Decorative Sheet Embossing Mold for Distinctive 3D Patterns
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Solution Overview
Problem
Existing decorative sheets lack distinct concavo-convex patterns, making them indistinguishable from competitors, and current manufacturing methods do not effectively create the desired three-dimensional effects and design properties.
Innovation Solution
A decorative sheet with a concavo-convex pattern formed by an embossing process using an emboss processing mold that includes specific mold portions to create first concave, convex, and second concave portions, enhancing design properties and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional embossing methods are used, then manufacturing process is simple, but the concavo-convex pattern lacks distinctiveness and three-dimensional effect
Solution Approach 1:
The embossing mold is segmented into multiple independent mold portions (first embossing portion, second embossing portion, third embossing portion) that form different concave and convex portions. This segmentation allows each portion to be designed and manufactured independently, achieving complex three-dimensional patterns while maintaining manufacturing feasibility through modular construction
Solution Approach 2:
The invention transitions from conventional two-dimensional embossing to three-dimensional embossing by creating concave portions that extend through the thickness of the base material. The first concave portion, second concave portion, and convex portions are arranged in multiple layers and depths, adding a third dimension (depth/thickness) to the pattern, which enhances visual distinctiveness and tactile effect
2Illumination intensity
If conventional embossing methods are used, then manufacturing cost is low, but visibility and design properties are insufficient
Solution Approach 1:
Different regions of the embossing mold are designed with different properties: the first embossing portion creates deep concave portions for shadow effects, the second embossing portion creates smaller concave portions for detail texture, and the third embossing portion creates convex portions for highlight areas. This local differentiation of mold properties enhances overall visibility through varied light reflection and shadow patterns
Solution Approach 2:
The second concave portion is nested within the first concave portion, creating a hierarchical structure where smaller features are contained within larger features. This nesting arrangement allows multiple levels of detail to be visible simultaneously, enhancing the overall visibility and design complexity without requiring separate manufacturing processes
3Adaptability or versatility
If simple embossing patterns are used, then manufacturing is easy, but the sheet cannot stand out visually from competitors
Solution Approach 1:
The embossing pattern employs asymmetric arrangements of concave and convex portions, where the first concave portion and second concave portion have different sizes, shapes, and positions relative to each other. This asymmetry creates unique visual characteristics that differentiate the product from competitors while maintaining manufacturing precision through carefully designed mold geometries
Solution Approach 2:
The embossing mold is designed with pre-configured multiple embossing portions that simultaneously create complex three-dimensional patterns in a single processing step. This preliminary arrangement of mold features ensures that the differentiated design is achieved without requiring multiple sequential operations, maintaining manufacturing precision while enabling design differentiation
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 embossing process effectively forms a concavo-convex pattern on the decorative sheet, improving visibility and design properties, allowing the sheet to stand out visually and maintain a three-dimensional effect.
Implementation Method 1
The temperature of the embossing roll is set to 100 to 250° C. The temperature of the heat roll is set to 100 to 250° C.
Implementation Method 2
In the cushioning material, a portion to be thermally fused is compressed.
Implementation Method 3
an outer material, a lining material and a cushioning material are thermally fused to each other by heating and pressing of the embossing portions
Data Source
AI summary
In a decorative sheet, a concavo-convex pattern is provided on a surface of a base material. The concavo-convex pattern includes a first concave, a convex and a second concave. The first concave is a bottomed concave. The convex is adjacent to the first concave. The second concave opens at the bottom surface of the first concave. The second concave is a bottomed concave. The second concave is provided in a first region of the bottom surface of the first concave which is a region spaced apart from a boundary between the first concave and the convex not less than a maximum dimension which is a dimension in an opening direction orthogonal to a thickness direction of an opening end of the second concave which is a side of the bottom surface of the first concave in the thickness direction of the base material.