Vacuum Forming of Three-Dimensional Leather Objects
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Solution Overview
Problem
Existing manufacturing processes for three-dimensional leather objects often result in loss of softness and tactile perception, are expensive, and are limited to mass production due to the use of high-temperature forming processes that alter the mechanical, aesthetic, and organoleptic features of leather.
Innovation Solution
A process involving the application of a hardener additive on the flesh side of the leather, followed by a vacuum forming technique at a low temperature, allowing the leather to maintain its shape without compromising its elasticity and softness, and enabling the creation of complex geometries without the need for expensive molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high-temperature forming processes are used to create three-dimensional leather objects, then the leather maintains its shape permanently, but the leather loses softness and tactile perception
Solution Approach 1:
The patent changes the temperature parameter from high-temperature forming (traditional method) to low-temperature vacuum forming. This parameter change allows the leather to maintain its shape permanently while preserving its softness and tactile perception, as the low temperature avoids the harmful effects of heat on leather's sensory qualities
Solution Approach 2:
The patent replaces the thermal-mechanical forming system (heat and pressure in molds) with a vacuum-based mechanical system. By using vacuum pressure differential to form the leather at low temperature, the process achieves permanent shape retention without the harmful thermal effects that eliminate leather's softness
2Manufacturing precision
If traditional hot forming processes with molds are used, then production precision and repeatability are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive, durable metal molds with a disposable or reusable vacuum bag system. The vacuum bag is a much cheaper alternative that can be used multiple times without the high manufacturing cost of precision metal molds, thereby reducing overall manufacturing costs while still achieving acceptable precision and repeatability
Solution Approach 2:
The patent uses a supporting structure or master model that defines the desired geometry, and the vacuum forming process creates a copy of this shape in the leather. This copying approach allows for precise reproduction of complex geometries without requiring expensive custom molds for each design
3Object-affected harmful factors
If vacuum forming at low temperature is used, then leather sensory qualities are preserved, but the process must be optimized for complex geometries
Solution Approach 1:
The patent applies a hardener additive to the leather in advance before vacuum forming. This preliminary action modifies the leather's properties to enable it to hold complex three-dimensional shapes formed at low temperature, overcoming the limitation of leather's natural elasticity while preserving its sensory qualities
Solution Approach 2:
The patent introduces a hardener additive as an intermediary substance that facilitates the vacuum forming process for complex geometries. The additive temporarily modifies the leather's mechanical properties during forming, allowing it to conform to complex shapes, and then sets to provide permanent shape retention without requiring high temperature
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 allows for the efficient production of three-dimensional leather objects that maintain their original sensory qualities and can be easily applied to various structures, offering a cost-effective and versatile solution for creating complex shapes without the limitations of traditional hot forming methods.
Implementation Method 1
a vacuum sack (6) is provided, in such a way to enclose the piece of leather (1) and the supporting structure (4)
Implementation Method 2
A hardener additive (2) is applied on the flesh side (1a) of the piece of leather, in such a way to be absorbed by the leather fibers without reaching the grain side (1b) of the piece of leather
Data Source
AI summary
A manufacturing process of three-dimensional leather objects, including the following steps: applying a hardener additive on the flesh side of a piece of leather, positioning the flesh side of the piece of leather on a shape, introducing the shape with the piece of leather in a vacuum sack, applying rough vacuum in the vacuum sack, heating the vacuum sack with the shape and the piece of leather, and progressively applying vacuum during the heating step, stopping the vacuum pressure and cooling the vacuum sack with the shape and the piece of leather, opening the sack and extracting the shape with the piece of leather from the vacuum sack and removing the piece of leather from the shape in such a way that the piece of leather has the shape of a three-dimensional object.