Leather composite having an electronic layer
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Solution Overview
Problem
Existing leather composites for automotive applications, such as steering wheels, face challenges with electronic layers being positioned on the back, leading to reduced signal transmission and heat output, and complex joining processes, while also risking short circuits due to sweat and fat penetration.
Innovation Solution
A leather composite design where electronic layers are mechanically sewn to leather composite parts along a seam, with the contact area positioned at a greater distance from the visible surface, using T-joints, sharpened and folded joints, or conductive bridge elements to form electrical contacts, and applying additional contact and sealing materials to prevent moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electronic layer is positioned on the back of the leather composite, then the joining process is simplified, but the signal transmission and heat output are significantly reduced
Solution Approach 1:
The patent transitions the electronic layer from a two-dimensional back-surface position to a three-dimensional integrated position within the leather composite structure. By embedding the electronic layer between the leather layer and finishing layers, the invention achieves better signal and heat transmission while maintaining manageable manufacturing complexity through standardized lamination processes.
2Reliability
If the electronic layer is positioned closer to the surface to improve signal transmission, then the desired effect is enhanced, but the risk of short circuits due to sweat and grease penetration increases
Solution Approach 1:
The patent implements a nested structure where the electronic layer is embedded within multiple protective layers. The electronic layer is positioned between the leather layer and one or more finishing layers, creating a protective envelope that shields the electronic components from sweat and grease while maintaining close proximity to the surface for optimal signal transmission and heat output.
Solution Approach 2:
The patent uses thin film finishing layers to encapsulate the electronic layer. These flexible finishing layers provide effective protection against moisture and contaminants while maintaining the close positioning of the electronic layer to the surface, allowing signal and heat transmission without excessive exposure to harmful factors.
3Reliability
If composite parts are sewn together with contact points aligned for electron ic layer contact, then signal transmission is maintained, but the joining process becomes extremely complex and difficult
Solution Approach 1:
The patent combines the electronic layer with the leather composite parts through lamination before the sewing process. By integrating the electronic layer into the composite structure in advance, the invention eliminates the need for complex contact point alignment during joining, as the electronic layers are already positioned and connected within the laminated structure.
Solution Approach 2:
The patent performs the electronic layer integration and connection preparation in advance through lamination, before the final sewing assembly. This preliminary action of embedding and pre-positioning the electronic layers simplifies the subsequent joining process, eliminating the need for complex real-time alignment of contact points during assembly.
4Adaptability or versatility
If leather composites are made from multiple small composite components, then design flexibility and affordability are improved, but the number of contact points and joining complexity increases
Solution Approach 1:
The patent creates universal leather composite parts with integrated electronic layers that can be used in multiple design configurations. By embedding the electronic layers within the composite structure during manufacturing, the invention enables these parts to be assembled in various arrangements without requiring complex contact point alignment, thus maintaining design flexibility while reducing joining complexity.
Data Source
Figure 1A~1B
Figure 2~3
AI summary
The invention relates to a leather composite, comprising at least two composite parts (2), which are characterized by a layer structure that comprises: a leather layer (3) produced from a hide or a layer of artificial leather; a leather dressing (4) applied to a leather surface of the leather layer (3) or to a sanding base; and at least one electronic layer (7), which is inserted into the leather dressing (4) or applied to the leather dressing (4). At least two composite parts (2) are mechanically sewn to one another, with mutually facing surfaces (9, 10) of the leather dressing (4) and/or of the electronic layers (7), along at least one seam (8) of a connection (1, 20, 30), the electronic layers (7) of the composite parts (2) additionally forming at least one common electrical contact in at least one contact region (13) of the connection (1, 20, 30), which contact region (13) has a greater distance (A) from a visible surface (5) of the leather composite than the seam (8) does.