Artificial leather with three-dimensional pattern and manufacturing method thereof
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Solution Overview
Problem
Conventional PVC foam artificial leather lacks light weight, color diversification, and design enhancement, limiting its functionality in applications such as furniture and automotive interiors.
Innovation Solution
A novel artificial leather structure comprising a base fabric with a polyvinyl chloride film, a bonding layer, a patterned foam layer, a color layer, and a surface treatment layer, allowing for multiple three-dimensional patterns and colors, achieved through a manufacturing process involving coating, drying, and hot-pressing to form the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional PVC foam artificial leather is used, then it provides basic functionality for furniture and automotive interiors, but it lacks light weight, color diversification, and design enhancement
Solution Approach 1:
The artificial leather is divided into multiple functional layers including base fabric, bonding layer, foam layer, color layer, and surface treatment layer. Each layer serves a specific function and can be independently optimized, enabling color diversification while maintaining manageable structural complexity through modular design
Solution Approach 2:
The invention introduces a multi-layered vertical structure with distinct functional zones. The color layer and foam layer are positioned at different depths, allowing color patterns to be embedded within the structure rather than just on the surface, thereby achieving color diversification without proportionally increasing overall structural complexity
2Manufacturing precision
If multiple layers are added to achieve three-dimensional patterns and colors, then aesthetic and functional properties are improved, but manufacturing process complexity increases
Solution Approach 1:
Color patterns are pre-formed in the color layer before the final foam expansion process. This preliminary action ensures precise pattern positioning and allows subsequent foam layers to conform to the established color design, achieving high pattern precision while streamlining the overall manufacturing sequence
Solution Approach 2:
The manufacturing process utilizes controlled thermal and pressure parameters during hot-pressing to achieve precise foam expansion and pattern formation. By optimizing temperature, pressure, and time parameters, the process achieves high pattern precision without requiring excessively complex manufacturing equipment or procedures
3Strength
If traditional PVC foam artificial leather is used, then it provides basic durability, but it lacks lightweight properties and design enhancement
Solution Approach 1:
The foam layer is designed with a controlled porous structure that provides both lightweight properties and mechanical durability. The cellular foam structure reduces density and weight while maintaining structural integrity and tensile strength, thereby achieving weight reduction without sacrificing durability
Solution Approach 2:
The invention uses composite construction combining base fabric, bonding adhesive, foam polymer, color pigments, and surface treatment coatings. This composite material system optimizes the weight-strength ratio by selecting materials with high strength-to-weight ratios and combining them in a multi-layer architecture that distributes mechanical stresses effectively
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 results in a lightweight artificial leather with enhanced three-dimensional patterns and colors, improving its aesthetic and functional properties compared to traditional PVC foam artificial leather.
Implementation Method 1
hot-pressing to form the layers
Data Source
AI summary
Provided are an artificial leather and a method of manufacturing the same. The artificial leather includes: a base fabric; a polyvinyl chloride film bonded to a surface of the base fabric; bonding layer formed on a surface of the film; a first foam layer formed on the bonding layer in a patterned shape; a first color layer formed on a surface of the foam layer and having the same pattern as the first foam layer; and a surface treatment layer formed on a surface of the first color layer with the same pattern as the first color layer or formed on a surface of the bonding layer without the first foam layer and the surface of the first color layer. to the artificial leather of the present invention may have a light weight and implement various three-dimensional patterns and colors as compared with a conventional PVC foam artificial leather.