Split Leather Skin Layer with Entangled Nonwoven Fabric
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Solution Overview
Problem
Conventional split leather products and suede-finished artificial leathers fail to replicate the appearance and feel of natural leather due to limitations in supply, cost, and physical strength, and they also lack flame retardancy, leading to issues like seam puckering and poor surface texture when bent.
Innovation Solution
A split leather product is created using a base material of split leather with a skin layer composed of an entangled nonwoven fabric and polymeric elastomer, which mimics the top grain layer's texture and strength, and a resin layer is applied to achieve a leather-like appearance and feel, while also enhancing flame retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a resin layer is coated on split leather to improve appearance, then the surface texture resembles full grain leather, but the irregularities on split leather surface become manifest causing roughening
Solution Approach 1:
The patent applies a composite material structure consisting of multiple layers: split leather base material, intermediate adhesive layer, and top resin layer. This composite structure allows the resin layer to provide a smooth leather-like surface while the adhesive layer compensates for underlying irregularities, preventing roughening when the product is stretched or formed.
Solution Approach 2:
The patent creates different functional zones within the split leather product: the base split leather layer provides structural support and flexibility, the adhesive layer provides bonding and surface leveling, and the resin layer provides aesthetic appearance. Each layer has localized properties optimized for its specific function, allowing the surface to resemble full grain leather while maintaining the underlying split leather's advantages.
2Quantity of substance
If conventional split leather products are used to reduce cost, then the price is lower than full grain leather, but they lack flame retardancy and physical strength
Solution Approach 1:
The patent creates a composite material system where the resin layer is formulated with flame-retardant properties and enhanced mechanical strength. This allows the product to maintain cost-effectiveness by using split leather as the base while the added resin layer provides the missing flame retardancy and physical strength properties, making it suitable for automotive interiors and other safety-critical applications.
3Quantity of substance
If suede-finished artificial leather is used to reduce cost, then the price is lower than napped leather, but the feel and texture do not resemble natural leather
Solution Approach 1:
The patent carefully controls the parameters of the resin layer including its thickness, composition, and surface properties to replicate the tactile characteristics of natural suede or napped leather. By adjusting these parameters, the product achieves a texture and feel that closely resembles natural leather while maintaining the cost advantages of using split leather as the base material.
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 split leather product that closely resembles natural leather in appearance and feel, with improved physical strength and flame retardancy, reducing the occurrence of roughening and seam puckering, and maintaining a supple texture.
Implementation Method 1
a skin layer which comprises a composite body of an entangled nonwoven fabric formed from microfine fibers
Implementation Method 2
a polymeric elastomer that impregnates the gaps in the entangled nonwoven fabric
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
An aspect of the invention is a split leather product provided with a base material comprising split leather, and a skin layer laminated on a surface of the base material. The skin layer comprises a composite body of an entangled nonwoven fabric formed from microfine fibers, and a polymeric elastomer that impregnates the gaps in the entangled nonwoven fabric. The entangled nonwoven fabric in such a split leather product has the effect of increasing physical strength without detracting from a leather-like texture, in the same way as the longitudinally and transversally crisscrossing collagen fibers in the reticular layer. It is thus possible to obtain a split leather product that resembles leather not only in outward appearance but also in the feel derived from wrinkles and the like resulting when the leather is bent.