Composite Leather Cladding for Vehicle Interiors
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Solution Overview
Problem
Current leather claddings for sports and electric cars are heavy due to their thickness, leading to reduced robustness, elasticity, and workability when thinned, resulting in shorter lifespan and higher costs.
Innovation Solution
A composite material comprising a leather layer and a support layer made of isotropic polyethersulfone fabric with a polyamide adhesive, reducing weight while maintaining tensile strength and elasticity, achieved by using a semi-aniline, nappa, or embossed leather with a thin polyethersulfone fabric and a minimal adhesion layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the thickness of leather cladding is reduced to lower specific weight, then weight is decreased, but robustness, elasticity and workability are lost
Solution Approach 1:
The patent applies composite materials by bonding a thinned leather layer (0.6-0.9mm) to a textile support layer, creating a composite structure that combines the aesthetic and tactile properties of leather with the mechanical strength and elasticity of textile, thereby reducing weight while maintaining robustness
Solution Approach 2:
The patent segments the cladding material into distinct functional layers: a thinned leather layer for aesthetics and a textile support layer for structural integrity, allowing each layer to optimize its specific function without compromising the other
2Weight of moving object
If the thickness of leather cladding is reduced, then specific weight is lowered, but the material becomes more prone to breaking and lifespan is reduced
Solution Approach 1:
The composite structure provides the thinned leather layer with a reinforcing textile backbone, preventing breakage and extending lifespan while maintaining the weight reduction benefits
Solution Approach 2:
The patent uses an adhesive layer as an intermediary between the leather and textile layers, ensuring strong bonding that prevents delamination and maintains structural integrity during use
3Reliability
If chrome-tanned leather is used to ensure wear resistance, then durability is improved, but specific weight increases above 700 g/m2
Solution Approach 1:
The patent replaces heavy chrome-tanned leather with a composite of thinned chrome-tanned leather (0.6-0.9mm) bonded to lightweight textile, achieving wear resistance through the composite structure rather than relying solely on thick leather
Solution Approach 2:
The patent changes the thickness parameter of the leather layer from the conventional 1-1.2mm to a thinned 0.6-0.9mm, and compensates for the reduced durability through the added textile support layer in the composite structure
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 composite material achieves a lower specific weight without compromising the aesthetic and tactile properties, maintaining robustness, elasticity, and tensile strength, thus extending the lifespan and reducing production costs.
Implementation Method 1
a composite material comprising a leather layer and a support layer made of isotropic polyethersulfone fabric with a polyamide adhesive
Data Source
AI summary
A composite leather-based material, in particular suitable for cladding components of a vehicle, which comprises a leather layer having a predetermined thickness of less than 0.8 mm, a first external face and a second internal face, a support layer made of a thermoplastic material in the form of fabric or a net having a predetermined thickness of about 0.4 mm, adherent to said second face of said leather layer, as well as advantageously a polyamide adhesive arranged between the leather layer and the support layer. Said composite material has a thickness of less than 1 mm and a specific weight that is less than or equal to 650 g/m2.