Field of Invention This invention is related to a manufacturing method which brings in patterns and textures on the artificial leather that is produced to be used in furniture, shoe, bag, garment and accessories sector, wherein the said manufacturing method developed by this invention is based on the transfer of the pattern and texture on the pattern ring which is coated by specially made rubber, silicone or nickel with hollow center and mounted on the core cylinder that is heated or cooled by means of water, grease, electricity or heating/cooling cylinders by means of an air bed or a system that can be turned on/off manually or automatically, onto the PU and PVC based artificial leather by applying pressure.

Background of the Invention (Prior Art) In the prior art, 3 methods are used to bring in three dimensional pattern and texture on PU and PVC based artificial leather:

1. Pattern paper;

2. Emboss printing with steel, nickel or silicone cylinder,

3. Plate emboss printing.

1. FORMATION OF PATTERN AND TEXTURE BY MEANS OF PATTERN PAPER

1.1 Manufacturing process for the formation of pattern and texture on PU and PVC based artificial leather by means of pattern paper according to the prior art:

This manufacturing technique utilizes special silicone papers which are called as transfer paper (release paper); specially designed for the artificial leather production and used to form and transfer patterns on PU or PVC coating. Special mixture of PU or PVC is spread over the special paper in 1, 2, 3 or 4 layers in a way to allow to obtain the requested weight and thickness. After each spreading process, the product is put inside the kiln and subject to solvent vaporization and drying process. Following the formation of the last layer, the fabric having the required characteristics is laminated; and put into the kiln finally for drying, solvent vaporization and curing process, when the product is yet wet. The product is removed from the transfer paper; therefore the transfer paper transfers its pattern on the product.

In this manufacturing technique, the pattern of the fabric is limited with the number of the manufacturer of the transfer papers; and the patterns are not sufficiently deep. The document numbered KR 20040055846 in the conventional technique discloses a process wherein three dimensional patterns are applied on artificial leather. The system described in the said publication requires the coating of the pattern paper with a mixture made of transparent or semi-transparent polyurethane for the manufacturing of patterned leather. Accordingly, the pattern paper is dried to become more stable and applied on the leather. The artificial leather which is integrated with the pattern paper is passed through again a heating and drying process. The goal for this action is to ensure that the pattern on the pattern paper is well penetrated into the leather. After this step, the pattern paper is separated from the artificial leather, thereby transferring the pattern on the said pattern paper onto the product. 2. FORMATION OF THREE DIMENSIONAL PATTERN AND TEXTURE ON THE

ARTIFICIAL LEATHER BY MEANS OF EMBOSS PRINTING WITH STEEL, NICKEL OR SILICONE CYLINDER

2.1 Manufacturing Process for the formation of pattern and texture on PU and PVC based artificial leather by means of emboss printing with steel, nickel or silicone cylinder according to the prior art:

Similar to the formation of patterns through the transfer paper, the pattern is made by emboss printing cylinder on the product following the completion of the coating process. The cylinders used in this process may be made of silicone, nickel or steel. Emboss cylinders carries the pattern which is requested to be transferred to the product. The said cylinder transfers the pattern to the product by being printed onto the product at high pressure after the product is heated with infra-red or the cylinder itself is heated.

The level of printing of the pattern depth to be transferred onto the product is adjusted by the pattern structure of the cylinder in the process of emboss cylinders. In this method, it may damage the product to apply the printing excessively in order to achieve high level of pattern depth. Details of fine patterns are either transferred at relatively low quality or are not transferred at all. Besides, cylinder costs are high. Furthermore, when it is required to use different cylinders for different patters, the cylinders are replaced in a long period. The document numbered KR 20030077901 in the prior art defines a process for the formation of patterns on the artificial leathers by means of joint use of pattern paper and emboss cylinder. The system mentioned in this application applies printing process by emboss cylinders on an artificial leather bearing dry form and a polyurethane layer. 1 to 3 steel cylinder is used in the process of application of pressure on the artificial leather subject to the printing process; and their temperature can be adjusted between 80 to 300 ⁰ C.

Steel cylinders which are 1 to 3 in quantity and can be adjusted between 80 and 300 ⁰ C in temperature heat the back surface of the artificial leather patterned by paper and the pattern on the emboss cylinder is transferred to the top surface of the artificial leather by means of printing.

In the system developed by this invention, differently from the mentioned invention in the conventional technique, the product is heated either by infrared method or by heating the core cylinder covered by the pattern ring not by its back surface (fabric side) but by its top surface (artificial leather side); and the patterns are applied by printing the core cylinder covered by the pattern ring on the artificial leather

KR 20030077736 discloses a similar manufacturing process which uses emboss cylinders and steel cylinder together; and explains the removal of irregularities on the fabric caused by the treatment of the emboss cylinder on the artificial leather with an increase in the number of steel cylinders; and their replacements. However, as it is mentioned above, an application like in the system developed by this invention wherein the emboss cylinders are placed on steel cylinders is not mentioned in the application numbered KR 20030077736.

The document numbered KR 20030023840 that uses emboss and steel cylinders and is available within the existing technique is related to artificial leather to which a squeezing process is applied through an emboss cylinder treated with polyurethane and another cylinder. KR 20030023840 further describes the patterned appearance of the artificial leather that is treated with pressure through the steel cylinder heated by the heating system and emboss cylinder at low temperature. The document numbered KR 20030023840 lacks any application with pattern paper; and is different from the system developed by this invention as it uses the emboss cylinders separately from the steel cylinders in the manufacturing process. 3. FORMATION OF THREE DIMENSIONAL PATTERN AND TEXTURE ON THE ARTIFICIAL LEATHER BY MEANS OF PLATE EMBOSS PRINTING METHOD

3.1 Manufacturing Process for the formation of pattern and texture on PU and PVC based artificial leather by means of plate emboss printing method: In this method of manufacturing, the product yielded as a result of the technique applied by coating with paper is put into "Plate Emboss Printing Process". The said product is placed between square or rectangular patterned plate and vertically mobile felted plate. Vertically mobile felted plate presses with high pressure; and ensures that the pattern on the fixed plate is transferred to the product between two plates. For better patterns, the plate is heated.

Plates conduct opening and closing motions in vertical direction; and transfer the pattern in pieces. However, it is possible to achieve patterns with high level of depth; it significantly diminishes the manufacturing; and the process is carried on slowly.

In the prior art, ES 8705923 describes a pattern process wherein the patterns are transferred by a patterned plate onto the artificial leather. In this process, initially the artificial leather is coated by micro-scale elastomeric pieces; and heated up to 20-120 ⁰ C; and the plate is squeezed by embossing method at the interval of 80-120 ⁰ C. The product is finalized by being coated with colored or non-colored copolymers depending on the request.

In an alternative embodiment, it is mentioned that the said plate embossing method could be applied by means of a transfer paper that is subjected to a thermoplastic material before the patterning process.

The Objectives for the Development of the Invention

The development of the process for the formation of three dimensional pattern and texture on the artificial leather by means of emboss printing with pattern ring, being the subject of this invention aims at the followings:

• To ensure the manufacturing of an artificial leather having deeper patterns than the patterns obtained through embossing with transfer paper, emboss printing with steel, nickel or silicone cylinder; and plate emboss printing in the prior art; • To minimize the time loss frequently observed in the existing systems and supply of equipment being one of the difficulties encountered in manufacturing; • To minimize the time loss in mounting the supplied equipment, cylinders etc. to the system; replacement of each equipment, cylinders, etc. in changing patterns;

• To gain advantage in cost in consideration of the cylinder cost;

• To minimize time loss which is mentioned above and may occur during the operation of the system; and to create a continuous manufacturing process structure;

• To minimize the level of loss which may result from the dislocation of the patterns thanks to the continuous manufacturing;

• To decrease high costs in the supply of parts; and minimize the manufacturing and operation costs as a result of time gained in the manufacturing process; • To allow the selection of the requested patterns freely, in other words offering the option to use more patterns,

• To facilitate the storage of the pattern rings having a weight of five kilograms in this invention, when it is compared with the fact that the supply period of the pattern ring is short; and with the steel cylinders in two hundred and fifty kilograms of weight in the conventional technique.

Description of the Figures

Figure 1 - Top sectional view of the pattern ring Figure 2 - Front sectional view of the pattern ring Figure 3 - Sectional view of the core cylinder

Figure 4 - Sectional view of the core cylinder wearing the pattern ring

Figure 5 - Side view of the production line

Figure 6 - View of the production line from the core cylinder

The definitions of the elements/parts/components developing this invention are as follows:

1. Pattern ring

2. Air bed

3. Core cylinder

4. Air bed inlet 5. Heating or cooling inlet

6. Artificial leather

7. Infra-red heat source

8. Patterned artificial leather

Detailed Description of the Invention

Polymer is a large molecular structure which is constructed by the linkage of smaller molecules called as monomer with each other by means of covalent bonds. This may be associated with the chain of people who hold hands. The most convenient polymers for the development of this invention are the polymers in the thermoplastic class like PVC (Poly Vinyl Chloride) and PU (Polyurethane). They may melt when heated up to the glass transition temperature and have the necessary characteristics to be treated. When cooled, they become hardened as it is required. Moreover, they melt again when they are heated and may be reshaped. This feature of the polymers is used in this invention to establish the infrastructure for the formation of pattern and texture on the product by printing.

PVC and PU mixture is spread over the paper bearing the required pattern with a scraper. Transfer paper is put into the kiln and the mixture is purified from the volatile materials. The remaining solid material is rendered into a stable layer. This process is repeated depending on the required thickness. In the last step, the adhesive mixture is spread over all of the layers and the fabric is pasted by printing. At this step the edges of the fabric which are covered by the mixture inside the kiln become hardened and adhere to the fabric. PVC or PU layers laminated with fabric are removed from the transfer paper that is out of the kiln. This product is the artificial leather (6) which we will pattern by emboss printing. Instead of embossing machine or plate embossing machine including classical steel, silicone or nickel coated cylinders, the method developed by this invention is comprised by core cylinder (3) that has an air bed; can be electrical, water, gas or grease cooled/heated; and expanded or shrank manually or automatically; and a pattern ring (1) that has the required depth and pattern and will pass over the said cylinder by the help of air bed (2) or a cylinder that can expand or shrink manually or automatically.

Special pattern ring (1) coated with rubber, silicone or nickel becomes ready to transfer pattern onto the artificial leather (6) by covering the core cylinder (3) through the air bed inlet (4) on the core cylinder (3) by the help of the air bed (2) filled with air; or instead the air bed (2) passing over the core cylinder (3) that can expand or shrink manually or automatically, As the next steps, pattern and texture are formed on the artificial leather (6) with the following methods: • Artificial leather (6) is heated by infra-red heat source (7) or heating cylinders without heating or cooling the core cylinder (3);

• Artificial leather (6) is heated by infra-red heat source (7) or heating cylinders; and cold water or cooling gas is extruded inside the core cylinder (3) by means of heating or cooling inlet (5); • Artificial leather (6) is heated by infra-red heat source (7) or heating cylinders; and the core cylinder (3) is heated by using hot water, heating grease or electrical heating system;

• Core cylinder (3) is heated with hot water, heating grease or electrical heating system by means of the heating or cooling inlet (5) without heating the artificial leather (6);

• The pattern on the core cylinder (3) is transferred to the artificial leather (6) by the printing applied by the core cylinder (3) without heating either the artificial leather (6) or the core cylinder (3).

In the method developed by this invention, the special pattern ring (1) is easily mounted on the core cylinder (3) by the help of the air bed (2). With the interruption of the air flow released from the air bed inlet (4), pattern ring (1) is firmly placed on the core cylinder (3). Following the completion of the patterning process, air is again released from the air bed inlet (4) and the pattern ring (1) is removed easily.

The process for the formation of pattern and texture on the artificial leather (1) with the pattern ring (1) that is coated by special rubber, silicone or nickel and mounted on the core cylinder (3) by the help of the air bed (2) is used in the technique for the first time.

It is possible to develop various applications of the process for the formation of three dimensional pattern and texture on the artificial leather by means of emboss printing with the pattern ring within the framework of this basic concept, without any limitations to the examples specified in this invention; and it is essentially as it is described in the claims.