EP4194221A1 - Méthode de reproduction en série de motifs en relief sur des matériaux laminaires flexibles - Google Patents

Méthode de reproduction en série de motifs en relief sur des matériaux laminaires flexibles Download PDF

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Publication number
EP4194221A1
EP4194221A1 EP22213163.3A EP22213163A EP4194221A1 EP 4194221 A1 EP4194221 A1 EP 4194221A1 EP 22213163 A EP22213163 A EP 22213163A EP 4194221 A1 EP4194221 A1 EP 4194221A1
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EP
European Patent Office
Prior art keywords
patterns
cast
sub
sample
plate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22213163.3A
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German (de)
English (en)
Inventor
Massimo Pajusco
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gruppo Mastrotto SpA
Original Assignee
Gruppo Mastrotto SpA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gruppo Mastrotto SpA filed Critical Gruppo Mastrotto SpA
Publication of EP4194221A1 publication Critical patent/EP4194221A1/fr
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/24—Pressing or stamping ornamental designs on surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
    • B44B5/00—Machines or apparatus for embossing decorations or marks, e.g. embossing coins
    • B44B5/02—Dies; Accessories
    • B44B5/026—Dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/02—Superimposing layers
    • B44C3/025—Superimposing layers to produce ornamental relief structures

Definitions

  • the present invention generally relates to the field of industrial printing and it particularly relates to a method for reproducing relief patterns on a visible surface of flexible laminar materials, such as natural and synthetic leather, regenerated leather, microfibres, synthetic coated and layered products.
  • Such decorative patterns may be predetermined geometric shapes and/or drawings, writings, or imitations of animal skins such as for example crocodile or snake skins.
  • the pattern may be engraved also on a press which is then brought into contact with the surface of the leather to be treated.
  • JPH07241909A discloses a method for providing a system for processing leather surfaces.
  • the method comprises scanning the surface of a leather article whose pattern is to be reproduced, so as to obtain digital data which represent the 3D surface structure.
  • the method allows to display the scanned surface on a computer so as to correct any defects and/or unevenness, such as for example scratches, bulges, etc., by modifying the data corresponding to such positions.
  • this allows to carry out corrections considering the degree of deformation due to the thermal shrinkage when transferring the pattern onto the surface made of leather.
  • the plate will have deformations, and will therefore require to create a new plate with the relative additional costs.
  • TW201125754A discloses a method for reproducing a surface pattern starting from a sample by using silicone mixtures.
  • the sample made of leather whose surface pattern is to be reproduced, is placed on a work surface and a part of the surface thereof is delimited by means of a frame.
  • a silicone mixture is poured and suitably spread, which once solidified presents a cast of the surface pattern.
  • This procedure is subsequently repeated by pouring the mixture on the cast so as to obtain a mould.
  • the latter is then covered with a silicone mixture and treated under vacuum to obtain a template which is a negative of the initial sample.
  • the negative so obtained is covered with a polyurethane mixture, polyvinyl chloride mixture, etc., so as to obtain a material similar to the leather having the same surface pattern as the sample.
  • the object of the present invention is to solve the technical problem by providing a method for making a surface pattern on flexible laminar materials that does not incur deformations with respect to the initial sample intended to be reproduced.
  • the object of the present invention is to solve the aforementioned problem by providing a method for reproducing relief patterns on a visible surface of flexible laminar materials, which method is highly effective and cost-effective.
  • a particular object of the present invention is to provide a method for reproducing relief patterns of the type described above which allows to obtain patterns in a simple and quick manner.
  • Another object of the present invention is to provide a method for reproducing relief patterns of the type described above capable of obtaining patterns, even complex ones.
  • a further object of the present invention is to provide a method for reproducing relief patterns of the type described above in which the patterns are well defined.
  • Another object of the present invention is to provide a method for reproducing relief patterns of the type described above which does not ruin the quality of the laminar material used.
  • the method provides the steps of preparing first digital data of original patterns to be printed having predetermined shape and size, three-dimensional reproduction of the original patterns on the outer surface of a first sample so as to obtain relief patterns thereon, forming a first negative three-dimensional cast of the sample made of polymeric material, anchoring the first cast to a plate made of rigid material to define a first printing plate to stabilise the first cast, and compressing the first printing plate against a visible surface of a flexible laminar material to transfer the negative patterns of the first cast thereonto to obtain a first laminar product with reproduced three-dimensional patterns.
  • the relief patterns are made on the outer surface of the first sample by means of a three-dimensional printing with UV ink to take a substantially pyramid-like final shape with deviations in shape and size with respect to the original patterns.
  • the method also provides a step of modifying the reproduced three-dimensional patterns obtained on the first product to compensate the deviations in shape and size with respect to the original patterns induced during the forming of the first cast and during the compression step.
  • the step for modifying the patterns comprises a sub-step of detecting the shape and size of the reproduced three-dimensional patterns on the first laminar product to detect the deviations and then a further sub-step of modifying the first digital data to eliminate the deviations and obtain second digital data.
  • the modification of the first digital data provides for a computer program dedicated to automatically modify vector files.
  • these second digital data are used to obtain a second sample, a second cast, and a second printing plate to obtain a second modified laminar product.
  • this sampling cycle may be repeated up to obtaining a final laminar product with modified patterns the closest possible to the original ones.
  • the method comprises that the printing plate is subjected to the sub-steps of heating to a first predetermined forming temperature maintaining the cast facing upwards, spraying a water or solvent-based polyurethane mixture, possible repetition of the latter two steps and cooling the plate to a second predetermined temperature lower than the first temperature.
  • a section made of flexible laminar material is subsequently deposited on the cast by interposing an adhesive in liquid state, mechanically compressing the flexible laminar material against the plate so as to transfer the patterns to be reproduced onto the section, fully evaporating the adhesive and detaching from the plate the section made of flexible laminar material with the reproduced patterns on the surface facing the cast to obtain a printed laminar product.
  • FIG. 1 With particular reference to FIG. 1 , there is shown a method for the serial reproduction of relief patterns on flexible laminar materials P such as natural and synthetic leather, regenerated leather, microfibres, coated and layered products.
  • flexible laminar materials P such as natural and synthetic leather, regenerated leather, microfibres, coated and layered products.
  • the method provides the steps of a) providing first digital data 3 of original patterns N to be printed having predetermined size and shape and b) three-dimensional reproduction of these original patterns N on the outer surface S 1 of a first sample 1 so as to obtain relief patterns M.
  • the sample 1 consists of a flexible base material 2 selected from the group comprising natural leather, regenerated leather, coated polyurethane product and the like, on which the original patterns N are reproduced by means of a three-dimensional printing.
  • the original patterns N to be reproduced on the outer surface S 1 of the sample 1 consist of vector files obtained using algorithms and mathematical equations defining first digital data 3 .
  • the first digital data 3 are uploaded on a storage unit of a microprocessor device connected to a three-dimensional printing equipment of the plotter type or 3D printer, not shown in the figures.
  • Such three-dimensional printing equipment allow to obtain relief patterns M which may be formed by one or more images, writings, symbols, etc., even with considerable geometric complexity.
  • the printing is carried out by depositing UV ink on the flexible base material 2 .
  • the three-dimensional printing equipment connected to the microprocessor device, may consist of a compartment inside which there is a first track on which there is mounted a first movable carriage with the printer heads and some UV lamps. Possibly, the lamps may be mounted on a second carriage slidable on a second track arranged adjacent to the first track.
  • the flexible base material 2 on which the patterns are to be printed.
  • the flexible material 2 may be placed on a fixed surface while only the carriage with the printer heads and the UV lamps moves.
  • the belt or the fixed surface on which the base material 2 is placed has a plurality of holes for applying vacuum so as to stably hold the base material 2 when carrying out the 3D printing.
  • the printing equipment receives the first digital data 3 and it starts the printing by advancing the base material 2 in a horizontal direction through the belt, while the first carriage, moving transversely along the first track, deposits the ink on the surface S 1 of the base material 2 .
  • the second carriage is moved so as to irradiate the base material 2 and fix the ink onto the surface S 1 thereof due to the polymerisation induced by the UV lamps.
  • the base material 2 continues to advance and the deposition of the ink, followed by the polymerisation, continues until the relief pattern M is made, therefore obtaining the first sample 1.
  • a substantially square-shaped sample 1 preferably measuring between 50x50 cm and 170x170 cm in size or even larger.
  • the printed patterns are designed to obtain an aesthetic effect, they are made with a thin thickness, so as to be a surface pleasant to touch and sight, while at the same time limiting wastage of UV ink.
  • the relief patterns M are made on the outer surface S 1 of the first sample 1 with a maximum thickness of 200 ⁇ m.
  • the first sample 1 is subjected to a sub-step b 1 ) of anchoring it to a flat support plain 4 made of substantially rigid material, such as for example a panel made of wood, and a sub-step b 2 ) of delimiting the peripheral edge of the sample 1 with a frame 5 for forming a confinement compartment 6 above it.
  • a sub-step b 1 of anchoring it to a flat support plain 4 made of substantially rigid material, such as for example a panel made of wood
  • a sub-step b 2 of delimiting the peripheral edge of the sample 1 with a frame 5 for forming a confinement compartment 6 above it.
  • the first sample 1 anchored to the rigid support 4 is placed on a work plane with the relief pattern M printed facing upwards.
  • the edges of the sample 1 are delimited with a frame 5, preferably made of aluminium, which has a greater thickness than that of the sample 1 , so as to create a confinement compartment 6 above the surface of the sample 1 , as shown in FIG. 3 .
  • the method provides a step c) of forming a first negative three-dimensional cast 7 of the sample 1 made of polymeric material.
  • this first cast 7 initially is carried out a sub-step c 1 ) of pouring a polymeric resin mixture 8 in liquid state into the confinement compartment 6 , a sub-step c 2 ) of levelling the polymeric resin mixture 8 by means of a blade 9 or the like, shown in FIG. 4 , so as to complementarily cover the confinement compartment 6, and lastly a sub-step c 3 ) in which is carried out the cross-linking and detachment of the first cast 7 from the compartment 6, shown schematically in FIGS. 5 and 6 .
  • step c 3 the resin mixture 8 is therefore left to stand in the confinement compartment 6 under standard conditions for about 24 hours so as to allow the full cross-linking of the polymers to form a first silicone cast 7 which represents the negative of the relief patterns M present on the surface S 1 of the first sample 1.
  • the cross-linking step c 3 ) may be quickened maintaining the first cast 7 at a temperature higher than the environmental one for a predetermined time.
  • the polymeric resin mixture 8 is prepared separately and comprises at least two silicone compounds.
  • the method continues with a step d) of anchoring the first cast 7 to a plate 10 made of rigid material to define a first printing plate 11 to stabilise the first cast 7.
  • the cast 7 is flexible, it is coupled with the rigid plate 10 keeping the negative patterns O facing upwards, so as to form a first printing plate 11 with sufficient structural stability so that it can be used in the subsequent steps of the method.
  • the step d) of anchoring the first cast 7 to the plate 10 is carried out by interposition of a cloth.
  • the plate 10 made of metal material is made of aluminium, with plan dimensions at least equal to those of the silicone cast 7 , and a thickness measuring a few tenths of millimetres.
  • the first printing plate 11 obtained by the coupling between the first cast 7 and the metal plate 10 is subjected to a refining process.
  • this step there is provided a sub-step d 1 ) of heating the first plate 11 to a first predetermined forming temperature keeping the first cast 7 facing upwards.
  • such first heating temperature is proximate to 100°C.
  • a water or solvent-based polyurethane mixture is sprayed on the first plate 11 in a spraying sub-step d 2 ) .
  • a sub-step d 3 in which the optional repetition of the previous steps d 1 ) and d 2 ) is carried out, so as to spray a predetermined amount of polyurethane mixture, and subsequently cool the first plate 11 to a second predetermined temperature lower than the first temperature.
  • This second temperature is about 25°C and it is suitable to cool the first plate 11 .
  • the first printing plate 11 is suitable to be used in the last steps of the method in which the patterns are reproduced on a visible surface S 2 made of flexible laminar material P .
  • a sub-step d 4 of depositing a flexible laminar material P on the first cast 7 by interposing an adhesive 12 in liquid state.
  • the adhesive 12 in liquid state may be prepared on the cast 7 or on the laminar material P , and it may be possibly pre-dried to improve the adhesion.
  • the layer formed by the adhesive 12 and by the polyurethane mixture will therefore take the shape of the cast 7 and of its negative patterns O.
  • the flexible laminar material P deposited on the first cast 7 in the sub-step d 4 ) is a section T made of flexible laminar material P.
  • a step e) of compressing the first printing plate 11 against an exposed surface S2 of the flexible laminar material P is carried out to transfer the negative patterns O of the first cast 7 thereon, to obtain a first laminar product 13 with reproduced three-dimensional patterns Q.
  • this compression step e) provides a sub-step e 1 ) of mechanically compressing the section T made of flexible laminar material P against the first plate 11 so as to impress and transfer the negative patterns O on the latter, and a sub-step e 2 ) of fully evaporating the adhesive 12 and detaching the first plate 11 from the section T made of flexible material P with the reproduced relief patterns Q on the visible surface S 2 facing the first cast 7 to obtain the first laminar product 13 as shown in FIG . 12 .
  • the layer formed by the adhesive 12 and by the polyurethane mixture is adhered to the surface S 2 of the section T made of flexible material P by fixing the reproduced patterns Q thereonto.
  • the reproduced three-dimensional patterns Q solidified and fixed to the surface S 2 of the section T are obtained by the layer comprising the adhesive 12 and the polyurethane mixture.
  • the mechanical compression sub-step e 1 ) may be obtained by calandering and/or pressing using a substantially flat press subsequently to the sub-step d 4 ) of depositing the adhesive 12 .
  • the cast 7 and the flexible laminar material P are firstly calendered using a cylinder 14 , or preferably a pair of opposite cylinders, afterward they are pressed by a substantially flat press and subsequently treated in a furnace at about 100°C to promote the full evaporation of the water or solvent-based adhesive 12 .
  • the laminar material P is detached from the first cast 7 and filed, eliminating any surplus adhesive 12 , and then refined using techniques known in the industry.
  • the three-dimensional printing induces deformations in a pattern, generally due to the fact that during the fixing the UV ink takes a pyramid-like shape which therefore causes a narrowing of the profile of the printed pattern with respect to the dimensions contained in the data received by the printer.
  • the relief patterns M made on the outer surface S 1 of the first sample 1 by means of a three-dimensional printing using UV ink take a substantially pyramid-like final shape with different deviations ⁇ in shape and size with respect to the original patterns N .
  • the negative patterns O may no longer reflect the original patterns N .
  • the negative patterns O will be transferred onto the flexible laminar material P by mechanical compression, which will induce further substantial deformations.
  • the reproduced three-dimensional patterns Q on the laminar material P could substantially differ from the original patterns N , therefore leading to obtaining a product that does not correspond to customer's request.
  • this modification step f) provides a sub-step f 1 ) of detecting the shape and size of the reproduced patterns Q on the first laminar product 13 to detect the deviations ⁇ as shown in FIG. 14 .
  • Such step f 1 ) of detecting the shape and size of the patterns Q on the first laminar product 13 to compare them with the original patterns N can be carried out by an operator or using optical means.
  • the first digital data 3 are modified to eliminate the detected deviations ⁇ so as to obtain second digital data 16 to be used to obtain a second sample 1' , 1" ,..., a second cast 7' , 7" ,..., a second printing plate 11' , 11" ,..., and subsequently to obtain a second modified laminar product 13' , 13" , ... .
  • the dimensional values of the patterns N to be printed can be modified without losing in terms of definition.
  • the vector files consist of unitary elements each positioned in a virtual space in predetermined coordinates so as to form the image of the requested pattern N .
  • modifying the coordinates of the single elements and/or adding new ones allows to modify the pattern N therefore obtaining the second data 16 .
  • the step f) of modifying the first digital data 3 provides a dedicated processing programme for automatically modifying the vector files.
  • the second sample 1' , 1" , ... , the second cast 7' , 7" , ... , the second printing plate 11' , 11" , ... , and the second modified laminar product 13' , 13" , ... are obtained through the steps b)-e) of the method, as described above.
  • the second sample 1' , 1" , ... is obtained following the procedure of step b) , the second cast 7' , 7" , ... , according to step c), the second printing plate 11' , 11" , ... , according to step d) and the second laminar product 13' , 13" , ... , according to step e) .
  • the second laminar product 13' , 13" , ... will have modified patterns V with respect to the first printed laminar product 13.
  • a possible sub-step f 3 ) of repeating this sampling cycle that is steps b)-e) or b)-f) , will be carried out up to obtaining a final laminar product 17 with the patterns V the closest possible to the original ones N requested by a customer.
  • the method allows to achieve a final laminar product 17 quickly, therefore reducing the cost and production times thereof.
  • the final laminar product 17 with the relief patterns V will therefore be used to obtain a leather article which can be used in the footwear, automotive, clothing, furnishing industries and the like.
  • the method for reproducing relief patterns on a visible surface of flexible laminar materials such as natural and synthetic leather, regenerated leather, microfibres, synthetic coated and layered products according to the invention achieves the pre-established objects and in particular it allows to reproduce, on the surface of a flexible laminar material, even complex relief patterns in a quick and cost-effective manner without deformations with respect to the original project requested by a customer.
  • This method allows to avoid having to use the 3D printing for all the products (a technique that would generally require 2 hours to obtain patterns on 1 m 2 ), starting from a single initial sample there can be obtained a plurality of products in a short time (250 m 2 per hour of treated flexible laminar material).
  • the present invention can be applied at industrial level given that it can be manufactured on industrial scale by industries belonging to any from the leather tanning, footwear, automotive, furnishing and clothing industries.

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  • Printing Methods (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
  • Laminated Bodies (AREA)
EP22213163.3A 2021-12-13 2022-12-13 Méthode de reproduction en série de motifs en relief sur des matériaux laminaires flexibles Pending EP4194221A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IT102021000031211A IT202100031211A1 (it) 2021-12-13 2021-12-13 Metodo per la riproduzione seriale di disegni in rilievo su materiali laminari flessibili

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EP4194221A1 true EP4194221A1 (fr) 2023-06-14

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH07241909A (ja) * 1994-03-07 1995-09-19 Dainippon Printing Co Ltd 合成皮革原版作製システム及び合成皮革原版作製方法
WO2008047127A1 (fr) * 2006-10-18 2008-04-24 Flotek International Limited Procédé de gaufrage d'un substrat
US20110159243A1 (en) * 2009-12-24 2011-06-30 Lg Innotek Co., Ltd. Decorating material with cubic effect
TW201125754A (en) 2010-01-20 2011-08-01 Shou-Bin Chen Leather texture mold plate and method thereof for forming leather texture on imitation leather
EP3539792A1 (fr) * 2018-03-15 2019-09-18 SWISS KRONO Tec AG Procédé de fabrication de structures sur un substrat

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH07241909A (ja) * 1994-03-07 1995-09-19 Dainippon Printing Co Ltd 合成皮革原版作製システム及び合成皮革原版作製方法
WO2008047127A1 (fr) * 2006-10-18 2008-04-24 Flotek International Limited Procédé de gaufrage d'un substrat
US20110159243A1 (en) * 2009-12-24 2011-06-30 Lg Innotek Co., Ltd. Decorating material with cubic effect
TW201125754A (en) 2010-01-20 2011-08-01 Shou-Bin Chen Leather texture mold plate and method thereof for forming leather texture on imitation leather
EP3539792A1 (fr) * 2018-03-15 2019-09-18 SWISS KRONO Tec AG Procédé de fabrication de structures sur un substrat

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IT202100031211A1 (it) 2023-06-13

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