Dimensional enhancement of artificial leather polyurethane composite material

Abstract

A composite material formed by combining a polyurethane material with an unclickable foam layer and a scrim layer through roll and flat form technology. The composite material is embossed to form pillowlike chambers or cells delineated by a network of emboss pattern lines formed by the bonding between these layers.

Description

[0001] Cross References to Related Applications [0002] This application claims priority to US Provisional Patent Application No. 62065470, filed October 17, 2014, which is hereby incorporated by reference in its entirety. technical field [0003] The present invention relates generally to artificial leather devices and methods, and more particularly to three-dimensional reinforcement of composites / laminates of artificial leather. Background technique [0004] Synthetic leather materials are used in various industries. For example, in the automotive industry, synthetic leather is widely used to cover seats, steering wheels, interior panels, etc. This material is superior to animal leather in terms of environmental impact, cost, durability and customizability for many reasons. Synthetic leather is generally lighter in weight, more efficiently produced, and is significantly less expensive than real / animal leather. [0005] Among the different types of synthetic leather, po...

AI Technical Summary

Problems solved by technology

In previous embossing attempts, the surface of the PU material was cut or damaged due to a number of reasons including problems with the heating or pressing steps which resulted in melting and cutting of the material and induced stress at the corners of such embossing

Additionally, the embossing pattern transfer devices used previously were problematic, including cuts or damage to the PU surface layer caused by rollers or plates with excessively sharp edges, or even worse, cuts through the underlying composite layer

The use of unsuitable materials, including unsuitable foams and textile scrims, has caused further problems: such as following the embossing process, and up to the manufacture of final products comprising synthetic leather materials such as car seats as an example Deformation in shape and depth of the embossed design, etc.

While the three-dimensional properties of facestocks formed with composite layers of material, foam, and scrim are superior to those formed using flat embossing, these existing attempts are still insufficient to achieve embossing goals

Specifically, they do not adequately protect the composite material from, for example, melting or cutting during the embossing process

Additionally, the materials used to provide the "pillow" effect do not adequately retain the desired embossed shape

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