Decorative Sheet Relief Pattern Sharpness via Dual Protective Layers
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Solution Overview
Problem
Existing decorative sheets fail to effectively create a visually relief appearance with a wood surface texture, as they either lack sharpness in pattern edges due to surface tension issues or have poor durability due to the absence of a protective film.
Innovation Solution
A decorative sheet with a substrate, a pattern layer, and two surface protective layers, where the second surface protective layer contains synthetic resin beads with a specific particle diameter, providing a difference in glaze that conforms to the pattern and enhances the tactile impression, and includes a matte agent for improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a coating composition is coated on the substrate to form relief patterns, then the substrate surface gains relief appearance, but the edge between convex and concave parts becomes rounded and lacks sharpness due to surface tension
Solution Approach 1:
The substrate surface is pre-treated to create regions of different wettability before coating. The pattern-forming coating is applied to create depressed regions, then a second coating composition is applied that selectively fills only the depressed regions. This preliminary structuring of the surface allows the final relief pattern to achieve sharp edges without the rounding caused by surface tension during the coating process.
Solution Approach 2:
The invention creates local differences in surface properties by forming depressed regions with different wettability characteristics compared to the surrounding areas. The second coating composition is applied in a way that it selectively adheres to and fills only the depressed regions, creating local quality differences that result in sharp pattern edges while maintaining the overall relief appearance.
2Shape
If ultraviolet ray curing printing ink is used to create woodgrain pattern, then the pattern provides visual texture, but the part coated with ink lacks protective film and deteriorates in durability
Solution Approach 1:
The coating system is segmented into multiple functional layers: the first coating composition creates the depressed pattern regions that form the woodgrain visual texture, while the second coating composition is applied as a separate protective layer that fills the depressed regions and provides durability. This segmentation allows each layer to perform its specific function without compromising the other.
Solution Approach 2:
The invention uses composite coating materials where the first coating composition contains agents that create the woodgrain pattern appearance, and the second coating composition contains protective agents that provide weather resistance, water resistance, and wear resistance. The combination of these composite materials in a multi-layer structure achieves both aesthetic and durability requirements.
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 visually recognized concave pattern with a relief appearance and wood surface texture, providing a sophisticated appearance and hand feeling similar to real wood, while also improving durability through the use of synthetic resin beads and a matte agent.
Implementation Method 1
synthetic resin beads having an average particle diameter of from 10 to 30 μm, the synthetic resin beads protruding above the resin layer constituting the second surface protective layer
Implementation Method 2
the first surface protective layer and the second surface protective layer each containing a curable resin composition having been crosslinked and cured
Implementation Method 3
the first surface protective layer and the second surface protective layer each containing a curable resin composition having been crosslinked and cured
Data Source
Figure 1
AI summary
A decorative sheet contains a substrate having thereon at least a pattern layer, a homogeneous and uniform first surface protective layer covering the whole surface, and a second surface protective layer provided partly on the first surface protective layer, the first surface protective layer and the second surface protective layer each contain a curable resin composition having been crosslinked and cured, the first surface protective layer contains a matte agent, the second surface protective layer contains synthetic resin beads having an average particle diameter of from 10 to 30 µm, the synthetic resin beads protrude above a resin layer constituting the second surface protective layer, a region of the second surface protective layer and a region of the first surface protective layer exposed on the outermost surface have a difference in glaze, and the difference in glaze is conformed to a pattern of the pattern layer. Such a decorative sheet can be provided that has a pattern formed on the surface thereof, has a difference in glaze corresponding to the pattern, in which the difference in glaze is visually recognized as a concave part, and has a relief appearance on the surface thereof, and the decorative sheet also has wood surface texture.