Vehicle Interior Layered Sheet for Molding and Cushion Feel
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Solution Overview
Problem
Current interior materials for vehicles face challenges in achieving high emotional and aesthetic quality while maintaining molding quality, particularly with artificial leather, due to limitations in post-processing efficiency and elongation properties of PVC and PU skin layers, as well as base layers made of polyester and nylon woven fibers.
Innovation Solution
A layered sheet composition for vehicle interiors is proposed, featuring a skin layer with a polyurethane (PU) layer and a polyvinyl chloride (PVC) sheet layer, along with a base layer of thermoplastic olefin (TPO), polyurethane foam, or soft-polypropylene (S-PP) foam, which enhances emotional quality and molding quality through adjustable thickness and surface treatments, ensuring improved processability and physical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional artificial leather with PVC and PU skin layers is used, then emotional quality is maintained, but molding quality and elongation properties are insufficient
Solution Approach 1:
The patent applies composite materials by creating a multi-layer structure combining PVC sheet layer, PU layer, and base layer. This composite structure resolves the contradiction by allowing each layer to contribute its strengths: PVC provides molding quality and elongation, while PU provides emotional quality and softness, achieving both high molding precision and tensile strength simultaneously
2Strength
If skin layer thickness is increased to improve emotional quality, then cushion feeling is enhanced, but molding quality and processability deteriorate
Solution Approach 1:
The patent segments the skin layer into two distinct layers: a PVC sheet layer (0.2-0.5mm) for molding quality and a PU layer (0.03-0.2mm) for emotional quality. This segmentation resolves the contradiction by assigning different functions to different layers, allowing the PVC layer to maintain thin dimensions for good moldability while the PU layer provides cushioning without compromising processability
3Stability of the object's composition
If base layer is made of polyester or nylon woven fibers, then structural stability is achieved, but cushion feeling and emotional quality are insufficient
Solution Approach 1:
The patent changes the parameters of the base layer by using foam materials (polyester foam, polyurethane foam, or polypropylene foam) with specific density ranges (0.02-0.08 g/cm³) instead of traditional woven fibers. This parameter change provides both structural stability through the foam matrix and enhanced cushion feeling through the cellular structure, resolving the contradiction between stability and comfort
Data Source
AI summary
A layered sheet for interior material of vehicles and a method for manufacturing the same are disclosed. To improve both emotional quality and molding quality, the layered sheet includes: a skin layer including a polyurethane (PU) and a polyvinyl chloride (PVC) sheet layer disposed under the PU layer; and a base layer disposed under the PVC sheet layer. The base layer includes thermoplastic olefin (TPO), PU foam, or soft polypropylene (S-PP) foam.