Polyurethane-Impregnated Suede Leather Structure With Softness and Strength
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Solution Overview
Problem
Existing methods for producing high-quality artificial leather with a suede-like appearance struggle to achieve both enhanced mechanical resistance and softness, while maintaining a uniform appearance and tactile characteristics on both sides, due to the limitations of binder usage and interlacing processes which often result in structural weakening and visual inconsistencies.
Innovation Solution
A process involving the preparation of a multilayer intermediate product impregnated with polyurethane, where microfibrous non-woven layers are combined with reinforcing textile layers using thermoplastic adhesives, followed by polyurethane impregnation, allowing for enhanced mechanical resistance and uniform appearance without the need for twisted yarns or excessive binder usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the amount of binder is increased to enhance mechanical resistance and tear resistance, then the mechanical properties improve, but the softness and formability deteriorate
Solution Approach 1:
The patent uses a bi-component fiber system where polyester microfibers provide mechanical strength and polyamide microfibers provide softness and formability. This composite fiber structure allows both properties to coexist without requiring excessive binder. The differential solubility of the two components enables selective removal of polyamide, leaving a reinforced polyester skeleton that maintains both strength and softness.
Solution Approach 2:
The patent changes the chemical parameters of the fiber components by using polymers with different solubility characteristics (polyester and polyamide). This allows selective dissolution of one component to modify the structural and mechanical parameters of the final product, achieving enhanced strength while preserving softness through the remaining fiber network.
2Stability of the object's composition
If mechanical needling is used to interface microfibers, then the felt structure is formed with predefined density, but the fibers may break causing structural weakening
Solution Approach 1:
The patent introduces a polyvinyl alcohol binder as an intermediary substance that coats and binds the microfibers together during the needling process. This binder protects the fibers from breaking by providing a cushioning matrix that distributes mechanical stresses, allowing dense felt formation while preserving fiber integrity and overall structural strength.
3Stability of the object's composition
If polyvinyl alcohol binder is used to hold microfibers during processing, then the felt structure is stabilized, but the binder must be removed in a subsequent phase adding process complexity
Solution Approach 1:
The patent extracts only the necessary binding function from the polyvinyl alcohol binder without requiring its complete removal. The binder serves its stabilizing function during processing and can remain in the final product in controlled amounts, eliminating the need for additional removal steps and simplifying the overall process while maintaining structural stability.
4Strength
If adhesive coupling is used to combine microfibrous layers with textile supports, then mechanical resistance is enhanced, but the softness of the product deteriorates
Solution Approach 1:
The patent applies local quality by using adhesive coupling only at specific interfaces between layers rather than throughout the entire product structure. The microfibrous layers maintain their inherent softness and formability in the bulk, while the adhesive provides localized mechanical reinforcement at the bonding interfaces, achieving both softness and enhanced strength.
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 process produces artificial leather with improved mechanical properties and uniform appearance on both sides, suitable for various applications without additional coupling, while maintaining the softness and formability required for high-quality suede-like materials.
Implementation Method 1
microfibrous non-woven layers are combined with reinforcing textile layers using thermoplastic adhesives
Implementation Method 2
impregnating the multilayer intermediate product with a solution of polyurethane
Data Source
AI summary
In one embodiment, a process is disclosed for the preparation of a multilayer intermediate product impregnated with polyurethane that is useful for the production of soft synthetic leather having enhanced mechanical resistance. The process comprises the steps of: a. producing a microfibrous non-woven intermediate product that includes microfibers of one or more polymers selected from the group consisting of polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyacrylonitrile, and polyamide; b. producing an intermediate multilayer product by adhesive coupling, the intermediate multilayer product including at least one layer of the non-woven microfibrous intermediate product and at least one layer of a reinforcing textile product; and c. impregnating the multilayer intermediate product with one or more polyurethane solutions, thereby obtaining a multilayer intermediate product impregnated with polyurethane.