Flocked Resin Sheet Structure for Secondary Molding Tactility
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Solution Overview
Problem
Existing resin sheets lose their good tactile sensation when subjected to secondary molding due to the separation of hair-like bodies from the base layer.
Innovation Solution
A thermoplastic resin sheet with hair-like bodies arranged regularly on a base layer, where a continuous phase is formed without a structural boundary, using a urethane-based elastomer composition with specific molecular weight ratios of polyol and aliphatic diol, ensuring integral formation of the base layer and hair-like bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hair-like bodies are arranged regularly on a base layer to provide good tactile sensation, then tactile sensation is improved, but the hair-like bodies separate from the base layer during secondary molding
Solution Approach 1:
The patent merges the base layer and hair-like bodies into a single integral structure by forming a continuous phase without structural boundaries between them. This is achieved through specific urethane-based elastomer composition (component A: polyol with Mn 450-900, component B: aliphatic diol with carbon number 2-10, molar ratio 60:40 to 88:12), eliminating the separation issue during secondary molding while preserving the tactile sensation provided by the regularly arranged hair-like bodies.
Solution Approach 2:
The patent uses a composite material system consisting of urethane-based elastomer formed from specific polyol and aliphatic diol components. This composite composition creates a continuous phase that integrates the base layer and hair-like bodies, providing both the tactile properties of arranged hair-like structures and the structural stability needed to prevent separation during secondary molding processes.
2Adaptability or versatility
If secondary molding is performed to affix the resin sheet to an object surface, then the resin sheet can be applied to various uses, but the hair-like bodies are lost and tactile sensation deteriorates
Solution Approach 1:
The patent merges the base layer and hair-like bodies into a single integral structure by forming a continuous phase without structural boundaries between them. This is achieved through specific urethane-based elastomer composition (component A: polyol with Mn 450-900, component B: aliphatic diol with carbon number 2-10, molar ratio 60:40 to 88:12), eliminating the separation issue during secondary molding while preserving the tactile sensation provided by the regularly arranged hair-like bodies.
3Ease of manufacture
If a structural boundary exists between the base layer and hair-like bodies, then manufacturing is simplified, but the hair-like bodies separate during secondary molding
Solution Approach 1:
The patent merges the base layer and hair-like bodies into a single integral structure by forming a continuous phase without structural boundaries between them. This is achieved through specific urethane-based elastomer composition (component A: polyol with Mn 450-900, component B: aliphatic diol with carbon number 2-10, molar ratio 60:40 to 88:12), eliminating the separation issue during secondary molding while preserving the tactile sensation provided by the regularly arranged hair-like bodies.
Data Source
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AI summary
The purpose of the present invention is to provide a resin sheet wherein a good tactile sensation can be maintained after secondary molding, and a molded article thereof. Provided is a thermoplastic resin sheet having hair-like bodies arranged regularly on at least one surface of a base layer and in which a continuous phase is formed without a structural boundary between the base layer and the hair-like bodies, wherein a thermoplastic resin composition constituting the base layer and the hair-like bodies comprises a urethane-based elastomer, the urethane-based elastomer comprises a component (A) derived from a polyol with a number-average molecular weight of 450-900 and a component (B) derived from an aliphatic diol with a carbon number of 2-10, and the molar ratio of (A) and (B) is 60:40 to 88:12.