Microfibrous product and the use thereof for the preparation of covers and cases
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing microfibrous non-woven fabrics have a thick, mottled appearance that is not suitable for consumer goods, particularly electronic devices, as it can be perceived as a defect and lacks the necessary pliancy and magnetic strength, and the production process faces issues with roll breakage and softer intermediate products during dyeing.
Innovation Solution
A modified production process that includes a final splitting step to achieve a thickness of 0.65 mm or less, with buffing and finishing adjustments to achieve a flat or slightly mottled appearance, and a concurrent orientation of fibers to ensure uniformity and resistance, resulting in a non-woven fabric with a nap length of 350 µm or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the non-woven fabric thickness is reduced to meet consumer goods requirements, then the suitability for electronic device covers is improved, but the structural integrity and resistance during processing deteriorate
Solution Approach 1:
The fabric production process is segmented into distinct phases: initial formation at normal thickness, dyeing process, and final splitting into two thinner layers. This segmentation allows the fabric to maintain adequate thickness during processing for structural integrity, then be divided into thin layers (0.65mm or less) suitable for consumer goods applications.
Solution Approach 2:
The fabric is prepared and dyed at a greater thickness before the final splitting step. This preliminary action at increased thickness provides the necessary structural integrity and resistance during the dyeing and processing stages, and the thin final product is achieved through the subsequent splitting operation.
2Shape
If the fabric is processed with traditional buffing to create nap, then the suede-like appearance is improved, but the mottling effect increases which is perceived as a defect
Solution Approach 1:
The buffing parameters are modified to control nap length at 350 µm or less. This parameter change in nap length creates the desired suede-like appearance while minimizing the mottling effect that would otherwise be perceived as a defect in the fabric surface.
Solution Approach 2:
The buffing process is applied with controlled local effects to create uniform nap across the fabric surface. By controlling the nap length parameter locally through adjusted buffing conditions, the fabric achieves consistent suede-like appearance without excessive mottling.
3Ease of operation
If the fabric thickness is reduced for pliancy, then the flexibility for covering various shapes is improved, but the magnetic strength in closures is reduced
Solution Approach 1:
The fabric is split into two thinner layers after the dyeing process. This segmentation creates thin, flexible layers suitable for covering various shapes while allowing strategic placement of magnetic components in the closure areas, where the fabric thickness does not interfere with magnetic strength requirements.
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 process produces a microfibrous non-woven fabric with a homogeneous, thin, and flexible texture suitable for electronic device covers, maintaining resistance and reducing mottling, thus addressing the thickness and appearance issues in existing technologies.
Implementation Method 1
The sea component, constituting the sheath of the microfibres, is subsequently dissolved with a selective solvent, preferably trichloroethylene
Implementation Method 2
Finally, the polyurethane coagulates and at the same time, the adhesive dissolves
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention refers to a process for the preparation of a microfibrous non-woven fabric based on polyester or polyamide microfibres immersed in a polyurethane matrix, and having a thickness equal to or less than 0.65 mm, a flat or slightly mottled appearance and a nap length of less than 350 mum. The non-woven fabric is used for the preparation of coverings for consumer goods, particularly for the preparation of covers and cases for electronic products.