Decorative Sheet Layering for Scratch Resistance and 3D Gloss
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Solution Overview
Problem
Conventional decorative sheets are susceptible to gouging and denting under heavy loads, which compromises their scratch resistance.
Innovation Solution
A decorative sheet comprising a pattern layer, a first surface protective layer with a thermosetting resin having a urethane bond, and a second surface protective layer, where the sheet base material has a T-type peeling strength of 130 gf/15 mm or more and air permeability of 150 seconds or more, ensuring resistance to gouging and denting while maintaining a visual stereoscopic effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional sheet base material is used in decorative sheets, then the decorative sheet can be manufactured, but the sheet base material is susceptible to gouging and denting under heavy loads, leading to reduced scratch resistance
Solution Approach 1:
The patent applies parameter changes by specifying precise physical property ranges for the sheet base material: T-type peeling strength of 130-210 gf/15 mm and air permeability of 150 seconds or more per JIS P 8117. These parameter optimizations enable the thin paper to achieve both flexibility and resistance to gouging and denting under heavy loads, resolving the contradiction between manufacturability and durability.
Solution Approach 2:
The patent employs composite materials by combining the thin paper sheet base material with multiple protective layers including a pattern layer, first surface protective layer, and second surface protective layer. This composite structure provides enhanced scratch resistance and protection against gouging and denting while maintaining the base material's inherent properties.
2Weight of moving object
If the sheet base material is made thinner to achieve a lightweight decorative sheet, then the decorative sheet becomes more flexible and easier to handle, but the sheet base material becomes more susceptible to gouging and denting under heavy loads
Solution Approach 1:
The patent optimizes the physical parameters of thin paper to achieve a weight-to-strength balance. By controlling T-type peeling strength (130-210 gf/15 mm) and air permeability (≥150 seconds), the patent enables thin paper to maintain flexibility and lightness while achieving sufficient resistance to gouging and denting under heavy loads.
Solution Approach 2:
The patent uses composite material construction with multiple protective layers applied to the thin paper base material. This composite structure compensates for the reduced inherent strength of thinner materials, providing enhanced protection against gouging and denting while maintaining the lightweight advantage.
3Strength
If the first surface protective layer is formed with high gloss to provide scratch resistance, then the scratch resistance is improved, but the visual stereoscopic effect may be reduced due to the high gloss reflecting light
Solution Approach 1:
The patent applies local quality by creating different surface characteristics in different areas. The first surface protective layer provides high gloss for scratch resistance, while the second surface protective layer provides a different surface quality that enhances the visual stereoscopic effect. Each layer performs its specific function locally without compromising the other.
Solution Approach 2:
The patent segments the surface protective structure into multiple distinct layers: a pattern layer, a first surface protective layer with high gloss, and a second surface protective layer with different surface properties. This segmentation allows each layer to contribute its specific functionality, maintaining both scratch resistance and visual stereoscopic effect.
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 scratch resistance and maintains a visual stereoscopic effect by using a thin paper sheet base material with specific peeling strength and air permeability, combined with thermosetting resins in the protective layers, enhancing the durability and design aesthetics of the decorative sheet and plate.
Implementation Method 1
the first surface protective layer contains a thermosetting resin having a urethane bond
Implementation Method 2
the second surface protective layer contains either a thermosetting resin having a urethane bond or an ionizing radiation curable resin
Data Source
AI summary
A pattern layer formed on a sheet base material, a first surface protective layer formed on the pattern layer, and a second surface protective layer partially formed on the first surface protective layer. The first surface protective layer and the second surface protective layer each have a gloss different to each other. The sheet base material is a thin paper that has a T-type peeling strength of 130 gf/15 mm or more and 210 gf/15 mm or less and an air permeability in accordance with JIS P 8117 of 150 seconds or more.