Artificial leather

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Solution Overview

Problem

Existing artificial leather manufacturing processes are complex and environmentally unfriendly due to the use of solvents, and they fail to achieve high peeling strength required for shoe upper materials.

Innovation Solution

A multi-layer thermoplastic polyurethane (TPU) mesh structure is created using a meltblowing process without solvents, where TPU pellets are heated and formed into layers with varying fiber fineness to enhance peeling strength, and the layers are then heat-pressed to produce artificial leather with a high peeling strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional multilayer artificial leather manufacturing processes are used, then artificial leather can be produced, but the manufacturing process becomes complex and requires solvent usage

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges multiple manufacturing steps into a single integrated process. Specifically, it combines the formation of multiple TPU mesh layers with different fiber fineness (5-30 μm) into one continuous manufacturing process, eliminating the need for separate resin dipping and fiber dissolving steps that were required in traditional methods. This integration directly reduces process complexity while maintaining the multilayer structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the fundamental manufacturing parameters by replacing solvent-based processes with a solvent-free TPU pellet extrusion and melting process. By controlling the fiber fineness parameter (5-30 μm) and using heat-pressing at controlled temperatures, the process achieves the desired multilayer structure without requiring the complex solvent-based resin dipping and fiber dissolving steps of traditional methods.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If traditional manufacturing processes with solvents are used, then artificial leather can be manufactured, but environmental protection requirements are not met

Engineering Contradiction:

ImprovemanufacturabilityVSAvoidsolvent pollution

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and eliminates the harmful solvent component from the manufacturing process. By using TPU pellets that are extruded and melted directly to form the mesh layers, the process completely removes the need for solvents used in traditional resin dipping and fiber dissolving steps. This extraction of the harmful element maintains manufacturability while achieving environmental protection goals.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the traditional harmful solvent-based process into a beneficial solvent-free process. By utilizing the melting properties of TPU pellets through controlled heating and extrusion, the process achieves the desired artificial leather structure without any solvent pollution, transforming an environmentally harmful approach into an eco-friendly manufacturing method.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If traditional artificial leather structures are used, then basic leather properties are achieved, but peeling strength greater than 2.5 Kg/cm is not achieved

Engineering Contradiction:

Improvemanufacturing feasibilityVSAvoidpeeling strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies local quality by creating TPU mesh layers with different fiber fineness (5-30 μm) at different positions within the multilayer structure. This variation in local fiber density and fineness creates optimized bonding interfaces between layers, significantly enhancing peeling strength. The finer fibers (5 μm) provide stronger interlayer adhesion while coarser fibers (30 μm) maintain structural integrity, achieving peeling strength >2.5 Kg/cm.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining TPU pellets of different fiber fineness (5-30 μm) into a multilayer mesh structure. This composite approach creates layers with complementary properties: finer TPU fibers provide strong bonding for high peeling strength, while coarser fibers provide structural framework. The heat-pressing process integrates these composite layers into a unified structure with enhanced mechanical properties.

Inventive Principle:

Principle #40Composite materials

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 process simplifies the manufacturing of artificial leather, eliminates the use of solvents, and achieves a peeling strength greater than 2.5 Kg/cm, meeting environmental protection requirements and the standards for shoe upper materials.

Implementation Method 1

heating TPU pellets to be melted

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

meltblowing the melted TPU to form a first TPU mesh layer

Methodology Applied

Scientific EffectMeltblowing:

Implementation Method 3

heat pressing the multi-layer TPU mesh layer structure to form an artificial leather

Methodology Applied

Scientific EffectHeat pressing:

Data Source

PatentUS11505895B2Artificial leather

Publication Date: 2022.11.22 SAN FANG CHEM IND

AI summary

The present disclosure is relates to an artificial leather. The artificial leather includes multi-layer thermoplastic polyurethane (TPU) mesh layers. Fiber fineness of the TPU mesh layers ranges from 5 μm to 30 μm, and peeling strength of the TPU mesh layers is greater than 2.5 Kg/cm.