WO2011024053A2 - Mold for leathers hot forming and corresponding use and manufacturing processes - Google Patents

Mold for leathers hot forming and corresponding use and manufacturing processes Download PDF

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Publication number
WO2011024053A2
WO2011024053A2 PCT/IB2010/002076 IB2010002076W WO2011024053A2 WO 2011024053 A2 WO2011024053 A2 WO 2011024053A2 IB 2010002076 W IB2010002076 W IB 2010002076W WO 2011024053 A2 WO2011024053 A2 WO 2011024053A2
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WO
WIPO (PCT)
Prior art keywords
thermosetting resin
leather
slab
piece
mold
Prior art date
Application number
PCT/IB2010/002076
Other languages
French (fr)
Other versions
WO2011024053A3 (en
Inventor
Luigino De Lazzari
Original Assignee
Cielle S.R.L.
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 Cielle S.R.L. filed Critical Cielle S.R.L.
Publication of WO2011024053A2 publication Critical patent/WO2011024053A2/en
Publication of WO2011024053A3 publication Critical patent/WO2011024053A3/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C14—SKINS; HIDES; PELTS; LEATHER
    • C14B—MECHANICAL TREATMENT OR PROCESSING OF SKINS, HIDES OR LEATHER IN GENERAL; PELT-SHEARING MACHINES; INTESTINE-SPLITTING MACHINES
    • C14B1/00—Manufacture of leather; Machines or devices therefor
    • C14B1/44—Mechanical treatment of leather surfaces
    • C14B1/56—Ornamenting, producing designs, embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/42—Moulds or cores; Details thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
    • B29C33/424—Moulding surfaces provided with means for marking or patterning

Definitions

  • the present invention relates to a mold for the hot forming of leathers and to the corresponding use and manufacturing processes.
  • the present invention relates to a mold for the hot forming of tanned leather, to the corresponding manufacturing process, and to a method for forming a piece of tanned leather; use to which the following description refers purely by way of example without implying any loss of generality.
  • embossed inscriptions and/or decorative patterns can be directly realized on a tanned leather by means of a hot forming process which envisages to press with force, and for a few seconds, a mold made of metal material onto the piece of tanned leather with the aid of a hydraulic or power press, while, at the same time, bringing the mold to a temperature ranging between 70 0 C and 200 0 C.
  • the combined action of temperature and pressure causes a permanent plastic deformation of the surface of the tanned piece of leather.
  • the temperature of the mold and the time in which the mold remains in contact with the tanned piece of leather varies according to the type and thickness of tanned leather to be formed.
  • the mold intended to come into contact with the piece of tanned leather currently consists of a flat plate made of aluminum or aluminum alloy (e.g. Ergal) , usually from 5 to 30 millimeters thick, which has on the front face , i.e. on the face intended to come into contact with the tanned leather, a surface impression which traces out the inverse shape of the embossed inscription or decorative pattern to be made by plastic deformation on the surface of the piece of leather.
  • aluminum or aluminum alloy e.g. Ergal
  • the impression is normally made by material removal using a numerical control milling machine which carves the front face of the metal plate so as to point by point remove the material in excess with respect to the desired profile.
  • the time needed to shape the front face of the metal plate depends on the complexity of the decorative pattern and rapidly increases along with the extension of the impression on the front face of the plate, even greatly exceeding 500 hours of work on the numerical control machine when the surface impression has an extension of approximately 1,5 square meters. Extension that is normally reached by molds which are mounted on the common commercialized presses.
  • the mold production costs are closely related to the time employed by the numerical control machine to realize the impression on the front face of the plate, and can reach values so high to make the adoption of a determined embossed decorative pattern economically unfeasible.
  • Aim of the present invention is thus to realize a mold for the hot forming of tanned leather, which is very quick, and thus more cost-effective, to make with respect to the current molds made of metal .
  • a manufacturing process of a leather hot-forming mold wherein the mold comprises a hard and rigid material body which is provided with a front face intended to come into contact with the piece of leather to be formed, and wherein said front face is provided with, a surface impression whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be made on the piece of leather; the manufacturing process being characterized by comprising the step of engraving, by means of a laser beam, the surface impression directly on the surface of a thermosetting resin slab of predetermined thickness; the hard and rigid material body consisting of said thermosetting resin slab.
  • the manufacturing process of a mold for leather hot forming is moreover characterized in that the thermosetting resin slab is an epoxy- and/or phenolic- based thermosetting resin slab.
  • thermosetting resin slab is a thermosetting resin slab which includes inert powders and/or additives and/or sheet-like reinforcement materials .
  • the manufacturing process of a mold for leather hot forming is moreover characterized in that the thermosetting resin slab is formed by a stack of Kraft paper sheets soaked in an epoxy- and/or phenolic- resin matrix.
  • the manufacturing process of a mold for leather hot forming is moreover characterized in that the thermosetting resin slab is made of one or more superimposed layers of glass fibers and/or carbon fibers and/or aramidic fibers and/or cotton fibers and/or flax fibers and/or hemp fibers and/or fibers of another organic or inorganic material, conveniently superimposed and/or interwoven with one another and soaked in a matrix of epoxy and/or phenolic thermosetting resin.
  • a method for forming a piece of leather characterized by comprising:
  • thermosetting resin slab of predetermined thickness by means of a laser beam, a front face of a thermosetting resin slab of predetermined thickness, so as to form on surface of said slab a surface impression whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be realized on the piece of leather;
  • thermosetting resin slab on a press, so that the surface impression realized on the front face of the thermosetting resin slab directly faces the surface of the piece of leather to be processed;
  • thermosetting resin slab - bringing and/or maintaining the thermosetting resin slab to/at a temperature higher than 60 0 C;
  • thermosetting resin slab against the piece of leather, so as to produce on the surface of the piece of leather, via a permanent plastic deformation of the surface of the piece of leather, reliefs which trace out the shape of the surface impression on the front face of the thermosetting resin slab.
  • the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is a slab of epoxy- and/or phenolic- based thermosetting resin.
  • the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is a thermosetting resin slab which includes inert powders and/or additives and/or sheet-like reinforcement materials.
  • the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is formed by a stack of Kraft paper sheets soaked in an epoxy- and/or phenolic- resin matrix.
  • the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is made up of one or more superimposed layers of glass fibers and/or carbon fibers and/or aramidic fibers and/or cotton fibers and/or flax fibers and/or hemp fibers and/or fibers of another organic or inorganic material, conveniently superimposed and/or interwoven with one another and soaked in a matrix of epoxy and/or phenolic thermosetting resin.
  • the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is from 2 to 30 millimeters thick.
  • the method for forming a piece of leather is moreover characterized in that, during the pressing of the thermosetting resin slab on the piece of leather, said thermosetting resin slab is maintained at a temperature comprised between 7O 0 C and 150 0 C.
  • the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is a flat or tubular cylindrical shaped slab.
  • the method for forming a piece of leather is moreover characterized in that the step of fixing the thermosetting resin slab onto the press comprises the step of arranging/ placing the thermosetting resin slab on the flat surface of a mold-holder platform; and the step of sucking the air from the gap which is formed between the rear face of the thermosetting resin slab and the flat surface of said mold-holder platform.
  • a mold for the hot forming of leather comprising a hard and rigid material body, which is provided with a front face intended to come into contact with the piece of leather to be formed, and wherein said front face is provided with a surface impression whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be made on the piece of leather;
  • the mold being characterized in that the hard and rigid material body consists of thermosetting resin slab of given thickness, and in that the surface impression is directly realized on surface of the thermosetting resin slab by means of a laser-beam engraving .
  • the mold for leather hot forming is moreover characterized in that the thermosetting material slab is a slab of epoxy- and/or phenolic- based thermosetting resin.
  • the mold for leather hot forming is moreover characterized in that the thermosetting resin slab is a slab of thermosetting resin which includes inert powders and/or additives and/or sheet-like reinforcement materials.
  • the mold for leather hot forming is moreover characterized in that the thermosetting resin slab is formed by a stack of Kraft paper sheets soaked in an epoxy and/or phenolic resin matrix.
  • the mold for leather hot forming is moreover characterized in that the thermosetting resin slab is made of one or more superimposed layers of glass fibers and/or carbon fibers and/or aramidic fibers and/or cotton fibers and/or flax fibers and/or hemp fibers and/or fibers of another organic or inorganic material, conveniently superimposed and/or interwoven with one another and soaked in a matrix of epoxy and/or phenolic thermosetting resin.
  • the mold for leather hot forming is moreover characterized in that the hard and rigid material body is a flat sheet.
  • the mold for leather hot forming is moreover characterized in that the hard, rigid material body is a cylindrical tubular jacket.
  • FIG. 1 is an axonometric view of a mold for leather forming realized in accordance with the teachings of the present invention
  • FIG. 2 schematically shows a step of the manufacturing process of the Figure 1 mold
  • FIG. 3 shows an axonometric view of a variation of the Figure 1 mold for leather forming
  • Figure 4 schematically shows, with parts in section and parts removed for clarity, a mold-holder platform which allows to fix the Figure 1 mold to a press for leather hot forming.
  • number 1 indicates as a whole a mold for the hot forming of leather which is particularly suitable to hot form embossed inscriptions and/or decorative patterns on tanned leathers.
  • Mold 1 is basically formed by a preferably, though not necessarily, rectangular- or square- shaped flat plate 2 which is made of a hard and rigid material, and is provided with a front face 2a intended to come into contact with the piece of tanned leather to be formed, and with a rear face 2b intended to be stably fixed to, or anyway arranged, to rest upon, a known-type hydraulic and/or power press for the hot forming of leather (not shown) .
  • Front face 2a of flat plate 2 is further centrally provided with a surface impression 3 whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be realized on the piece of tanned leather.
  • the surface impression 3 takes up an extension area smaller than the entire surface of the plate front face 2a, but could also extend to affect the entire surface of front face 2a.
  • front plate 2 consists of a monolithic slab 2 of epoxy- and/or phenolic- based thermosetting resin, which may possibly include inert powders and/or additives and/or sheet-like reinforcement materials such as, for example, fabrics or sheets of paper, and surface impression 3 is realized on surface of slab 2 via laser engraving.
  • the thermosetting resin slab 2 has a thickness ranging between 2 and 30 millimeters, according to the type of tanned leather to be formed.
  • thermosetting resin slab 2 is preferably, though not necessarily, made of a stack of Kraft paper sheets soaked in an epoxy and/or phenolic resin matrix, so as to form, after polymerization of the resin, a very rigid and hard flat plate 2 having a nominal thickness preferably, though not necessarily, ranging between 4 and 10 millimeters.
  • thermosetting resin slab 2 may consist of one or more superimposed layers of glass fibers and/or carbon fibers and/or aramidic fibers and/or cotton fibers and/or flax fibers and/or hemp fibers and/or fibers of another organic or inorganic material, conveniently superimposed and/or interwoven with one another and soaked in a matrix of epoxy and/or phenolic thermosetting resin, so as to form, after polymerization of the resin, a very rigid and hard flat plate 2 having a nominal thickness preferably, though not necessarily, ranging between 4 and 10 millimeters.
  • Mold 1 is realized starting from a thermosetting resin slab 2 of appropriate size, and directly engraving the surface impression 3 onto one of the two faces of the thermosetting resin slab 2 by means of a laser beam which causes the localized ablation/vaporization/ disintegration of the material forming the surface of the slab 2, up to obtain the desired profile.
  • mold 1 can be realized by means of a common numerical control laser-engraving machine 11, which preferably, though not necessarily, comprises:
  • thermosetting resin slab 2 on which the thermosetting resin slab 2 is adapted to be positioned with the front face 2a facing upwards;
  • an engraving head 13 which is mobile over the work top 12 along two directrixes orthogonal to each another and parallel to the work top 12, and which is able to generate and direct towards the underneath work top 12 a laser beam L which, in turn, is able to engrave thermosetting resin slab 2 causing the localized vaporization of the material forming the surface of the latter ;
  • control unit (not shown) which is able to move the cutting head 13 over the work top 12, and adjust the intensity and focus of the laser beam L generated by the cutting head 13, so to engrave the desired surface impression 3 on the front face 2a of the thermosetting resin slab 2 in a completely automatic manner.
  • the laser engraving machine 11 is an apparatus already known in other technical fields and therefore won't be further described.
  • the hot pressing of a piece of tanned leather envisages to place mold 1 in abutment against the surface of the piece of tanned leather to be formed, with the possible interposition of a protective film or fabric, so that the surface impression 3 on the front face 2a of the thermosetting resin slab 2 directly faces the surface of the piece of tanned leather,- and then to press, for a predetermined period of time, mold 1 against the piece of tanned leather with the aid of a power and/or hydraulic press for the leather hot forming, so as to produce on the surface of the piece of tanned leather, via a permanent plastic deformation of the surface of the piece of tanned leather, a number of surface reliefs which trace out the shape of the surface impression 3 on the front face 2a of the thermosetting resin slab 2.
  • the hot forming process further envisage to bring and/or maintain the thermosetting resin slab 2 to/at a temperature higher than 60 0 C and preferably, though not necessarily, ranging between 70 0 C and 150 0 C.
  • the hot forming of the piece of tanned leather comprises the steps of:
  • thermosetting resin slab 2 of given thickness, so as to form, on surface of said slab 2, a surface impression 3 whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be realized on the piece of leather;
  • thermosetting resin slab 2 on a press for leather hot forming, so that the surface impression 3 realized on the front face 2a of the thermosetting resin slab 2 directly faces the surface of the piece of leather to be processed; - bringing and/or maintaining the thermosetting resin slab 2 to/at a temperature higher than 60 0 C;
  • thermosetting resin slab 2 pressing the thermosetting resin slab 2 against the piece of leather, so as to produce on surface of the piece of leather, via permanent plastic deformation of the surface of the piece of leather, reliefs which trace out the shape of the surface impression 3 on the front face 2a of the thermosetting resin slab 2.
  • thermosetting resin slab 2 may be stably fixed onto the metal-material mold-holder platform made of the press for leather hot forming by means of mechanical- type anchoring members, such as through screws and/or clamps,- or, more conveniently, it may be stably fixed onto the mold-holder platform pneumatically by means of a suction system which is structured to continuously such air from the gap which is formed between the rear face 2b of the thermosetting resin slab 2, and the surface of the mold-holder platform of the press.
  • the suction system can withhold the thermosetting resin slab 2 in abutment against the mold- holder platform of the press, by maintaining the rear face 2b of the thermosetting resin slab 2 under vacuum
  • the mold-holder platform 20 of the press on which the rear face 2b of the thermosetting resin slab 2 is intended to rest is made of a high-strength metal material and is provided with a flat surface 20a, which has a number of shallow-depth surface grooves 21 which are conveniently distributed along the entire portion of the flat surface 20a intended to be covered by the rear face 2b of the thermosetting resin slab 2.
  • surface groves 21 have preferably, though not necessarily, a substantially V or U shaped profile, and are preferably, though not necessarily, distributed according to two directrixes orthogonal to one another, so as to reciprocally cross and form a regular mesh which extends substantially underneath the entire surface of the rear face 2b of the thermosetting resin slab 2.
  • the mold-holder platform 20 of the press is further provided with at least one peripheral annular groove 22 which extends on the flat surface 20a so as to trace out the shape of the perimeter of the rear face 2b of the thermosetting resin slab 2, which completely surrounds the surface grooves 21 as a whole, and finally which stably accommodates an annular sealing gasket 23 which, in turn, is made of an elastically deformable material and is adapted to be arranged in abutment against the rear face 2b of the thermosetting resin slab 2, so as to close substantially airtight manner the perimeter of the rear face 2b of the thermosetting resin slab 2, forming a closed gap.
  • mold-holder platform 20 finally comprises a number of inner connecting ducts 24 which extend within the body of the mold-holder platform 20, so as to connect the surface grooves 21 to an outer air suction circuit 25, which, in turn, communicates with an electrically-operated vacuum pump 26 or the like.
  • mold-holder platform 20 may either be an integral part of the leather hot-forming press or may be a separate element which is structured so to be, in turn fixed, in rigid and stable, thought easily releasable manner, to the press for leather hot forming.
  • the anchoring of the mold 1 to the mold-holder platform 20 envisages to activate the vacuum pump 26, either before or after having positioned/rested the thermosetting resin slab 2 on the flat surface 20a of the mold-holder platform 20, exactly over the annular seal 23.
  • the pressure difference that the vacuum pump 26 produces and then maintains between the front face 2a and the rear face 2b of thermosetting resin slab 2 forces the thermosetting resin slab 2 to rest the rear face 2b on the flat surface 20a of the mold-holder platform 20 after compressing the annular seal 23.
  • the step of fixing the thermosetting resin slab 2 onto the press for leather hot forming comprises the step of positioning/resetting the thermosetting resin slab 2 on the flat surface 20a of the mold-holder platform 20; and then the step of sucking the air from the gap which is formed between the rear face 2b of the thermosetting resin slab 2, and the flat surface 20a of the mold-holder platform 20.
  • the shallow depth and the appropriate spacing of the surface grooves 21 on the flat surface 20a of the mold-holder platform 20 allow the rear face 2b of the thermosetting resin slab 2 to rest on the body of the mold-holder platform 20 in uniform manner thus avoiding localized deformations of slab 2 which could compromise the hot-forming quality.
  • the time needed to engrave by means of the laser the surface impression 3 on the front face 2a of the thermosetting resin slab 2 is much shorter than the time needed to carve the surface impression on the front face of a sheet of aluminum or aluminum alloy, therefore the production costs of the mold 2 are much lower than those of a metal mold of identical shape.
  • mold 1 has moreover a weight for surface unit which is significantly lower than that of a metal mold, with all the advantages that this implies when mold 1 must be positioned/installed on the press.
  • mold 1 consists of a cylindrical tubular jacket 4 made of a hard and rigid material, which is adapted to be fitted on a cylindrical supporting drum 5, so that the outer peripheral surface 4a of the cylindrical tubular jacket 4 can roll on a generic piece of leather to be formed.
  • the outer peripheral surface 4a of the jacket is centrally provided with a surface impression 3 — in this case preferably, though not necessarily, annular — whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be made on the piece of leather.
  • the cylindrical tubular jacket 4 consists of a monolithic slab 4 of epoxy- and/or phenolic- based thermosetting resin, which may possibly include inert powders and/or additives and/or sheet-like reinforcement materials such as, for example, fabrics or sheets of paper, and the surface impression 3 is realized on the surface of the slab 4 by means of a laser-beam engraving.
  • the thermosetting resin slab 4 has a thickness preferably, though not necessarily, ranging between 2 and 30 millimeters, according to the type of tanned leather to be formed.
  • the hot pressing of a piece of leather envisages to place the mold 1 in abutment against the surface of the piece of leather to be formed, so that the surface impression 3 on the outer peripheral surface 4a of the thermosetting resin slab 4 directly faces the surface of the piece of leather; and then to roll the mold on the surface of the piece of leather while, at the same time, pressing mold 1 with force against the piece of leather.
  • thermosetting resin slab 4 is brought and/or maintained to/at a temperature higher than 6O 0 C and preferably, though not necessarily, ranging between 70 0 C and 150 0 C.

Abstract

Mold (1) for the hot forming of leather consisting of a hard and rigid material body, in form of flat sheet (2) or cylindrical tubular jacket (4), which is provided with a front face (2a, 4a) intended to come into contact with the piece of leather to be formed, and wherein said front face (2a, 4a) is provided with a surface impression (3) whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be made on the piece of leather; the hard and rigid material body (2, 4) consisting of a thermosetting resin slab (2, 4) of predetermined thickness, in which the surface impression (3) is obtained on the surface (2a, 4a) of the thermosetting resin slab (2, 4) by laser-beam engraving.

Description

MOLD FOR LEATHERS HOT FORMING AND CORRESPONDING USE AND MANUFACTURING PROCESSES
TECHNICAL FIELD
The present invention relates to a mold for the hot forming of leathers and to the corresponding use and manufacturing processes.
More specifically, the present invention relates to a mold for the hot forming of tanned leather, to the corresponding manufacturing process, and to a method for forming a piece of tanned leather; use to which the following description refers purely by way of example without implying any loss of generality.
BACKGROUND ART
As is known, embossed inscriptions and/or decorative patterns can be directly realized on a tanned leather by means of a hot forming process which envisages to press with force, and for a few seconds, a mold made of metal material onto the piece of tanned leather with the aid of a hydraulic or power press, while, at the same time, bringing the mold to a temperature ranging between 700C and 2000C. The combined action of temperature and pressure causes a permanent plastic deformation of the surface of the tanned piece of leather.
The temperature of the mold and the time in which the mold remains in contact with the tanned piece of leather varies according to the type and thickness of tanned leather to be formed.
The mold intended to come into contact with the piece of tanned leather currently consists of a flat plate made of aluminum or aluminum alloy (e.g. Ergal) , usually from 5 to 30 millimeters thick, which has on the front face , i.e. on the face intended to come into contact with the tanned leather, a surface impression which traces out the inverse shape of the embossed inscription or decorative pattern to be made by plastic deformation on the surface of the piece of leather.
The impression is normally made by material removal using a numerical control milling machine which carves the front face of the metal plate so as to point by point remove the material in excess with respect to the desired profile.
Regretfully, the time needed to shape the front face of the metal plate depends on the complexity of the decorative pattern and rapidly increases along with the extension of the impression on the front face of the plate, even greatly exceeding 500 hours of work on the numerical control machine when the surface impression has an extension of approximately 1,5 square meters. Extension that is normally reached by molds which are mounted on the common commercialized presses.
Obviously, the mold production costs are closely related to the time employed by the numerical control machine to realize the impression on the front face of the plate, and can reach values so high to make the adoption of a determined embossed decorative pattern economically unfeasible.
In fact, very often the amount of tanned leather on which it is intended to make a particular embossed decorative pattern is so small to not justify the realization of a specific mold, unless an excessive increase of the production costs of the formed leather is accepted.
DISCLOSURE OF INVENTION
Aim of the present invention is thus to realize a mold for the hot forming of tanned leather, which is very quick, and thus more cost-effective, to make with respect to the current molds made of metal .
In compliance with the above aims, according to the present invention there is provided a manufacturing process of a leather hot-forming mold, wherein the mold comprises a hard and rigid material body which is provided with a front face intended to come into contact with the piece of leather to be formed, and wherein said front face is provided with, a surface impression whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be made on the piece of leather; the manufacturing process being characterized by comprising the step of engraving, by means of a laser beam, the surface impression directly on the surface of a thermosetting resin slab of predetermined thickness; the hard and rigid material body consisting of said thermosetting resin slab. Preferably, though not necessarily, the manufacturing process of a mold for leather hot forming is moreover characterized in that the thermosetting resin slab is an epoxy- and/or phenolic- based thermosetting resin slab.
Preferably, though not necessarily, the manufacturing process of a mold for leather hot forming is moreover characterized in that the thermosetting resin slab is a thermosetting resin slab which includes inert powders and/or additives and/or sheet-like reinforcement materials .
Preferably, though not necessarily, the manufacturing process of a mold for leather hot forming is moreover characterized in that the thermosetting resin slab is formed by a stack of Kraft paper sheets soaked in an epoxy- and/or phenolic- resin matrix.
Preferably, though not necessarily, the manufacturing process of a mold for leather hot forming is moreover characterized in that the thermosetting resin slab is made of one or more superimposed layers of glass fibers and/or carbon fibers and/or aramidic fibers and/or cotton fibers and/or flax fibers and/or hemp fibers and/or fibers of another organic or inorganic material, conveniently superimposed and/or interwoven with one another and soaked in a matrix of epoxy and/or phenolic thermosetting resin.
Moreover according to the present invention there is provided a method for forming a piece of leather characterized by comprising:
- engraving, by means of a laser beam, a front face of a thermosetting resin slab of predetermined thickness, so as to form on surface of said slab a surface impression whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be realized on the piece of leather;
- fixing the thermosetting resin slab on a press, so that the surface impression realized on the front face of the thermosetting resin slab directly faces the surface of the piece of leather to be processed;
- bringing and/or maintaining the thermosetting resin slab to/at a temperature higher than 600C; and
- pressing the thermosetting resin slab against the piece of leather, so as to produce on the surface of the piece of leather, via a permanent plastic deformation of the surface of the piece of leather, reliefs which trace out the shape of the surface impression on the front face of the thermosetting resin slab.
Preferably, though not necessarily, the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is a slab of epoxy- and/or phenolic- based thermosetting resin.
Preferably, though not necessarily, the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is a thermosetting resin slab which includes inert powders and/or additives and/or sheet-like reinforcement materials.
Preferably, though not necessarily, the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is formed by a stack of Kraft paper sheets soaked in an epoxy- and/or phenolic- resin matrix.
Preferably, though not necessarily, the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is made up of one or more superimposed layers of glass fibers and/or carbon fibers and/or aramidic fibers and/or cotton fibers and/or flax fibers and/or hemp fibers and/or fibers of another organic or inorganic material, conveniently superimposed and/or interwoven with one another and soaked in a matrix of epoxy and/or phenolic thermosetting resin.
Preferably, though not necessarily, the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is from 2 to 30 millimeters thick.
Preferably, though not necessarily, the method for forming a piece of leather is moreover characterized in that, during the pressing of the thermosetting resin slab on the piece of leather, said thermosetting resin slab is maintained at a temperature comprised between 7O0C and 1500C.
Preferably, though not necessarily, the method for forming a piece of leather is moreover characterized in that the thermosetting resin slab is a flat or tubular cylindrical shaped slab.
Preferably, though not necessarily, the method for forming a piece of leather is moreover characterized in that the step of fixing the thermosetting resin slab onto the press comprises the step of arranging/ placing the thermosetting resin slab on the flat surface of a mold-holder platform; and the step of sucking the air from the gap which is formed between the rear face of the thermosetting resin slab and the flat surface of said mold-holder platform.
Moreover according to the present invention there is provided a mold for the hot forming of leather comprising a hard and rigid material body, which is provided with a front face intended to come into contact with the piece of leather to be formed, and wherein said front face is provided with a surface impression whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be made on the piece of leather; the mold being characterized in that the hard and rigid material body consists of thermosetting resin slab of given thickness, and in that the surface impression is directly realized on surface of the thermosetting resin slab by means of a laser-beam engraving . Preferably, though not necessarily, the mold for leather hot forming is moreover characterized in that the thermosetting material slab is a slab of epoxy- and/or phenolic- based thermosetting resin.
Preferably, though not necessarily, the mold for leather hot forming is moreover characterized in that the thermosetting resin slab is a slab of thermosetting resin which includes inert powders and/or additives and/or sheet-like reinforcement materials.
Preferably, though not necessarily, the mold for leather hot forming is moreover characterized in that the thermosetting resin slab is formed by a stack of Kraft paper sheets soaked in an epoxy and/or phenolic resin matrix.
Preferably, though not necessarily, the mold for leather hot forming is moreover characterized in that the thermosetting resin slab is made of one or more superimposed layers of glass fibers and/or carbon fibers and/or aramidic fibers and/or cotton fibers and/or flax fibers and/or hemp fibers and/or fibers of another organic or inorganic material, conveniently superimposed and/or interwoven with one another and soaked in a matrix of epoxy and/or phenolic thermosetting resin.
Preferably, though not necessarily, the mold for leather hot forming is moreover characterized in that the hard and rigid material body is a flat sheet.
Preferably, though not necessarily, the mold for leather hot forming is moreover characterized in that the hard, rigid material body is a cylindrical tubular jacket.
BRIEF DESCRIPTION OF THE DRAWINGS
A non-limiting embodiment of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
- Figure 1 is an axonometric view of a mold for leather forming realized in accordance with the teachings of the present invention;
- Figure 2 schematically shows a step of the manufacturing process of the Figure 1 mold;
- Figure 3 shows an axonometric view of a variation of the Figure 1 mold for leather forming; whereas
Figure 4 schematically shows, with parts in section and parts removed for clarity, a mold-holder platform which allows to fix the Figure 1 mold to a press for leather hot forming.
BEST MODE FOR CARRYING OUT THE INVENTION
With reference to Figure 1, number 1 indicates as a whole a mold for the hot forming of leather which is particularly suitable to hot form embossed inscriptions and/or decorative patterns on tanned leathers.
Mold 1 is basically formed by a preferably, though not necessarily, rectangular- or square- shaped flat plate 2 which is made of a hard and rigid material, and is provided with a front face 2a intended to come into contact with the piece of tanned leather to be formed, and with a rear face 2b intended to be stably fixed to, or anyway arranged, to rest upon, a known-type hydraulic and/or power press for the hot forming of leather (not shown) . Front face 2a of flat plate 2 is further centrally provided with a surface impression 3 whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be realized on the piece of tanned leather.
In the example shown, in particular, the surface impression 3 takes up an extension area smaller than the entire surface of the plate front face 2a, but could also extend to affect the entire surface of front face 2a.
Differently from currently known molds, front plate 2 consists of a monolithic slab 2 of epoxy- and/or phenolic- based thermosetting resin, which may possibly include inert powders and/or additives and/or sheet-like reinforcement materials such as, for example, fabrics or sheets of paper, and surface impression 3 is realized on surface of slab 2 via laser engraving. Preferably, though not necessarily, the thermosetting resin slab 2 has a thickness ranging between 2 and 30 millimeters, according to the type of tanned leather to be formed.
More specifically, in the example shown, the thermosetting resin slab 2 is preferably, though not necessarily, made of a stack of Kraft paper sheets soaked in an epoxy and/or phenolic resin matrix, so as to form, after polymerization of the resin, a very rigid and hard flat plate 2 having a nominal thickness preferably, though not necessarily, ranging between 4 and 10 millimeters.
Moreover, in a different embodiment, the thermosetting resin slab 2 may consist of one or more superimposed layers of glass fibers and/or carbon fibers and/or aramidic fibers and/or cotton fibers and/or flax fibers and/or hemp fibers and/or fibers of another organic or inorganic material, conveniently superimposed and/or interwoven with one another and soaked in a matrix of epoxy and/or phenolic thermosetting resin, so as to form, after polymerization of the resin, a very rigid and hard flat plate 2 having a nominal thickness preferably, though not necessarily, ranging between 4 and 10 millimeters.
Mold 1 is realized starting from a thermosetting resin slab 2 of appropriate size, and directly engraving the surface impression 3 onto one of the two faces of the thermosetting resin slab 2 by means of a laser beam which causes the localized ablation/vaporization/ disintegration of the material forming the surface of the slab 2, up to obtain the desired profile.
With reference to Figure 2, in the example shown, mold 1 can be realized by means of a common numerical control laser-engraving machine 11, which preferably, though not necessarily, comprises:
a horizontal work top 12, on which the thermosetting resin slab 2 is adapted to be positioned with the front face 2a facing upwards; - an engraving head 13 which is mobile over the work top 12 along two directrixes orthogonal to each another and parallel to the work top 12, and which is able to generate and direct towards the underneath work top 12 a laser beam L which, in turn, is able to engrave thermosetting resin slab 2 causing the localized vaporization of the material forming the surface of the latter ; and
- a control unit (not shown) which is able to move the cutting head 13 over the work top 12, and adjust the intensity and focus of the laser beam L generated by the cutting head 13, so to engrave the desired surface impression 3 on the front face 2a of the thermosetting resin slab 2 in a completely automatic manner.
The laser engraving machine 11 is an apparatus already known in other technical fields and therefore won't be further described.
In use, the hot pressing of a piece of tanned leather envisages to place mold 1 in abutment against the surface of the piece of tanned leather to be formed, with the possible interposition of a protective film or fabric, so that the surface impression 3 on the front face 2a of the thermosetting resin slab 2 directly faces the surface of the piece of tanned leather,- and then to press, for a predetermined period of time, mold 1 against the piece of tanned leather with the aid of a power and/or hydraulic press for the leather hot forming, so as to produce on the surface of the piece of tanned leather, via a permanent plastic deformation of the surface of the piece of tanned leather, a number of surface reliefs which trace out the shape of the surface impression 3 on the front face 2a of the thermosetting resin slab 2.
During the pressing of mold 1 on the piece of tanned leather, the hot forming process further envisage to bring and/or maintain the thermosetting resin slab 2 to/at a temperature higher than 600C and preferably, though not necessarily, ranging between 700C and 1500C.
In other words, the hot forming of the piece of tanned leather comprises the steps of:
engraving, by means of a laser beam, the front face 2a of a thermosetting resin slab 2 of given thickness, so as to form, on surface of said slab 2, a surface impression 3 whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be realized on the piece of leather;
- fixing the thermosetting resin slab 2 on a press for leather hot forming, so that the surface impression 3 realized on the front face 2a of the thermosetting resin slab 2 directly faces the surface of the piece of leather to be processed; - bringing and/or maintaining the thermosetting resin slab 2 to/at a temperature higher than 600C; and
pressing the thermosetting resin slab 2 against the piece of leather, so as to produce on surface of the piece of leather, via permanent plastic deformation of the surface of the piece of leather, reliefs which trace out the shape of the surface impression 3 on the front face 2a of the thermosetting resin slab 2.
As regards to the stable fixing of mold 1 to the press, thermosetting resin slab 2 may be stably fixed onto the metal-material mold-holder platform made of the press for leather hot forming by means of mechanical- type anchoring members, such as through screws and/or clamps,- or, more conveniently, it may be stably fixed onto the mold-holder platform pneumatically by means of a suction system which is structured to continuously such air from the gap which is formed between the rear face 2b of the thermosetting resin slab 2, and the surface of the mold-holder platform of the press.
In other words, the suction system can withhold the thermosetting resin slab 2 in abutment against the mold- holder platform of the press, by maintaining the rear face 2b of the thermosetting resin slab 2 under vacuum
(i.e. at a pressure lower than ambient pressure).
More specifically, with reference to Figure 4, the mold-holder platform 20 of the press on which the rear face 2b of the thermosetting resin slab 2 is intended to rest is made of a high-strength metal material and is provided with a flat surface 20a, which has a number of shallow-depth surface grooves 21 which are conveniently distributed along the entire portion of the flat surface 20a intended to be covered by the rear face 2b of the thermosetting resin slab 2.
In particular, in the example shown, surface groves 21 have preferably, though not necessarily, a substantially V or U shaped profile, and are preferably, though not necessarily, distributed according to two directrixes orthogonal to one another, so as to reciprocally cross and form a regular mesh which extends substantially underneath the entire surface of the rear face 2b of the thermosetting resin slab 2.
The mold-holder platform 20 of the press is further provided with at least one peripheral annular groove 22 which extends on the flat surface 20a so as to trace out the shape of the perimeter of the rear face 2b of the thermosetting resin slab 2, which completely surrounds the surface grooves 21 as a whole, and finally which stably accommodates an annular sealing gasket 23 which, in turn, is made of an elastically deformable material and is adapted to be arranged in abutment against the rear face 2b of the thermosetting resin slab 2, so as to close substantially airtight manner the perimeter of the rear face 2b of the thermosetting resin slab 2, forming a closed gap.
With reference to Figure 4, mold-holder platform 20 finally comprises a number of inner connecting ducts 24 which extend within the body of the mold-holder platform 20, so as to connect the surface grooves 21 to an outer air suction circuit 25, which, in turn, communicates with an electrically-operated vacuum pump 26 or the like.
Obviously, mold-holder platform 20 may either be an integral part of the leather hot-forming press or may be a separate element which is structured so to be, in turn fixed, in rigid and stable, thought easily releasable manner, to the press for leather hot forming.
If a "vacuum" system is used, the anchoring of the mold 1 to the mold-holder platform 20 envisages to activate the vacuum pump 26, either before or after having positioned/rested the thermosetting resin slab 2 on the flat surface 20a of the mold-holder platform 20, exactly over the annular seal 23. The pressure difference that the vacuum pump 26 produces and then maintains between the front face 2a and the rear face 2b of thermosetting resin slab 2 forces the thermosetting resin slab 2 to rest the rear face 2b on the flat surface 20a of the mold-holder platform 20 after compressing the annular seal 23.
In other words, the step of fixing the thermosetting resin slab 2 onto the press for leather hot forming, comprises the step of positioning/resetting the thermosetting resin slab 2 on the flat surface 20a of the mold-holder platform 20; and then the step of sucking the air from the gap which is formed between the rear face 2b of the thermosetting resin slab 2, and the flat surface 20a of the mold-holder platform 20. The shallow depth and the appropriate spacing of the surface grooves 21 on the flat surface 20a of the mold-holder platform 20 allow the rear face 2b of the thermosetting resin slab 2 to rest on the body of the mold-holder platform 20 in uniform manner thus avoiding localized deformations of slab 2 which could compromise the hot-forming quality.
The advantages deriving from the particular structure of the mold 1 for the hot forming of leather are noteworthy.
Firstly, the time needed to engrave by means of the laser the surface impression 3 on the front face 2a of the thermosetting resin slab 2 is much shorter than the time needed to carve the surface impression on the front face of a sheet of aluminum or aluminum alloy, therefore the production costs of the mold 2 are much lower than those of a metal mold of identical shape.
By virtue of the use of the thermosetting resin slab 2, mold 1 has moreover a weight for surface unit which is significantly lower than that of a metal mold, with all the advantages that this implies when mold 1 must be positioned/installed on the press.
Furthermore, experimental tests have proven that making the slab 2 with a phenolic- and/or epoxy- based thermosetting resin allows to realize hard and rigid flat sheets 2, i.e. molds 1 for hot forming of leather, which have an optimal structural stiffness, an optimal high temperature resistance and an optimal thermal conductivity for the hot forming of tanned leather.
Clearly, changes may be made to the mold 1 for leather forming and to the mold manufacturing process without however departing from the scope of the present invention.
For example, with reference to Figure 3, in a different embodiment, mold 1 consists of a cylindrical tubular jacket 4 made of a hard and rigid material, which is adapted to be fitted on a cylindrical supporting drum 5, so that the outer peripheral surface 4a of the cylindrical tubular jacket 4 can roll on a generic piece of leather to be formed. Like the front face 2a of the flat plate 2, the outer peripheral surface 4a of the jacket is centrally provided with a surface impression 3 — in this case preferably, though not necessarily, annular — whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be made on the piece of leather.
Also in this embodiment, the cylindrical tubular jacket 4 consists of a monolithic slab 4 of epoxy- and/or phenolic- based thermosetting resin, which may possibly include inert powders and/or additives and/or sheet-like reinforcement materials such as, for example, fabrics or sheets of paper, and the surface impression 3 is realized on the surface of the slab 4 by means of a laser-beam engraving. The thermosetting resin slab 4 has a thickness preferably, though not necessarily, ranging between 2 and 30 millimeters, according to the type of tanned leather to be formed.
Obviously, in this embodiment, the hot pressing of a piece of leather envisages to place the mold 1 in abutment against the surface of the piece of leather to be formed, so that the surface impression 3 on the outer peripheral surface 4a of the thermosetting resin slab 4 directly faces the surface of the piece of leather; and then to roll the mold on the surface of the piece of leather while, at the same time, pressing mold 1 with force against the piece of leather.
Also in this case, during the pressing of the mold 1 against the piece of leather, the thermosetting resin slab 4 is brought and/or maintained to/at a temperature higher than 6O0C and preferably, though not necessarily, ranging between 700C and 1500C.

Claims

1. Method for forming a piece of leather characterized by comprising:
- engraving, by means of a laser beam, a front face (2a, 4a) of a thermosetting resin slab (2, 4) of predetermined thickness, so as to form on surface of said slab (2, 4) a surface impression (3) whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be realized on the piece of leather;
- fixing the thermosetting resin slab (2, 4) on a press, so that the surface impression (3) realized on the front face (2a, 4a) of the thermosetting resin slab (2, 4) directly faces the surface of the piece of leather to be processed;
- bringing and/or maintaining the thermosetting resin slab (2, 4) to/at a temperature higher than 600C; and
- pressing the thermosetting resin slab (2, 4) against the piece of leather, so as to produce on the surface of the piece of leather, via a permanent plastic deformation of the surface of the piece of leather, reliefs which trace out the shape of the surface impression (3) on the front face (2a, 4a) of the thermosetting resin slab (2, 4) .
2. Method for forming a piece of leather according to Claim 1, characterized in that the thermosetting resin slab (2, 4) is a slab of epoxy- and/or phenolic- based thermosetting resin.
3. Method for forming a piece of leather according to Claim 1 or 2, characterized in that the thermosetting resin slab (2, 4) is a thermosetting resin slab which includes inert powders and/or additives and/or sheet- like reinforcement materials.
4. Method for forming a piece of leather according to Claims 2 and 3, characterized in that the thermosetting resin slab (2, 4) is formed by a stack of Kraft paper sheets soaked in an epoxy- and/or phenolic- resin matrix.
5. Method for forming a piece of leather according to Claims 2 and 3, characterized in that the thermosetting resin slab (2, 4) is made up of one or more superimposed layers of glass fibers and/or carbon fibers and/or aramidic fibers and/or cotton fibers and/or flax fibers and/or hemp fibers and/or fibers of another organic or inorganic material, conveniently superimposed and/or interwoven with one another and soaked in a matrix of epoxy and/or phenolic thermosetting resin.
6. Method for forming a piece of leather according to any one of the foregoing claim, characterized in that the thermosetting resin slab (2, 4) is from 2 to 30 millimeters thick.
7. Method for forming a piece of leather according to any one of the foregoing claims, characterized in that during the pressing of the thermosetting resin slab (2, 4) on the piece of leather, said thermosetting resin slab (2, 4) is maintained at a temperature comprised between 700C and 1500C.
8. Method for forming a piece of leather according to any one of the foregoing claims, characterized in that the thermosetting resin slab (2, 4) is a flat or tubular cylindrical shaped slab.
9. Method for forming a piece of leather according to any one of the foregoing claims, characterized in that the step of fixing the thermosetting resin slab (2, 4) onto the press comprises the step of arranging/ placing the thermosetting resin slab (2) on the flat surface (20a) of a mold-holder platform (20) ; and the step of sucking the air from the gap which is formed between the rear face (2b) of the thermosetting resin slab (2) and the flat surface (20a) of said mold-holder platform (20) .
10. Manufacturing process of a mold (1) for leather hot forming, wherein the mold (1) comprises a hard and rigid material body (2, 4) which is provided with a front face (2a, 4a) intended to come into contact with the piece of leather to be formed, and wherein said front face (2a, 4a) is provided with a surface impression (3) whose shape traces out the inverse shape of the embossed inscription and/or decorative pattern to be made on the piece of leather; the manufacturing process being characterized by comprising the step of engraving, by means of a laser beam, the surface impression (3) directly on the surface (2a, 4a) of a thermosetting resin slab (2, 4) of predetermined thickness; the hard and rigid material body (2, 4) consisting of said thermosetting resin slab (2, 4).
11. Manufacturing process of a mold for leather hot forming according to Claim 10, characterized in that the thermosetting resin slab (2, 4) is an epoxy- and/or phenolic- based thermosetting resin slab.
12. Manufacturing process of a mold for leather hot forming according to Claim 10 or 11, characterized in that the thermosetting resin slab (2, 4) is a thermosetting resin slab which includes inert powders and/or additives and/or sheet- like reinforcement materials.
13. Manufacturing process of a mold for leather hot forming according to Claims 11 and 12, characterized in that the thermosetting resin slab (2, 4) is formed by a stack of Kraft paper sheets soaked in an epoxy- and/or phenolic- resin matrix.
14. - Manufacturing process of a mold for leather hot forming according to Claims 11 and 12, characterized in that the thermosetting resin slab (2, 4) is made of one or more superimposed layers of glass fibers and/or carbon fibers and/or aramidic fibers and/or cotton fibers and/or flax fibers and/or hemp fibers and/or fibers of another organic or inorganic material, conveniently superimposed and/or interwoven with one another and soaked in a matrix of epoxy and/or phenolic thermosetting resin.
15.- A mold (1) for leather forming, characterized by being made via a manufacturing process as defined in any one of Claim from 10 to 14.
PCT/IB2010/002076 2009-08-25 2010-08-24 Mold for leathers hot forming and corresponding use and manufacturing processes WO2011024053A2 (en)

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ITTV2009A000164A IT1395672B1 (en) 2009-08-25 2009-08-25 MOLD FOR MOLDING LEATHER AND ITS MANUFACTURING PROCEDURE
ITTV2009A000164 2009-08-25

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Family Cites Families (5)

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Publication number Priority date Publication date Assignee Title
GB1097454A (en) * 1965-05-21 1968-01-03 Peter Whymant Method of producing improved plates for embossing leather or other appropriate thin and relatively flexible sheet material
US5798202A (en) * 1992-05-11 1998-08-25 E. I. Dupont De Nemours And Company Laser engravable single-layer flexographic printing element
DE4326874C3 (en) * 1993-08-11 1999-11-25 Benecke Kaliko Ag Method of engraving a pattern on a surface of a workpiece
DE102005045047A1 (en) * 2005-09-21 2007-03-22 Basf Ag Method for producing matrices for the production of decorative finishes
CN1986217A (en) * 2006-09-15 2007-06-27 梁文柱 Process of making embossing board of leather mold

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* Cited by examiner, † Cited by third party
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ITTV20090164A1 (en) 2011-02-26
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