Decorative Sheet Ridged Surface Control for Smooth Tactile Feel
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Solution Overview
Problem
Existing decorative sheets lack a smooth and highly uniform feel, particularly in terms of tactile sensation, due to variations in surface texture and roughness.
Innovation Solution
A decorative sheet with a surface protection layer having a specific uneven structure, characterized by ridged portions with controlled peak height and composition, including a mass ratio of silicon, carbon, and oxygen, and a thickness range that provides a uniform tactile experience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a surface protection layer is formed to improve durability and scratch resistance, then the surface durability is improved, but the surface becomes rough and loses smoothness
Solution Approach 1:
The invention changes the surface morphology parameters by controlling the reduced peak height Rpk to be 3.0 μm or less (preferably 0.5-2.0 μm) and the mean width of roughness profile elements RSm to be within specific ranges. This parameter optimization allows the surface to maintain both durability (through the uneven structure) and smoothness (through controlled dimensions), resolving the contradiction between durability improvement and surface smoothness preservation
Solution Approach 2:
The surface protection layer is formed as a composite structure combining an uneven surface morphology with specific compositional ratios (Si: 0.1-5.0 mass%, C: 20-80 mass%, O: 5-70 mass%). This composite approach allows the layer to simultaneously provide durability through the protective function and smoothness through the optimized composition and controlled surface topology
2Illumination intensity
If matting agent is added to achieve low gloss, then the gloss is reduced, but the surface uniformity and smooth feel are compromised
Solution Approach 1:
The invention achieves low gloss (10-50°) through controlled surface morphology parameters (Rpk ≤ 3.0 μm, specific RSm ranges) rather than through matting agents. This physical morphology control maintains surface chemical uniformity and composition consistency, avoiding the heterogeneity and aggregation issues that matting agents would introduce, thus resolving the contradiction between gloss reduction and surface uniformity
Solution Approach 2:
The invention replaces the chemical approach (adding matting agents) with a physical approach (controlling surface morphology through synthesis conditions). This substitution eliminates the need for foreign particles that compromise uniformity, achieving the desired low gloss effect through the inherent surface topology of the protective layer itself
Data Source
AI summary
A decorative sheet includes a primary film layer and a surface protection layer provided on one surface of the primary film layer. The surface protection layer has a surface provided with an uneven structure having a plurality of ridged portions protruding in a ridged pattern. The uneven structure of the surface protection layer has a reduced peak height Rpk of less than 3.5 μm. The surface protection layer has a mass concentration of carbon C (% by mass), a mass concentration of oxygen O (% by mass), and a mass concentration of silicon Si (% by mass) satisfying the following relational expression: 0.5≤{Si/(C+O+Si)}×100.