leathery structure

Abstract

A leather-like structure comprising a support base (10) including two semi-finished base materials (2, 3), wherein the support base (10) includes polyester fibers and leather fibers, the two semi-finished base materials (2, 3) are fixedly connected to each other at two joint surfaces (8, 9) of each, defining two outer surfaces (11, 12) of the support base (10), and the joint surfaces (8, 9) contain a higher concentration of polyester fibers than the outer surfaces (11, 12). The leather-like structure (1) further comprises a surface base material (4) disposed on one of the outer surfaces (11).

Description

Technical Field

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[0001] [Cross - reference to Related Applications] This patent application claims the priority of Italian Patent Application No. 102023000009111 filed on May 8, 2023, and all of its disclosure contents are incorporated herein by reference.

[0002] The present invention relates to a leather - like structure.

[0003] The present invention is preferably applied to the field of decoration of clothing, footwear, leather products, and vehicles such as yachts, private aircraft, and automobiles, but is not limited thereto. Hereinafter, such applications will be taken as examples.

Background Art

[0004] Leather (referred to as natural leather or leather) made from animal skins is frequently used not only in the manufacture of clothing, shoes, accessories, etc., but also in the interiors of high - end vehicles such as yachts, private aircraft, and luxury cars.

[0005] Despite sometimes being expensive, natural leather products are highly regarded for the tactile sensation, so - called texture, appearance, durability, etc. obtained by subjecting raw skins to numerous processes such as washing, tanning, finishing, and preservation.

[0006] Processing raw leather is known to be equivalent to up - cycling by - products of the food industry. More than 99% of raw leather is derived from animals (cows, sheep, goats, pigs) raised for the purpose of producing foods such as meat and milk.

[0007] However, a large amount of water and chemicals are consumed in the process of processing raw skins (especially the tanning process), and these two important aspects need to be considered because of their significant environmental impact.

[0008] Due to growing awareness of environmental and ethical issues (such as animal rights), and the soaring price of natural leather, alternative materials such as synthetic leather are appearing on the market.

[0009] Imitation leather, also known as faux leather, eco-leather, or ecological leather, is a product traditionally obtained by applying polyurethane (PU) or polyvinyl chloride (PVC) based products to various materials such as fabrics and microfibers. The quality and properties of these products are defined by the UNI11427:2022 standard.

[0010] Known solutions involve fabricating a leather-like structure from a semi-finished substrate and then coating it with polyurethane (PU)-based and polyvinyl chloride (PVC)-based products, often mixed with adhesives or silicones. Other known solutions involve layering and bonding multiple semi-finished substrates before coating. After coating, finishing processes are performed as needed to give the structure a specific color and texture.

[0011] U.S. Patent No. 3,537,871 (Patent Document 1) describes a leather-like structure comprising a nonwoven base fabric made from a mixture of collagen fibers and natural or synthetic fibers, and an amino acid resin coating film bonded to the base fabric by an intermediate layer of resin binder.

[0012] Chinese Patent Application Publication No. 109353088 (Patent Document 2) describes a recycled leather-based fabric produced by wet layup of multilayer and multimesh collagen fibers, and related manufacturing methods.

[0013] International Publication No. 2022 / 219484 (Patent Document 3) describes a dry method for producing nonwoven fabric from tanned leather waste.

[0014] Chinese Patent Application Publication No. 114561746 (Patent Document 4) describes a method for manufacturing animal fiber composite full-layer leather.

[0015] Generally, materials manufactured using these technologies have modest aesthetic performance and abrasion resistance. Furthermore, their price is significantly lower than that of natural leather, making them highly competitive in the market.

[0016] However, these materials have very poor breathability and look very different from genuine leather. Furthermore, their manufacture involves the use of plastics containing many pollutants such as PU and PVC, which deviates significantly from environmental sustainability goals.

[0017] Based on the above, there is a need to develop a leather alternative that possesses an aesthetic appearance, performance, texture, breathability, and workability as close as possible to natural leather, while simultaneously having a lower environmental impact than natural leather or the other known solutions mentioned above, and generally having the lowest possible environmental impact.

[0018] Furthermore, it is felt that the material should not contain adhesives or silicones as flocculants or fixing structures such as mesh, and should be composed mainly of readily available (recycled) non-virgin materials, ultimately creating a recyclable material. [Prior art documents] [Patent Documents]

[0019] [Patent Document 1] U.S. Patent No. 3537871 [Patent Document 2] Chinese Patent Application Publication No. 109353088 Specification [Patent Document 3] International Publication No. 2022 / 219484 [Patent Document 4] Chinese Patent Application Publication No. 114561746 Specification [Overview of the project]

[0020] The objective of this invention is to meet the above-mentioned needs in an optimized and cost-effective manner.

[0021] The foregoing object is achieved by a structure like leather as described in the appended claims.

Brief Description of the Drawings

[0022] To better understand the present invention, preferred embodiments will be described below by way of non-limiting examples while referring to the appended drawings.

[0023] [Figure 1] It is a schematic cross-sectional view of the leather-like structure according to the present invention. [Figure 2] It is a schematic cross-sectional view showing a part of the leather-like structure of FIG. 1.

Modes for Carrying Out the Invention

[0024] In FIG. 1, a leather-like structure according to the present invention used for manufacturing leather products such as vehicle or clothing interiors is generally indicated by reference numeral 1.

[0025] In the illustrated embodiment, the leather-like structure 1 is a multilayer sheet, that is, it has a thickness and width visible in the cross-section of FIG. 1 and a length in the direction normal to the cross-sectional plane, and the thickness is much smaller than the length and width, for example, at least one order of magnitude smaller.

[0026] The leather-like structure 1 includes a support substrate 10 including two semi-finished substrates 2 and 3 each containing polyester fibers and leather fibers.

[0027] In particular, the semi-finished substrates 2 and 3 have a configuration in which the weight ratios of polyester fibers and leather fibers are complementary to each other, and do not include additives such as binders and aggregating agents (silicone, resin, etc.) and fixing structures such as meshes. In other words, the semi-finished substrates 2 and 3 contain only polyester fibers and leather fibers.

[0028] Considering the total weight of the semi-finished substrate, the weight percentage of polyester fibers is calculated from the ratio of the weight of polyester fibers to the total weight.

[0029] According to a preferred embodiment, the polyester fibers used in the manufacture of the semi-finished base materials 2, 3 are obtained at least in part from recycled materials, and in particular, about 50% of the polyester fibers in total are obtained from recycled PET such as PET bottles, industrial polyester, or clothing waste.

[0030] The leather fibers used in the manufacture of semi-finished base materials 2 and 3 are typically obtained from processing waste of natural leather.

[0031] The manufacturing process for semi-finished substrates (which is known in itself and will not be described in detail below) allows for the production of semi-finished substrates containing varying weight percentages of leather fibers and polyester fibers.

[0032] The two semi-finished base materials 2 and 3 are fixedly connected to each other on their respective two joint surfaces 8 and 9, defining the two outer surfaces 11 and 12 of the support base material 10.

[0033] During the manufacturing process, the composition of leather fibers and polyester fibers within the semi-finished substrate becomes non-uniform in the thickness direction. In other words, within the semi-finished substrate, the weight ratio of polyester fibers to leather fibers changes from the surface where the weight ratio of polyester fibers is minimum to the opposite surface where the weight ratio of polyester fibers is maximum.

[0034] In detail, the preferred bonding surfaces 8 and 9 contain a higher weight percentage (i.e., maximum content) of polyester fibers than the outer surfaces 11 and 12 (i.e., minimum content). Therefore, the outer surfaces 11 and 12 contain a higher weight percentage (i.e., maximum content) of leather fibers than the bonding surfaces 8 and 9 (i.e., minimum content).

[0035] Therefore, the two semi-finished substrates 2 and 3 are connected to each other by aligning the surfaces 8 and 9, which have a high concentration of polyester fibers.

[0036] Advantageously, the leather-like structure 1 comprises a surface substrate 4 disposed on one of the outer surfaces 11, 12 of the support substrate 10. According to the illustrated non-limiting embodiment, the surface substrate 4 is disposed on the outer surface 11. In particular, the surface substrate 4 completely covers the outer surface 11.

[0037] Preferably, the semi-finished base materials 2 and 3 have a weight percentage of leather fibers of 60% or more and a weight percentage of polyester fibers of 40% or less.

[0038] In particular, semi-finished base materials 2 and 3 have a weight percentage of leather fibers of 80% or more and a weight percentage of polyester fibers of 20% or less.

[0039] In a preferred embodiment, the weight percentage of leather fibers in both semi-finished base materials 2 and 3 is equal to 85%, and the weight percentage of polyester fibers is equal to 15%.

[0040] Preferably, the thickness of the support base material 10 is 0.4 mm or more and 2.8 mm or less. In particular, the thickness of the support base material 10 is 0.6 mm or more and 2.6 mm or less. These thicknesses are suitable for the thickness required in a typical tanning process, and in particular, the above thicknesses are suitable even when an additional surface layer 4 is added.

[0041] In a preferred embodiment, the thickness of the support base material 10 is 1.5 mm, and in particular, the thickness of the semi-finished base materials 2 and 3 is half the total thickness of the support base material 10, i.e., 0.75 mm. In other embodiments not shown, the thicknesses of the semi-finished base materials 2 and 3 are different from each other.

[0042] Preferably, as shown in Figure 2, the surface substrate 4 comprises a primer substrate 5 positioned in contact with the outer surface 11, a finishing substrate 6 positioned on the primer substrate 5, and a fixing substrate 7 positioned on the finishing substrate 6.

[0043] Advantageously, the primer substrate 5 contains acrylic resin, polyurethane resin, synthetic or natural casein, and wax in varying weight percentages.

[0044] Preferably, the primer substrate 5 also includes various weight percents of coating material. In particular, examples of coating material include matting materials and coating fillers.

[0045] In particular, the primer substrate 5 is applied directly to the outer surface 11 and is adjusted and activated to facilitate the adhesion of the next substrate.

[0046] Advantageously, the finishing substrate 6 comprises acrylic resin, polyurethane resin, and (synthetic or natural) casein and wax in varying proportions.

[0047] Preferably, the finishing substrate 6 also includes a coating material in various weight percentages. In particular, the coating material may be a matte material.

[0048] In particular, the finishing substrate 6 substantially consists of a varnish layer or other layer or film that provides the desired color to the leather-like structure 2.

[0049] Advantageously, the fixing substrate 7 also contains acrylic resin, polyurethane resin, and (synthetic or natural) casein and wax in varying proportions.

[0050] Preferably, the fixing substrate 7 also includes a coating material in various weight percentages. In particular, the coating material may be a mat material.

[0051] In detail, the fixing substrate 7 is configured to block the finishing substrate 6, particularly by a catalyst in its composition, thereby "fixing" the coloring against abrasion and scratching.

[0052] Preferably, both the primer substrate 5 and the finishing substrate 6 and fixing substrate 7 contain different weight percentages of coating material.

[0053] According to possible embodiments, the surface substrate 4 includes polyurethane and / or polyvinyl chloride. Although not in line with the goal of being environmentally friendly, if the leather-like structure 1 is required to have special properties, such as waterproofing, these compounds may be applied using a coating process instead of, or in addition to, the surface substrate 4.

[0054] The present invention also relates to a method for manufacturing the leather-like structure 1 described above. The first semi-finished substrate 3 is placed on the second semi-finished substrate 2 such that the surfaces 8 and 9 of the respective semi-finished substrates 3 and 2, which have a high weight ratio of polyester fibers, are in contact with each other. The steps include: 1. Fixing and connecting the first semi-finished substrate 3 and the second semi-finished substrate 2 to obtain a support substrate 10; The steps include: coating the outer surface 11 of the support substrate 10 with the surface substrate 4, Includes.

[0055] Preferably, the step of fixing and connecting the semi-finished substrates 3 and 2 is carried out by water jet technology. In particular, no petrochemical binders or adhesives are added in this step.

[0056] Preferably, the step of coating the surface substrate 4 is: • The step of applying the primer substrate 5, • The step of applying the finishing substrate 6, • The step of applying the fixing substrate 7, This includes a subsequent step comprising the following:

[0057] From the above, the advantages of the leather-like structure 1 according to the present invention are clear.

[0058] Due to the advantageous arrangement of the semi-finished base materials 2 and 3 described above, the outer surfaces 11 and 12 of the support base material 10 contain a higher weight percentage of leather fibers, which determines the properties of the structure 1 in terms of aesthetics and functionality. In fact, because of the high weight percentage of leather fibers, these properties are close to those of natural leather structures, i.e., leather obtained directly from animal hides.

[0059] Furthermore, the presence of the surface substrate 4 improves the surface properties of the leather-like structure 1 in terms of both appearance, texture, and technical performance.

[0060] In particular, by applying the surface substrate 4 to the outer surface 11 of the support substrate 10, the leather-like structure 1 can be made to have the same appearance as natural leather and breathability similar to natural leather.

[0061] Therefore, according to the proposed leather-like structure 1 and the method for manufacturing the leather-like structure 1, it is possible to obtain a natural leather substitute material that has an aesthetic appearance, performance, texture, breathability, and workability similar to natural leather.

[0062] Furthermore, the proposed leather-like structure 1 and the proposed method for manufacturing the structure have a much lower environmental impact than natural leather and other known solutions, and generally produce the lowest-impact materials.

[0063] In detail, the proposed leather-like structure 1 does not include adhesives or silicones as flocculants, nor anchor structures such as meshes, and is composed mainly of readily available (recycled) non-virgin materials, making it recyclable.

[0064] It is clear that modifications can be made to the leather-like structure 1 and the related manufacturing method described, without exceeding the scope of protection defined by the claims.

[0065] For example, the width and thickness of structure 1 can vary, as can its shape and / or the composition of the semi-finished substrates 2 and 3.

[0066] Furthermore, the appearance and composition of the surface substrate 4 can vary. For example, the surface layer 4 may be placed on the outer surface 12. More generally, the surface layer 4 may cover only a portion of the outer surfaces 11, 12.

[0067] In detail, the leather-like structure 1 may have different coloring and / or surface treatments, perforations and / or thickness reductions, insofar as it has the operational characteristics defined in the claims. [Explanation of Symbols]

[0068] 1 Leather-like structure 2, 3 Semi-finished product base material 4 Surface base material 5. Primer substrate 6. Finishing base material 7 Fixing substrate 8, 9 Joint surface 10 Supporting base material 11, 12 External surface

Claims

1. A support base (10) comprising two semi-finished base materials (2, 3), each of the semi-finished base materials (2, 3) comprising polyester fiber and leather fiber, and the two semi-finished base materials being fixedly connected to each other at their respective two joining surfaces (8, 9), thereby defining two outer surfaces (11, 12) of the support base (10), A surface substrate (4) is placed on one of the outer surfaces (11), A leather-like structure (1) having, The joining surfaces (8, 9) contain a leather-like structure (1) that contains a greater weight percentage of polyester fibers than the outer surfaces (11, 12).

2. The leather-like structure according to claim 1, wherein the semi-finished base material (2, 3) has a weight percentage of leather fibers of 60% or more and a weight percentage of polyester fibers of 40% or less.

3. The leather-like structure according to claim 1 or 2, wherein the semi-finished base material (2, 3) has a weight percentage of leather fibers of 80% or more and a weight percentage of polyester fibers of 20% or less.

4. The leather-like structure according to any one of claims 1 to 3, wherein the thickness of the support base material (10) is 0.4 mm or more and 2.8 mm or less.

5. The leather-like structure according to any one of claims 1 to 4, wherein the thickness of the support base material (10) is 0.6 mm or more and 2.6 mm or less.

6. The leather-like structure according to any one of claims 1 to 5, wherein the surface substrate (4) comprises polyurethane and / or polyvinyl chloride.

7. The surface substrate (4) is - A primer substrate (5) is placed in contact with the outer surface (11), - A finishing substrate (6) placed on the primer substrate (5), - A fixing substrate (7) is placed on the finishing substrate (6), A leather-like structure according to any one of claims 1 to 6, comprising:

8. The leather-like structure according to claim 7, wherein the primer substrate (5) comprises acrylic resin, polyurethane resin, synthetic or natural casein and wax in various weight percentages.

9. The leather-like structure according to claim 7 or 8, wherein the finishing substrate (6) comprises acrylic resin, polyurethane resin, synthetic or natural casein and wax in various weight percentages.

10. The leather-like structure according to any one of claims 7 to 9, wherein the fixing substrate (7) comprises acrylic resin, polyurethane resin, synthetic or natural casein and wax in various weight percentages.

11. The leather-like structure according to claim 7, wherein the primer substrate (5) and / or the finishing substrate (6) and / or the fixing substrate (7) comprises different weight percentages of coating material.

12. A method for manufacturing a leather-like structure (1), - The step of placing the first semi-finished substrate (3) on the second semi-finished substrate (2) such that the surfaces (8, 9) of the respective semi-finished substrates (2, 3) with a high weight percentage of polyester fibers are in contact with each other, - The steps of fixing and connecting the first semi-finished substrate (3) and the second semi-finished substrate (2) to obtain a support substrate (10), - A step of coating the outer surface (11) of the support substrate with the surface substrate (4), A method for producing a leather-like structure (1) comprising the above.

13. The manufacturing method according to claim 12, wherein the step of fixing and connecting the semi-finished substrates (2, 3) is carried out by water jet technology.

14. The step of coating with the aforementioned surface substrate (4) is: - A step of applying the primer substrate (5), - A step of applying the finishing substrate (6), - A step of applying the fixing substrate (7), A manufacturing method according to claim 12 or 13, including the method described in claim 12 or 13.

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