Cellular Multi-Layer Covering Material for Clean Edge Creasing
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Solution Overview
Problem
Elastomeric composites used for cover materials, such as consolidated polyurethanes, tend to pull away from surfaces when folded, making it difficult to achieve a smooth, efficient covering process that mimics the look and feel of leather or other decorative materials.
Innovation Solution
A multi-layer material comprising a polymeric cellular layer and a nonwoven backing layer, with a creasability angle between 20 and 160 degrees, is developed, where the cellular layer is formed by entraining air or gas into a polymer to create a froth, which is then applied to the backing layer, enhancing the material's ability to hold creases and adhere effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If elastomeric composites are used to simulate leather look and feel, then aesthetic quality is improved, but creasability and ease of application deteriorate
Solution Approach 1:
The material is divided into multiple functional layers: a nonwoven substrate layer providing structural support and creasability, and an elastomeric composite layer providing leather-like aesthetics. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The invention uses a composite structure combining a nonwoven substrate with an elastomeric composite layer. This composite material approach integrates the advantages of both materials: the substrate's creasability and the elastomeric layer's aesthetic properties, resolving the contradiction between appearance quality and ease of application.
2Ease of operation
If the composite is folded over edges or corners, then coverage is achieved, but the material pulls away from the target surface
Solution Approach 1:
By separating the creasability function (substrate layer) from the adherence function (elastomeric layer), the material can fold cleanly without the elastomeric layer pulling away. The substrate layer handles the mechanical stress of folding while the elastomeric layer maintains surface adherence.
Solution Approach 2:
Different layers are assigned different local properties: the nonwoven substrate provides local flexibility and creasability at fold lines, while the elastomeric composite provides local adherence and aesthetic quality at the covered surface. This local differentiation resolves the contradiction between folding capability and surface adherence.
3Device complexity
If a single-layer elastomeric composite is used, then material simplicity is maintained, but creasability is insufficient
Solution Approach 1:
The single-layer elastomeric composite is segmented into a two-layer structure with a dedicated nonwoven substrate layer for creasability and an elastomeric layer for aesthetics. This segmentation directly addresses the creasability deficiency while maintaining reasonable structural simplicity.
Solution Approach 2:
The invention transforms a single-material system into a composite material system combining nonwoven substrate and elastomeric polymer. This composite approach introduces the necessary creasability through the substrate while preserving the aesthetic qualities of the elastomeric layer.
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 multi-layer material improves creasability, allowing for easier application and adherence to surfaces, resulting in a smooth, efficient covering process that maintains a desired texture and appearance, suitable for various applications like journals, diaries, and boxes.
Implementation Method 1
entraining air or gas into a polymer to create a polymer froth
Implementation Method 2
applying an adhesive to either the article or to a nonwoven backing layer of the material
Data Source
Figure 1~2
AI summary
A multi-layer material suitable for use as a covering for an article includes a polymeric cellular layer and nonwoven backing layer. The multi-layer material having a creasability angle of between about 20 and about 160 degrees.