Structured artificial leather material comprising water-laden particles from a renewable raw material
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Solution Overview
Problem
Existing artificial leather materials face ecological concerns due to petrochemical origins and labor-intensive, less convincing methods for achieving a visually authentic surface structure, which are not sustainable and require nonrenewable raw materials.
Innovation Solution
A structured artificial leather material with a support layer and an overlay layer containing water-laden particles of renewable raw materials, such as silverskin of coffee fruits, which creates a unique, authentic visual effect through surface rupturing during embossing, reducing the need for additional labor-intensive structuring processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional artificial leather materials made from petrochemicals (PVC, PU) are used, then the material provides durability and structural integrity, but the ecological footprint increases due to nonrenewable raw materials
Solution Approach 1:
The patent changes the chemical composition parameters of the overlay layer by replacing petrochemical plastics (PVC, PU) with a composite of natural fibers (cotton, linen, hemp, etc.) bound with polyol and crosslinking agent. This parameter change maintains material durability while eliminating dependence on nonrenewable petrochemical resources, thereby reducing ecological footprint.
Solution Approach 2:
The patent creates a composite material system combining natural fibers (cellulose-based), polyol (polymer), and crosslinking agents to form an ecologically sustainable overlay layer. This composite structure replaces conventional plastic-based artificial leather while maintaining structural integrity and durability through the synergistic combination of natural and synthetic components.
2Shape
If labor-intensive embossing processes are used to create surface structure, then the visual appearance resembles genuine leather, but the manufacturing complexity and time increase
Solution Approach 1:
The patent incorporates structuring agents (particles with diameter of 0.1-2.0 mm, preferably 0.3-1.0 mm) into the overlay layer composition before final formation. These pre-integrated structuring agents create surface texture automatically during the embossing or forming process, eliminating the need for subsequent labor-intensive embossing operations and reducing manufacturing complexity.
Solution Approach 2:
The structuring agents within the overlay layer self-organize to create surface structure during the material formation process. The particles naturally distribute and arrange themselves to produce an authentic leather-like surface texture without requiring external embossing intervention, thereby simplifying the manufacturing process.
3Shape
If conventional embossing processes are used to create surface structure, then the visual appearance is improved, but the process requires multiple steps and is time-consuming
Solution Approach 1:
The patent merges the structuring function into the overlay layer composition itself by incorporating particles and structuring agents during the material formation stage. This combines the surface structuring function with the base material formation process, eliminating separate embossing steps and reducing total manufacturing time while maintaining authentic visual appearance.
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 material achieves a strong, visually attractive, and ecologically sustainable product with a reduced ecological footprint, using high proportions of renewable raw materials while simplifying the manufacturing process and eliminating the need for extensive embossing, resulting in a unique and authentic surface structure.
Implementation Method 1
the particles are laden with water
Implementation Method 2
the particles are loaded with water... produced by a rupturing of the surface of the artificial leather material during the embossing step
Data Source
AI summary
A structured artificial leather material comprising a support layer and an application layer, the application layer comprising particles from a renewable raw material, which are laden with water. A method for producing such a structured artificial leather material is also provided.