Leather-like structure

Abstract

A leather-like structure (1) comprising a semi-finished substrate (3), which comprises polyester fiber and leather fiber and defines a first outer surface (11) and a second outer surface (8); the first outer surface (11) comprises a higher percentage of polyester fiber than the second outer surface (8); a surface substrate (4) is arranged on the first outer surface (11) or second outer surface (8).

Description

[0001] "LEATHER- LI KE STRUCTURE"

[0002] Cross-Reference to Related Application

[0003] This Patent Appl ication claims priority from Italian Patent Application No . 102023000025329 filed on November 28 , 2023 , the entire disclosure of which is incorporated herein by reference .

[0004] Technical Field

[0005] The present invention relates to a leather-like structure .

[0006] The present invention is preferably, although not exclusively, applied to the field of clothing, footwear, leather goods , and decoration of vehicles such as yachts , private planes or cars . In the following, reference will be made to such application by way of example .

[0007] Background of the Invention

[0008] Leather derived from animal skin ( called natural leather or leather ) is frequently employed for the production, for example , of garments , shoes , accessories as well as for the interior decoration of luxury vehicles such as yachts , private planes or high-end cars .

[0009] It is known that the processing of rawhides into leather represents an upcycling of a by-product of the food industry : for over 99% of cases , rawhide derives from animals ( cattle , sheep, goats , pigs ) which are farmed for the purpose of producing food, such as meat and milk .

[0010] However, the machining processes to which the rawhide is subj ected (particularly the tanning process ) involve a high consumption of water and use of chemicals , two important aspects to take into account due to their signi ficant environmental impact .

[0011] The growing awareness for environmental and ethical issues ( e . g . animal rights ) , as well as the occasionally high prices of natural leather, have led to the appearance on the market of materials alternative to natural leather, among which imitation leather .

[0012] Imitation leather, also known as faux leather, eco- leather, or ecological leather, is a product traditionally obtained by spreading polyurethane-based ( PU) and polyvinyl chloride-based ( PVC ) products onto bases of various kinds , among which fabric or microfibers . The quality and characteristics of these products are governed by standard UNI 11427 : 2022 .

[0013] According to known solutions , a leather-like structure is produced from a semi- finished substrate , onto which polyurethane-based ( PU) and polyvinyl chloride-based ( PVC ) products , often admixed with adhesives or silicones , are spread . According to other known solutions , multiple semifinished substrates are overlaid and glued to then be spread . After the spreading, a finishing process is performed, i f necessary, to impart particular colors or textures to the structure .

[0014] Document CN114561746B describes a method for producing animal fiber composite full-layer leather, comprising the steps of fiber disintegration, fiber mixing, opening, web forming, web laying, pre-needle punching, wind perforation, main needling, post-treatment , and film trans fer .

[0015] Document US3537871A describes a leather-like structure composed of a non-woven base fabric made of a mixture of collagen fibers and natural or synthetic fibers , and a coating film of amino acid resin which adheres to the base fabric by means of an intermediate layer of resin binder .

[0016] Document CN108301224B describes a method for preparing eco- friendly Crystal leather, comprising the steps of 1 ) coating a foamy resin; 2 ) coating a polyurethane intermediate layer ; 3 ) casting a polyurethane colorless surface layer ; 4 ) coating a colorless polyurethane transparent layer ; and 5 ) rolling a polyurethane layer .

[0017] Generally, the aesthetic performance of the materials produced by means of these techniques is modest , as well as their wear resistance . Furthermore , their price is signi ficantly lower than that of natural leather, making them particularly competitive on the market .

[0018] However, the presence of several semi- finished substrates and spread PVC or PU layers makes the thickness of the known structures unsuitable to the manufacturing of small-si zed products , such as watch straps . Furthermore , for their production, particularly polluting plastics ( PU and PVC ) are used, which considerably depart from the environmental sustainability goals .

[0019] In view of the foregoing, the need is felt to create a material alternative to leather having performance and machinability as suitable as possible to the manufacturing of small-si zed items and simultaneously having an environmental impact lower than natural leather and the other known solutions mentioned above , and generally, as low as possible . Furthermore , the need is felt to create a material which does not contain adhesives or silicones as aggregants or anchoring structures such as meshes , and which is mainly composed of available ( recycled) and non-virgin materials , and which is finally recyclable .

[0020] The obj ect of the present invention is to meet the needs set forth above in an optimi zed and cost-ef fective manner .

[0021] Summary of the Invention

[0022] The aforementioned obj ect is obtained thanks to a leather-like structure as claimed in the appended claims .

[0023] Brief Description of the Drawings

[0024] In order to better understand the present invention, a preferred embodiment is described in the following by way of non-limiting example and with reference to the accompanying drawings , wherein :

[0025] • Figure 1 is a schematic section view of a leather-l ike structure according to the present invention; and

[0026] • Figure 2 is a schematic section view of a portion of the leather-like structure of Figure 1 .

[0027] Detailed Description of the Invention

[0028] In Figure 1 , a leather-like structure according to the invention for the production of leather goods , for example , accessories or garments , is shown as a whole by reference numeral 1 .

[0029] In the illustrated embodiment , the leather-like structure 1 is a multilayer sheet , i . e . having a thickness and a width, visible in the section of Figure 1 , and a length, in the normal direction to the section plane , where the thickness is much less than length and width, e . g . at least by an order of magnitude.

[0030] The leather-like structure 1 comprises a semi-finished substrate 3, which only comprises polyester fiber and leather fiber in complementary weight percentages.

[0031] In other words, the semi-finished substrate 3 does not comprise further elements other than polyester fiber and leather fiber. For example, the semi-finished substrate 3 does not comprise binders and / or aggregants (silicones, resins, etc.) nor anchoring structures such as meshes.

[0032] Considering the total weight of a semi-finished substrate, the weight percentage of polyester fiber is calculated from the ratio between the weight of polyester fiber and the total weight. Likewise, the weight percentage of leather fiber is calculated from the ratio between the weight of leather fiber and the total weight. Therefore, in detail, the expression "complementary weight percentages" means that the total weight of the semi-finished substrate is only obtained from the sum of the weight of leather fiber and the weight of polyester fiber. In other words, the sum of the weight percentage of leather fiber and the weight percentage of polyester fiber is equal to 100, namely to the total (representing the weight of the substrate) .

[0033] According to a preferred embodiment, the polyester fibers used for the production of the semi-finished substrate 3 come from, at least in part, recycled materials; in particular, polyester fibers are derived for about 50% in total from recycled PET, for example from PET bottles or from industrial polyester or clothing waste.

[0034] The leather fibers used for the production of the semi- finished substrate 3 usually come from the natural leather machining waste.

[0035] The production process of semi-finished substrates (known per se and therefore not described in detail in the following) allows obtaining a semi-finished substrate containing weight percentages of leather fibers and polyester fibers in varying proportions.

[0036] Following the production process, within a semifinished substrate, the composition of leather fiber and polyester fiber results to be non-uniform in the direction of its thickness. In other words, the weight percentage of polyester fibers and leather fibers varies within the semifinished substrate from a surface with a minimum weight percentage of polyester fiber to an opposite surface with a maximum weight percentage of polyester fiber.

[0037] As is illustrated in Figure 1, the semi-finished substrate 3 defines an outer surface 11 and an outer surface 8. The outer surface 11 comprises a higher weight percentage (or concentration) of polyester fiber, i.e. a maximum percentage, than the outer surface 8, i.e. a minimum percentage. Consequently, the outer surface 8 has a greater weight percentage (or concentration) of leather fiber, i.e. a maximum percentage, than the outer surface 11, i.e. a minimum percentage.

[0038] A surface substrate 4 is arranged on the outer surface 11 or outer surface 8.

[0039] In the illustrated non-limiting embodiment, the surface substrate 4 is arranged only on the outer surface 11. In other words, the surface substrate is arranged on the outer surface with a greater weight percentage of polyester. In particular, the surface substrate 4 entirely covers the outer surface 11.

[0040] Preferably, the semi-finished substrate 3 comprises a weight percentage of leather fiber higher than or equal to 60% and a weight percentage of polyester fiber lower than or equal to 40%.

[0041] In particular, the semi-finished substrate 3 comprises a weight percentage of leather fiber higher than or equal to 80% and a weight percentage of polyester fiber lower than or equal to 20%.

[0042] According to a preferred embodiment, the weight percentage of leather fiber of the semi-finished substrate 3 is equal to 85%, and the weight percentage of polyester fiber is equal to 15%.

[0043] Preferably, the semi-finished substrate 3 comprises a thickness higher than or equal to 0.3 mm and lower than or equal to 1.5 mm. In particular, the semi-finished substrate 3 comprises a thickness higher than or equal to 0.6 mm and lower than or equal to 1.2 mm. According to a preferred embodiment, the semi-finished substrate 3 has a thickness of 0.75 mm. The semi-finished substrate substantially has the aspect of a sheet.

[0044] Preferably, as is visible in Figure 2, the surface substrate 4 comprises a primer substrate 5 arranged in contact with the outer surface 11, a finishing substrate 6 arranged on the primer substrate 5, and a fixative substrate 7 arranged on the finishing substrate 6.

[0045] Advantageously, the primer substrate 5 comprises varying positive weight percentages of acrylic resins , polyurethane resins , synthetic or natural caseins and waxes .

[0046] Preferably, the primer substrate 5 also comprises varying weight percentages of covering materials . In particular, the covering materials can be matting substances and covering fillers .

[0047] In particular, the primer substrate 5 is directly applied to the outer surface 11 to adj ust and activate it so as to favor the anchoring of the following substrate .

[0048] Advantageously, the finishing substrate 6 comprises varying positive weight percentages of acrylic resins , polyurethane resins , ( synthetic or natural ) caseins and waxes .

[0049] Preferably, the finishing substrate 6 also comprises varying weight percentages of covering materials . In particular, the covering materials can be matting substances .

[0050] In particular, the finishing substrate 6 substantially consists of a varnish layer or other layer or film which provides the desired coloring to the leather-like structure 1 .

[0051] Advantageously, also the fixative substrate 7 comprises varying positive weight percentages of acrylic resins , polyurethane resins , ( synthetic or natural ) caseins and waxes .

[0052] Preferably, the fixative substrate 7 also comprises varying weight percentages of covering materials . In particular, the covering materials can be matting substances . In detail , the fixative substrate 7 is configured to block the finishing substrate 6 , in particular, thanks to catalysts within its composition, and " fixes" the color with respect to abrasions or scratches .

[0053] Preferably, both the primer substrate 5 and the finishing substrate 6 as well as the fixative substrate 7 comprise varying weight percentages of covering materials .

[0054] According to a possible embodiment , the surface substrate 4 comprises polyurethane and / or polyvinyl chloride . Although not in line with eco- friendly goals , these compounds can be applied by using spreading processes in place of or in addition to the surface substrate 4 in the event particular performance techniques of the leather-like structure 1 are required with respect to , for example , waterproofing .

[0055] The invention also relates to a method for producing a leather-like structure 1 from a semi- finished substrate 3 as described above , which comprises an outer surface 11 and an outer surface 8 , where the outer surface 11 comprises a higher weight percentage of polyester fiber than the outer surface 8 . The method comprises the step of coating one of the two outer surfaces 11 , 8 with a surface substrate 4 .

[0056] Preferably, but not limitedly, the step of coating with a surface substrate 4 is performed on the outer surface 11 . In other words , the outer surface with a greater weight percentage of polyester fiber is coated with the surface substrate 4 .

[0057] Preferably, the step of coating with the surface substrate 4 comprises in turn the subsequent steps of : • applying a primer substrate 5 ;

[0058] • applying a finishing substrate 6 ; and

[0059] • applying a fixative substrate 7 .

[0060] In view of the foregoing, the advantages of the leatherlike structure 1 according to the invention are apparent .

[0061] Thanks to the presence of a single semi- finished substrate 3 and the absence of PVC or PU layers spread thereon, the final thickness of the leather-like structure 1 is suitable to the manufacturing of small-si zed products , such as watch straps .

[0062] Moreover, the use of a single substrate 3 , instead of two substrates , as in the case of known solutions , allows halving the material utili zed for a single structure ( sheet ) and thus reducing the costs of materials . Therefore , for all applications requiring the machining of small-si zed components , the use of the proposed leather-like structure 1 brings about both technical (machining) and economic advantages .

[0063] Furthermore , the presence of the surface substrate 4 allows improving the surface characteristics of the leatherlike structure 1 in terms of both appearance and technical performance .

[0064] The proposed leather-like structure 1 and method for producing said leather-like structure 1 thus allow obtaining a material alternative to leather having performance and machinability suitable to the manufacturing of small-si zed items and simultaneously having an environmental impact lower than natural leather and other known solutions mentioned above , and generally, as low as possible . In detail , the proposed leather-like structure 1 does not contain any adhesives or silicones as aggregants , or any anchoring structures such as meshes , and it is mainly composed of available ( recycled) and non-virgin materials , and it is recyclable .

[0065] It is evident that modi fications may be made to the leather-like structure 1 and to the relative production method described, which do not go beyond the scope of protection defined by the claims .

[0066] For example , the width and the thickness of the structure 1 may vary as well as its shape and / or the composition of the semi- finished substrate 3 .

[0067] In addition, the appearance of the surface substrate 4 as well as its arrangement may vary . For example , the surface layer 4 may be arranged on the outer surface 8 . In other words , the surface substrate may be arranged on the outer surface at a greater weight percentage of leather fiber .

[0068] More generally, the surface layer 4 may cover even only partially the outer surface 11 ; 8 .

[0069] In detail , the leather-like structure 1 may have di f ferent coloring and / or surface machining, perforations and / or thickness reductions , as long as it comprises the claimed operating characteristics .

Claims

CLAIMS1. - A leather-like structure (1) comprising a semifinished substrate (3) , said semi-finished substrate (3) comprising only polyester fiber and leather fiber in complementary weight percentages, and defining a first outer surface (11) and a second outer surface (8) ; said first outer surface (11) comprising a higher weight percentage of polyester fiber than said second outer surface (8) ; a surface substrate (4) is arranged on said first outer surface (11) or said second outer surface (8) .

2. - The leather-like structure (1) according to claim1, wherein said surface substrate (4) is arranged on said first outer surface (11) .

3. - The leather-like structure according to claim 1 or2, wherein said semi-finished substrate (3) comprises a weight percentage of leather fiber higher than or equal to 60% and comprises a weight percentage of polyester fiber lower than or equal to 40%.

4. - The leather-like structure according to any one of claims 1 to 3, wherein said semi-finished substrate (3) comprises a weight percentage of leather fiber higher than or equal to 80% and comprises a weight percentage of polyester fiber lower than or equal to 20%.

5. - The leather-like structure according to any of the preceding claims, wherein said semi-finished substrate (3) comprises a thickness higher than or equal to 0.3 mm and lower than or equal to 1.5 mm.

6. - The leather-like structure according to any of the preceding claims, wherein said semi-finished substrate (3)comprises a thickness higher than or equal to 0.6 mm and lower than or equal to 1.2 mm.

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

8. - The leather-like structure according to any of the preceding claims, wherein said surface substrate (4) comprises :• a primer substrate (5) arranged in contact with said outer surface (11) ;• a finishing substrate (6) arranged on said primer substrate (5) ; and• a fixative substrate (7) arranged on said finishing substrate ( 6 ) .

9. - The leather-like structure according to claim 8, wherein the primer substrate (5) comprises varying positive weight percentages of acrylic resins, polyurethane resins, and synthetic or natural caseins and waxes.

10. - The leather-like structure according to claim 8 or 9, wherein the finishing substrate (6) comprises varying positive weight percentages of acrylic resins, polyurethane resins, and synthetic or natural caseins and waxes.

11. - The leather-like structure according to any of claims 8 to 10, wherein the fixative substrate (7) comprises varying positive weight percentages of acrylic resins, polyurethane resins, and synthetic or natural caseins and waxes .

12. - The leather-like structure according to claim 8, wherein the primer substrate (5) and / or the finishingsubstrate (6) and / or the fixative substrate (7) comprise varying positive weight percentages of covering materials.

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

14. - The method according to claim 13, wherein the step of coating with said 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 said surface substrate (4) comprises the subsequent steps of:• applying a primer substrate (5) ;• applying a finishing substrate (6) ; and• applying a fixative substrate (7) .

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