Cork-Embedded Elastomeric Textile for Leather-Like Flexibility
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Solution Overview
Problem
Existing cork-based textile articles often result in stiff substrates when laminated, failing to replicate the flexibility and tactile features of leather, and when using cork powder, they require additional substrates without cork, deviating from the original cork appearance.
Innovation Solution
A textile article comprising a woven or non-woven fabric substrate mixed with cork particles, an elastomeric polymer, and a curing agent, combined with an elastomeric film that exposes cork particles, and a lamination process at high pressure to create a flexible, environmentally friendly fabric with aesthetic and tactile features similar to leather.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If laminated cork is used to create a textile article, then the article has structural integrity and stability, but the final product becomes too stiff and loses flexibility
Solution Approach 1:
The patent applies different qualities to different parts of the material: the base fabric provides structural integrity while the cork-embossed polymeric layer provides surface characteristics. The cork particles are distributed locally in the polymeric layer to create leather-like appearance and tactile features without making the entire substrate stiff.
Solution Approach 2:
The patent creates a composite material combining base fabric, polymeric material, and cork particles. This composite structure allows the fabric substrate to maintain flexibility while the cork-containing polymeric layer provides the desired surface properties and aesthetic features.
2Ease of operation
If cork powder is used instead of laminated cork, then flexibility is improved, but additional substrates without cork are required, deviating from original cork appearance
Solution Approach 1:
The patent merges the benefits of both approaches by combining cork particles embedded in a polymeric material that is then applied to a fabric substrate. This integration ensures cork appearance is maintained throughout the product while achieving flexibility, eliminating the need for additional cork-free substrates.
Solution Approach 2:
The patent changes the parameters of cork particle size (40-400 micrometres) and their distribution within the polymeric layer to optimize both appearance fidelity and flexibility. The fine cork particles provide authentic cork appearance while the polymeric matrix ensures flexibility.
3Manufacturing precision
If fine cork particles (40-400 micrometres) are used, then aesthetic and tactile features similar to leather are achieved, but manufacturing complexity increases
Solution Approach 1:
The patent performs preliminary actions by pre-mixing cork particles with the polymeric material before application to the fabric substrate. This preliminary mixing ensures uniform distribution of fine cork particles, achieving consistent aesthetic and tactile features while simplifying the overall manufacturing process.
Solution Approach 2:
The polymeric material acts as an intermediary between the cork particles and the fabric substrate. It binds the fine cork particles together and to the fabric, enabling the use of small cork particles for authentic appearance while managing manufacturing complexity through a unified application process.
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 solution allows for the creation of flexible, environmentally friendly fabrics with physical, aesthetic, and tactile features similar to leather, utilizing fine cork particles and bio-based additives, achieving a high cork residue content and reducing waste and emissions.
Implementation Method 1
an elastomeric polymer, and a curing agent
Implementation Method 2
a lamination process at high pressure
Data Source
AI summary
Cork-based textile article and process for the manufacturing thereof In a cork-based textile article, comprising: a first substrate (F,1) comprising a natural/synthetic fabric or non-woven fabric obtained from a mixture of fibres and cork particles; and a second substrate (B,10) comprising an elastomeric polymer mixed with an amount of cork particles not lower than 5% by weight, and a curing agent, the first and the second substrates (1,10) being coupled therebetween at high pressure, so as to obtain a curing of the elastomeric polymer, whereby an effect wholly similar to leather, or suede or a biodenim, with a high cork content, is obtained.