Microfiber Textile Composite Breathability and VOC Reduction
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Solution Overview
Problem
Conventional textile composites with polyurethane foam for upholstery furniture lack air permeability, generate harmful volatile organic compounds, and are not environmentally friendly due to solvent use.
Innovation Solution
A microfiber textile composite is created by laminating a microfiber fabric with a solvent-free polyurethane foam layer, using an adhesive, and optionally incorporating a non-woven structural layer, eliminating solvent-based processes and enhancing breathability and skin-friendliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polyurethane film is applied to completely cover the surface of the non-woven fabric, then the composite has good wear resistance and structural integrity, but the air permeability becomes insufficient
Solution Approach 1:
The patent applies a porous polyurethane foam layer instead of a solid film, allowing air to pass through the open pores while maintaining the protective function. The foam structure provides both wear resistance and breathability by combining structural integrity with permeable architecture.
Solution Approach 2:
The patent creates a composite structure combining non-woven fabric carrier with polyurethane foam layer, where each material contributes its strengths: the fabric provides tensile strength and the foam provides porosity and cushioning, achieving both durability and breathability.
2Reliability
If solvent-based polyurethane resins are used in the coating process, then the film formation and adhesion are improved, but volatile organic compounds and odors are generated creating environmental and health hazards
Solution Approach 1:
The patent changes the chemical composition parameters of the polyurethane system from solvent-based to water-based or solvent-free formulations. This substitution maintains the necessary adhesion and film-forming properties while eliminating harmful volatile organic compounds, making the process environmentally friendly.
Solution Approach 2:
The patent converts the traditionally harmful solvent role into a beneficial water-based system that not only eliminates VOCs but also provides a safer working environment, reduced odors, and compliance with environmental regulations while achieving the same technical performance.
3Ease of operation
If microfibers are woven as pile warp onto reinforced threads to create artificial leather, then the fabric has lower stretch and better softness, but the production process becomes complex requiring multiple dipping and precipitation steps
Solution Approach 1:
The patent combines the carrier fabric and foam layer into a single integrated composite structure, eliminating the need for separate dipping and precipitation steps. The foam layer is applied directly to the microfiber fabric in one process, simplifying manufacturing while maintaining softness and structural 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 composite is more wear-resistant, odorless, environmentally friendly, and offers improved breathability and comfort, suitable for upholstery furniture with reduced thickness and enhanced processing properties.
Implementation Method 1
a foam layer based on polyurethane foam which is arranged on a surface of the carrier layer and has an open-pored and breathable structure
Implementation Method 2
The microfiber fabric is laminated to the foam layer with the aid of an adhesive
Data Source
Figure 1~2
Figure 3
AI summary
Microfiber textile composite (1) with a base fabric (B) comprising a carrier layer (4) as a woven, knitted or nonwoven fabric of synthetic and/or natural materials and a foam layer (3) based on polyurethane foam having an open-pored and breathable structure arranged on a surface of the carrier layer, wherein the microfiber textile composite (1) comprises a cover layer (2) of microfiber fabric (M) arranged on the free surface of the foam layer (3), which is permeable to water vapor, and a first adhesive layer (9) between the base fabric (B) and the microfiber fabric (M) in order to achieve an addition of the respective favorable material properties.Method for producing the microfiber textile composite (1) comprising the steps: (i) applying polyurethane to the top of the carrier layer (4), (ii) precipitation of the polyurethane in water to form the foam layer (3), (iii) weaving microfibers to form the microfiber fabric (M), (iv) laminating the microfiber fabric (M) with the adhesive (9) onto the foam layer (3), whereby the overall thickness of the microfiber textile composite (1) decreases.