Stainable decorative sheet and method of staining decorative sheet
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Solution Overview
Problem
The use of a PVC base material in decorative sheets leads to increased costs and environmental issues due to chlorine gas generation, while switching to a paper base material results in adhesion problems between the paper and nonwoven fabric, loss of tactile sensation, reduced transparency, and difficulty in balancing water resistance and solvent resistance.
Innovation Solution
A stainable decorative sheet structure comprising a paper base material, an adhesive layer, a nonwoven fabric layer with partial resin filling, and a transparency improving layer, where the nonwoven fabric layer has areas filled with adhesive and transparency improving resins to enhance adhesion and transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PVC base material is used, then the decorative sheet has good adhesion and stainability, but the cost increases and environmental problems occur due to chlorine gas generation
Solution Approach 1:
The patent replaces expensive PVC base material with a cheaper paper base material that can be disposed of more environmentally friendly, eliminating chlorine gas generation during incineration while maintaining the required functional performance through the multi-layer structure
Solution Approach 2:
The patent creates a composite structure combining paper base material, adhesive layer, and nonwoven fabric layer to achieve the adhesion and stainability properties previously only available with PVC, thereby eliminating harmful factors while maintaining reliability
2Object-affected harmful factors
If a paper base material is used, then cost decreases and environmental problems are reduced, but adhesion between paper and nonwoven fabric deteriorates
Solution Approach 1:
The patent introduces an adhesive layer as an intermediary between the paper base material and nonwoven fabric layer, enabling effective adhesion between these two materials that naturally have poor bonding compatibility, thus resolving the adhesion problem while maintaining the environmental and cost advantages of paper
3Reliability
If the nonwoven fabric is densely filled with resin to improve adhesion, then adhesion improves, but the tactile sensation and transparency are lost
Solution Approach 1:
The patent applies resin filling locally rather than uniformly throughout the nonwoven fabric layer, creating regions with different properties: areas with resin filling provide adhesion, while areas with retained voids maintain tactile sensation and transparency, thus resolving the contradiction through spatial differentiation of functions
4Reliability
If the nonwoven fabric is densely filled with resin to improve adhesion, then adhesion improves, but transparency is reduced
Solution Approach 1:
The patent implements selective resin filling in specific regions of the nonwoven fabric layer rather than complete filling, preserving voids in areas critical for light transmission to maintain transparency while providing sufficient resin adhesion in bonding regions, thus resolving the contradiction between adhesion and transparency
5Illumination intensity
If the nonwoven fabric is left with many voids to maintain transparency, then transparency is maintained, but adhesion deteriorates
Solution Approach 1:
The adhesive layer serves as a mediator that compensates for the poor adhesion caused by voids in the nonwoven fabric, allowing the structure to maintain transparency through void retention while achieving sufficient adhesion through the intermediary adhesive layer
6Object-affected harmful factors
If a paper base material is used, then cost and environment are improved, but water resistance and solvent resistance cannot be balanced
Solution Approach 1:
The patent creates a composite structure where the paper base material provides cost and environmental advantages, while the adhesive layer and nonwoven fabric layer work together to provide water and solvent resistance, thus resolving the contradiction through material composition
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 provides a decorative sheet with good adhesion, tactile sensation, and stainability, while maintaining excellent transparency, addressing the challenges of using a paper base material.
Implementation Method 1
an adhesive layer disposed on at least one surface side of the paper base material
Implementation Method 2
a filling area A, in which a part of the voids of the fibers constituting the nonwoven fabric layer is filled with the resin forming the adhesive layer
Implementation Method 3
a filling area B, in which a part of the voids of the fibers constituting the nonwoven fabric layer is filled with the resin forming the transparent improving layer
Data Source
AI summary
A stainable decorative sheet having good adhesion between a paper base material and a nonwoven fabric with a surface excellent in tactile sensation and stainability, excellent transparency, and a method for coloring the stainable decorative sheet. The stainable decorative sheet includes a paper base material, an adhesive layer, a nonwoven fabric layer, and a transparency improving layer in a predetermined structure, wherein the nonwoven fabric layer partially has a filling part A and a filling part B in a part of voids among fibers of the nonwoven fabric layer.