Decorative Molded Article Surface Roughness for Sparkle Prevention
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Solution Overview
Problem
The partially-matted transfer-molded articles exhibit sparkle and reduced contrast due to uneven surface structures, particularly in the matted parts, which affect the design decorativeness and antiglare performance.
Innovation Solution
A decorative molded article with a protective layer having specific surface roughness parameters, including arithmetic average roughness (Rax1) and ten-point average roughness (Rzx1), is developed, along with a transfer sheet design that ensures the protective layer's surface meets these requirements to prevent sparkle and enhance contrast and antiglare performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a transfer layer with a release layer entirely containing a matting agent is used to create a matted texture, then antiglare performance is improved, but sparkle occurs and contrast is reduced
Solution Approach 1:
The invention applies different surface roughness characteristics to different regions of the protective layer. Region (P) has controlled unevenness with specific roughness parameters to prevent sparkle, while region (Q) has different roughness characteristics. This local differentiation allows the matted part to provide antiglare performance without causing sparkle and contrast reduction, as each region is optimized for its specific function.
Solution Approach 2:
The invention controls the surface roughness parameters of the protective layer within specific ranges: arithmetic average roughness (Rax1) at cutoff value of 0.8 mm, arithmetic average roughness (Ray1) at cutoff value of 0.08 mm, and ten-point average roughness (Rzx1) at cutoff value of 0.8 mm. By precisely controlling these parameters, the invention achieves the optimal balance between antiglare performance and prevention of sparkle, resolving the technical contradiction through quantitative parameter optimization.
2Object-affected harmful factors
If the surface of the protective layer has unevenness to prevent glare, then antiglare performance is improved, but sparkle and fine brightness fluctuation occur
Solution Approach 1:
The protective layer is divided into region (P) with controlled unevenness for antiglare performance and region (Q) with different characteristics. The unevenness in region (P) is precisely controlled within specific roughness parameter ranges, creating a local quality that provides glare protection without generating sparkle. This spatial differentiation of surface properties resolves the contradiction between antiglare performance and sparkle prevention.
Solution Approach 2:
The invention specifies precise ranges for surface roughness parameters: arithmetic average roughness (Rax1) at cutoff value of 0.8 mm, arithmetic average roughness (Ray1) at cutoff value of 0.08 mm, and ten-point average roughness (Rzx1) at cutoff value of 0.8 mm. These controlled parameter changes create the optimal unevenness that prevents glare while avoiding the fine brightness fluctuation characteristic of sparkle.
Data Source
AI summary
Provided are a decorative molded article that prevents sparkle and has a high contrast, a method for producing the decorative molded article, and a transfer sheet for use for the decorative molded article. The decorative molded article 10 is provided with a protective layer 2 having unevenness on a resin molded article 1, wherein in the surface of the protective layer 2, the arithmetic average roughness (Rax1) according to JIS B0601:1994 at a cutoff value of 0.8 mm, the arithmetic average roughness (Ray1) according to JIS B0601:1994 at a cutoff value of 0.08 mm, and the ten-point average roughness (Rzx1) according to JIS B0601:1994 at a cutoff value of 0.8 mm satisfy the following requirements (1) to (3): 0.30≤(Rax1−Ray1)/Ray1≤0.85 (1), Rzx1/Rax1≤15.0 (2), Rax1≥0.14 μm (3).