Needlepunched Nonwoven Fabric with Central Binder
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Solution Overview
Problem
Existing methods for producing artificial leather substrates often result in non-uniform surfaces and internal structures, leading to issues like the 'orange peel' effect and requiring additional resin application for durability, which increases costs and complexity.
Innovation Solution
A process involving needlepunching staple fibers into a thermoplastic binder layer, followed by uniform pressure and heat application between smooth surfaces to melt the binder without deforming the fibers, creating a smooth and uniform nonwoven fabric that can be finished with various substances for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive resins are applied to nonwoven fabric surfaces or impregnated throughout, then durability and dimensional stability are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent removes the separate adhesive resin application step entirely by incorporating thermoplastic binder layers directly into the nonwoven fabric structure during the needlepunching process. The binder layers are integrated as core components rather than added as separate finishing steps, eliminating the need for subsequent resin application, sanding, or surface finishing operations.
Solution Approach 2:
The patent combines the binder function and structural function into a single integrated system. The thermoplastic binder layers serve both as adhesive agents and as structural components that provide dimensional stability and durability. This merging eliminates the need for separate adhesive application steps and reduces manufacturing complexity.
2Shape
If adhesive resins are applied to nonwoven fabric surfaces, then surface smoothness is improved, but additional processing steps and costs are required
Solution Approach 1:
The patent incorporates the binder layers and performs the bonding action during the initial needlepunching process rather than as a subsequent finishing step. The thermoplastic binders are positioned and activated within the fabric structure before final product formation, eliminating the need for later surface treatment operations like sanding or brushing.
3Reliability
If extra layers are laminated on nonwoven fabric, then appearance and physical properties are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple functions into the single nonwoven fabric structure with integrated thermoplastic binder layers. The binders provide both adhesive properties and structural reinforcement that would otherwise require separate laminated layers. This integration eliminates the need for additional lamination steps while maintaining or improving physical properties.
4Shape
If uniform internal density is achieved in nonwoven fabric, then orange peel effect is prevented, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses centrally-located or centrally-restricted binder layers that provide localized reinforcement and density control. This strategic placement of binders in specific regions creates uniformity where it is most needed (at the fabric core) while allowing more flexibility in other regions, achieving overall surface uniformity without requiring extreme precision throughout the entire fabric structure.
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 produces a cost-effective, smooth, and uniform wearable fabric with improved conformability, thermal stability, and resistance to creasing and tearing, eliminating the need for expensive resin impregnation and surface finishing processes.
Implementation Method 1
heating the composite, while continuing to restrain the composite, for a finite time period to remove the thermal stresses in the composite
Implementation Method 2
each thermoplastic binder layer is fully melted
Implementation Method 3
restraining the composite between two smooth surfaces of an apparatus, which are positioned to apply uniform pressure under about 50 psi throughout the upper and lower surfaces
Implementation Method 4
restraining the composite between two smooth surfaces of an apparatus, which are positioned to apply uniform pressure
Data Source
AI summary
The present invention concerns a process for forming a wearable and functional fabric from a composite material comprising a nonwoven face layer containing a plurality of fibers, and at least one thermoplastic binder layer disposed underneath. The fibers are initially arranged in a generally planar web and subsequently needlepunched through at least one binder layer. The fiber layers can also be placed on both sides of one or more centrally-located binder layers, and further reinforced with scrims. In an innovative aspect of the invention, the composite is heated under low and uniform pressure to remove thermal stresses, resulting in at a least one relatively smooth face that can be coated to form a wearable fabric, e.g., artificial leather, odor absorbing fabric, and the like.