Shaped Sheet with Ink Layer for Decorative Plate Texture

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Solution Overview

Problem

Existing methods for creating decorative plates with fine irregular patterns are limited by the need for expensive molds, surface treatments, and poor releasability, resulting in high production costs and inability to achieve high-grade, realistic textures.

Innovation Solution

A shaping sheet comprising a substrate with an ink layer and a surface shaped layer formed by crosslinking and curing an ionizing radiation-curable resin composition, featuring a convex shape above the ink layer, which allows for a fine irregular pattern with high-grade feel and excellent releasability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If an embossed metal mold with surface treatments (blasting and etching) is used to form irregular shapes, then the decorative plates can achieve an irregular surface pattern, but the fineness of the irregular shape is limited and production costs increase due to expensive molds and surface treatments

Engineering Contradiction:

Improvefineness of irregular shapeVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent uses an irregular resin sheet as a copying tool to transfer its surface irregularity pattern onto the decorative plate during molding. This eliminates the need for expensive embossed metal molds with surface treatments, achieving fine irregular shapes through the resin sheet's pre-formed pattern while reducing manufacturing costs.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent employs a disposable irregular resin sheet instead of expensive, durable metal molds. The resin sheet is consumed in the molding process, eliminating the need for costly mold fabrication, surface treatments, and maintenance, thereby reducing production costs while achieving fine irregular patterns.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of manufacture

If an irregular resin sheet is used to form the irregular shape, then production costs are reduced, but the sheet is hardly peeled or separated from the cured thermosetting resin decorative plates, requiring interposition of aluminum foil or polypropylene film which makes it difficult to form fine irregular patterns with good sharpness

Engineering Contradiction:

Improveproduction costVSAvoidsharpness of irregular pattern

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent modifies the resin composition parameters by incorporating specific releasing agents (silicone oil, wax, or soap) into the irregular resin sheet. This changes the surface properties of the resin sheet to reduce adhesion to the cured decorative plate, enabling easy peeling while maintaining fine irregular pattern sharpness without requiring interposed films.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If the ink layer is made thin to achieve fine concave portions, then the irregular pattern sharpness is improved, but the convex portions become too small and lack realism in patterns such as woodgrain

Engineering Contradiction:

Improveirregular pattern sharpnessVSAvoidrealism of pattern

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies local quality by creating varying ink layer thicknesses in different regions of the irregular pattern. The ink layer is made thin in concave portions to achieve sharpness while maintaining adequate thickness in convex portions to ensure realism and proper coloring, with the resin sheet's releasing agent properties ensuring uniform peeling across all regions.

Inventive Principle:

Principle #3Local quality

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 enables the creation of decorative plates with fine, realistic irregular patterns, such as woodgrain patterns, that mimic actual wood textures, while reducing production costs and improving the durability and peelability of the shaping sheet.

Implementation Method 1

the surface shaped layer is formed by crosslinking and curing an ionizing radiation-curable resin composition

Methodology Applied

Scientific EffectCrosslinking and curing: Photopolymerisation

Implementation Method 2

ionizing radiation-curable resin composition

Methodology Applied

Scientific EffectIonizing radiation: Radiation

Data Source

PatentUS9120248B2Shaped sheet

Publication Date: 2015.09.01 DAI NIPPON PRINTING CO LTD

AI summary

There are provided a shaping sheet provided on a surface thereof with a fine irregular shape which is capable of forming a fine pattern with a high-grade feel on a material to be shaped, and is excellent in releasability from the material, as well as a decorative plate shaped by the shaping sheet. The shaping sheet of the present invention includes a substrate, at least an ink layer partially formed on the substrate and a surface shaped layer which is present on and contacted with the ink layer so as to cover a whole surface including both a region where the ink layer is formed and a region where no ink layer is formed, wherein the surface shaped layer is formed by crosslinking and curing an ionizing radiation-curable resin composition, and has a convex shape on a surface thereof which is located in a portion just above the ink layer and in the vicinity of the portion. The shaping sheet is provided on a surface thereof with a fine irregular shape, which is capable of forming a fine pattern with a high-grade feel on a material to be shaped, and excellent in releasability from the material.