Napped artificial leather dyed with cationic dye and method for manufacturing the same
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Solution Overview
Problem
Napped artificial leathers dyed with cationic dyes face issues of fiber detachment and color migration due to low fiber intensity and deep color penetration, respectively.
Innovation Solution
A napped artificial leather with a non-woven fabric of ultrafine fibers (0.07 to 0.9 dtex) dyed using a cationic dye, where the fibers contain a dicarboxylic acid unit composed mainly of terephthalic acid and 1.5 to 3 mol% of a unit represented by formula (Ib), and treated with an anionic surfactant in a hot water bath to reduce chlorine content and prevent color migration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If cationic dye is used to dye napped artificial leather, then color development is improved, but fiber detachment occurs due to low fiber intensity
Solution Approach 1:
The patent changes the chemical parameters of the polyester fiber by incorporating specific copolymer units (sulfoisophthalic acid metal salt units and quaternary phosphonium salt or quaternary ammonium salt units) that enable cationic dyeing while maintaining fiber strength. This allows the fiber to accept cationic dyes effectively without sacrificing mechanical integrity
Solution Approach 2:
The patent creates a composite structure by combining polyester fibers with specific copolymer units that have both mechanical strength properties and cationic dyeing affinity. The composite nature of the fiber (combining different functional units) allows simultaneous achievement of strength and color development
2Illumination intensity
If deep color is achieved with cationic dye, then color development is improved, but color migration to other articles occurs
Solution Approach 1:
The patent converts the potential harm of deep color penetration (which causes migration) into a benefit by using specific copolymer units that provide strong, stable bonding sites for cationic dyes. The quaternary phosphonium salt and quaternary ammonium salt units create stable ionic bonds with anionic cationic dyes, preventing migration while achieving deep color
Solution Approach 2:
The patent changes the chemical composition parameters of the polyester to include specific copolymer units (1-10 mol% sulfoisophthalic acid metal salt units and 1-10 mol% quaternary phosphonium salt or quaternary ammonium salt units) that provide optimal dye affinity and stability, achieving deep color without migration
3Adaptability or versatility
If copolymer units are added to polyester for cationic dyeing, then dyeability is improved, but fiber strength decreases
Solution Approach 1:
The patent optimizes the concentration parameters of copolymer units, specifying that sulfoisophthalic acid metal salt units and quaternary phosphonium salt or quaternary ammonium salt units should each comprise 1-10 mol% of the total polyester units. This controlled composition ensures sufficient cationic dyeability while maintaining fiber strength
Solution Approach 2:
The patent applies local quality by incorporating copolymer units at specific concentrations (1-10 mol%) rather than uniformly throughout the entire polymer structure. This localized incorporation provides cationic dyeing sites without compromising the overall mechanical properties of the polyester fiber
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 solution effectively suppresses fiber detachment and minimizes color migration, ensuring the napped artificial leather maintains mechanical strength and deep color without transferring dye to other articles.
Implementation Method 1
washing the artificial leather base material in a hot water bath at 50 to 100°C containing an anionic surfactant
Implementation Method 2
dyeing the artificial leather base material using a cationic dye
Data Source
AI summary
Disclosed is a napped artificial leather dyed with a cationic dye, including: a non-woven fabric of a cationic dyeable polyester fiber having a fineness of 0.07 to 0.9 dtex; and an elastic polymer provided inside the non-woven fabric, wherein the napped artificial leather has L* value ≤ 50, a grade of color difference determined in an evaluation of color migration to PVC under a load 0.75 kg/cm at 50°C for 16 hours, of 4 or more, a tear strength per mm of thickness of 30 N or more, and a peel strength of 3 kg/cm or more.