Plant-based man-made leather structure and method for making the same

Abstract

Mixture comprising 29-82 wt.% powdered lentil with tannic acid, acetic acid or lactic acid is stirred into water. 2-56 wt.% glycerine, palm oil or olive oil is added to the suspension which is then h

Description

BACKGROUND OF THE INVENTION

[0001] 1. Technical Field

[0002] The present invention relates to techniques in man-made leather. More particularly, the invention relates to a plant-based man-made leather structure and a method for making the same.

[0003] 2. Description of Related Art

[0004] Common man-made leather (also referred to as synthetic leather) is mostly polyvinyl chloride (PVC) or plastic polymer (e.g., polyurethane (PU))-based leather structures composed of a chemical mixture. Nowadays, man-made leather is frequently used in such fields as footwear, bags, clothing materials, balls, furniture, toys, dolls, and garments. Featuring different levels of wear resistance, different colors, and different kinds of sheen, man-made leather has more colors and surface patterns, higher water resistance, and lower prices than real leather.

[0005] The foregoing techniques, however, still have certain impact on the environment or even depart from the good intention of sustainable environmental development of the current 17 Sustainable Development Goals (SDGs) of the United Nations. The applicant, therefore, has strived to make improvements aiming to provide man-made leather that has good performance in environmental protection. BRIEF SUMMARY OF THE INVENTION

[0006] To improve the problems existing in the prior art, the present invention provides a plant-based man-made leather structure and a method for making the same. One of the technical features of the man-made leather structure and the method is that the plant-based raw material of the man-made leather structure can be used in its entirety, and this enables a relatively great reduction in the waste produced and thereby contributes to achieving the objective of sustainable environmental development of the current 17 SDGs of the United Nations.

[0007] To achieve the foregoing, the present invention provides a plant-based man-made leather structure that includes a lentil-based composite layer, an adhesive layer, and a latex composite layer, wherein the adhesive layer is provided between the lentil-based composite layer and the latex composite layer.

[0008] The present invention further provides a method for making a plant-based man-made leather structure, and the steps of the method include: step 1 - providing lentils having a mass concentration in the range from 29.0 wt.% to 82.0 wt.%, and grinding the lentils into lentil powder with a grinding machine; step 2 - providing powdery tannic acid having a mass concentration in the range from 1.0 wt.% to 12.0 wt.%, mixing the powdery tannic acid with the lentil powder having a mass concentration in the range from 29.0 wt.% to 82.0 wt.% such that a powder mixture is formed, immediately tipping the powder mixture into a container containing a pure water solution, and stirring the powder mixture into the pure water solution until thoroughly mixed and a preliminary mixed solution is formed; step 3 - pouring glycerin having a mass concentration in the range from 2.0 wt.% to 56.0 wt.% into the container, and stirring the glycerin into the preliminary mixed solution in the container until thoroughly mixed and a plant-based mixed solution is formed; step 4 - performing a heating process on the plant-based mixed solution in the container by means of a heating device; step 5 - performing a cooling process on the plant-based mixed solution in the container; step 6 - pouring the plant-based mixed solution in the container into a first predetermined mold; step 7 - tipping calcium chloride into a container containing pure water, stirring the calcium chloride into the pure water until thoroughly mixed and a calcium chloride solution having a mass concentration in the range from 10.0 wt.% to 15.0 wt.% is formed, and applying the calcium chloride solution evenly on the plant-based mixed solution in the first predetermined mold such that a lentil-based composite layer is formed; step 8 - tipping zinc oxide into a container containing pure water, stirring the zinc oxide into the pure water until thoroughly mixed and a zinc oxide solution having a mass concentration in the range from 0.5 wt.% to 4.0 wt.% is formed, pouring the zinc oxide solution into a container containing natural latex having a mass concentration in the range from 96.0 wt.% to 99.5 wt.%, stirring the zinc oxide solution into the natural latex until thoroughly mixed and a mixed latex solution is formed, and immediately pouring the mixed latex solution into a second predetermined mold; step 9 - performing a heating process on the second predetermined mold containing the mixed latex solution by means of the heating device; step 10 - performing a cooling process on the second predetermined mold containing the mixed latex solution such that a latex composite layer is formed; and step 11 - applying an adhesive layer evenly on the lentil-based composite layer, and connecting the latex composite layer fixedly to the lentil-based composite layer through the adhesive layer such that the man-made leather structure is formed.

[0009] The plant-based man-made leather structure disclosed herein and the method disclosed herein for making the same have the technical feature that the plant-based raw material of the lentil-based composite layer can be used in its entirety, and this allows the waste produced to be reduced to a relatively great extent. Therefore, in addition to significantly enhancing the already real-leather-like tactile feel and texture of vegan leather, the invention helps achieve the objective of sustainable environmental development of the current 17 SDGs of the United Nations. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0010] FIG. 1 is a sectional perspective view of a preferred embodiment of the present invention and mainly discloses a plant-based man-made leather structure. DETAILED DESCRIPTION OF THE INVENTION

[0011] To start with, the applicant wishes to point out that throughout this specification (which includes the embodiments described below and each of the appended claims), all the direction-related terms make reference to the directions shown in the drawing listed in BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS. Moreover, in the following description of the embodiments and the accompanying drawings, the same reference numeral indicates identical or similar elements or structural features. In addition, although the structural details, features, and methods of assembly, use, and production of the present invention will be described below in the following detailed description of the embodiments, a person of ordinary skill in the art would understand that the following detailed description and the embodiments provided herein serve only to support and expound the invention so that the invention can be implemented accordingly; the detailed description and the embodiments are not intended to be restrictive of the scope of the claims.

[0012] Referring to FIG. 1, a preferred embodiment of the present invention discloses a plant-based man-made leather structure 1 that includes a lentil-based composite layer 10, an adhesive layer 20, and a latex composite layer 30, wherein the adhesive layer 20 is provided between the lentil-based composite layer 10 and the latex composite layer 30.

[0013] Another preferred embodiment of the present invention discloses a method for making the plant-based man-made leather structure 1, and the method includes the following steps.

[0014] Step 1: A plant-based raw material is provided and is ground into powder. In this preferred embodiment of the present invention, lentils having a mass concentration in the range from 29.0 wt.% to 82.0 wt.% are ground into lentil powder with a grinding machine. It is worth mentioning that in step 1, the lentil powder obtained by grinding the lentils has a particle size in the range from 50 micrometers to 1000 micrometers (i.e., from 50 pm to 1000 pm).

[0015] Step 2: A powdery acidic raw material is provided and is stirred into the powdery plant-based raw material until thoroughly mixed. In this preferred embodiment of the present invention for example, powdery tannic acid having a mass concentration in the range from 1.0 wt.% to 12.0 wt.% is mixed with the lentil powder having a mass concentration in the range from 29.0 wt.% to 82.0 wt.% to form a powder mixture, and immediately after that, the powder mixture is tipped into a container containing a pure water solution and is stirred into the pure water solution until thoroughly mixed and a preliminary mixed solution is formed. It is worth mentioning that in step 2, the tannic acid can be replaced by acetic acid having a concentration of 4.0% or lactic acid having a concentration of 88.0%; moreover, the volume of the pure water solution is in the range from 10 milliliters to 100 milliliters (i.e., from 10 ml to 100 ml).

[0016] Step 3: A plant-based mixed solution is formed. In this preferred embodiment of the present invention for example, glycerin having a mass concentration in the range from 2.0 wt.% to 56.0 wt.% is poured into the container and is stirred into the preliminary mixed solution in the container until thoroughly mixed and the plant-based mixed solution is formed. It is worth mentioning that in step 3, a different stirrer can be used for the stirring and mixing, wherein the stirring speed of this stirrer is controlled within the range from 50 rpm to 1000 rpm; moreover, the glycerin can be replaced by palm oil or olive oil.

[0017] Step 4: A heating device performs a heating process on the plant-based mixed solution in the container. It is worth mentioning that in step 4, the heating process should last for 120 minutes if the temperature of the heating device is controlled at 50±3°C. Preferably, the temperature of the heating device is controlled at 75°C±3°C, and in that case, the heating process should last for 70 minutes. More preferably, the temperature of the heating device is controlled at 120°C±3°C, and in that case, the heating process should last for 15 minutes.

[0018] Step 5: The plant-based mixed solution in the container is subjected to a cooling process until the temperature of the plant-based mixed solution in the container is lowered to 27°C±2°C.

[0019] Step 6: The plant-based mixed solution in the container is poured into a first predetermined mold. In this preferred embodiment of the present invention for example, sodium alginate is tipped into a container containing pure water and is stirred into the pure water until thoroughly mixed and a sodium alginate solution having a mass concentration in the range from 6.0 wt.% to 16.0 wt.% is formed; immediately after that, the sodium alginate solution is poured into the container containing the plant-based mixed solution and is thoroughly mixed with the plant-based mixed solution; and then the mixture of the sodium alginate solution and the plant-based mixed solution is poured into the first predetermined mold. It is worth mentioning that in step 6, the volume of the pure water is in the range from 50 ml to 300 ml; moreover, a different stirrer can be used for stirring the mixture of the sodium alginate solution and the plant-based mixed solution until thoroughly mixed, wherein the stirring speed of this stirrer is controlled within the range from 50 rpm to 1000 rpm.

[0020] Step 7: The lentil-based composite layer 10 is formed. In this preferred embodiment of the present invention for example, calcium chloride is tipped into a container containing pure water and is stirred into the pure water until thoroughly mixed and a calcium chloride solution having a mass concentration in the range from 10.0 wt.% to 15.0 wt.% is formed, and then the calcium chloride solution is even applied or evenly sprayed on the plant-based mixed solution in the first predetermined mold to form the lentil-based composite layer 10. It is worth mentioning that in step 7, the volume of the pure water is in the range from 50 ml to 300 ml; moreover, if the temperature of the first predetermined mold containing the plant-based mixed solution as a whole is controlled at 5±2°C, it takes 168 hours for the lentil-based composite layer 10 to take form. Preferably, the temperature of the first predetermined mold containing the plant-based mixed solution as a whole is controlled at 40±2°C, and in that case, it takes 105 hours for the lentil-based composite layer 10 to take form. More preferably, the temperature of the first predetermined mold containing the plant-based mixed solution as a whole is controlled at 70±2°C, and in that case, it takes 24 hours for the lentil-based composite layer 10 to take form.

[0021] Step 8: A mixed latex solution is formed. In this preferred embodiment of the present invention for example, zinc oxide is tipped into a container containing pure water and is stirred into the pure water until thoroughly mixed and a zinc oxide solution having a mass concentration in the range from 0.5 wt.% to 4.0 wt.% is formed; the zinc oxide solution is then poured into a container containing natural latex having a mass concentration in the range from 96.0 wt.% to 99.5 wt.% and is stirred into the natural latex until thoroughly mixed and the mixed latex solution is formed; and immediately after that, the mixed latex solution is poured into a second predetermined mold. It is worth mentioning that in step 8, the volume of the pure water is in the range from 5 ml to 30 ml.

[0022] Step 9: The heating device performs a heating process on the second predetermined mold containing the mixed latex solution. It is worth mentioning that in step 9, the heating process should last for 20 minutes if the temperature of the heating device is controlled at 50±3°C. Preferably, the temperature of the heating device is controlled at 100°C±3°C, and in that case, the heating process should last for 9 minutes. More preferably, the temperature of the heating device is controlled at 140°C±3°C, and in that case, the heating process should last for 1 minute.

[0023] Step 10: The second predetermined mold containing the mixed latex solution is subjected to a cooling process in order to form the latex composite layer 30. It is worth mentioning that in step 10, it takes 48 hours for the latex composite layer 30 to take form if the temperature of the second predetermined mold containing the mixed latex solution as a whole is controlled at 5±2°C. Preferably, the temperature of the second predetermined mold containing the mixed latex solution as a whole is controlled at 30±2°C, and in that case, it takes 30 hours for the latex composite layer 30 to take form. More preferably, the temperature of the second predetermined mold containing the mixed latex solution as a whole is controlled at 50±2°C, and in that case, it takes 12 hours for the latex composite layer 30 to take form.

[0024] Step 11: The adhesive layer 20 is evenly applied to the lentil-based composite layer 10, and the latex composite layer 30 is fixedly connected to the lentil-based composite layer 10 via the adhesive layer 20 to form the plant-based man-made leather structure 1. It is worth mentioning that in step 11, the adhesive medium of the adhesive layer 20 may be selected from, for example, a latex resin, beeswax, rosin, an environmentally friendly polyurethane (PU) glue, an environmentally friendly polyvinyl acetate resin, an environmentally friendly epoxy resin-based two-part adhesive, environmentally friendly polyethylene, and an environmentally friendly PU adhesive.

[0025] The technical features of the plant-based man-made leather structure 1 (and of its components) disclosed in a preferred embodiment of the present invention have been described above. The following paragraphs disclose the intended effects of the plant-based man-made leather structure 1 disclosed in the preferred embodiment of the invention.

[0026] First, the technical features of the plant-based man-made leather structure 1 disclosed in the preferred embodiment of the present invention can enhance the already real-leather-like tactile feel and texture of vegan leather significantly.

[0027] Second, the plant-based raw material (i.e., lentils) of the lentil-based composite layer 10 of the man-made leather structure 1 can be used in its entirety. This technical feature allows the waste produced to be reduced to a relatively great extent, thereby contributing to achieving the objective of sustainable environmental development of the current 17 SDGs of the United Nations.

Claims

1. A method for making a man-made leather structure, comprising:step 1: providing lentils having a mass concentration in a range from 29.0 wt.% to 82.0 wt.%, and grinding the lentils into lentil powder with a grinding machine;step 2: providing powdery tannic acid having a mass concentration in a range from 1.0 wt.% to 12.0 wt.%, mixing the powdery tannic acid with the lentil powder having a mass concentration in the range from 29.0 wt.% to 82.0 wt.% such that a powder mixture is formed, immediately tipping the powder mixture into a container containing a pure water solution, and stirring the powder mixture into the pure water solution until thoroughly mixed and a preliminary mixed solution is formed;step 3: pouring glycerin having a mass concentration in a range from 2.0 wt.% to 56.0 wt.% into the container, and stirring the glycerin into the preliminary mixed solution in the container until thoroughly mixed and a plant-based mixed solution is formed;step 4: performing a heating process on the plant-based mixed solution in the container by using a heating device;step 5: performing a cooling process on the plant-based mixed solution in the container;step 6: pouring the plant-based mixed solution in the container into a first predetermined mold;step 7: tipping calcium chloride into a container containing pure water, stirring the calcium chloride into the pure water until thoroughly mixed and a calcium chloride solution having a mass concentration in a range from 10.0 wt.% to 15.0 wt.% is formed, and applying the calcium chloride solution evenly on the plant-based mixed solution in the first predetermined mold such that a lentil-basedcomposite layer is formed;step 8: tipping zinc oxide into a container containing pure water, stirring the zinc oxide into the pure water until thoroughly mixed and a zinc oxide solution having a mass concentration in a range from 0.5 wt.% to 4.0 wt.% is formed, pouring the zinc oxide solution into a container containing natural latex having a mass concentration in a range from 96.0 wt.% to 99.5 wt.%, stirring the zinc oxide solution into the natural latex until thoroughly mixed and a mixed latex solution is formed, and immediately pouring the mixed latex solution into a second predetermined mold;step 9: performing a heating process on the second predetermined mold containing the mixed latex solution, by using the heating device;step 10: performing a cooling process on the second predetermined mold containing the mixed latex solution such that a latex composite layer is formed; andstep 11: applying an adhesive layer evenly on the lentil-based composite layer, and connecting the latex composite layer fixedly to the lentil-based composite layer through the adhesive layer such that the man-made leather structure is formed.

2. The method for making a man-made leather structure as claimed in claim 1, wherein in the step 2, the tannic acid is replaceable with acetic acid having a concentration of 4.0% or lactic acid having a concentration of 88.0%.

3. The method for making a man-made leather structure as claimed in claim 2, wherein in the step 3, the glycerin is replaceable with palm oil or olive oil.

4. The method for making a man-made leather structure as claimed in claim 3, wherein the step 4 comprises: controlling a temperature of the heating device at 75°C±3°C; and performing the heating process for 70 minutes.

5. The method for making a man-made leather structure as claimed in claim 4, wherein the step 6 comprises: tipping sodium alginate into a container containing purewater; stirring the sodium alginate into the pure water until thoroughly mixed and a sodium alginate solution having a mass concentration in a range from 6.0 wt.% to 16.0 wt.% is formed; immediately pouring the sodium alginate solution into the container containing the plant-based mixed solution; mixing the sodium alginate solution with the plant-based mixed solution thoroughly; and pouring a resulting mixture of the sodium alginate solution and the plant-based mixed solution into the first predetermined mold.

6. The method for making a man-made leather structure as claimed in claim 5, wherein the step 7 comprises: controlling a temperature of the first predetermined mold containing the plant-based mixed solution as a whole at 70±2°C such that it takes 24 hours for the lentil-based composite layer to take form.

7. The method for making a man-made leather structure as claimed in claim 6, wherein the step 9 comprises: controlling the temperature of the heating device at 100°C±3°C; and performing the heating process for 9 minutes.

8. The method for making a man-made leather structure as claimed in claim 7, wherein the step 10 comprises: controlling a temperature of the second predetermined mold containing the mixed latex solution as a whole at 50±2°C such that it takes 12 hours for the latex composite layer to take form.

9. The method for making a man-made leather structure as claimed in claim 8, wherein in the step 11, the adhesive layer is selected from the group consisting of a latex resin, beeswax, rosin, an environmentally friendly polyurethane (PU) glue, an environmentally friendly polyvinyl acetate resin, an environmentally friendly epoxy resin-based two-part adhesive, environmentally friendly polyethylene, and an environmentally friendly PU adhesive.

10. A man-made leather structure made by the method for making a man-made leather structure as claimed in any of claims 1 to 9, comprising:the lentil-based composite layer, the adhesive layer, and the latex composite layer,wherein the adhesive layer is provided between the lentil-based composite layer and the latex composite layer.

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