Sheet-like material
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Solution Overview
Problem
Existing sheet-like materials with piloerection, particularly those using plant-derived components, face challenges in achieving uniform and elegant piloerection, flexibility, strength, and form stability while minimizing environmental impact and fossil resource depletion.
Innovation Solution
A sheet-like material comprising a nonwoven fabric with microfibers of 0.3 to 7 μm diameter and a polyurethane resin with specific copolymerized polycarbonate diols and a chain extender, where the elastomer resin is present within the nonwoven fabric, providing improved heat resistance, abrasion resistance, and flexibility without increasing the density of the woven or knitted fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a woven or knitted fabric is entangled and integrated with a nonwoven fabric to enhance strength and flexibility, then the mechanical properties are improved, but the woven or knitted fabric is damaged by the needle and the inherent mechanical properties cannot be sufficiently utilized
Solution Approach 1:
The patent applies preliminary action by pre-coating the woven or knitted fabric with a binder solution before the needle punching process. This binder coating is applied in advance to protect the fabric and facilitate the integration process, preventing damage during needle entanglement while ensuring proper bonding between the fabric layers and the nonwoven fabric.
2Strength
If the density of the woven or knitted fabric is increased to compensate for strength loss, then the rigidity is increased, but the flexibility and light weight are reduced
Solution Approach 1:
The patent applies parameter changes by optimizing the binder solution composition and coating conditions rather than increasing fabric density. By adjusting binder concentration, coating amount, and curing parameters, the patent achieves the required strength and rigidity while maintaining the original fabric's light weight and flexibility characteristics.
3Object-affected harmful factors
If plant-derived components are used to reduce environmental impact, then the environmental load is reduced, but the heat resistance and abrasion resistance are insufficient
Solution Approach 1:
The patent applies composite materials by combining plant-derived polyester components with carefully selected elastomer resins and binder systems. This composite approach allows the material to benefit from the environmental advantages of plant-derived components while the elastomer and binder provide the necessary heat resistance and abrasion resistance properties.
4Ease of operation
If polycarbonate-based polyurethane is used to achieve low temperature characteristics and flexible texture, then the texture is improved, but the abrasion characteristics and heat resistance are insufficient
Solution Approach 1:
The patent applies local quality by using different diol components in specific regions or phases of the material structure. The polycarbonate-based polyurethane providing flexibility is combined with other elastomer components that provide abrasion and heat resistance, creating a multi-phase structure where each component performs its specialized function in the appropriate location.
Data Source
AI summary
The present invention provides a sheet-like material in which a plant-derived raw material of low environmental impact is used. The invention also provides a sheet-like material that ideally has a uniform and refined nap and a sheet-like material that is strong, has excellent shape stability, is lightweight and is very pliable. This sheet-like material is characterized in being made of nonwoven fabric that is made of polyester microfiber containing a 1,2-propanediol-derived component in an amount prescribed in the present application and a polyurethane elastomer resin containing structural monomers prescribed in the present application. This sheet-like material is also made of a base sheet, in which a nonwoven fabric that has microfibers as the main component is laminated and unified with a woven or knitted material, and an elastomer resin, and is characterized in that the woven or knitted material is configured from fibers containing polyester as the main component and that 1-500 ppm of a 1,2-propanediol-derived component are contained in the polyester.