Laminated molded body and method for manufacturing same
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Solution Overview
Problem
Conventional methods for producing quilted products, such as vehicle seats, result in corners being formed at the boundaries of convex and concave portions, leading to a deterioration of the soft design finish due to the skin material being folded along stitches or thread shrinkage, which affects the display of softness in designs.
Innovation Solution
A layered body comprising a skin layer, a cushioning layer, and an adhesive layer, where the cushioning layer has concave portions with valleys separated by a predetermined distance of at least 5 mm, allowing spaces between the skin and cushioning layers to prevent corner formation, and a method involving forming concave portions, providing an adhesive layer, pressing, and reforming to achieve a smooth, gently curved surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the skin material is bonded to the cushioning material and then sewn together, then the quilting structure is formed, but corners are generated at the boundaries of convex and concave portions, deteriorating the soft design finish
Solution Approach 1:
The invention forms convex portions on the cushioning material before bonding the skin material. By pre-forming the three-dimensional shape of the cushioning material, the skin material can be bonded in a flat state and then the convex portions are formed, preventing corner generation at the boundaries of concave portions while achieving the desired quilting effect
Solution Approach 2:
The invention divides the cushioning material into multiple convex portions that are separated by concave portions. This segmentation allows each convex portion to be independently formed without causing corner formation at the boundaries, as the concave portions act as separation zones that prevent stress concentration
2Productivity
If the skin material is pressed by an ultrasonic bonding device with a flat tip to form narrow concave portions, then the quilting pattern is created, but corners are generated between the pressed portions and surroundings
Solution Approach 1:
Instead of pressing the skin material to form concave portions (the conventional approach), the invention forms convex portions on the cushioning material first, then bonds the skin material. This inverted approach prevents corner formation because the skin material is not subjected to localized pressing that would cause folding and corner generation
3Ease of manufacture
If a single stitch is used to form concave portions, then the stitching process is simple, but the concave portions become narrow and corners are generated along the stitch
Solution Approach 1:
The invention forms the convex portions on the cushioning material before any stitching or bonding operations. This preliminary formation of the three-dimensional shape eliminates the need for subsequent pressing or stitching to create concave portions, thereby avoiding corner generation while maintaining manufacturing simplicity
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 solution improves the softness and design finish of the layered body by preventing corner formation, resulting in a more aesthetically pleasing and visually effective shape with enhanced designability and relief expression.
Implementation Method 1
an adhesive layer made from an adhesive and provided between the skin layer and the cushioning layer
Data Source
Figure 1
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AI summary
To provide a layered body and a method for producing the layered body which can improve softness of the design finish with regard to a shape of the layered body. A layered body (100) includes a cover or skin layer (1), a cushion layer 82 (2), an adhesive layer (30, 31). The skin layer (1) is made from a cover or skin material. The cushion layer (2) is made from a cushioning material. The adhesive layer (30, 31) is made from an adhesive and provided between the skin layer (1) and the cushion layer (2). A portion of the skin layer (1) located between valleys (2V) of the cushion layer (2) and corresponding to a bottom portion of a concave portion (2T) has negative curvature in the side view. The bottom portion of the concave portion (2T) between the valleys (2V) in a surface of the cushioning layer (2) on which the adhesive layer (31) is provided has positive curvature or is flat in the side view.