Artificial Leather Sheet Composition for Wear and Oil Resistance
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Solution Overview
Problem
Existing artificial leather sheets produced with polyvinyl chloride or polyolefin lack wear resistance, oil resistance, flame retardant properties, and tend to lose embossing patterns, necessitating the development of a material with enhanced stability and embossing retention.
Innovation Solution
A sheet composition comprising a polystyrene-based copolymer and an ethylene vinyl acetate-based copolymer with vinyl acetate content exceeding 50 wt%, combined with optional additives like flame retardants and photostabilizers, which is embossed and laminated with a base and surface primer layers to achieve superior wear, oil, and aging resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyvinyl chloride or polyolefin is used for producing artificial leather, then the material can be manufactured with standard processes, but the sheet has poor wear resistance, poor oil resistance, poor flame retardant properties, and the embossing surface can be broken
Solution Approach 1:
The invention uses a composite material system consisting of polyolefin resin as the base material and polyvinyl acetate resin as a functional additive. This composite approach allows the sheet to inherit the good processability and chemical resistance of polyolefin while gaining enhanced wear resistance, oil resistance, and embossing retention from the polyvinyl acetate component. The specific formulation (0.1-10 parts polyvinyl acetate per 100 parts polyolefin) creates a synergistic effect that improves multiple properties simultaneously without requiring complete process redesign.
Solution Approach 2:
The invention modifies the chemical composition parameters of the sheet by controlling the type and amount of polyvinyl acetate resin added to the polyolefin matrix. By adjusting the vinyl acetate content (5-40% by weight) and the ratio of polyvinyl acetate to polyolefin, the sheet's wear resistance, oil resistance, and embossing retention can be optimized. This parameter adjustment allows achieving high reliability while maintaining compatibility with existing manufacturing processes.
2Reliability
If painting process is performed on the surface of the sheet to improve properties, then surface properties can be enhanced, but energy consumption increases due to hot air drying and overall cost increases
Solution Approach 1:
The invention incorporates the polyvinyl acetate resin into the sheet material during the extrusion or molding process, before the sheet is formed. This preliminary incorporation ensures that the functional properties (wear resistance, oil resistance) are built into the material itself rather than being applied later through painting and drying processes. The resin distributes uniformly in the matrix during manufacturing, eliminating the need for subsequent energy-intensive drying operations.
Solution Approach 2:
The sheet material provides its own surface protection properties through the integrated polyvinyl acetate resin, eliminating the need for external painting processes. The resin naturally migrates to the surface during processing and forms a protective layer that provides wear and oil resistance intrinsically, allowing the sheet to serve its own functional needs without additional coating steps.
3Reliability
If painting process is performed on the sheet surface, then surface properties can be improved, but Volatile Organic Compound (VOC) is generated causing environmental pollution
Solution Approach 1:
The invention converts the potential harm of using additional chemical coatings (which would generate VOCs) into a benefit by integrating the functional resin directly into the sheet material during manufacturing. The polyvinyl acetate resin is incorporated in a controlled manner during extrusion or molding, where it bonds with the polyolefin matrix without requiring volatile solvents or subsequent drying that would release VOCs. This transforms what would be a harmful emission source into a clean, integrated material solution.
Data Source
AI summary
The present invention relates to a sheet composition containing at least one of either a polystyrene-based copolymer or an methylene vinyl acetate-based copolymer, to a sheet produced from the same, to a laminated sheet containing the sheet, and to a composite sheet containing the laminated sheet. The sheet according to the present invention is provided with a high functional stability including wear resistance, oil resistance, and aging resistance, and superior embossing retention characteristics.