Mat Release Sheet Coating for Durable Low-Gloss Forming
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Solution Overview
Problem
Conventional release sheets fail to produce a formed article with a low-gloss, mat-style surface effectively, as they lack the necessary refined and deep unevenness, and their durability and uniformity are inadequate for industrial production.
Innovation Solution
A release sheet with a mat making layer and a release layer formed using a coating film of releasable resin containing ultra micro particles, providing a refined uneven surface and superior heat resistance and mechanical strength, ensuring consistent low-gloss finish even with repeated use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional release sheets with emboss processing are used, then high gloss mirror style can be formed, but low gloss mat style cannot be achieved
Solution Approach 1:
The invention changes the surface roughness parameter by providing a mat making layer with refined uneven surface having an arithmetical mean surface roughness of 0.5 to 15 μm, and further controlling the release layer to have an arithmetical mean surface roughness of 0.05 to 5 μm. This parameter change enables the formation of low gloss mat style surfaces while maintaining manufacturing precision and uniformity.
2Illumination intensity
If coating method is used to form refined uneven on release layer, then mat style can be formed, but durability and uniformity are insufficient for industrial production
Solution Approach 1:
The invention segments the release sheet structure into three distinct layers: substrate sheet, mat making layer, and release layer. The mat making layer specifically provides the refined uneven surface for mat style, while the release layer provides release functionality. This segmentation allows each layer to optimize its function, improving durability and uniformity for repeated industrial use.
Solution Approach 2:
The invention uses composite material structure with mat making layer containing releasable resin and ultra micro particles (0.01 to 0.3 μm) dispersed uniformly. This composite structure provides both the mat style surface and enhanced mechanical strength, ensuring reliability for repeated industrial production while maintaining gloss control.
3Illumination intensity
If deep refined uneven is formed for large area, then low gloss mat style can be achieved, but embossing roll manufacturing becomes difficult
Solution Approach 1:
Instead of directly forming deep refined uneven on the embossing roll, the invention creates a mat making layer that copies the desired uneven surface profile. The mat making layer is applied as a coating that self-forms refined uneven during the coating process, eliminating the need to manufacture complex deep uneven embossing rolls while achieving the same low gloss mat style effect.
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 release sheet achieves a homogeneous, low-gloss surface on synthetic leathers and decorative laminated plates with improved durability and uniformity, maintaining the mat style and gloss consistency throughout multiple uses.
Implementation Method 1
a release layer which is formed with a coating film layer of releasable resin containing organic or inorganic ultra micro particles
Implementation Method 2
transferring an embossing pattern of the surface of the release sheet on the surface of the extruded product
Data Source
AI summary
The present invention relates to a release sheet which comprises a mat making layer forming a refined uneven of mat style on a surface, the mat making layer being provided on at least one surface of a substrate sheet, and a release layer formed with a coating film layer of releasable resin containing ultra micro particles having an average particle size of 0.01 to 0.3 μm, the release sheet being provided on a surface of the mat making layer. The release sheet of the present invention has superior heat resistance and mechanical strength for a long time, and can prevent change of mat style having low gloss of the surface or of gloss, even if repeat uses are conducted. By using the release sheet of the present invention, a formed article such as synthetic leathers and decorative laminated plates having uniformity quality, can be provided.