Bio-Based Artificial Leather and Method
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Solution Overview
Problem
The production of artificial leather using petroleum-derived polymers is unsustainable and faces environmental scrutiny, while conventional synthetic leathers fail to meet sustainability objectives, and there is a growing demand for bio-based materials that replicate the properties of natural leather.
Innovation Solution
A bio-based artificial leather composition comprising a base layer of polymerized epoxidized vegetable oil, a foam layer also made from epoxidized vegetable oil, and a fabric layer, preferably cotton, using anhydrides like dodecenyl succinic anhydride for curing, and a method involving polymerization and foaming processes to create a flexible and durable leather substitute.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If petroleum-derived polymers (PVA, PU) are used to produce artificial leather, then mechanical and functional performance can be achieved, but environmental sustainability is compromised
Solution Approach 1:
The patent changes the chemical composition parameters by replacing petroleum-derived polymers with epoxidized vegetable oils as the base material. This substitution maintains the functional performance of artificial leather while eliminating dependence on non-renewable resources and reducing environmental harm associated with petroleum extraction and processing
Solution Approach 2:
The invention creates a composite material system combining epoxidized vegetable oil, anhydride curing agents, and foam agents to produce artificial leather. This composite approach integrates multiple bio-based components to achieve the mechanical properties previously only attainable with synthetic polymers, thereby resolving the contradiction between performance and sustainability
2Productivity
If conventional synthetic leather is produced using petroleum polymers, then production efficiency is maintained, but sustainability objectives are not met
Solution Approach 1:
The patent modifies the material parameters by using epoxidized vegetable oils that can be processed through established polymerization and foaming techniques. This allows the bio-based material to be produced using conventional manufacturing infrastructure and processes, maintaining productivity while achieving sustainability goals
3Object-affected harmful factors
If bio-based materials are used to create sustainable artificial leather, then environmental impact is reduced, but replicating natural leather properties becomes more difficult
Solution Approach 1:
The invention develops a multi-component composite system where epoxidized vegetable oil provides the base polymer matrix, anhydrides enable crosslinking for enhanced mechanical strength, and foam agents create the characteristic porous structure. This composite approach allows bio-based materials to replicate the complex properties of natural leather including flexibility, porosity, and durability
Solution Approach 2:
The patent applies different functional components to different regions of the artificial leather structure. The epoxidized vegetable oil forms the continuous matrix providing baseline properties, while the foam phase creates localized porous regions for breathability, and the crosslinked network provides localized strength enhancement, collectively replicating natural leather's heterogeneous structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The bio-based artificial leather achieves mechanical and functional performance comparable to natural leather, with improved sustainability and reduced environmental impact, offering flexibility, durability, and eco-friendly production.
Implementation Method 1
a base layer having a first polymerized epoxidized vegetable oil
Implementation Method 2
the epoxidized cottonseed oil is cured with an anhydride, such as dodecenyl succinic anhydride (DDSA)
Implementation Method 3
curing the second epoxidized vegetable oil with an anhydride and foaming agent to form a foam layer
Data Source
AI summary
There is disclosed a bio-based artificial leather composition, which includes a base layer having a first polymerized epoxidized vegetable oil. The composition also includes a foam layer attached to the base layer and having a second polymerized epoxidized vegetable oil. The bio-based artificial leather also includes a fabric layer attached to the foam layer. There is also disclosed a method of preparing a bio-based artificial leather composition including the step of providing a first epoxidized vegetable oil and polymerizing the epoxidized vegetable oil to form a base layer. The method also includes the step of providing a second epoxidized vegetable oil and curing the second epoxidized vegetable oil with an anhydride and foaming agent to form a foam layer. The base layer is attached to the foam layer. A fabric layer is attached to the foam layer.