Decorative Sheet Protective Layer for Soft Feel and Scratch Resistance
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Solution Overview
Problem
Existing decorative sheets lack good scratch resistance and do not provide a soft and supple feel, which are important aesthetic and functional properties.
Innovation Solution
A decorative sheet with a surface protective layer containing asperities and specific particle sizes and ratios, along with a cured resin, provides a soft and supple feel while maintaining low gloss and high scratch resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a surface protective layer is formed to improve scratch resistance, then durability is improved, but the surface becomes hard and lacks a soft and supple feel
Solution Approach 1:
The surface protective layer incorporates particles with a average particle size of 3 μm or more and 11 μm or less, creating local variations in surface topology. These particles form asperities that provide tactile softness while the cured resin matrix maintains overall scratch resistance. The particle concentration (3-11 parts by mass relative to 100 parts by mass of resin) optimizes this local quality distribution.
Solution Approach 2:
Instead of making the entire surface hard for scratch resistance, the invention inverts the approach by creating a soft tactile surface through particles embedded in the protective layer. The asperities formed by these particles provide the soft and supple feel, while the cured resin provides the underlying protective function.
2Illumination intensity
If a matting agent is added to achieve low gloss, then aesthetic property is improved, but scratch resistance deteriorates
Solution Approach 1:
The invention changes the parameter of particle size to 3-11 μm, which is larger than conventional matting agents. This size parameter creates sufficient light scattering for low gloss (gloss less than 10) while the particles remain embedded in the cured resin matrix, maintaining scratch resistance. The particle size distribution creates asperities that provide both aesthetic and functional properties.
3Ease of operation
If particles are added to provide soft and supple feel, then tactile property is improved, but manufacturing precision deteriorates
Solution Approach 1:
The invention specifies a narrow particle size range (3-11 μm) to control the formation of asperities. This parameter control ensures that particles form consistent ridgelike structures without causing excessive surface irregularities. The particle concentration is limited to 3-11 parts by mass relative to 100 parts by mass of resin, preventing overcrowding and maintaining surface uniformity.
Solution Approach 2:
The surface protective layer is formulated as a composite material containing particles dispersed in a cured resin matrix. This composite structure allows the particles to provide tactile softness while the resin matrix maintains surface integrity and manufacturing precision. The composite formulation ensures proper particle distribution and embedding during the coating and curing processes.
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 enhanced scratch resistance and a soft, supple tactile experience, offering improved durability and aesthetic appeal.
Implementation Method 1
the surface protective layer has a gloss less than 10
Implementation Method 2
the surface protective layer contains a cured resin
Data Source
AI summary
A decorative sheet that has good scratch resistance and provides a soft and supple feel is provided. In the decorative sheet, a surface of the surface protective layer is provided with asperities including ridge portions. In a power spectrum image obtained by applying a two-dimensional fast Fourier transform to their surface shape image, when the average luminance in the spatial frequency range of: i) 95-105 cycles/mm is P_100, ii) 195-205 cycles/mm is P_200, iii) 695-705 cycles/mm is P_700, and the ratio of the difference between P_100 and P_700 to the difference between P_200 and P_700 is Rt_P, the average of Rt_P is within the range of 1.57-1.82. The surface protective layer contains 100 parts by mass of a cured resin and 3-11 parts by mass of particles with an average particle size of 3 μm or more, and has a thickness of 2-18 μm and a gloss <10.