PVC Artificial Leather Production Process

1. Coating method

(1) Direct coating method: the PVC plastisol is directly coated on the pretreated fabric base with a scraper or roller, and then the process of producing PVC artificial leather through plasticization, ginning, cooling, coiling and other processes is called direct coating method. This method is the earliest and simplest process method, which can produce ordinary leather, foam leather, floor leather, etc. Due to the simple equipment, low investment cost, and high production efficiency. The disadvantages are that a large amount of emulsion resin is required, the product quality is not easy to control (especially affected by the substrate), the fabric substrate needs to be pretreated, and the low-strength fabric substrate (such as knitted fabrics, paper, inferior recycled fabrics, etc.) cannot be used, which is suitable for the production of thin leather.

(2) Carrier transfer coating method: the plastisol is coated on the circulating carrier with a scraper or roller for pre-gelation, the bottom base is laminated with the semi-gelatinized coating, and after complete plasticization and cooling, the adhesive is peeled off from the carrier, and then PVC artificial leather is manufactured by film or surface treatment and ginning, which is called the carrier transfer coating method. This process is suitable for the production of knitted fabrics or foam artificial leather based on non-woven fabrics, and can also be applied to commercial fabrics, recycled fabrics, canvases, etc. The carriers used are stainless steel strips, metal mesh, release paper, silicone rubber belts, etc., and stainless steel strips are mostly used in China.

2. Calendering method

The kneaned mixture is made into the required film or sheet on the calender, laminated with the preheated fabric base, and then embossed, cooled, surface treated, etc. to make artificial leather, which is called calendering. It can produce general artificial leather and foam artificial leather. The operating temperature of each step before calendering in the production of foam leather must be controlled below the decomposition temperature of the blowing agent, and the foaming must be carried out after plasticization. In order to improve the adhesion strength of the film layer to the subbase and prevent the rubber from penetrating the subbase, it is usually necessary to apply a layer of adhesive to the subbase. This method has high production efficiency, and the raw material is easy to solve (with suspended resin), which is the main production method of artificial leather.

3. Layer legality

In this method, the sheet is first made by calendering, the adhesive is pre-applied to the fabric base, and the treated fabric base and sheet are bonded together with a laminating device that can be embossed at the same time. There are two ways to laminate: one is to apply the adhesive to the PVC sheet and then apply the base layer. The other is to make the prefabricated sheet bonded to the fabric base after heating according to the hot melt properties of the thermoplastic. In this way, PVC leather and foam leather can be produced. It is characterized by simple operation, convenient replacement of varieties, multi-layer lamination, suitable for the production of thick leather more than 1mm.