Comparison of Production Processes, Advantages, and Disadvantages Among PVC, PU, and TPU Leathers
Main raw materials: PVC resin, plasticizers (e.g., DOP/DBP), stabilizers, fillers, colorants.
Basic process: Raw material mixing → Plasticization → Calendering or coating → Laminating with base fabric → Foaming (optional) → Embossing → Surface treatment → Cooling → Winding.
Key processes:
- Calendering method: PVC material is rolled into a film using a multi-roller calender, then laminated with a base fabric.
- Coating method: PVC paste is directly spread onto the base fabric and heated in an oven to form a solid film.
Main raw materials: Polyester/polyether polyol, MDI/TDI, DMF solvent, additives.
Basic process:
- Wet process: Base fabric is dipped → Coated with PU slurry → Immersed in a coagulation bath (DMF-H₂O) → Washed → Dried → Surface-treated.
- Dry process: Release paper is coated → Dried → Laminated with base fabric → Cured → Peeled off → Post-treated.
Key differences:
- Wet PU has good breathability, so it’s often used for high-end shoes and clothing.
- Dry PU offers diverse surface effects, making it popular for bags and furniture.
Main raw materials: TPU granules (polyester or polyether type), additives.
Basic process:
- Extrusion casting method: TPU is melted and extruded → Rolled into a film → Laminated with base fabric → Embossed → Cooled and shaped.
- Blow molding method: TPU is melted and blown into a film → Combined with base material → Post-treated.
- Coating method: TPU granules are dissolved, then coated → Dried and cured.
Advantages:
- Lowest cost; raw materials are easy to obtain.
- Mature production process; simple to process.
- Good resistance to acids, alkalis, and weather.
- Can be made into various colors and patterns.
Disadvantages:
- Plasticizers easily migrate, causing hardening and brittleness.
- Poor breathability; feels stiff.
- Weak low-temperature performance (prone to cracking).
- Poor environmental friendliness (contains chlorine; may have heavy metals).
- Short service life (usually 2–3 years).
Advantages:
- Feels closer to genuine leather: soft and elastic.
- Better breathability and moisture permeability than PVC.
- Good abrasion and flex resistance.
- More biodegradable than PVC.
- Diverse varieties (e.g., microfiber, suede-like).
Disadvantages:
- Higher cost than PVC (about 30–50% more).
- Complex production process (requires solvent recovery).
- Poor hydrolysis resistance (especially polyester-based PU).
- Prone to sticking at high temperatures and hardening at low temperatures.
- Some products have DMF residues.
Advantages:
- Environmentally friendly and non-toxic (no plasticizers or halogens).
- Excellent elasticity and abrasion resistance.
- Good low-temperature performance (remains soft at −30℃).
- Outstanding oil and hydrolysis resistance.
- Can be hot-melt welded; 100% recyclable.
Disadvantages:
- Highest raw material cost (1.5–2 times that of PU).
- Narrow processing temperature range; difficult to control.
- Slightly “plastic-like” feel; lower 仿真度 (simulation quality).
- Higher cost for improved breathability versions.
- Low market awareness.
| Material |
Main Application Fields |
Typical Products |
| PVC |
Low-end luggage, cover binding, car floor mats, simple furniture |
Student backpacks, ID holders, cheap sofas |
| PU |
Mid-to-high-end footwear, apparel, handbags, furniture, car interiors |
Sneaker uppers, designer bags, business sofas |
| TPU |
High-end outdoor gear, medical devices, electronic protectors |
Hiking shoes, wetsuits, phone cases, medical braces |
- PVC: Chlorine-containing process; may produce dioxins.
- PU: Requires DMF solvent recovery.
- TPU: Mainly uses solvent-free processes.
- PVC: Difficult to degrade; incineration releases HCl.
- PU: Partially biodegradable.
- TPU: Thermoplastically recyclable; partially degradable.
- PVC: May contain lead/cadmium stabilizers or phthalate plasticizers.
- PU: May have DMF residues or amine catalysts.
- TPU: Usually meets REACH and RoHS standards.
- PVC: Shifting to lead-free calcium-zinc stabilizers and bio-based plasticizers.
- PU: Water-based PU and solvent-free PU are key R&D focuses.
- TPU: Market share grows as environmental demands rise.
Common trends: Bionic structures, functionalization (e.g., antibacterial, flame-retardant), and use of sustainable raw materials.
Each material has unique strengths and weaknesses. The choice depends on performance needs, cost, and environmental goals for specific applications. With technological advances, high-performance, eco-friendly synthetic leathers are closing the gap with natural leather.
(The above content is for reference only.)
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