Artificial leather and method for manufacturing same
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Solution Overview
Problem
Existing methods for manufacturing artificial leather using water-dispersible polyurethane face challenges in achieving both supple texture and durability while maintaining manufacturing efficiency, with issues related to adhesion and the need for multiple polyurethane additions.
Innovation Solution
The use of a polyurethane with a hydrophilic group and specific mass retention ratio, combined with polyester ultrafine fibers and controlled fiber entanglement, to create a fibrous base material with optimized density and molecular weight, enhancing flexibility and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyvinyl alcohol is added to adjust adhesion state, then both supple texture and durability are achieved, but polyvinyl alcohol elution treatment is required which reduces manufacturing efficiency
Solution Approach 1:
The invention removes polyvinyl alcohol from the formulation entirely, extracting the problematic component that required elution treatment. Instead, it uses a fibrous base material with specific physical properties (apparent density 0.25-0.35 g/cm³, fiber diameter 1-10 μm) that inherently provides the desired adhesion state without requiring additional chemical additives and subsequent removal steps.
Solution Approach 2:
The invention changes the physical parameters of the fibrous base material (apparent density, fiber diameter, fiber length) to achieve the desired adhesion state. By optimizing these parameters, the system attains both supple texture and durability without needing polyvinyl alcohol, thereby eliminating the elution treatment step and improving manufacturing efficiency.
2Reliability
If polyurethane is added twice to achieve both supple texture and durability, then both properties are improved, but manufacturing efficiency is reduced due to multiple addition steps
Solution Approach 1:
The invention merges the functions of multiple polyurethane additions into a single addition step. By optimizing the fibrous base material properties and using a water-dispersible polyurethane with specific characteristics (molecular weight 50,000-200,000, solid content 10-30%), the system achieves both supple texture and durability in one impregnation step, eliminating redundant operations.
Solution Approach 2:
The fibrous base material is designed to serve multiple functions simultaneously: providing structural support, controlling adhesion state, and enabling uniform polyurethane distribution. This multi-functionality allows a single polyurethane addition to achieve results that previously required multiple steps, improving manufacturing efficiency.
3Ease of operation
If adhesion state between polyurethane and ultrafine fibers is relaxed, then supple texture is achieved, but abrasion resistance deteriorates
Solution Approach 1:
The invention optimizes the physical parameters of the fibrous base material (apparent density, fiber diameter, fiber length) to create an optimal adhesion state. This balanced adhesion provides both supple texture and excellent abrasion resistance, resolving the contradiction between flexibility and strength.
Solution Approach 2:
The invention creates a composite structure where the fibrous base material and polyurethane work synergistically. The specific physical properties of the fibrous base material enhance the interface between polyurethane and fibers, providing both flexibility and abrasion resistance through the composite effect rather than relying on strong chemical adhesion.
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 artificial leather with both supple texture and excellent durability, achieved through an environmentally friendly process without organic solvents, with improved manufacturing efficiency.
Implementation Method 1
a water-dispersible polyurethane prepared by dispersing a polyurethane resin into water
Implementation Method 2
a capillary porous body having a specific apparent density
Data Source
Figure 1
AI summary
Artificial leather including: a fibrous base material including polyester ultrafine fibers having an average single-fiber diameter of 0.1 µm or more and 10.0 µm or less; and a polyurethane having a hydrophilic group, the fibrous base material and the polyurethane being constituents of the artificial leather, wherein a content rate of the polyurethane having a hydrophilic group in the artificial leather is 15 mass% or more and 25 mass% or less, after the artificial leather is immersed in N,N-dimethylformamide at 25°C for 24 hours, the polyurethane having a hydrophilic group has a mass retention ratio of 50 mass% or more and 80 mass% or less, and after the artificial leather is immersed in N,N-dimethylformamide at 25°C for 24 hours, a component dissolved in the N,N-dimethylformamide has a weight average molecular weight of 50000 or more and 100000 or less. Artificial leather is provided that achieves both a supple texture and excellent durability while obtained by an environmentally friendly process without using an organic solvent, and a method for manufacturing the artificial leather is provided.