Encapsulated Foil Transfer on Leather for Durable Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The adhesion of foil design elements to leather surfaces in automotive applications is compromised by the presence of silicone dispersions and isocyanate crosslinkers in top coatings, leading to poor bonding and failure under mechanical abrasion or wear.
Innovation Solution
A method involving a base coat, a color coat free of isocyanates and silicones, a heat-activated adhesive for embossing a foil transfer, and a top coat with silicones and isocyanate crosslinkers is used to secure the foil transfer to the leather, ensuring strong adhesion and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicone dispersions and isocyanate crosslinkers are included in the top coating to ensure durability and performance, then the durability and aesthetic requirements are met, but the adhesion properties of temperature-activated adhesives are reduced, preventing proper bonding of foil design elements
Solution Approach 1:
The patent divides the coating system into two separate segments: a base coat/adhesion layer containing silicone dispersions and isocyanate crosslinkers for durability, and a top coat free of these components to maintain adhesive bonding. This segmentation allows each layer to perform its specific function without interference, resolving the contradiction between durability and adhesion.
Solution Approach 2:
The patent extracts the harmful components (silicone dispersions and isocyanate crosslinkers) from the top coat layer where they would interfere with adhesive bonding. By removing these components specifically from the top coat while retaining them in the base coat, the patent maintains both durability and adhesion properties.
2Reliability
If multiple waterborne coatings are applied to meet stringent performance and aesthetic requirements, then the performance and aesthetics are improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent segments the coating system into functionally distinct layers (base coat/adhesion layer and top coat), where each layer is optimized for its specific purpose. This segmentation allows for simplified formulation of each individual layer while achieving overall high performance through the combination of layers.
Solution Approach 2:
The patent applies local quality by giving different compositional characteristics to different layers: the base coat contains silicone and isocyanates for durability, while the top coat is free of these components to ensure adhesion. Each layer has locally optimized properties suited to its specific function in the overall coating system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the adhesion and durability of foil transfers on leather surfaces, preventing adhesion failure and maintaining aesthetic and performance requirements under mechanical stress.
Implementation Method 1
A foil transfer is embossed into and secured with an adhesive to the finished leather segment
Implementation Method 2
secured with an adhesive to the finished leather segment
Data Source
AI summary
A leather product such as a leather covering for a vehicular part includes a segment of leather with a base coat applied to a hide side and a color coat applied to the base coat to create an intermediate stage leather segment. A foil transfer is embossed into and secured with an adhesive to the intermediate stage leather segment. A top coat is then applied to the foil transfer and a surrounding portion of the intermediate stage leather segment after the foil transfer is secured to complete the leather product. A system and method of making the leather product is also disclosed.