Transfer Sheet with Dual Release Substrates for Uniform Functional Layer Application
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Solution Overview
Problem
Existing methods for transferring functional layers onto adherends using transfer sheets often result in insufficient functional performance compared to insert molding or direct coating.
Innovation Solution
A method for manufacturing a transfer sheet involving the application of a coating liquid to form a transfer layer on a release substrate, followed by lamination of another release substrate to create a transfer sheet with specific peel strengths, allowing for efficient transfer and uniform distribution of functional layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insert molding is used to impart functional properties to the adherend surface, then the functional layer can be effectively applied, but the overall thickness of the molded body increases and the texture of the adherend is impaired
Solution Approach 1:
The patent divides the functional film into two separate layers: a support layer that provides mechanical strength and a functional layer that provides the desired surface properties. By separating these functions into distinct layers with different thicknesses, the support layer can be thin enough not to significantly increase overall thickness, while the functional layer maintains its effectiveness.
Solution Approach 2:
The patent extracts the functional layer from the support layer to create a separate, independent functional component. This allows the functional properties to be applied without the bulk of the support structure, thereby reducing the overall thickness increase while maintaining functional effectiveness.
2Length of stationary object
If direct coating is used to apply functional coating material to the adherend surface, then the thickness problem is avoided, but ununiform coating results in ununiform functional properties
Solution Approach 1:
The patent introduces a support layer as an intermediary substrate that provides a flat, stable surface for applying the functional layer. This intermediary structure ensures uniform coating application by providing a consistent base, thereby achieving uniform functional properties without directly coating the adherend surface.
Solution Approach 2:
The patent applies the functional layer to the support layer before the final molding process. This preliminary application ensures uniform coating distribution on a stable substrate, which then transfers uniformly to the adherend, avoiding the ununiformity problems of direct coating.
3Ease of manufacture
If conventional transfer sheets are used to transfer functional layers onto adherends, then the functional layer can be transferred, but the transferred layer often cannot sufficiently exert its function
Solution Approach 1:
The patent optimizes key parameters of the transfer sheet including the thickness ratio between support layer and functional layer, the peel strength between layers, and the surface properties of the support layer. These parameter changes ensure that the functional layer transfers completely and maintains its functional effectiveness on the adherend surface.
Solution Approach 2:
The patent creates a composite transfer sheet structure combining a support layer and a functional layer with specifically designed material properties. The support layer uses materials with appropriate mechanical strength and surface characteristics, while the functional layer uses materials optimized for the desired surface function, creating a composite structure that ensures both transferability and functional performance.
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 method enables the manufacture of transfer sheets that can impart sufficient functions to adherends, resulting in molded bodies with effective anti-glare and antifouling properties.
Implementation Method 1
a peel strength 2 between the release substrate 2 and the transfer layer larger than a peel strength 1 between the release substrate 1 and the transfer layer
Data Source
AI summary
Provided is a method for manufacturing a transfer sheet which can impart a sufficient function to an adherend. The method for manufacturing a transfer sheet includes performing the following steps (1) and (2) in order: (1) applying a coating liquid for forming a transfer layer onto a release substrate 1 to form a transfer layer comprising at least one functional layer; and (2) laminating a release substrate 2 onto the transfer layer to obtain a transfer sheet A comprising the release substrate 1, the transfer layer and the release substrate 2 in the presented order and having a peel strength 2 between the release substrate 2 and the transfer layer larger than a peel strength 1 between the release substrate 1 and the transfer layer.