Infrared-Synchronized Decorative Sheet Embossing for Realistic Texture
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Solution Overview
Problem
Decorative sheets lack the natural texture and design expression found in genuine wood and stone, leading to a less appealing aesthetic compared to their expensive counterparts.
Innovation Solution
A production method involving a base material layer, a pictorial pattern layer with a material having higher light absorption properties, a transparent resin layer, and a surface protective layer, where an embossed shape is formed by irradiating with light of a specific wavelength to synchronize with the pattern, allowing for a textured and visually appealing design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If decorative sheets use flat surface textures, then manufacturing is simple and cost-effective, but the design expression and visual appeal are insufficient compared to genuine wood and stone
Solution Approach 1:
The patent applies parameter changes by using light absorption properties of specific materials at predetermined wavelengths to create selective embossing. The pictorial pattern layer uses materials with different light absorption characteristics, and irradiation with light of specific wavelengths causes localized softening, enabling the embossing plate to form three-dimensional textures that synchronize with the pictorial pattern, thus achieving realistic surface textures while maintaining manufacturing efficiency
Solution Approach 2:
The patent replaces traditional mechanical embossing methods with a photochemical-thermal process. Instead of applying high mechanical pressure throughout the entire surface, the system uses light irradiation to selectively soften resin portions, allowing the embossing plate to form textures with minimal mechanical force, thereby achieving both manufacturing simplicity and high texture realism
2Productivity
If decorative sheets lack texture variation, then production is efficient and uniform, but the design properties and aesthetic quality are inferior to genuine articles
Solution Approach 1:
The patent applies local quality by creating different surface textures in different regions of the decorative sheet. The pictorial pattern layer is formed using materials with varying light absorption properties, and irradiation with light of predetermined wavelengths causes selective softening in specific areas, enabling the embossing plate to create localized three-dimensional textures that match the pictorial pattern, thus achieving both high production efficiency and accurate texture variation
Solution Approach 2:
The patent uses periodic action through the sequential process of irradiation and embossing. Light of predetermined wavelengths is irradiated in a controlled manner to periodically soften specific resin portions, followed by embossing plate contact that creates textures during the softening periods, allowing efficient production with high texture accuracy through rhythmic application of energy and mechanical force
3Ease of manufacture
If decorative sheets use uniform coloring, then manufacturing is straightforward, but the visual appeal and design expression fail to capture the complexity of genuine wood and stone
Solution Approach 1:
The patent applies parameter changes by utilizing the light absorption characteristics of different materials at specific wavelengths. The pictorial pattern layer uses materials with varying absorption properties, and irradiation with light of predetermined wavelengths selectively affects different regions, causing synchronized color and texture variations that match genuine wood and stone while maintaining straightforward manufacturing processes
Solution Approach 2:
The patent uses composite materials by combining the pictorial pattern layer with the transparent resin layer and surface protective layer. The composite structure allows the pictorial pattern to provide color and design expression while the resin layers provide structural integrity and enable three-dimensional embossing, achieving both manufacturing simplicity and high color-texture synchronization accuracy
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 method creates a decorative sheet with a texture closer to genuine wood or stone, enhancing design properties and providing a more realistic and visually engaging surface.
Implementation Method 1
performing irradiation with irradiation light for which a power of the light of a predetermined wavelength is higher than a power of light of other wavelengths
Implementation Method 2
performing irradiation with irradiation light... after the depositing, and pressing the embossing plate for forming an embossed shape onto the surface protective layer after performing the irradiation with irradiation light
Data Source
AI summary
There is provided a production method for a decorative sheet having a texture that is closer to that of a genuine article and having excellent design properties. To do so, the method includes forming a pictorial pattern layer (5) on which a pictorial pattern is drawn using a predetermined material having higher light absorption properties with respect to infrared light than a transparent thermoplastic resin layer (6) (FIG. 2A), depositing the transparent thermoplastic resin layer (6) and a surface protective layer (7) on the pictorial pattern layer (5) in this order (FIG. 2B), performing irradiation with infrared light after the depositing (FIG. 2C), and pressing an embossing plate onto the surface protective layer (7) after performing the irradiation with infrared light. (FIG. 2D).