Composite Material 3D Texture Molding

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Solution Overview

Problem

Existing methods for creating three-dimensional textures on composite materials, such as laser engraving and embossing, result in uneven surfaces, environmental hazards, and limited design flexibility, along with long development times that hinder market responsiveness.

Innovation Solution

A composite material with a surface layer that is heated and molded using a suction force against a textured mold, ensuring uniform thickness and density, and allowing for rapid design changes and reduced environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If laser engraving or abrasive machining is used to remove resin layer, then three-dimensional texture is formed, but surface is uneven and burnt edge phenomenon occurs

Engineering Contradiction:

Improvethree-dimensional textureVSAvoidsurface smoothness

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical removal methods (laser engraving, abrasive machining) with a molding process where a surface layer is heated and conformally pressed against a textured mold. This substitution eliminates burnt edges and surface unevenness by forming the texture through controlled deformation rather than material removal.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state of the surface layer by heating it to a softened state, enabling it to conform to the mold texture. This parameter change (temperature increase) allows the material to flow and replicate the mold surface precisely, achieving smooth three-dimensional textures without mechanical removal defects.

Inventive Principle:

Principle #35Parameter changes

2Shape

If laser engraving or abrasive machining is used, then three-dimensional texture is formed, but pungent smell of burning resin is generated

Engineering Contradiction:

Improvethree-dimensional textureVSAvoidburning resin smell

Core Design Contradiction:

ShapeVSObject-generated harmful factors

Solution Approach 1:

The patent replaces thermal and mechanical removal processes that cause resin burning with a controlled molding process. The surface layer is heated to a manageable temperature for softening and molding, avoiding the excessive heat and combustion associated with laser engraving, thus eliminating pungent burning smells.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Shape

If embossing or release paper transfer is used to pressurize resin layer, then three-dimensional texture is formed, but texture depth is uniformly undesired and hand feel is poor

Engineering Contradiction:

Improvethree-dimensional textureVSAvoidtexture depth uniformity

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent uses temperature as a control parameter to soften the surface layer, enabling it to conform precisely to the mold texture. This thermal softening allows for controlled texture depth replication without the uniform undesired pressing associated with conventional embossing, as the material flows to match the mold's three-dimensional pattern accurately.

Inventive Principle:

Principle #35Parameter changes

4Shape

If embossing or release paper transfer is used, then three-dimensional texture is formed, but development to mass production takes relatively long time

Engineering Contradiction:

Improvethree-dimensional textureVSAvoiddevelopment time

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The patent uses a pre-textured mold that can be reused for mass production. The mold is prepared in advance with the desired texture pattern, and the surface layer is simply heated and pressed against it. This preliminary preparation of the mold enables rapid replication of textures without repeated development time, facilitating quick transition from design to mass production.

Inventive Principle:

Principle #10Preliminary action

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 method produces composite materials with uniform three-dimensional textures that enhance tactile sensation and allow for quicker market introduction, while minimizing environmental pollution and design limitations.

Implementation Method 1

heating and softening the surface layer

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

applying a suction force from a second surface of the mold, so that the surface layer is attached to the first surface of the mold

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentUS10040267B2Composite material having three-dimensional texture and method for making the same

Publication Date: 2018.08.07 SAN FANG CHEM IND

AI summary

The present invention relates to a composite material having a three-dimensional texture and a method for making the same. The composite material includes a base material and a surface layer. The surface layer is disposed on a surface of the base material, and has a substantially uniform thickness. The surface layer includes at least one first portion and at least one second portion. The first portion is attached to the surface of the base material. The second portion is spaced apart from the surface of the base material to form at least one hole.