Elastic Artificial Leather With Wave Structure for MD Stretchability
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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, particularly due to issues with substrate shrinkage and adhesive use.
Innovation Solution
A production method involving an entangled fiber body with microfine fibers, an elastic polymer, and a wave-like structure formed by mechanical stretching and heat-setting, which allows for moderate elasticity and resistance to further stretching without using adhesives, enhancing mechanical properties and surface smoothness.
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 stretchability, but the productivity decreases due to additional adhesive application and removal steps
Solution Approach 1:
The invention extracts and eliminates the adhesive bonding step from the production process. Instead of using adhesives to bond the elastomer sheet to the entangled fiber body, the patent uses direct thermal bonding where the elastomer sheet is heated and pressed onto the fiber body, allowing the elastomer to bond thermally without any adhesive agents. This removes the harmful adhesive application and removal steps, improving productivity while maintaining stretchability.
Solution Approach 2:
The invention replaces the mechanical adhesive bonding system with a thermal bonding system. The elastomer sheet is bonded to the entangled fiber body through heat and pressure rather than chemical adhesives. This substitution eliminates the need for adhesive application and removal steps, directly improving productivity while achieving the same functional result of creating a bonded composite structure with stretchability.
2Strength
If the substrate for artificial leather is forced to shrink by the shrinking force of the elastomer sheet, then the artificial leather gains elasticity, but the process passing properties become poor due to curling toward the elastomer sheet side
Solution Approach 1:
The invention applies local quality by creating a wave-like structure with different local characteristics. The entangled fiber body is compressed to form localized wave patterns rather than uniform compression. This creates regions of varying density and structure that allow the substrate to shrink uniformly without curling, as the wave structure distributes the shrinkage forces evenly across the material surface.
Solution Approach 2:
The invention introduces curvature by forming a wave-like structure in the entangled fiber body. Instead of a flat compressed substrate, the wave pattern creates a three-dimensional curved structure that naturally accommodates shrinkage without curling. The wave structure acts as a buffer that absorbs dimensional changes, allowing the substrate to maintain its shape while gaining elasticity.
3Strength
If a high-density substrate for artificial leather is shrunk, then the mechanical properties are enhanced, but it is difficult to achieve high shrinkage due to insufficient shrinking force
Solution Approach 1:
The invention applies preliminary action by pre-compressing the entangled fiber body to form a wave-like structure before the elastomer sheet bonding process. This pre-compression creates internal stress and a structured framework that facilitates subsequent uniform shrinkage. The wave structure prepared in advance provides a pathway for controlled dimensional reduction, enabling high-density substrates to achieve the required shrinkage rates without excessive force.
Solution Approach 2:
The invention changes physical parameters by transforming the substrate structure from a dense uniform state to a wave-patterned state with varying local density. This structural parameter change creates regions of different compressibility and shrinkage resistance, allowing the overall material to achieve high shrinkage rates. The wave structure acts as a template that guides the shrinkage process, enabling controlled dimensional reduction while maintaining mechanical integrity.
4Strength
If adhesive is used to bond the elastomer sheet, then the artificial leather gains stretchability, but the surface quality becomes poor
Solution Approach 1:
The invention extracts and completely removes adhesive materials from the production process. Instead of applying adhesive layers that would contaminate or degrade the surface quality, the patent uses direct thermal bonding where the elastomer sheet is heated and pressed onto the entangled fiber body. This eliminates adhesive-related surface defects while maintaining the bonded composite structure necessary for stretchability.
Solution Approach 2:
The invention replaces the chemical adhesive bonding system with a physical thermal bonding system. The elastomer sheet bonds to the fiber body through heat and pressure rather than chemical adhesion. This substitution eliminates all adhesive-related surface quality issues such as residue, discoloration, and uneven bonding, while achieving the same functional outcome of creating a durable bonded structure with stretchable properties.
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 stretchability and mechanical properties in the machine direction, maintaining surface quality and wear resistance, 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 while being stretched; the artificial leather is brought into close contact with the heated cylinder, is stretched by the heated cylinder, and is heat-treated while being stretched
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
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.