Napped leather-like sheet-shaped article
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Solution Overview
Problem
Existing leather-like sheet-shaped articles using woven or knitted fabrics as substrates face issues with fluff loss due to wear and inferior surface conformability, and the appearance of structure lines, leading to a less desirable surface appearance.
Innovation Solution
A napped leather-like sheet-shaped article is developed using a woven or knitted fabric as a fibrous substrate, with a resin applied, featuring specific yarn and fiber densities, nap structures, and resin application to enhance surface appearance and conformability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fiber entangled body composed of ultrafine fibers is used as the fibrous substrate, then the naps have high density and good surface appearance, but fluff loss occurs due to wear and surface conformability is inferior
Solution Approach 1:
The invention uses a composite structure combining a woven or knitted fabric base layer with a fiber entangled body layer. The woven/knitted fabric provides structural stability and fluff loss resistance, while the fiber entangled body layer provides dense naps and good surface appearance. This composite material approach resolves the contradiction by combining materials with complementary properties.
2Reliability
If a woven or knitted fabric is used as the fibrous substrate, then fluff loss resistance and surface conformability are improved, but the denseness of naps is insufficient and structure lines appear on the surface
Solution Approach 1:
The invention combines a woven or knitted fabric base layer with a fiber entangled body layer to create a composite material. The base layer provides fluff loss resistance, while the fiber entangled body layer provides dense naps that cover structure lines and improve surface appearance.
Solution Approach 2:
The invention adds a third dimension by creating a layered structure where the fiber entangled body is applied on top of the woven/knitted fabric. This dimensional addition allows the naps to protrude from the surface, providing density and appearance improvement without compromising the base layer's structural integrity.
3Manufacturing precision
If the number of structure points of yarns is increased to improve nap density, then the denseness of naps improves, but the constant load elongation rate decreases and surface conformability worsens
Solution Approach 1:
The composite structure allows the fiber entangled body layer to provide high nap density while the woven/knitted base layer maintains elasticity and surface conformability. The base layer's structure points are optimized separately from the nap layer's fiber density.
Solution Approach 2:
The invention segments the functional requirements into two separate layers: the woven/knitted fabric handles structural requirements including elongation and conformability, while the fiber entangled body handles surface requirements including nap density and appearance. This segmentation allows independent optimization of each function.
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 provides a napped leather-like sheet-shaped article with improved fluff loss resistance, surface conformability, and a superior surface appearance by utilizing woven or knitted fabrics with controlled yarn densities and resin application.
Implementation Method 1
a resin applied to the fibrous substrate... the naps having the resin adhering thereto
Data Source
AI summary
A napped leather-like sheet-shaped article includes a fibrous substrate which is a woven fabric or a knitted fabric, and a resin applied to the fibrous substrate, and includes, on a front surface thereof, a napped surface having naps with the resin adhering thereto. The number of structure points of yarns constituting the fibrous substrate per 25.4 mm square is 1,500 to 10,000 in the case of a woven fabric, and is 3,000 to 9,000 in the case of a knitted fabric. The total number of fibers involved in crossing or entanglement at structure points per 25.4 mm square is 396,000 to 2,640,000 in the case of a woven fabric, and is 912,000 to 8,208,000 in the case of a knitted fabric. The constant load elongation rate is 5% or more, and the constant load set rate is less than 10%.