Leather-Like Cellulose Web Processing with Cyclic Wrinkle Forming
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Solution Overview
Problem
Existing methods for producing imitation leather face issues such as poor strength and durability of the finishing layer, lack of breathability and consistency similar to natural leather, long production times, high production costs, and the need for complex and expensive equipment.
Innovation Solution
A process using cellulose fibre impregnated with a copolymer, specifically styrene-butadiene, and vulcanizing and aging agents, where the material is treated with a liquid soaking product to enhance malleability and then compressed and spread to create wrinkles, mimicking natural leather's appearance and structure, allowing for long-lasting creasing and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a base support of cellulose fibre is treated with aqueous solutions and multiple coating layers (binding agents, acrylic polymer, vinylic copolymer, acrylic copolymers) to produce imitation leather, then the appearance and structure similar to natural leather is achieved, but the finishing layer has poor strength and easily degrades and detaches from the underlying intermediate layer
Solution Approach 1:
The patent uses a composite structure consisting of a cellulose fibre base support impregnated with styrene-butadiene copolymer, combined with a superimposed layer of the same or different copolymer. This composite material approach creates strong interlayer bonding while maintaining the leather-like appearance, resolving the contradiction between aesthetic shape and structural strength.
Solution Approach 2:
The patent changes the chemical parameters by using styrene-butadiene copolymer with specific vulcanizing and aging agents, and treating with liquid soaking products. These parameter changes enhance the adhesion between layers and improve the overall strength of the imitation leather material while preserving its visual characteristics.
2Shape
If multiple coating layers and chemical treatments are applied to achieve leather-like appearance, then the aesthetic characteristics are improved, but the production time and costs increase
Solution Approach 1:
The patent incorporates vulcanizing and aging agents directly into the cellulose fibre base support during the impregnation stage, before the final forming process. This preliminary action eliminates the need for separate post-treatment steps, reducing production time while maintaining the desired aesthetic characteristics through proper material preparation.
Solution Approach 2:
The patent merges multiple functions into the base support material itself by impregnating cellulose fibres with copolymer and aging agents during manufacturing. This consolidation of functions (structural support, aesthetic appearance, and durability) into a single integrated material reduces the number of separate production steps required.
3Ease of manufacture
If synthetic material sheets are used and cut into short lengths for drum treatment, then the processing is simplified, but the production efficiency decreases and production costs increase
Solution Approach 1:
The patent segments the production process by using continuously produced band-form base supports that can be processed in long lengths without cutting. This segmentation of the material form (from sheets to continuous bands) allows for more efficient processing while maintaining ease of manufacture through standardized band dimensions and continuous production methods.
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 results in a material with appearance and consistency similar to natural leather, suitable for clothing and furnishing, with long-lasting creasing and reduced production time and costs, enabling large-scale production without the need for cutting materials into short sheets.
Implementation Method 1
a base material, in band form, consisting of cellulose fibres impregnated with a copolymer, in particular styrene-butadiene, and preferably containing vulcanizing and aging agents
Implementation Method 2
a base material, in band form, consisting of cellulose fibres impregnated with a copolymer, in particular styrene-butadiene, and preferably containing vulcanizing and aging agents
Implementation Method 3
a step of impregnating the base material with a liquid soaking product to make the base material more malleable
Implementation Method 4
a step of compressing the base material inside a duct, in which the base material is compressed transversally in the direction of its own width sliding longitudinally inside at least one compression portion of such a duct
Implementation Method 5
a step of spreading out the base material, in which the base material opens out at least partially along its own width outside of the aforementioned compression portion of the duct
Data Source
Figure 1
AI summary
Process for producing a material similar to leather, which foresees: - a step of providing a base material (1) in band form and comprising a cellulose fibre impregnated with a copolymer dispersion; - a step of impregnating the base material (1) in band form with at least one liquid product; - a step of compressing the base material (1) in band form in a duct (2), wherein the base material (1) in band form is compressed transversally in the direction of its own width sliding in a compression portion of the duct (2) having a smaller width than the width of the base material (1); - a step of spreading out the base material (1) in band form, wherein the latter opens out at least partially along its own width outside of the compression portion of the duct (2); Moreover, the process in object foresees that the compression step and the spreading out step are repeated cyclically.