 40-70 parts of propylene-based elastomer, 5-15 parts of ultra-high melt strength polypropylene, and 20-40 parts of organosilicon copolymer. The other adjuvants are 5 to 15 parts; The organosilicon copolymer contains silane components at a weight ratio greater than or equal to 90%.

9. An automobile seat characterized by comprising: The car seat comprises the artificial leather as described in any one of claims 1-5 or the artificial leather obtained by the preparation method described in any one of claims 6-7.

10. A car, characterized in that, The invention includes automotive interiors, which include automotive seats, and the automotive seats include artificial leather as described in any one of claims 1-5 or artificial leather obtained by the preparation method described in any one of claims 6-7.

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