Multi-layer textile sheet
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Solution Overview
Problem
Existing artificial leather materials for vehicle interiors rely heavily on petroleum-based raw materials, which are environmentally detrimental, and struggle with emission control, uniform structure, flexibility, and durability, necessitating a shift towards more eco-friendly alternatives without compromising performance.
Innovation Solution
A multilayer fabric is developed using non-petroleum-based materials, particularly in the PVC and textile carrier layers, incorporating epoxidized vegetable oils and fatty acid esters as plasticizers, along with crosslinking and specific additives to enhance durability and reduce emissions, and utilizing renewable fibers like cellulose and lyocell for the textile carrier layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If petroleum-based plasticizers and synthetic fibers are used in artificial leather, then the material achieves good flexibility and durability, but environmental harm and high emission values increase
Solution Approach 1:
The patent changes the chemical composition parameters by replacing petroleum-based plasticizers with epoxidized vegetable oils and epoxidized fatty acid esters, and replacing synthetic fibers with natural fibers. This substitution maintains the functional properties (flexibility, durability) while fundamentally altering the material source from fossil fuels to renewable resources, thereby reducing emission values and environmental harm.
Solution Approach 2:
The invention creates a composite material system combining PVC with epoxidized vegetable oils, epoxidized fatty acid esters, and natural fibers. This composite approach allows the integration of multiple materials with complementary properties - the PVC provides structural integrity, the epoxidized oils and esters provide flexibility and plasticization, and the natural fibers provide reinforcement - while achieving low emission values through renewable material selection.
2Object-affected harmful factors
If a high proportion of non-petroleum-based raw materials is used in the fabric, then ecological advantage is improved, but the desired properties (emission values, uniform structure, flexibility, durability) may be impaired
Solution Approach 1:
The patent optimizes the formulation parameters by selecting specific ratios of epoxidized vegetable oils (45-130 parts by weight based on 100 parts by weight of PVC) and epoxidized fatty acid esters as plasticizers. These parameter optimizations ensure that the renewable material composition achieves the desired flexibility and uniform structure while maintaining high ecological advantage through non-petroleum-based raw materials.
Solution Approach 2:
The invention develops a composite material system where PVC is combined with epoxidized vegetable oils, epoxidized fatty acid esters, and natural fibers in optimized proportions. This composite approach ensures that the high proportion of non-petroleum-based materials (>50% by weight) maintains uniform structure, flexibility, and durability through the synergistic interaction of different materials with complementary properties.
3Ease of operation
If conventional plasticizers are used in PVC layers, then the fabric achieves desired flexibility, but fogging (evaporation of volatile substances) increases
Solution Approach 1:
The patent changes the chemical composition of the plasticizer by using epoxidized vegetable oils and epoxidized fatty acid esters instead of conventional petroleum-based plasticizers. These epoxidized materials have lower volatility and better thermal stability, which reduces fogging (evaporation of volatile substances) while maintaining the desired flexibility of the PVC layers through their plasticizing effect.
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 solution achieves a high proportion of non-petroleum-based materials (>50% by weight) while maintaining desired properties such as low emissions, flexibility, and durability, reducing fogging and embrittlement, and providing a sustainable alternative for vehicle interiors.
Implementation Method 1
The plasticizer in the PVC layer is a mixture of at least one epoxidized vegetable oil and at least one epoxidized fatty acid ester. The combination of epoxidized vegetable oil with epoxidized fatty acid ester as a plasticizer also prevents the fabric from becoming brittle or hardening when stored in heat.
Implementation Method 2
If the PVC layers are additionally crosslinked, it is advantageous to increase the crosslinking rates if crosslinking aids, such as trimethylolpropane triacrylate (TMPTA) or trimethylolpropane trimethacrylate (TMPTMA), are added to the PVC composition
Data Source
Figure 1
AI summary
Multi-layer sheet material comprises: at least one textile carrier layer (5); and at least one layer of softener-containing polyvinyl chloride (2), where the layers comprise raw materials, which are not based on crude oil, and the entire sheet material exhibits more than 50 wt.% of the raw materials.