Decorative Sheet Ridged Coating for Uniform Tactile Feel
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Solution Overview
Problem
Existing decorative sheets lack a rough and highly uniform tactile feel, and there is a need for improved durability and processability without compromising design qualities such as gloss and scratch resistance.
Innovation Solution
A decorative sheet with a surface protection layer featuring an uneven structure with ridged portions, specific mass concentrations of carbon, oxygen, and silicon, and a thickness that provides a rough and uniform tactile feel, achieved through a coating process using ionizing radiation-curable resin and silica particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a matting agent is added to the surface protection layer to achieve low gloss, then the gloss is reduced, but the tactile uniformity and rough feel are insufficient
Solution Approach 1:
The patent changes the surface morphology parameters by forming ridged portions with specific dimensions (peak height Rpk of 3.5 μm or more and mean width RSm of 150 μm or more), transforming the surface from a uniformly matted texture to a structured uneven texture that provides both low gloss and uniform tactile feel
Solution Approach 2:
The surface protection layer is formulated as a composite material containing ionizing radiation-curable resin and silica particles with specific mass concentration ratios (Si/(C+O+Si) of 0.3 or more), which enables the formation of ridged structures that simultaneously achieve low gloss and improved tactile uniformity
2Strength
If the surface protection layer thickness is increased to improve durability, then scratch resistance improves, but the tactile uniformity and rough feel deteriorate
Solution Approach 1:
The patent applies local quality by creating ridged portions with specific dimensional characteristics (peak height and mean width within defined ranges) distributed across the surface, rather than uniformly increasing the entire layer thickness. This localized structuring provides durability through the ridged portions while maintaining tactile uniformity through controlled distribution
Solution Approach 2:
The patent optimizes the thickness parameter of the surface protection layer to be 8 μm or more, combined with specific surface morphology parameters (Rpk and RSm), to achieve the balance between durability and tactile uniformity without simply increasing overall thickness
3Manufacturing precision
If the mass concentration of silica particles is increased to improve rough feel, then the roughness increases, but the uniformity of the rough feel and contamination resistance worsen
Solution Approach 1:
The patent optimizes the mass concentration ratio of silica particles by controlling the Si/(C+O+Si) ratio to be 0.3 or more, which ensures sufficient silica content for rough feel while maintaining uniform distribution and contamination resistance through the ridged structure formation
Solution Approach 2:
The surface protection layer is designed as a composite material with optimized composition (ionizing radiation-curable resin and silica particles in specific ratios), where the ridged structure formation process ensures uniform distribution of silica particles, achieving rough feel uniformity without compromising contamination resistance
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 offers a highly uniform rough feel, enhanced durability, and improved processability while maintaining low gloss and resistance to scratches and contamination.
Implementation Method 1
achieved through a coating process using ionizing radiation-curable resin and silica particles
Data Source
AI summary
A decorative sheet includes a primary film layer and a surface protection layer provided on one surface of the primary film layer. The surface protection layer has a surface provided with an uneven structure having a plurality of ridged portions protruding in a ridged pattern. The uneven structure of the surface protection layer 5 has a reduced peak height Rpk of 3.5 μm or more. The surface protection layer has a mass concentration of carbon C (% by mass), a mass concentration of oxygen O (% by mass), and a mass concentration of silicon Si (% by mass) satisfying the following relational expression: 0.5≤{Si/(C+O+Si)}×100.