Solvent-Free Meltblown Artificial Leather for Simplified Manufacturing
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Solution Overview
Problem
Existing artificial leather manufacturing processes are complex and not environmentally friendly, often requiring solvents and involving multiple steps, which complicates the production and fails to meet environmental protection requirements.
Innovation Solution
An environmental-friendly artificial leather is produced using a single meltblown process without solvents, utilizing thermoplastic polyurethane (TPU) for all fiber webs and filament fabrics, with the filament fabric sandwiched between or integrated with the fiber webs through meltblown techniques to enhance physical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional multilayer artificial leather manufacturing processes are used, then the physical properties can be achieved, but the manufacturing process becomes complex and requires solvents
Solution Approach 1:
The patent combines multiple manufacturing operations into a single meltblown process. The resin impregnation, fiber dissolving, and web formation steps that were previously separate are merged into one continuous meltblown operation, eliminating the need for multiple process stages and reducing overall process complexity while maintaining product quality
Solution Approach 2:
The patent changes the physical state and processing parameters of the material from solvent-based liquid resins to meltblown thermoplastic materials. This parameter change eliminates the need for solvent evaporation steps and allows direct formation of the fiber web, simplifying the manufacturing process while achieving the same structural outcome
2Stability of the object's composition
If solvent-based resin impregnation or fiber dissolving processes are used, then the artificial leather structure can be formed, but environmental protection requirements are not met
Solution Approach 1:
The patent extracts and removes the harmful solvent component from the manufacturing process entirely. By using meltblown thermoplastic materials that can be processed without solvents, the harmful chemical agents are eliminated while the essential function of forming the artificial leather structure is maintained through alternative physical processing methods
Solution Approach 2:
The patent converts the potential harm of complex chemical processing into benefit by using a simpler physical meltblown process. The elimination of solvent evaporation and chemical dissolution steps not only removes environmental harm but also creates a more efficient and cleaner manufacturing process that produces the same structural outcome
3Shape
If multiple manufacturing processes are used, then the required structure can be achieved, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple discrete manufacturing steps into a single integrated meltblown process. Instead of separately performing resin impregnation, fiber dissolution, web formation, and drying steps, all these operations are combined into one continuous meltblown operation, reducing equipment requirements, labor costs, and processing time while maintaining the multilayer structure
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 simplifies the manufacturing process, meets environmental protection standards by eliminating solvent use, and improves the physical properties of the artificial leather, including tensile strength and tearing strength, while being recyclable.
Implementation Method 1
a first fiber web, which is a meltblown fiber web; a woven or knitted fabric, thus comprising yarns made of filaments disposed on the first fiber web; and a second fiber web disposed on the filament fabric, wherein the second fiber web is a meltblown fiber web
Implementation Method 2
The laminate is heat pressed
Data Source
Figure 1~3
Figure 4A
Figure 4B
AI summary
The present disclosure relates to an environmental-friendly artificial leather and a method of manufacturing the same. The manufacturing method of the environmental-friendly artificial leather includes steps in which a first fiber web is formed by meltblown. The method continues with step in which a filament fabric is disposed on the first fiber web. The method continues with step in which a second fiber web is meltblown on the filament fabric, so as to form a multilayer fiber structure. The method continues with step in which the multilayer fiber structure is heat pressed to form the environmental-friendly artificial leather.