Micro-Protrusion TPE Skin for Soft-Touch Vehicle Interiors
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Solution Overview
Problem
Existing skins on the market, typically made of plastic materials like polyethylene or polypropylene, fail to provide a good soft touch and do not effectively manage friction coefficients and acceleration.
Innovation Solution
A skin with microscopic protrusions on its surface, formed by integral injection molding of a thermoplastic elastomer and compatible resin, which reduces contact area and deforms under pressure to enhance frictional properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic materials like polyethylene or polypropylene are used for skin, then manufacturing cost and ease of manufacture are improved, but soft touch and friction properties deteriorate
Solution Approach 1:
The patent uses a composite material system consisting of thermoplastic elastomer (TPE) as the base material and compatible resin (such as polyethylene or polypropylene) as the additive. The TPE provides the soft touch and elastic properties, while the compatible resin improves processability and friction characteristics. This composite approach allows the skin to maintain both ease of manufacture and superior soft touch properties.
Solution Approach 2:
The patent modifies the material parameters by controlling the ratio of TPE to compatible resin, adjusting molecular weight, and optimizing processing conditions. These parameter changes enable the material to exhibit both the manufacturability of conventional plastics and the soft touch characteristics of elastomers.
2Device complexity
If conventional smooth surface skin is used, then manufacturing simplicity is improved, but friction coefficients and soft touch deteriorate
Solution Approach 1:
The skin surface is segmented into numerous microscopic protrusions (peaks) distributed across the surface. Each protrusion acts as an independent contact element that can deform and rebound. This segmentation creates a suede-like surface structure that significantly improves friction coefficients and soft touch characteristics compared to smooth surfaces.
Solution Approach 2:
The patent transitions from a two-dimensional smooth surface to a three-dimensional micro-structured surface with protrusions having specific height (20-400 μm), width (10-300 μm), and spacing (30-400 μm). This dimensional change creates surface roughness that enhances friction and soft touch properties.
3Reliability
If microscopic protrusions are added to the skin surface, then soft touch and friction properties are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent optimizes the parameter ranges of the protrusions to balance performance and manufacturability. The height is set at 20-400 μm, width at 10-300 μm, and spacing at 30-400 μm. These ranges are wide enough to accommodate normal manufacturing variations while still achieving the desired soft touch and friction properties.
Solution Approach 2:
The patent uses injection molding with textured molds to create the protrusions, which is a cost-effective and scalable manufacturing method. The mold surface is prepared with the desired micro-structure, and each injection cycle produces skin with the required protrusion pattern, making the process suitable for mass production.
4Reliability
If thermoplastic elastomer and compatible resin are used, then material properties and friction characteristics are improved, but material cost increases
Solution Approach 1:
The patent uses a composite material system where thermoplastic elastomer (TPE) serves as the base material providing soft touch and elastic properties, and compatible resin (such as polyethylene or polypropylene) is added in controlled amounts (typically 5-50 wt%) to improve processability and friction characteristics. This composite approach optimizes the balance between performance and cost.
Solution Approach 2:
The patent optimizes the composition ratio of TPE to compatible resin, controlling the weight percentage of each component to achieve the desired friction characteristics while minimizing material cost. The optimal ratio depends on the specific application requirements for soft touch and friction performance.
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 skin exhibits improved dynamic and static friction coefficients and maximum acceleration, providing a better soft touch and wear resistance suitable for automotive interiors.
Implementation Method 1
the protrusions deform at the surface as the fingers press and stroke, thereby reducing frictional resistance, and the protrusions' morphology then rebounds and recovers
Implementation Method 2
the skin is formed by integral injection molding of a material comprising a thermoplastic elastomer and a compatible resin
Implementation Method 3
the contact area between the sample surface and the fingers is reduced; and the protrusions deform at the surface as the fingers press and stroke, thereby reducing frictional resistance
Data Source
AI summary
The present invention relates to a skin with protrusions on a surface, and a component with the skin for use in the interior of a vehicle. The present invention further relates to a forming method for the component. The present invention comprises: a base layer with an upper surface; and a plurality of microscopic protrusions spaced apart and distributed in at least a part of the area of the upper surface, which enables the upper surface of the base layer to be configured as a suede surface. The skin is formed by integrated injection molding of a material comprising a thermoplastic elastomer and a compatible resin.