Decorative Sheet Resin Coating Streak Prevention
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Solution Overview
Problem
Decorative sheets with resin coatings often suffer from coating streaks and wrinkles, and have limited extensibility, making them unsuitable for applications requiring high-gloss finishes and formability in furniture and appliances.
Innovation Solution
A method involving pressing a thermoplastic resin film on a preheated heating drum with a transfer film having a hot-melt adhesive, resin coating, and release coating layer, followed by sequential cooling through chill rolls to prevent constriction differences and ensure interlayer adhesion, resulting in a streak-free, high-gloss, and extensible resin coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a resin composition coating material is applied on the thermoplastic resin film surface, then scratch resistance and abrasion resistance are improved, but coating streaks and wrinkles are formed and extensibility deteriorates
Solution Approach 1:
The invention changes the physical and chemical parameters of the coating material by using a thermoplastic resin composition with specific viscosity (100-5000 Pa·s at 23°C) and molecular weight characteristics. This parameter optimization allows the coating to flow properly during application (preventing streaks) while maintaining strength properties.
Solution Approach 2:
The invention uses a composite resin composition containing specific additives (leveling agents, flow control agents) combined with thermoplastic resin base materials. This composite approach balances the contradictory requirements of surface smoothness and mechanical strength.
2Strength
If a resin composition coating material is applied on the thermoplastic resin film surface, then scratch resistance and abrasion resistance are improved, but extensibility deteriorates
Solution Approach 1:
The invention optimizes the molecular weight and viscosity parameters of the thermoplastic resin composition to achieve a balance between strength and extensibility. The specific viscosity range (100-5000 Pa·s) ensures the coating remains flexible enough for forming operations while providing adequate scratch resistance.
Solution Approach 2:
The thermoplastic resin composition maintains continuous flexibility and extensibility throughout the forming process (membrane press forming, vacuum forming), allowing the coating to deform with the substrate without cracking, while still providing ongoing scratch protection.
3Strength
If conventional coating methods are used, then scratch resistance is improved, but high-gloss mirror-like finish cannot be achieved
Solution Approach 1:
The invention controls the viscosity and surface tension parameters of the thermoplastic resin composition to achieve high-gloss finishes. The optimized flow properties allow the coating to level properly and create a smooth, reflective surface while maintaining scratch resistance.
Solution Approach 2:
The invention replaces conventional coating application methods with a process that utilizes the inherent flow and leveling properties of the optimized thermoplastic resin composition, achieving mirror-like gloss without complex mechanical finishing operations.
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 method produces decorative sheets with improved membrane press formability, vacuum formability, and wrapping formability, free from coating defects, suitable for various decorative applications.
Implementation Method 1
a transfer film (b) having a hot-melt adhesive layer, a resin coating, a release coating layer, and a film base material in order from the outermost-layer side
Implementation Method 2
pressing a thermoplastic resin film (a) on a preheated rotating heating drum
Implementation Method 3
sequentially passing a laminated sheet obtained in the Step (β) through a first chill roll whose temperature is set to 50° C. to 90° C., and a second chill roll whose temperature is set to a temperature of 20° C. to 70° C.
Implementation Method 4
a transfer film (b) having a hot-melt adhesive layer, a resin coating, a release coating layer, and a film base material
Data Source
AI summary
A method for producing a decorative sheet includes the steps of: (α) pressing a thermoplastic resin film (a) on a preheated rotating heating drum, and then pressing a transfer film (b) having a hot-melt adhesive layer, a resin coating, a release coating layer, and a film base material in order such that the hot-melt adhesive layer is positioned in the film (a) side; (β) feeding/supplying a pressed body obtained in the Step (α) between a rotating design-imparting roll and a rotating receiving roll such that the transfer film (b) is positioned in the design-imparting-roll side; and (γ) sequentially passing a laminated sheet obtained in the Step (β) through a first chill roll whose temperature is set to 50° C. to 90° C., and a second chill roll whose temperature is set to a temperature of 20° C. to 70° C. which is lower than the first-chill roll temperature to cool the laminated sheet.