Inline Leather Embossing Module Using Partially Cured Coatings
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Solution Overview
Problem
Conventional embossing methods for leather products cause undesirable stiffening, uneven thickness, and visible defects, and require multiple process steps, leading to reduced flexibility, softness, and increased production costs.
Innovation Solution
A module comprising an application means and a pressure group, which integrates foil application and embossing, using partially cured coating layers, to minimize damage and process time, and allows inline processing without separate conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional embossing methods are used with high pressure and high temperature, then embossing pattern is obtained, but leather stiffening and loss of softness occurs
Solution Approach 1:
The patent changes the physical state parameters of the coating layer from fully cured to partially cured, enabling embossing at lower pressure (50-150 bar) and temperature (40-80°C). This parameter change allows the leather to be embossed without the harmful stiffening effects caused by conventional high pressure and temperature, while still achieving the desired embossing pattern.
Solution Approach 2:
The patent applies a partially cured coating layer before embossing, which acts as a protective and flexible medium during the embossing process. This preliminary action of partial curing (rather than full curing) allows the coating to provide protection while maintaining flexibility, preventing leather stiffening during embossing.
2Shape
If conventional embossing methods are used, then embossing pattern is obtained, but leather thickness is reduced and structure is compacted
Solution Approach 1:
The patent uses lower pressure (50-150 bar) and temperature (40-80°C) parameters combined with partially cured coating layers, which prevents excessive compaction and thickness reduction of the leather. The partially cured state allows embossing without the severe structural compression that occurs with conventional high pressure embossing.
3Manufacturing precision
If multiple process steps are used for upgrading and embossing, then quality improvement is achieved, but production time increases
Solution Approach 1:
The patent combines the upgrading coating application and embossing operations into a single integrated process step. The partially cured coating layer is applied and then embossed in sequence without complete curing in between, merging what would traditionally be separate upgrading and embossing processes into one continuous operation, thereby reducing production time while maintaining quality improvement.
Solution Approach 2:
The patent maintains continuous processing by embossing the leather while the coating layer is still partially cured, without interrupting for full curing or separate handling steps. This continuity eliminates idle time between upgrading and embossing operations, reducing overall production time while achieving both quality improvement and embossing.
4Manufacturing precision
If upgrading coats are applied to hide damages, then visible defects are reduced, but leather flexibility and softness are decreased
Solution Approach 1:
The patent changes the curing state of the coating layer from full cure to partial cure, which maintains the coating's protective and defect-hiding properties while preserving leather flexibility. The partially cured state allows the coating to remain flexible and compliant with the leather substrate, preventing the stiffening that would otherwise occur with fully cured thick coating layers.
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 module reduces the risk of visible damage, minimizes process time, and maintains leather flexibility and softness, while enabling efficient production of high-quality embossed leather products.
Implementation Method 1
a pressure group (20) configured to, in use, apply an embossing pressure to the laminate between a second pair of rollers (21, 23)
Implementation Method 2
the foil and coated leather product are bound by the partially cured coat
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3B
AI summary
The present disclosure concerns a module (100) for inline embossing of a leather product (1) comprising a leather support sheet (2) having a surface finish layer of one or more partially cured coating layers. The module comprises an application means (10) to apply a protective foil (4) onto the partially cured layer (3) to form a laminate (5). The module also comprises a pressure group (20) including an embossing roller (21) having an outer surface with a relief structure (22) so as to emboss a negative of the surface relief structure into the leather product, across the protective foil.