Automobile interior material and manufacturing method thereof
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Solution Overview
Problem
Existing automobile interior materials with printed patterns deform or appear rough on curved surfaces, and are prone to external contamination, lacking durability and aesthetic appeal.
Innovation Solution
A multi-layered automobile interior material comprising a non-woven fabric base layer, a coating layer, a print layer with a predetermined pattern, a transparent film layer, and an adhesive layer, where the film and adhesive layers have high transparency and include perforations for gas discharge and sound absorption, providing a three-dimensional aesthetic and tactile effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a printed pattern is applied to fabric for aesthetic purposes, then visual appeal is improved, but the pattern deforms on curved surfaces
Solution Approach 1:
The fabric is divided into multiple independent layers (base layer, coating layer, print layer, film layer) that can move independently. This segmentation allows the print layer to maintain its pattern integrity while the base layer conforms to curved surfaces, preventing pattern deformation.
Solution Approach 2:
A transparent film layer is introduced as a flexible protective shell over the print layer. This film layer has sufficient flexibility to accommodate curved surfaces while maintaining the underlying pattern's integrity and preventing deformation during installation and use.
2Ease of manufacture
If the fabric surface is textured for aesthetic purposes, then visual appeal is improved, but the texture appears rough in curved sections
Solution Approach 1:
The transparent film layer acts as a smoothing shell that covers the textured surface. When stretched over curved surfaces, this film maintains a smooth external appearance while allowing the textured base layer to provide aesthetic qualities, preventing rough appearance in curved sections.
3Illumination intensity
If the print layer is exposed for pattern visibility, then color expression is improved, but the pattern is vulnerable to external contamination
Solution Approach 1:
A transparent film layer is positioned over the print layer, creating a protective barrier that shields the pattern from external contamination such as dust, moisture, and chemicals. The film's transparency ensures that color expression remains vibrant and visible while providing protection.
Solution Approach 2:
The transparent film layer serves as an intermediary between the print layer and the external environment. It mediates by allowing light to pass through for color visibility while blocking harmful contaminants from directly contacting the pattern, thus protecting it.
4Reliability
If a multi-layered structure is added for protection and aesthetics, then durability and appearance are improved, but device complexity increases
Solution Approach 1:
Multiple functional layers (protection, printing, flexibility, smoothing) are merged into a single integrated fabric structure. The layers are bonded together to form one cohesive material that provides all desired functions simultaneously, reducing the complexity of assembling separate components.
Solution Approach 2:
The fabric uses composite material construction with different layers serving specific functions (base layer for flexibility, coating layer for adhesion, print layer for pattern, film layer for protection). This composite approach achieves high durability and aesthetics while maintaining manufacturability through established composite material techniques.
Data Source
AI summary
Provided is an automobile interior material comprising a non-woven fabric base layer, an acrylic resin coating layer, a print layer with a predetermined pattern, a transparent film layer made of thermoplastic polyurethane resin (TPU), and a transparent adhesive layer. Both the film and adhesive layers have a total light transmittance of 90% or more and a haze value between 70% and 80%. The material may include perforations for air bubble removal and enhanced sound absorption, with the film layer featuring protruding and depressed parts. The manufacturing method involves forming these layers, printing the pattern, applying the adhesive, adhering the film, and perforating to remove air bubbles.