Method for manufacturing an artificial leather
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing artificial leather for motor vehicle interiors are complex and costly due to the need for adhesive layers between the spacer fabric and the surface coating, which complicates the production process and affects the mechanical properties and appearance of the final product.
Innovation Solution
A method involving a three-layer PVC coating applied successively to a textile carrier material without adhesive layers, using a detachable substrate and vacuum embossing to achieve a strong, flexible, and aesthetically pleasing artificial leather, where the first layer is directly applied to the carrier material, the second layer is foamed for elasticity, and the third layer is embossed for a natural leather grain appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive layers are used to connect the spacer fabric and surface coating, then the bond strength between layers is improved, but the production process becomes more complex and costly
Solution Approach 1:
The invention extracts and eliminates the adhesive layer from the multi-layer structure, achieving direct bonding between the spacer fabric and surface coating through chemical or physical interactions at the interface, thereby simplifying the production process while maintaining layer adhesion
Solution Approach 2:
The invention merges the functions of the adhesive layer into the interface between the spacer fabric and surface coating, allowing direct bonding through surface treatment or chemical interaction, thus reducing the number of components and process steps
2Strength
If adhesive layers are used to connect the spacer fabric and surface coating, then the bond strength between layers is improved, but the production cost increases
Solution Approach 1:
The invention removes the adhesive layer component, eliminating the cost associated with adhesive materials and their application processes, while achieving bonding through direct interface interaction between the spacer fabric and surface coating
Solution Approach 2:
The invention replaces expensive adhesive layers with a simpler, more cost-effective direct bonding interface between layers, reducing material costs and processing expenses
3Strength
If the carrier material has protruding threads or fringes to improve adhesion, then the bond strength is improved, but the surface quality and appearance are worsened
Solution Approach 1:
The invention applies different surface characteristics to different regions: the area contacting the coating has enhanced adhesion properties through chemical treatment or micro-structure, while the visible surface maintains smoothness and aesthetic quality, achieving both strong bonding and high surface quality
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
This approach eliminates the need for adhesive layers, ensuring high-quality mechanical properties, excellent processability, and a premium appearance while maintaining the three-dimensional structure and elasticity of the carrier material, with enhanced resistance to temperature and light aging, making it suitable for motor vehicle interior applications.
Implementation Method 1
The first, second and/or third layer is preferably dried at a temperature of 140 to 240° Celsius in appropriate drying ovens
Implementation Method 2
embossing at least the third layer of the coating, where a three-dimensional carrier material is used as the carrier material and the embossing takes place at a temperature of 130° to 250° Celsius in the vacuum embossing process
Implementation Method 3
the embossing takes place at a temperature of 130° to 250° Celsius in the vacuum embossing process
Data Source
AI summary
Synthetic leather comprises a three-dimensional textile carrier material (1) and a coating (2) applied on one side of the carrier material, which is based on polyvinyl chloride and consists of three layers that are applied successively, of which the first layer (21) is directly applied on the carrier material without adhesion-promoting adhesive layer, the second layer (22) is directly applied on the first layer and is formed as an intermediate layer, and the third layer (23) is directly applied on the second layer as a top layer. Independent claims are also included for: (1) producing the above mentioned synthetic leather, comprising (a) applying the third layer of the coating forming the subsequent top layer, in a paste-form on a releasable substrate and drying the third layer, (b) applying the second layer of the coating as an intermediate layer on the dried third layer, and drying the second layer, (c) applying the first layer of the coating in paste-form on the dried second layer, (d) applying the textile carrier material on the first layer in paste-form and drying the first layer, and (e) detaching the third layer from the substrate; and (2) interior trim parts of a motor vehicle, comprising a visible surface made of the above mentioned synthetic leather.