Synthetic Leather Pattern Layer Encapsulation Against Fading and Peeling
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Solution Overview
Problem
Conventional synthetic leather patterns printed on the surface tend to fade and are prone to peeling off, especially when exposed to contact or ingestion by children, leading to health risks and aesthetic issues.
Innovation Solution
A method involving a blocking layer and a surface layer sandwiching the pattern layer, where a mixture of isocyanate polymer, hydroxy compound, and color material is coated on a substrate, followed by printing the pattern on the blocking layer and then forming a surface layer to encapsulate it, preventing fading and peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pattern is printed on the surface of substrate, then the appearance is enhanced, but the pattern fades in color and is prone to peeling off after long time use
Solution Approach 1:
The pattern layer is nested between the blocking layer and surface layer, creating a sandwich structure where the pattern is encapsulated within protective layers, preventing direct exposure to external environment while maintaining visual appearance
Solution Approach 2:
The blocking layer and surface layer act as flexible protective films that encapsulate the pattern layer, providing mechanical protection against peeling and chemical protection against color fading while allowing the synthetic leather to maintain its flexibility
2Reliability
If the pattern is printed on the surface of synthetic leather, then the observability is enhanced, but the pattern is exposed to outside contact and may be ingested by children
Solution Approach 1:
The pattern layer is nested between the blocking layer and surface layer, creating a sandwich structure where the pattern is encapsulated within protective layers, preventing direct exposure to external environment while maintaining visual appearance
Solution Approach 2:
The blocking layer and surface layer serve as intermediary protective barriers between the pattern layer and external environment (including children), preventing direct contact and potential ingestion while allowing the pattern to remain visible
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 effectively prevents color fading and peeling of the pattern, ensuring the synthetic leather maintains its appearance and safety by isolating the pattern from the substrate and external contact.
Implementation Method 1
a first coating step (B) in which the mixture is coated on a substrate to form a blocking layer
Implementation Method 2
a printing step (C) in which a determined pattern is printed on the surface of blocking layer to form a pattern layer
Implementation Method 3
a second coating step (D) in which at least the mixture is coated on the pattern layer to form a surface layer
Data Source
AI summary
A method of manufacturing a synthetic leather formed with a pattern includes a mixing step (A) in which at least a first material and a second material are properly mixed in proportion into a mixture; a first coating step (B) in which the mixture is coated on a substrate to form a blocking layer; a printing step (C) in which a determined pattern is printed on the surface of blocking layer to form a pattern layer; and a second coating step (D) in which at least the mixture is coated on the pattern layer to form a surface layer, thereby a product being finished. Thus, the pattern layer may be sandwiched between the blocking layer and the surface layer, which prevents the pattern layer contacting the substrate or outside from fading in color and shedding off and prevents the child from eating, by accident, the fall-off pattern layer.