Porous Leather-Like Sheet for Durable Inkjet Image Adhesion
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Solution Overview
Problem
Conventional leather-like sheets face challenges with abrasion resistance, light-resistant fastness, resistance to color migration, adhesion strength, and flexibility, particularly when used in outdoor applications such as sport shoes and athletic balls, due to limitations in inkjet printing methods and the use of dye or pigment inks.
Innovation Solution
A leather-like sheet with a porous layer having open pores of 1 μm or more and a surface image definition of 5 dots/mm or more, formed using a fibrous substrate and an inkjet printing method, which enhances adhesion and durability by using pigment inks and a protective elastic polymer layer for improved abrasion resistance and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pigment ink is used for inkjet printing on leather-like sheet, then light-resistant fastness and resistance to color migration are improved, but abrasion resistance and adhesion strength are degraded
Solution Approach 1:
The patent introduces an undercoating agent layer as an intermediary between the leather-like sheet surface and the pigment ink. This undercoating layer serves as a mediator that enhances adhesion between the pigment particles and the substrate, preventing peeling while allowing the pigment ink to maintain its superior light-resistant fastness and color migration resistance properties.
Solution Approach 2:
The patent creates a composite structure consisting of the leather-like sheet, undercoating agent layer, and pigment ink pattern. This composite material system combines the advantages of pigment ink (light-resistant fastness) with the adhesive properties of the undercoating agent, resolving the contradiction between durability and adhesion strength.
2Reliability
If conventional printing methods (gravure, roller, transfer) are used, then adhesion and durability are maintained, but manufacturing time and cost increase due to repeated engraving and color matching
Solution Approach 1:
The patent replaces the mechanical engraving and transfer processes of conventional printing methods with non-contact inkjet printing technology. This substitution eliminates the need for repeated engraving of patterns on rolls and manual color matching, dramatically improving manufacturing efficiency while maintaining pattern quality and adhesion through the use of undercoating agent.
3Quantity of substance
If alumina hydrate porous layer is used for inkjet printing, then ink receiving capacity is improved, but abrasion resistance is degraded due to frictional fall-off
Solution Approach 1:
The patent employs a porous undercoating agent layer that provides adequate ink receiving capacity through its porous structure, while the material composition and bonding properties of the undercoating agent ensure strong adhesion and abrasion resistance, eliminating the frictional fall-off problem associated with alumina hydrate layers.
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 results in a leather-like sheet with excellent abrasion resistance, light-resistant fastness, resistance to color migration, and flexibility, enabling durable and long-lasting images on artificial leather products.
Implementation Method 1
a porous layer having a surface having open pores with a diameter of 1 μm or more and having a surface image with a definition of 5 dots/mm or more formed by an inkjet printing method
Data Source
AI summary
The invention is to provide a leather-like sheet having a fine image drawn by an inkjet printing method, etc., on its surface and having practically sufficient physical properties. This invention includes a leather-like sheet including (i) a fibrous substrate and (ii) a porous layer thereon, the porous layer having a surface having open pores with a diameter of 1 μm or more and the porous layer having the surface having an image whose definition is 5 dots/mm or more, and a process for the production thereof.