Seat Covering Material Embossing with Variable-Height Roll Sections
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Solution Overview
Problem
Conventional seat covering materials with embossed patterns have a monotonous aesthetic appearance due to the uniformity of their three-dimensional patterns, lacking complexity and depth, which limits their aesthetic and tactile enhancement.
Innovation Solution
A method involving an embossing roll with varying height embossing portions and a heated flat roll to create a complex three-dimensional pattern by forming depressions of different depths and inclinations, allowing for a more intricate and aesthetically pleasing surface through the use of stepped and beveled embossing portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If embossing portions with uniform height are used, then the manufacturing process is simple, but the aesthetic appearance becomes monotonous
Solution Approach 1:
The embossing portions are designed with locally varied heights (first, second, and third heights) within different regions (first, second, and third sections) of the embossing roll surface. This local variation in height creates diverse depression depths and light reflection characteristics, achieving complex aesthetic appearance while maintaining a systematic manufacturing approach.
Solution Approach 2:
The embossing roll surface is segmented into multiple sections (first, second, third sections) with distinct height variations. Each section contains embossing portions at different heights, creating a segmented pattern that produces complex three-dimensional visual effects through varied light reflection and shadow formation.
2Shape
If embossing portions with varying heights are used, then the aesthetic appearance becomes complex, but the manufacturing precision requirements increase
Solution Approach 1:
The invention systematically varies the height parameter of embossing portions across different sections of the roll, establishing three distinct height levels (first height > second height > third height). This parameter variation creates complex aesthetic effects while maintaining controllable manufacturing precision through defined height relationships rather than arbitrary variations.
3Device complexity
If only the embossing roll is heated, then the process is simple, but the material may overheat at the pressed sections
Solution Approach 1:
A heating flat roll serves as an intermediary heating element that contacts the elongated material on the opposite side from the embossing roll. This intermediary heating system distributes thermal energy more evenly through the material thickness, preventing localized overheating at pressed sections while maintaining effective heat treatment.
4Temperature
If both rolls are heated, then temperature distribution is improved, but energy consumption increases
Solution Approach 1:
While both the embossing roll and flat roll are heated, the heating is applied partially to different regions - the embossing roll heats the surface in contact with it, and the flat roll heats the opposite surface. This partial heating approach achieves uniform temperature distribution through the material thickness without excessive energy consumption that would result from heating the entire system uniformly at high temperatures.
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 produces a seat covering material with a complex three-dimensional appearance that varies in light reflection and shine when viewed from different angles, enhancing both aesthetic and tactile qualities while maintaining even heat distribution and preventing overheating.
Implementation Method 1
both the heating embossing roll and the heating flat roll are heated... even heat distribution and preventing overheating
Data Source
AI summary
A heating embossing roll has a base surface on which a plurality of embossing portion is formed. An elongated material passes between the heating embossing roll and a heating flat roll so that the elongated material is pressed by the embossing portions of the heating embossing roll. The embossing portion is formed to have a height from the base surface that varies by section.