Artificial leather having excellent surface appearance and method of manufacturing the same

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Solution Overview

Problem

Conventional artificial leather manufacturing methods result in non-uniform surface treatment layers due to uneven application of surface treatment agents on embossed patterns, leading to mottled appearances and reduced gloss differences between valleys and crests.

Innovation Solution

The method involves coating a back layer with a solution, forming pre-foam and skin layers, laminating them, applying a water-based surface treatment agent, and irradiating with infrared light before embossing to form a uniform surface treatment layer with a thickness ratio of 0.7 to 1 between crests and valleys, ensuring even gloss distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If surface treatment agent is applied after embossing pattern formation, then embossed texture is imparted to skin layer, but surface treatment layer thickness becomes non-uniform causing mottled appearance

Engineering Contradiction:

Improvesurface treatment layer thickness uniformityVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies surface treatment agent to the skin layer before embossing pattern formation. This preliminary action ensures that the surface treatment layer is deposited uniformly on the flat skin layer surface, avoiding the non-uniform thickness that would occur if applied after embossing. The embossing pattern is then formed on top of this uniform surface treatment layer through roller pressing, resolving the contradiction between thickness uniformity and process complexity.

Inventive Principle:

Principle #10Preliminary action

2Illumination intensity

If embossed pattern is formed before surface treatment, then texture similar to natural leather is achieved, but gloss difference between valleys and crests occurs

Engineering Contradiction:

Improvegloss uniformityVSAvoidsurface texture

Core Design Contradiction:

Illumination intensityVSShape

Solution Approach 1:

The patent performs surface treatment before embossing pattern formation. The surface treatment agent is applied to the flat skin layer, creating a uniform surface treatment layer. Subsequently, the embossing pattern is formed by roller pressing on this pre-treated surface. This sequence ensures that both the valleys and crests of the embossed pattern have uniform surface treatment layer thickness, eliminating gloss differences while preserving the natural leather-like texture.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If surface treatment layer thickness ratio between crest and valley is not controlled, then application process is simple, but artificial leather appearance becomes mottled

Engineering Contradiction:

Improveapplication process simplicityVSAvoidsurface appearance quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies surface treatment agent before embossing pattern formation, which simplifies the application process while ensuring uniform thickness distribution. The surface treatment layer is deposited on the flat skin layer surface, naturally achieving uniform thickness without complex control mechanisms. The subsequent embossing process then creates the desired texture pattern on top of this uniform layer, maintaining both process simplicity and appearance quality.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent inverts the conventional sequence by applying surface treatment before embossing instead of after. This inversion fundamentally changes the thickness distribution outcome: the surface treatment layer is applied uniformly to the flat substrate first, and the embossing pattern is then formed on top. This approach eliminates the need for complex thickness control during application while ensuring uniform gloss and preventing mottled appearance.

Inventive Principle:

Principle #13The other way round (Inversion)

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 approach results in artificial leather with a uniform surface appearance, texture similar to natural leather, and enhanced cushioning by preventing foam cell distortion, while maintaining a soft feel and excellent mechanical properties.

Implementation Method 1

irradiating an upper surface of the surface treatment layer with infrared light

Methodology Applied

Scientific EffectInfrared radiation heating: Infrared Radiation

Implementation Method 2

forming an embossed pattern through vacuum adsorption molding on upper surfaces of the skin layer and surface treatment layer heated by irradiation with infrared light

Methodology Applied

Scientific EffectVacuum adsorption molding: Vacuum

Data Source

PatentUS12024817B2Artificial leather having excellent surface appearance and method of manufacturing the same

Publication Date: 2024.07.02 LG HAUSYS LTD

AI summary

The present invention relates to artificial leather, and more particularly, to artificial leather for automobile seat covers having excellent surface appearance and a method of manufacturing the artificial leather. When the artificial leather of the present invention is manufactured, surface treatment is performed before embossing molding that imparts a texture and cushioning similar to natural leather to artificial leather. Accordingly, the artificial leather of the present invention may be provided with a surface treatment layer having a uniform thickness, thereby exhibiting excellent surface appearance.