Apparatus for carrying out a skin embellishment process

Abstract: The process for the embellishment of skins (91) comprises the following operations: application of an embellishing film (6) on a support belt (4); drying the embellishing film; coupling the skins (91) to the embellishing film after addition of a gluing material; applying pressure to the skins (91) and to the embellishing film (6); separating the skins (91) together with the embellishing film (6) which have been glued together from the support belt (4). The gluing material is applied directly to the surface (910) of the skins (91) prior to coupling skins to the embellishing film (6).

Description: FIELD OF THE INVENTION The present invention relates to an apparatus for embellishing skins, preferably splits or regenerated leather, according to the general part of claim 1. BACKGROUND OF THE INVENTION The skins which are commonly used in the clothing, furnishing and shoe fields are frequently prepared by means of a process of embellishment of the splits. It is well known that this process consists essentially of depositing a polyurethanic film on top of a support belt which has an embossed surface and then gluing a split to the polyurethanic film. In this manner there is obtained a skin which has the softness of the split and on the grain side the design of the embossment impressed on the polyurethanic film which characterizes the aesthetic appearance. This process of embellishing is widely used because it permits to achieve skins which have softness and are pleasant to the touch comparable to the fine grain skins with the advantage that compared with the latter, they are substantially less expensive. The apparatuses which are used for the embellishment of the skins are installations which are in continuous operation and which essentially comprise a pair of cylinders disposed one upstream and another downstream of the installation and a continuous belt which is made to travel between the two cylinders. This continuous belt which has an embossed surface goes through one or more groups for applications provided with systems of rollers, doctor systems or spraying systems which deposit on the embossed surface of the belt a thin layer of the polyurethanic material. There is obtained in this manner a thin elastic film which has impressed the design of the embossing of the continuous belt and which will constitute the embellishing film which, when applied on the split, will constitute the fine grain side. Downstream of the above application groups there is used a drying oven where the polyurethanic film is dried prior to entering a further application group in which roller systems or the doctor systems or spraying systems cover the surface of the embellishing film with a gluing substance. After the application of the glue, conveying systems are used for the application of the splits to the embellishing film to which splits adhere due to the adhesive action of the glue which has been deposited previously together with the compression action exerted by a press or a calender disposed downstream of the application group of the glue. After the calender, the split and the embellishing film which adheres to it enter into a dryer in which the drying of the glue ensures the stable adhesion between the split and the embellishing film. After the drying oven a skin obtained in this manner is separated from the continuous belt. The skin presents the fine grain side with the appearance and the design which the embossment in the continuous belt has impressed in the embellishing film. Independently from the fact that the installations used to achieve the embellishment of the skin are provided with groups for the application of the embellishing film of a coating type or may be with a doctor system or with a spraying system or by means of rollers, all of them carry out the same process which consists essentially of forming the embellishing polyurethanic film on a continuous support belt and depositing on this embellishing film a layer of glue and causing the adherence of the skin to the embellishing film. This procedure, however, offers some drawbacks. The first drawback consists of the fact that the deposit of the gluing material on the entire surface of the embellishing film deposited on the support belt involves a useless waste of the gluing material and therefore an increase in the cost which is not justified. In fact, the known process involves the deposit of the gluing material on the entire continuous surface of the embellishing film and therefore also on that part of the film which will not be involved subsequently in the application to the split and which at the end of the operation will constitute the scrap which will be discarded. If one considers that the scrap which is produced is in substantial amount, one will realize that the waste of gluing material and the cost which is involved are really high, particularly because this gluing material is particularly expensive. Another drawback of the known process resides in the fact that the embellishing film presents the surface which must adhere to the split substantially smooth and it is not always possible to obtain perfect adherence of the skin to the embellishing film when they are coupled. In fact, when the layer of gluing material applied on the embellishing film is not sufficiently thick, it may happen that the gluing material is completely absorbed by the split which has a porous surface and is very highly absorbent. If this happens, it may occur that on the final product, there are areas which are poorly glued and in which the separation of the embellishing film may happen. This event which is damaging by itself on the final embellished skin becomes even more serious if it occurs on the final product which is made from these skins such as shoes, bags, clothing articles, furnishing articles and similar articles because the final article is being discarded with substantial requirements of indemnification on the part of the client. In the document FR-A-2146748 is described a process for the embellishment of the skins which comprises the following operations: application on the surface of a continuous support belt of at least one layer of an elastic material capable of providing an embellishing film; drying the embellishing film which has been disposed on the continuous support belt; coupling the skins with the embellishing film after application of at least one layer of gluing materal capable of ensuring the reciprocal adherence between the skins and the embellishing film; application of pressure to the skins and the embellishing film which have been coupled together in order to obtain the reciprocal gluing together; separation of the skins and the embellishing film which have been glued together from the continuous support belt. The process is further characterized by the fact that at least one layer of the gluing material is applied directly on the surface of the skins prior to putting the skins together with the embellishing film. Moreover the document FR-A-2146748 describes also an apparatus for performing such a process, which comprises : a first cylinder placed at the beginning of the cycle of operation and which cooperates with a second cylinder located at the end of the same cycle, the two cylinders being capable of winding and/or unwinding the same support belt which is extended between them; one or more stations for the application of one or more layers of elastic material on the support belt capable of providing the embellishing film; at least one station for drying the embellishing film which has been deposited on the continuous belt, each one of the drying groups being placed downstream with respect to a corresponding application group of the same elastic material; at least one station for the application of at least one layer of gluing material on the skins; conveying means capable of achieving the coupling of the skins with the embellishing film; at least one station for the application of pressure on the skins and on the embellishing film which have been coupled together; at least one discharge station for the separation of the skins and the embellishing film which has been glued to them from the continuous support belt. In the document FR1581307 is described an apparatus for the continuous application of the gluing material onto the skins. Aim of the invention is to provide some particular conformations of this apparatus in order to better perform the process already described. This is obtained by an apparatus according to the definition of claim 1. BRIEF DESCRIPTION OF THE DRAWINGS The object and the advantages according to the present invention are described in some detail with reference to the drawings of which: Fig. 1 shows the installation used to carry out the process according to the present invention according to a first embodiment; Fig. 2 shows the installation used to carry out the embellishing process according to the present invention and specifically according to a second embodiment; Fig. 3 shows the detail of a station for the application of the elastic material to the support belt which is used in both installations according to Fig. 1 and Fig. 2; Fig. 4 illustrates a station used for the application of the gluing material to the skins which is used in both embodiments according to Figs. 1 and 2. The apparatus according to the invention is described by reference to the two embodiments shown in Figs. 1 and 2. Both apparatusses comprise: a first cylinder 2 and a second cylinder 3 which are located respectively at the beginning and at the end of the operation cycle of the apparatus with the support belt 4 being wound and/or unwound between the two cylinders; a station 5 for the application on the support belt 4 of an elastic material capable of forming an embellishing film 6; a drying station 7 being located downstream of the application station 5 and which comprises oven 71; a station 8 for the application of gluing material on the surface of the skins 91; conveying means 9 for locating the skins 91 on the embellishing film 6; a pressure station constituted by calender 101; a drying station 20 constituted by dryer 201 which may be of the independent type as shown in the first embodiment 1A or may be combined with the preceding drying station 7 according to the second embodiment of the invention 1B; a station 30 for the removal of the product being formed. The arrangement of the stations described hereinabove obviously has been provided merely for the purpose of illustration because the stations which carry out the application of the products may be more than one for each type of the product being deposited. Further, each apparatus may comprise any number of dryers and presses. In addition, between the several stations there may also be located further devices capable of achieving particular effects on the embellishing film which has been deposited or on the skin being applied to the film or on the final article. With respect to station 5 it should be noted that this station is located downstream with respect to the first cylinder 2 and comprises application cylinder 51 which is located above the support belt 4 and at least a pair of countercylinders 54 located on the opposite side of the support belt 4. The support belt 4 travels being extended between cylinders 51 and 54 and receives on its surface the deposit of the elastic material 53 which is contained in the container 52 in which there is placed the application cylinder 51. The material 53 which is contained in the container 52 consists preferably of a polyurethanic resin in an aqueous solution and catalyzing substances. As shown in Fig. 3 this material is placed on the support belt 4 when the latter travels in the direction 41 due to the action of the application cylinder 51. In particular, it is noted that the application cylinder 51 rotates in clockwise direction 55 and therefore in a direction contrary to the direction of travel 41 of the support belt 4. In this manner, there is obtained on the latter a controlled deposit of the elastic embellishing material 53 due to the presence of the scraping blade 152 of the container 52 which cooperates with the application cylinder 51. Downstream of the application station 5 the elastic material 53 forms an embellishing film 6 on the support belt 4, the film 6 being then dried by passing through the drying group 7. The latter is constituted by oven 71 in a manner that the film is solidified when it reaches the second application station which is indicated overall by numeral 8 and which is shown also in Fig. 4. Also the application station 8, similarly to application group 5 which has been described hereinabove, comprises an application cylinder 81 which is located in container 82 which contains the gluing liquid material 83. Underneath the application cylinder 81 there is placed countercylinder 84 which serves as support for the skins 91, the latter being conveyed by a station shown overall with numeral 40 and which is located above the belt. Each skin 91 travels along the direction 920 and the upper surface 910 comes in contact with the application cylinder 81. The latter rotates according to the counterclockwise direction 85 and therefore in a direction contrary to the direction of travel of the skins 91, in this manner also for the purpose of achieving a controlled distribution of the gluing liquid material 83. The controlled distribution of the gluing materal 83 is favored by the presence of the scraping blade 182 of container 82 which cooperates with the application cylinder 81. The application surface of the cylinder 81 is provided with roughness 181 which exerts on the surface 910 of skin 91 a slight abrasive effect which favors the penetration of the gluing material. In this manner one obtains an ideal penetration of the gluing material into the surface 910 of the skin 91 which guarantees a greater adhesion of the skin itself to the embellishing film 6 after the coupling thus avoiding on the final article the possibility of reciprocal separation between the embellishing film and the skin. At the exit from the application station 8 the skin 91 through conveying means 9 is coupled to the embellishing film 6 by turning against it the surface 910 on which is placed the gluing material. It should be noted that the conveying means 9 in the first embodiment of the invention according to Fig. 1 are constituted by a conveying belt 11A which functions with a travelling speed greater with respect to the traveling speed of the support belt 4 which is located under it while in the second embodiment of the invention the conveying means are constituted by transporting belt 11B as shown in Fig. 1B which functions with a travelling speed equal to the travelling speed of the support belt 4 which is located above it. The continuous travel of the support belt 4 in the direction 41 introduces the skin 91, coupled to the embellishing film 6 in the interior of the pressure group 10 which is constituted by calender 101 which is provided with a plurality of counterposed pressure cylinders 102, the latter favoring due to pressure the close adherence between the skin and the embellishing film. The stability of this adherence is then perfected in the drying group 20 which is constituted by dryer 201 in the interior of which the skin and the embellishing film are introduced due to the continuous travel of the support belt 4 on which they are placed. At the exit of dryer 201 the skin 91 which at that stage is anchored to the embellishing film 6 in a stable manner and therefore has been embellished, reaches the discharge station 30 where one or more workers provide for separating the skin from the traveling belt 9. The skin which has been embellished is superimposed to other skins which have been previously removed and placed on top of a pallet 60 or other support means such as for instance a similar stand or similar device. It is clear that corresponding to the discharge station 30 the embellished skins may be removed from the travelling belt 4 and may be placed stacked on the pallet 60 or a stand or similar supporting devices by means of a robot or other automatic means of any type. On the basis of what has been described hereinabove, it is clear that the apparatus according to the present invention permits to achieve the stated objects. First of all, the apparatus of the invention permits to obtain the same production which has been obtained with known apparatusses by employing a smaller amount of the gluing material. In fact, in the apparatus according to the present invention, only the surface 910 of skin 91 which is caused to adhere to the embellishing film is coated with the gluing material and it is clear that one obtains a saving of the corresponding amount of the gluing material which in the known apparatus on the contrary has been wasted because it has been distributed on the entire surface of the embellishing film and therefore also in that part of the embellishing film which constitutes the discard during the operation. Further also the object of obtaining a better adherence between the skin and the embellishing film is achieved. In fact, as already stated, the application cylinder 81 of the gluing material 83 has its lateral surface provided with roughness 181 and rotates according to direction 85 which is contrary to the travelling direction 920 of the skin 91 so that one contemporaneously achieves a controlled distribution of the gluing material 83 and a slight abrasive action on the surface of the skin which improves the absorption and the close contact with the gluing material. The apparatus according to the invention may also assume configurations different from the two embodiments described hereinabove because it may be provided with any number of application stations of the polyurethanic material on the support belt and each one of them may be followed by one or more stations which may carry out the drying, the application of pressure or other operation having the purpose of applying on the embellishing film particular properties, designs or others. Also with respect to the application of the gluing material this operation may be carried out in more than one phase and one or more application stations depending upon the requirements of the client.

Claims: An apparatus capable of carrying out the process for the embellishment of skins (91) which process comprises the steps of: 1) applying on the surface of a continuous support belt (4) at least one layer of an elastic material capable of achieving an embellishing film (6); 2) drying said embellishing film (6) disposed on said continuous support belt (4); 3) coupling said skins (91) with said embellishing film (6) after application of at least one layer of gluing material (83) capable of ensuring reciprocal adherence between said skins (91) and said embellishing film (6); 4) applying pressure on said skins (91) and said embellishing film (6) coupled between themselves in order to ensure the reciprocal gluing; 5) separating said skins (91) and embellishing film (6) which have been reciprocally glued from said continuous belt (4); wherein at least one of said layer of gluing material is applied directly on the surface (910) of said skins (91) prior to coupling said skins (91) to said embellishing film (6), the apparatus comprising: a) a first cylinder (2) located at the beginning of the operation cycle of said installation, said cylinder (2) cooperating with a second cylinder (3) located at the end of the operation cycle of said installation, a support belt (4) being wound and unwound between said first and second cylinders; b) at least one station (5) for the application of at least one layer of elastic material on said support belt (4) capable of forming an enbellishing film (6); c) at least one drying station (7) for drying said embellishing film (6) deposited on said continuous belt (4), each one of said drying stations being located downstream with respect to said station of application of said elastic material; d) at least one station (8) for the application of at least one layer of gluing material on said skins (91); e) a conveying means (9) capable of achieving the coupling of said skins (91) together with said embellishing film (6); f) at least one station (10) for the application of pressure on said skins (91) and said embellishing film (6) which have been coupled between themselves; g) at least one discharge station (30) for the separation of said skins (91) and said embellishing film (6) which has been glued thereto from said continuous support belt (4), the apparatus being characterized by the fact that each of said stations (5) for the application of said layer of elastic material is constituted by at least one pair of countercylinders (54), said countercylinders (54) supporting said continuous support belt (4) and the apparatus comprises at least one application cylinder (51) pressing said countercylinders (54), a container (52) for the embellishing elastic material (53), at least said one application cylinder (51) being located in contact with said embellishing elastic material (53) in the container (52). The apparatus according to claim 1 characterized by the fact that each pressure station (10) is followed by at least one drying station (20). The apparatus according to claim 1 or 2 characterized by the fact that each drying station (7) and (20) is constituted by a drying oven (71),201), said ovens being separated one from the other or constituting a single unit. The apparatus according to claim 1 which comprises a container (82), said gluing material being placed in said container, and the apparatus is further characterized by the fact that at least one of said station (8) for the application of at least one layer of said gluing material on said skins (91) comprises a countercylinder (84) to support said skins (91) and the apparatus comprises a cylinder (81) located above said countercylinder (84) for applying said gluing material (83), said cylinder (81) being located in contact with said gluing material (83) in the container (82). The apparatus according to claim 1 characterized by the fact that said conveying means (9) comprises a transport belt (11A) which provides means for guiding said skins (91) having their glued surface turned towards said embellishing film (6), the latter being located underneath said skins, said support belt (4) being located underneath said transport belt (11A). The apparatus according to claim 1 characterized by the fact that said conveying means (9) comprises a transport belt (11B) provided with means for guiding said skins (91) with their glued surface turned towards said embellishing film (6), said embellishing film (6) being located above said transport belt (11B), and said support belt (4) being located above said transport belt (11B). The apparatus according to claim 6 characterized by the fact that said application cylinder (81) rotates with a direction (85) opposite to the direction (920) of the travel of said skins (91). The apparatus according to claim 6 characterized by the fact that said application cylinder (81) has a lateral surface provided with roughness (181). The apparatus according to claim 1 characterized by the fact that each of said pressure stations (10) is constituted by at least one calender (101). The apparatus according to claim 1 characterized by the fact that said continuous support belt (4) has a surface thereof, said surface having an embossing, said surface being in contact with said embellishing film (6). The apparatus according to claim 1 characterized by the fact that said application cylinder (51) rotates with the direction (55) opposite to the direction of travel (41) of said continuous support belt (4). The apparatus according to anyone of claims 1 to 3 characterized by the fact that said container (52, 82) is of the type having a scraping blade (152,182) cooperating with said application cylinder (51,81).

Inventors: AGOSTI GIACOMINO ADOLFO, MAITAN GIANNI, AGOSTI, GIACOMINO ADOLFO, MAITAN, GIANNI
Applicants: GE MA TA SPA, GIDUE S R L, GE.MA.TA. S.P.A., GIDUE S.R.L.
Application year: 1996
Main classification: B32B31
IPC codes: C14C11, B32B37