Fabric and method for producing fabric
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Solution Overview
Problem
Existing leather-like fabrics often require a backing material, which complicates recycling and may not provide the desired texture and properties, such as high strength, wrinkle resistance, and flame retardancy, while also being heavy and lacking in temperature regulation.
Innovation Solution
A fabric composed of a woven or knitted fabric layer laminated with a resin film layer, where both layers are embossed to create a leather-like texture without a backing, using polyester for the fabric layer and resin film, which can be recycled, and incorporating shrinkage yarns to enhance bulkiness and embossing depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a backing material is used in leather-like fabric, then structural stability is improved, but recyclability deteriorates and weight increases
Solution Approach 1:
The invention extracts and removes the backing material from the leather-like fabric structure, creating a single-layer woven or knitted fabric that achieves structural stability through its own construction rather than relying on an additional backing layer, thereby improving recyclability
Solution Approach 2:
The invention uses composite material strategies by combining different yarn types (shrinkage yarns with non-shrinkage yarns) within the single fabric layer to achieve both structural stability and desired texture without requiring a separate backing material
2Stability of the object's composition
If a backing material is used in leather-like fabric, then structural stability is improved, but weight increases
Solution Approach 1:
The invention removes the backing material that adds weight, creating a lighter single-layer fabric that achieves structural stability through its own construction, directly reducing the overall weight of the leather-like fabric
3Manufacturing precision
If embossing is applied to create leather-like texture, then surface quality is improved, but manufacturing complexity increases
Solution Approach 1:
The invention changes material parameters by using shrinkage yarns with specific shrinkage rates (5-50%) that respond to temperature changes during embossing, allowing the fabric to self-adjust and enhance embossing depth without requiring complex manufacturing equipment or multiple processing steps
4Ease of manufacture
If polyester is used for fabric layer and resin film, then recyclability is improved, but texture quality may deteriorate
Solution Approach 1:
The invention uses composite material strategies by combining different yarn types (shrinkage yarns with non-shrinkage yarns) within the single fabric layer to achieve both structural stability and desired texture without requiring a separate backing material
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 fabric achieves a high-quality leather-like texture with improved recyclability, reduced weight, and enhanced properties like water repellency, flame retardancy, and temperature regulation, while maintaining stability and uniform tensile strength.
Implementation Method 1
incorporating shrinkage yarns to enhance bulkiness and embossing depth
Data Source
AI summary
Provided is a fabric of a woven fabric or a knitted fabric provided with a pattern expressed by embossing, the fabric including: a fabric layer; and a resin film layer which is laminated on the fabric layer. The fabric layer and the resin film layer may be embossed. In the fabric, a melting point of the resin film layer may be lower than a melting point of the fabric layer. Provided is a method for producing a fabric, the method including: preparing a fabric layer of a woven fabric or knitted fabric; laminating a resin film layer on the fabric layer; and embossing the fabric layer and the resin film layer.