Artificial leather, production method therefor, and artificial leather backing material
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Solution Overview
Problem
Existing artificial leathers with ultrafine fibers and elastomers face challenges in achieving both flame retardancy and moderate air permeability while maintaining a flexible texture and elegant appearance, as previous methods often compromise on spinnability, texture durability, or lead to unstable flame retardancy and moisture-related issues.
Innovation Solution
An artificial leather with a fiber entanglement of ultrafine fibers and an elastomer, where the flame retardant is applied to one surface with specific tackiness and opening portions, ensuring both functionality and aesthetic qualities, including a phosphorus-based compound and a woven/knitted fabric structure for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flame retardant is applied to ultrafine fibers or the entire artificial leather surface, then flame retardancy is improved, but air permeability deteriorates and texture becomes rigid
Solution Approach 1:
The patent applies flame retardant only to specific localized areas (opening portions) rather than the entire surface. The flame retardant is concentrated in vent holes and localized regions where it is most needed for flame safety, while the rest of the suede surface remains free of flame retardant coating, preserving its natural texture and air permeability properties.
Solution Approach 2:
The patent utilizes a porous nonwoven fabric structure with controlled voids and opening portions. These porous structures allow air to pass through while providing surfaces for flame retardant application in specific areas. The inherent porosity of the nonwoven fabric maintains breathability even with localized flame retardant treatment.
2Reliability
If flame retardant is applied to achieve high flame retardant performance, then flame retardancy is improved, but the flexible texture and elegant appearance deteriorate
Solution Approach 1:
Flame retardant is applied selectively only to opening portions and vent holes rather than the entire surface. This localized application ensures that the majority of the suede surface maintains its original flexible texture and elegant appearance, while still achieving adequate flame retardancy at critical areas.
Solution Approach 2:
The patent applies flame retardant to only a partial area (opening portions) rather than the entire surface. This partial action is sufficient to achieve the required flame retardant performance while minimizing impact on the overall texture and appearance of the artificial leather.
3Reliability
If copolymerized polyester with organophosphorus component is used for ultrafine fibers, then flame retardancy is improved, but spinnability and thread strength deteriorate
Solution Approach 1:
The patent uses an intermediary approach by applying flame retardant as a separate coating or treatment to the finished nonwoven fabric rather than incorporating it into the fiber polymer structure. This allows the use of standard, easily spinable polyester or polyamide fibers while still achieving flame retardancy through surface application to opening portions.
Solution Approach 2:
The flame retardant function is segmented from the fiber structure itself. Instead of making the entire fiber flame-retardant through copolymerization, the flame retardant is applied separately to specific areas (opening portions), allowing the bulk fiber material to maintain its original spinnability and strength properties.
4Reliability
If flame retardant is applied to control opening portion, then flame retardancy is improved, but manufacturing complexity increases
Solution Approach 1:
The patent creates opening portions and vent holes during the nonwoven fabric formation process itself, before final flame retardant application. This preliminary structuring allows subsequent flame retardant coating to be applied efficiently to predefined areas, simplifying the overall manufacturing process compared to post-processing modifications.
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 provides artificial leather with excellent flame retardancy, moderate air permeability, and a flexible texture that mimics natural suede, while maintaining an elegant appearance and good formability of opening portions, suitable for various applications including vehicle interiors.
Implementation Method 1
the functional agent has a tackiness of 0.1 N/cm2 or more and 2.0 N/cm2 or less
Data Source
AI summary
An artificial leather is provided having excellent flame retardancy and moderate air permeability and a flexible texture, where the artificial leather feels like natural suede and has an elegant appearance, the artificial leather including a fiber entanglement including an ultrafine fiber having an average single fiber diameter of 0.1 μm or more and 10 μm or less, and an elastomer, in which one surface is a napped surface having a raised nap, the other surface is a flame retardant surface having a flame retardant, and the following requirements 1 and 2 are satisfied: requirement 1: at least the flame retardant surface has a plurality of opening portions; requirement 2: the flame retardant has a tackiness of 0.1 N/cm2 or more and 2.0 N/cm2 or less.