Multilayer composite material and related production method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multilayer materials face challenges in achieving proper adhesion between layers, especially when made of non-woven fabrics, and lack sufficient mechanical strength, flexibility, and stability, particularly when combined with different materials having varying mechanical characteristics.
Innovation Solution
A multilayer material production method involving forming a microfibre layer and a support layer with ultra-high-molecular-weight polyethylene (UHMWPE) and polyamide fibres, impregnating the microfibre layer with polyurethane resin, coagulating it, and joining both layers using a polyurethane adhesive to achieve stable adhesion and high mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding is used to join microfibre layer and support layer, then adhesion between layers is improved, but production complexity increases and homogeneous colouring becomes difficult
Solution Approach 1:
The patent introduces a specific adhesive composition (polyurethane-based with particular molecular weight and flexibility characteristics) as an intermediary substance between the microfibre layer and support layer. This mediator enables strong bonding while maintaining production feasibility and colouring uniformity, resolving the contradiction between adhesion strength and production complexity.
Solution Approach 2:
The patent optimizes specific parameters of the adhesive system including polyurethane molecular weight (10,000-100,000), adhesive layer thickness (0.1-1.0 mm), and bonding temperature ranges. By controlling these parameters, the patent achieves strong interlayer adhesion while simplifying the production process and enabling homogeneous colouring throughout the multilayer structure.
2Strength
If needling process is used to combine microfibre layer and support layer, then adhesion is achieved, but the technique cannot be used with all materials especially high density materials
Solution Approach 1:
The patent develops a universal adhesive bonding system that can bond diverse materials including high-density materials that cannot be processed by needling. The polyurethane-based adhesive with controlled flexibility and molecular weight parameters creates a versatile bonding solution applicable to various material combinations, thereby increasing material compatibility while maintaining strong adhesion.
3Strength
If thermoplastic adhesive and polyurethane resin impregnation are used, then multilayer material is obtained, but the method is not suitable for materials with melting temperature lower than coagulation temperature (150°C)
Solution Approach 1:
The patent fundamentally changes the bonding temperature parameter by using polyurethane adhesive that cures at lower temperatures (below 150°C) compared to traditional thermoplastic adhesives. This parameter change enables the processing of heat-sensitive materials with low melting points while maintaining structural integrity and strong interlayer bonding.
Solution Approach 2:
The patent replaces the high-temperature thermoplastic bonding mechanism with a low-temperature polyurethane curing mechanism. This substitution allows materials that would melt or deform at 150°C to be processed successfully, expanding the range of compatible materials while achieving equivalent or superior structural integrity.
4Ease of manufacture
If conventional multilayer material is used, then production is feasible, but tensile strength and mechanical strength are insufficient
Solution Approach 1:
The patent creates a composite multilayer structure combining microfibre layers with support layers, bonded by optimally formulated polyurethane adhesive. This composite construction achieves high tensile strength and mechanical properties while maintaining production feasibility. The synergistic combination of materials and controlled adhesive bonding creates superior strength characteristics compared to conventional single-layer or poorly bonded multilayer materials.
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 method results in a multilayer material with enhanced flexibility, tensile strength, and resistance to fraying, allowing for stable adhesion to various surfaces and materials, including leather, while maintaining softness and preventing wrinkle formation.
Implementation Method 1
impregnating the at least one microfibre layer with a polyurethane resin
Implementation Method 2
subjecting the impregnated microfibre layer to coagulation to obtain a coagulated microfibre layer
Implementation Method 3
joining the coagulated microfibre layer and the support layer using polyurethane adhesive to obtain a multilayer material
Data Source
Figure 1
AI summary
A multilayer material (100) comprising at least one first layer (1', 1") made of coagulated microfibre and at least one support layer (2) that is made of high-resistance synthetic fabric and coupled to said at least one first coagulated microfibre layer (1', 1"), wherein said support layer (2) is joined to said at least one first layer (1', 1") using a polyurethane adhesive, wherein the support layer (2) comprises between 25-100% by weight of ultra-high-molecular-weight polyethylene (UHMWPE). A method for producing a multilayer material (100) comprises the following phases: forming at least one microfibre layer of polymeric material; forming a support layer (2) containing 25-100% by weight of ultra-high-molecular-weight polyethylene; impregnating said at least one microfibre layer with a polyurethane resin and subjecting said at least one impregnated microfibre layer to coagulation to obtain a coagulated microfibre layer (1', 1"); combining said coagulated microfibre layer (1', 1") and said support layer (2) using polyurethane adhesive to obtain a multilayer material (100). Layered material comprising two outer microfibre layers (1', 1") between which an inner layer (2) of high-resistance synthetic fabric is included and joined.