Elastomeric Skin Production Using Solid Spot Particles
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Solution Overview
Problem
Existing methods for producing elastomeric skins with a visually spotted appearance are difficult to control for uniform dot size and distribution, often requiring multiple compositions and nozzles, leading to increased time and complexity.
Innovation Solution
Incorporating solid spot forming particles with a longest dimension of at least 40 μm into the liquid skin forming composition, which remain visible and embedded in the elastomeric skin, allowing for a uniform and visually perceptible spotted appearance without the need for multiple compositions or nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two different liquid skin forming compositions are successively sprayed onto the mould surface to produce a visually spotted elastomeric skin, then the elastomeric skin has a spotted appearance, but it is very difficult to achieve uniform dot size and distribution
Solution Approach 1:
The patent combines multiple functions into a single liquid skin forming composition by incorporating solid spot forming particles. Instead of using two separate compositions sprayed through multiple nozzles, the invention uses one composition containing both the liquid matrix and solid particles that will form the spotted appearance, thereby simplifying the spraying system while achieving uniform dot distribution
Solution Approach 2:
The patent changes the physical state and size parameters of the spot-forming elements by using solid particles with controlled size ranges (0.1-2 mm diameter) suspended in the liquid composition. This parameter control allows uniform dot size and distribution to be achieved through a single spraying operation, resolving the contradiction between precision and complexity
2Manufacturing precision
If the first liquid skin forming composition is applied to cover a very large area of the mould surface, then the second composition will appear as spotted, but the dimensions and uniformity of dots cannot be controlled
Solution Approach 1:
The solid spot forming particles are pre-dispersed uniformly throughout the liquid skin forming composition before spraying. This preliminary uniform distribution ensures that when the composition is sprayed, the spots are automatically and uniformly distributed across the entire mould surface area, eliminating the difficulty of controlling dot uniformity during the spraying process
3Manufacturing precision
If the first liquid skin forming composition is applied to cover only a very limited area of the mould surface, then the first composition will appear as spotted, but the droplet size is increased due to impact and flattening
Solution Approach 1:
The patent changes the size parameter of the spot-forming elements from micro-scale droplets (50-500 μm) to controlled solid particles (0.1-2 mm diameter). These solid particles maintain their size and shape upon impact with the mould surface, preventing the flattening and merging that occurs with liquid droplets, thus enabling small uniform dots to be achieved across large surface areas
4Manufacturing precision
If multiple different liquid skin forming compositions are sprayed onto the mould surface to obtain the desired visual effects, then the spotted appearance is achieved, but the production time increases and the process becomes more complex
Solution Approach 1:
The patent merges the functions of multiple compositions into a single composition by suspending solid spot forming particles within the liquid skin forming matrix. This unified composition can be sprayed through a single nozzle in one operation, eliminating the need for multiple spraying passes and significantly reducing production time while maintaining the spotted appearance quality
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 achieves a more efficient and less complex production of elastomeric skins with uniformly distributed small dots, enhanced abrasion resistance, and improved surface characteristics, while maintaining a visually appealing spotted appearance.
Implementation Method 1
spraying said liquid skin forming composition in the form of a spray of droplets onto at least a portion of said mould surface
Implementation Method 2
allowing the liquid skin forming composition to harden
Data Source
AI summary
A method for producing an elastomeric skin having visually spotted appearance may include providing a liquid skin forming composition having solid spot forming particles having a longest dimension that is at least 40 μm and spraying the liquid skin forming composition in the form of a spray of droplets onto a mold surface. The provision of solid spot forming particles that are comparable in size to the droplet size may aid in projecting the solid spot forming particles forward upon impact on the mold surface such that a percentage thereof appear visible on the front face of the elastomeric skin after demolding thereby resulting in a front face with a spotted appearance without having to use multiple liquid skin forming compositions.