Multilayer Polyolefin-SBC Composite for Abrasion-Resistant Synthetic Leather
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Solution Overview
Problem
Existing synthetic leathers based on PVC, polyurethane, and polyolefins face issues such as high density, embrittlement, environmental hazards, poor abrasion resistance, and complex recycling, failing to meet the demands of seating applications while being sustainable.
Innovation Solution
A multi-layer composite with a thermoplastic polyolefin carrier layer and a functional layer comprising more than 50 wt.% styrene block copolymer (SBC) provides improved abrasion resistance, softness, and flexibility, enabling recyclability and reduced environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If PVC or PUR is used for artificial leather, then abrasion resistance and scratch resistance are improved, but density and weight increase
Solution Approach 1:
The patent uses a composite structure combining thermoplastic polyolefin carrier layer with functional layer containing styrene block copolymer and thermoplastic elastomer. This composite approach achieves high abrasion resistance through the functional layer's elastomeric properties while the polyolefin carrier layer maintains low density (approx. 0.9-1.0 g/cm³), resolving the contradiction between durability and weight.
2Ease of operation
If plasticizers are added to PVC to make it soft and flexible, then flexibility is improved, but embrittlement occurs due to migration of short-chain molecules
Solution Approach 1:
The patent changes the material composition parameters by using styrene block copolymer and thermoplastic elastomer in the functional layer, which inherently provide softness and flexibility through their molecular structure rather than relying on plasticizers. This eliminates the embrittlement problem associated with plasticizer migration while maintaining the desired flexibility for seating applications.
3Strength
If PUR is cross-linked to improve durability, then strength is improved, but embossing capability is lost
Solution Approach 1:
The patent applies local quality by having the carrier layer provide structural strength and durability while the functional layer provides the embossable surface. The thermoplastic elastomer in the functional layer maintains embossing capability even when the carrier layer is cross-linked for enhanced durability, as the embossing process affects primarily the functional layer.
4Adaptability or versatility
If functional coating and textile backing are made of different materials, then functionality is improved, but recycling becomes complex or impossible
Solution Approach 1:
The patent applies homogeneity by making both the carrier layer and functional layer based on thermoplastic polymers with similar chemical composition. The carrier layer uses thermoplastic polyolefin and the functional layer uses styrene block copolymer with thermoplastic elastomer, allowing both layers to be processed together during recycling without complex separation requirements, thus simplifying recycling while maintaining functional performance.
Data Source
AI summary
The invention relates to a multi-layer composite comprising at least one single-layer or multi-layer carrier layer and at least one single-layer or multi-layer functional layer, wherein the carrier layer comprises at least one thermoplastic polyolefin and wherein the functional layer comprises more than 50 wt. % of a styrene block copolymer based on the total weight of the functional layer. The invention also relates to seating furniture comprising a cover made from such a multi-layer composite. The invention relates to a multi-layer composite comprising at least one single-layer or multi-layer carrier layer and at least one single-layer or multi-layer functional layer, wherein the carrier layer comprises at least one thermoplastic polyolefin and wherein the functional layer comprises more than 50 wt. % of a styrene block copolymer based on the total weight of the functional layer. The invention also relates to seating furniture comprising a cover made from such a multi-layer composite.