Automobile instrument panel surface material and method for manufacturing same
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Solution Overview
Problem
Current automobile instrument panel surface materials lack durability against direct sunlight, elegant appearance, and soft touch, with existing materials either fading or causing fogging issues.
Innovation Solution
A microfiber-based surface material with polycarbonate polyurethane and a UV absorber, combined with silicone oil, providing enhanced light fastness and heat resistance, ensuring a soft touch and elegant appearance while maintaining durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If microfiber materials are used to achieve elegant appearance and soft touch, then appearance quality and touch comfort are improved, but light resistance and heat resistance deteriorate causing fading and fogging
Solution Approach 1:
A silicone oil layer is introduced as an intermediary substance between the microfiber base material and the external environment. This silicone oil layer serves as a mediator that provides both light resistance (preventing fading) and heat resistance (preventing fogging) while allowing the microfiber to maintain its elegant appearance and soft touch characteristics. The silicone oil acts as a protective barrier that resolves the contradiction between aesthetic qualities and durability.
Solution Approach 2:
The invention creates a composite material structure consisting of microfiber base material combined with a silicone oil coating. This composite structure integrates the advantages of both components: the microfiber provides elegant appearance and soft touch, while the silicone oil provides light resistance and heat resistance. The composite material approach allows simultaneous achievement of aesthetic qualities and environmental durability.
2Strength
If resin materials are used to achieve durability, then strength and durability are improved, but appearance quality and touch comfort deteriorate becoming hard and commonplace
Solution Approach 1:
The invention uses a thin film of silicone oil coating on the microfiber surface to provide protective functions. This thin film approach allows the material to maintain flexibility and softness characteristic of microfiber, unlike rigid resin materials. The silicone oil film provides the necessary durability and environmental resistance without sacrificing the flexible, soft characteristics that give the material its elegant appearance and comfortable touch.
3Reliability
If hindered amine light stabilizer is added to improve light resistance, then light fastness is improved, but fogging occurs when content exceeds 5% by mass
Solution Approach 1:
The invention changes the chemical composition parameter by using silicone oil instead of hindered amine light stabilizer as the primary protective agent. This parameter change allows achieving light resistance and heat resistance without the fogging side effect that occurs when hindered amine light stabilizer content exceeds 5% by mass. The silicone oil provides a different mechanism of protection that avoids the harmful fogging effect.
Solution Approach 2:
The invention extracts or removes the hindered amine light stabilizer component from the material composition to eliminate the fogging problem. By taking out this problematic substance and replacing it with silicone oil, the invention achieves the necessary light resistance without generating the harmful fogging effect that occurs with high concentrations of hindered amine light stabilizer.
4Strength
If resin materials are used to achieve durability, then strength is improved, but resistance to direct sunlight deteriorates causing fading
Solution Approach 1:
Silicone oil is introduced as an intermediary protective layer that provides resistance to direct sunlight. This intermediary substance protects the underlying microfiber and resin materials from UV degradation and fading while allowing the material to maintain its structural durability. The silicone oil acts as a shield against sunlight exposure, resolving the contradiction between strength and light resistance.
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 material achieves a high light fastness rating and low glass haze, ensuring the surface remains resistant to sunlight and heat without fogging, providing a durable and aesthetically pleasing instrument panel surface.
Implementation Method 1
the polyurethane contains a UV absorber having a vapor pressure of 1.0 × 10 E-7 Pa or less at 20°C
Implementation Method 2
0.01 to 5% by mass of a silicone oil in mass percentage relative to a total mass of the microfiber and the polyurethane
Data Source
AI summary
The present invention provides an automobile instrument panel surface material having an elegant appearance and a soft touch of nap, and a method for manufacturing the same. The automobile instrument panel surface material according to the present invention contains: a microfiber having an average single fiber diameter of 0.3 to 7 µm; and polyurethane, and the automobile instrument panel surface material has nap formed of the microfiber, has, of light fastnesses measured according to a light fastness measurement method of JIS L 0843:2006 under conditions of a xenon arc intensity of 110 MJ/m2, a fading by gray scale evaluation of grade 3.5 or higher, and has a glass haze of 10.0% or less as measured according to a glass haze evaluation method of ISO 6452:2007 under conditions of a heating temperature of 100°C and a heating time of 20 hours.