Skin material and method for producing the same
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Solution Overview
Problem
Conventional methods for producing skin materials with concave parts on the front surface side fail to clearly express elongated line- or dotted line-shaped convex parts on the bottom surface, limiting design freedom.
Innovation Solution
A method involving heat-pressing a raw material between an embossing die and an elastic sheet, where a pressing rib with a gap part forms a concave part on the front surface and pushes the material into the gap to create a convex part on the bottom surface, allowing for the expression of elongated line- or dotted line-shaped convex parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If heat-pressing is performed between an embossing die and a metal pedestal to form a concave part, then the concave part is formed on the front surface, but elongated line- or dotted line-shaped convex parts cannot be clearly expressed on the bottom surface of the concave part
Solution Approach 1:
An elastic sheet is introduced as an intermediary between the metal pedestal and the raw material. This elastic sheet enables the formation of clearly expressed convex parts on the bottom surface of concave parts by allowing material to be pushed into its recessed portions during heat-pressing, while still supporting the formation of the concave part on the front surface.
2Shape
If heat-pressing is performed between an embossing die and a metal pedestal, then the concave part is formed, but the design freedom in the skin material is limited
Solution Approach 1:
The elastic sheet serves as a mediator that enables diverse design expressions by allowing the formation of various convex part patterns (elongated line-shaped, dotted line-shaped, small dot-shaped) on the bottom surface of concave parts, thereby increasing design freedom while maintaining concave part formation capability.
3Object-affected harmful factors
If the embossing die surface is spaced apart from the front surface of the raw material during heat-pressing, then thermal deterioration of the front surface is suppressed, but the pressing rib must be designed with gap parts
Solution Approach 1:
The pressing rib is designed with gap parts at specific locations where convex parts need to be formed. This local modification allows material to be pushed into the gaps by the elastic sheet's repulsive force, creating clearly expressed convex parts on the bottom surface of concave parts while maintaining the overall simplicity of the embossing die structure.
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
This method increases design freedom by clearly forming elongated line- or dotted line-shaped convex parts on the skin material, while also suppressing thermal deterioration of the front surface.
Implementation Method 1
a part of the raw material may be pushed out into the gap part by repulsive force of the elastic sheet due to the pressing of the pressing rib to form the convex part
Implementation Method 2
a concave heat-deformed part in which the thermoplastic resin fibers are thermally deformed may be formed at a position corresponding to the concave part
Data Source
AI summary
The method for producing a skin material is a method for producing a skin material having a concave part formed on the front surface side, comprising heat-pressing a raw material between an embossing die and an elastic sheet to form the concave part and, at the same time, forming a convex part on a bottom surface of the concave part.