Leather Laminate Textured Surface via Reinforcing Fabric Constraint

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Solution Overview

Problem

Leather products often face challenges in balancing natural grain structure and strength, with full grain leathers being stiff and strong but unsuitable for flexible applications, while corrected and split grain leathers lack natural grain and strength, and artificial embossing can damage the leather.

Innovation Solution

A method involving laminating a reinforcing fabric with high-strength fibers to a leather layer, followed by exposure to water and dry milling, which creates a unique, aesthetically pleasing textured surface that maintains natural appearance and enhances strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If full grain leather is used to maintain natural grain structure and strength, then strength is improved, but flexibility and comfort deteriorate due to stiffness and weight

Engineering Contradiction:

Improvetear and tensile strengthVSAvoidflexibility and comfort

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The invention divides the leather product into two functional layers: a thin outer leather layer that provides natural grain structure, aesthetics, and flexibility, and a separate reinforcing mesh layer that provides strength. This segmentation allows each layer to perform its specialized function without compromising the other properties.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates a composite material structure by combining leather with a reinforcing mesh (polymer or metal). This composite structure integrates the aesthetic and flexible properties of leather with the strength properties of the mesh, resolving the contradiction between natural appearance and mechanical strength.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If chrome-dyed leather is used to improve softness and flexibility, then ease of operation is improved, but strength deteriorates due to reduced tear and tensile strength

Engineering Contradiction:

Improvesoftness and flexibilityVSAvoidtear and tensile strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The invention separates the functional requirements into two layers: the chrome-dyed leather layer provides softness and flexibility, while the reinforcing mesh layer compensates for the reduced strength, allowing the leather to be processed into thin, soft sheets without sacrificing mechanical integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

By combining chrome-dyed leather with a reinforcing mesh, the invention creates a composite that achieves both softness (from the leather) and high strength (from the mesh), enabling applications requiring both flexibility and durability.

Inventive Principle:

Principle #40Composite materials

3Shape

If artificial embossing is applied to create surface texture on corrected or split grain leather, then aesthetic appearance is improved, but the natural grain structure and strength are lost

Engineering Contradiction:

Improvesurface texture and appearanceVSAvoidinherent grain structure strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The reinforcing mesh is attached to the leather layer before final processing, providing structural support that allows the leather to be worked and shaped without losing strength. This preliminary reinforcement enables subsequent aesthetic treatments while maintaining mechanical integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The composite structure of leather plus reinforcing mesh allows the leather surface to be treated (sanded, embossed, corrected) to create desired surface textures while the mesh layer maintains the inherent strength and structural integrity that would otherwise be lost in thin corrected or split grain leathers.

Inventive Principle:

Principle #40Composite materials

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 leather laminates that are strong, flexible, and have a unique, random textured surface that retains its appearance even when stretched or bent, unlike artificially embossed surfaces, while maintaining the natural look and feel of the original leather.

Implementation Method 1

the water causing the leather to expand. However, the combination of adhesive and reinforcing fabric constrains the leather, restricting its ability to change its overall physical dimensions. The expansion caused by the water consequently manifests itself at the surface of the laminate

Methodology Applied

Scientific EffectSwelling:

Implementation Method 2

dry milling the leather laminate to form a milled leather laminate

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS11279110B2Leather laminate having textured surface

Publication Date: 2022.03.22 ECCO SKO A S

AI summary

The present invention relates to a method for making a leather laminate having a textured surface, and leather laminates made by this method. The laminates comprise a leather layer bonded to a reinforcing fabric with an adhesive, the reinforcing fabric providing strength to the laminate. The method involves dry milling the laminate in humid air, during which the reinforcing fabric constrains the laminate causing the textured surface to form.