Electrocompacted Collagen Leather to Reduce Environmental Impact
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Solution Overview
Problem
Current synthetic leather alternatives fail to replicate the unique properties of natural leather, such as breathability, handfeel, and aesthetic qualities, and are not made from collagen or collagen-like proteins, leading to environmental concerns and animal welfare issues associated with traditional leather production.
Innovation Solution
The development of biofabricated leather materials through electrocompaction or electrospinning methods, involving the application of non-human monomeric collagen solutions, fibrillation, stabilization, and incorporation of lubricants, which allows for the creation of a dense collagen network that mimics the structure and properties of natural leather without animal-derived materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional animal skin tanning is used, then leather with desirable strength and aesthetic properties is produced, but environmental pollution and animal welfare issues occur
Solution Approach 1:
The patent creates a synthetic leather material that copies the collagen fiber structure and aesthetic properties of natural leather without using animal products. The electrocompaction process produces a dense network of collagen-like fibers that mimic the appearance, texture, and mechanical properties of traditional leather, thereby achieving the desired strength and aesthetics without the harmful environmental and animal welfare consequences
Solution Approach 2:
The patent uses composite materials by combining collagen proteins with electrocompaction technology to create a new material that replicates leather properties. The resulting material is a composite structure with collagen fibers arranged in a dense network, providing both the environmental benefits of plant-based or synthetic collagen sources and the mechanical properties of traditional leather
2Object-generated harmful factors
If synthetic leather alternatives are used, then environmental concerns are reduced, but breathability, handfeel, and aesthetic qualities are not replicated
Solution Approach 1:
The patent applies local quality by creating variations in the collagen fiber structure at different locations within the material. The electrocompaction process produces regions with different fiber densities, orientations, and diameters, creating local variations that mimic the natural heterogeneity of leather grain. This results in different aesthetic qualities and tactile properties across the material surface, enhancing breathability, handfeel, and visual appeal while maintaining environmental benefits
3Reliability
If electrocompaction is used to create dense collagen network, then leather-like properties are achieved, but complex manufacturing process is required
Solution Approach 1:
The patent replaces traditional mechanical leather processing methods with an electrocompaction system that uses electrical fields to arrange collagen fibers. Instead of mechanical pressing, heating, and chemical treatments required by conventional leather manufacturing, the electrocompaction process uses controlled electrical currents to self-organize collagen into dense, leather-like networks, simplifying the overall manufacturing process while achieving superior material properties
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 resulting biofabricated leather exhibits desirable strength, softness, and aesthetic properties similar to natural leather, offering a sustainable alternative that can be used in various applications, from footwear to upholstery, while reducing environmental impact and animal slaughter.
Implementation Method 1
compacting the collagen into a dense network with an electrical field
Implementation Method 2
inducing fibrillation of the collagen with an electrical field
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
Biofabricated leathers made by electrocompaction. Described herein are biofabricated leather materials derived from electrocompacted collagen networks. These electrocompacted leathers may have leather-like properties and may be processed as native leather and used to form leather goods.