Artificial Leather Composition for Crease-Free Flexed Regions
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Solution Overview
Problem
Artificial leather with inferior elongation properties leads to creases during manufacturing, particularly in flexed regions like vehicle headliners, and excessive elongation results in quality deterioration.
Innovation Solution
Artificial leather with a polymeric elastomer concentration of 20-30% by weight and a non-woven fabric density of 0.160-0.250 g/cm³, manufactured using a sea-island type fiber process, optimizing elongation at 20-40% in the longitudinal direction and 40-80% in the widthwise direction under constant load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the elongation property of artificial leather is increased to prevent creases in flexed regions, then the artificial leather can be used in applications like vehicle headliners, but excessive elongation causes quality deterioration
Solution Approach 1:
The patent optimizes the concentration of polymeric elastomer (20-30% by weight) and the density of non-woven fabric (0.160-0.250 g/cm³) to achieve optimal elongation properties. This parameter optimization ensures the artificial leather has sufficient elongation (20-40% in longitudinal direction, 40-80% in widthwise direction) to prevent creases while maintaining manufacturing quality and avoiding excessive elongation that would cause defects.
2Ease of operation
If the polymeric elastomer concentration is increased to improve elongation, then the artificial leather becomes more flexible, but the structural integrity and dimensional stability deteriorate
Solution Approach 1:
The patent establishes an optimal concentration range for polymeric elastomer (20-30% by weight) that balances flexibility and dimensional stability. Within this range, the artificial leather achieves sufficient flexibility for flexed regions while maintaining structural integrity. The patent also optimizes the density of non-woven fabric (0.160-0.250 g/cm³) to further balance these properties.
Solution Approach 2:
The patent uses a composite structure consisting of non-woven fabric and polymeric elastomer impregnated within it. This composite material approach allows the non-woven fabric to provide structural framework for dimensional stability while the polymeric elastomer provides flexibility and elongation properties. The synergistic combination of these two materials resolves the contradiction between flexibility and dimensional stability.
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 achieves optimal elongation properties, allowing for effective use in flexed regions without excessive creasing or deterioration, enhancing the quality and usability of artificial leather products.
Implementation Method 1
impregnating polymeric elastomer into non-woven fabric
Implementation Method 2
preparing a sea-island type fiber comprising first and second polymers with the different solubility properties in solvent
Implementation Method 3
eluting and removing the first polymer corresponding to the sea component from the non-woven fabric
Data Source
AI summary
Artificial leather with optimal elongation and a method for manufacturing the same is disclosed, the artificial leather comprising a non-woven fabric with micro-fibers and a polymeric elastomer impregnated into the non-woven-fiber, wherein the polymeric elastomer is 20 to 30% by weight with respect to a total weight of the artificial leather, and a density of the non- woven fabric is within the range of 0.160 to 0.250g/cm3, wherein the artificial leather can be easily used for the goods with lots of flexed regions, for example, the headliner of vehicle.