Decorative sheet, decorative material, and method of producing decorative sheet
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Solution Overview
Problem
Decorative sheets with projections and recesses are prone to scratches due to external loads, as existing technologies do not adequately address the need for both scratch resistance and designability.
Innovation Solution
A decorative sheet comprising a thermoplastic resin substrate layer, a transparent thermoplastic resin layer, and a surface protective layer with an ionizing radiation-curable resin containing a multifunctional hexamethylene diisocyanate oligomer, where the outermost layer has an arithmetic mean height of 15 μm or more and a maximum height of 38 μm, enhancing scratch resistance while maintaining design features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If projections and recesses are formed on the surface of a decorative sheet to improve designability, then designability is improved, but scratch resistance deteriorates because projections receive external load at one point
Solution Approach 1:
The surface protective layer is divided into multiple layers (first surface protective layer and second surface protective layer) with different functions. The first layer provides basic protection, while the second layer with projections and recesses provides designability. This segmentation allows each layer to be optimized for its specific function without compromising the other.
Solution Approach 2:
The second surface protective layer has local variations in thickness with projections and recesses formed on its outer surface. These local thickness variations provide designability while the overall layered structure ensures that external loads are distributed across multiple layers, preventing concentration at single points and improving scratch resistance.
2Reliability
If a single-layer surface protective coating is applied to improve scratch resistance, then scratch resistance is improved, but designability deteriorates due to lack of surface texture variations
Solution Approach 1:
The surface protective layer is segmented into multiple functional layers. The first layer provides uniform scratch resistance, while the second layer introduces surface texture variations with projections and recesses for designability. This segmentation resolves the contradiction by separating the protective and aesthetic functions into distinct layers.
Solution Approach 2:
The surface protective layer combines multiple resin materials with different properties. The first surface protective layer and second surface protective layer are made of different resins, creating a composite structure that provides both scratch resistance and designability through the combination of different material characteristics.
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 solution significantly improves scratch resistance by reducing the contact area under external loads and maintaining design integrity, effectively suppressing scratches on the decorative sheet.
Implementation Method 1
an outermost layer that is a layer located furthest from the transparent thermoplastic resin layer among layers constituting the surface protective layer contains an ionizing radiation-curable resin containing a multifunctional hexamethylene diisocyanate oligomer
Data Source
AI summary
A decorative sheet that includes at least a thermoplastic resin substrate layer, a transparent thermoplastic resin layer and a surface protective layer in this order. The surface protective layer is formed by laminating at least two layers. At least a second surface protective layer, which constitutes an outermost layer that is a layer located furthest from the transparent thermoplastic resin layer among layers constituting the surface protective layer contains an ionizing radiation-curable resin containing a multifunctional hexamethylene diisocyanate oligomer at a weight ratio of 60% or more. The arithmetic mean height of a profile curve measured from the second surface protective layer in accordance with JIS B 0601 is 15 μm or more, and the maximum height of the profile curve is 38 μm or more.