Improved method for making a product with an upgrading layer and related system
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Solution Overview
Problem
Existing methods for manufacturing upgraded leather products using synthetic laminar supports result in irreversible alterations and wrinkles when the products are folded or stretched, due to the polyurethane resin layer's spatial arrangement changes, leading to unacceptable deterioration.
Innovation Solution
A method involving a supporting element with an embossed surface, where a first substance is applied, partially removed, and subjected to heat treatment before being pressed against a laminar support, with a second substance applied to the support to achieve partial setting and reproduction of the embossed pattern, reducing wrinkles and improving product softness and aesthetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a polyurethane resin layer is applied on an embossed surface and then polymerized, then the upgrading layer can be formed on the laminar support, but the layer undergoes irreversible alterations and wrinkles when the product is folded or stretched
Solution Approach 1:
The upgrading layer is divided into discrete projections corresponding to the embossed surface features, with each projection independently formed and spaced apart. This segmentation allows each projection to flex independently during folding or stretching, preventing the irreversible alterations and wrinkles that occur in continuous polymerized layers.
Solution Approach 2:
The upgrading layer is designed to be non-polymerized or partially polymerized, maintaining a flexible, dynamic state that can adapt to mechanical deformations. This dynamic structure allows the layer to return to its original configuration after folding or stretching, unlike rigid polymerized layers that undergo permanent alterations.
2Productivity
If the polyurethane resin layer is made thinner to reduce production time, then production efficiency increases, but the covering uniformity over projections and recesses deteriorates
Solution Approach 1:
Instead of applying a thin uniform layer that barely covers the embossed surface, the method applies a relatively thick layer of polyurethane resin that substantially and uniformly covers all projections and recesses. This excessive application ensures complete coverage and uniformity, while the subsequent removal process eliminates excess material to achieve the desired final thickness.
Solution Approach 2:
The polyurethane resin layer is applied in excess beforehand to ensure complete and uniform coverage of the embossed surface features. The excess material is then removed after the supporting element is detached, allowing the upgrading layer to achieve both uniform coverage and appropriate thickness without compromising production efficiency.
3Manufacturing precision
If a thick layer of polyurethane resin is applied to ensure uniform coverage, then surface coverage uniformity improves, but the production time and costs increase
Solution Approach 1:
The polyurethane resin layer is applied in excess beforehand to ensure complete and uniform coverage of the embossed surface features. The excess material is then removed after the supporting element is detached, allowing the upgrading layer to achieve both uniform coverage and appropriate thickness without compromising production efficiency.
Solution Approach 2:
The method combines multiple operations into a single integrated process: applying the polyurethane resin layer, attaching the laminar support, detaching the supporting element, and removing excess material are performed in sequence without intermediate steps. This merging of operations streamlines production and reduces overall cycle time while maintaining high surface coverage uniformity.
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 method produces a softer, more pleasant-to-the-touch product with reduced production time and costs, and increased production efficiency, while maintaining the desired aesthetic characteristics comparable to full grain leather, without the issue of irreversible alterations when folded or stretched.
Implementation Method 1
said method comprising at least one step c1) in which said residual quantity of said first substance is subjected to a heat treatment in order to make said residual quantity of said first substance at least partially set
Implementation Method 2
applying pressure to said supporting element and/or to said laminar support, in such a way as to press said residual quantity of said first substance against said laminar support
Implementation Method 3
making said residual quantity of said first substance set at least partially
Data Source
Figure 1A~2
Figure 3A~3C
Figure 4A~4C
AI summary
The present patent concerns a method for making a product (1; 1') comprising a laminar support (9) and an upgrading layer (F). The method comprises the following steps: preparing a supporting element (12) provided with a non- smooth embossed surface (2) comprising projections (52) and recesses (54); applying a layer of a first substance (4) on the embossed surface (2) so as to cover said projections (52) and said recesses (54) and carrying out a removal operation intended to remove at least a part of said first substance (4); moving said supporting element (12) near said laminar support (9) and applying a pressure (P) to said supporting element (12) and/or to said laminar support (9) to make the residual quantity of said first substance (4) set at least partially; removing said embossed surface (2) from said residual quantity of said previously set first substance (4).