Rubberized Leather Tanning for Uniform Elastic Properties
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Solution Overview
Problem
Existing tanning processes for producing rubberized leather face challenges in achieving consistent aesthetic and functional characteristics, particularly in terms of stitch-tear resistance, break grain resistance, homogeneity of physical and mechanical properties, and optimizing drying and pressing processes, while conventional methods result in uneven leather quality and potential wrinkling.
Innovation Solution
A tanning process that incorporates a rubberizing treatment using carboxylated thermoplastic elastomers during the wet phase, followed by controlled drying and pressing, to create stable carbo-amide bonds between the elastomers and leather fibers, ensuring uniform distribution and enhanced properties throughout the leather thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rubberizing treatment is applied during wet phase, then elastic properties are improved, but homogeneity of physical and mechanical properties deteriorates
Solution Approach 1:
The patent applies different treatment conditions to different stages of the tanning process. Specifically, the rubberizing treatment is applied during the wet phase with controlled elastomer concentration (0.1-5% of leather weight), followed by a distinct drying phase where water is removed to below 100% humidity. This staged approach ensures uniform penetration of elastomers throughout the leather matrix while maintaining consistent physical and mechanical properties across the final product.
Solution Approach 2:
The patent controls critical parameters including elastomer concentration (0.1-5% of leather weight), humidity levels (maintaining wet phase conditions during treatment, then reducing to below 100% during drying), and treatment duration (15-60 minutes). These parameter controls ensure homogeneous distribution of elastomers and consistent mechanical properties throughout the leather thickness.
2Productivity
If drying process is accelerated, then productivity is improved, but wrinkling and quality defects increase
Solution Approach 1:
The patent performs preliminary actions during the wet phase treatment by ensuring uniform elastomer penetration and distribution before the drying process begins. The leather is thoroughly impregnated with elastomers while in the wet state, creating a homogeneous structure that resists wrinkling during subsequent drying. This preliminary uniform impregnation allows for faster drying without quality defects.
Solution Approach 2:
The patent maintains continuous control over the drying process by monitoring humidity levels and ensuring they remain below 100% throughout drying. This continuous control prevents sudden moisture loss that could cause wrinkling, while still maintaining efficient drying rates through optimized process conditions and equipment.
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 process results in leather with improved stitch-tear resistance, break grain resistance, and homogeneous mechanical properties, along with optimized drying and pressing, preventing wrinkling and ensuring high-definition patterns and shape memory.
Implementation Method 1
stable carbo-amide bonds between the elastomers and leather fibers
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
In a wet phase of the tanning process, the skins or hides are subjected to a treatment of so- called "rubberizing" in which in the treatment environment, whether it be the inside of a drum, a washing machine, a steady tub or other suitable means of treatment, are introduced certain elastomers that penetrate deeply into the dermis giving the leathers peculiar aesthetic and functional properties. The rubberizing procedure preferably occurs according to certain parameters of absolute humidity of the leather, temperature of the bath and duration of treatment, together with the retanning, dyeing or fatliquoring operations and yet may advantageously also be performed at other wet phases of the tanning process, possibly also after the leather has already suffered finishing operations. The tanning process which comprises the rubberizing treatment also includes the subsequent preservation of the leather immersed in water until the beginning of the drying operations which include, preferably, a vacuum drying.