Artificial Leather Laminate With Modified TPO for Low-Emission Bonding

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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, with the modified layer enhancing adhesiveness through maleic anhydride blending and corona discharge processing, allowing for improved processability and reduced emissions.

Engineering Contradictions & Design Principles

VSEngineering 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

Engineering Contradiction:

Improvecarbon emissions and energy consumptionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent uses composite materials including modified thermoplastic polyolefin resin (containing maleic anhydride grafted polyethylene or polypropylene), thermoplastic polyurethane resin, and polyvinylidene fluoride resin in a multi-layer structure. This composite approach reduces carbon emissions and energy consumption while maintaining manufacturability through controlled layer integration.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by modifying specific layers with different properties: the lower layer uses modified thermoplastic polyolefin for adhesion, the intermediate layer uses thermoplastic polyurethane for flexibility, and the upper layer uses polyvinylidene fluoride for durability. Each layer is optimized locally to reduce overall environmental impact while maintaining ease of manufacture.

Inventive Principle:

Principle #3Local quality

2Reliability

If materials with similar properties are used to maintain adhesion between layers, then adhesion is maintained, but processability and surface variability are greatly limited

Engineering Contradiction:

Improveadhesion between layersVSAvoidsurface variability and processability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes material parameters by using modified thermoplastic polyolefin resin containing maleic anhydride grafted polyethylene or polypropylene, which alters the chemical properties to enhance adhesion. The resin contains 5-50 wt% grafted component, creating optimal bonding without requiring similar materials throughout, thus enabling surface variability while maintaining reliability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The modified thermoplastic polyolefin layer acts as an intermediary between the fabric substrate and the upper polyurethane layer. This intermediate layer with specific adhesive properties enables strong bonding while allowing the upper layers to have different properties for surface variability, resolving the contradiction between adhesion and versatility.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If a multi-layer structure with modified resin is used, then adhesiveness and processability are enhanced, but the device complexity increases

Engineering Contradiction:

Improveprocessability and adhesivenessVSAvoidmulti-layer structure complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent segments the artificial leather into distinct functional layers: a lower layer (modified thermoplastic polyolefin, 0.1-1.0 mm), an intermediate layer (thermoplastic polyurethane, 0.1-1.0 mm), and an upper layer (polyvinylidene fluoride, 0.1-1.0 mm). This segmentation enhances processability and adhesiveness while managing complexity through clear functional division.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent merges multiple resins into a integrated multi-layer structure where modified thermoplastic polyolefin, thermoplastic polyurethane, and polyvinylidene fluoride are combined in specific proportions. This merging creates synergistic effects that improve adhesiveness and processability while the overall structure remains manageable through controlled integration.

Inventive Principle:

Principle #5Merging (Combining)

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 solution reduces carbon emissions and energy consumption while enhancing the adhesiveness and processability of artificial leather, meeting the physical requirements of shoemaking and enabling diverse surface textures and colors.

Implementation Method 1

the modified layer enhancing adhesiveness through maleic anhydride blending and corona discharge processing

Methodology Applied

Scientific EffectCorona discharge: Corona Discharge

Data Source

PatentEP4438292A1Artificial leather and method for manufacturing the same

Publication Date: 2024.10.02 SAN FANG CHEM IND

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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.