Polyolefin Synthetic Leather Layers for Flexible, Abrasion-Resistant Interiors
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Solution Overview
Problem
Synthetic leathers made of polyvinylchloride (PVC) used in automotive interiors pose health and environmental risks due to harmful plasticizers, necessitating a safer alternative.
Innovation Solution
A synthetic leather composition comprising a base layer and two polyolefin layers with specific Shore A hardness ranges, one providing softness and the other abrasion resistance, along with optional flame retardants and UV absorbers, to replace PVC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If PVC is used for synthetic leather, then flexibility and molding processability are improved, but harmful plasticizers are released affecting health and environment
Solution Approach 1:
The patent uses a composite structure consisting of a base layer and a polyolefin layer. The base layer provides structural support while the polyolefin layer provides the leather-like surface properties. This composite approach allows achieving the desired flexibility and appearance without using harmful PVC plasticizers throughout the entire material.
Solution Approach 2:
The patent specifies Shore A hardness parameters for the polyolefin layer (40A to 70A) to ensure flexibility comparable to PVC while using safe polyolefin materials. By controlling the hardness parameter, the invention achieves the desired operational flexibility without the harmful chemical composition of PVC.
2Ease of operation
If a single soft polyolefin layer is used, then flexibility is improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent applies the local quality principle by creating a multi-layer structure where each layer has different properties optimized for its specific function. The base layer provides structural support and abrasion resistance, while the polyolefin layer provides flexibility and surface quality. This localized optimization of properties in different layers resolves the contradiction between overall flexibility and surface abrasion resistance.
Solution Approach 2:
The invention uses a composite material system with a base layer (woven or non-woven fabric) and a polyolefin layer with specific hardness characteristics. This composite structure allows the base layer to provide abrasion resistance while the polyolefin layer maintains flexibility, achieving both requirements simultaneously through material composition rather than a single material.
3Strength
If polyolefin layers with high abrasion resistance are used, then durability is improved, but flexibility deteriorates
Solution Approach 1:
The patent assigns different functional qualities to different layers: the base layer is designed for structural strength and abrasion resistance, while the polyolefin layer is designed for flexibility and surface appearance. This local differentiation of material properties allows each layer to excel at its specific function without compromising the other.
Solution Approach 2:
The invention segments the synthetic leather into distinct functional layers: a base layer for structural support and abrasion resistance, and a polyolefin layer for flexibility and surface properties. By segmenting the material system into specialized components, each layer can be optimized for its specific function, resolving the contradiction between overall durability and flexibility.
Data Source
AI summary
The present disclosure provides a synthetic leather including a base layer, a first polyolefin layer and a second polyolefin layer. The first polyolefin layer is disposed on the base layer, and a Shore A hardness thereof is about 40A to about 70A. The second polyolefin layer is disposed on the first polyolefin layer, and a Shore A hardness thereof is about 75 to about 98.