TPU-TPS Composite Sheet for Simplified Artificial Leather Lamination
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Solution Overview
Problem
Existing composite structures for artificial leather require multiple layers to achieve a balance of softness, flexibility, and ease of processing, such as sewing, while also ensuring improved adhesion and production efficiency, which complicates the manufacturing process.
Innovation Solution
A sheet comprising a support layer and a cover layer with a thermoplastic polyurethane (TPU) and thermoplastic styrenic elastomer (TPS), where the cover layer contains at least 20 mass% of each component, and the two layers are directly bonded, facilitating a one-step lamination process and improved adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers are used in composite structures, then adhesion and production efficiency are improved, but device complexity and manufacturing process are complicated
Solution Approach 1:
The patent merges the functions of multiple traditional layers (support layer, adhesive layer, cover layer) into a direct bond between support layer and cover layer. The cover layer itself provides both structural support and adhesion functions, eliminating the need for separate adhesive layers and reducing the total number of layers while maintaining reliable bonding.
Solution Approach 2:
The cover layer is designed to perform multiple functions simultaneously: it provides the outer protective surface, ensures adhesion to the support layer through direct bonding, and contributes to the overall mechanical properties. This multi-functionality reduces the need for specialized intermediate layers.
2Reliability
If multiple layers are used in composite structures, then adhesion is improved, but ease of manufacture deteriorates
Solution Approach 1:
By combining the adhesion function into the cover layer itself through direct bonding, the manufacturing process is simplified. There is no need for separate adhesive application steps, curing processes, or alignment of multiple thin layers, making the overall manufacturing easier and more efficient.
3Ease of operation
If thermoplastic polyurethane and thermoplastic styrenic elastomer are combined in the cover layer, then needle penetration and thermal stability are enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies precise compositional parameters for the TPU-TPS blend in the cover layer, with specific weight ratio ranges optimized to balance needle penetration and thermal stability. By controlling the composition within defined parameters, the material achieves optimal performance characteristics for cut-and-sew applications.
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 sheet exhibits reduced wrinkle formation, easier handling, and lower manufacturing costs due to fewer layers, with enhanced needle penetration and thermal stability, making it suitable for cut and sew applications and vehicle interior use.
Implementation Method 1
the two layers are directly bonded, facilitating a one-step lamination process and improved adhesion
Data Source
AI summary
A sheet comprising a support layer and a cover layer, wherein the cover layer contains a thermoplastic polyurethane as component (a) and a thermoplastic styrenic elastomer as component (b); a sewn product obtainable by sewing the sheet; a method of preparing the sheet; the use of the sheet or the sewn product as an artificial leather, in particular as a cover material in the interior of a vehicle.