Decorated natural leather
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Solution Overview
Problem
The manufacturing of high-quality, personalized, and customized natural leather articles faces challenges due to labor-intensive screen printing methods and inferior quality digital printing on finished leather, leading to increased costs, time delays, and reduced luxury feel.
Innovation Solution
A method involving inkjet printing decorative images and identification codes directly onto tanned leather, using pigmented inks and a base coat to ensure high image quality and machine-readable codes for efficient cutting and assembly, allowing for personalized designs and improved logistics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screen printing is used to decorate natural leather, then decoration can be applied, but the process becomes labour intensive and costly with individual screens required for each colour
Solution Approach 1:
The patent replaces the mechanical screen printing system with a digital printing system that uses digital files and print heads to deposit ink directly onto leather, eliminating the need for physical screens and manual operations
Solution Approach 2:
The patent changes the fundamental parameters of the printing process by transitioning from analog screen printing to digital inkjet printing, allowing for variable data printing and customization without requiring physical screen changes
2Productivity
If inkjet printing with heat transfer paper is used on tanned leather, then digital printing is achieved, but the image quality is inferior with light fading and poor scratch resistance
Solution Approach 1:
The patent uses a primer layer as an intermediary between the leather substrate and the pigmented ink, improving ink adhesion and preventing light fading while enhancing scratch resistance
Solution Approach 2:
The patent changes the ink formulation from dye-based to pigmented ink, and modifies the printing parameters by printing at controlled depths into the leather grain to achieve superior image quality, light fastness, and scratch resistance
3Adaptability or versatility
If decoration is applied at the leather article manufacturer phase, then customization is possible, but delivery time increases reducing the luxury feel
Solution Approach 1:
The patent enables decoration to be applied during the tanning phase rather than at the final manufacturing stage, allowing leather to arrive at the article manufacturer already decorated and ready for immediate production
Solution Approach 2:
The patent uses digital files to store and reproduce decorative designs, allowing for rapid customization without physical templates or screens that would require manufacturing time
4Ease of manufacture
If traditional manufacturing processes are used, then production can proceed, but waste increases and errors occur without identification systems
Solution Approach 1:
The patent implements a traceability system using identification codes that provide feedback throughout the manufacturing process, enabling tracking of leather pieces from tanning through to final product assembly
Solution Approach 2:
The patent applies identification codes during the tanning phase, enabling preliminary organization and tracking before the leather enters the manufacturing process, reducing errors and waste in subsequent cutting and assembly operations
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
This method reduces waste, minimizes errors, and enhances the luxury feel by enabling efficient production and customization of leather articles with improved image quality and machine-readable tracking, while maintaining secrecy until sale, thus addressing the need for faster delivery and cost-effectiveness.
Implementation Method 1
inkjet printing a decorative image on the base coat using one or more pigmented inkjet inks
Data Source
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AI summary
A manufacturing method of decorated natural leather including the steps of: applying a base coat (44) on crusted leather (45); inkjet printing (4) a decorative image (8) on the base coat (44) using one or more pigmented inkjet inks; and applying one or more identification codes (9).