Leather-like fabric
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Solution Overview
Problem
Current artificial leather products fail to replicate the napped feel and air permeability of suede leather while achieving high wear resistance, with existing methods either damaging resin layers or compromising on quality and comfort.
Innovation Solution
A leather-like fabric with ultrafine fibers and a polymeric elastomer, featuring a napped surface with discontinuously arranged resin layers, each with a three-layer structure, providing a balanced wear resistance and air permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a resin solution is applied to a napped surface and separated by chemical/mechanical techniques to expose napped fibers, then the surface shows nubuck-like characteristics, but the resin layer parts are seriously damaged leading to poor wear resistance
Solution Approach 1:
The resin layer is divided into multiple discrete layers (first resin layer and second resin layer) rather than forming a single continuous layer. This segmentation allows the napped fibers to remain exposed between resin portions, maintaining wear resistance while achieving the desired surface texture.
Solution Approach 2:
The resin layers are arranged discontinuously on the surface, creating local resin portions and local napped portions with different properties. The resin portions provide durability and structural integrity, while the napped portions provide the characteristic nubuck texture and breathability.
2Strength
If the surface of a polyurethane resin base is polished and a leather design is printed on it, then wear resistance is improved, but napped fibers are absent and air permeability is low leading to poor quality and comfortability
Solution Approach 1:
The discontinuous arrangement of resin layers creates a porous structure with spaces between resin portions that allow air to pass through. This maintains high air permeability while the resin layers themselves provide the necessary wear resistance.
Solution Approach 2:
The invention combines resin portions and napped fiber portions in a composite structure. The resin provides durability and the napped fibers provide breathability and characteristic texture, achieving a synergistic effect that neither component could achieve alone.
3Strength
If resin layers are applied continuously on the fabric surface, then wear resistance is improved, but the napped feel and air permeability of suede leather are lost
Solution Approach 1:
The continuous resin layer is segmented into multiple discrete layers with spaces between them. This allows the resin to provide wear resistance while leaving gaps that maintain air permeability and allow napped fibers to be felt on the surface.
Solution Approach 2:
The resin layers are arranged in a multi-layered vertical structure rather than a single continuous horizontal layer. This dimensional arrangement allows resin portions to overlap vertically while leaving horizontal spaces for air flow and napped fiber exposure.
Data Source
AI summary
A leather-like fabric has a feel of natural nubuck leather and a napped feel and air permeability of suede leather, as well as high wear resistance. The leather-like fabric includes a fibrous structure including ultrafine fibers having an average monofilament fineness of 0.0001 dtex or more and 0.5 dtex or less, at least one surface of the fibrous structure being napped, the napped surface having resin layers located discontinuously, and each of the resin layers containing two or more layers.