Decorative Sheet Primer Layer Crosslinking for Chemical Resistance
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Solution Overview
Problem
Existing decorative sheets face challenges in handling warping due to hardening shrinkage of the surface protective layer, complex curing agent adjustments, and limited control over viscosity and glossiness, which affect their peeling resistance and material properties.
Innovation Solution
A decorative sheet comprising a base material with an ink layer, a curable primer layer containing a curing agent reactive with the resin in the ink layer, and an active energy ray-curable surface protective layer, which includes silicone (meth)acrylate and surface-untreated silica, allowing for improved adhesion and resistance to solvents, chemicals, and cellophane tape peeling without complicating the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the surface protective layer is increased to obtain resistance to solvents, contamination and chemicals, then the resistance to solvents and chemicals is improved, but the coated product is severely warped by hardening shrinkage and handling becomes difficult
Solution Approach 1:
The patent applies parameter changes by carefully controlling the thickness of the surface protective layer within a specific range (3-10 μm) and adjusting the composition ratios of components (silicone acrylate 0.1-5 parts, matting agent 1-20 parts, active energy ray-curable monomer/oligomer 100 parts) to achieve the desired balance between chemical resistance and minimal warping during hardening
Solution Approach 2:
The patent uses composite materials by formulating the surface protective layer as a composite composition containing multiple components: silicone acrylate for peeling resistance, matting agents for surface properties, active energy ray-curable monomers and oligomers for crosslinking, and optional additives. This composite structure provides both chemical resistance and controlled hardening behavior
2Reliability
If a curing agent is added to the ink layer to cure the ink layer, then the adhesion is improved, but production efficiency is decreased due to complicated adjustment of curing agent amount and adhesion to the surface protective layer is deteriorated
Solution Approach 1:
The patent extracts the curing function from the ink layer and relocates it to the surface protective layer. The ink layer contains no curing agent and simply dries, while the surface protective layer contains the active energy ray-curable components that provide crosslinking and adhesion. This separation eliminates the complications of curing agent adjustment in the ink layer
Solution Approach 2:
The patent introduces a primer layer as an intermediary between the ink layer and surface protective layer. This primer layer facilitates adhesion between the two layers without requiring curing agents in the ink layer itself, thereby maintaining production efficiency while achieving good adhesion
3Reliability
If the viscosity of the composition is controlled to make silicone acrylate move easily to the surface, then the resistance to cellophane tape peeling is improved, but the ratio of mobility varies according to coating speed and the amount of oligomer is limited
Solution Approach 1:
The patent controls the viscosity parameter by specifying precise amounts of each component: silicone acrylate (0.1-5 parts), matting agent (1-20 parts), and active energy ray-curable monomer/oligomer (100 parts). This compositional parameter control ensures appropriate viscosity for silicone acrylate migration without requiring complex viscosity adjustment procedures
Solution Approach 2:
The patent applies local quality by allowing silicone acrylate to migrate locally to the surface of the coating film where it is needed for peeling resistance, while the bulk composition maintains the viscosity required for proper coating application. The matting agent and other components remain distributed throughout the layer
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 enhances the decorative sheet's solvent resistance, chemical resistance, and cellophane tape peeling resistance while reducing production complexity and costs, resulting in a high-quality, cost-effective product with improved environmental protection.
Implementation Method 1
an active energy ray-curable surface protective layer
Implementation Method 2
a curable primer layer containing a curing agent reactive with a resin contained in the ink layer
Data Source
AI summary
The present invention provides a decorative paper which is excellent in solvent resistance, and chemical resistances such as alkali resistance, acid resistance and alcohol resistance without carrying out complicated steps such as an addition of a curing agent into a ink layer because the ink layer which is poor at solvent resistance and chemical resistance is crosslinked. The decorative sheet of the present invention comprises a base material, an ink layer, a curable primer layer containing a curing agent reactive with a resin in the ink layer, and an active energy ray-curable surface protective layer, which are provided in the order of the curable primer layer/ink layer/active energy ray-curable surface protective layer on the base material.