Infrared Reflective Patterned Product with Oriented Tabular Metal Particles
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Solution Overview
Problem
Existing infrared reflective patterned products have a low ratio of reflectance of the infrared reflective pattern portion to the non-pattern portion at specific wavelengths when obliquely irradiated with infrared rays, leading to poor reading accuracy and formability issues.
Innovation Solution
An infrared reflective patterned product with an uneven structure containing 60% or greater tabular metal particles in a hexagonal or circular shape, oriented within a 0° to ±30° angle range, and an overcoat layer with a refractive index difference of 0.05 or less, enhancing diffusion reflectance and retroreflectance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional infrared reflective materials are used, then the pattern can be formed, but the ratio of reflectance of the infrared reflective pattern portion to the non-pattern portion is small when obliquely irradiated with infrared rays
Solution Approach 1:
The patent changes the physical parameters of the infrared reflective material by using tabular metal particles with specific dimensional ratios (length-to-width ratio of 0.01 to 2.0) and controlling their orientation distribution. This parameter optimization enables high reflectance ratio when obliquely irradiated with infrared rays, resolving the contradiction between formability and reading accuracy.
Solution Approach 2:
The patent employs a composite structure consisting of tabular metal particles dispersed in a transparent resin matrix. This composite material configuration allows the infrared reflective pattern portion to exhibit high reflectance ratio when obliquely irradiated, while maintaining good formability and pattern definition.
2Ease of operation
If the infrared reflective pattern portion is obliquely irradiated with infrared rays, then reading can be performed, but the reflectance in the direction of irradiation is insufficient
Solution Approach 1:
The patent optimizes the dimensional parameters of tabular metal particles (length-to-width ratio of 0.01 to 2.0) and controls their orientation distribution to enhance reflectance intensity in the direction of oblique irradiation. This parameter optimization enables effective reading operation with oblique irradiation.
Solution Approach 2:
The patent introduces orientation distribution control as an additional dimensional parameter, specifying that particles with principal planes oriented within ±30° from the surface normal constitute 50% or more of total particles. This dimensional control enables enhanced reflectance intensity in the oblique irradiation direction.
3Reliability
If tabular metal particles are used for infrared reflection, then retroreflectance can be achieved, but the particles may aggregate or settle during manufacturing
Solution Approach 1:
The patent controls the dimensional parameters of tabular metal particles (length-to-width ratio of 0.01 to 2.0) to optimize both retroreflectance performance and manufacturing processability. This parameter control prevents aggregation and settling during manufacturing while maintaining retroreflectance capability.
Solution Approach 2:
The patent applies local quality control by specifying that particles with principal planes oriented within ±30° from the surface normal constitute 50% or more of total particles. This localized orientation control achieves retroreflectance performance while ensuring uniform distribution and preventing aggregation during manufacturing.
4Measurement precision
If the reflectance ratio is increased for better reading accuracy, then reading precision improves, but the device complexity increases
Solution Approach 1:
The patent achieves high reading accuracy by optimizing particle parameters (length-to-width ratio of 0.01 to 2.0 and orientation distribution) rather than complicating the device structure. This parameter-based solution improves reading precision without increasing device complexity.
Solution Approach 2:
The patent uses a simple coating process where tabular metal particles are dispersed in a transparent resin and applied to form the pattern. This copying approach creates the infrared reflective pattern through material composition rather than complex structural fabrication, maintaining device simplicity.
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 significantly increases the reflectance ratio of the infrared reflective pattern portion to the non-pattern portion, improving reading accuracy and formability, while maintaining high transmittance and visibility.
Implementation Method 1
enhancing diffusion reflectance and retroreflectance
Implementation Method 2
enhancing diffusion reflectance and retroreflectance
Implementation Method 3
it has been desired to preferably increase the reflectance in a direction which is approximately the same as the direction in which infrared rays are radiated and to more preferably retroreflect the infrared rays to the direction in which the infrared rays are radiated
Data Source
AI summary
An infrared reflective patterned product includes an infrared reflective pattern portion which has an infrared reflective material in a region constituting at least a part of a support. The infrared reflective pattern portion has an uneven structure which includes a plurality of protruding or recessed portions. Metal particles are contained on surfaces of the protruding or recessed portions. The particles include 60 number-percent or greater of tabular metal particles in a hexagonal or circular shape, and the tabular particles which are plane-oriented so that an angle between a principal plane of the particle and a surface of the uneven structure closest to the particle is in a range of 0° to ±30° are adjusted to be 50 number-percent or greater of all tabular metal particles. In the patterned product, the ratio of the reflectance of the infrared reflective pattern portion at a wavelength with the highest reflectance in an infrared region of 780 nm to 2500 nm to the reflectance of a non-pattern portion is large in a case where the infrared reflective pattern portion is obliquely irradiated with infrared rays.