Composite sheet material
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Solution Overview
Problem
Existing composite sheet materials for vehicle interiors and furniture face challenges with high formability and strength, as they tend to lose strength during thermoforming and have inadequate resistance to heat and stains, especially when using heat fusible fibers for bonding processes.
Innovation Solution
A composite sheet material comprising a skin sheet attached with a woven fabric through an adhesive resin layer, where the skin sheet is made of an entangled fiber network of ultra-fine fibers and an elastic polymer, with polyester fibers containing a 1,2-propanediol-derived component, providing high flexibility, strength, and thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heat fusible fibers are used for bonding the outer knit layer to the non-woven fabric layer, then formability and resistance to stain are improved, but the elegant appearance of suede-like artificial leather is greatly impaired by heat during the bonding process
Solution Approach 1:
The patent changes the bonding mechanism from thermal (heat fusible fibers) to mechanical (cold-setting adhesive), altering the process parameters to avoid heat exposure. This allows the bonding process to occur at lower temperatures that do not damage the suede-like appearance while still achieving high formability through the adhesive bonding method.
Solution Approach 2:
The patent introduces an adhesive resin layer as an intermediary bonding agent between the knit layer and non-woven fabric layer, replacing the direct thermal bonding method. This intermediary substance enables strong bonding without requiring high temperatures, thus preserving the aesthetic quality of the suede-like surface.
2Reliability
If heat fusible fibers are used for bonding, then resistance to stain is improved, but the elegant appearance of suede-like artificial leather is greatly impaired by heat during the bonding process
Solution Approach 1:
The patent changes the bonding temperature parameter from high (heat fusible) to low (cold-setting adhesive), thereby eliminating the harmful thermal effect on appearance while maintaining the functional performance including stain resistance through the adhesive bonding structure.
Solution Approach 2:
The adhesive resin layer serves as an intermediary that provides both bonding function and stain resistance without requiring thermal processing, thus achieving reliability improvement without compromising appearance.
3Ease of manufacture
If conventional sheet materials are used for integral molding, then manufacturing is simplified, but effusion of molten resin on the surface of artificial leather occurs
Solution Approach 1:
The adhesive resin layer acts as a protective intermediary barrier between the molten resin and the artificial leather surface. This intermediate layer prevents direct contact and effusion of molten resin onto the surface, maintaining surface quality while allowing the integral molding process to proceed.
Solution Approach 2:
The patent applies a protective layer or treatment beforehand to cushion against the harmful effect of molten resin effusion. This pre-protection measure ensures that even during simplified integral molding processes, the surface quality is preserved by preventing resin penetration and damage.
4Ease of manufacture
If conventional sheet materials are used for integral molding, then manufacturing is simplified, but degradation of artificial leather due to high temperature of molten resin occurs
Solution Approach 1:
The adhesive resin layer serves as a thermal intermediary that protects the artificial leather from direct exposure to high temperatures of molten resin. This intermediate barrier allows the simplified integral molding process to occur while preventing thermal degradation and maintaining the durability of the artificial leather component.
Solution Approach 2:
The patent implements pre-protection measures through the adhesive layer and surface treatment to cushion against thermal degradation before the high-temperature molding process begins, thereby preserving reliability while maintaining manufacturing simplicity.
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 sheet material maintains high strength and flexibility, with minimal strength loss during thermoforming, and exhibits excellent wear resistance and thermal stability, making it suitable for vehicle interiors and furniture applications.
Implementation Method 1
a composite sheet material comprising a skin sheet attached with a woven fabric through an adhesive resin layer
Implementation Method 2
the skin sheet is formed by impregnating an elastic polymer, also known as a polymeric elastomer, into an entangled fiber network
Implementation Method 3
an adhesive resin that forms the adhesive resin layer is a moisture-curable resin
Data Source
AI summary
A composite sheet material includes a skin sheet and a woven fabric, wherein the skin sheet is formed by impregnating an elastic polymer into a base material consisting of an entangled fiber network, such as a nonwoven fabric, and wherein the composite sheet material has high thermal resistance and high formability suitable for integral molding. The composite sheet material is a composite sheet material including a skin sheet attached with a woven fabric through an adhesive resin layer, wherein the skin sheet is made of an entangled fiber network including ultra-fine fibers with an average single fiber diameter of 0.1 to 8 μm and of an elastic polymer, and wherein the woven fabric includes polyester fibers in which the polyester contains a 1,2-propanediol-derived component at a concentration of 1 to 500 ppm.