Embossed Decoration Sheet With PETG Transparent Layer
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Solution Overview
Problem
Conventional decoration sheets with embossed patterns face challenges in forming fine and delicate designs due to elongation or deformation during heat processes, and they are prone to scratches and staining, failing to display a luxurious 3-dimensional pattern effectively.
Innovation Solution
A decoration sheet comprising a transparent layer with a mirror surface made of glycol-modified polyethyleneterephthalate (PETG), an embossed pattern layer formed using a photo-curable or thermo-curable resin composition, a colored film, and a printed or metal deposition layer adhered with an opaque adhesive, which maintains the pattern's shape and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an embossed pattern is formed on a polypropylene film or polyvinyl film through extruding or calendering process, then a decoration sheet can be manufactured, but the embossed pattern is elongated or deformed in subsequent heat processes
Solution Approach 1:
The embossed pattern is formed on the transparent layer before the subsequent heat lamination process. By pre-forming the pattern on the transparent layer rather than on the decorative layer, the pattern avoids exposure to heat that would cause elongation or deformation, thus maintaining shape accuracy while still enabling the manufacturing process to proceed
Solution Approach 2:
The decoration sheet is divided into multiple layers with distinct functions: a transparent layer that carries the embossed pattern, and a separate decorative layer that is laminated onto it. This segmentation allows the pattern-forming layer to be processed separately from the heat-lamination process, preventing pattern deformation while maintaining ease of manufacture
2Ease of manufacture
If a mirror surface sheet has an embossed pattern formed on its surface, then it provides decorative effect, but the embossed pattern is damaged due to scratches and is easily stained
Solution Approach 1:
The embossed pattern is moved from the surface dimension to the interior structure by forming it on the transparent layer beneath the decorative layer. This dimensional relocation protects the pattern from direct surface contact with scratches and stains, while the transparent layer's clarity ensures the pattern remains visible and decorative
3Ease of manufacture
If conventional mirror surface sheet is used, then it provides basic decorative effect, but it cannot show a softly-glowing and luxurious 3-dimensional pattern
Solution Approach 1:
The transparent layer is given the specific quality of optical clarity and refractive properties that enable light to interact with the embossed pattern in a way that creates soft glow and 3-dimensional effects. This localized quality enhancement in the transparent layer, combined with the protected embossed pattern, achieves luxurious visual effects without compromising the mirror surface functionality
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 enables the creation of a decoration sheet with a durable, fine, and uniform 3-dimensional pattern that retains its shape and appearance, offering excellent formability, surface smoothness, and stain resistance, suitable for various applications without deformation or staining.
Implementation Method 1
an embossed pattern layer that is formed on the lower side of the transparent layer and includes a cured product of a photo-curable or thermo-curable resin composition
Data Source
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AI summary
Provided are a decoration sheet and a method of manufacturing the same. The decoration sheet may have a mirror effect on a surface thereof, and have a 3-dimensional pattern on the inside. The decoration sheet may include an embossed pattern layer having a fine and uniform 3-dimensional pattern, which is not elongated or deformed due to heat generated during processing or in use. The decoration sheet has excellent surface properties such as wear resistance and scratch resistance, and formability, and is effectively applied in thermal or membrane forming.