Polyolefin Artificial Leather Multilayer Structure for Softness and Adhesion
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Solution Overview
Problem
Artificial leathers made from polyolefin (PO) based resins face challenges such as high melting point, fast cooling due to crystallization, tackiness, and poor adhesion to polar materials, making them less suitable as replacements for PVC-based resins, despite efforts to increase softness through elastomeric blending and paraffin oil use.
Innovation Solution
A multilayer structure comprising a top skin layer, a middle foam layer, and a bottom fabric layer, where both the skin and foam layers are composed of propylene-alpha-olefin copolymers combined with elastomeric compounds, and the fabric layer is made of flexible polymeric material, with optional primer and top coating layers for improved adhesion and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If elastomeric material is blended with PO-based resin to increase softness, then flexibility is improved, but compatibility issues and requirement for paraffin oil arise
Solution Approach 1:
The patent uses a polyolefin-compatible elastomer as an intermediary substance that bridges the PO-based resin and the desired flexibility requirement. This elastomer is specifically selected to be compatible with polyolefins, eliminating the need for paraffin oil and resolving compatibility issues while achieving the desired softness and flexibility.
Solution Approach 2:
The patent changes the material parameters by selecting specific elastomers with compatible chemical structures and molecular weights that work seamlessly with PO-based resins. This parameter optimization allows achieving flexibility without introducing compatibility complexities or requiring additional plasticizers like paraffin oil.
2Ease of manufacture
If PO-based resin is used to replace PVC-based resin, then cost is reduced and environmental issues are avoided, but adhesion to polar materials deteriorates
Solution Approach 1:
The patent creates a composite material system combining PO-based resin with specifically selected elastomers that improve adhesion to polar materials. This composite approach maintains the cost and environmental advantages of PO-based resins while overcoming their poor adhesion characteristics through synergistic material combinations.
Solution Approach 2:
The patent modifies the chemical and physical parameters of the PO-based resin system by incorporating elastomers with appropriate functional groups and molecular characteristics. These parameter changes enable the non-polar PO resin to achieve acceptable adhesion to polar substrates without sacrificing cost effectiveness or environmental benefits.
3Productivity
If PO-based resin is processed through roll processing, then production efficiency is maintained, but cooling rate increases due to crystallization
Solution Approach 1:
The patent adjusts the molecular weight and comonomer content parameters of the PO-based resin to control crystallization behavior. By optimizing these parameters, the resin maintains processability through roll processing while reducing the cooling rate and minimizing crystallization-induced defects, thus preserving production efficiency.
4Object-affected harmful factors
If PO-based resin is used, then environmental friendliness is improved by eliminating halogenated compounds, but melting point increases
Solution Approach 1:
The patent formulates a composite system using PO-based resin combined with elastomers having lower melting points. This composite approach maintains the environmental friendliness and halogen-free composition of PO-based resins while the elastomer component compensates for the high melting point, achieving a balanced thermal profile suitable for various applications.
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 multilayer structure achieves non-halogenated formulations with physical properties similar to natural leather, reduced density, UV stability, recyclability, and comparable mechanical properties to PVC-based formulations, while eliminating the need for PVC and PU compounds, providing enhanced flexibility, softness, and thermal insulation.
Implementation Method 1
The top skin layer is not foamed, and comprises a propylene-alpha-olefin copolymer in combination with one or more elastomeric compounds
Implementation Method 2
the foam layer also comprises a propylene-alpha-olefin copolymer in combination with one or more elastomeric compounds
Data Source
Figure 1A~1B
Figure 1C~1D
AI summary
Artificial leather comprising a multi-layer structure comprises a top coating layer, a middle foam layer, and a bottom fabric layer. The top coating layer comprises a propylene- alpha-olefin copolymer in combination with one or more elastomeric compounds, the foam layer also comprises a propylene-alpha-olefin copolymer in combination with one or more elastomeric compounds plus a blowing agent, and the fabric layer comprises a nonwoven spunbond material.