Vehicular Interior Printing Blanket Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing vehicular interior materials, such as liquid pressure transfer printing, IML, and TOM, face challenges with low precision, difficulty in printing curves, complex processes, and high costs, which hinder the achievement of excellent texture and workability while maintaining economic feasibility.
Innovation Solution
A method involving the formation of a molded article with a concavo-convex surface and the application of a printing layer using a predetermined blanket, where the convex portion's width is equal to or greater than the concave portion's width, to enhance precision and prevent ink spreading, thereby ensuring high-resolution designs and various indoor atmospheres.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional printing methods (liquid pressure transfer printing, IML, TOM) are used on molded articles, then various aesthetics and textures can be expressed, but printing precision is low and curve printing is difficult
Solution Approach 1:
The patent applies preliminary action by pre-forming a concavo-convex shape on the molded article surface before printing. This pre-structured surface guides the printing blanket to conform precisely to curved geometries, enabling high-resolution printing on complex shapes without requiring complex printing equipment or multi-step processes.
Solution Approach 2:
The patent introduces an intermediary element - the concavo-convex shaped surface - that mediates between the printing blanket and the final printed pattern. This intermediate structure allows the blanket to maintain contact with curved surfaces while transferring ink precisely, solving the problem of low printing precision on curved geometries.
2Productivity
If existing manufacturing methods are used, then vehicular interior materials can be produced, but the process is complicated and cost is high
Solution Approach 1:
The patent merges the shaping and printing operations into a single integrated process. By forming the concavo-convex shape and applying the printing layer in one continuous operation using a blanket, the method eliminates separate steps for surface preparation, positioning, and printing, thereby simplifying the overall manufacturing process and reducing costs.
Solution Approach 2:
The concavo-convex shaped surface serves a dual function: it defines both the geometric shape and the printing pattern. The shape itself guides the printing blanket to automatically conform to the surface geometry, eliminating the need for complex positioning systems or additional control mechanisms, thus reducing device complexity.
3Manufacturing precision
If a printing layer is formed on a concavo-convex surface using a blanket, then high-resolution designs can be achieved, but ink spreading may occur reducing precision
Solution Approach 1:
The patent applies local quality by designing the concavo-convex shape with specific dimensional relationships where the convex portion width is equal to or greater than the concave portion width. This local geometric feature creates natural ink barriers at the convex portions, preventing ink from spreading into adjacent areas, thereby maintaining high printing precision without requiring additional ink control mechanisms.
Data Source
AI summary
Provided are a vehicular interior material manufacturing method and a vehicular interior material, the method comprising the steps of: forming a molded article including a surface having an uneven shape; and forming a printing layer on the surface of the molded article by using a predetermined blanket.