Skin, method for producing skin, and layered product

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Solution Overview

Problem

Vinyl chloride resin molded sheets with plasticizers exhibit poor appearance and significant thermal shrinkage when used as automobile interior materials lined with foamed polyurethane, leading to degradation.

Innovation Solution

A surface skin comprising a vinyl chloride resin molded sheet with a plasticizer content of 50 parts by mass or more per 100 parts by mass of vinyl chloride resin, combined with a foamed vinyl chloride resin molded sheet of 2.3 mm or more thickness, disposed on one side, effectively reduces thermal shrinkage when lined with a foamed polyurethane molded product.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a vinyl chloride resin molded sheet containing a plasticizer is used as a surface skin, then flexibility and processability are improved, but thermal shrinkage occurs under high temperature conditions when lined with foam

Engineering Contradiction:

ImproveflexibilityVSAvoidthermal shrinkage

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The surface skin is divided into two distinct layers: a vinyl chloride resin molded sheet (X) containing plasticizer for flexibility, and a foamed vinyl chloride resin molded sheet (Y) without plasticizer for thermal stability. This segmentation allows each layer to perform its specific function independently, resolving the contradiction between flexibility and thermal shrinkage resistance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates a composite material structure by combining two different vinyl chloride resin formulations - one with plasticizer and one without - into a laminated surface skin. This composite approach enables the material to simultaneously exhibit both flexibility (from the plasticized layer) and thermal shrinkage resistance (from the non-plasticized foamed layer).

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If the thickness of the foamed vinyl chloride resin molded sheet is increased to reduce thermal shrinkage, then thermal stability is improved, but the overall weight and material consumption increase

Engineering Contradiction:

Improvethermal stabilityVSAvoidweight

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The foamed vinyl chloride resin molded sheet utilizes a porous foam structure to achieve thermal stability with reduced material density. The foam cells provide thermal insulation and dimensional stability while maintaining a lower overall weight compared to a solid sheet of equivalent thickness, thus mitigating the weight penalty of increased thickness.

Inventive Principle:

Principle #31Porous materials

Data Source

PatentEP3779033B1Skin, method for producing skin, and layered product

Publication Date: 2023.10.18 ZEON CORP

AI summary

Disclosed is a surface skin which comprises a vinyl chloride resin molded sheet (X) which comprises a vinyl chloride resin and a plasticizer; and a foamed vinyl chloride resin molded sheet (Y), wherein an amount of the plasticizer contained in the vinyl chloride resin molded sheet (X) is 50 parts by mass or more per 100 parts by mass of the vinyl chloride resin, and the foamed vinyl chloride resin molded sheet (Y) is disposed on one side in a thickness direction of the vinyl chloride resin molded sheet (X).