Fabric having uneven-surface design, and method for producing same
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Solution Overview
Problem
Existing methods for imparting a fine uneven-surface design to fabrics fail to achieve a balance between flexibility and wear resistance due to the elasticity of fibers, and the use of resin films can impair the soft feel and durability of the fabric.
Innovation Solution
A fabric with a polyurethane resin applied portion, where the application depth is 50 to 200 µm, filling ratio of polyurethane resin is 15% to 45%, and filling ratio of fibers is 50% to 80%, allowing the resin to permeate between fibers and form a lump state, thereby enhancing flexibility and wear resistance while suppressing compression resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If heat pressing is performed through embossing to impart a fine uneven-surface shape, then the surface design is improved, but the shaping effect is insufficient due to compression resilience caused by fiber elasticity
Solution Approach 1:
The patent applies a resin composition layer containing polyurethane resin and silicone oil onto the fabric surface. This composite material system combines the structural support of resin with the flexibility and compression resistance of silicone oil, creating a material that maintains fine uneven-surface shapes while suppressing fiber elasticity. The resin forms a matrix that locks in the embossed pattern, preventing recovery from compression.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the fabric surface by applying a resin composition with specific properties (polyurethane resin with silicone oil). This changes the surface characteristics from pure fiber structure to a resin-coated structure with different mechanical properties, including reduced compression resilience and improved shape retention.
2Shape
If fibers with small fineness are used to reduce compression resilience, then a fine uneven-surface shape can be imparted, but the shape lacks durability and disappears due to wear
Solution Approach 1:
The patent uses a composite material system where fine fibers provide the base structure for fine uneven-surface shapes, while an added resin composition layer (polyurethane resin with silicone oil) provides durability and wear resistance. The resin layer protects the fine fiber structure from degradation while maintaining the desired surface geometry.
3Shape
If a resin film is formed on the fabric surface to improve shaping properties, then a fine uneven-surface shape can be imparted, but the soft feel and appearance of fibers are impaired and cracking may occur
Solution Approach 1:
The patent changes the resin formulation from conventional pure resin to a resin composition containing polyurethane resin and silicone oil. This parameter change in material composition reduces cracking tendency and maintains soft feel while achieving fine uneven-surface shaping. The silicone oil component specifically addresses the cracking issue.
Solution Approach 2:
The silicone oil acts as an intermediary substance within the resin composition, modifying the resin's properties to reduce brittleness and cracking. It serves as a plasticizer or flexible agent that allows the resin film to maintain flexibility and soft feel while still providing sufficient shaping capability.
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 fabric with a fine uneven-surface design that is both flexible and wear-resistant, maintaining the soft feel and durability of the fibers while effectively shaping the embossed pattern.
Implementation Method 1
a polyurethane resin which permeates between fibers at least in a surface portion of the fabric
Implementation Method 2
the surface of the fabric is subjected to embossing
Implementation Method 3
heat pressing is performed through the embossing
Data Source
Figure 1~2
Figure 3~4
AI summary
Provided is a fabric to which an uneven-surface design which is fine and has flexibility and wear resistance is imparted. The fabric has a polyurethane resin applied portion on at least a portion of a surface side of the fabric, and an uneven-surface design shaped on the polyurethane resin applied portion. The polyurethane resin applied portion is a region in which a polyurethane resin which is applied is present, and the polyurethane resin permeates between the fibers at least in a surface portion of the fabric such that a surface of the fabric is formed by the polyurethane resin and the fibers. In the polyurethane resin applied portion, an application depth of the polyurethane resin is 50 to 200 µm, a filling ratio of the polyurethane resin is 15% to 45%, and a filling ratio of the fibers of the fabric is 50% to 80%.