Multilayer Suede-Like Artificial Leather for Strength and Softness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing high-quality artificial leather with a suede-like appearance struggle to balance mechanical resistance and softness, often requiring excessive polyurethane binders that compromise formability and visual homogeneity, and fail to achieve evenly dyed products with consistent appearance on both sides.
Innovation Solution
A multilayer intermediate product impregnated with polyurethane is produced by combining microfibrous and reinforcing textile layers using thermoplastic adhesives before dyeing, ensuring similar tactile and visual characteristics on both sides and enhanced mechanical properties without excessive binder usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If excessive polyurethane binders are used to improve mechanical resistance, then strength is improved, but softness and formability deteriorate
Solution Approach 1:
The patent uses a composite structure combining microfibrous non-woven fabric with reinforcing textile layers (woven or knitted) to achieve enhanced mechanical resistance. The reinforcement layers provide strength through their structural integrity rather than relying solely on excessive binder content, thus maintaining the softness and formability of the microfibrous surface layer.
2Strength
If polyurethane binders are used to hold microfibres, then strength is improved, but softness deteriorates
Solution Approach 1:
The invention combines microfibrous non-woven fabric with reinforcing textile layers to achieve tear resistance. The reinforcement layers (woven or knitted textiles) provide the necessary mechanical strength and tear resistance, allowing the polyurethane binder content to be reduced while maintaining softness in the final artificial leather product.
3Manufacturing precision
If adhesive coupling is performed before dyeing, then manufacturing precision is improved, but process complexity increases
Solution Approach 1:
The patent performs adhesive coupling of the microfibrous non-woven fabric with reinforcing textile layers before the dyeing process. This preliminary bonding ensures that the layers remain properly aligned and bonded during subsequent dyeing operations, preventing delamination and ensuring uniform appearance. The process complexity increase is justified by the significant improvement in manufacturing precision and product quality.
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 results in artificial leather with improved mechanical resistance, softness, and formability, along with uniform dyeing and appearance on both surfaces, suitable for various applications without additional coupling, while maintaining the typical suede-like appearance and tactile impact.
Implementation Method 1
combining microfibrous and reinforcing textile layers using thermoplastic adhesives
Implementation Method 2
Impregnation of the above microfibrous material with a solution of polyurethane (PU) in organic solvents
Data Source
AI summary
A process is described for the preparation of a multilayer intermediate product impregnated with polyurethane, useful for the production of soft synthetic leather, with enhanced mechanical resistance, comprising: a. production of a microfibrous non-woven intermediate product consisting of microfibres of one or more polymers selected from polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyacrylonitrile, polyamide; b. preparation, by coupling effected by means of adhesives, of an intermediate multilayer product comprising at least one layer of the above non-woven microfibrous intermediate product and at least one layer of a reinforcing textile product; c. impregnation with one or more polyurethane solutions of the multilayer intermediate product produced in step (b), thus obtaining a multilayer intermediate product impregnated with polyurethane.