Artificial leather and manufacturing method therefor

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Solution Overview

Problem

The existing artificial leather manufacturing processes rely on hazardous solvents and materials, leading to environmental concerns and high production costs, while also failing to meet the high quality requirements for durability, physical strength, and odor resistance.

Innovation Solution

A new artificial leather structure comprising a substrate layer, a radiation cross-linked polyolefin elastomer composite layer with a foamed and modification layer, and a polyurethane layer, which reduces odor, enhances aging resistance, and lowers production costs, while improving resilience and processing ease.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional artificial leather manufacturing uses polyurethane or polyvinyl chloride as substrate with organic solvents and plasticizers, then production cost and surface properties are improved, but environmental pollution and harmful factors increase

Engineering Contradiction:

Improvesurface physical propertiesVSAvoidenvironmental pollution

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by replacing polyurethane/polyvinyl chloride substrates with polyethylene/polypropylene nonwoven fabrics, and substituting organic solvents with water-based or solvent-free polyurethane coatings, thereby reducing environmental harm while maintaining manufacturing quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure combining nonwoven fabric substrate with polyolefin elastomer intermediate layer and polyurethane surface layer, achieving both environmental friendliness and excellent surface physical properties through material composition optimization

Inventive Principle:

Principle #40Composite materials

2Object-generated harmful factors

If ethylene vinyl acetate copolymer is used as substrate structure, then environmental friendliness and cost are improved, but odor resistance deteriorates

Engineering Contradiction:

Improveenvironmental friendlinessVSAvoidodor

Core Design Contradiction:

Object-generated harmful factorsVSObject-affected harmful factors

Solution Approach 1:

The patent changes the substrate material from ethylene vinyl acetate copolymer to polyethylene or polypropylene nonwoven fabrics, which have inherently lower odor, while maintaining environmental friendliness and cost-effectiveness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts and removes the odor-causing components by eliminating ethylene vinyl acetate copolymer from the structure, replacing it with odor-free polyethylene or polypropylene materials

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If radiation cross-linking is applied to polyolefin elastomer composite layer, then aging resistance and processing performance are improved, but device complexity increases

Engineering Contradiction:

Improveaging resistanceVSAvoidprocessing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional chemical cross-linking methods with radiation cross-linking technology, which uses electromagnetic radiation to induce cross-linking without complex chemical catalysts or high-temperature processing, thereby simplifying the overall process while achieving superior aging resistance

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If foamed layer is added to polyolefin elastomer composite layer, then resilience and softness are improved, but production cost increases

Engineering Contradiction:

ImproveresilienceVSAvoidproduction cost

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent introduces a foamed layer with controlled porosity into the polyolefin elastomer composite, where the foam structure provides air pockets that enhance resilience and softness while using less material, thereby improving mechanical properties without proportionally increasing production cost

Inventive Principle:

Principle #31Porous 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 solution results in an artificial leather with low odor, excellent aging resistance, and improved processing performance, meeting high quality standards while being environmentally friendly and cost-effective.

Implementation Method 1

a polyolefin elastomer composite layer, provided on a surface of the substrate layer, and comprising at least one foamed layer and at least one modification layer, the polyolefin elastomer composite layer being radiation cross-linked

Methodology Applied

Scientific EffectRadiation cross-linking: Photopolymerisation

Data Source

PatentUS20240384463A1Artificial leather and manufacturing method therefor

Publication Date: 2024.11.21 SHANGHAI HIUV NEW MATERIALS CO LTD

AI summary

The present application relates to an artificial leather and a manufacturing method therefor. The artificial leather comprises a substrate layer; a polyolefin elastomer composite layer, and a polyurethane resin solution layer, wherein the polyolefin elastomer composite layer is provided on a surface of the substrate layer, and the polyolefin elastomer composite layer comprises at least one foamed layer and at least one modification layer, and the polyurethane resin solution layer is provided on a surface of the polyolefin elastomer composite layer away from the substrate layer.