Decorative sheet, decorative material
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Solution Overview
Problem
Decorative materials mimicking natural stone appearance suffer from low designability due to weight issues and difficulty conforming to curved surfaces, leading to surface damage and deterioration.
Innovation Solution
A decorative sheet comprising a substrate layer, an aggregate layer with a specific acrylic resin and inorganic filler mixture, a print pattern layer, and a surface protective layer, all with controlled thicknesses and properties, mimicking natural stone texture and providing embossed patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If natural stone is used to form decorative materials, then the appearance and texture are authentic, but the weight is excessive and conformity to curved surfaces is poor
Solution Approach 1:
The patent creates a decorative sheet that copies the appearance, texture, and tactile properties of natural stone through a multi-layer structure including an aggregate layer with inorganic particles and embossed patterns, while using lightweight synthetic materials instead of actual stone
Solution Approach 2:
The decorative sheet is constructed as a flexible, thin-film composite structure with multiple layers (substrate layer, aggregate layer, print pattern layer, surface protective layer) that can conform to curved surfaces without the rigidity and weight of natural stone
2Reliability
If natural stone is used to form decorative materials, then the appearance is authentic, but the surface is easily damaged leading to deterioration in designability
Solution Approach 1:
The patent employs a composite material structure with a substrate layer providing structural support, an aggregate layer with inorganic particles (85-95 mass %) providing stone-like texture and durability, a print pattern layer for design flexibility, and a surface protective layer for enhanced protection against damage
Solution Approach 2:
The patent optimizes specific parameters including the aggregate layer thickness (0.2-4.0 mm), acrylic resin content (5-15 mass %), and inorganic filler particle size (50-500 μm) to achieve the desired balance between durability and designability
3Weight of moving object
If printed stone patterns are used, then weight is reduced, but the appearance lacks authenticity compared to natural stone
Solution Approach 1:
The patent combines multiple materials and techniques including a substrate layer, an aggregate layer with inorganic particles (85-95 mass %) for three-dimensional texture, a print pattern layer for color and pattern replication, and a surface protective layer to create a composite structure that authentically reproduces natural stone appearance
Solution Approach 2:
The patent incorporates embossed patterns and three-dimensional surface structures in the aggregate layer that replicate the curved, irregular surfaces and textures of natural stone, enhancing tactile authenticity beyond simple flat printing
Data Source
AI summary
A decorative material includes a substrate, and a decorative sheet laminated on one surface of the substrate. The decorative sheet includes a substrate layer, an aggregate layer, a print pattern layer, and a surface protective layer. The aggregate layer contains a mixture of an acrylic resin and an inorganic filler such that a mixing ratio of the acrylic resin with respect to 100 mass % of the aggregate layer is in a range of 5 mass % or more and 15 mass % or less and a mixing ratio of the inorganic filler with respect to 100 mass % of the aggregate layer is in a range of 85 mass % or more and 95 mass % or less. The aggregate layer has a thickness in a range of 0.2 mm or more and 4.0 mm or less.