Decorative Sheet Protective Layer for Low Gloss and Soft Feel
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Solution Overview
Problem
Existing decorative sheets lack a combination of low gloss and a soft, supple feel, while also requiring high weatherability and durability.
Innovation Solution
A decorative sheet with a surface protective layer containing asperities and a specific power ratio in its power spectrum, formed by a cured resin and particles, provides a low gloss and a soft, supple feel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a matting agent is added to the surface protective layer to achieve low gloss, then the gloss is reduced, but the scratch resistance and stain resistance deteriorate
Solution Approach 1:
The patent changes the surface morphology parameters by controlling the formation of asperities with specific spatial frequency characteristics (power ratio x between 4.0-13.5) instead of changing chemical composition with matting agents. This physical parameter change achieves low gloss while preserving the protective layer's durability and resistance properties.
Solution Approach 2:
The surface protective layer forms a composite structure combining a cured resin base material with embedded asperities having specific surface profile characteristics. This composite structure achieves both aesthetic properties (low gloss) and functional properties (scratch and stain resistance) simultaneously.
2Illumination intensity
If excimer light is used to form wrinkles for low gloss, then the gloss is reduced, but the manufacturing complexity and energy consumption increase
Solution Approach 1:
The patent replaces the complex excimer light irradiation system with a simpler mechanical or chemical method for forming asperities. The surface profile is created through controlled deformation or phase separation during coating formation, eliminating the need for specialized UV irradiation equipment while achieving similar low-gloss effects.
Solution Approach 2:
Instead of using high-energy excimer light to create surface wrinkles, the patent achieves low gloss by controlling the spatial frequency parameters of asperities formed during the coating process itself, using more straightforward parameters like surface tension, viscosity, and controlled deformation.
3Illumination intensity
If the surface protective layer is made smooth for high gloss, then the aesthetic property is improved, but the tactile feel becomes harsh and durability decreases
Solution Approach 1:
The patent optimizes the spatial frequency parameters of surface asperities (power ratio x between 4.0-13.5) to create a surface that reflects light diffusely for low gloss while maintaining a tactile profile that feels soft and supple. The specific frequency range ensures the asperities are fine enough to feel smooth to touch but sufficient to scatter light effectively.
Solution Approach 2:
The asperities on the surface have rounded, ridge-like profiles rather than sharp edges, creating a curved surface topology that feels soft to the touch. The ridge portions protruding in a ridge-like shape provide a gentle tactile experience while effectively scattering light to achieve low gloss.
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 decorative sheet achieves low gloss and a soft, supple tactile experience, enhancing aesthetic and durability properties.
Implementation Method 1
a surface of the surface protective layer has asperities including a plurality of ridge portions each protruding in a ridge-like shape, in a power spectrum obtained by Fourier transforming a surface profile of a cross section of the surface protective layer, a power ratio x of the mean of the common logarithm of power within a spatial frequency range of 500 cycles/mm or more and 1000 cycles/mm or less, log Pf500-1000, to the mean of the common logarithm of power within a spatial frequency range of 3000 cycles/mm or more and 3500 cycles/mm or less, log Pf3000-3500, is within a range of 4.0 to 13.5, and the surface protective layer has a gloss of less than 10
Implementation Method 2
the surface protective layer contains a cured resin and particles
Data Source
AI summary
A decorative sheet includes: a primary film layer; and a surface protective layer provided on one surface of the primary film layer. A surface of the surface protective layer has asperities including a plurality of ridge portions each protruding in a ridge-like shape, in a power spectrum obtained by Fourier transforming a surface profile of a cross section of the surface protective layer, a power ratio x of the mean of the common logarithm of power within a spatial frequency range of 500 cycles/mm or more and 1000 cycles/mm or less, log Pf500-1000, to the mean of the common logarithm of power within a spatial frequency range of 3000 cycles/mm or more and 3500 cycles/mm or less, log Pf3000-3500, is within a range of 4.0 to 13.5, and the surface protective layer has a gloss of less than 10.