PVC Resin Composition for Bonding to Foamed Polyurethane

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Solution Overview

Problem

Conventional vinyl chloride resin molded products used as surface skins in automobile interiors do not adhere well to foamed polyurethane molded products, leading to potential peeling issues in laminates.

Innovation Solution

A vinyl chloride resin composition containing a vinyl chloride resin, a plasticizer, and a vinyl chloride-(meth)acrylate copolymer is used to form a molded product with enhanced adhesiveness to foamed polyurethane, with specific ranges for copolymer and plasticizer content to improve tensile characteristics and heat shrinkage resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional vinyl chloride resin composition is used for powder molding, then the molded product can be produced with basic properties, but the adhesiveness to foamed polyurethane molded product is insufficient

Engineering Contradiction:

Improveadhesiveness to foamed polyurethaneVSAvoidcompatibility with foamed polyurethane lining

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies composite materials by combining vinyl chloride resin particles with vinyl chloride-acrylate copolymer fine particles to create a composite resin composition. The copolymer particles (0.1-10 μm) form a adhesive layer on the molded product surface that specifically enhances bonding to foamed polyurethane, while the base vinyl chloride resin maintains the structural properties. This composite approach resolves the contradiction by integrating two material systems with complementary functions.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by concentrating the adhesive functionality in a specific component (vinyl chloride-acrylate copolymer fine particles) rather than uniformly distributing adhesive properties throughout the entire resin composition. The copolymer particles preferentially locate at the molded product surface during powder molding, creating a localized adhesive layer that enhances bonding to foamed polyurethane while the bulk material retains its original mechanical properties.

Inventive Principle:

Principle #3Local quality

2Reliability

If the content of vinyl chloride-acrylate copolymer is increased to improve adhesiveness, then bonding to foamed polyurethane improves, but tensile characteristics may deteriorate

Engineering Contradiction:

Improveadhesiveness to foamed polyurethaneVSAvoidtensile characteristics

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies parameter changes by precisely controlling the content of vinyl chloride-acrylate copolymer fine particles within a specific range (0.1-10 parts by mass per 100 parts by mass of vinyl chloride resin particles). This optimized concentration ensures sufficient adhesive functionality while preventing excessive copolymer content from compromising the tensile strength and elongation properties of the molded product. The fine particle size (0.1-10 μm) is also controlled to ensure proper distribution and bonding without creating weak points.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12466943B2Vinyl chloride resin composition, vinyl chloride resin molded product, and laminate

Publication Date: 2025.11.11 ZEON CORP

AI summary

Provided is a vinyl chloride resin composition that can form a vinyl chloride resin molded product having excellent adhesiveness to a foamed polyurethane molded product. The vinyl chloride resin composition contains a vinyl chloride resin, a plasticizer, and a vinyl chloride-(meth)acrylate copolymer.