Self-Healing Polyolefin Multilayer Construct with Removable Top Layers
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Solution Overview
Problem
Polyolefin-based products, such as artificial leather, lack softness, self-healing properties, and easy design customization, requiring complete replacement for wear and tear or surface renewal, and do not allow sequential removal of layers for cleaning.
Innovation Solution
A polyolefin mono- or multilayer construct incorporating polyisobutylene-containing polyolefin layers with 0.1 to 75 parts by weight of polyisobutylene per 100 parts by weight of polyolefin, enabling self-healing and removable top layers for surface renewal without replacing the entire construct.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyolefin-based products are used for artificial leather, then durability and chemical resistance are improved, but softness is reduced
Solution Approach 1:
The patent combines polyolefin dispersions with polyisobutylene to create a composite material system. The polyolefin provides durability and chemical resistance, while the polyisobutylene component enhances softness and flexibility, resolving the contradiction between durability and softness in artificial leather applications.
2Reliability
If polyolefin-based materials are used, then chemical resistance is improved, but self-healing properties are lost
Solution Approach 1:
The patent modifies the chemical composition parameters of the polyolefin dispersion by incorporating polyisobutylene at specific weight ratios (0.1 to 75 parts by weight per 100 parts by weight of polyolefin). This parameter change enables the material to exhibit self-healing properties while maintaining chemical resistance, as the polyisobutylene component can flow and seal minor scratches and damage.
3Reliability
If the entire upholstery material is replaced to renew the surface, then wear and tear are eliminated, but cost increases
Solution Approach 1:
The patent creates a segmented multilayer structure where the top layer can be selectively removed and replaced while retaining the underlying layers. This segmentation allows only the worn surface to be replaced rather than the entire material, reducing waste and cost. The layers are separated by adhesion layers with controlled bonding properties that enable clean separation.
Solution Approach 2:
The patent enables selective discarding of the top layer when worn while recovering and retaining the underlying functional layers. The controlled adhesion between layers allows the top layer to be removed without damaging the base layers, which can be reused, thereby reducing material waste and cost.
4Adaptability or versatility
If a layered structure is used for synthetic leather, then design customization is improved, but sequential layer removal is not enabled
Solution Approach 1:
The patent implements a segmented layered structure with distinct top layers and underlying layers separated by adhesion layers. This segmentation enables sequential removal of top layers for design customization or surface renewal while maintaining the integrity of underlying layers, combining design versatility with ease of repair.
Solution Approach 2:
The patent creates a dynamic layered structure where the bonding between layers can be controlled and modified. The adhesion layers are designed with controlled bonding properties that allow layers to be joined during manufacturing but separated during maintenance or design changes, enabling both structural integrity and sequential layer removal.
5Ease of manufacture
If polyolefin dispersions are used, then application flexibility is improved, but softness is limited
Solution Approach 1:
The patent combines polyolefin dispersions with polyisobutylene to create a composite material system. The polyolefin dispersion provides application flexibility and can be applied via conventional coating processes, while the polyisobutylene component enhances softness and flexibility, resolving the contradiction between application flexibility and softness.
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 polyolefin construct achieves self-healing, allows sequential removal and reconnection of layers, and enables design customization by replacing the top layer, providing a virus- and bacteria-free surface with adjustable thermal activation for adhesion control.
Implementation Method 1
Polyisobutylene polymers are known for their cold flow properties, which depend on the polymer's molecular weight
Implementation Method 2
These functional groups are usually necessary to obtain a stable dispersion due to the increased hydrophilicity and electrostatic repulsion between the latex particles
Implementation Method 3
local thermal activation of the interfaces through IR-transparent Cool Color pigments in the top layer and IR-absorbing materials or colorants, ideally carbon black, in the sublayer
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a polyolefin mono- or multilayer construction comprising one or more polyolefin layers formed by a polyolefin dispersion on a substrate, wherein at least one polyolefin layer is a polyisobutylene-containing polyolefin layer containing 0.1 to 75 parts by weight of polyisobutylene per 100 parts by weight of polyolefin in the layer, and a method for producing the latter. The invention is suitable as a covering material or artificial leather, in particular as a self-healing covering material or artificial leather, or as a covering material or artificial leather with a renewable surface.