Sewable thermoplastic elastomer artificial leather

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Solution Overview

Problem

Thermoplastic elastomer artificial leather cannot be sewn due to poor adhesion between the base fabric layer and the thermoplastic elastomer surface layer, leading to issues like poor feel, high VOC levels, and high costs when bonded with glue.

Innovation Solution

A sewable thermoplastic elastomer artificial leather is created by using a base fabric layer with yarns composed of long filaments and short fiber yarns, where the short fiber yarns are twisted with long filaments to form hairs that project into the thermoplastic elastomer surface layer, and the layers are bonded using a hot-press joining process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If glue is used to bond the TPO artificial surface material to the base fabric, then the bonding is achieved, but the adhesion is poor and VOC levels are high

Engineering Contradiction:

ImproveadhesionVSAvoidVOC level

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The invention removes the glue layer from the structure, replacing chemical bonding with mechanical interlocking. The short fibers protruding from the yarn surface provide direct physical anchoring into the TPO layer, eliminating the need for adhesive substances that generate VOCs.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The short fibers act as an intermediary mechanical connector between the base fabric and TPO layer. Instead of using chemical adhesives, the protruding fiber ends serve as physical mediators that interlock with the TPO, providing adhesion through mechanical means rather than chemical bonding.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If glue is used to bond the TPO artificial surface material to the base fabric, then the bonding is achieved, but the cost is high

Engineering Contradiction:

ImproveadhesionVSAvoidcost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention uses inexpensive short fibers that are already part of the yarn structure as the bonding mechanism. These fibers serve as disposable mechanical connectors that eliminate the need for expensive adhesive materials and complex bonding processes.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention eliminates the glue component entirely from the manufacturing process, replacing it with a structural feature of the yarn itself. This removal of the adhesive layer reduces material costs and simplifies the manufacturing process.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If glue is used to bond the TPO artificial surface material to the base fabric, then the bonding is achieved, but the feel is poor

Engineering Contradiction:

ImproveadhesionVSAvoidfeel

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The invention creates localized mechanical interlocking points at the yarn surface where short fibers protrude and embed into the TPO layer. This localized structural feature provides adhesion without requiring a uniform glue layer, preserving the natural texture and feel of the materials.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The short fibers serve as numerous small mechanical anchors distributed across the fabric surface. These fiber ends provide multiple small contact points for bonding, creating a more natural and flexible connection that maintains the tactile properties of the materials better than a continuous glue layer.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

This approach enhances adhesion between the base fabric layer and the thermoplastic elastomer surface layer, improving the feel and reducing VOC levels and costs while allowing for sewing applications.

Implementation Method 1

the yarn has a base body and hairs extending from the base body into the thermoplastic elastomer surface layer, the yarn comprises long filaments and short fiber yarns which are joined together by twisting

Methodology Applied

Scientific EffectMechanical interlocking:

Implementation Method 2

the thermoplastic elastomer surface layer and the base fabric layer are bonded together by a hot-press joining process

Methodology Applied

Scientific EffectHot-press joining:

Data Source

PatentEP3895887B1Sewable thermoplastic elastomer artificial leather

Publication Date: 2023.10.25 BENECKE CHANGSHUN AUTO TRIM (ZHANGJIAGANG) CO LTD

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AI summary

Disclosed in the present utility model is a sewable thermoplastic elastomer artificial leather, comprising a base fabric layer and a thermoplastic elastomer surface layer, the base fabric layer comprising a number of yarns, wherein the yarn has a base body and hairs extending from the base body into the thermoplastic elastomer surface layer, the yarn comprises long filaments and short fiber yarns which are joined together by twisting, and based on the total number of the long filaments and the short fiber yarns, the yarn contains the short fiber yarns in a proportion of 30% - 60%. In the present utility model, the base fabric layer formed of the yarn containing the long filaments and the short fiber yarns is joined to the thermoplastic elastomer surface layer; the long filaments and the short fiber yarns are joined by twisting to form the yarn, and in the process of twisting, some of the short fibers on the short fiber yarns project from the surface of the base body of the yarn to form hairs configured to enter the thermoplastic elastomer surface layer; in this way, adhesion between the base fabric layer and the thermoplastic elastomer surface layer is increased.