Artificial leather and method for producing the same
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Solution Overview
Problem
Existing methods for producing artificial leather rely heavily on organic solvents with high boiling points, leading to environmental pollution, high adhesive temperatures, and poor hand feeling and smoothness.
Innovation Solution
The production method involves a substrate with a thermoplastic polyurethane fiber adhesive layer, a thermoplastic polyurethane fiber layer, and a paste layer with a specific adhesive temperature between 60° C. to 150° C., using thermosetting or high solid-content pastes with low boiling point solvents, reducing the need for high temperatures and organic solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If organic solvents with high boiling points are used in large amounts, then the bonding between surface layer and stacked material can be achieved, but environmental pollution increases and adhesive temperature must be high
Solution Approach 1:
The patent changes the boiling point parameter of the solvent from high (conventional organic solvents like DMF) to low (alcohols, esters, or water with boiling points below 100°C). This parameter change enables the use of environmentally friendly solvents while maintaining bonding capability through adjusted adhesive formulation and processing temperature (60-150°C range).
Solution Approach 2:
The patent employs conventional, easily degradable solvents (alcohols, esters, water) that are environmentally benign and can be quickly evaporated or disposed of, replacing persistent organic solvents. These solvents leave minimal environmental impact and can be removed at lower temperatures, reducing energy consumption and pollution.
2Reliability
If high adhesive temperature is used for bonding, then the bonding between layers can be achieved, but energy consumption increases
Solution Approach 1:
The patent changes the processing temperature parameter from high (conventional high-temperature bonding) to low (60-150°C range). This is achieved by formulating adhesives that remain effective at lower temperatures, using solvents with lower boiling points, and adjusting the rheological properties of the adhesive to maintain bonding capability without requiring excessive thermal energy.
3Reliability
If large amount of organic solvent is used during bonding, then the bonding process can be completed, but the smoothness of the artificial leather is lowered
Solution Approach 1:
The patent replaces heavy organic solvents with lighter, more volatile solvents (alcohols, esters, water) that evaporate completely or leave minimal residue. These solvents do not compromise the smoothness of the artificial leather surface while still providing adequate bonding performance during the processing period.
4Productivity
If conventional methods are used to produce artificial leather, then the production process can be completed, but the hand feeling of the artificial leather is poor
Solution Approach 1:
The patent changes multiple parameters including solvent type, temperature, and adhesive composition to produce an artificial leather with improved hand feeling. The lower processing temperature and use of benign solvents preserve the natural texture and softness of the material, while the modified adhesive formulation ensures proper bonding without compromising surface quality.
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
This approach allows for low-temperature adhesion, improving the hand feeling and smoothness of the artificial leather while minimizing energy consumption and environmental impact.
Implementation Method 1
a thermoplastic polyurethane fiber adhesive layer is meltblown on the substrate
Implementation Method 2
a thermoplastic polyurethane fiber layer is meltblown on the thermoplastic polyurethane fiber adhesive layer
Implementation Method 3
the substrate, the thermoplastic polyurethane fiber adhesive layer and the thermoplastic polyurethane fiber layer are thermally bonded to form a stacked material
Implementation Method 4
the paste layer is heated to an adhesive temperature to adhere the paste layer to the thermoplastic polyurethane fiber layer of the stacked material
Data Source
AI summary
The present invention relates to an artificial leather and a method for producing the same. The artificial leather includes a substrate, a thermoplastic polyurethane fiber adhesive layer, a thermoplastic polyurethane fiber layer, a paste layer, and a surface layer. The paste layer has a thermosetting paste or a high solid-content paste, and the paste has a specific adhesive temperature. A bonding can be performed at low temperature in the method for producing the same, and the artificial leather made by the method for producing the same has excellent hand feeling and/or smoothness.