Artificial leather base material, method for production thereof, and napped artificial leather
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Solution Overview
Problem
Conventional artificial leathers face challenges in maintaining high stretchability and enhanced mechanical properties while achieving a napped feel, as they often struggle to balance these properties effectively.
Innovation Solution
An artificial leather base material composed of a non-woven fabric entangle body of crimped fibers and ultrafine fibers, where the crimped fibers are formed from two types of resins with different intrinsic viscosities and the ultrafine fibers have a fineness of less than 0.6 dtex, combined with an elastic polymer, to achieve balanced stretchability and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional artificial leather structures are used, then mechanical properties are maintained, but stretchability and napped feel cannot be achieved simultaneously
Solution Approach 1:
The patent employs a composite non-woven fabric structure combining two distinct fiber types: crimped fibers (providing mechanical strength and elasticity) and ultrafine fibers (providing napped feel and stretchability). This composite approach allows simultaneous achievement of mechanical properties, stretchability, and napped surface characteristics that cannot be obtained with single-material structures.
Solution Approach 2:
The invention applies different fiber properties to different functional requirements within the same material structure. Crimped fibers with specific intrinsic viscosity ranges are positioned to provide mechanical strength and elasticity, while ultrafine fibers are incorporated to create the napped surface feel and enhance stretchability. This local differentiation of material properties resolves the contradiction between mechanical strength and surface characteristics.
2Ease of operation
If crimped fibers are used to improve stretchability, then elongation rate increases, but mechanical strength decreases
Solution Approach 1:
The patent specifies precise parameter ranges for the crimped fibers, including intrinsic viscosity (0.6-1.5 dl/g for first resin, 0.3-1.0 dl/g for second resin) and fineness (0.5-2.0 dtex). By optimizing these parameters, the crimped fibers achieve both high elongation rates (50-150%) and adequate mechanical strength, resolving the trade-off between stretchability and strength.
Solution Approach 2:
The composite structure combines crimped fibers (for stretchability) with ultrafine fibers (for mechanical reinforcement). The ultrafine fibers compensate for the strength loss from using highly crimped, elastic fibers, allowing the material to achieve both high stretchability and adequate mechanical strength simultaneously.
3Shape
If ultrafine fibers are used to achieve napped feel, then surface quality improves, but mechanical strength decreases
Solution Approach 1:
The patent incorporates ultrafine fibers (average fineness 0.01-0.5 dtex) specifically to create the napped surface feel, while relying on the crimped fibers to provide the bulk of the mechanical strength. This localized application of ultrafine fibers to the surface layer achieves the desired aesthetic and tactile qualities without compromising overall structural integrity.
Solution Approach 2:
The composite non-woven fabric structure uses ultrafine fibers for surface quality and napped feel, while crimped fibers provide mechanical strength and elasticity. The synergistic combination allows the material to achieve both excellent surface characteristics and adequate mechanical properties, resolving the contradiction between surface quality and strength.
4Reliability
If elastic polymer is applied to enhance stretchability, then elongation recovery improves, but manufacturing complexity increases
Solution Approach 1:
The crimped fibers themselves provide elastic recovery functionality through their inherent crimp structure and material properties (intrinsic viscosity and fineness specifications). The fibers' physical structure enables them to recover from elongation without requiring additional elastic polymer coatings or complex multi-layer constructions, thereby reducing manufacturing complexity while maintaining high elongation recovery rates (50-90%).
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 results in an artificial leather with high stretchability, enhanced mechanical properties, and a napped feel, maintaining these characteristics even after repeated elongation, with an elongation rate of 10% or more and elongation recovery rate of 55% or more after 20 cycles.
Implementation Method 1
the fibers (A) are crimped fibers that are formed from two types of resins with intrinsic viscosities different from each other... An artificial leather having good stretchability... elongation rate and elongation recovery rate
Implementation Method 2
an elastic polymer applied inside the non-woven fabric... maintains a high peel strength, as well as a high elongation rate and a high elongation recovery rate
Data Source
AI summary
Disclosed is an artificial leather base material including: a non-woven fabric that is an entangle body of fibers (A) and fibers (B); and an elastic polymer applied inside the non-woven fabric, wherein the fibers (A) are crimped fibers that are formed from two types of resins with intrinsic viscosities different from each other, and that are filaments of 0.6 dtex or more, and the fibers (B) are ultrafine fibers of less than 0.6 dtex.