Multifibrous multilayer composite material for applications in the automotive sector
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Solution Overview
Problem
Existing multilayer composite materials for automotive applications, such as vehicle headliners, face challenges in achieving both uniform dyeing and high mechanical performance, particularly in terms of elasticity and formability, due to the limitations of binder usage and differing structural appearances between layers.
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 and formability characteristics, ensuring uniform color and appearance on both surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polymeric binder is used to bind microfibres in the non-woven fabric, then mechanical strength and wear resistance are improved, but softness and formability deteriorate
Solution Approach 1:
The patent removes the polymeric binder from the non-woven fabric structure, retaining only the microfibres bound by entanglement. This extraction eliminates the binder's negative effect on formability while preserving mechanical strength through the entangled fibre network itself.
Solution Approach 2:
The patent creates a non-woven fabric with a porous structure formed by entangled microfibres without binder. This porous entangled structure provides both mechanical strength through fibre interlocking and formability through the flexible open architecture that can deform and conform to complex shapes.
2Strength
If the microfibrous layer is coupled with a textile support before dyeing, then mechanical performance is improved, but uniform dyeing becomes difficult due to adhesive resistance
Solution Approach 1:
The patent performs the dyeing process on the microfibrous layer before coupling it with the textile support. This preliminary dyeing action allows uniform penetration of dye throughout the microfibres without interference from adhesives, and the subsequent coupling preserves this uniform coloration while providing mechanical reinforcement.
3Adaptability or versatility
If a fabric support is coupled to the microfibrous layer, then elasticity and formability are improved, but the visual appearance differs significantly between layers
Solution Approach 1:
The patent applies different visual characteristics to different layers: the microfibrous layer provides a suede-like aesthetic appearance on the visible surface, while the textile support layer provides mechanical reinforcement on the reverse side. Each layer performs its local function optimally without compromising the other's visual or mechanical properties.
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 increased elongation at break and formability, making it suitable for complex automotive components like vehicle headliners with uniform appearance and improved resistance to stress conditions.
Implementation Method 1
coupling a microfibrous non-woven fabric with a polyethylene terephthalate fabric using a thermoplastic polyurethane adhesive
Data Source
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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.