Thermoplastic artificial leather, method for manufacturing the same and thermoplastic composite laminate
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Solution Overview
Problem
Conventional methods for manufacturing thermoplastic artificial leather face challenges such as the use of organic solvents, which are difficult to recycle and pose environmental concerns, and result in products with poor touch feeling and abrasion resistance.
Innovation Solution
A thermoplastic artificial leather is created using a composite laminate structure comprising a foamed thermoplastic elastic layer, an unfoamed thermoplastic elastic layer, and a thermoplastic adhesive layer, laminated with a textile base, which eliminates the need for solvents and enhances abrasion resistance and touch feeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional dry coating or wet coating processes are used to manufacture artificial leather, then the manufacturing process can be completed, but organic solvents must be used which are difficult to recycle and pose environmental concerns
Solution Approach 1:
The invention changes the fundamental parameter of the coating process by replacing organic solvent-based coatings with water-based coatings. This parameter change eliminates the use of harmful organic solvents while maintaining the manufacturability of artificial leather, directly resolving the contradiction between ease of manufacture and environmental harm.
Solution Approach 2:
The invention substitutes the chemical mechanism of organic solvent-based coating with a water-based coating mechanism. This substitution replaces harmful organic chemicals with water as the carrier, eliminating environmental pollution while preserving the coating process's functionality and ease of manufacture.
2Ease of manufacture
If conventional coating processes are used to manufacture artificial leather, then the product can be produced, but the touch feeling and abrasion resistance are poor
Solution Approach 1:
The invention employs composite materials by combining water-based polyurethane resin with specific additives and using a multi-layer coating structure. This composite approach enhances both the touch feeling and abrasion resistance of the artificial leather while maintaining manufacturing feasibility, resolving the contradiction between ease of manufacture and product reliability.
Solution Approach 2:
The invention applies local quality by creating different layers with specific functions: a base layer for structure, intermediate layers for adhesion and flexibility, and a top layer optimized for touch feeling and abrasion resistance. This localized optimization of material properties throughout the coating structure simultaneously achieves good manufacturability and superior product performance.
3Ease of manufacture
If thermoplastic film is laminated on modified cross-section fibers without foamed structure, then the leather can be manufactured, but the leather is too hard and the touch feeling is poor
Solution Approach 1:
The invention introduces a foamed structure with controlled porosity into the thermoplastic layer. This porous structure reduces the hardness of the leather and provides a softer touch feeling while maintaining manufacturing simplicity. The foam cells create air pockets that reduce density and increase flexibility, directly addressing the contradiction between ease of manufacture and touch feeling quality.
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 achieves a thermoplastic artificial leather with improved abrasion resistance (Stoll abrasion >3000+) and peeling strength (>4.0 kg/cm2) while providing a soft touch feeling, all while being environmentally friendly by eliminating solvent use.
Implementation Method 1
a foamed thermoplastic elastic layer (122), an unfoamed thermoplastic elastic layer (124) and a thermoplastic adhesive layer (126)... The foamed thermoplastic elastic layer (122) has a first surface (122A), a second surface (122B) and a plurality of foamed structures (122F)
Implementation Method 2
The thermoplastic adhesive layer is disposed on the second surface of the foamed thermoplastic elastic layer. The textile base is laminated on the thermoplastic adhesive layer of the thermoplastic composite laminate... peeling strength (>4.0 kg/cm2)
Data Source
AI summary
A thermoplastic artificial leather includes a thermoplastic composite laminate and a textile base. The thermoplastic composite laminate includes a foamed thermoplastic elastic layer, an unfoamed thermoplastic elastic layer and a thermoplastic adhesive layer. The foamed thermoplastic elastic layer has a first surface, a second surface and a plurality of foamed structures. The second surface is opposite to the first surface. The unfoamed thermoplastic elastic layer is disposed on the first surface of the foamed thermoplastic elastic layer. The thermoplastic adhesive layer is disposed on the second surface of the foamed thermoplastic elastic layer. The textile base is laminated on the thermoplastic adhesive layer of the thermoplastic composite laminate.