Laminate material
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Solution Overview
Problem
Existing composite materials for car interior components lack a balance of low weight, sound and heat insulation, pressure elasticity, pleasant feel, and environmental sustainability, while also being prone to layer separation and high CO2 emissions during production and use.
Innovation Solution
A composite material is developed with a high proportion of open cells in the polyurethane foam carrier layer, combined with a top layer and intermediate layer using a polyurethane dispersion and adhesive, which includes a knitted fabric or fleece for reinforcement, and a surface structure that can be laser-patterned, ensuring excellent bonding and environmental friendliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If natural leather or heavy leather imitations are used, then durability and pleasant feel are improved, but weight increases and CO2 emissions increase
Solution Approach 1:
The patent uses open-cell polyurethane foam as the carrier layer, which provides lightweight properties while maintaining structural integrity. The open-cell structure allows for air permeability and reduced weight compared to dense materials like natural leather, while still providing the necessary durability for headliner applications.
Solution Approach 2:
The patent creates a multi-layer composite structure consisting of open-cell polyurethane foam carrier layer, adhesive layer with reinforcing mesh, and top layer with surface structure. This composite approach combines the lightweight properties of foam with the strength of reinforced adhesive layers to achieve both low weight and high durability.
2Stability of the object's composition
If molded foam parts with closed skin are produced, then structural integrity is improved, but breathability and condensation resistance deteriorate
Solution Approach 1:
The patent specifically uses open-cell polyurethane foam rather than closed-cell foam, allowing water vapor and air to pass through the material. This prevents condensation buildup between the metallic car roof and headliner while maintaining the structural integrity needed for headliner applications.
3Strength
If adhesive layers are used to connect layers, then bonding strength is improved, but layer separation tendency increases
Solution Approach 1:
The patent introduces a reinforcing mesh (knitted fabric, woven fabric, or fleece) as an intermediary element within the adhesive layer. This mesh acts as a bridge between the carrier layer and top layer, mechanically interlocking with both surfaces and preventing adhesive failure and layer separation while maintaining strong bonding.
4Object-affected harmful factors
If heavy materials are used for headliners, then sound and heat insulation are improved, but weight increases and recyclability deteriorates
Solution Approach 1:
The open-cell structure of the polyurethane foam provides excellent sound and heat insulation properties due to the air trapped in the open cells, while keeping the material lightweight. This eliminates the need for heavy dense materials to achieve the same insulation performance.
Solution Approach 2:
The multi-layer composite structure optimizes insulation properties through the combination of open-cell foam (providing thermal and acoustic insulation) with reinforced adhesive layers (providing structural stability), achieving high insulation performance with low weight.
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 lightweight, flexible, and durable solution with excellent insulation and comfort properties, reduced CO2 emissions, and easy recyclability, while maintaining a pleasant appearance and preventing condensation issues.
Implementation Method 1
The binding layer (7), which fulfills the function of an adhesive layer, has partially penetrated into a surface region (7') of a carrier layer (2), with the binding layer (7) forming the connection between the carrier layer (2) and the top layer (4) or the intermediate layer (5)
Implementation Method 2
a thin, lightweight mesh, knitted fabric or fleece is inserted or embedded in the adhesive layer and/or the knitted fabric or mesh or fleece rests on or rests on the surface of the carrier layer and/or on the surface of the carrier layer is bonded, preferably by flame lamination
Implementation Method 3
the intermediate layer or the binding layer, optionally a knitted fabric or mesh or nonwoven fabric inserted or attached to the carrier layer, penetrates at least in places by 0.02 to 0.8 mm, preferably 0.05 to 0.5 mm, is introduced or penetrated into the open-cell polyurethane foam of the carrier layer
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a composite material having a polymeric upper layer (4) which is connected via at least one adhesive layer to a substrate (2). According to the invention the substrate (2) is predominantly or entirely formed by an open-cell polyurethane foam onto which the upper layer (4), containing between 2 and 12 wt % of polysiloxane, is bonded by the adhesive layer. An intermediate layer (5) or a double layer, i.e. a composite of the intermediate layer (5) with a bonding layer (7) located between the substrate (2) and the intermediate layer (5), is provided between the upper layer (4) and the substrate (2) as an adhesive layer for joining the upper layer (4) and the substrate (2). The regions of the substrate (2) into which the polyurethane dispersion of the adhesive layer has penetrated in a controlled manner during application have a density which is between 12 % and 48 %, preferably between 18 % and 30 %, above the density of the regions of the substrate (2) without the adhesive layer.