Polyurethane Coating Transfer for Continuous Composite Production
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Solution Overview
Problem
Current methods for producing velvet or velvet-like surfaces on carrier materials are labor-intensive and limited in scale, requiring manual handling and processing, which hinders their application in industries like textiles due to restrictions on size and cycle time, and lack efficiency in producing multi-layered composite bodies cost-effectively in large numbers.
Innovation Solution
A continuous process for producing multilayer composite bodies involving a carrier material, a connecting layer, and a polyurethane layer with capillaries, where the polyurethane layer is produced in a matrix and applied to a web-shaped carrier material using automated feeding and pressing, allowing for continuous winding and treatment without manual handling, increasing efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual handling and processing methods are used to produce velvet surfaces on carrier materials, then individual design and quality control are achieved, but labor intensity increases and production scale is limited
Solution Approach 1:
The patent uses matrices as reusable molds that can be applied repeatedly to produce identical velvet surface patterns on large areas of carrier material. The matrices capture the design once and replicate it continuously through the coating process, enabling industrial-scale production while maintaining design consistency.
Solution Approach 2:
The patent implements a continuous coating process where the carrier material moves through the system and receives the polyurethane coating with velvet structure in an uninterrupted manner. This eliminates manual handling between steps and enables high-volume production while maintaining quality.
2Manufacturing precision
If piece goods are placed by hand on pre-treated matrices, then coating quality is maintained, but processing area is limited to 160 cm x 160 cm and cycle time increases
Solution Approach 1:
The patent divides the large-area coating process into multiple matrices arranged in a array, where each matrix handles a portion of the carrier material. This allows the system to process areas larger than a single matrix while maintaining the same coating quality through standardized replication.
Solution Approach 2:
The patent transitions from processing single large pieces to processing multiple smaller matrix units in parallel, effectively expanding the processing area by adding spatial arrangement of multiple matrices rather than enlarging a single processing zone.
3Reliability
If press treatment residence time is extended to ensure proper bonding, then coating adhesion is improved, but cycle time per matrix increases and productivity decreases
Solution Approach 1:
The patent optimizes the pressing parameters including temperature, pressure, and time to achieve the minimum effective treatment duration. By precisely controlling these parameters, the system achieves proper adhesion with reduced cycle time compared to conventional extended pressing.
Solution Approach 2:
The patent prepares the matrices and carrier material in advance with pre-treatment steps that reduce the required pressing time. The matrices are pre-coated with polyurethane composition and the carrier material is pre-positioned, so that the actual pressing operation requires minimal time to achieve proper bonding.
4Ease of operation
If finished goods are removed by hand and require complex transport and storage, then individual piece handling is possible, but labor requirements increase and efficiency decreases
Solution Approach 1:
The patent implements continuous transport of the carrier material through the entire coating process and direct winding of finished goods onto rolls. This eliminates manual removal and complex transport steps, maintaining ease of handling while dramatically improving productivity through uninterrupted material flow.
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
This method enables the efficient production of breathable, multi-layered composite bodies on an industrial scale, reducing manual labor, increasing throughput, and allowing for easier handling and cost savings by processing large areas of web-shaped materials continuously, such as textiles or leather, without the need for pre-fabrication.
Implementation Method 1
The die has a temperature between 80°C and 170°C and has a heat capacity ranging between 100 and 20,000 J/K·m2
Implementation Method 2
treatment of a composite of matrix and web-shaped carrier material in a pressing device with transfer of the at least one polyurethane layer to the web-shaped carrier material
Implementation Method 3
formed by applying a liquid plastic dispersion to the surface of the matrix, which consists of a hydrophobic, flexible plastic, and then solidifying the plastic dispersion
Implementation Method 4
These are formed by laser treatment of the surface. The center-to-center distance between adjacent cup-like depressions is between 50 μm and 150 μm and the depth of the cup-like depressions is between 50 μm and 150 μm
Implementation Method 5
at least one polyurethane layer which has capillaries that run across the entire thickness of the polyurethane layer
Data Source
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AI summary
The invention relates to a method for producing multilayer composite bodies and to a production system (12, 60) for the method. The multilayer composite bodies comprise at least one support material (64, 66), at least one composite layer, and at least one polyurethane layer which has capillaries that extend through the entire thickness of the at least one polyurethane layer. At least one polyurethane layer is first produced in a die (15) while passing through at least one coating station (26, 30) and multiple heating stations (24, 28, 32). The die (15) which has been treated in such manner is then supplied (76) to a conveying station (74) of a transport line (60) for a strip-shaped support material (64, 66). A structured face (78) of the die (15) is applied onto the strip-shaped support material (64, 66) which is continuously passing through the transport line (60). A composite made of the die (15) and the strip-shaped support material (64, 66) is treated in a heatable pressing device (82) while transferring the at least one polyurethane layer from the die to the upper face of the strip-shaped support material (64, 66). The die (15) is finally removed from the strip-shaped support material (64, 66) and transferred to a treatment section (12), and the strip-shaped support material (64, 66) is rolled at a rolling station (100) after the die has been removed.