Artificial leather base material, and artificial leather base material manufacturing method
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Solution Overview
Problem
Existing artificial leather base materials made from polyamide ultrafine long fibers lack shape stability when wetted with water, and conventional methods to improve this stability either increase production steps or reduce resin flexibility.
Innovation Solution
The artificial leather base material is formulated with polyamide fibers where the ratio of γ-type crystal peak intensity to α-type crystal peak intensity (γ/α) is set between 0.690 and 1.100, incorporating an olefin-maleic anhydride resin to enhance compatibility and stability, and produced using a solvent-free process involving a specific spinning and impregnation method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a water-soluble thermoplastic resin with melting point not lower than nylon 6 by 30°C or more is used, then the resin can be removed with water to create environment-compatible artificial leather, but the tension during spinning cannot adequately act on the nylon 6, resulting in low crystal orientation and poor shape stability when wetted with water
Solution Approach 1:
The patent changes the melting point parameter of the water-soluble thermoplastic resin to be lower than nylon 6 by more than 30°C. This parameter change allows the sea component to be removed more effectively during spinning, enabling adequate tension to act on the nylon 6 fibers and achieve proper crystal orientation (α-type crystal peak intensity) for shape stability when wetted with water
Solution Approach 2:
The patent applies preliminary anti-action by carefully selecting the melting point difference between the water-soluble thermoplastic resin and nylon 6 before the spinning process. By ensuring the thermoplastic resin melts at a sufficiently lower temperature, the patent prevents the problem of inadequate tension transmission to the nylon 6 fibers during spinning, thereby preemptively ensuring proper crystal orientation and shape stability
2Reliability
If a drawing treatment is performed after spinning to improve crystal orientation, then the shape stability when wetted with water is improved, but the number of production steps increases, reducing productivity
Solution Approach 1:
The patent applies preliminary action by pre-optimizing the spinning conditions, specifically the melting point difference between the water-soluble thermoplastic resin and nylon 6. This preliminary optimization ensures that adequate tension acts on the nylon 6 fibers during spinning itself, achieving proper crystal orientation without requiring subsequent drawing treatments, thereby eliminating extra production steps
Solution Approach 2:
The patent extracts the drawing treatment step from the production process by ensuring that proper crystal orientation is achieved during the spinning process itself through appropriate selection of water-soluble thermoplastic resin with melting point lower than nylon 6 by more than 30°C, thereby simplifying the production flow and improving productivity
3Adaptability or versatility
If the melting point difference between water-soluble thermoplastic resin and nylon 6 is reduced, then the degree of freedom in resin selection is improved, but the tension during spinning cannot adequately act on nylon 6, resulting in poor crystal orientation
Solution Approach 1:
The patent establishes a specific parameter threshold: the melting point of the water-soluble thermoplastic resin must be lower than that of nylon 6 by more than 30°C. This parameter change ensures that sufficient temperature differential exists during spinning to allow tension to adequately act on the nylon 6 fibers, achieving proper crystal orientation while still allowing flexibility in resin selection within this parameter range
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 material achieves excellent shape stability when wetted with water, maintaining quality and reducing environmental impact through a more efficient production process.
Implementation Method 1
a step of removing the water-soluble thermoplastic resin from the ultrafine fiber-generating fiber at any time from before the impregnation to after the impregnation of the elastic polymer
Implementation Method 2
a step of impregnating the entangled fiber sheet with an elastic polymer
Data Source
AI summary
Provided is an artificial leather base material containing a polyamide fiber having excellent shape stability when wetted with water, and the artificial leather base material contains a polyamide fiber and an elastic polymer, in which in measurement data obtained by X-ray diffraction measurement of the polyamide fiber, a peak intensity γ of a diffraction peak corresponding to a γ-type crystal of a polyamide resin constituting the polyamide fiber and a peak intensity α of a diffraction peak corresponding to an α-type crystal of the polyamide resin satisfy a relationship of 0.690 ≤ γ/α ≤ 1.100.