Decorative Sheet Embossing with Patterned Concave Depths
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Solution Overview
Problem
Existing decorative sheets lack the ability to create a visually distinct impression of varying concave portion depths, which is essential for differentiating products in a competitive market, as they often fail to effectively mimic the appearance of concave portions with different depths.
Innovation Solution
A decorative sheet with a base material featuring a combination of first and second concave portions, where the first concave portion includes a first concavo-convex pattern on its inner surface and the second concave portion does not, allowing for the creation of an impression of varying depths when viewed from different angles, achieved through an embossing method and die design that includes specific mold portions for each type of concave portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a decorative sheet uses uniform concave portions without additional patterns, then the manufacturing process is simple, but the visual differentiation capability is insufficient
Solution Approach 1:
The patent applies local quality by differentiating the inner surfaces of concave portions: some concave portions have smooth inner surfaces while others have concavo-convex patterns on their inner surfaces. This local variation in surface quality creates different light reflection characteristics, enabling visual differentiation of depths while maintaining a relatively simple manufacturing process using a single embossing die with varied mold portion designs.
2Ease of manufacture
If all concave portions have the same surface texture, then the manufacturing process is straightforward, but the ability to create depth perception is limited
Solution Approach 1:
The embossing die incorporates mold portions with different surface characteristics: some mold portions have smooth outer surfaces that create smooth concave portions, while others have concavo-convex patterns on their outer surfaces that create corresponding patterns on the concave portion inner surfaces. This local differentiation in mold portion design enables precise depth perception through varied light reflection while keeping the embossing process straightforward.
Solution Approach 2:
The patent adds a dimensional aspect to the concave portions by incorporating concavo-convex patterns on the inner surfaces, transforming simple single-dimensional depth variations into multi-dimensional surface structures. This additional surface dimension enhances light scattering and reflection properties, improving depth perception accuracy without complicating the basic embossing process.
3Illumination intensity
If concave portions have smooth inner surfaces, then light reflection is regular and predictable, but visual interest and product differentiation are reduced
Solution Approach 1:
The patent strategically places concavo-convex patterns on the inner surfaces of specific concave portions to create localized irregular light reflection. This selective application of surface texture variation generates visual interest and enhances product differentiation through diverse light scattering patterns, while other concave portions maintain smooth surfaces for regular light reflection, achieving a balanced visual appeal.
4Adaptability or versatility
If the embossing die includes multiple types of mold portions with different patterns, then the decorative effect is enhanced, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single embossing die by integrating various types of mold portions (smooth and concavo-convex patterned) within one die structure. This consolidation allows the die to simultaneously create different concave portion types in a single embossing operation, enhancing decorative effect variety while avoiding the complexity of multiple separate dies or multi-step processes.
Solution Approach 2:
The embossing die is designed with multi-functionality, where a single die structure performs multiple functions by incorporating mold portions with different surface characteristics. This universal die design can create both smooth concave portions and those with concavo-convex patterns, reducing the need for specialized dies for each pattern type and thereby managing device 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
The solution effectively gives the impression of multiple concave portions with different depths on the decorative sheet, enhancing product differentiation by creating a visually appealing and distinct appearance, while also suppressing irregular light reflection on smoother surfaces.
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 plurality of concave portions. The plurality of concave portions are 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 plurality of concave portions includes a first concave portion and a second concave portion. The first concave portion includes a first concavo-convex pattern on a first inner surface of the first concave portion. The second concave portion does not include the first concavo-convex pattern on a second inner surface of the second concave portion.