Deco sheet
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Solution Overview
Problem
Decorative sheets face challenges with limited moldability on curved surfaces, high manufacturing costs, and lack of scratch resistance, particularly with PETG sheets which are more expensive than PET and PVC sheets that generate endocrine disruptors upon burning.
Innovation Solution
A decorative sheet with a multi-layer structure comprising a top and rear surface layer of PETG resin and an intermediate layer of PET and ester-based resin, with a hard coating layer, allowing for a low and wide moldable temperature range and high scratch resistance, while avoiding the use of PVC and reducing costs by incorporating PET resin in the intermediate layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If PET sheets are used to replace PVC sheets for environmental friendliness, then harmful factors are reduced, but moldability deteriorates due to higher molding temperature requirements and narrower molding temperature range
Solution Approach 1:
The patent modifies the glass transition temperature parameter of the polyester resin by incorporating specific ester-based resins (polybutylene terephthalate, polytrimethylene terephthalate) with lower Tg values into the PET structure. This parameter change lowers the overall molding temperature requirement and widens the molding temperature range, thereby improving moldability while maintaining environmental friendliness
Solution Approach 2:
The patent creates a composite resin system combining PET resin with ester-based resins (specifically polybutylene terephthalate and/or polytrimethylene terephthalate) in controlled proportions. This composite material approach leverages the environmental benefits of PET while incorporating resins that facilitate easier molding, thus resolving the contradiction between environmental friendliness and manufacturability
2Ease of manufacture
If PETG sheets are used to improve moldability and eliminate crystallization defects, then moldability is improved, but manufacturing cost increases by about 30% compared to PET sheets
Solution Approach 1:
The patent applies different resin compositions to different functional layers: the decorative layer uses PETG resin for excellent printability and surface quality, while the intermediate layer uses a cost-effective composite of PET and ester-based resins for moldability. This local differentiation maintains necessary moldability without requiring expensive PETG throughout the entire sheet structure
Solution Approach 2:
The patent replaces expensive PETG resin in the intermediate layer with a more economical composite of PET and ester-based resins. While PETG offers superior properties, the patent demonstrates that the cost-effective resin composite can achieve sufficient moldability for the intermediate layer, reducing overall manufacturing cost while maintaining functional performance
3Strength
If decorative sheets are coated with hard coating layer to provide scratch resistance, then surface hardness is improved, but adhesion between layers may deteriorate due to lifting or delamination
Solution Approach 1:
The patent introduces an intermediate layer composed of a specific composite resin (PET and ester-based resin with controlled Tg) that acts as a mediator between the decorative surface layer and the hard coating layer. This intermediate layer provides chemical and mechanical bonding properties that ensure strong adhesion, preventing lifting or delamination while allowing the hard coating to provide scratch resistance
4Productivity
If PVC sheets are used to achieve low cost and excellent processability, then manufacturing cost and ease of manufacture are improved, but harmful factors increase due to dioxin generation upon burning
Solution Approach 1:
The patent replaces PVC resin, which generates harmful dioxin upon burning, with environmentally friendly polyester-based resins (PET and ester-based resins). While this substitution increases material cost slightly, the patent achieves cost control through optimized resin formulation and processing efficiency. The harmful dioxin generation is eliminated while maintaining economic viability through balanced material selection
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 excellent moldability on severely curved surfaces, high scratch resistance, and economic manufacturing, while being environmentally friendly by avoiding endocrine disruptors, with improved surface hardness and printability.
Implementation Method 1
the glass-transition temperature of the ester-based resin is lower than the glass-transition temperature of the glycol-modified polyethylene terephthalate (PETG) resin
Implementation Method 2
excellent thermal deformability
Implementation Method 3
In order to give a scratch resistance, decorative sheets are coated with hard coating layer on the top surface layer
Data Source
AI summary
Provided is a decorative sheet which comprises a top surface layer, a rear surface layer and at least one intermediate layer between the top surface layer and the rear surface layer, wherein: the top surface layer and the rear surface layer each independently are formed from a first composite resin composition comprising a glycol-modified polyethylene terephthalate resin and an ester-based resin; the intermediate layer(s) is (are) formed from a second composite resin composition comprising a glycol-modified polyethylene terephthalate resin, a polyethylene terephthalate resin and an ester-based resin; the glass-transition temperature of the ester-based resin is lower than the glass-transition temperature of the glycol-modified polyethylene terephthalate resin; the glass-transition temperature of the ester-based resin is lower than the glass-transition temperature of the polyethylene terephthalate resin; and the content of the polyethylene terephthalate resin in the second composite resin composition is between about 5 and about 30 wt%.