Decorative Sheet Low-Gloss Pattern Layer Scratch Resistance
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Solution Overview
Problem
Decorative resin molded articles lack sufficient scratch resistance, chemical resistance, and design properties, particularly in maintaining gloss and three-dimensional moldability during the molding process.
Innovation Solution
A decorative sheet comprising a base film layer, a second picture layer, and a surface protective layer with a low-gloss pattern layer formed by an interaction between a thermoplastic resin and an ionizing radiation curable resin, where the surface protective layer is crosslinked using polycarbonate (meth)acrylate and/or acrylsilicone (meth)acrylate, providing excellent scratch resistance and chemical resistance while maintaining a low-gloss appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ionizing radiation curable resin is used to form the surface protective layer, then three-dimensional moldability is improved, but surface scratch resistance and chemical resistance are insufficient
Solution Approach 1:
The patent uses a composite resin composition containing both thermoplastic resin and ionizing radiation curable resin in the surface protective layer. The thermoplastic resin provides scratch resistance and chemical resistance, while the ionizing radiation curable resin enables excellent three-dimensional moldability. This composite approach allows both contradictory requirements to be satisfied simultaneously.
Solution Approach 2:
The patent specifies precise compositional parameters for the resin mixture, including the content ratios of thermoplastic resin to ionizing radiation curable resin, molecular weight ranges, and functional group characteristics. By optimizing these parameters, the surface protective layer achieves both high moldability and superior surface properties.
2Ease of manufacture
If ionizing radiation curable resin is used to form the surface protective layer, then three-dimensional moldability is improved, but design property and gloss maintenance are insufficient
Solution Approach 1:
The composite resin composition maintains gloss by combining thermoplastic resin (which provides gloss retention) with ionizing radiation curable resin (which provides moldability). The specific formulation ensures that the surface protective layer maintains its decorative appearance while achieving excellent three-dimensional molding.
Solution Approach 2:
The patent controls the molecular weight, functional group content, and compositional ratios of the resin components to maintain gloss and design properties. By adjusting these parameters, the surface protective layer achieves both high moldability and superior aesthetic quality with consistent gloss maintenance.
3Reliability
If thermoplastic resin is used as the binder resin for the second picture layer, then scratch resistance is improved, but three-dimensional moldability becomes insufficient
Solution Approach 1:
The surface protective layer uses a composite resin composition where thermoplastic resin provides scratch resistance and ionizing radiation curable resin provides three-dimensional moldability. This composite structure allows the binder resin to achieve both contradictory properties simultaneously through the synergistic effect of the two resin types.
Solution Approach 2:
The patent optimizes the compositional parameters of the resin mixture, including the ratio of thermoplastic to ionizing radiation curable resin, molecular weight distribution, and functional group content. These parameter adjustments enable the binder resin to achieve both high scratch resistance and excellent three-dimensional moldability.
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 achieves a decorative resin molded article with enhanced scratch resistance, chemical resistance, and design properties, maintaining a consistent gloss and excellent three-dimensional moldability, addressing the limitations of existing technologies.
Implementation Method 1
the surface protective layer is a layer obtained by crosslinking and curing an ionizing radiation curable resin composition
Implementation Method 2
inside the surface protective layer, a low-gloss pattern layer having a low-luster region is formed by an interaction between the ionizing radiation curable resin and the thermoplastic resin
Data Source
AI summary
A decorative sheet which comprises, on a base film layer, a second picture layer that is partially provided and a surface protective layer that is present on and in contact with the second picture layer and covers the entire surface of the base film layer including the region where the second picture layer is formed and the region where the second picture layer is not formed. The decorative sheet is characterized in that: a binder resin for a second picture ink that constitutes the second picture layer is a thermoplastic resin; the surface protective layer is formed of a crosslinking-cured product of an ionizing radiation curable resin composition that contains a polycarbonate (meth)acrylate and/or an acrylic silicone (meth)acrylate; and a low gloss pattern layer that has a low luster region is formed in the surface protective layer right above the second picture layer by the interaction between the ionizing radiation curable resin and the thermoplastic resin. A decorative resin molded article which is obtained using the decorative sheet.