Decorative Sheet Ridge Texture for Low Gloss and Rough Feel
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Solution Overview
Problem
Existing decorative sheets lack a combination of low gloss and a rough feel, which are important for aesthetic and durability properties, while also maintaining processability.
Innovation Solution
A decorative sheet design featuring a surface protective layer with a specific uneven structure, including ridge-like protrusions and a controlled ratio of ether to ester bonds, achieved through a process involving ionizing radiation curable resin with acrylate as a main component, and a controlled irradiation process to create a wrinkled surface texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a surface protective layer with matting agent is added to achieve low gloss, then gloss is reduced, but the surface becomes smooth and lacks rough feel
Solution Approach 1:
The surface protective layer is designed with local quality variations through the formation of ridge portions and uneven structures at specific locations. This creates a rough feel in certain areas while maintaining low gloss characteristics, resolving the contradiction between smooth surface and rough texture requirements
Solution Approach 2:
The invention introduces a dimensional aspect by forming three-dimensional ridge portions and uneven structures on the surface protective layer. This adds vertical dimensionality that provides rough feel while the overall surface maintains low gloss properties through controlled light scattering
2Reliability
If the surface protective layer is made thicker to improve durability, then scratch resistance improves, but the surface becomes less responsive to touch and loses rough feel
Solution Approach 1:
The surface protective layer incorporates local quality variations with ridge portions and uneven structures that maintain surface responsiveness even when the overall layer thickness is increased for durability. The local unevenness ensures tactile feedback while the thicker layer provides scratch resistance
3Illumination intensity
If a uniform smooth surface is formed to achieve high gloss, then aesthetic appearance improves, but the surface lacks durability against scratches and contamination
Solution Approach 1:
The surface protective layer is designed with local quality variations including ridge portions and uneven structures that are distributed throughout the layer. This creates a dual characteristic surface that maintains aesthetic appearance with controlled gloss while providing enhanced durability against scratches and contamination through the reinforced local structures
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 provides a decorative sheet with low gloss and a rough feel, enhancing durability and processability, while maintaining scratch resistance and aesthetic appeal.
Implementation Method 1
ionizing radiation curable resin with acrylate as a main component, and a controlled irradiation process
Data Source
AI summary
A decorative sheet including a primary film layer and a surface protective layer provided to one side of the primary film layer, wherein the surface protective layer has a surface provided with an uneven structure including a plurality of ridge portions each protruding in a ridge-like shape; the uneven structure of the surface protective layer has a protruding peak height Rpk of 3.5 μm or more; and an absorption spectrum obtained from Fourier infrared spectrometry of the surface protective layer 5 has a ratio I1095/I1725 of 0.65 or more, between a maximum value I1095 in a wavenumber range of 1085 to 1105 cm−1 and a maximum value I1725 in a wavenumber range of 1715 to 1735 cm−1.