Thermally Expandable Sheet With Dual-Elasticity Base For Curved Surface Forming

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Solution Overview

Problem

Existing three-dimensionally shaped objects formed from thermally expandable sheets cannot be easily deformed into curved surfaces or used to replicate microscopic surface unevennesses, such as those found in materials like leather, due to limitations in elasticity and deformation capabilities.

Innovation Solution

A three-dimensionally shaped object forming sheet with a thermally expansive layer and a base having different elasticities, where a photothermal conversion layer converts absorbed light to heat, allowing the thermally expansive layer to distend and form unevennesses, enabling the sheet to be deformed into desired curved shapes and affixed to articles with macroscopic undulating surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a non-elastic base is used to ensure strength and prevent wrinkles, then the sheet maintains structural integrity, but the sheet cannot be deformed into curved surfaces or replicate microscopic surface unevennesses

Engineering Contradiction:

Improvestructural integrityVSAvoiddeformation capability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The base is divided into two layers with different elastic properties: a first base layer with high elasticity for deformation and a second base layer with low elasticity for strength. This segmentation allows each layer to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The base is constructed as a composite structure combining a first base material with high elasticity and a second base material with low elasticity. This composite approach enables the base to simultaneously provide both deformability and structural strength.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If the base is made highly elastic to enable deformation into curved surfaces, then the sheet can be shaped, but wrinkles and undulations form during transport and handling

Engineering Contradiction:

Improvedeformation capabilityVSAvoidsurface smoothness

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The base is segmented into two functional layers: the first base layer provides elasticity for deformation, while the second base layer provides stability and prevents wrinkles. This segmentation resolves the conflict between deformability and surface smoothness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

By creating a composite base structure with a soft elastic layer and a rigid stable layer, the patent achieves both deformation capability and surface smoothness, preventing wrinkles while enabling curved surface formation.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If a single-layer base is used for simplicity, then the structure is easy to manufacture, but the sheet cannot simultaneously provide strength and deformation capability

Engineering Contradiction:

Improvestructural simplicityVSAvoidfunctional performance

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The base is segmented into two layers, each performing a specific function: the first layer handles elasticity and deformation, while the second layer handles strength and stability. This segmentation enables complex functionality while maintaining relatively simple manufacturing processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The composite base structure combines materials with complementary properties, achieving superior functional performance while remaining manufacturable. The layered composite approach balances complexity and performance.

Inventive Principle:

Principle #40Composite materials

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

Enables the creation of three-dimensionally shaped objects that can be easily deformed into curved surfaces and used to decorate articles with macroscopic undulating surfaces, improving productivity and precision in forming microscopic surface unevennesses for decorative purposes.

Implementation Method 1

on at least one side of the three-dimensionally shaped object forming sheet a photothermal conversion layer for converting absorbed light to heat is formed

Methodology Applied

Scientific EffectPhotothermal conversion:

Implementation Method 2

a pattern of a microcapsule-containing thermally expansive layer that distends due to heat is formed on a base

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

a thermally expandable sheet (also referred to as 'thermally foamable sheet')

Methodology Applied

Scientific EffectThermal foamation:

Data Source

PatentUS11685185B2Three-dimensionally shaped object forming sheet, three-dimensionally shaped object and production method for same, and production method for decorated three-dimensional object

Publication Date: 2023.06.27 CASIO COMPUTER CO LTD

AI summary

A three-dimensionally shaped object forming sheet includes: a thermally expansive layer distending at a predetermined temperature or higher; a base laminated on one side thereof with the thermally expansive layer; and a photothermal conversion layer for converting absorbed light to heat, formed on at least one side, wherein the base includes a first base and a second base that are laminated; and the first base has an elasticity that is greater than an elasticity of the second base.