Split Leather Reinforcement via Pre-Splitting Adhesive Layer
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Solution Overview
Problem
Existing methods for producing split leather from animal skins are limited in achieving thin, lightweight layers with sufficient mechanical strength, particularly on the flesh side, which has low internal cohesion and density, making it difficult to split thinly and efficiently.
Innovation Solution
Applying a strengthening layer, comprising a binder and/or textile/fleece layer, to both the grain and flesh sides of the animal hide before splitting, providing additional mechanical strength and allowing for thinner layers to be split off, which are then tanned and further processed for enhanced mechanical properties and surface uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the flesh side of the animal skin is split thinly without reinforcement, then the leather becomes lighter and thinner, but the mechanical strength and internal cohesion deteriorate
Solution Approach 1:
A strengthening layer is applied to the flesh side of the animal skin before the splitting process. This preliminary reinforcement enables the flesh side to be split into thinner layers without compromising mechanical strength, as the strengthening layer provides the necessary structural support during and after splitting
Solution Approach 2:
The flesh side leather is combined with a strengthening layer (comprising binder and textile/fleece material) to create a composite structure. This composite material achieves both thinness and high mechanical strength, as the strengthening layer compensates for the low internal cohesion of thin flesh side leather
2Productivity
If multiple layers are split from the animal hide, then the quantity of leather products increases, but the thickness of each layer decreases leading to reduced mechanical strength
Solution Approach 1:
The strengthening layer is applied to the animal skin before splitting into multiple layers. This allows each subsequent layer, especially thinner ones, to maintain adequate mechanical strength despite reduced thickness, enabling higher productivity through increased number of usable layers per hide
Solution Approach 2:
The strengthening layer is selectively applied to specific areas or sides of the animal skin where thin layers will be produced. This local reinforcement ensures that areas requiring thin layers (flesh side, central gap) gain the necessary strength, while allowing optimal utilization of the entire hide for multiple layers
3Ease of manufacture
If the flesh side is split without strengthening layer, then the processing is simpler and faster, but the splitting precision and layer uniformity deteriorate
Solution Approach 1:
The strengthening layer is applied in advance to the flesh side and central gap areas before splitting. This preliminary step, while adding a processing stage, actually simplifies the splitting operation itself by providing a uniform base that splits more evenly and predictably, improving manufacturing precision without significantly increasing overall complexity
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 production of extremely thin, robust, and lightweight leather layers with improved mechanical strength and surface quality, suitable for various applications, including aircraft seats and electronics, by enhancing the splitting process and final leather product properties.
Implementation Method 1
Application of a strengthening layer (7) on the grain side (2) and/or on the flesh side (3) which gives the animal skin (1) additional mechanical strength when it is split off
Data Source
Figure 1~3
AI summary
The method involves providing animal skin (1). The animal skin is split into a grain split (4) and a flesh split (6). The split grain split and the flesh split are tanned. A solidification layer (7) is applied to a grain side (2) and onto a flesh side (3). An additional mechanical strength is given to the animal skin by the solidification layer during splitting. A textile or non-woven layer is made from the fibers, such as fabrics, knitted fabrics, synthetic fibers, particularly nylon or polyester, natural fibers, particularly cotton or wool, carbon fiber, particularly aramid fiber. An independent claim is included for a leather intermediate product during a process for manufacturing leather.