Skin material, method for producing same, and interior material
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Solution Overview
Problem
Conventional skin materials with embossed patterns lack the necessary designability and three-dimensional effect required for advanced industrial applications, particularly in terms of tactile sensation and aesthetic appeal.
Innovation Solution
A skin material comprising a base cloth layer with a surface fabric and a back fabric bound by a thermoplastic resin fiber binding yarn, forming a gap between them, and a foam layer that enhances thermal dispersion and rigidity, allowing for a more pronounced three-dimensional design and improved thermal deformation without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a three-dimensional knitted fabric with bound front and back layers is used as the base cloth layer to form an embossed pattern, then an excellent aesthetic appearance and high degree of design freedom are achieved, but the designability and three-dimensional effect are still insufficient for advanced industrial applications
Solution Approach 1:
The base cloth layer is segmented into surface fabric and back fabric as separate layers, bound by binding yarn to create independent structural zones. This segmentation allows each layer to contribute differently to the overall three-dimensional effect, with the surface fabric providing the visible pattern and the back fabric offering structural support, thereby enhancing both designability and three-dimensional effect
Solution Approach 2:
The invention transitions from conventional two-dimensional embossed patterns to three-dimensional structures by erecting binding yarns that create vertical gaps between the surface fabric and back fabric. This dimensional change enables pronounced three-dimensional effects while maintaining design flexibility through varied gap formations and binding patterns
2Manufacturing precision
If thermal deformation of thermoplastic resin fiber binding yarn is used to adjust concave part thickness and form embossed patterns, then an embossed pattern with excellent aesthetic appearance is obtained, but thermal dispersion is insufficient leading to waviness and concave-convex reflections
Solution Approach 1:
The invention changes the physical parameters of the binding yarn by selecting thermoplastic resin fibers with specific melting points and thermal properties. During heat pressing, these fibers undergo controlled thermal deformation at predetermined locations, adjusting the thickness of concave parts and forming precise embossed patterns while maintaining thermal stability to prevent waviness
Solution Approach 2:
The base cloth layer is constructed as a composite structure combining surface fabric, back fabric, and thermoplastic resin binding yarn. This composite material system provides enhanced thermal dispersion properties, distributing heat evenly during the embossing process to prevent localized overheating and resulting defects like waviness and concave-convex reflections
3Shape
If the binding yarn is erected to form a gap between surface fabric and back fabric, then a more excellent three-dimensional effect is achieved, but structural stability may be compromised
Solution Approach 1:
The binding yarn structure is designed to be dynamic rather than rigid, allowing controlled movement and deformation during thermal processing. The erected binding yarns maintain the gap structure for three-dimensional effect while being capable of adjusting their configuration during heat pressing, ensuring structural stability is maintained throughout the manufacturing process and final product
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 material exhibits a more excellent three-dimensional effect with increased thermal dispersion and rigidity, maintaining chemical resistance and friction durability while preventing waviness and concave-convex reflections, thus offering a superior tactile and visual experience.
Implementation Method 1
a concave thermally-deformed part is adjusted to a predetermined thickness by thermal deformation of a thermoplastic resin fiber as the binding yarn
Implementation Method 2
a foam layer that enhances thermal dispersion and rigidity, allowing for a more pronounced three-dimensional design and improved thermal deformation without damage
Data Source
AI summary
A skin material includes: a design layer; and a base cloth layer. The design layer includes a surface layer and a foam layer. The base cloth layer includes a surface fabric and a back fabric, and a binding yarn that binds the surface fabric and the back fabric. The binding yarn is a thermoplastic resin fiber erected between the surface fabric and the back fabric to form a gap between the surface fabric and the back fabric. The foam layer and the surface fabric are joined. An interior material includes the skin material and a base material to which the skin material is attached. A method for producing the skin material includes joining the surface layer and the base cloth layer via a foamable adhesive to serve as the foam layer.