Thermoplastic Decorative Pieces with Urethane-Bead Suede Texturing
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Solution Overview
Problem
Existing decorative pieces made of thermoplastic synthetic resin lack a suede-like unevenness, failing to provide a high-class impression comparable to leather or fabric-made embroidered patches.
Innovation Solution
A method involving silk screen printing with urethane beads on the upper layer material, followed by high-frequency dielectric heating using an engraved die to create a suede-like surface texture, mimicking the appearance of suede.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-frequency dielectric heating is used to form three-dimensional shape, then manufacturing efficiency is improved, but surface appearance quality deteriorates (plastic-like appearance without suede-like unevenness)
Solution Approach 1:
The patent applies preliminary action by printing the decorative ink with urethane beads onto the upper layer material before the high-frequency dielectric heating process. This pre-application of the decorative layer ensures that the suede-like unevenness is formed in advance, allowing the subsequent heating process to maintain both high productivity and improved surface appearance quality without requiring post-processing steps.
Solution Approach 2:
The patent employs composite materials by combining the thermoplastic synthetic resin upper layer material with a decorative ink containing urethane beads. This composite structure allows the decorative piece to achieve both the manufacturability of thermoplastic materials and the aesthetic quality of suede-like surfaces, resolving the contradiction between manufacturing efficiency and appearance quality.
2Ease of manufacture
If smooth surface is used for thermoplastic decorative piece, then ease of manufacture is improved, but aesthetic quality deteriorates (lacks high-class impression)
Solution Approach 1:
The patent applies local quality by creating a non-uniform surface structure through the printed decorative ink with urethane beads. Instead of treating the entire surface uniformly, the decorative layer is applied selectively to create localized suede-like unevenness on specific areas of the upper layer material, thereby improving aesthetic quality while maintaining ease of manufacture through targeted decoration rather than complex overall surface treatment.
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 decorative pieces with a suede-like unevenness that enhances the luxurious appearance, providing a finish similar to genuine leather or fabric, while maintaining flexibility and lightweight properties.
Implementation Method 1
A method for manufacturing decorative pieces made of thermoplastic synthetic resin through high-frequency dielectric heating is known in the art
Implementation Method 2
softening the upper layer material to form into a three-dimensional shape
Data Source
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AI summary
The present invention provides a method for manufacturing a decorative piece made of a thermoplastic synthetic resin and capable of providing a suede-like appearance. The method for manufacturing the decorative piece 10 comprises preparing a film-like or sheet-like upper layer material 30 made of thermoplastic synthetic resin, placing the upper layer material on a table 46 that serves as a lower electrode, putting an engraved die 41 that serves as an upper electrode on the upper layer material, and subjecting the upper layer material to high-frequency dielectric heating by oscillating high-frequency between the table and the engraved die, wherein the upper layer material is printed with a decorative ink containing urethane beads mixed in medium on a specified surface area 31 thereof, and wherein the engraved die has a texture engraved surface 42 formed by a laser engraving process on an area opposing the specified surface area of the upper layer material, whereby a suede-like unevenness is formed in the specified area of the upper layer material by the high-frequency dielectric heating.