Elastic Artificial Leather Shrink-Setting for Machine-Direction Stretch
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Solution Overview
Problem
Existing methods for producing elastically stretchable artificial leathers fail to effectively enhance stretchability and mechanical properties in the machine direction while maintaining surface quality and wear resistance, often requiring adhesives that compromise productivity and surface quality.
Innovation Solution
A production method involving the creation of a microfiberizable fiber web, entanglement to form a nonwoven fabric, conversion to microfine fibers, and subsequent processing with an elastomer sheet stretched in the machine direction, followed by mechanical shrinking and heat-treating to form a wave-like structure, which enhances elasticity and resistance to further stretching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an elastomer sheet is adhesively bonded to an entangled fiber body and then forced to shrink, then the artificial leather gains elasticity, but the productivity decreases due to adhesive application and removal steps
Solution Approach 1:
The invention extracts and eliminates the adhesive from the production process. Instead of using adhesive to bond the elastomer sheet to the entangled fiber body, the method directly forces the elastomer sheet to shrink while in contact with the fiber body, achieving the same elastic effect without the productivity-reducing adhesive application and removal steps
Solution Approach 2:
The elastomer sheet itself serves the dual function of providing elasticity and acting as a processing medium. By forcing the elastomer sheet to shrink directly without adhesive, the system uses the elastomer's own properties to achieve both the elastic effect and simplify the production process
2Strength
If the substrate for artificial leather is forced to shrink by the elastomer sheet, then the artificial leather gains elasticity, but the process passing properties deteriorate due to curling toward the elastomer sheet side
Solution Approach 1:
The invention applies preliminary action by pre-coordinating the shrinkage of the elastomer sheet with the processing steps. The elastomer sheet is forced to shrink in a controlled manner before subsequent processing operations, preventing curling issues that would otherwise occur during later handling and processing steps
3Device complexity
If only the shrinking force of the elastomer sheet is used to shrink the substrate, then the production process is simple, but high-density substrates cannot achieve high shrinkage
Solution Approach 1:
The invention uses a composite approach by combining the elastomer sheet with a heating device. The heating device provides additional thermal energy to facilitate shrinkage of high-density substrates that cannot achieve sufficient shrinkage through elastomer sheet force alone, while maintaining relative process simplicity
4Strength
If adhesive is used to bond the elastomer sheet, then the artificial leather gains elasticity, but the surface quality deteriorates
Solution Approach 1:
The invention extracts and removes the adhesive from the production process entirely. By forcing the elastomer sheet to shrink directly without adhesive bonding, the surface quality is preserved while the elastic function is maintained through the mechanical action of the shrinking elastomer sheet
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 method produces artificial leather with improved elasticity and resistance to further stretching in the machine direction, maintaining high mechanical properties and surface quality, suitable for various applications including clothing and interior decorations.
Implementation Method 1
the artificial leather is allowed to shrink in the machine direction simultaneously with allowing the elastomer sheet to shrink in the machine direction by relaxing elongation of the elastomer sheet
Implementation Method 2
the artificial leather is heat-treated in shrunk state
Data Source
AI summary
A production method of an elastically stretchable artificial leather which includes a step of making microfiberizable fibers into a web; a step of entangling the obtained web to produce an entangled nonwoven fabric; a step of converting the microfiberizable fibers in the nonwoven fabric to microfine fibers, thereby producing a substrate for artificial leather; a step of producing an artificial leather by using the obtained substrate for artificial leather; and a step wherein the obtained artificial leather is brought into close contact with an elastomer sheet stretched in a machine direction by 5 to 40%; the artificial leather is allowed to shrink in the machine direction simultaneously with allowing the elastomer sheet to shrink in the machine direction by relaxing elongation of the elastomer sheet; the artificial leather is heat-treated in shrunk state; and then the artificial leather is peeled off from the elastomer sheet.