Method for making a multilayer laminar product and system thereto
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Solution Overview
Problem
Existing leather upgrading techniques are limited by the maximum width of embossed paper, requiring hides to be cut, leading to material waste and increased costs due to the need for protective film application and removal devices, as well as frequent paper replacement.
Innovation Solution
A method and system that use a polymeric resin applied to a laminar support, where a chemically incompatible laminar element and embossed surface impress patterns without the need for embossed paper, allowing processing of wider hides without cutting and eliminating the need for protective film application and removal devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If embossed paper is used to cover the polyurethane resin layer, then the pattern can be impressed on the resin, but the paper must be removed after polymerization which requires a protective film and increases process complexity
Solution Approach 1:
The invention extracts the embossed surface from the paper substrate, using only the essential embossed surface element while eliminating the paper portion that causes removal difficulties. The embossed surface is applied directly to the polyurethane resin layer without requiring protective films or complex removal mechanisms.
Solution Approach 2:
The embossed surface is designed as a disposable element that remains on the product after polymerization, eliminating the need for protective films and removal devices. This single-use approach simplifies the overall process by removing the complexity of film application and removal systems.
2Ease of manufacture
If embossed paper with predefined width is used, then the paper is readily available, but hides wider than the paper must be cut reducing the field of application
Solution Approach 1:
The invention segments the embossed surface into interchangeable elements that can be selected or combined to match different hide widths. This allows the system to accommodate various hide sizes without requiring cutting, thereby maintaining versatility while preserving ease of manufacture through standardized components.
Solution Approach 2:
The embossed surface elements are designed to be universally applicable to different hide widths through selection or arrangement of standardized components. This multi-functional approach allows the same system to handle various hide sizes without modification, enhancing adaptability while maintaining manufacturing simplicity.
3Reliability
If the embossed paper is covered with a protective film of polyurethane resin, then the paper does not adhere to the resin layer, but the film becomes an integral part of the resin and must be removed downstream increasing system dimensions and costs
Solution Approach 1:
The invention extracts the protective film function from the process by using an embossed surface that inherently prevents adhesion without requiring an additional film layer. This eliminates the need for film removal devices and reduces system dimensions while maintaining reliable prevention of paper adhesion.
Solution Approach 2:
The embossed surface serves as a disposable release agent that prevents adhesion during the process and remains on the final product, eliminating the need for protective films and their removal. This approach reduces system complexity and dimensions by removing the film removal device entirely.
4Manufacturing precision
If embossed paper is used, then the pattern can be transferred to the resin, but the paper must be periodically replaced increasing process costs
Solution Approach 1:
The embossed surface is designed as a disposable element that is applied directly to the resin layer and remains there after polymerization. This eliminates the need for periodic removal and replacement, allowing continuous operation and improving productivity while maintaining pattern transfer quality.
Solution Approach 2:
The embossed surface remains in place on the polymerized product, enabling continuous production without interruption for paper replacement. This continuous action improves productivity by eliminating periodic downtime associated with replacing embossed paper while maintaining manufacturing precision.
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
Enables the processing of wide hides without material waste, reduces system and processing costs, and allows for continuous operation with interchangeable embossed surfaces, enhancing the quality and efficiency of the leather upgrading process.
Implementation Method 1
the polyurethane resin is successively polymerized, in such a way as to make it adhere to the laminar support in a stable manner
Implementation Method 2
pushing an embossed surface against said covering layer in order to impress the pattern of said embossed surface on said covering layer
Data Source
Figure 1(a)~1(f)
Figure 2
Figure 3
AI summary
The invention is a method for making a multilayer laminar product (22), comprising the following operations: preparing a laminar support (16); covering a first side (16a) of the laminar support (16) with a covering layer (17) made of a non-completely polymerized polymeric resin; preparing a laminar element (18) provided with a first side (18a) chemically incompatible with the polymeric resin; pushing an embossed surface (6) against the covering layer (17) after interposing the laminar element (18) in order to impress the pattern of the embossed surface (6) on the covering layer (17), the laminar element (18) being arranged in such a way that its first side (18a) is facing towards the covering layer (17); once the pattern has been impressed, polymerizing the covering layer (17) in order to obtain a stabilized covering layer (19); separating the laminar element (18) from the stabilized covering layer (19).