Interior Material Light Emission via Laser-Etched Grooves and Transparent Film
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Solution Overview
Problem
Existing methods for manufacturing interior materials with light-emitting logo patterns face issues such as reduced transmittance due to dust accumulation in hollow lighting grooves, weak durability, difficulty in forming various logo patterns, and challenges in precise injection molding of island portions without adequate support.
Innovation Solution
A method involving a blocking layer with a hot-melt interlayer, support tape for island support, laser-etched lighting grooves, and a transparent film binder, followed by injection molding at high temperature to fill grooves and prevent foreign material entry, ensuring clear light emission and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If hollow lighting grooves are formed under the real wood layer, then light can pass through the logo portion, but dust accumulates in the hollow portion reducing transmittance
Solution Approach 1:
A transparent film is introduced as an intermediary material to fill the lighting grooves. This transparent film serves as a mediator between the light source and the external environment, allowing light to pass through while preventing dust accumulation, thus resolving the contradiction between light transmittance and transmittance stability
Solution Approach 2:
The patent utilizes a transparent film (thin film) to fill and seal the lighting grooves. This thin film structure allows light transmission while creating a closed environment that prevents dust entry, solving the problem of dust accumulation in hollow grooves
2Ease of manufacture
If the molded article is made with simple structure, then manufacturing is easier, but durability is weak
Solution Approach 1:
The patent employs a composite structure consisting of multiple layers including real wood layer, adhesive layer, transparent film, and light-blocking layer. This composite material structure enhances durability while maintaining manufacturability, as each layer serves a specific function and can be processed using standard manufacturing techniques
3Adaptability or versatility
If various logo patterns are required, then aesthetic expression is improved, but it becomes difficult to form diverse patterns
Solution Approach 1:
The patent applies local quality by allowing different logo patterns to be formed in specific regions of the transparent film. The light-blocking layer can be selectively positioned and shaped in different areas to create various logo patterns, while the overall manufacturing process remains consistent, enabling pattern diversity without complicating production
4Device complexity
If the island portion is not supported during injection molding, then the structure is simpler, but precise injection molding becomes difficult
Solution Approach 1:
The support tape is attached to the upper surface of the real wood layer before the injection molding process. This preliminary action provides necessary support for the island portion during molding, ensuring precise injection molding without requiring complex support structures in the mold itself
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 enables clear and durable light emission through various logo patterns by preventing dust entry and enhancing structural integrity, allowing for precise molding and cost-effective production.
Implementation Method 1
bonding a blocking layer for blocking the transmission of light below a material layer with a hot-melt layer interposed therebetween
Implementation Method 2
forming lighting grooves, through which light passes, by laser-etching a predetermined portion from the blocking layer to the material layer
Implementation Method 3
the injection molding process is performed at high temperature such that the transparent film is melted and stretched to fill the lighting grooves
Data Source
Figure 1~2a
Figure 2b~3a
Figure 3b~3e
AI summary
Disclosed herein is a method of manufacturing an interior material, which can implement various and distinct light emission effects by disposing a light-blocking layer configured to block light emitted from a light source on a wood layer or transparent film and then allowing the component of the transparent film to fill lighting grooves formed by laser-etching. Since a tape configured to support an island is employed, stable manufacturing is possible throughout an overall process.