Artificial Leather Venting Process to Prevent Air Cell Defects
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Solution Overview
Problem
Conventional methods for manufacturing artificial leather often result in the formation of air cells due to trapped gas, leading to surface unevenness and reduced quality and yield of the leather article.
Innovation Solution
A method involving a stacked set with a leather precursor and a pressing member, both formed with vents, is heated and vacuumized to prevent gas entrapment, allowing the polymer material to form a flexible leather article without air cells, using a process that can include a release member and an airtight layer with vents to facilitate gas evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the polymer material is heated to remove organic solvent and allow thermal melt or crosslink, then the artificial leather is formed, but gas may be trapped resulting in air cells that affect quality
Solution Approach 1:
The patent applies preliminary action by providing vents in the pressing member and release member before the heating process begins. These vents are pre-positioned to allow gas to escape during the subsequent heating and solvent removal process, preventing air cell formation in the artificial leather product.
Solution Approach 2:
The patent extracts the harmful gas from the system by incorporating vents that allow trapped gas to escape during the heating process. This extraction principle directly addresses the air cell formation problem by providing a designated pathway for gas removal from the polymer material.
2Productivity
If conventional manufacturing process is used, then production is simplified, but air cells form reducing yield and quality
Solution Approach 1:
The vents are incorporated into the pressing member and release member before production begins, allowing gas to escape during the heating process. This preliminary structural design enables continuous production without compromising surface quality, thereby maintaining high yield while ensuring surface uniformity.
3Manufacturing precision
If vents are added to the pressing member and release member, then gas can escape preventing air cells, but device complexity increases
Solution Approach 1:
The pressing member and release member serve multiple functions: they apply pressure during heating, provide structural support, and simultaneously function as gas escape pathways through the incorporated vents. This multi-functionality allows gas removal without significantly increasing overall device complexity.
Solution Approach 2:
The pressing member and release member are designed with vent structures that create controlled porosity or openings, allowing gas to pass through while maintaining the structural integrity and pressing function of the members. This approach enables gas escape without requiring completely porous or complex filtering structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively prevents air cell formation, enhancing the quality and yield of the leather article by ensuring a smooth surface and improved tensile strength, while also simplifying the manufacturing process and reducing environmental impact.
Implementation Method 1
The stacked set is heated and vacuumized, such that the leather precursor forms the leather article
Implementation Method 2
The stacked set is heated and vacuumized, such that the leather precursor forms the leather article
Data Source
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AI summary
A method for manufacturing a leather article (600, 600a, 600b, 600c) includes steps as follows. A leather precursor (200, 200a, 200b, 200c) is provided, wherein the leather precursor (200, 200a, 200b, 200c) includes a polymer material (220a, 220b, 220c). A stacked set (500, 500a, 500b, 500c, 500d, 500e) with a plurality of vents (V), is provided, wherein the stacked set (500, 500a, 500b, 500c, 500d, 500e) includes the leather precursor (200, 200a, 200b, 200c) and a pressing member (400, 400a, 400b, 400b', 400c) . The stacked set (500, 500a, 500b, 500c, 500d, 500e) is heated and vacuumized, such that the leather precursor (200, 200a, 200b, 200c) forms the leather article (600, 600a, 600b, 600c) . The leather article (600, 600a, 600b, 600c) is separated from the pressing member (400, 400a, 400b, 400b', 400c) .