Stretchable Artificial Leather With Tricot Substrate for 3D Shape Fit
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Solution Overview
Problem
Artificial leather used in automobile interiors with complicated three-dimensional shapes faces issues with visual quality due to poor shape follow-up properties, leading to wrinkles and visible pinholes, and has poor seam fatigue and sitting comfort due to limited stretchability and durability.
Innovation Solution
The use of tricot knitted fabric as a fibrous substrate with a polyurethane resin layer, providing fixed load elongation between 30-60% in multiple directions to maintain visual quality and enhance seam fatigue and comfort, while controlling elongation balance and density to prevent wrinkles and pinholes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If weft knitted fabric is used as fibrous substrate to improve stretchability, then stretchability is improved, but pinholes become highly visible and seam fatigue properties deteriorate
Solution Approach 1:
The patent changes the knitting structure parameter from weft knitted to tricot knitted fabric, and controls the fixed load elongation parameter within 30-60% range, to simultaneously achieve good stretchability and prevent pinhole visibility while improving seam fatigue resistance
Solution Approach 2:
The patent creates a composite structure by laminating a polyurethane resin layer onto the tricot knitted fabric substrate, combining the stretchability of the knitted fabric with the durability and pinhole-covering properties of the resin layer
2Adaptability or versatility
If weft knitted fabric is used as fibrous substrate to improve stretchability, then stretchability is improved, but wrinkles are generated and visual quality deteriorates
Solution Approach 1:
The patent changes the knitting structure parameter from weft knitted to tricot knitted fabric, and controls the fixed load elongation parameter within 30-60% range, to simultaneously achieve good stretchability and prevent wrinkle formation while maintaining visual quality
Solution Approach 2:
The patent creates a composite structure by laminating a polyurethane resin layer onto the tricot knitted fabric substrate, combining the stretchability of the knitted fabric with the smooth surface properties of the resin layer that prevent wrinkle visibility
3Stability of the object's composition
If non-woven fabric and woven fabric are used as fibrous substrate to maintain dimensional stability, then dimensional stability is improved, but stretchability and shape follow-up properties deteriorate
Solution Approach 1:
The patent creates a composite structure by laminating a polyurethane resin layer onto the tricot knitted fabric substrate, combining the dimensional stability of the knitted fabric structure with the stretchability provided by the controlled elongation properties
Solution Approach 2:
The patent changes the fibrous substrate from non-woven/woven fabric to tricot knitted fabric with controlled fixed load elongation of 30-60%, to simultaneously achieve good dimensional stability and stretchability for complicated three-dimensional shapes
Data Source
AI summary
Stretchable artificial leather comprising a fibrous substrate comprising tricot knitted fabric, and a polyurethane resin layer laminated on the surface of the fibrous substrate, the stretchable artificial leather having fixed load elongation of from 30 to 60% in each of a longitudinal direction, a lateral direction and a bias direction.