Method for making a product of the type comprising a laminar supporting element and an upgrading layer and corresponding production system
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing imitation leather or upgraded leather result in products that are stiff, require multiple processing steps, and increase production costs due to the use of high pressures and temperatures, which affect the softness and flexibility of the final product, and necessitate complex systems and frequent interruptions.
Innovation Solution
A method involving the application of a synthetic substance to a laminar support, followed by a protective substance on a supporting film, which is then coupled and embossed under controlled moisture and pressure conditions to reproduce morphological characteristics without significantly affecting the softness or thickness of the leather, allowing for a more efficient and cost-effective production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If high pressure and high temperature are used in the pressing operation to impress grain or pattern on the synthetic material layer, then the desired aesthetic characteristics are achieved, but the softness and flexibility of the hide are deteriorated and rigidity increases
Solution Approach 1:
The invention changes the parameters of the pressing operation by using lower pressures (50-150 atm instead of 250-300 atm) and lower temperatures (80-100°C instead of 100-110°C), combined with controlled moisture content (15-25%) of the synthetic material layer, to achieve the desired grain or pattern while preserving the softness and flexibility of the hide
Solution Approach 2:
The invention applies a preliminary moisture treatment to the synthetic material layer before pressing, maintaining its moisture content within 15-25% to optimize its deformability and responsiveness to the embossing operation, thereby achieving the desired aesthetic characteristics without requiring excessive pressure and temperature
2Ease of operation
If multiple treatment steps including stretching or tumbling are applied to restore softness after pressing, then the pleasant feel to the touch is improved, but production time increases and production speed is limited
Solution Approach 1:
The invention extracts and eliminates the unnecessary stretching or tumbling treatment steps from the production process by using optimized pressing parameters from the beginning, thereby reducing production time and increasing production speed while maintaining the pleasant feel to the touch
Solution Approach 2:
The invention enables a continuous production process where the optimized pressing operation directly produces the final product with desired aesthetic characteristics and tactile properties, without interruptions for additional treatment steps, thereby maintaining high production speed
3Shape
If the synthetic material layer is applied to increase aesthetic characteristics, then the product appearance is improved, but the thickness of the product increases and flexibility is reduced
Solution Approach 1:
The invention changes the parameters of the synthetic material layer by controlling its thickness, moisture content (15-25%), and composition to achieve the desired aesthetic characteristics while maintaining flexibility, avoiding the need for thick layers that would reduce flexibility
4Ease of manufacture
If successive processing steps are performed in different remote systems or at third party premises, then specialized treatments can be applied, but production speed is limited and production costs increase
Solution Approach 1:
The invention merges multiple processing steps including application of synthetic material, moisture treatment, pressing operation, and finishing treatments into a single integrated production line, eliminating the need to move hides between different remote systems or third party premises, thereby increasing production speed and reducing costs
5Adaptability or versatility
If frequent interruptions are introduced between successive processing steps for moving and repositioning hides, then different specific treatments can be applied at appropriate locations, but production speed is limited and production costs increase
Solution Approach 1:
The invention implements a continuous production process where all processing steps are performed in sequence without interruptions or repositioning of hides, with the production line continuously moving materials through application, moisture treatment, pressing, and finishing operations, thereby maintaining high production speed while providing adaptability for different treatments
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 and more pleasant-to-the-touch product with characteristics similar to full-grain leather, reducing production time and costs by minimizing the number of processing steps and eliminating the need for additional treatments like stretching or tumbling, while enabling continuous processing within a single system.
Implementation Method 1
treating said at least one layer of said synthetic substance in such a way that said synthetic substance has an absolute moisture value included between 12% and 25%
Implementation Method 2
coupling said supporting film provided with said protective substance to said laminar support provided with said layer of synthetic substance
Implementation Method 3
embossing said layer of synthetic substance by exerting a predetermined force per unit of surface area on said supporting film and/or on said laminar support by means of an embossed surface
Data Source
Figure 1A~1G
Figure 2A~2G
Figure 3A~3G
AI summary
The invention concerns a method for producing imitation leather or upgraded leather (1) comprising a laminar support (9) and an upgrading layer (F), comprising the following steps: applying a layer (10) of a synthetic substance (11) to a surface (8) of the laminar support (9); applying a layer of a protective substance (4) to a surface of a supporting film (2); treating the layer (10) of synthetic substance (11) in such a way that the synthetic substance (11) has an absolute moisture value included between 12% and 25%; coupling the supporting film (2) provided with the protective substance (4) with the laminar support (9) provided with the layer (10) of synthetic substance (1 1) in such a way as to place the protective substance (4) in contact with the synthetic substance (11); embossing the layer of synthetic substance (11) by exerting a predetermined force per unit of surface area on the supporting film (2) and/or on the laminar support (9) by using an embossed surface (102; 302; 402) that is placed in contact with the supporting film (2) in such a way as to press said protective substance (4) against the synthetic substance (1 1) and in such a way that the morphological characteristics impressed on the embossed surface (102; 302; 402) are reproduced on the layer of synthetic substance (1 1); consolidating the union between the protective substance (4) and the synthetic substance (1 1); removing the supporting film (2) from the layer of protective substance (4). The invention concerns also the corresponding production system (100; 200; 300; 400; 500).