Recycled PET Decorative Sheet Brightness and Color Control
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Solution Overview
Problem
Existing decorative sheets using recycled resin face challenges in achieving high brightness, small color variation, and sufficient hiding power, especially for white or light-colored designs, due to limitations in using recycled PET-based resins and the need for high virgin resin content to manage color variations.
Innovation Solution
A decorative sheet comprising 90% or more recycled PET-based resin derived from PET bottles, with 10 to 18 parts by mass of titanium oxide white pigment per 100 parts of resin, optimized in thickness and pigment content to achieve high brightness and small color variation, using a method that involves mixing recycled PET-based resin with a masterbatch containing titanium oxide and molding to produce a sheet with specific CIE 1976 L*a*b* color coordinates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high proportion of recycled resin is used in the decorative sheet, then environmental friendliness and cost are improved, but color variation increases and brightness decreases
Solution Approach 1:
The patent changes the parameter of titanium oxide content to a specific range (10-18 parts by mass per 100 parts of resin component) to achieve high brightness (L*≥92) while maintaining high recycled resin content (≥90%). This parameter optimization resolves the contradiction by finding the precise dosage that maximizes brightness without compromising the high recycled resin proportion.
Solution Approach 2:
The patent creates a composite material system combining recycled PET-based resin with titanium oxide white pigment in specific proportions. This composite approach allows the decorative sheet to achieve both high environmental friendliness (90%+ recycled content) and high brightness (L*≥92) by leveraging the complementary properties of the recycled resin and titanium oxide pigment.
2Reliability
If a high proportion of recycled resin is used in the decorative sheet, then environmental friendliness is improved, but color variation between raw material lots and sheet locations increases
Solution Approach 1:
The patent optimizes the titanium oxide content parameter to 10-18 parts by mass per 100 parts of resin component, which suppresses color variation (ΔE≤1.5) while maintaining high recycled resin content. This parameter control ensures consistent coloration across different raw material lots and sheet locations.
Solution Approach 2:
The patent uses titanium oxide white pigment to actively manage and standardize the color appearance of the decorative sheet. By controlling the pigment concentration, the patent achieves uniform color (L*≥92, a*=-1.5 to +1.0, b*=0 to +4.5) across variations in recycled resin batches, effectively suppressing color variation.
3Illumination intensity
If titanium oxide is added to recycled resin to improve brightness, then white pigment content increases, but hiding power remains insufficient
Solution Approach 1:
The patent optimizes the product of sheet thickness and titanium oxide content to achieve a value of 2.300 or more. This parameter combination ensures both high brightness (L*≥92) and sufficient hiding power, resolving the contradiction by finding the optimal balance between pigment concentration and sheet thickness.
4Manufacturing precision
If virgin resin content is increased to suppress color variation, then color uniformity is improved, but the proportion of recycled resin decreases
Solution Approach 1:
The patent sets the titanium oxide content to 10-18 parts by mass per 100 parts of resin component, which enables color uniformity (ΔE≤1.5) to be achieved with 90% or more recycled resin. This parameter optimization eliminates the need to increase virgin resin content for color control.
Solution Approach 2:
The patent uses titanium oxide white pigment as a color standardizing agent that allows high recycled resin content (≥90%) to be maintained while achieving uniform color appearance (L*≥92, a*=-1.5 to +1.0, b*=0 to +4.5). The pigment compensates for color variations inherent in recycled resin without requiring virgin resin blending.
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 an environmentally friendly decorative sheet with high brightness, small color variation between raw material lots and sheet locations, and excellent moldability, while maintaining a high proportion of recycled resin, thus addressing the limitations of previous technologies.
Implementation Method 1
the content of the titanium oxide white pigment is 10 to 18 parts by mass with respect to 100 parts by mass of the resin component, and a product of the thickness (mm) of the decorative sheet and the content (parts by mass) of the white pigment is 2.300 or more
Implementation Method 2
titanium oxide white pigment
Data Source
AI summary
The present invention provides a decorative sheet which is an environmentally friendly sheet having a high proportion of recycled resin in all resin components and which is a white or light-colored decorative sheet having high brightness, small color variation between raw material lots or sheet locations, high hiding power, and excellent moldability during production, and a method for producing the same. A decorative sheet is provided, including: a resin component; and a white pigment, in which the resin component includes 90% by mass or more of a recycled PET-based resin derived from a PET bottle, the content of the white pigment is 10 to 18 parts by mass with respect to 100 parts by mass of the resin component, and a product of the thickness (mm) of the decorative sheet and the content (parts by mass) of the white pigment is 2.300 or more.