# US 2025/0084243 A1 · Polyvinyl chloride synthetic leather without foaming structure and method for producing the same

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- Number: US 2025/0084243 A1
- Document ID: US20250084243A1
- Status: Published application
- Kind: A1
- Application number: 18/388,263
- Filed: 2023-11-09
- Published: 2025-03-13
- Earliest claimed: 2023-09-12
- Assignees: Nan Ya Plastics Corporation
- Applicants: Nan Ya Plastics Corporation
- Inventors: TE-CHAO LIAO; WEI-SHENG CHENG; CHAO-TUNG WU
- Web page: https://patentgrep.com/patent/US20250084243A1

## CPC

- C08L 27/06: Homopolymers or copolymers of vinyl chloride
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/22: using plasticisers
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 37/156: {at least one layer is calendered and immediately laminated}
- C09D 127/06: Homopolymers or copolymers of vinyl chloride
- B32B 2250/02: 2 layers
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2262/0238: Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
- B32B 2262/0276: Polyester fibres
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
- B32B 2305/18: Fabrics, textiles
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2327/06: PVC, i.e. polyvinylchloride
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)

## Abstract

A polyvinyl chloride synthetic leather without a foaming structure and a method for producing the same are provided. The polyvinyl chloride synthetic leather includes a base fabric layer and a top fabric layer. The top fabric layer is formed of a fabric composition that includes a polyvinyl chloride resin and a polymer plasticizer. The polymer plasticizer is formed from a dibasic acid raw material and a diol raw material through a polycondensation reaction, and is end-capped by an end-capped fatty acid. A chemical structure of the end-capped fatty acid has a long carbon chain (C8 to C22). An end of the long carbon chain has a carboxyl group, and another end thereof does not have any carboxyl group. A residual amount of the diol raw material in the polymer plasticizer is less than 300 ppm. An acid value of the polymer plasticizer is less than 1 mg KOH/g.

## Claims

### Claim 1

A polyvinyl chloride synthetic leather without a foaming structure, comprising:
a base fabric layer; and
a top fabric layer formed on the base fabric layer; wherein the top fabric layer is formed of a fabric composition, and based on a total weight of the fabric composition being 100 parts by weight, the fabric composition contains: 25 parts by weight to 65 parts by weight of a polyvinyl chloride resin and 20 parts by weight to 60 parts by weight of a polymer plasticizer;
wherein the polymer plasticizer is formed by a polycondensation reaction of a dibasic acid raw material and a diol raw material, and is end-capped by an end-capped fatty acid; wherein the end-capped fatty acid is a biomass-derived fatty acid, a chemical structure of the end-capped fatty acid has a long carbon chain having a carbon number ranging from C8 to C22, an end of the long carbon chain has a carboxyl group, and another end of the long carbon chain does not have any carboxyl group;
wherein a residual amount of the diol raw material in the polymer plasticizer is less than 300 parts per million (ppm), and an acid value of the polymer plasticizer is less than 1 mg KOH/g.

### Claim 2 (depends on 1)

The polyvinyl chloride synthetic leather according to claim 1, wherein the end-capped fatty acid is selected from the group consisting of lauric acid, stearic acid, palmitic acid, linoleic acid, n-caprylic acid, capric acid, and myristic acid.

### Claim 3 (depends on 1)

The polyvinyl chloride synthetic leather according to claim 1, wherein, in the polycondensation reaction, a first initial molar amount of the dibasic acid raw material is less than a second initial molar amount of the diol raw material.

### Claim 4 (depends on 1)

The polyvinyl chloride synthetic leather according to claim 1, wherein the fabric composition further includes 3 parts by weight to 5 parts by weight of a stabilizer; wherein the stabilizer is 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 caprylate.

### Claim 5 (depends on 1)

The polyvinyl chloride synthetic leather according to claim 1, wherein no foaming layer is disposed between the top fabric layer and the base fabric layer, and the top fabric layer does not have foaming pores.

### Claim 6

A method for producing a polyvinyl chloride synthetic leather without a foaming structure, comprising processes of:
providing a base fabric layer; and
forming a top fabric layer on a side surface of the base fabric layer, wherein the top fabric layer is formed of a fabric composition;
wherein, based on a total weight of the fabric composition being 100 parts by weight, the fabric composition contains: 25 parts by weight to 65 parts by weight of a polyvinyl chloride resin and 20 parts by weight to 60 parts by weight of a polymer plasticizer;
wherein the polymer plasticizer is formed by a polycondensation reaction of a dibasic acid raw material and a diol raw material, and is end-capped by an end-capped fatty acid;
wherein the end-capped fatty acid is a biomass derived fatty acid, a chemical structure of the end-capped fatty acid has a long carbon chain having a carbon number ranging from C8 to C22, an end of the long carbon chain has a carboxyl group, and another end of the long carbon chain does not have any carboxyl group;
wherein a residual amount of the diol raw material in the polymer plasticizer is less than 300 parts per million (ppm), and an acid value of the polymer plasticizer is less than 1 mg KOH/g.

### Claim 7 (depends on 6)

The method according to claim 6, wherein the polymer plasticizer is formed by:
performing an esterification process that includes: mixing the dibasic acid raw material with the diol raw material to form a reaction mixture, and heating the reaction mixture to carry out the polycondensation reaction, so as to form a high-molecular-weight polyester polyol; wherein ends of a chemical structure of the high-molecular-weight polyester polyol have excessive hydroxyl groups (—OH); and
performing an end-capping process that includes: adding the biomass derived fatty acid into the reaction mixture to end-cap the excessive hydroxyl groups on the high molecular weight polyester polyol, so as to terminate the polycondensation reaction and form the polymer plasticizer.

### Claim 8 (depends on 7)

The method according to claim 7, wherein, in the esterification process, a first initial molar amount of the dibasic acid raw material added in the reaction mixture is less than a second initial molar amount of the diol raw material added in the reaction mixture.

### Claim 9 (depends on 8)

The method according to claim 8, wherein, in the end-capping process, a third initial molar amount of the end-capped fatty acid added in the reaction mixture is greater than a difference value obtained by subtracting the first initial molar amount of the dibasic acid raw material from the second initial molar amount of the diol raw material, and the third initial molar amount is 1.5 to 3 times the difference value.

### Claim 10 (depends on 9)

The method according to claim 9, wherein a molar ratio between the first initial molar amount of the dibasic acid raw material, the second initial molar amount of the diol raw material, and the third initial molar amount of the end-capped fatty acid is 0.27 to 0.31:0.32 to 0.35:0.06 to 0.09.