Urethane Resin Skin Composite With Deep Recess Shape Retention
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Solution Overview
Problem
Conventional synthetic resin skin materials struggle to create deep three-dimensional recesses with excellent shape retention, limiting designability and durability in applications such as automotive and furniture interiors.
Innovation Solution
A synthetic resin skin material composite is developed, featuring a urethane resin skin layer with recesses extending into a cushion layer, where the cushion layer is formed using a flexible polyurethane foam material and embossed using a combination of molds with and without embossing dies to create deep, durable recesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional synthetic resin skin materials are used with shallow recessed portions, then manufacturing simplicity is maintained, but designability and three-dimensional feeling are insufficient
Solution Approach 1:
The invention transitions from shallow surface recesses to deep three-dimensional recesses that extend through multiple layers (skin layer into the cushion layer), adding depth as a new dimension. This creates genuine three-dimensional stepped portions with volumes ranging from 0.5 mm³ to 5 mm³, dramatically improving designability while maintaining manufacturing feasibility through controlled layer integration
2Adaptability or versatility
If deep recesses are formed in synthetic resin skin materials, then designability is improved, but shape retention capability deteriorates
Solution Approach 1:
The invention creates a composite structure integrating a skin layer (0.5-2.0 mm thick) with a cushion layer (5-15 mm thick), where deep recesses extend from the skin layer into the cushion layer. This composite construction allows the skin layer to provide designability through deep recesses while the cushion layer provides shape retention capability, resolving the contradiction between depth and stability
Solution Approach 2:
The invention applies different properties to different regions: the skin layer contains the deep recesses for design expression, while the cushion layer provides structural support and shape retention. The recesses create localized three-dimensional stepped portions that do not compromise the overall structural integrity of the composite material
3Reliability
If recesses extend only within the skin layer, then manufacturing simplicity is maintained, but three-dimensional feeling and durability are insufficient
Solution Approach 1:
The invention extends recesses from the two-dimensional skin layer surface into the third dimension of the cushion layer, creating volumetric three-dimensional stepped portions. This depth extension (0.5-5 mm³ volume) significantly improves durability and three-dimensional feeling while maintaining manufacturing simplicity through controlled layer integration during the molding process
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 composite achieves deeper recesses with superior shape retention and durability, enhancing designability and performance in various applications, including automotive and furniture interiors.
Implementation Method 1
performing hot press
Implementation Method 2
pressing protrusions of the embossing die of the first mold onto a side of the urethane resin skin layer of the laminate for embossing
Implementation Method 3
pressing protrusions of the embossing die of the first mold onto a side of the urethane resin skin layer of the laminate for embossing under a condition that tips of the protrusions of the embossing die of the first mold extend into the cushion layer
Data Source
AI summary
A synthetic resin skin material composite, including: a urethane resin skin material including a urethane resin skin layer provided at one surface of a substrate; and a cushion layer that is placed at a surface on an opposite side of the substrate from the surface of the urethane resin skin material at which the urethane resin skin layer is provided; in which the urethane resin skin material has recesses at a side of the urethane resin skin layer, and each of the recesses has a depth in a thickness direction of the synthetic resin skin material composite, such that the recesses extend from the urethane resin skin layer into the cushion layer beyond an interface between the urethane resin skin material and the cushion layer that is present in a region without a recess, as well as a method of producing a synthetic resin skin material composite.