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PVC ARTIFICIAL LEATHER ECO SYNTHETIC LEATHER ECO-FRIENDLY PVC SYNTHETIC LEATHER PVC ARTIFICIAL LEATHER ECO SYNTHETIC LEATHER ECO-FRIENDLY PVC SYNTHETIC LEATHER PVC ARTIFICIAL LEATHER ECO SYNTHETIC LEATHER ECO-FRIENDLY PVC SYNTHETIC LEATHER
The company's products include over 100 varieties of artificial and synthetic leather such as automotive interior leather, clothing leather, interior decorative leather, shoe upper leather, and luggage leather.The company's main customer base for artificial leather products manufacturers and leather sales middlemen, at the same time for the market high-end leather consumer groups.
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The BMW Group is relying more intensively than ever before on new, forward-looking and resource-saving materials in the fight against climate change. This represents an important element of the BMW Group's beyond example sustainability strategy. The BMW Group aims to meet its own extremely ambitious climate targets by drastically reducing its carbon footprint per vehicle by 2030. This is driving forward the use of secondary materials with the introduction of the “Neue Klasse” and intensifying the research and development of sustainable materials and substances used in vehicles.
The BMW Group’s view is that only a holistic approach to proven and new materials can reduce CO2 emissions permanently and sustainably. This is why the BMW Group is not only pushing ahead with the successful development of a market for secondary materials, but is also intensifying its cooperation with innovative start-ups in future-oriented materials.
Steady path: “We are rethinking materials”
Despite the enormous research and development work on resource-saving materials, the BMW Group’s top priority is to blend sustainability and premium quality, as Uwe Köhler, Head of Body, Exterior and Interior Development, emphasises: “We are setting new standards for sustainable premium quality. This path requires us to rethink materials, focusing even more specifically on resource-saving material alternatives and renewable materials that have an outstanding capacity to be dismantled. This represents a steady path – a path towards holistic sustainable product development, the responsible use of resources and the transformation to a circular economy.”
Grouping into innovative material groups
Sustainable materials are the basis for resource-saving automotive construction. The BMW Group has defined several material groups, all of which cover the four areas of the circular economy:
RE:THINK, RE:DUCE, RE:CYCLE and RE:USE.
Natural raw materials
Using renewable raw materials and natural fibres such as hemp, kenaf and flax not only minimises the use of materials, but also reduces a vehicle’s weight. This has a positive effect on the CO2 footprint, as natural fibres absorb CO2 while emitting oxygen during their growth phase.
The BMW Group is also researching new types of wood foams. Wood foam consists of 100 per cent renewable raw materials and is so strong that it completely eliminates the need to use synthetic adhesives
Plastic recyclates
The BMW Group already relies on up to 100 per cent plastic recyclate – i.e. recycled materials – for individual thermoplastic components. Together with innovative plastics manufacturers, it is constantly working on developing new plastic recyclates and bioplastics with particularly low carbon footprints.
Alternative to leather
The BMW Group is also working with innovative start-ups to explore new possibilities in vegan leather alternatives: artificial leather with bio-based raw materials, 100 per cent recycled polyester textile and cork particles enable CO2 emissions to be reduced by up to 45 per cent compared to today’s PVC artificial leather. The BMW Group is working with the start-up Adriano di Marti S.A de C.V. to research a sustainable material called DeserttexTM, which consists of powdered cactus fibres and a bio-based polyurethane matrix. The fully recyclable MirumTM also offers a conscientious alternative to traditional leather. The BMW Group’s involvement with the start-up company Natural Fiber Welding opens up new opportunities in developing and implementing plant-based material options.
Recyclable textiles
Synthetic textile variants, which are largely used in seat covers at the BMW Group, are made of 100 per cent recycled material and can be recycled over and over again in the course of their product life to be used several times. The BMW Group’s goal is to focus on more environmentally-friendly monomaterials rather than multimaterial approaches.
Circular path for a sustainable future
The BMW Group aims to use these and many other innovative measures to raise general awareness for sustainable materials and provide a transparent insight into their circular path to a sustainable future – with the goal of reducing CO2 emissions by more than 40 per cent over the life cycle of all BMW Group products by 2030.
A new type of pure synthetic leather meets the high requirements of the European Ecodesign Regulation. Made from a bio-based plastic, it is biodegradable and meets the requirements for a closed recycling process.
Many synthetic leathers consist of a textile substrate to which a polymer layer is applied. The polymer layer usually consists of an adhesive layer and a top layer, which is usually embossed. The textile backing and the top coat are usually completely different materials. Woven, knitted, or nonwoven fabrics made of PET, PET/cotton, or polyamide are often used as textile substrates. PVC and various polyurethanes are commonly used for coatings.
The use of these established composite materials does not meet today's sustainability criteria. Recycling them by type is very costly or even impossible. They are not biodegradable. Therefore, the search for alternative materials for the production of artificial leather is urgent. In 2022, the EU adopted the Sustainable Products Initiative (SPI) ("Green Deal"). It includes an eco-design regulation that considers a product's life cycle in the conservation of resources. For textile and product design, this means incorporating closing the loop or end-of-life into product development.
In an AiF project carried out in close cooperation between the DITF and the Freiberg Institute gGmbH (FILK), it has now been possible to develop a synthetic leather in which both the fiber material and the coating polymer are identical. The varietal purity is a prerequisite for an industrial recycling concept.
The aliphatic polyester polybutylene succinate (PBS) was recommended as the base material because of its properties. PBS can be produced from biogenic sources and is now available on the market in several grades and in large quantities. Its biodegradability has been demonstrated in tests. The material can be processed thermoplastically; this applies to both the fiber material and the coating. Subsequent product recycling is facilitated by the thermoplastic properties.
In order to realize a successful primary spinning process and to obtain PBS filaments with good textile mechanical properties, process adjustments were made in the cooling shaft at the DITF. In the end, it was possible to spin POY yarns at relatively high speeds of up to 3,000 m/min, and they had a tenacity of just under 30 cN/tex when stretched. The yarns could be easily processed into pure PBS fabrics. These in turn were used at FILK as a textile base substrate for the subsequent extrusion coating, where PBS was also used as a thermoplastic.
With optimized production steps, PBS composite materials with the typical structure of artificial leather could be produced. Purity and biodegradability fulfill the requirements for a closed recycling process.
What are the differences between PVC artificial leather and PU artificial leather? PU stands for polyurethane and PVC is the abbreviation of polyvinyl chloride. People are accustomed to referring to artificial leather produced from PVC resin as PVC artificial leather (abbreviated as artificial leather). Artificial leather produced from PU resin is called PU artificial leather (referred to as PU leather for short); artificial leather produced from PU resin and non-woven fabric is called PU synthetic leather (referred to as synthetic leather for short).
The differences between PU artificial leather and PVC artificial leather:
PU leather is less toxic and more environmentally friendly than PVC leather (environmentally friendly leather mostly refers to PU leather), and it feels softer than PVC leather.
If placed in a poor environment for a long time, it may crack (hydrolyze), but precisely because of this, it will not cause secondary pollution to the environment. When the product is discarded, it can naturally degrade, while PVC will not decompose for thousands of years.
The base of PVC artificial leather is generally looser, while the base of PU synthetic leather is usually denser.
All PVC artificial leather has a foamed layer, while PU is a mixture of pulp and fabric base.
PU artificial leather, anti-yellowing agent, yellowing resistance up to grade 4 standard.
PVC leather is more durable, tear-resistant, scratch-resistant, flame-retardant and weather-resistant than PU leather.
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