Polyvinyl chloride artificial leather without a foaming structure

Patent metadata

Field	Value
Publication number	US-12209359-B2
Application number	US-202217903023-A
Country	US
Kind code	B2
Filing date	Sep 5, 2022
Priority date	Sep 14, 2021
Publication date	Jan 28, 2025
Grant date	Jan 28, 2025

Abstract

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.

First claim

What is claimed is:

1. A polyvinyl chloride artificial leather without a foaming structure, which has an odor level lower than 3.5 measured according to Volkswagen odor test standard PV3900C3, the polyvinyl chloride artificial leather comprising:
a base fabric layer; and
a top fabric layer directly formed on the base fabric layer, wherein the top fabric layer has a solid structure extendedly formed from one surface of the top fabric layer away from the base fabric layer to the base fabric layer, the solid structure is formed by a fabric composition, and the solid structure has a predetermined thickness within a range from 100 micrometers to 600 micrometers, and wherein 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,
wherein the polymer plasticizer has a first weight average molecular weight 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; wherein a concentration of the at least one soft segment having the ether group in the polymer plasticizer is within a range from 10 wt % to 50 wt %, and the polymer plasticizer has a glass transition temperature within a range from −80° C. to −15° C.

2. The polyvinyl chloride artificial leather according to claim 1 , wherein no foaming layer is provided between the top fabric layer and the base fabric layer, and the solid structure of the top fabric layer does not have any foaming pores.

3. The polyvinyl chloride artificial leather according to claim 1 , wherein the at least one soft segment having the ether group is embedded at a central portion or an end portion of the molecular structure of the polymer plasticizer.

4. The polyvinyl chloride artificial leather according to claim 1 , wherein the polymer plasticizer is a high-molecular polyester prepared by a poly-condensation reaction between a dibasic acid raw material and a diol raw material, and the at least one soft segment having the ether group is formed by at least one of the dibasic acid raw material and the diol raw material.

5. The polyvinyl chloride artificial leather according to claim 4 , wherein the dibasic acid raw material is at least one selected from the group consisting of adipic acid, maleic acid, decanedioic acid, and dodecanedioic acid.

6. The polyvinyl chloride artificial leather according to claim 4 , wherein the diol raw material is at least one selected from the group consisting of diethylene glycol, triethylene glycol, tetraethylene glycol, poly-tetra-hydrofuran, propane-1,2-diol, 2-methyl-1,3-propanediol, neopentyl glycol, and 1,4-cyclohexanedimethanol.

7. The polyvinyl chloride artificial leather according to claim 4 , wherein the polymer plasticizer is further end-capped by an end-capped fatty alcohol, so as to end the poly-condensation reaction; wherein the end-capped fatty alcohol is a monool, and the monool is at least one selected from the group consisting of 2-ethylhexan-1-ol, 2-propylheptanol, lauryl alcohol, diethylene glycol monobutyl ether, and diethylene glycol monomethyl ether.

8. The polyvinyl chloride artificial leather according to claim 1 , wherein the fabric composition further includes from greater than 0 and less than or equal to 15 parts by weight of a processing aid; wherein the processing aid is an aliphatic dibasic acid ester that is in a linear shape, and the processing aid has a second weight average molecular weight within a range from 300 to 800.

9. The polyvinyl chloride artificial leather according to claim 8 , wherein the processing aid is at least one selected from the group consisting of di-octyl sebacate, di-octyl adipate, di-isononyl adipate, di-isodecyl adipate, and di-isononyl sebacate.

10. The polyvinyl chloride artificial leather according to claim 1 , wherein the fabric composition further includes 0.5 to 5 parts by weight of a stabilizer, 0 to 15 parts by weight of fillers, and 2 to 8 parts by weight of a flame retardant, and wherein the fabric composition does not include any foaming agent.

11. The polyvinyl chloride artificial leather according to claim 10 ,
wherein the stabilizer is at least one selected from the group consisting of: lithium stearate, magnesium stearate, calcium stearate, barium stearate, zinc stearate, magnesium laurate, barium laurate, zinc laurate, calcium ricinoleate, barium ricinoleate, zinc ricinoleate, and zinc octoate;
wherein the fillers are at least one selected from the group consisting of: calcium carbonate, silicon dioxide, aluminium oxide, clay, talc, diatomaceous earth, and ferrite as metal oxides; glass, carbon black, and metal as fibers and powders; and glass ball, graphite, aluminum hydroxide, barium sulfate, magnesium oxide, magnesium carbonate, magnesium silicate, and calcium silicate; and
wherein the flame retardant is at least one selected from the group consisting of: aluminum hydroxide, magnesium hydroxide, antimony trioxide, and zinc borate as inorganic compounds; cresyl diphenyl phosphate, trichloroethyl phosphate, trichloropropyl phosphate, and tris-dichloropropyl phosphate as phosphorus compounds; and chlorinated paraffin as a halogen compound.

12. The polyvinyl chloride artificial leather according to claim 1 , further comprising a surface treatment layer formed on the top fabric layer, wherein the surface treatment layer is formed by a waterborne surface treatment agent, and the waterborne surface treatment agent is a waterborne polyurethane system agent without N-ethylpyrrolidone.

Assignees

• Nan Ya Plastics Corp

Inventors

• Liao Te-Chao
• Cheng Wei-Sheng
• Wu Chao-Tung

Classifications

• D06N3/0063

  Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds · CPC title

• D06N2209/067

  Flame resistant, fire resistant · CPC title

• D06N2211/28

  Artificial leather · CPC title

• D06N3/0059

  Organic ingredients with special effects, e.g. oil- or water-repellent, antimicrobial, flame-resistant, magnetic, bactericidal, odour-influencing agents; perfumes (D06N3/0065 takes precedence) · CPC title

• D06N3/08 Primary

  with a finishing layer consisting of polyacrylates, polyamides or polyurethanes {or polyester} · CPC title