Napped artificial leather, polyester fiber, and non-woven fabric
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Solution Overview
Problem
Conventional napped artificial leathers suffer from low-quality 'sharp bending' and nonuniform appearances due to angled edges and density unevenness, with existing solutions either compromising on flexibility or productivity.
Innovation Solution
A napped artificial leather with polyester fibers having a Young's modulus of 1 to 6 GPa, average fiber-toughness of 8 to 40 cN·%, and crystallinity of 35% or less, combined with an elastic polymer in a non-woven fabric, is buffed to create a flexible and uniform surface that avoids sharp bending and maintains elegance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high tenacity polyester fibers are used, then mechanical strength is improved, but the napped fibers become too long and gather, resulting in rough appearance with density unevenness
Solution Approach 1:
The patent applies parameter changes by precisely controlling the fiber-toughness parameter within 8 to 40 cN·% and Young's modulus within 1 to 6 GPa. This optimization ensures that the polyester fibers have sufficient mechanical strength while maintaining appropriate brittleness for effective cutting during buffing, preventing fiber gathering and achieving uniform surface appearance.
2Strength
If thick polyester fibers are used, then mechanical strength and color development are improved, but the fibers become hard and difficult to cut, resulting in sharp bending when bent
Solution Approach 1:
The patent optimizes the fiber-toughness parameter to a specific range of 8 to 40 cN·% and controls the Young's modulus between 1 to 6 GPa. These parameter changes ensure that the fibers maintain adequate strength while achieving the right balance of softness and flexibility, allowing them to be properly cut during buffing and preventing sharp bending when the artificial leather is flexed.
Solution Approach 2:
The patent uses composite materials by combining polyester fibers with specific elastic polymers (such as polyurethane or polycarbonate-based polyurethane) in a non-woven fabric structure. This composite approach enhances the overall flexibility and suppleness of the artificial leather while maintaining the mechanical strength provided by the polyester fibers.
3Manufacturing precision
If conventional napping processes are used on high strength fibers, then surface finish is improved, but the fibers cannot be easily cut and tend to gather, creating density unevenness
Solution Approach 1:
The patent changes the critical parameter of fiber-toughness to within 8 to 40 cN·% and Young's modulus to 1 to 6 GPa, creating an optimal balance that allows conventional napping processes to effectively cut and flatten the fibers. This parameter optimization enables both good surface finish and efficient productivity without fiber gathering or density unevenness.
Data Source
AI summary
Disclosed is a napped artificial leather including: an artificial leather base material that includes a non-woven fabric of polyester fibers having a Young's modulus of 1 to 6 GPa, an average fiber-toughness of 8 to 40 cN·%, and a crystallinity of 35% or less, and an elastic polymer, the artificial leather base material having, on at least one surface thereof, a napped surface on which the polyester fibers are napped. Also disclosed are polyester fibers having a Young's modulus of 1 to 6 GPa, an average fiber-toughness of 8 to 40 cN·%, and a crystallinity of 35% or less, and a non-woven fabric including the polyester fibers.