Decorative Sheet Laminated Structure for Shape Retention
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Solution Overview
Problem
The production of decorative resin molded articles with uneven shapes faces challenges in maintaining the shape during injection molding or vacuum molding due to deformation or elimination under heat or pressure, and there is a need for enhanced chemical resistance, especially against skincare and alcohol-containing chemicals.
Innovation Solution
A decorative sheet with an uneven shape is developed, featuring a laminated structure with a first protective layer formed from a cured product of an ionizing radiation curable resin and thermoplastic resin, and a second protective layer formed from a cured product of an ionizing radiation curable resin composition containing polycarbonate (meth)acrylate, which maintains the uneven shape and provides excellent chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a decorative sheet with an uneven shape is used, then the decorative resin molded article achieves design impression and touch feeling, but the uneven shape is deformed or eliminated by heat or pressure during injection molding or vacuum molding
Solution Approach 1:
The protective layer is divided into multiple layers with different material compositions. The first protective layer contains a thermoplastic resin that provides heat resistance, while the second protective layer contains a thermosetting resin that provides structural stability. This segmentation allows each layer to contribute differently to maintaining the uneven shape under heat and pressure during molding.
Solution Approach 2:
The protective layer is formed as a composite material combining thermoplastic resin and thermosetting resin components. The thermoplastic resin provides flexibility and heat resistance, while the thermosetting resin provides rigidity and shape stability. This composite structure enables the protective layer to maintain the uneven shape during injection molding or vacuum molding processes.
2Ease of manufacture
If a single-layer protective coating is applied, then the manufacturing process is simple, but the chemical resistance against skincare products and alcohol-containing chemicals is insufficient
Solution Approach 1:
The protective layer is segmented into multiple functional layers. The first layer provides baseline protection, while the second layer adds enhanced chemical resistance specifically against skincare products and alcohol-containing chemicals. This segmentation allows each layer to be optimized for specific protective functions while maintaining a relatively simple two-step coating process.
Solution Approach 2:
The protective layer uses a composite structure with thermoplastic resin providing heat resistance and thermosetting resin providing enhanced chemical resistance. This composite material approach achieves superior chemical resistance against diverse chemicals including skincare products and alcohol-containing substances, while the coating process remains practical for manufacturing.
3Ease of manufacture
If the protective layer contains only thermoplastic resin, then the molding process is easy, but the chemical resistance to high surface erodibility chemicals is insufficient
Solution Approach 1:
The protective layer is formulated as a composite material combining thermoplastic resin and thermosetting resin. The thermoplastic resin component facilitates easy molding and shaping, while the thermosetting resin component provides enhanced resistance to chemical erosion from high surface erodibility chemicals. This composite approach balances manufacturing ease with superior chemical resistance.
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 decorative sheet effectively maintains the uneven shape and exhibits superior chemical resistance, ensuring the decorative resin molded article retains its design impression and touch feeling while withstanding exposure to chemicals like sunscreen cosmetics and alcohol-containing substances.
Implementation Method 1
a first protective layer forming the uneven shape, and a second protective layer, in this order from the outer surface, the first protective layer being formed of a cured product of a resin composition containing an ionizing radiation curable resin
Implementation Method 2
the second protective layer being formed of a cured product of an ionizing radiation curable resin composition containing polycarbonate (meth)acrylate
Data Source
AI summary
The present invention provides a decorative sheet which is provided with a relief pattern in the outer surface, while having excellent chemical resistance, wherein the relief pattern is suitably maintained even after molding. A decorative sheet which is provided with a relief pattern in the outer surface, while sequentially having, from the outer side, at least a first protective layer that constitutes the relief pattern and a second protective layer. The first protective layer is formed of a cured product of a resin composition that contains an ionizing radiation curable resin and a thermoplastic resin; and the second protective layer is formed of a cured product of an ionizing radiation curable resin composition that contains a polycarbonate (meth)acrylate.