Reverse Coating Process for Composite Leather Film Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of genuine leather is labor-intensive, expensive, and limited by individual piece production, with challenges in achieving consistent quality, design options, and durability, particularly in high-end applications like luxury vehicles and premium interiors.
Innovation Solution
A reverse coating process is used to produce composite leather films by coating a carrier tape with a plastic mass, applying a leather layer on a reactive adhesive, and then removing the carrier tape, allowing for automated production of high-quality, consistent leather with enhanced surface properties and design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If genuine leather is produced using traditional individual piece production methods, then the leather quality and prestige are maintained, but the production is labor-intensive, expensive, and has limited productivity
Solution Approach 1:
The patent inverts the traditional leather production approach by applying plastic coatings to leather sheets in a reverse coating process, rather than treating individual leather pieces manually. This allows continuous roll-to-roll production while maintaining genuine leather quality, resolving the contradiction between productivity and manufacturing ease
Solution Approach 2:
The patent applies plastic coatings and adhesive layers to leather sheets before final assembly, preparing the material in advance for automated processing. This preliminary coating enables subsequent automated lamination and production steps, reducing manual work intensity while increasing productivity
2Reliability
If genuine leather is used in luxury vehicles, then the perceived quality and prestige are improved, but the cost and production complexity increase
Solution Approach 1:
The patent creates composite leather structures by combining genuine leather sheets with plastic coatings and adhesive layers. This composite approach maintains the prestige and quality of genuine leather while enabling automated production processes, reducing production complexity
Solution Approach 2:
The patent divides the leather treatment process into separate functional layers (adhesive layer, plastic coating layers) that can be applied independently in automated processes. This segmentation allows complex quality requirements to be met through standardized production steps, reducing overall production complexity
3Reliability
If leather is coated with protective coatings to ensure durability, then the serviceability is improved, but the coating temperature must be kept low since leather is not temperature-resistant
Solution Approach 1:
The patent uses adhesive layers and plastic compounds that cure or bond at low temperatures suitable for leather. By changing the chemical parameters of the coating materials to enable low-temperature bonding, the patent achieves durable protective coatings without exposing leather to damaging high temperatures
4Manufacturing precision
If individual leather skins are coated manually to achieve uniform quality, then the design options are limited, but the coating uniformity is difficult to achieve
Solution Approach 1:
The patent replaces manual mechanical coating processes with automated reverse coating machinery that applies adhesive layers and plastic coatings uniformly across leather sheets. This mechanical automation ensures coating uniformity while freeing up design options that were previously limited by manual processing constraints
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
This method enables cost-effective, high-volume production of genuine leather with improved color fastness, abrasion resistance, and surface quality, eliminating manual steps and allowing for extensive design possibilities, suitable for luxury vehicle interiors and other premium applications.
Implementation Method 1
this first plastic mass, i.e. the top coat, is cured in a subsequent heat treatment
Implementation Method 2
a second plastic compound is applied as an adhesive layer to this first plastic layer
Data Source
Figure 1
AI summary
The method for producing a leather composite film in a reverse coating process, comprises coating a carrier strip (2) with a first adhesive mass, hardening the first adhesive mass in a subsequent heat treatment, applying a second adhesive mass as adhesive layer (5) on the first plastic layer, applying a leather on the non-reactive adhesive layer, and removing the carrier strip after sufficient drying/reaction of the resulting leather composite film made of plastic and leather layers. A reactive polyurethane mass is applied as first and/or second adhesive masses with a solvent. The method for producing a leather composite film in a reverse coating process, comprises coating a carrier strip (2) with a first adhesive mass, hardening the first adhesive mass in a subsequent heat treatment, applying a second adhesive mass as adhesive layer (5) on the first plastic layer, applying a leather on the non-reactive adhesive layer, and removing the carrier strip after sufficient drying/reaction of the resulting leather composite film made of plastic and leather layers. A reactive polyurethane mass is applied as first and/or second adhesive masses with a solvent. A low-solvent system made of polyurethane-, acrylate-, polyolefin- and/or latex dispersion is applied as first and/or second adhesive masses or a low-solvent system made of polyvinyl chloride plastisols is applied as first and/or second adhesive masses. A reactive or non-reactive thermoplastic polymer and/or a reactive solvent-free thermoplastic on polyurethane basis that cross-links under moisture effect are applied as second mass. The application of the leather takes place in the yet undried adhesive layer after its introduction, takes place in the dried adhesive layer that is liquefied again by heat input, and takes place in the form of individual leather pieces and/or endless leather films. The carrier strip is pitted with a negative structure of the surface of the leather composite film. The surface of the leather composite film is embossed after removing the carrier strip with a pit structure. A foamed plastic layer is applied between the first and second adhesive masses. The plastic layers present between the carrier strip and the leather have a total thickness of less than 0.15 mm. The first plastic layer is provided with a further lacquer layer after removing the carrier strip. The leather composite film is provided on rear-side with further foam and/or lacquer layers. The plastic layers have an air permeability corresponding to the leather after the hardening.