Stretched Decorative Sheet Composition for Flame-Retardant Forming
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Solution Overview
Problem
Existing decorative sheets using polyolefin-based resins lack post-processability and flame-retardant properties.
Innovation Solution
A decorative sheet comprising multiple resin layers, including uniaxially or biaxially stretched resin sheets made of a thermoplastic resin composition with added inorganic pigment vesicles, where the vesicles have a monolayer outer membrane and a dichroic ratio R ≥ 0.3, enhancing flame retardancy and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polyolefin-based resin is used for decorative sheet, then the decorative sheet can be manufactured with good processability, but the decorative sheet lacks flame-retardant properties and has poor post-processability
Solution Approach 1:
The patent uses a composite material system consisting of polyolefin-based resin combined with inorganic pigment vesicles containing flame-retardant inorganic pigments. This composite structure allows the decorative sheet to maintain the good processability of polyolefin while gaining flame-retardant properties through the inorganic pigment vesicles. The vesicle structure ensures uniform dispersion and maintains mechanical strength.
Solution Approach 2:
The patent modifies the polyolefin-based resin by adding inorganic pigment vesicles, changing the compositional parameters of the material. This parameter change introduces flame-retardant properties while maintaining processability. The specific parameter of dichroic ratio R ≥ 0.3 is controlled to ensure both flame retardancy and post-processability.
2Reliability
If flame-retardant inorganic pigment is added to polyolefin-based resin, then flame-retardant properties are improved, but post-processability deteriorates
Solution Approach 1:
The patent uses inorganic pigment vesicles as an intermediary carrier to deliver flame-retardant inorganic pigments into the polyolefin matrix. The vesicle structure acts as a mediator that prevents direct aggregation of inorganic pigments, ensuring uniform dispersion. This intermediary approach maintains post-processability while achieving flame-retardant properties, as the vesicles protect the resin from excessive rigidity caused by pigment aggregation.
Solution Approach 2:
The inorganic pigment vesicles have a flexible membrane structure that allows them to integrate smoothly into the polyolefin resin matrix. This flexible shell structure prevents stress concentration and maintains the ductility and formability of the decorative sheet, ensuring good post-processability even with high flame-retardant pigment content.
3Reliability
If inorganic pigment is added to enhance flame retardancy, then flame-retardant properties are improved, but mechanical strength decreases
Solution Approach 1:
The inorganic pigment vesicles serve as intermediaries that distribute flame-retardant pigments uniformly throughout the polyolefin matrix without causing aggregation. This uniform distribution prevents stress concentration points that would weaken the material. The vesicle membrane acts as a buffer that maintains the continuous polymer matrix, preserving mechanical strength while achieving flame retardancy.
Solution Approach 2:
The patent creates a composite material where inorganic pigment vesicles are dispersed in polyolefin-based resin. This composite structure combines the toughness and flexibility of polyolefin with the flame-retardant properties of inorganic pigments. The vesicle-based composite approach maintains the continuous polymer phase, ensuring mechanical strength is not compromised by pigment addition.
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 provides a decorative sheet with improved post-processability and flame-retardant properties, meeting stringent flame-retardant material criteria and maintaining mechanical strength.
Implementation Method 1
The inorganic pigment vesicle contains a flame-retardant inorganic pigment in a vesicle having a monolayer outer membrane
Implementation Method 2
The uniaxially stretched resin sheet and the biaxially stretched resin sheet have a value of a dichroic ratio R of R ≥ 0.3
Data Source
Figure 1
AI summary
An object of the present invention is to provide a decorative sheet excellent in post-processability and usable for flame-retardant application. A decorative sheet (1) according to one aspect of the present invention includes a plurality of resin layers. At least one layer of the resin layers is formed of a uniaxially stretched resin sheet (3) or a biaxially stretched resin sheet (3) constituted of a thermoplastic resin composition. The thermoplastic resin composition is produced by adding an inorganic pigment vesicle to a polyolefin-based resin. The inorganic pigment vesicle is produced by including an inorganic pigment in a vesicle having a monolayer outer membrane. The uniaxially stretched resin sheet (3) and the biaxially stretched resin sheet (3) have a value of a dichroic ratio R of R ≥ 0.3. The value is calculated from absorbance peak values at a wave number of 997 (±5) cm-1 of an infrared absorption spectrum in a direction parallel to an extrusion direction during film manufacturing and an infrared absorption spectrum in a direction perpendicular to the extrusion direction during the film manufacturing obtained by a polarized Fourier type infrared spectroscopy measurement using the following Formula (1). [Formula 1] Dichroic ratio R=Absorbance peak value in parallel direction−Absorbance peak value in perpendicular direction/Absorbance peak value in parallel direction+Absorbance peak value in perpendicular direction