Decorative Sheet Release Layer for Matte Finish and Selective Peeling
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Solution Overview
Problem
Existing decorative sheets for resin-impregnated decorative plates struggle to balance the functions of selective peeling of the cured resin layer and exhibiting a gloss matte design due to the trade-off relationship between peeling property and gloss matte designability.
Innovation Solution
A decorative sheet comprising a porous substrate, a design layer, and a release layer with specific parameters such as a 60° gloss value of 10 or less, a pure water contact angle of 85° or more, and an Spc (arithmetic average curvature at mountaintop point) of 80 mm^-1 or more, allowing for selective peeling and gloss matte design through the gloss difference between the release and cured resin layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the release layer is designed to have high peeling property, then the cured resin layer can be selectively peeled off, but the gloss matte designability deteriorates
Solution Approach 1:
The release layer is designed with a specific surface structure characterized by Spc ≥ 80 mm⁻¹, creating local surface characteristics that simultaneously enable both peeling functionality and gloss matte appearance. The arithmetic average curvature at mountaintop points provides localized surface features that facilitate selective peeling while maintaining the desired visual effect.
Solution Approach 2:
The invention specifies precise parameter ranges for the release layer: 60° gloss value ≤ 10, pure water contact angle ≥ 85°, and Spc ≥ 80 mm⁻¹. By controlling these parameters within specific ranges, the release layer achieves the optimal balance between peeling property and gloss matte designability, transforming the trade-off relationship into a controlled design space.
2Manufacturing precision
If the release layer is designed to exhibit good gloss matte design, then the matte tone design feeling is improved, but the selective peeling property deteriorates
Solution Approach 1:
The release layer incorporates surface structures with specific local characteristics (Spc ≥ 80 mm⁻¹) that create both the desired gloss matte visual effect and the necessary peeling functionality. The mountaintop point curvature provides localized features that serve dual purposes: aesthetic appearance and peeling initiation sites.
Solution Approach 2:
The release layer functions as a composite structure combining surface treatment characteristics (high Spc, low gloss, high contact angle) that integrate both peeling and aesthetic functions into a single layer, eliminating the need for separate functional layers and resolving the contradiction between peeling property and gloss matte designability.
3Strength
If the decorative sheet is pressurized to cure the resin, then the resin layer is formed, but the matte tone design feeling may be lost
Solution Approach 1:
The release layer is pre-designed with specific surface properties (Spc ≥ 80 mm⁻¹, 60° gloss ≤ 10, contact angle ≥ 85°) that act as a cushion or buffer during the pressurizing step. These pre-established characteristics protect the matte tone design feeling from being lost during resin curing, allowing the aesthetic features to be maintained throughout the manufacturing process.
Solution Approach 2:
By specifying the release layer parameters (Spc, gloss value, contact angle) before the pressurizing step, the invention ensures that these parameters remain within ranges that preserve both the cured resin layer formation and the matte tone design feeling, preventing the loss of aesthetic properties during the curing process.
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 enables selective peeling of the cured resin layer and exhibits a gloss matte design effectively, maintaining the matte tone design feeling even after the pressurizing step.
Implementation Method 1
a pure water contact angle of the release layer is 85° or more
Implementation Method 2
a 60° gloss value of the release layer is 10 or less; and a Spc (arithmetic average curvature at mountaintop point) of the release layer is 80 mm -1
Data Source
Figure 1~3
Figure 4(a)~4(d)
Figure 5(a)~5(b)
AI summary
The present disclosure provides a decorative sheet used for a production of a resin-impregnated decorative plate, the decorative sheet comprising a porous substrate; a design layer; and a release layer formed in a pattern, in this order in a thickness direction, wherein a 60° gloss value of the release layer is 10 or less; a pure water contact angle of the release layer is 85° or more; and a Spc (arithmetic average curvature at mountaintop point) of the release layer is 80 mm-1 or more.