Process for obtaining a fabric with the appearance of leather, imitation leather, and the fabric obtained
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Solution Overview
Problem
Existing leather and imitation leather fabrics are cold in winter and hot in summer, not breathable, not water-repellent, prone to degradation, difficult to maintain, and lack fire resistance and flexibility, making them unsuitable for protective and ergonomic applications.
Innovation Solution
A process involving a paste of acrylic resin with inorganic fillers, melamine resins, silicone antifoam, polyethylene glycol, urea, and synthetic thickeners is applied to a technical fabric support to create a fabric-resin complex that is breathable, fire-resistant, and durable, with properties similar to leather, including elasticity and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional polyurethane-based imitation leather is used, then leather-like appearance is achieved, but breathability and water-repellency are poor
Solution Approach 1:
The invention uses a composite resin system combining acrylic resin as the main component (60-80% by weight) with polyurethane resin (20-40% by weight), along with inorganic fillers and functional additives. This composite formulation achieves both leather-like appearance and improved breathability与水 repellency that pure polyurethane coatings cannot provide
Solution Approach 2:
The invention modifies the chemical composition parameters of the coating resin, specifically adjusting the acrylic-to-polyurethane ratio and adding functional additives like polyethylene glycol (5-15% by weight) to enhance breathability. The paste viscosity is controlled at 10,000-15,000 cP and application thickness at 50-200 micrometers to optimize both appearance and functional properties
2Reliability
If traditional leather fabrics are used, then durability and appearance are achieved, but fire resistance and ease of maintenance are poor
Solution Approach 1:
The invention replaces traditional leather and suede with a synthetic fabric-resin complex that can be easily manufactured and maintained. The coating can be applied to conventional or technical fabrics, creating a durable yet replaceable material that doesn't require delicate leather care
Solution Approach 2:
The acrylic-based coating system is designed to be inherently fire-resistant and easy to maintain without requiring special leather care products. The material can be washed and dried at home, performing its own maintenance function without external intervention
3Strength
If imitation leather is made to be durable, then resistance to abrasion and tearing is improved, but flexibility and elasticity are reduced
Solution Approach 1:
The invention applies different properties to different aspects of the material: the acrylic resin provides durability and fire resistance, while the polyurethane component and elastic fabric base provide flexibility and elasticity. Technical yarns with elastic properties are used in the fabric base to ensure the final product has both strength and adaptability to body movements
Solution Approach 2:
The composite resin system combines acrylic resin (60-80% by weight) for durability and fire resistance with polyurethane resin (20-40% by weight) for flexibility. The fabric base uses technical yarns including elastic components, creating a multi-layer composite structure that achieves both strength and flexibility simultaneously
4Object-affected harmful factors
If protective features are added to fabric, then fire resistance and abrasion resistance are improved, but breathability and comfort are reduced
Solution Approach 1:
The invention uses acrylic resin as the primary coating material (60-80% by weight) which inherently provides fire resistance without requiring thick protective layers. The paste viscosity is optimized at 10,000-15,000 cP and applied at controlled thickness (50-200 micrometers) to maintain breathability while achieving protective properties
Solution Approach 2:
The invention selectively adds protective properties where needed: the acrylic resin provides fire resistance, while the fabric base with technical yarns provides abrasion resistance. The coating formulation includes polyethylene glycol (5-15% by weight) specifically to enhance breathability, ensuring that protective features don't compromise comfort
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 resulting fabric is waterproof, stain-resistant, comfortable, and ergonomic, with enhanced resistance to abrasion, tearing, and impact, allowing for domestic washing and drying, and maintaining a leather-like appearance and performance.
Implementation Method 1
subsequently dried and polymerised
Implementation Method 2
subsequently dried and polymerised to ensure stability and solidity
Implementation Method 3
The resulting base paste is applied on the fabric as a coating by rotary screen, over perforated cylinder, air scraper or transfer processes
Implementation Method 4
silicone antifoam
Data Source
AI summary
The invention refers to the way of obtaining a fabric with the appearance of leather, imitation leather, from a fabric that can be an elastic technical fabric, to which a paste is applied, formulated with an acrylic base resin with inorganic fillers, melamine resins, silicone antifoam, polyethylene glycol, urea, synthetic acrylic thickeners and water-based dyes, in suitable percentages for obtaining a fabric with the appearance of hide or leather that is antistatic, rupture resistant, tear resistant, cut resistant, abrasion resistant and impact resistant, providing an appearance similar to leather and with a high capacity for recovering the initial form of the fabric, due to its elasticity. The invention also refers to the product or fabric obtained with this process.