Artificial leather and method for manufacturing the same
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Solution Overview
Problem
Conventional artificial leather manufacturing processes have high carbon emissions and energy consumption, and the structure limits the surface variability, requiring materials with similar properties for adhesion, which restricts processability.
Innovation Solution
The artificial leather comprises a fabric layer, a thermoplastic polyolefin layer, a modified thermoplastic polyolefin layer, and a polyurethane surface layer, where the modified thermoplastic polyolefin layer is blended with maleic anhydride to enhance adhesiveness, and a corona discharge processing is applied to improve surface adhesiveness, allowing for better processability and reduced emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional materials and processes are used for artificial leather manufacturing, then the structure is simple and easy to manufacture, but carbon emissions and energy consumption are high
Solution Approach 1:
The patent changes the chemical composition parameters by introducing a modified thermoplastic polyolefin layer containing maleic anhydride (3-50 wt%) instead of conventional materials. This compositional change enables reduced processing temperatures and lower energy consumption while maintaining manufacturing feasibility through the specific chemical properties of the modified polymer
2Reliability
If materials with similar properties are used to maintain adhesion between layers, then adhesion is ensured, but surface variability and processability are limited
Solution Approach 1:
The patent applies local quality by creating distinct layers with different functional properties: the modified thermoplastic polyolefin layer (with maleic anhydride) provides adhesion to the fabric layer, while the polyurethane surface layer provides the desired surface properties. This localized functional differentiation enables both strong adhesion and surface variability without requiring similar materials throughout
Solution Approach 2:
The patent uses composite materials by combining thermoplastic polyolefin with maleic anhydride modification, then layering it with polyurethane. This composite structure integrates the adhesion benefits of polyolefin with the surface properties of polyurethane, achieving both reliable bonding and enhanced processability with diverse surface options
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 configuration reduces carbon emissions and energy consumption while enabling improved adhesiveness and processability, meeting the diverse needs of shoemaking with a more environmentally friendly manufacturing process.
Implementation Method 1
a modified thermoplastic polyolefin layer, and a polyurethane surface layer, where the modified thermoplastic polyolefin layer is blended with maleic anhydride to enhance adhesiveness
Implementation Method 2
a corona discharge processing is applied to improve surface adhesiveness
Data Source
AI summary
An artificial leather and a method for manufacturing the artificial leather are provided. The artificial leather includes a fabric layer, a thermoplastic polyolefin layer, a modified thermoplastic polyolefin layer, and a polyurethane surface layer. The thermoplastic polyolefin layer is disposed on the fabric layer. The modified thermoplastic polyolefin layer is disposed on the thermoplastic polyolefin layer. The polyurethane surface layer is attached to the modified thermoplastic polyolefin layer through an adhesive.