Composite Film Transfer Layer Loss Factor Optimization
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Solution Overview
Problem
Conventional decorative films require a release layer that becomes waste after use, necessitating costly disposal methods and increasing material costs.
Innovation Solution
A composite film with a transfer layer having a specific loss factor (between 0.015 and 0.1) that can be peeled off and transferred onto a target substrate, eliminating the need for a separate release layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a release layer is used in conventional decorative film for transferring the color layer, then the decorative layer can be transferred onto the target substrate, but the release layer becomes waste material requiring costly combustion or other disposal methods
Solution Approach 1:
The patent merges the release layer and color layer into a single integrated transfer layer. This transfer layer contains both the decorative color pattern and the release functionality, eliminating the need for a separate release layer. The transfer layer is designed with specific adhesive properties that allow it to be applied to the substrate and then easily removed, leaving only the decorative color pattern on the substrate while the transfer layer itself is discarded as minimal waste.
Solution Approach 2:
The transfer layer serves multiple functions simultaneously: it acts as the color layer providing decorative patterns, and it acts as the release layer enabling easy transfer and removal. This multi-functional design eliminates the need for separate dedicated release layer materials, reducing overall material usage and waste generation while maintaining the decorative transfer capability.
2Ease of manufacture
If a separate release layer is used in conventional decorative film, then the color layer can be transferred, but material costs increase due to additional layers and waste treatment requirements
Solution Approach 1:
The patent combines the release layer and color layer into a single integrated transfer layer structure. This reduces the total quantity of materials required since separate release layer materials are eliminated. The transfer layer is formulated with specific adhesive characteristics that enable both the decorative function and the release function, thereby reducing material costs while maintaining transferability.
Solution Approach 2:
The transfer layer is designed to perform multiple functions: providing decorative color patterns and enabling easy release/transfer. This multi-functionality eliminates the need for additional dedicated release layer materials, directly reducing material quantity and associated costs while maintaining the decorative transfer capability.
3Ease of manufacture
If the transfer layer has strong adhesion to the substrate, then the decorative layer transfers well, but the peeling strength becomes too high making removal difficult
Solution Approach 1:
The patent optimizes the adhesive parameters of the transfer layer by controlling the loss factor within a specific range (0.05 to 0.15). This parameter optimization ensures that the transfer layer has sufficient adhesion to transfer the decorative pattern effectively onto the substrate, while simultaneously maintaining manageable peeling strength that allows for easy removal of the transfer layer after transfer. The loss factor serves as a key parameter to balance these opposing requirements.
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 film enables efficient transfer of the decorative layer onto the substrate with controlled peeling strength, reducing material costs and waste treatment procedures.
Implementation Method 1
a transfer layer disposed on a surface of the substrate... the transfer layer has a loss factor (tan δ) in a range between 0.015 and 0.1... controlled peeling strength
Implementation Method 2
the transfer layer has a loss factor (tan δ) in a range between 0.015 and 0.1... peeling strength
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4B
AI summary
A composite film (100), a decorative film and a method of decorating a target substrate are provided. The composite film includes a substrate (110) and a transfer layer (120) disposed on a surface of the substrate. The transfer layer has a loss factor (tan δ) in a range between 0.015 and 0.1. The composite film is configured to prepare a laminated thin film, a cold pressed film and a hot pressed film. By controlling property of the transfer layer, material cost of the processes for decorating the target substrate and procedure of waste treatment can be decreased.