Napped Artificial Leather Dark Color via Carbon Black Binder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing napped artificial leathers face challenges in achieving a high-quality dark color with excellent light resistance, color migration resistance, and peel strength, often resulting in low-quality products with distinct two-color impressions and reduced fiber strength.
Innovation Solution
A napped artificial leather is developed using a non-woven fabric of polyester fibers with an average fineness of 0.07 to 0.9 dtex, containing 0.5 to 10 mass% of carbon black, and an elastic polymer applied within the fabric. The leather has a napped surface with a lightness L* value of ≤ 20 and a peel strength of 3 kg/cm or more, along with enhanced color migration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If disperse dye is used to color polyester ultrafine fibers in a dark color, then dark color development is achieved, but light resistance and color migration resistance are reduced
Solution Approach 1:
The patent introduces a binder as an intermediary substance that mediates between the disperse dye and the polyester ultrafine fibers. The binder contains specific functional groups (carboxyl, hydroxyl, or amino groups) that enable strong adhesion to the dye particles, preventing color migration while maintaining dark color development. This intermediary binding mechanism resolves the contradiction by providing a stable connection that prevents dye transfer without compromising color depth.
Solution Approach 2:
The patent creates a composite coloring system combining disperse dye particles with a binder substance on the fiber surface. This composite approach allows the dark color development of disperse dye to be achieved while the binder provides protective functionality against color migration and improves light resistance. The composite material formed on the fiber surface simultaneously delivers both desired properties.
2Reliability
If cationic dye is used to achieve excellent color fastness, then color migration resistance is improved, but fiber strength is reduced and two-color impression occurs
Solution Approach 1:
The patent uses a binder as an intermediary that adsorbs disperse dye particles onto the fiber surface without requiring cationic modification of the fiber itself. This intermediary binding approach prevents direct chemical interaction between dye and fiber that would weaken the fiber structure, while still achieving excellent color migration resistance through the binder's adhesion mechanism.
Solution Approach 2:
The patent applies coloring and binding functionality locally on the fiber surface rather than modifying the entire fiber structure. The binder and dye are concentrated on the surface layer, allowing the bulk fiber material to maintain its original strength properties. This local application prevents the two-color impression by ensuring uniform surface coloring without affecting the fiber's internal structure.
3Illumination intensity
If large amount of disperse dye is deposited to achieve dark color, then dark color development is improved, but color migration resistance is reduced
Solution Approach 1:
The binder serves as an intermediary that anchors large amounts of disperse dye particles to the fiber surface through strong adhesion forces. This intermediary mechanism allows high dye deposition for dark color development while preventing the dye particles from migrating to other surfaces. The binder's functional groups create stable bonding that secures the dye in place even in high-concentration applications.
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 achieves a strong dark color development with high light resistance and color migration resistance, while maintaining a high peel strength, resulting in a high-quality napped artificial leather.
Implementation Method 1
the polyester fibers contain 0.5 to 10 mass% of a dark color pigment, wherein the dark color pigment is carbon black
Data Source
AI summary
Disclosed is a napped artificial leather including: a non-woven fabric containing polyester fibers having an average fineness of 0.07 to 0.9 dtex; and an elastic polymer applied in the non-woven fabric, wherein the polyester fibers contain 0.5 to 10 mass% of a dark color pigment, the napped artificial leather has a napped surface on which the polyester fibers on at least one side thereof are napped, and the napped surface has a lightness L* value based on the L*a*b* color system, of ≤ 20, and the napped artificial leather has a peel strength of 3 kg/cm or more, and a grade of color difference, determined using a Grey scale for assessing staining in an evaluation of color migration to a multifiber adjacent fabric (co-woven fabric No. 1; the same applied to the following) during pressurization under heating in a wet state under a load of 4 kPa at 200°C for 60 seconds, of 4 or more.