Multi-layer material and method of application
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Solution Overview
Problem
Elastomeric composites used for cover materials, such as consolidated polyurethanes, tend to pull away from surfaces when folded, making it difficult to achieve a smooth and efficient covering process, particularly when simulating materials like leather.
Innovation Solution
A multi-layer material comprising a polymeric cellular layer and a nonwoven backing layer with a creasability angle between 20 and 160 degrees, where the cellular layer is formed by entraining air or gas into a polymer to create a froth, which is applied uniformly to the backing layer, enhancing the material's ability to hold creases and adhere to surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If elastomeric composite material is used to simulate leather, then aesthetic appearance and tactile properties are improved, but creasability and ability to conform to surfaces deteriorate
Solution Approach 1:
The material is divided into multiple functional layers: a polymeric cellular layer providing creasability and a separate nonwoven backing layer providing adhesion and stability. This segmentation allows each layer to specialize in one function, resolving the contradiction between creasability and adhesion.
Solution Approach 2:
The invention uses a composite structure combining polymeric cellular material with nonwoven backing material. The composite leverages the advantages of both materials - the cellular layer's ability to crease and the nonwoven layer's ability to adhere - thereby resolving the contradiction between these opposing properties.
2Ease of operation
If polymeric cellular layer is added to improve creasability, then ease of folding is improved, but material complexity increases
Solution Approach 1:
The polymeric cellular layer is merged with the nonwoven backing layer into a single integrated composite material structure. This combining approach allows the material to achieve improved ease of folding while presenting as a unified material system rather than separate components, thereby mitigating the increase in complexity.
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 multi-layer material effectively addresses the issue of creasability, allowing for easier wrapping around corners and edges, providing a stable and aesthetically pleasing cover with improved adhesion and tactile properties.
Implementation Method 1
entraining air or gas into a polymer to create a polymer froth
Data Source
AI summary
A multi-layer material suitable for use as a covering for an article includes a polymeric cellular layer and nonwoven backing layer. The multi-layer material having a creasability angle of between about 20 and about 160 degrees.