Incombustible Decorative Sheet With Fluorine Resin Layer
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Solution Overview
Problem
Conventional decorative sheets face issues with incombustibility, processability, weatherability, contamination resistance, and solvent resistance, particularly due to low contamination and solvent resistance, and the difficulty in removing dirt and the risk of generating dioxin when disposed of.
Innovation Solution
A decorative sheet comprising multiple thermoplastic resin layers, including a fluorine resin outermost layer and a weather-resistant resin layer made from a mixture of acrylic resin and acrylic resin-based rubber, stacked on a polypropylene substrate, with specific mass and thickness ratios to ensure incombustibility, processability, and weatherability, while maintaining contamination and solvent resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If acrylic resin is used as the outermost layer for excellent weatherability, then weatherability is improved, but contamination resistance and solvent resistance deteriorate
Solution Approach 1:
The patent uses a composite structure with two resin layers: an acrylic resin layer (inner layer) for weatherability and a fluorine resin layer (outer layer) for contamination and solvent resistance. This composite material approach allows each layer to contribute its superior properties, resolving the contradiction between weatherability and resistance to contaminants/solvents.
Solution Approach 2:
The patent applies different material properties to different layers: the inner acrylic resin layer provides weatherability while the outer fluorine resin layer provides contamination and solvent resistance. Each layer is optimized for its specific function, with the fluorine resin layer specifically engineered to resist contaminants and solvents while the acrylic layer handles weathering.
2Adaptability or versatility
If conventional decorative sheets are used, then basic decorative function is provided, but incombustibility and processability deteriorate
Solution Approach 1:
The patent changes the material parameters by selecting specific resin types (acrylic resin and fluorine resin) and controlling their thickness ratios. The fluorine resin layer thickness is set to 1/10 to 4/10 of the total decorative sheet thickness, and the acrylic resin layer thickness is set to 20 μm to 80 μm, optimizing both incombustibility and processability while maintaining decorative function.
3Object-affected harmful factors
If dirt is attached to acrylic resin surface, then contamination occurs, but the ability to remove dirt with solvent deteriorates
Solution Approach 1:
The fluorine resin layer forms a chemically inert, low-surface-energy barrier that prevents contaminants from bonding to the underlying acrylic resin. This composite structure allows dirt to remain on the surface without chemically attaching, making it easily removable with solvents while maintaining contamination resistance.
Data Source
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AI summary
An object is to provide a decorative sheet which ensures good incombustibility, processability and weatherability along with weatherability, contamination resistance and solvent resistance. An incombustible decorative sheet (10) having incombustibility includes a weather-resistant resin layer (4) and a fluorine resin layer (5) laminated on a substrate layer (1) in this order, wherein the weather-resistant resin layer is made of a mixture of an acrylic resin and an acrylic resin-based rubber having a ratio by mass between the acrylic resin-based rubber and the acrylic resin within a range of 30:70 to 60:40. The ratio between the fluorine resin layer (5) and the weather-resistant resin layer (4) is within a range of 10:90 to 40:60.