Leather-like structure

Abstract

A leather-like structure (1) includes a semi-finished substrate (3) comprising polyester fibers and leather fibers and defining a first outer surface (11) and a second outer surface (8); the first outer surface (11) comprises a higher percentage of polyester fibers than the second outer surface (8); and a surface substrate (4) is disposed on the first outer surface (11) or the second outer surface (8).

Description

Cross-reference to related applications

[0001] This patent application claims priority to Italian Patent Application No. 102023000025329, filed on November 28, 2023, the entire disclosure of which is incorporated herein by reference. Technical Field

[0002] This invention relates to leather-like structures.

[0003] This invention is preferably, but not exclusively, applied to the fields of clothing, footwear, leather goods, and the decoration of vehicles such as yachts, private aircraft, or automobiles. Examples of such applications will be used in the following description. Background Technology

[0004] Leather derived from animal fur (called natural leather or leather) is often used to produce items such as clothing, shoes, accessories, and interior trim for luxury vehicles such as yachts, private jets, or high-end cars.

[0005] Processing raw hides into leather is an upgraded use of by-products from the food industry: in more than 99% of cases, raw hides come from animals raised for the purpose of producing food such as meat and milk (such as cattle, sheep, goats, and pigs).

[0006] However, the processing of raw hides (especially the tanning process) consumes a large amount of water and uses chemical agents. These two important factors are considered due to their significant environmental impact.

[0007] As people become increasingly aware of environmental and ethical issues (such as animal rights), and as the price of natural leather remains high, a variety of alternative materials to natural leather have gradually emerged in the market, among which imitation leather is one of them.

[0008] Imitation leather, also known as synthetic leather, eco-leather, or environmentally friendly leather, is a product traditionally made by coating various substrates (such as fabrics or microfibers) with materials such as polyurethane (PU) and polyvinyl chloride (PVC). The quality and properties of these products are regulated by standard UNI 11427:2022.

[0009] According to known solutions, leather-like structures are made by coating a semi-finished substrate with polyurethane (PU) and polyvinyl chloride (PVC) materials, which are typically used in combination with adhesives or silicone. Other known solutions involve bonding multiple layers of semi-finished substrates together before coating. After coating, the material can be surface-treated as needed to impart specific colors or textures.

[0010] Document CN114561746B describes a method for producing animal fiber composite full-layer leather, the steps of which include: fiber defibering, fiber blending, opening, web forming, web laying, pre-needling, air-punching, main needle punching, post-treatment, and transfer film.

[0011] Document US3537871A describes a leather-like structure consisting of a nonwoven base fabric made of a blend of collagen fibers and natural or synthetic fibers, and a coating film of amino acid resin attached to the base fabric via a resin adhesive interlayer.

[0012] Document CN108301224B describes a method for preparing environmentally friendly crystal leather, including the following steps: 1) coating with foaming resin; 2) coating with polyurethane intermediate layer; 3) casting with colorless polyurethane top layer; 4) coating with colorless polyurethane transparent layer; 5) roller coating with polyurethane layer.

[0013] Materials produced using these technologies typically offer decent aesthetics and durability. Furthermore, their price is significantly lower than that of natural leather, making them highly competitive in the market.

[0014] However, due to the presence of multiple semi-finished substrates and PVC or PU coatings, the thickness of existing structures is generally unsuitable for producing small products such as watch straps. Furthermore, the production process uses highly polluting plastics (such as PU and PVC), which is far removed from environmental sustainability goals.

[0015] In view of the above, there is an urgent need in the market for a new material that can replace leather. Its performance and processability should meet the manufacturing requirements of small products as much as possible, while its environmental impact should be lower than that of natural leather and other known alternatives, and should achieve the lowest possible environmental impact.

[0016] In addition, a new type of material is needed that does not contain adhesives or silicones, does not use anchoring structures such as meshes, and primarily consists of available (including recyclable) and non-native materials, ultimately achieving recyclability.

[0017] The purpose of this invention is to meet the above-mentioned needs in an optimized and cost-effective manner. Summary of the Invention

[0018] The above objective is achieved by the leather-like structure claimed in the appended claims. Attached Figure Description

[0019] To better understand the present invention, preferred embodiments will be described below by way of non-limiting examples in conjunction with the accompanying drawings, wherein: Figure 1 This is a schematic cross-sectional view of a leather-like structure according to the present invention; and Figure 2 yes Figure 1 A schematic cross-sectional view of a portion of a leather-like structure. Detailed Implementation

[0020] exist Figure 1 In the figures, the leather-like structures for producing leather articles (e.g., jewelry or clothing) according to the present invention are generally indicated by reference numeral 1.

[0021] In the illustrated embodiment, the leather-like structure 1 is a multi-layered sheet structure, that is, it has thickness and width (in... Figure 1 (See in the cross-section) and length (along the normal direction of the cross-section), where the thickness is much smaller than the length and width, for example, by at least an order of magnitude.

[0022] The leather-like structure 1 includes a semi-finished substrate 3, which contains only polyester fiber and leather fiber, and the weight percentages of the two are complementary.

[0023] In other words, the semi-finished substrate 3 does not contain any other components besides polyester fibers and leather fibers. For example, the semi-finished substrate 3 does not contain binders and / or adhesives (such as silicone, resin, etc.), nor does it contain anchoring structures such as mesh.

[0024] When calculating the total weight of the semi-finished substrate, the weight percentage of polyester fiber is calculated as the ratio of the weight of polyester fiber to the total weight. Similarly, the weight percentage of leather fiber is calculated as the ratio of the weight of leather fiber to the total weight. Therefore, specifically, the expression 'complementary weight percentages' means that the total weight of the semi-finished substrate is obtained solely from the sum of the weight of leather fiber and the weight of polyester fiber. In other words, the sum of the weight percentages of leather fiber and polyester fiber equals 100, which equals the total amount (representing the weight of the substrate).

[0025] According to a preferred embodiment, the polyester fibers used to produce the semi-finished substrate 3 are at least partially derived from recycled materials; in particular, approximately 50% of the total polyester fibers are derived from recycled PET, such as from PET bottles, industrial polyester waste, or clothing waste.

[0026] The leather fibers used to produce semi-finished substrate 3 are usually derived from waste materials from natural leather processing.

[0027] The production process of the semi-finished substrate (which is known in itself and will not be described in detail below) allows for obtaining semi-finished substrates with different weight percentages of leather fibers and polyester fibers.

[0028] In the semi-finished substrate obtained according to this production method, the composition of leather fibers and polyester fibers results in non-uniformity in its thickness direction. In other words, within the semi-finished substrate, the weight percentage of polyester fibers and leather fibers varies from the surface with the lowest weight percentage of polyester fibers to the opposite surface with the highest weight percentage of polyester fibers.

[0029] like Figure 1 As shown, the semi-finished substrate 3 defines outer surface 11 and outer surface 8. Outer surface 11 contains a higher weight percentage (or concentration) of polyester fibers than outer surface 8, i.e., outer surface 11 has the highest percentage, while outer surface 8 has the lowest percentage. Therefore, the weight percentage (or concentration) of leather fibers in outer surface 8 is higher than that in outer surface 11, i.e., outer surface 8 has the highest percentage, while outer surface 11 has the lowest percentage.

[0030] The surface substrate 4 is disposed on the outer surface 11 or the outer surface 8.

[0031] In the non-limiting embodiment shown, the surface substrate 4 is disposed only on the outer surface 11. In other words, the surface substrate is disposed on the outer surface at a higher weight percentage than the polyester. Specifically, the surface substrate 4 completely covers the outer surface 11.

[0032] Preferably, the semi-finished substrate 3 includes leather fibers with a weight percentage greater than or equal to 60% and polyester fibers with a weight percentage less than or equal to 40%.

[0033] Specifically, the semi-finished substrate 3 includes leather fibers with a weight percentage greater than or equal to 80% and polyester fibers with a weight percentage less than or equal to 20%.

[0034] According to a preferred embodiment, the semi-finished substrate 3 has a leather fiber weight percentage of 85% and a polyester fiber weight percentage of 15%.

[0035] Preferably, the thickness of the semi-finished substrate 3 is greater than or equal to 0.3 mm and less than or equal to 1.5 mm. Specifically, the thickness of the semi-finished substrate 3 is greater than or equal to 0.6 mm and less than or equal to 1.2 mm. According to a preferred embodiment, the thickness of the semi-finished substrate 3 is 0.75 mm. The semi-finished substrate is essentially in the form of a sheet.

[0036] Preferably, such as Figure 2 As shown, the surface substrate 4 includes a primer substrate 5 that is in contact with the outer surface 11, a finishing substrate 6 disposed on the primer substrate 5, and a fixative substrate 7 disposed on the finishing substrate 6.

[0037] Advantageously, the primer substrate 5 contains different positive weight percentages of acrylic resin, polyurethane resin, synthetic or natural casein and wax.

[0038] Preferably, the primer substrate 5 also includes different weight percentages of covering material. In particular, the covering material may be matting substances and covering fillers.

[0039] Specifically, the primer substrate 5 is applied directly to the outer surface 11 to regulate and activate the outer surface, thereby facilitating the anchoring of the subsequent substrate.

[0040] Advantageously, the finishing substrate 6 contains different positive weight percentages of acrylic resin, polyurethane resin, (synthetic or natural) casein and wax.

[0041] Preferably, the finishing substrate 6 also includes a covering material in different weight percentages. In particular, the covering material may be a matte material.

[0042] In particular, the finishing substrate 6 is basically composed of a varnish layer or other layers or films that provide the desired color for the leather-like structure 1.

[0043] Advantageously, the fixative substrate 7 contains different positive weight percentages of acrylic resin, polyurethane resin, (synthetic or natural) casein and wax.

[0044] Preferably, the fixative substrate 7 also comprises a covering material in different weight percentages. In particular, the covering material may be a matte substance.

[0045] In detail, the fixative substrate 7 is configured to block the finishing substrate 6, particularly by means of the catalyst in its composition, and to 'fix' the color to prevent wear or scratches.

[0046] Preferably, the primer substrate 5, the finishing substrate 6, and the fixative substrate 7 all contain different weight percentages of covering material.

[0047] According to possible embodiments, the surface substrate 4 comprises polyurethane and / or polyvinyl chloride. Although not in line with environmental targets, these compounds can be applied by a coating process to replace or supplement the surface substrate 4 when specific properties such as water resistance are required for the leather-like structure 1.

[0048] The present invention also relates to a method for producing a leather-like structure 1 from a semi-finished substrate 3 as described above, the semi-finished substrate 3 comprising an outer surface 11 and an outer surface 8, wherein the outer surface 11 comprises a higher weight percentage of polyester fibers than the outer surface 8. The method includes the step of coating one of the two outer surfaces 11, 12 with a surface substrate 4.

[0049] Preferably, but not limited to, the coating step with the surface substrate 4 is performed on the outer surface 11. In other words, the outer surface of the polyester fiber having a large weight percentage is coated with the surface substrate 4.

[0050] Preferably, the coating step of the surface substrate 4 includes the following subsequent steps in sequence: Apply primer to substrate 5; Apply finishing substrate 6; and Apply fixative to substrate 7.

[0051] In summary, the advantages of the leather-like structure 1 according to the present invention are obvious.

[0052] Because there is a single semi-finished substrate 3 and no PVC or PU layer is coated on it, the final thickness of the leather-like structure 1 is suitable for manufacturing small-sized products, such as watch straps.

[0053] Furthermore, unlike known solutions that use two substrates, using a single substrate 3 halves the material used in a single structure (sheet), thereby reducing material costs. Therefore, for all applications requiring the fabrication of small-sized parts, the proposed leather-like structure 1 offers both technical (processing) and economic advantages.

[0054] Furthermore, the presence of the surface substrate 4 can improve the surface properties of the leather-like structure 1 in terms of both aesthetics and technical performance.

[0055] Therefore, the proposed leather-like structure 1 and the method for producing the leather-like structure 1 can obtain a leather alternative material that has properties and processability suitable for manufacturing small-sized items, while having a lower environmental impact than natural leather and other known solutions mentioned above, and is as low as possible overall.

[0056] Specifically, the proposed leather-like structure 1 contains no adhesives or silicones, nor any anchoring structures such as mesh, and is primarily composed of available (recycled) non-virgin materials and is recyclable.

[0057] It is obvious that modifications can be made to the leather-like structure 1 and the related production method, but such modifications do not exceed the scope of protection defined by the claims.

[0058] For example, the width and thickness of structure 1, as well as its shape and / or the composition of the semi-finished substrate 3, can vary.

[0059] Furthermore, the appearance and arrangement of the surface substrate 4 can be varied. For example, the surface layer 4 can be disposed on the outer surface 8. In other words, the surface substrate can be disposed on the outer surface with a higher weight percentage of leather fibers.

[0060] More generally, the surface layer 4 may cover even only part of the outer surface 11; 8.

[0061] Specifically, the leather-like structure 1 may have different coloring and / or surface treatments, perforations and / or thinning, as long as it contains the operational characteristics for which protection is required.

Claims

1. A leather-like structure (1) comprising a semi-finished substrate (3) comprising only polyester fibers and leather fibers in complementary weight percentages, and defining a first outer surface (11) and a second outer surface (8); the first outer surface (11) comprising a higher weight percentage of polyester fibers than the second outer surface (8); A surface substrate (4) is provided on the first outer surface (11) or the second outer surface (8).

2. The leather-like structure (1) according to claim 1, wherein, The surface substrate (4) is disposed on the first outer surface (11).

3. The leather-like structure according to claim 1 or 2, wherein, The semi-finished substrate (3) includes leather fibers of 60% or more by weight and polyester fibers of 40% or less by weight.

4. The leather-like structure according to any one of claims 1 to 3, wherein, The semi-finished substrate (3) includes leather fibers of 80% or more by weight and polyester fibers of 20% or less by weight.

5. The leather-like structure according to any of the preceding claims, wherein, The thickness of the semi-finished substrate (3) is greater than or equal to 0.3 mm and less than or equal to 1.5 mm.

6. The leather-like structure according to any of the preceding claims, wherein, The thickness of the semi-finished substrate (3) is greater than or equal to 0.6 mm and less than or equal to 1.2 mm.

7. The leather-like structure according to any of the preceding claims, wherein, The surface substrate (4) includes polyurethane and / or polyvinyl chloride.

8. The leather-like structure according to any of the preceding claims, wherein, The surface substrate (4) includes: The primer substrate (5) is disposed in contact with the outer surface (11); The finishing substrate (6) is applied to the primer substrate (5); and A fixative substrate (7) is disposed on the finishing substrate (6).

9. The leather-like structure according to claim 8, wherein, The primer substrate (5) contains different positive weight percentages of acrylic resin, polyurethane resin, and synthetic or natural casein and wax.

10. The leather-like structure according to claim 8 or 9, wherein, The finishing substrate (6) contains different positive weight percentages of acrylic resin, polyurethane resin, and synthetic or natural casein and wax.

11. The leather-like structure according to any one of claims 8 to 10, wherein, The fixative substrate (7) contains different positive weight percentages of acrylic resin, polyurethane resin, and synthetic or natural casein and wax.

12. The leather-like structure according to claim 8, wherein, The primer substrate (5) and / or the finishing substrate (6) and / or the fixative substrate (7) contain different positive weight percentages of covering material.

13. A method for producing a leather-like structure (1) from a semi-finished substrate (3); the semi-finished substrate (3) comprises only polyester fibers and leather fibers in complementary weight percentages and defines a first outer surface (11) and a second outer surface (8); the first outer surface (11) comprises a higher weight percentage of polyester fibers than the second outer surface (8); the method includes the step of coating the first outer surface (11) or the second outer surface (8) with a surface substrate (4).

14. The method according to claim 13, wherein, The step of coating with the surface substrate (4) is performed on the first outer surface (11).

15. The method according to claim 13 or 14, wherein, The step of coating with the surface substrate (4) includes the following steps: Apply primer to substrate (5); Apply finishing substrate (6); and Apply a fixative to the substrate (7).

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