Decorative Sheet Surface-Protecting Layer for Easy Cleanability
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Solution Overview
Problem
Decorative sheets in living environments face challenges with dirt accumulation from fine particle powders, which are difficult to clean due to their fine nature and ability to penetrate surface irregularities, and lack impact resistance.
Innovation Solution
A decorative sheet with a surface-protecting layer having a specific micro concave-convex surface shape and containing an inorganic filler, optimized for easy cleanability and impact resistance, where the surface roughness and filler size are carefully controlled to prevent dirt accumulation and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the decorative sheet has a smooth surface, then it is easy to clean, but fine particle powder easily penetrates into surface irregularities causing dirt accumulation
Solution Approach 1:
The patent applies local quality by creating a surface with specifically controlled micro-irregularities rather than a completely smooth surface. The arithmetic average roughness Ra is controlled within 0.05-0.50 μm and the maximum height of roughness profile elements Rz is controlled within 0.20-2.00 μm, creating localized surface characteristics that prevent fine particle penetration while maintaining overall cleanability.
Solution Approach 2:
The patent changes the surface parameter characteristics by precisely controlling the roughness parameters (Ra and Rz) within specific ranges. This parameter optimization creates a surface that balances smoothness for easy cleaning with controlled irregularities to prevent fine particle powder accumulation, resolving the contradiction between smooth surface and dirt prevention.
2Ease of operation
If the decorative sheet has a rough surface to prevent dirt accumulation, then easy cleanability improves, but impact resistance decreases due to scratches from dropped articles
Solution Approach 1:
The patent changes the surface parameters by controlling both Ra (arithmetic average roughness) and Rz (maximum height of roughness profile elements) within specific ranges. This dual-parameter control creates a surface that is sufficiently rough to prevent fine particle accumulation but not so rough as to be prone to scratching from impacts, thus balancing cleanability with impact resistance.
Solution Approach 2:
The patent uses a composite coating layer comprising multiple components including polyurethane resin, polyester resin, and inorganic fillers. This composite material structure provides both the necessary surface characteristics for preventing dirt accumulation and the mechanical strength for impact resistance, resolving the contradiction between cleanability and durability.
3Object-affected harmful factors
If the surface is made highly resistant to fine particle penetration, then dirt accumulation is prevented, but the surface becomes more susceptible to scratches from impact
Solution Approach 1:
The patent employs a composite coating material containing polyurethane resin, polyester resin, and inorganic fillers. This composite structure provides a balanced surface that resists fine particle penetration while maintaining scratch resistance from impact, as the different materials contribute different properties that collectively resolve the contradiction.
Solution Approach 2:
The patent optimizes surface parameters by controlling Ra within 0.05-0.50 μm and Rz within 0.20-2.00 μm. This precise parameter control creates a surface topology that prevents fine particle accumulation while maintaining sufficient structural integrity to resist scratching from dropped articles, resolving the contradiction between particle resistance and scratch resistance.
Data Source
Figure 1~2
AI summary
An object of the present invention is to provide, for use in living environments, a decorative sheet that has excellent, easy cleanability and excellent impact resistance and from which dirt due to the adherence of a daily used contaminant, such as fine particle powder, that is not easy to clean is easily removed. The present invention provides a decorative sheet having a surface-protecting layer on the uppermost surface thereof, wherein (1) Ra(i)/Ra(ii) is 0.62 or more and 1.63 or less, the Ra(i)/Ra(ii) being calculated using an arithmetic average roughness Ra(i) measured along an arbitrary direction on the surface of the surface-protecting layer, and an arithmetic average roughness Ra(ii) measured along the perpendicular direction to the arbitrary direction, under measurement conditions in accordance with JIS B0633:2001 and by a measurement method in accordance with JIS B0601:2001; (2) RSm(i)/RSm(ii) is 0.75 or more and 1.33 or less, the RSm(i)/RSm(ii) being calculated using a mean width of roughness profile elements RSm(i) measured along an arbitrary direction on the surface of the surface-protecting layer, and a mean width of roughness profile elements RSm(ii) measured along the perpendicular direction to the arbitrary direction, under measurement conditions in accordance with JIS B0633:2001 and by a measurement method in accordance with JIS B0601:2001; and (3) an arithmetic average roughness Ra measured on the surface of the surface-protecting layer at a cutoff value (λc) of 0.08 mm with an evaluation length of 0.4 mm by a measurement method in accordance with JIS B0601:2001 is 0.40 µm or less, and a mean width of roughness profile elements RSm measured on the surface of the surface-protecting layer at a cutoff value (λc) of 0.08 mm with an evaluation length of 0.4 mm by a measurement method in accordance with JIS B0601:2001 is 22.90 µm or more.