Low-Gloss Decorative Sheet Surface for Scratch Resistance and Soft Feel
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Solution Overview
Problem
Existing decorative sheets lack good scratch resistance and do not provide a soft and supple feel, failing to balance aesthetic properties with durability and tactile comfort.
Innovation Solution
A decorative sheet design featuring a surface protective layer with asperities, including ridge-like protrusions, a specific luminance ratio (Rt_P), and a combination of cured resin and particles, which provides a thickness of 2 µm to 18 µm, and a gloss less than 10, enhancing scratch resistance and offering a soft and supple tactile experience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a surface protective layer is formed to improve scratch resistance, then durability is improved, but the surface becomes hard and less comfortable to touch
Solution Approach 1:
The surface protective layer incorporates particles with specific physical properties (size, shape, hardness) distributed throughout the layer to create localized tactile comfort zones. These particles form asperities on the surface that provide a soft, supple feel while the cured resin matrix maintains overall scratch resistance. This local quality modification resolves the contradiction by making specific regions of the surface comfortable to touch without compromising the protective function.
Solution Approach 2:
The surface protective layer is constructed as a composite material containing cured resin and particles (3-11 μm in size) in specific proportions (3-11 parts by mass per 100 parts by mass of resin). This composite structure combines the hardness and scratch resistance of the cured resin with the tactile comfort provided by the particles, simultaneously achieving both durability and tactile comfort.
2Illumination intensity
If a matting agent is added to reduce gloss, then aesthetic property is improved, but scratch resistance deteriorates
Solution Approach 1:
Instead of using matting agents that compromise scratch resistance, the invention changes the physical parameters of the surface protective layer by incorporating particles with specific size ranges (3-11 μm) and controlling their content (3-11 parts by mass per 100 parts by mass of resin). This parameter modification achieves the desired gloss reduction while maintaining or improving scratch resistance through the particle-reinforced structure.
Solution Approach 2:
The invention replaces traditional matting agents with a composite structure of cured resin and dispersed particles. This composite approach achieves the matting effect through the physical presence and distribution of particles rather than chemical matting agents, thereby maintaining scratch resistance while achieving the desired low gloss appearance (gloss less than 10).
3Ease of operation
If particles are added to improve tactile feel, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The invention specifies precise parameter ranges for particle size (3-11 μm) and particle content (3-11 parts by mass per 100 parts by mass of resin) to achieve consistent tactile comfort while maintaining manufacturing precision. The asperity height ratio parameter (Rt_P between 1.57-1.82) provides an additional control parameter that ensures uniform surface characteristics despite the presence of particles.
Solution Approach 2:
The particles are distributed throughout the surface protective layer to create localized tactile comfort features rather than requiring perfect uniformity across the entire surface. This approach accepts local variations in particle positioning while maintaining overall surface uniformity through controlled particle size and content, resolving the contradiction between tactile comfort and manufacturing precision.
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 improved scratch resistance and a soft, supple feel through the optimized surface protective layer, balancing durability and tactile comfort.
Implementation Method 1
in a power spectrum image obtained by applying a two-dimensional fast Fourier transform to a surface shape image of the asperities
Implementation Method 2
the surface protective layer contains a cured resin and particles
Data Source
Figure 1~2
Figure 3
AI summary
A decorative sheet that has good scratch resistance and provides a soft and supple feel is provided. In the decorative sheet (1), a surface of the surface protective layer (5) is provided with asperities including ridge portions. In a power spectrum image obtained by applying a two-dimensional fast Fourier transform to their surface shape image, when the average luminance in the spatial frequency range of 95 to 105 cycles/mm is defined as P_100, the average luminance in the spatial frequency range of 195 to 205 cycles/mm is defined as P_200, the average luminance in the spatial frequency range of 695 to 705 cycles/mm is defined as P_700, and the ratio of the difference between P_100 and P_700 to the difference between P_200 and P_700 is defined as Rt_P, the average of Rt_P is within the range of 1.57 to 1.82. The surface protective layer contains 100 parts by mass of a cured resin and 3 to 11 parts by mass of particles with an average particle size of 3 µm or more, and has a thickness of 2 to 18 µm and a gloss less than 10.