Film
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Solution Overview
Problem
Current methods for partially printing or engraving on polyurethane-coated surfaces, such as leather and artificial leather, face issues with ink durability, abrasion resistance, and the production of toxic gases during laser treatment, limiting the achievement of multi-color effects and safe processing.
Innovation Solution
A multilayer film with a thin, crosslinked polyester or polyacrylate top layer and a thermoplastic polyolefin or PVC base layer, where the top and base layers have different colors and compositions, allowing for laser-induced two-color effects without toxic gas production, and featuring polysiloxane and thermoplastic hollow microspheres for improved durability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser treatment is used to create partial color application on polyurethane-coated surfaces, then multi-color effects can be achieved, but toxic decomposition products including hydrocyanic acid are produced
Solution Approach 1:
The patent uses a composite material system consisting of a polyolefin base layer and a polyurethane top layer. The polyolefin base layer is specifically chosen because it produces no toxic gases during laser treatment, while the polyurethane top layer provides the desired surface properties and color. This composite structure allows laser treatment to create multi-color effects by removing the top layer in selected areas to expose the base layer, without producing toxic decomposition products.
2Ease of manufacture
If printing ink is applied to polyurethane-coated surfaces with separating substances, then partial color application is possible, but the ink dissolves or abrasion resistance is insufficient
Solution Approach 1:
The patent segments the surface into two distinct layers: a top layer with separating substances (polyurethane coating with wax) and a base layer without separating substances (polyolefin). This segmentation allows for durable partial color application because the laser treatment removes the top layer in specific areas to expose the base layer, creating permanent color contrast that is inherently abrasion-resistant since both layers are integral parts of the film structure rather than applied ink.
3Ease of manufacture
If the top layer is made thinner for better laser removal, then two-color effect is improved, but abrasion resistance may be compromised
Solution Approach 1:
The patent optimizes the thickness parameters of both layers to achieve the desired balance. The top layer is made thin enough (specific thickness range specified) to allow efficient laser removal for creating the two-color effect, while the base layer provides sufficient thickness and mechanical strength to maintain abrasion resistance. The specific thickness parameters are carefully selected so that the top layer can be effectively removed by laser while the base layer remains intact to provide structural support and durability.
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 enables the creation of durable, abrasion-resistant, two-color surfaces with reduced toxic gas production during laser treatment, suitable for various applications, including automotive interiors, and maintains the surface's integrity and feel.
Implementation Method 1
A pattern can be formed in the cover layer by removing material by means of a laser
Implementation Method 2
the film can be embossed and deformed by means of heat and pressure during the laser process
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a multilayer film comprising an at least single-layer top layer (1) and a base layer (2) surface-connected to the top layer (1), the top layer (1) being a layer of polyurethane and/or polyacrylate and/or mixtures thereof. According to the invention, the cover layer (1) has a thickness of 0.01 mm and 0.06 mm and is a layer of aliphatic, crosslinked polyurethane and/or polyacrylate and/or mixtures thereof, which may no longer have thermoplastic properties that the base layer (2) is thermoplastic and has a thickness between 0.15 mm and 0.40 mm and consists of polyolefin or PVC and that the top layer (1) and the base layer (2) have different colors and/or their content of color pigments is different in size.