Method for producing a multilayer laminar product and plant for implementing said method

Solution Overview

Problem

Existing leather ennobling methods face limitations such as the use of embossed paper with limited width, high cost, and complexity, which restricts the processing of large leather sizes and increases production costs, while also compromising the quality and softness of the finished product.

Innovation Solution

A method involving the application of polymer resins on a laminar support, followed by partial consolidation and embossing using a laminar element, without the need for embossed paper, to create a multilayer laminar product with improved softness and quality, utilizing low-cost materials and simpler plant configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If embossed paper is used for leather ennobling, then the leather surface can be improved and grain pattern can be reproduced, but the production cost increases and the maximum width is limited to 2200 mm

Engineering Contradiction:

Improveleather surface qualityVSAvoidplant complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the embossed paper component from the traditional ennobling process. Instead of using paper as an intermediary carrier, the invention directly applies polymer resin composition onto the leather surface, which is then embossed and cured to form the protective layer with grain pattern, completely removing the need for embossed paper and its associated handling equipment

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The polymer resin composition serves multiple functions simultaneously: it acts as the embossing medium, provides the protective coating, reproduces the grain pattern, and forms the final finished surface. This multi-functional approach replaces the traditional multi-component system of embossed paper, adhesive, and protective coating, simplifying the overall process and equipment requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If embossed paper is used for leather ennobling, then the leather surface can be improved, but the production cost increases due to paper cost and downstream processing equipment

Engineering Contradiction:

Improveleather surface qualityVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention replaces expensive, reusable embossed paper with a disposable polymer resin composition that is applied directly to the leather. The resin is applied in controlled amounts, embossed, and cured to form the protective layer, eliminating the need for costly paper materials and the downstream equipment required to remove and reuse paper

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent merges the functions of embossing, protective coating application, and surface finishing into a single integrated process step. The polymer resin composition is applied and embossed in one operation, eliminating the need for separate paper application, adhesive bonding, and protective coating steps, thereby reducing both material and equipment costs

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If embossed paper is used for leather ennobling, then the leather surface can be improved, but larger leather sizes (3400-3600 mm) cannot be processed

Engineering Contradiction:

Improveleather surface qualityVSAvoidprocessable leather area

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The invention changes the physical state and application method of the embossing medium from solid embossed paper to a liquid or paste polymer resin composition. This allows the material to be applied in liquid form and then cured to form the protective layer, enabling processing of any leather size without the width limitations of pre-manufactured paper rolls

Inventive Principle:

Principle #35Parameter changes

4Manufacturing precision

If embossed paper is used for leather ennobling, then the leather surface can be improved, but the process complexity and plant size increase

Engineering Contradiction:

Improveleather surface qualityVSAvoidplant size

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the embossed paper component from the traditional ennobling process. Instead of using paper as an intermediary carrier, the invention directly applies polymer resin composition onto the leather surface, which is then embossed and cured to form the protective layer with grain pattern, completely removing the need for embossed paper and its associated handling equipment

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The polymer resin composition serves multiple functions simultaneously: it acts as the embossing medium, provides the protective coating, reproduces the grain pattern, and forms the final finished surface. This multi-functional approach replaces the traditional multi-component system of embossed paper, adhesive, and protective coating, simplifying the overall process and equipment requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reduces production costs, enables processing of larger leather sizes, and results in a softer, higher-quality finished product by eliminating the need for embossed paper and minimizing material waste, thus enhancing the efficiency and reliability of the production process.

Implementation Method 1

partially consolidating said first covering layer (2) by heating, so as to give it a compact consistency

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

the embossed surface (107) is pushed against said first covering layer (2), with interposition of said laminar element (4), so as to imprint the embossing on said covering layers (2, 3)

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

a treatment assembly (133) causes the polymerization of the first covering layer (2) and of the second covering layer (3), so as to obtain a single stabilized covering layer (5)

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentEP4650514A1Method for producing a multilayer laminar product and plant for implementing said method

Publication Date: 2025.11.19 GE MA TA

Figure 1(a)~1(h)
Figure 2

AI summary

A method for producing a multilayer laminar product (6), comprising the operations of arranging a laminar support (1), covering a first face (1a) of the laminar support (1) with a first covering layer (2), consolidating, at least partially, this first covering layer (2). The method also provides for arranging a laminar element (4), covering a first face (4a) of the laminar element (4) with a second covering layer (3), consolidating the second covering layer (3), arranging above said laminar support (1) the laminar element (4) so that the first covering layer (2) and the second covering layer (3) are in contact with each other, pushing an embossed surface (107) against the first covering layer (2) and the second covering layer (3) with interposition of the laminar element (4) to imprint on the first covering layer (2) and on the second covering layer (3) the pattern of said embossed surface (107), and finally, after imprinting the pattern, causing the polymerization of the first covering layer (2) and of the second covering layer (3) to obtain a single stabilized covering layer (5).