Decorative Sheet Embossing That Preserves 3D Relief After Molding
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Solution Overview
Problem
Existing decorative sheets lose their stereoscopic feeling due to deformation during injection molding or vacuum molding, compromising the high-realistic design intended by internal uneven shapes.
Innovation Solution
A decorative sheet with a transparent resin film layer having an uneven shape and a decorative layer formed along this shape, featuring convex portions in a stepwise or varying height configuration, maintains excellent stereoscopic feeling post-molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a decorative sheet with an uneven shape is subjected to heat and pressure during injection molding or vacuum molding, then the molding process can be completed, but the uneven shape becomes gentler or smaller in size, compromising the realistic design feeling
Solution Approach 1:
The patent applies preliminary action by pre-forming the uneven shape on the transparent resin film layer before the molding process. The embossed pattern is created in advance on the decorative sheet, and this pre-formed structure is then integrated with the resin during molding. This allows the uneven shape to be established before the deforming forces of injection molding or vacuum molding are applied, preserving the design integrity while still completing the molding process.
2Shape
If the uneven shape is made more pronounced to enhance stereoscopic feeling, then the realistic design feeling improves, but the deformation during molding becomes more severe
Solution Approach 1:
The patent applies local quality by creating localized uneven shapes (embossed patterns) on specific regions of the transparent resin film layer. Rather than making the entire sheet uniformly pronounced, the embossing is applied locally to create the desired stereoscopic effect in key areas while maintaining overall shape stability. This localized approach allows enhanced stereoscopic feeling without causing excessive global deformation during molding.
3Device complexity
If a simple printing layer is used on the acrylic film, then the manufacturing process is simple, but only picture presentation is achieved without reality feeling
Solution Approach 1:
The patent merges two techniques: printing and embossing. The decorative sheet includes both a printing layer for picture presentation and an embossed uneven shape on the transparent resin film layer for realistic design feeling. By combining these two methods, the invention achieves both reality feeling from the three-dimensional embossed patterns and picture presentation from the printing, while maintaining a relatively simple manufacturing process that integrates well with existing molding operations.
Data Source
AI summary
Provided is a decorative sheet provided with excellent three-dimensional effect by an internal protruding and recessed shape even after molding. A decorative sheet comprising a transparent resin film layer having a protruding and recessed shape on one surface thereof, and a decorative layer formed along the protruding and recessed shape of the transparent resin film layer, wherein the protruding and recessed shape is provided with a plurality of protrusions protruding toward the decorative layer from the transparent resin film layer side, and the plurality of protrusions are each formed in a stepwise shape.