Decorative Sheet Surface-Protecting Layer Resin Composition
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Solution Overview
Problem
Conventional decorative sheets with ionizing radiation-curable resin surface-protecting layers face issues with contamination resistance, alkali resistance, and susceptibility to cracks and breakage due to curing shrinkage and brittleness, which can lead to instability over time.
Innovation Solution
A decorative sheet comprising a laminate structure with a base material sheet and a first surface-protecting layer made from a specific ionizing radiation-curable resin blend of aliphatic urethane acrylates with an isocyanurate and alicyclic skeleton, providing enhanced nanoindentation hardness and resistance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an ionizing radiation-curable resin is used for the surface-protecting layer, then contamination resistance and alkali resistance are improved, but the layer becomes brittle and prone to cracks and breakage
Solution Approach 1:
The patent changes the chemical composition parameters of the ionizing radiation-curable resin by specifying precise proportions of polyacrylonitrile (5-20 parts), polyurethane polyol (40-80 parts), and isocyanate (5-20 parts). This parameter optimization balances the curing shrinkage that provides contamination resistance with the flexibility needed to prevent cracks under impact.
Solution Approach 2:
The patent creates a composite resin system combining multiple components: polyacrylonitrile, polyurethane polyol, and isocyanate. This composite approach allows the surface-protecting layer to simultaneously achieve contamination resistance through controlled curing shrinkage and impact resistance through the synergistic properties of the composite material.
2Reliability
If an ionizing radiation-curable resin with inorganic filler is used, then contamination resistance is improved, but curing shrinkage causes adverse effects on surface quality
Solution Approach 1:
The patent optimizes the parameter ratios of the resin components to control the degree of curing shrinkage. By maintaining specific proportions of polyacrylonitrile, polyurethane polyol, and isocyanate, the patent achieves sufficient shrinkage for contamination resistance while minimizing adverse effects on surface quality and dimensional stability.
3Reliability
If a two-component curable acrylic polyol and aliphatic isocyanate are mixed to alleviate curing shrinkage, then contamination resistance is maintained, but physical properties become unstable over time
Solution Approach 1:
The patent changes the chemical composition parameters by replacing the unstable two-component system with a three-component system including polyacrylonitrile, polyurethane polyol, and isocyanate in optimized proportions. This parameter change stabilizes the physical properties over time while maintaining contamination resistance through controlled curing shrinkage.
Solution Approach 2:
The patent creates a more stable composite resin system by incorporating polyacrylonitrile alongside polyurethane polyol and isocyanate. This three-component composite provides superior long-term stability compared to the two-component system, while still achieving the necessary curing shrinkage for contamination resistance.
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 long-lasting contamination and alkali resistance while minimizing breakage and cracks under impact, maintaining performance over time.
Implementation Method 1
a first surface-protecting layer comprising an ionizing radiation-curable resin containing two kinds of aliphatic urethane acrylates
Data Source
AI summary
Specifically, the present invention provides a decorative sheet comprising a laminate, the laminate comprising at least a base material sheet and a first surface-protecting layer in sequence in the thickness direction; (1) the first surface-protecting layer comprising an ionizing radiation-curable resin containing two kinds of aliphatic urethane acrylates, i.e., resin A and resin B, wherein resin A is an aliphatic urethane acrylate with an isocyanurate skeleton, and resin B is an aliphatic urethane acrylate with an alicyclic skeleton without an isocyanurate skeleton, (2) the first surface-protecting layer having a nanoindentation hardness of 160 MPa or more and 240 MPa or less, and (3) the base material sheet comprising a polyolefin resin and having a nanoindentation hardness of 30 MPa or more and 80 MPa or less.