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Bio-based PBS is used in the manufacture of synthetic leather, which is degradable and recyclable
2024.08.07
A new type of pure synthetic leather meets the high requirements of the European Eco design Regulation. It is made of bio-based plastics, is biodegradable, and meets the requirements of a closed-loop recycling process.
Many synthetic leathers consist of a fabric substrate on which a polymer layer is applied. The polymer layer usually consists of an adhesive layer and a top layer that is usually embossed. Woven fabrics, knitted fabrics or non-woven fabrics made of PET, PET/cotton or polyamide are often used as fabric substrates. PVC and various polyurethanes are commonly used for coatings.
The use of these proven composites does not meet today's sustainability standards. The cost of recycling them by type is very high, if not impossible. They are not biodegradable. Therefore, it is urgent to find alternative materials for the production of synthetic leather. In 2022, the European Union adopted the Sustainable Products Initiative (SPI) (the "Green Deal"). It includes an eco design regulation that takes into account the life cycle of a product in the process of conserving resources. For textile and product design, this means incorporating closed-loop or end-of-life into product development.
In the AiF project, which DITF and Freiberg Institute gGmbH (FILK) worked closely together, it has now been possible to develop a synthetic leather in which both the fibrous material and the coated polymer are identical.
Aliphatic polyester polybutylene succinate (PBS) is recommended as a base material due to its properties. PBS can be produced from biological sources and is currently available in multiple grades and in large quantities on the market. Its biodegradability has been confirmed in tests. The material can be thermoplasticly processed; This applies to fibrous materials and coatings. The properties of thermoplasticity facilitate the recycling of subsequent products.
In order to achieve a successful primary spinning process and obtain PBS filaments with good textile mechanical properties, process adjustments were made in the cooling shaft of the DITF. Finally, POY yarns are able to be spun at relatively high speeds of up to 3000 m/min, and they have a strength of just under 30 cN/tex after stretching. The yarn can be easily processed into pure PBS fabric. FILK then uses it as a fabric substrate, and PBS can also be used as a thermoplastic for coatings.
By optimizing the production steps, it is possible to produce PBS composites with the typical structure of synthetic leather. Purity and biodegradability meet the requirements of a closed-loop recycling process.
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