Decorative Sheet Recess Projection Design Alignment
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Solution Overview
Problem
Conventional decorative sheets face challenges in achieving dimensional stability and design coherence between emboss processing and printing, leading to deviations in recess and projection designs, which affect the overall design properties.
Innovation Solution
A decorative sheet structure comprising a base material, image design layer, transparent adhesive layer, transparent thermoplastic resin layer, and surface protective layer, with a recess and projection design and pattern formed on the outermost surface, ensuring a height difference of 3 µm to 200 µm and precise alignment within 10 mm longitudinal and 3 mm width deviations, allowing simultaneous formation with one shaping plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If emboss processing and printing are used separately for recess/projection design and gloss design, then both tactile and visual three-dimensional effects are achieved, but the designs deviate from each other reducing design properties
Solution Approach 1:
The patent combines emboss processing and printing into a single integrated process where both the recess/projection design and gloss design are formed simultaneously in one operation, eliminating alignment deviations between separate processes while maintaining both tactile and visual three-dimensional effects
Solution Approach 2:
The shaping plate is designed to perform multiple functions simultaneously: it creates both the recess/projection geometry and the gloss pattern in a single operation, making the processing device universal for both embossing and printing functions
2Shape
If the height difference of recess and projection design is increased to enhance tactile three-dimensional effect, then tactile sense is improved, but the deviation between design and image design layer increases
Solution Approach 1:
The patent applies different height differences to different regions: the recess/projection design has a height difference of 3-200 μm for tactile effect, while the recess/projection pattern has a smaller height difference of 0.5-10 μm for gloss effect, with both precisely aligned to the image design layer through the integrated shaping plate
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
This configuration provides a three-dimensional effect by tactile sense and visual texture, enhancing design properties by ensuring the recess and projection designs and gloss patterns align accurately, resulting in a cohesive and visually appealing decorative sheet.
Implementation Method 1
a transparent thermoplastic resin layer provided on the front surface side of the transparent adhesive layer, and a surface protective layer provided on the front surface side of the transparent thermoplastic resin layer, in which (f), on the front surface side of the surface protective layer, a recess and projection design and a recess and projection pattern having a plurality of regions provided on each of the surfaces of recess portions and the surfaces of projection portions
Implementation Method 2
a transparent adhesive layer provided on the front surface side of the image design layer
Data Source
Figure 1
AI summary
There is provided a decorative sheet having a three-dimensional effect by a tactile sense and a visual three-dimensional effect or texture and excellent in design properties. A decorative sheet (10) according to this embodiment is provided with a base material (1), an image design layer (2) provided on a front surface (1a) side of the base material (1), a transparent adhesive layer (3) provided on a front surface (2a) side of the image design layer (2), a transparent thermoplastic resin layer (4) provided on a front surface (3a) side of the transparent adhesive layer (3), and a surface protective layer (5) provided on a front surface (4a) side of the transparent thermoplastic resin layer (4). On a front surface (5c) side of the surface protective layer (5), a recess and projection design (8) and a recess and projection pattern (9) having a plurality of regions (9a, 9b, 9c) which is provided on each of the surfaces of recess portions and the surfaces of projection portions of the recess and projection design (8) and in which recesses and projections are formed are provided. A height difference between the recess portions and the projection portions of the recess and projection design (8) is 3 µm or more and 200 µm or less. A height difference between recess portions and projection portions in each of the regions (9a, 9b, 9c) of the recess and projection pattern 9 is smaller than the height difference between the recess portions and the projection portions of the recess and projection design (8).