Decorative Sheet Embossing with Multi-Region Concavo-Convex Patterns
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Solution Overview
Problem
Existing decorative sheets lack the ability to create a design differentiation when viewed from different directions, as they typically feature uniform concave portions, which limits their visual appeal and product differentiation.
Innovation Solution
A decorative sheet with a concave portion on its front face featuring a first concavo-convex pattern in one region and a second concavo-convex pattern in a different region, allowing for varied light reflection and creating an illusion of multiple concave portions when viewed from various angles, achieved through an embossing method and die design with specific concavo-convex patterns on the inner surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform concave portion is formed on the decorative sheet, then the manufacturing process is simple, but the visual appeal and product differentiation are limited
Solution Approach 1:
The patent applies local quality by forming different concavo-convex patterns in different regions of the concave portion. Specifically, a first concavo-convex pattern is formed in a first region and a second concavo-convex pattern is formed in a second region, creating spatial variation in surface properties while maintaining a unified overall structure. This allows the decorative sheet to exhibit different visual characteristics from various viewing angles without complicating the fundamental embossing process.
Solution Approach 2:
The patent utilizes dimensional change by creating multi-directional viewing effects through the concavo-convex patterns. The decorative sheet is designed so that when viewed from different directions, the concave portions appear different due to the arrangement of concavo-convex patterns in different regions. This adds a dimensional aspect to the design differentiation, transforming a two-dimensional surface into a multi-perspective visual experience.
2Adaptability or versatility
If different concavo-convex patterns are formed in different regions of the concave portion, then design differentiation is enhanced, but the embossing die complexity increases
Solution Approach 1:
The embossing die is segmented into multiple regions, each responsible for forming a specific concavo-convex pattern in a corresponding region of the concave portion. The die includes a first region for forming the first concavo-convex pattern and a second region for forming the second concavo-convex pattern. This segmentation allows complex patterns to be created through modular die design, where each segment can be independently designed and manufactured.
Solution Approach 2:
The patent merges multiple embossing functions into a single integrated embossing die. By combining the first and second regions with different concavo-convex patterns into one die structure, the patent achieves multi-pattern embossing in a single processing step, avoiding the need for multiple separate embossing operations or multiple dies, thereby reducing overall system complexity.
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
Enriches design variation by creating an illusion of different concave portions when viewed from multiple directions, enhancing the visual appeal and differentiation of products.
Implementation Method 1
The embossing roll is set at a temperature of 100 to 250° C. The heat roll is set at a temperature of 100 to 250° C.
Implementation Method 2
a laminated sheet passes between an embossing roll and a heat roll while being pressed
Data Source
AI summary
A decorative sheet includes a base material and a concave portion. The concave portion is provided on a front face of the base material. In the concave portion, a depth direction coincides with a thickness direction of the base material. The concave portion includes a first concavo-convex pattern and a second concavo-convex pattern. The first concavo-convex pattern is provided in a first region of an inner surface of the concave portion. The second concavo-convex pattern is a concavo-convex pattern different from the first concavo-convex pattern. The second concavo-convex pattern is provided in a second region of the inner surface of the concave portion which is different from the first region.