Decorative Sheet With 3D Metallic Design via Transfer Embedding
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Solution Overview
Problem
Existing methods for creating decorative sheets with three-dimensional metallic designs are costly and time-consuming, especially when fine and complex patterns are involved, and often result in degraded reproduction characteristics due to the use of etching or laser processing.
Innovation Solution
A method involving a transfer target sheet with a transparent thermoplastic resin base and a reflection pattern formation layer, where pressure is applied using a transfer tool to embed a reflection pattern onto the target sheet, improving reproduction characteristics and reducing production time, allowing for the creation of an inexpensive decorative sheet with enhanced three-dimensionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If etching or laser processing is used to create designs on metal layers, then fine and complex patterns can be achieved, but production time increases and costs increase significantly
Solution Approach 1:
The patent uses a transfer sheet with a reflection pattern formation layer that is pressed onto the transfer target sheet to transfer the design pattern. This copying method replaces time-consuming etching or laser processing with a simple pressure-based transfer process, significantly reducing production time while maintaining fine pattern reproduction quality.
Solution Approach 2:
The patent replaces chemical etching or laser processing with a mechanical pressure-based transfer system. By using a transfer tool to apply pressure and embed the reflection pattern formation layer onto the transfer target sheet, the process achieves fine patterns without the time and cost penalties of traditional methods.
2Manufacturing precision
If etching or laser processing is used to create designs on metal layers, then fine and complex patterns can be achieved, but production costs increase significantly
Solution Approach 1:
The transfer sheet serves as a reusable template that can be used to copy the same design pattern onto multiple transfer target sheets. This eliminates the need for expensive etching or laser processing for each individual piece, significantly reducing production costs while maintaining consistent fine pattern quality across all products.
Solution Approach 2:
The patent changes the fundamental parameter of pattern formation from material removal (etching/laser) to material transfer via pressure. This parameter change enables the use of simpler, less expensive equipment and processes while achieving the same fine pattern reproduction quality, thereby reducing production costs.
3Ease of manufacture
If printing technique is used for pattern formation, then production cost decreases, but reproduction characteristics are degraded due to bleeding
Solution Approach 1:
The transfer sheet acts as a precise physical copy of the desired pattern, transferring it directly onto the transfer target sheet through pressure. This copying mechanism avoids the bleeding issues inherent in printing techniques while maintaining low production costs, as the transfer sheet can be reused multiple times without significant degradation.
Solution Approach 2:
The patent replaces the chemical/ink-based printing system with a mechanical pressure-based transfer system. This substitution eliminates the bleeding problem inherent in printing by using direct physical contact and embedding, while keeping production costs low through the reusability of the transfer sheet.
4Shape
If multiple metal layers are stacked to create three-dimensional metallic design, then three-dimensionality is achieved, but production complexity and cost increase
Solution Approach 1:
The patent combines the transfer target sheet with the reflection pattern formation layer into a single integrated structure after the transfer process. This merging eliminates the need for separate stacking and assembly of multiple metal layers, reducing production complexity while maintaining the three-dimensional metallic design effect through the embedded reflection pattern.
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
This method significantly reduces production time and costs while maintaining high reproduction quality, enabling the creation of decorative sheets with fine, three-dimensional metallic designs that are both affordable and visually appealing.
Implementation Method 1
pressing a transfer tool against a second major surface of the transfer base film to embed a portion of the reflection pattern formation layer onto the transfer target sheet and bond the portion to the transfer target sheet
Implementation Method 2
bond the portion to the transfer target sheet
Implementation Method 3
transparent film base including primarily a thermoplastic resin
Data Source
AI summary
An inexpensive decorative sheet has a fine three-dimensional metallic design. A base vapor deposition film and a transfer sheet are provided. The base vapor deposition film includes a transparent film base of primarily a thermoplastic resin and is light-transmissive, and an underlying metal layer. The transfer sheet includes a transfer base film and a reflection pattern formation layer including a pattern metal layer. The transfer sheet is placed onto the base vapor deposition film, and a transfer roller is pressed against the transfer base film to embed a portion of the reflection pattern formation layer onto the base vapor deposition film and bond the portion to the base vapor deposition film. The transfer roller includes a transfer surface, which corresponds to a predetermined design. The transfer sheet is peeled away from the base vapor deposition film to transfer a reflection pattern to the base vapor deposition film.