Polyolefin Elastomer Powder for Low-VOC Artificial Leather Molding
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Solution Overview
Problem
Existing artificial leather production methods for automotive seat coverings and interior trim applications face challenges with VOC emissions, inferior heat properties, and reduced durability due to softener bleeding in plastisol and organosol coating-agents, which fail to achieve desired surface strength and three-dimensional texture.
Innovation Solution
A thermoplastic polyolefin composition is developed, comprising olefin block copolymers or blends of linear ethylene and propylene polymers, suitable for paper transfer processes, with specific hardness, melting point, and molecular weight ratios, which forms a continuous polymeric layer that can be stripped to create artificial leather with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastisol or organosol coating-agents are used, then the artificial leather can be produced with a fabric substrate, but the softeners bleed over time resulting in reduced durability and strength
Solution Approach 1:
The patent changes the fundamental chemical parameters of the coating agent by replacing plastisol/organosol systems with polyurethane resins that have different molecular structures and bonding characteristics, eliminating the softener bleeding issue while maintaining manufacturability
Solution Approach 2:
The patent uses composite polyurethane resin systems combining different polyol and isocyanate components to create a multi-phase material structure that provides both ease of application and long-term durability without softener migration
2Reliability
If polyurethane resins are used as coating-agents, then the bleeding problem is eliminated, but the surface strength and thick feel are inferior
Solution Approach 1:
The patent applies local quality enhancement by incorporating specific high-molecular-weight polyurethane components and adjusting the resin composition to provide varying degrees of softness and strength in different layers of the coating, achieving both non-bleeding properties and desirable surface characteristics
Solution Approach 2:
The patent modifies key parameters including resin solids content, molecular weight distribution, and crosslink density to simultaneously achieve resistance to bleeding and enhanced surface strength with a thick, luxurious feel
3Ease of manufacture
If direct coating process with organic solvents is used, then the coating-agent can be applied to fabric substrate, but volatile organic compounds are emitted creating environmental problems
Solution Approach 1:
The patent replaces harmful organic solvent environments with water-based or solvent-free polyurethane resin systems, creating an inert or environmentally benign application atmosphere that eliminates VOC emissions while maintaining coating effectiveness
Solution Approach 2:
The patent fundamentally changes the solvent parameter from organic solvents to water or no solvent, eliminating VOC emissions while adjusting other parameters like viscosity and drying temperature to maintain ease of manufacture
4Ease of manufacture
If direct coating process is used, then the coating can be applied directly to fabric, but the surface is flat and lacks three-dimensional grain-like feeling
Solution Approach 1:
The patent applies preliminary action by incorporating embossing or texturing elements into the coating process, such as using patterned release papers or adding texture-modifying additives to the polyurethane resin before application, so the three-dimensional grain-like feeling is achieved during manufacturing rather than requiring post-processing
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 reduces VOC emissions, enhances heat resistance, maintains long-term physical properties, and achieves a desirable three-dimensional texture and surface strength, addressing the limitations of traditional coating-agents.
Implementation Method 1
heating said coating to form a continuous polymeric layer
Implementation Method 2
cooling said polymeric layer
Data Source
AI summary
The present invention relates to a thermoplastic polyolefin elastomer composition in powder form comprising (i) an olefin block copolymer or (ii) a substantially linear ethylene polymer and/or a linear ethylene polymer and propylene polymer blend. Said composition demonstrates good pulverizing and flow characteristics at ambient temperature. In another aspect, this invention relates to a process for preparing said thermoplastic polyolefin elastomer powder and applications for using said powder. In a further aspect, this invention relates to paper transfer molding said thermoplastic polyolefin elastomer composition into artificial leather, particularly for skins for automotive interior applications such as instrument panels.