PVC Multi-layer Sheet Radiation Crosslinking Grain Distortion
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Solution Overview
Problem
Existing multi-layer fabrics with a PVC top layer face challenges in deep-drawing due to grain distortion and surface discoloration, which are exacerbated by radiation crosslinking that degrades PVC, limiting their deep-drawability and color stability.
Innovation Solution
A multi-layer fabric with a top layer containing at least 50% PVC, 0-15% radiation crosslinking aids, and calcium hydroxide or Ca/Zn stabilizers, which is radiation-crosslinked to optimize grain distortion and minimize discoloration, along with a lacquer layer for improved abrasion and sun resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If radiation crosslinking is applied to improve deep-drawability and reduce grain distortion, then the deep-drawability improves, but PVC degradation occurs leading to surface discoloration
Solution Approach 1:
A zinc-containing stabilizer (0.5-10 wt% Zn) is introduced as an intermediary substance to mediate between the radiation crosslinking process and the PVC polymer. The zinc stabilizer acts as a radiation crosslinking aid that facilitates crosslinking while simultaneously preventing PVC degradation and discoloration during the process
Solution Approach 2:
The patent changes the chemical composition parameters of the PVC layer by incorporating specific amounts of zinc-containing stabilizer (0.5-10 wt% Zn) and calcium hydroxide (0.5-10 wt% Ca). This parameter modification enables the material to undergo radiation crosslinking with improved deep-drawability while maintaining color stability
2Object-affected harmful factors
If conventional stabilizers are used during radiation crosslinking, then PVC degradation is prevented, but deep-drawability and grain distortion remain problematic
Solution Approach 1:
The patent modifies the stabilizer composition by specifying zinc content (0.5-10 wt%) and calcium hydroxide content (0.5-10 wt%), creating a dual-function stabilizer system that simultaneously prevents degradation and enables effective radiation crosslinking for improved deep-drawability
Solution Approach 2:
The invention creates a composite stabilizer system combining zinc-containing compounds and calcium hydroxide in specific proportions within the PVC layer, forming a multi-functional material that provides both degradation protection and enhanced crosslinking capability
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 significantly reduces grain distortion and discoloration while maintaining thermal stability and chemical resistance, enabling the fabric to be used effectively in vehicle interior trim parts with improved deep-drawability and color retention.
Implementation Method 1
the multilayer sheet material is radiation crosslinked
Implementation Method 2
a calcium hydroxide stabilizer and/or a Ca/Zn stabilizer comprising 0.5 to 10 wt.% calcium and 0.5 to 10 wt.% zinc
Data Source
AI summary
The invention relates to a multi-layer sheet material, which contains at least one cover layer made of plasticizer-containing polyvinyl chloride and at least one coating facing outward on the cover layer. The invention further relates to a method for producing the multi-layer sheet material and to an interior trim part made of a sheet material for a vehicle. In order to solve the goal conflict between grain distortion of the surface during deep drawing and discoloration of the surface of the sheet material, the cover layer contains 50 to 100 wt% of at least one polyvinyl chloride and 0 to 15 wt% of at least one cross-linking aid, which is suitable for irradiation cross-linking, and a calcium hydroxide stabilizer and/or a Ca/Zn stabilizer, which has 0.5 to 10 wt% of calcium and 0.5 to 10 wt% of zinc, and at the same time the multi-layer sheet material is irradiation cross-linked.