Suede Microfibrous Artificial Leather With Carbon Black Light Fastness
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Solution Overview
Problem
Current synthetic leathers with a suede appearance face limitations in color fastness to light and durability, particularly in car interiors, where high-quality materials with consistent gray and black colors are required, and existing methods for enhancing light fastness compromise mechanical properties or result in suboptimal aesthetic and tactile qualities.
Innovation Solution
A high-quality artificial leather with a suede appearance is developed, utilizing a specific combination of carbon black in microfibers and polyurethane matrices, along with controlled tassel length and composition, to achieve high light fastness and durability, characterized by a polyurethane matrix with soft and hard segments, and a microfibrous component of polyester microfibers with carbon black, optimized for gray and black color shades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional dyeing methods with dispersed dyes are used on polyester microfibers, then the suede appearance and initial color quality are improved, but the light fastness deteriorates
Solution Approach 1:
The patent applies preliminary action by incorporating carbon black into the polyester microfiber during the spinning process, before the dyeing stage. This pre-incorporation of pigment creates a base color that protects the fiber from light degradation, and subsequent dyeing only adds tone rather than providing primary color protection, thereby achieving both suede appearance and high light fastness
Solution Approach 2:
The patent uses composite materials by combining carbon black pigment with polyester microfiber in a controlled concentration range (0.05-2.0% by weight). This composite approach allows the microfiber to possess both the aesthetic qualities of dyed suede and the protective light-fast properties of carbon black, resolving the contradiction between appearance and durability
2Reliability
If carbon black is added to polyester microfibers to improve light fastness, then color stability is improved, but the mechanical properties may deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the concentration of carbon black within a specific range (0.05-2.0% by weight). This optimized concentration ensures sufficient light fastness while maintaining the mechanical integrity of the polyester microfiber, avoiding the degradation that would occur with higher pigment loadings
Solution Approach 2:
The patent applies local quality by concentrating the carbon black primarily in the microfiber component rather than uniformly distributing it throughout the entire artificial leather structure. This localized approach ensures that the microfiber gains the necessary color stability without excessive pigment that would compromise its mechanical properties, while the polyurethane matrix provides structural support
3Strength
If polyurethane matrix is used to bind microfibers, then mechanical strength is improved, but the overall durability in oxidizing environments deteriorates
Solution Approach 1:
The patent converts the potential harm of polyurethane's susceptibility to oxidation by combining it with carbon black, which provides UV absorption and antioxidant protection. The carbon black acts as a protective agent that mitigates the degradation of polyurethane in oxidizing environments, transforming the weakness into a synergistic system where the matrix provides strength and the pigment provides environmental resistance
4Productivity
If conventional dyeing processes are used, then production efficiency is maintained, but dye consumption and environmental impact increase
Solution Approach 1:
The patent applies preliminary action by pre-incorporating carbon black during fiber spinning, which establishes the base color and reduces the amount of dye needed in subsequent processing. This approach maintains production efficiency by using standard dyeing procedures while significantly reducing dye consumption and associated environmental impacts
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 provides artificial leather with enhanced color fastness to light, maintaining mechanical resistance and aesthetic qualities, achieving ≥3 abrasion resistance and 80% retention of physical-mechanical characteristics after aging, with improved light fastness ratings and reduced dye consumption.
Implementation Method 1
The artificial leather... with enhanced color fastness to light... achieving ≥3 abrasion resistance and 80% retention of physical-mechanical characteristics after aging, with improved light fastness ratings
Implementation Method 2
a polyurethane matrix with soft and hard segments, and a microfibrous component of polyester microfibers with carbon black
Data Source
AI summary
An artificial leather having a suede appearance and colours within the grey - black range and high colour fastness comprising a microfibrous component and an elastomeric matrix; the microfibrous component consisting of polyester microf ibres having a count of 0.01 to 0.50 dtex; the elastomeric matrix consisting of polyurethane consisting of soft and hard segments; the ratio between the elastomeric matrix and the microfibrous component ranging from 20/80 and 50/50 by mass; the microfibrous component containing carbon black pigment in a percentage of 0.05 to 2.00% by mass; the elastomeric matrix containing carbon black pigment in a percentage of 0 to 10% by weight; the carbon black always having an average dimension smaller than 0.4 microns. The average length of the tassel is between 200 and 500 microns. The soft segments consist of at least one polycarbonate diol selected from polyalkylene carbonate diols and at least one polyester diol. The hard segments consist of urethane groups deriving from the reaction between free isocyanate groups and water. The total content of carbon black is between 0.025 and 6% by weight.