Solid PVC Artificial Leather Structure for Low-Odor Vehicle Interiors
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Solution Overview
Problem
Conventional polyvinyl chloride (PVC) artificial leathers with foaming structures often emit pungent odors due to the use of foaming agents and solvent-based surface treatment agents, which can negatively impact user experience and indoor air quality in vehicles.
Innovation Solution
A PVC artificial leather without a foaming structure, featuring a top fabric layer directly formed on a base fabric layer with a solid structure composed of a fabric composition containing 40-70 parts by weight of PVC resin and 30-60 parts by weight of a polymer plasticizer. The polymer plasticizer has a weight average molecular weight of 1,500-6,000, includes a linear soft segment with an ether group, and a glass transition temperature between -80°C and -15°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a foaming agent is used to generate a foaming structure in the PVC artificial leather, then a leather-like feel is provided, but a pungent odor is emitted
Solution Approach 1:
The patent removes the foaming agent from the composition entirely, extracting the harmful element while maintaining the leather-like tactile sensation through alternative means (surface treatment layer with specific texture)
Solution Approach 2:
The patent uses a composite structure combining PVC resin with specific plasticizers and a surface treatment layer to achieve leather-like properties without foaming agents, creating a multi-layer composite material system
2Manufacturing precision
If a solvent-based surface treatment agent is used to improve surface properties, then surface quality is enhanced, but odor level increases and health hazards arise
Solution Approach 1:
The patent changes the chemical composition parameters of the surface treatment agent, using water-soluble polymers instead of solvent-based agents, and adjusts molecular weight and functional group parameters to achieve both surface quality and low odor
Solution Approach 2:
The patent creates an inert environment by using water-based formulations without harmful solvents, eliminating the pungent odor associated with traditional solvent-based surface treatment agents
3Ease of manufacture
If phenolic acid plasticizer is added to improve fluidity of melted PVC, then processing temperature is reduced, but pungent odor is emitted
Solution Approach 1:
The patent extracts and removes phenolic acid plasticizers from the formulation, eliminating the source of pungent odor while maintaining processing benefits through alternative plasticizer systems
Solution Approach 2:
The patent employs a composite plasticizer system combining multiple types of plasticizers (including polymer plasticizers and compounds with specific functional groups) to achieve both low processing temperature and low odor performance
4Temperature
If PVC resin with high degree of aggregation is used, then melting temperature increases, but fluidity of melted PVC deteriorates
Solution Approach 1:
The patent changes the aggregation parameters and molecular structure parameters of the PVC resin, using resins with specific viscosity and molecular weight distributions to achieve both high melting temperature and good melt fluidity
Data Source
AI summary
A polyvinyl chloride artificial leather without a foaming structure is provided. The polyvinyl chloride artificial leather includes a base fabric layer and a top fabric layer directly formed on the base fabric layer. The top fabric layer has a solid structure extendedly formed from one surface of the top fabric layer to the base fabric layer, and the solid structure is formed by a fabric composition. The solid structure has a predetermined thickness. The fabric composition includes 40 to 70 parts by weight of a polyvinyl chloride resin and 30 to 60 parts by weight of a polymer plasticizer. A weight average molecular weight of the polymer plasticizer is within a range from 1,500 to 6,000, a molecular structure of the polymer plasticizer has at least one soft segment that is in a linear shape, and the at least one soft segment has an ether group.