Low-Gloss Decorative Sheet Surface for Scratch-Resistant Lamination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Decorative sheets face challenges in achieving a gloss of 15 or less while maintaining fingerprint resistance, scratch resistance, stain resistance, and processability, with issues such as decreased fingerprint resistance, scratch resistance, and processability due to the use of matting agents and increased crosslinking density leading to curling and tearing.
Innovation Solution
A decorative sheet design featuring a primary film layer with a surface protective layer having a ridge part in a ridge shape, composed of an ionizing radiation curable resin with a trifunctional acrylic resin as the main component, and specific surface roughness and hardness parameters, ensuring a gloss of 15 or less and improved durability and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a large amount of matting agent is added to achieve low gloss, then gloss is reduced, but fingerprint resistance decreases and scratch resistance decreases
Solution Approach 1:
The patent removes the matting agent from the surface protective layer composition entirely. Instead of using chemical additives to achieve low gloss, the invention uses a physical surface structure (ridges and valleys) formed by ionizing radiation curable resin to provide the matting effect, thereby eliminating the harmful effects of matting agents while maintaining low gloss appearance
Solution Approach 2:
The patent changes the approach from chemical parameter modification (adding matting agents) to physical structure modification (creating surface ridges). By controlling the surface morphology through ionizing radiation curing processes, the patent achieves low gloss without compromising the mechanical and protective properties of the surface layer
2Reliability
If crosslinking density is increased to improve scratch resistance, then scratch resistance improves, but the sheet curls significantly due to curing shrinkage
Solution Approach 1:
The patent optimizes the crosslinking density parameter by selecting specific ionizing radiation curable resins with controlled functionality (2-4 functional groups per molecule) and adjusting curing conditions. This achieves sufficient scratch resistance while controlling curing shrinkage to prevent excessive curling during the lamination process
Solution Approach 2:
The patent creates localized surface ridges and valleys through ionizing radiation curing, concentrating the structural features in specific areas rather than uniformly throughout the entire surface. This localized structuring provides scratch resistance where needed while allowing the bulk material to maintain appropriate flexibility and minimize curling
3Reliability
If crosslinking density is increased to improve scratch resistance, then scratch resistance improves, but the decorative sheet tears because the surface protective layer is too hard
Solution Approach 1:
The patent carefully controls the crosslinking density and resin composition to achieve an optimal balance. By using ionizing radiation curable resins with specific molecular weights and functional group counts, the patent creates a surface protective layer that is hard enough to resist scratches but not so hard that it becomes brittle and tears during handling or installation
4Illumination intensity
If matting agent is added to achieve low gloss, then gloss is reduced, but blushing occurs during bending and processability decreases
Solution Approach 1:
The patent eliminates matting agents from the formulation, removing the source of blushing problems during bending. The low gloss effect is achieved through the physical ridge structure on the surface, which does not interfere with the bending process or cause blushing, thereby maintaining good processability
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 decorative sheet achieves a gloss of 15 or less with enhanced fingerprint resistance, scratch resistance, stain resistance, and processability, while maintaining ease of lamination and preventing tearing.
Implementation Method 1
the surface protective layer contains an ionizing radiation curable resin as a main material
Data Source
AI summary
A decorative sheet comprises a primary film layer and a surface protective layer, wherein the surface protective layer has a gloss of 15 or less; the surface protective layer has a ridge part protruding in a ridge shape on tis surface to form an irregular shape; the surface protective layer has a Martens hardness within the range of 20 N/mm2 or more and 200 N/mm2 or less; the surface protective layer contains an ionizing radiation curable resin as a main material; the ionizing radiation curable resin contains a trifunctional acrylic resin having a repeating structure as a main component; the number of repetitions of the repeating structure is 3 or more; and the irregular shape of the surface protective layer has RSm/Ra within the range of 10 or more and 300 or less.