Microfiber Instrument Panel Surface for UV Resistance and Low Haze

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Solution Overview

Problem

Current automobile instrument panel surface materials lack durability against direct sunlight while also failing to provide an elegant appearance and a soft touch, with existing materials either discoloring or causing fogging issues.

Innovation Solution

A microfiber-based surface material with polycarbonate polyurethane and a UV absorber, combined with a silicone oil, that exhibits high light fastness and low glass haze, ensuring resistance to sunlight and maintaining a soft touch.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If microfiber materials are used to achieve elegant appearance and soft touch, then aesthetic quality is improved, but light resistance deteriorates causing discoloration and fading

Engineering Contradiction:
Improveaesthetic qualityVSAvoidlight resistance
Core Design Contradiction:
ShapeVSReliability

Solution Approach 1:

The patent uses a composite binder system combining polyurethane resin with specific additives (hindered amine light stabilizer at 0.1-5% by mass and UV absorber at 0.1-5% by mass) to create a material that maintains the aesthetic qualities of microfiber while providing superior light resistance. This composite approach allows the binder to protect the microfiber structure from UV degradation without compromising its soft touch and elegant appearance.

Inventive Principle:
Principle #40Composite materials

2Reliability

If hindered amine light stabilizer is added to improve light resistance, then light fastness is improved, but glass haze increases causing fogging when content exceeds 5% by mass

Engineering Contradiction:
Improvelight fastnessVSAvoidglass haze
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent optimizes the concentration parameters of light stabilizing agents to resolve the contradiction. By limiting the hindered amine light stabilizer content to 0.1-5% by mass and UV absorber to 0.1-5% by mass (both relative to polyurethane resin), the formulation achieves sufficient light fastness while preventing excessive glass haze that would cause fogging. This parameter optimization allows simultaneous achievement of light resistance and clarity.

Inventive Principle:
Principle #35Parameter changes

3Strength

If polyvinyl chloride resin or polyolefin resin is used to ensure durability, then durability is improved, but aesthetic quality deteriorates with hard touch and commonplace appearance

Engineering Contradiction:
ImprovedurabilityVSAvoidaesthetic quality
Core Design Contradiction:
StrengthVSShape

Solution Approach 1:

The patent employs a composite formulation using polyurethane resin as the base binder combined with microfiber and specific functional additives. This composite structure provides the durability needed for instrument panels while the microfiber component contributes soft touch and elegant appearance. The combination achieves both mechanical strength and aesthetic quality that neither material could provide alone.

Inventive Principle:
Principle #40Composite materials

4Shape

If microfiber materials are used to achieve soft touch, then surface quality is improved, but heat resistance deteriorates causing volatilization at high temperatures

Engineering Contradiction:
Improvesurface qualityVSAvoidheat resistance
Core Design Contradiction:
ShapeVSTemperature

Solution Approach 1:

The patent uses polyurethane resin as an intermediary binder material that protects the microfiber from direct exposure to high temperatures. The polyurethane resin has better heat resistance than the microfiber, acting as a protective matrix that prevents volatilization while allowing the microfiber to maintain its soft touch and aesthetic qualities on the surface.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 material achieves a high light fastness rating and low glass haze, providing durability and an elegant appearance with a soft touch, effectively addressing the limitations of existing materials.

Implementation Method 1

polyurethane, and the automobile instrument panel surface material has nap formed of the microfiber, has, of light fastnesses measured according to a light fastness measurement method of JIS L 0843:2006 under conditions of a xenon arc intensity of 110 MJ/m2

Methodology Applied
Scientific EffectUV absorption: Absorption (EM radiation)

Implementation Method 2

combined with a silicone oil, that exhibits high light fastness and low glass haze, ensuring resistance to sunlight and maintaining a soft touch

Methodology Applied
Scientific EffectLubrication: Lubrication

Data Source

PatentUS11629457B2Automobile instrument panel surface material and method of manufacturing same
Publication Date: 2023.04.18 TORAY INDUSTRIES INC

AI summary

An automobile instrument panel surface material includes a microfiber having an average single fiber diameter of 0.3 to 7 μm; and polyurethane, the automobile instrument panel surface material having nap formed of the microfiber, the automobile instrument panel surface material having, of light fastnesses measured according to a light fastness measurement method of JIS L 0843:2006 under conditions of a xenon arc intensity of 110 MJ/m2, a fading by gray scale evaluation of grade 3.5 or higher, the automobile instrument panel surface material having a glass haze of 10.0% or less as measured according to a glass haze evaluation method of ISO 6452:2007 under conditions of a heating temperature of 100° C. and a heating time of 20 hours.