Decorative Sheet Coating for Antiviral Action and Bending Workability
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Solution Overview
Problem
Decorative sheets with blended antiviral agents in molded resins face issues with reduced workability, such as bending processability, and lack of antiviral action on the surface.
Innovation Solution
A decorative sheet design with a colored layer, pattern layer, and a surface protective layer containing an antiviral agent, where the surface protective layer is composed of a curable resin with 0.2% to 10% by mass antiviral agent and 1 μm to 10 μm particle size, enhancing both antiviral properties and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an antiviral agent is blended into a molded resin or paint resin, then antiviral properties are provided, but workability such as bending processability decreases
Solution Approach 1:
The antiviral agent is segregated from the bulk resin and concentrated only in the surface protective layer. This segmentation allows the resin to maintain its inherent workability and bending processability while the surface layer provides the required antiviral properties. The antiviral agent is not distributed throughout the entire molded article but is localized to where it is needed for antiviral action.
Solution Approach 2:
The antiviral agent is applied locally to the surface protective layer rather than being uniformly distributed in the entire resin matrix. This local quality approach ensures that the antiviral function is provided at the surface where contact with viruses occurs, while the bulk material retains its original processing characteristics and workability.
2Reliability
If an antiviral agent is added to the outermost surface of the decorative sheet, then antiviral properties are improved, but the complexity of the structure increases
Solution Approach 1:
The antiviral agent is merged with the surface protective layer during the coating process. This combining of the antiviral function with the existing protective layer structure avoids adding separate complex components or layers, thereby providing antiviral properties without significantly increasing structural complexity.
Solution Approach 2:
The surface protective layer serves multiple functions: it provides mechanical protection against scratches and simultaneously delivers antiviral properties through the incorporated antiviral agent. This multi-functionality eliminates the need for separate antiviral coatings or treatments, simplifying the overall structure while achieving multiple objectives.
3Reliability
If the addition amount of antiviral agent is increased, then antiviral action is enhanced, but the processability and flexibility of the decorative sheet deteriorate
Solution Approach 1:
The antiviral agent is extracted from the bulk resin material and placed exclusively in the surface protective layer. This extraction allows for high concentration of antiviral agent at the surface (0.2% to 10% by mass in the surface layer) without compromising the processability of the main resin, which remains free of antiviral agent additions that would degrade its workability.
Solution Approach 2:
The concentration of antiviral agent is optimized within a specific range (0.2% to 10% by mass in the surface protective layer) to achieve effective antiviral action while maintaining compatibility with the resin system. This parameter optimization ensures sufficient antiviral performance without excessive loading that would harm processability.
4Reliability
If the antiviral agent is blended into the resin, then antiviral properties are achieved, but scratch resistance and surface durability are reduced
Solution Approach 1:
The antiviral agent is segmented and localized to the surface protective layer, separating it from the bulk resin structure. This segmentation preserves the integrity and mechanical strength of the main resin, ensuring high scratch resistance, while the surface layer provides antiviral protection without compromising overall durability.
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 decorative sheet achieves high scratch resistance and antiviral properties while maintaining flexibility and processability, with improved durability and designability.
Implementation Method 1
a surface protective layer that contains an antiviral agent and at least one of a heat-curable resin, an ultraviolet-curable resin, and an electron beam-curable resin
Implementation Method 2
a surface protective layer that contains an antiviral agent and at least one of a heat-curable resin, an ultraviolet-curable resin, and an electron beam-curable resin
Data Source
AI summary
A decorative sheet and a decorative member having both excellent antiviral properties and high processability. The decorative sheet is provided with a colored layer, a pattern layer, and a surface protective layer, wherein: the surface protective layer is provided with a first surface protective layer containing an antiviral agent and at least one of a heat-curable resin, an ultraviolet-curable resin, and an electron beam-curable resin; the addition amount of the antiviral agent is 0.2% by mass or more and 10% by mass or less with respect to the surface protective layer; and the average particle size of the antiviral agent is 1 μm or more and 10 μm or less.