Laminated Composite Interior Protrusions for Stable Soft Feel
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Solution Overview
Problem
Conventional laminated composite interior components with simple columnar protrusions exhibit unstable deformation under pressing loads, leading to varying feel and difficulty in achieving a soft feel due to high stiffness when ribs are formed instead of protrusions.
Innovation Solution
The laminated composite interior component features protrusions with anisotropic bending stiffness, arranged in a lattice pattern with specific bending directions, allowing for controlled deformation and improved feel through elastic deformation, with options including elongate shapes, asymmetrical cross-sections, and varying material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If simple columnar protrusions are formed, then the structure is simple and easy to manufacture, but the deformation manner is unstable and the feel varies
Solution Approach 1:
The protrusions are designed with asymmetric cross-sections where the thickness varies around the circumferential direction. Specifically, the thickness is smaller in the bending direction and larger in the direction perpendicular to the bending direction. This asymmetric geometry creates anisotropic bending stiffness, causing the protrusions to bend preferentially in a specific direction while maintaining stable and consistent deformation behavior across all protrusions.
2Strength
If ribs are formed instead of protrusions, then the stiffness increases, but it becomes difficult to obtain a sufficient soft feel
Solution Approach 1:
The protrusions incorporate locally varied thickness distributions, with thinner regions oriented in the bending direction and thicker regions in perpendicular directions. This local thickness variation creates directional stiffness characteristics: the protrusions exhibit lower stiffness in the bending direction (providing soft feel) while maintaining higher stiffness in perpendicular directions (providing structural support).
3Reliability
If protrusions with anisotropic bending stiffness are used, then the deformation manner becomes stable and soft feel is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The invention modifies the geometric parameters of the protrusions, specifically the thickness distribution around the circumferential direction. By varying the thickness parameter asymmetrically, the protrusions achieve anisotropic bending stiffness and stable deformation behavior. This parameter change approach maintains compatibility with conventional molding processes while achieving the desired performance.
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 configuration stabilizes the deformation manner of protrusions, enhances the soft feel by controlling bending directions, and achieves a balanced soft and stiff feel, reducing manufacturing costs and variations in feel when pressed.
Implementation Method 1
cushioning characteristics are imparted to the laminated composite interior component when distal ends of the protrusions are pressed against the mating surface and elastically deformed
Data Source
AI summary
A laminated composite interior component includes a first member that has a predetermined mating surface; and a second member made of an elastically deformable resin material. The second member has a plate-shaped portion that is substantially parallel to the mating surface and that has multiple protrusions which are formed integrally with the plate-shaped portion and which protrude toward the mating surface such that a space is formed between the mating surface and the plate-shaped portion. The second member is arranged so as to be laminated on the first member with the protrusions in contact with the mating surface.