Construction Member Pre-Mask Segmentation Flame Retardancy
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Solution Overview
Problem
Decorative films used in construction applications face challenges in achieving non-flammability or flame retardancy due to their multilayer structure, which increases the mass per unit area of combustible components, affecting handling ease and precision application, and require a surface glossiness that mimics a realistic texture like wood grain patterns.
Innovation Solution
A construction member comprising a decorative film with a transparent resin film having an embossed surface and a printed layer, combined with a pre-mask featuring a pressure-sensitive adhesive layer, allowing for improved affixing workability and maintaining texture while reducing film thickness for enhanced non-flammability and flame retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the overall layer thickness of the decorative film is reduced to improve non-flammability or flame retardancy, then the mass per unit area of combustible components decreases, but the handling ease of the decorative film is reduced and high-precision application becomes difficult
Solution Approach 1:
The invention divides the decorative film into two separate functional components: a thin decorative film (with embossed surface, printed layer, and adhesive layer) and a separate pre-mask with support film. This segmentation allows the decorative film to be thin for flame retardancy while the pre-mask provides the necessary handling support during application.
Solution Approach 2:
The pre-mask acts as an intermediary component that temporarily supports the thin decorative film during handling and application. The pre-mask's support film provides mechanical strength and handling ease, while its pressure-sensitive adhesive layer enables precise positioning. After application, the pre-mask is removed, leaving only the thin decorative film that satisfies flame retardancy requirements.
2Ease of operation
If a multilayer structure is used to support printed layer and colored film, then the decorative film has good handling properties, but the mass per unit area of combustible components increases, adversely affecting non-flammability
Solution Approach 1:
The invention separates the handling support function from the decorative film structure itself. Instead of adding multiple combustible layers to the decorative film, the support function is transferred to a separate pre-mask component that is removed after application.
Solution Approach 2:
The pre-mask is a temporary component that is discarded after serving its purpose of supporting the decorative film during application. By removing the pre-mask after application, the combustible mass of the final installed decorative film is minimized while still achieving good handling properties during the application process.
3Ease of manufacture
If the surface glossiness is reduced to render realistic texture patterns, then the decorative effect is improved, but the embossed surface may lose its structural integrity
Solution Approach 1:
The pre-mask with its pressure-sensitive adhesive layer acts as a protective intermediary that bonds to the embossed surface during application. This protective layer maintains the structural integrity of the embossed surface while allowing the decorative film to achieve low glossiness for realistic texture appearance.
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 solution provides a thin decorative film with excellent affixing workability and texture, meeting non-flammability and flame retardancy requirements, while maintaining the embossed surface's visual and tactile effects, as demonstrated by reduced total calorific values in cone calorimeter tests.
Implementation Method 1
a pressure-sensitive adhesive layer having an uneven surface and disposed on the first surface of the support film; and the first surface of the transparent resin film of the decorative film and the uneven surface of the pressure-sensitive adhesive layer of the pre-mask face each other
Data Source
AI summary
A construction member of one embodiment of the present disclosure includes a decorative film and a pre-mask: that is laminated to the decorative film and removed alter application of the decorative film is described. The decorative film includes: a transparent resin film having, an embossed first surface and a second surface opposite the first surface; a printed layer disposed on the second surface of the transparent resin: film; and a colored adhesive layer disposed on or above the printed layer. The pre-mask includes: a support film having a first surface and a second, surface opposite: the first surface; and a pressure-sensitive adhesive layer that has an uneven surface and: is disposed on the first, surface of the support film. The first surface of the transparent resin film of the decorative film and the uneven surface of the pressure-sensitive adhesive layer of the pre-mask face each other.