Hydrogenated Copolymer Laminate for Vinyl Chloride Substitution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional substitutes for vinyl chloride resins, such as olefin resins and hydrogenated styrene block copolymers, face issues with printability, filler dispersion, hardness, and temperature-related properties, lacking satisfactory alternatives for applications requiring flexibility, abrasion resistance, and low-temperature performance.
Innovation Solution
A hydrogenated copolymer-containing laminate comprising a substrate layer, an adhesive layer, and a hydrogenated copolymer composition layer with specific characteristics, including a hydrogenated copolymer and a rubbery polymer, optimized for vinyl aromatic monomer unit content, vinyl aromatic polymer block content, weight average molecular weight, and hydrogenation ratio, to achieve enhanced flexibility, abrasion resistance, and low-temperature properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If olefin resins are used as substitutes for vinyl chloride resins, then weight reduction is achieved, but printability and filler dispersion are poor
Solution Approach 1:
The patent uses a composite material system consisting of hydrogenated copolymer (I) and rubbery polymer (II) to achieve both light weight and good printability/filler dispersion. The hydrogenated copolymer provides structural integrity while the rubbery polymer enhances surface properties for printing and filler compatibility, resolving the contradiction between weight reduction and manufacturing ease.
2Ease of operation
If hydrogenated styrene block copolymers are used as substitutes for vinyl chloride resins, then flexibility is improved, but hardness and high-temperature properties deteriorate
Solution Approach 1:
The patent optimizes specific parameters of the hydrogenated copolymer (I) including vinyl aromatic monomer unit content (5-50 mass%), content of vinyl aromatic polymer block (10-80 mass%), weight average molecular weight (50,000-1,000,000), and hydrogenation ratio (80-100%). By precisely controlling these parameters, the material achieves both flexibility and heat resistance, resolving the contradiction between ease of operation and temperature resistance.
3Weight of stationary object
If conventional substitute materials are used, then weight reduction compared to vinyl chloride resin is achieved, but low-temperature properties and impact resilience are insufficient
Solution Approach 1:
The rubbery polymer (II) acts as an intermediary component that enhances low-temperature flexibility and impact resilience while maintaining the light weight advantage. The specific glass transition temperature range (-80°C to -25°C) ensures the rubbery polymer remains flexible at low temperatures, compensating for the brittleness of lightweight materials and resolving the contradiction between weight reduction and reliability.
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 laminate exhibits improved calendar-moldability, soft feeling at low temperatures, anti-blocking properties, heat resistance, and impact resilience, making it a suitable substitute for vinyl chloride resin sheets in applications like artificial leathers and automotive interiors.
Implementation Method 1
the hydrogenated copolymer (I) is obtained by hydrogenating a copolymer comprising conjugated diene monomer units and vinyl aromatic monomer units
Data Source
AI summary
A hydrogenated copolymer-containing laminate comprising a substrate layer, an adhesive layer, and a hydrogenated copolymer composition layer which is laminated on and bonded to the substrate layer through the adhesive layer, the hydrogenated copolymer composition layer comprising a hydrogenated copolymer (I), and a rubbery polymer (II), wherein the hydrogenated copolymer (I) is obtained by hydrogenating a conjugated diene/vinyl aromatic compound copolymer, the hydrogenated copolymer (I) having the following characteristics (1) to (4): (1) a vinyl aromatic monomer unit content of from more than 50% by weight to 90% by weight, (2) a content of a vinyl aromatic polymer block of not more than 40% by weight, (3) a weight average molecular weight of from 50,000 to 1,000,000, and (4) a hydrogenation ratio of 70% or more, as measured with respect to the double bonds in conjugated diene monomer units.