Artificial leather having water-based polyurethane foam layer and method of manufacturing the same
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Solution Overview
Problem
Conventional artificial leather for automobile seats lacks the physical strength, durability, moisture permeability, and aesthetic qualities of natural leather, and the manufacturing process using solvent-based polyurethane poses environmental and health risks due to the use of organic solvents like dimethylformamide.
Innovation Solution
A water-based polyurethane foam layer with open cells formed through mechanical foaming is integrated into artificial leather, comprising a fabric layer, binder layer, skin layer, and surface treatment layer, manufactured using a process that eliminates the need for organic solvents and enhances cushioning and moisture permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solvent-based polyurethane is used in artificial leather manufacturing, then physical strength and durability are improved, but environmental pollution and health risks increase due to organic solvent discharge
Solution Approach 1:
The patent changes the fundamental parameter of the polyurethane formulation from solvent-based to water-based system. This substitution of the dispersion medium (water instead of organic solvents like DMF) eliminates harmful emissions while maintaining the polyurethane foam layer's physical strength and durability through optimized water-based chemistry and foam structure
Solution Approach 2:
The patent converts the traditionally harmful organic solvent role into a beneficial water-based system. Water serves as the harmless dispersion medium that can be easily evaporated or retained, transforming the environmental hazard into an eco-friendly manufacturing approach while still achieving the desired material properties
2Quantity of substance
If conventional artificial leather is manufactured, then cost is reduced compared to natural leather, but moisture permeability and heat dissipation are insufficient
Solution Approach 1:
The patent incorporates a polyurethane foam layer with controlled porous structure that mimics natural leather's moisture permeability. The foam's cellular structure provides channels for moisture vapor transmission and heat dissipation, achieving natural leather-like comfort while maintaining the cost advantages of artificial leather
Solution Approach 2:
The patent creates a composite structure combining fabric substrate with polyurethane foam layer, integrating the benefits of both materials. The fabric provides structural integrity and cost-effectiveness, while the foam layer contributes moisture permeability and heat dissipation properties, together achieving natural leather performance at lower cost
3Reliability
If polyurethane foam layer is added to artificial leather, then cushioning and moisture permeability are improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical foam formation processes with a simplified chemical foaming mechanism. Water-based polyurethane components react to generate foam in-situ during coating and drying, eliminating the need for separate foam generation equipment and reducing manufacturing steps while achieving the desired cushioning properties
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
The artificial leather exhibits superior moisture permeability and heat dissipation, preventing the formation of wrinkles and reducing surface temperature, while being more environmentally friendly and cost-effective compared to traditional methods.
Implementation Method 1
the artificial leather has excellent cushioning and moisture permeability, may lower the surface temperature of automobile seats in summer
Implementation Method 2
may lower the surface temperature of automobile seats in summer
Data Source
AI summary
The present invention relates to artificial leather having a water-based polyurethane foam layer including a fabric layer 110; a binder layer 111 laminated on the upper portion of the fabric layer 110; a water-based polyurethane foam layer 120 laminated on the upper portion of the fabric layer 110; a skin layer 130 laminated on the upper portion of the water-based polyurethane foam layer 120; and a surface treatment layer 140 laminated on the upper portion of the skin layer 130, wherein open cells are formed in the water-based polyurethane foam layer 120 through mechanical foaming. According to the present invention, a water-based polyurethane foam layer having open cells formed through mechanical foaming is applied to artificial leather for automobile seats.