Artificial leather and production method therefor, and composite artificial leather
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Solution Overview
Problem
Existing artificial leathers used for wallpaper materials face challenges in achieving uniform and elegant surface quality, good touch sensation, wear resistance, and fire resistance, particularly when the weight per unit area is reduced to meet fire resistance standards, leading to non-uniform surfaces and insufficient touch sensation.
Innovation Solution
The artificial leather is produced by widening the sheet before and after dyeing to achieve a specific weight range, incorporating a nonwoven fabric of fine fibers and a polymer elastic body, with controlled micropores and a base layer, to maintain uniformity and elegance while ensuring fire resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the weight per unit area of artificial leather is reduced to meet fire resistance standards, then fire resistance is improved, but surface quality uniformity deteriorates and large pores are generated
Solution Approach 1:
The patent utilizes a nonwoven fabric with controlled microporous structure where micropores (5-50 μm) are intentionally created and regulated in number and distribution. This controlled porosity allows the material to maintain low weight per unit area for fire resistance while preventing large pores that would compromise surface quality uniformity. The micropores are distributed at specific densities to balance fire safety requirements with aesthetic surface appearance.
Solution Approach 2:
The patent specifies precise parameter ranges for the nonwoven fabric including weight per unit area (50-75 g/m²), micropore diameter (5-50 μm), and micropore number per unit area (0.1-5.0/mm²). By controlling these parameters within defined ranges, the invention achieves fire resistance through reduced weight while maintaining surface quality uniformity through regulated micropore distribution, preventing the formation of large detrimental pores.
2Object-affected harmful factors
If the weight per unit area of artificial leather is reduced to meet fire resistance standards, then fire resistance is improved, but wear resistance deteriorates
Solution Approach 1:
The patent creates a composite structure combining a nonwoven fabric base with a polymer elastic body layer. The nonwoven fabric provides the lightweight framework for fire resistance, while the polymer elastic body impregnated within it restores and enhances mechanical properties including wear resistance. This composite approach allows the material to achieve fire safety through low weight while the polymer matrix provides the necessary durability and wear resistance for practical wallpaper applications.
3Manufacturing precision
If a nonwoven fabric formed by wet papermaking with two layers is used to achieve uniform surface quality, then surface quality uniformity is improved, but weight per unit area increases and fire resistance deteriorates
Solution Approach 1:
The patent employs a single-layer nonwoven fabric with locally controlled micropore distribution rather than a two-layer structure. The micropores are strategically distributed at specific densities (0.1-5.0/mm²) to create uniform surface quality in critical areas while maintaining overall low weight. This localized quality control approach achieves surface uniformity without the weight penalty of multi-layer constructions, preserving fire resistance.
4Object-affected harmful factors
If the weight per unit area of artificial leather is reduced to meet fire resistance standards, then fire resistance is improved, but touch sensation deteriorates
Solution Approach 1:
The patent utilizes a nonwoven fabric with controlled microporous structure where micropores (5-50 μm) are intentionally created and regulated in number and distribution. This controlled porosity allows the material to maintain low weight per unit area for fire resistance while preventing large pores that would compromise surface quality uniformity. The micropores are distributed at specific densities to balance fire safety requirements with aesthetic surface appearance.
Solution Approach 2:
The patent creates a composite structure combining a nonwoven fabric base with a polymer elastic body layer. The nonwoven fabric provides the lightweight framework for fire resistance, while the polymer elastic body impregnated within it restores and enhances mechanical properties including wear resistance. This composite approach allows the material to achieve fire safety through low weight while the polymer matrix provides the necessary durability and wear resistance for practical wallpaper applications.
Data Source
AI summary
To provide an artificial leather which simultaneously achieves uniform and elegant surface quality, good touch sensation, and wear resistance while suppressing the total amount of heat generated at the time of combustion. Provided is an artificial leather including: a fiber-tangled body containing a nonwoven fabric made of fine fibers having an average single fiber diameter of 0.01 μm or more and 10.0 μm or less; and a polymer elastic body. The artificial leather satisfies the following requirements:requirement 1: the artificial leather has a weight per unit area of 25 g/m2 or more and 75 g/m2 or less; andrequirement 2: the number per unit area of micropores penetrating the artificial leather in the thickness direction and having a pore diameter of 35 μm or more and 500 μm or less is 0.1/mm2 or more and 5.0/mm2 or less.