Matte Release Sheet via Excimer Laser Crosslinking
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Solution Overview
Problem
High pressure decorative laminates are susceptible to fingerprint build-up on their surfaces, which existing chemically modified surfaces have not effectively addressed.
Innovation Solution
A textured release sheet with a matte surface is created using a UV curable acrylate mixture applied to a substrate, where the mixture is only crosslinked on the surface through excimer laser irradiation, producing a micro-convolution effect, and then fully crosslinked and hardened using electron beam irradiation, reducing gloss and enhancing scratch resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a smooth glossy surface is used for decorative laminates, then the surface has good appearance and ease of cleaning, but it is susceptible to fingerprint build-up
Solution Approach 1:
The patent applies a textured overlay only to the surface layer of the decorative laminate, while the core layers remain smooth. This localized texturing creates a matte finish that resists fingerprint accumulation without affecting the overall manufacturing process or structural integrity of the laminate.
Solution Approach 2:
The patent creates a composite structure by combining a smooth core laminate with a textured overlay layer. The overlay contains resinous material with embedded inert particles that create the matte texture, while the core provides structural support and traditional laminate properties.
2Object-affected harmful factors
If a textured matte surface is applied to reduce gloss and fingerprint visibility, then fingerprint resistance is improved, but scratch resistance may be reduced
Solution Approach 1:
The patent carefully controls the parameters of the textured overlay, including particle size (0.1-2.0 mm), particle concentration (5-50% by weight), and overlay thickness (0.01-0.1 mm). These parameter optimizations ensure the matte texture provides fingerprint resistance while maintaining adequate scratch resistance through proper material selection and formulation.
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 results in a decorative laminate with a matte finish that is resistant to fingerprint accumulation, maintaining a clean and clear appearance despite regular use, while also providing improved scratch resistance.
Implementation Method 1
the UV curable acrylate mixture is irradiated with UV-radiation via an excimer laser emitter to produce a UV-irradiated layer wherein the UV curable acrylate mixture is only crosslinked on the surface thereof
Implementation Method 2
The UV-irradiated layer is then subjected to irradiation to crosslink and harden the entire layer
Data Source
AI summary
A textured release sheet includes a substrate, which has been electron beam treated, including a top side and a bottom side. A matte surface is formed on the bottom side thereof, wherein the matte surface of the surfacing material is a coating of an radiation curable material applied to the bottom side of the substrate. The coating is an UV curable acrylate mixture applied to the substrate, wherein the UV curable acrylate mixture is irradiated with UV-radiation via an excimer laser emitter to produce a UV-irradiated layer wherein the UV curable acrylate mixture is only crosslinked on the surface thereof, which produces a matting surface through the effects of a micro-convolution.