Microfibrous Multilayer Composite for Uniformly Dyed Vehicle Headliners
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Solution Overview
Problem
Existing multilayer composite materials for vehicle interiors, such as headliners, face challenges in achieving both mechanical performance and uniform dyeing, with previous solutions compromising on either mechanical properties or appearance.
Innovation Solution
A multilayer composite material is produced by coupling a microfibrous non-woven fabric with a polyethylene terephthalate fabric using a thermoplastic polyurethane adhesive, allowing for downstream dyeing and achieving superior elongation, flexibility, and formability, ensuring uniform color and appearance on both surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polymeric binder is used to retain microfibres and enhance mechanical properties, then mechanical strength and wear resistance are improved, but softness and formability deteriorate
Solution Approach 1:
The patent extracts the binder from the composite structure by dissolving it in water or organic solvents, removing the component that causes the contradiction between mechanical strength and formability. This allows the microfibrous layer to be produced with enhanced mechanical properties while the binder is completely removed before final application, restoring formability.
Solution Approach 2:
The patent applies binder impregnation as a preliminary action during manufacturing to achieve necessary mechanical strength and wear resistance, then subsequently removes the binder through washing or solvent treatment. This preliminary reinforcement allows the material to withstand processing while maintaining formability for complex shapes like headliners.
2Strength
If adhesive is applied to couple microfibrous fabric with polyester fabric, then mechanical performance is improved, but dyeing uniformity deteriorates
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: first coupling the microfibrous fabric with polyester fabric using adhesive, then performing dyeing as a separate subsequent operation. This segmentation allows the adhesive to provide necessary mechanical bonding while the dyeing process can be optimized independently to achieve uniform color distribution across both layers.
Solution Approach 2:
The patent performs the adhesive coupling as a preliminary action before dyeing, ensuring mechanical integrity is established first. The dyeing process then follows as a subsequent action, allowing uniform penetration of dye throughout the composite structure without being interfered with by adhesive application, thereby achieving both strong bonding and uniform appearance.
3Adaptability or versatility
If binder amount is increased to prevent negative effects on softness, then mechanical properties are maintained, but wear resistance deteriorates
Solution Approach 1:
The patent removes the binder completely through water washing or solvent treatment after it has served its purpose during manufacturing. This extraction allows the use of sufficient binder amounts to maintain mechanical properties and softness during processing, while the final product achieves wear resistance through the binder-free microfibrous structure that can be properly finished and treated.
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 resulting composite material exhibits enhanced mechanical properties, including high elongation at break and formability, making it suitable for complex vehicle interior applications like headliners, while maintaining a uniform and aesthetically similar appearance on both surfaces.
Implementation Method 1
coupling a microfibrous non-woven fabric with a polyethylene terephthalate fabric using a thermoplastic polyurethane adhesive
Data Source
AI summary
The present invention concerns a process for preparing a microfibrous multilayer composite material comprising: 1) realizing a non-woven microfibrous semi-finished product made up of microfibres of one or more polymers dispersed in a polyurethane matrix (semi-finished product IE); 2) cutting the semi-finished product lengthwise into two layers; 3) buffing at least one layer on one side (side N) so as to extract the microfibres and form the nap, thereby obtaining a semi-finished raw product; 4) cutting at least one semi-finished raw product lengthwise parallel to the surfaces, producing an non-woven intermediate product, containing the buffed side (side N) and a waste layer (containing the side that has not been buffed—side S); 5) coupling the non-woven intermediate product (on the side opposite side N) to a fabric made of polyethylene terephthalate fibres by means of the application of a thermoplastic polyurethane adhesive that can be cross-linked between the non-woven intermediate product and the fabric; 6) submitting the multilayer composite material to a jet dyeing process. The invention also concerns a multilayer composite material that can be obtained by the process of the invention and the use thereof for covering the internal side of roofs or headliners of vehicles and for covering furnishing elements.