CN112223863A - 真实材料的复制膜、其制造方法以及包括该复制膜的汽车零件 - Google Patents
真实材料的复制膜、其制造方法以及包括该复制膜的汽车零件 Download PDFInfo
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- CN112223863A CN112223863A CN201911130008.9A CN201911130008A CN112223863A CN 112223863 A CN112223863 A CN 112223863A CN 201911130008 A CN201911130008 A CN 201911130008A CN 112223863 A CN112223863 A CN 112223863A
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- surface pattern
- resin layer
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Abstract
本公开涉及真实材料的复制膜、其制造方法以及包括该复制膜的汽车零件。详细地,真实材料的复制膜可包括:基材层;以及设置在基材层上的树脂层,该树脂层具有面对基材层的第一表面和与第一表面相对的第二表面,该第二表面具有与真实材料的表面图案相同的表面图案。
Description
技术领域
本公开涉及真实材料的复制膜、其制造方法以及包括该复制膜的汽车零件。
背景技术
该部分中的陈述仅提供与本公开有关的背景信息,并且可以不构成现有技术。
使用昂贵的真实碳纤维编织材料的内部/外部材料已经主要应用于高性能车辆,以改善汽车内部/外部材料的质量。然而,真实的碳材料的成本很高,并且当使用这些碳材料制造零件时,过程很复杂。
因此,已经进行了多种复制真实碳的尝试,例如通过使用模具的注模法形成具有类似于真实碳的表面图案形状的膜,并涂覆要施加到零件上的表面。
这些技术在节省成本方面具有优势,但是外观的质量相当低。特定的限制包括以下事实:现有技术的复制技术不能实现真实碳的线宽,并且不能实现特定的三维感和光泽感。
在该背景技术部分中公开的以上信息仅用于增强对本公开的背景的理解,并且因此,其可包括不构成本领域普通技术人员已知的现有技术的信息。
发明内容
本公开提供了一种通过精确地复制真实材料来显示真实材料的特定特性的复制膜以及一种生产该复制膜的方法。
本公开还提供了甚至可以应用于具有复杂的非平坦形状的汽车零件的复制膜以及生产该复制膜的方法。
本公开通过施加与真实材料的颜色不同的颜色来提高复制膜的商业价值。
本公开不限于以上描述的内容。根据以下描述,本公开提供的内容将变得更加清楚,并且将通过权利要求中描述的方法及其组合来实现。
根据本公开的一种形式的真实材料的复制膜包括基材层和设置在基材层上的树脂层。树脂层具有面对基材层的第一表面和与第一表面相对的第二表面,第二表面具有与真实材料的表面图案相同的表面图案。
基材层可以包括选自聚碳酸酯(PC)、聚甲基丙烯酸甲酯(PMMA)、聚对苯二甲酸乙二醇酯(PET)及其组合的组中的至少一种。
基材层的厚度可以为0.125mm至0.5mm。
真实材料可包括选自真实碳、真实木材、天然软木、真实石材、薄金属、韩纸及其组合的组中的至少一种。
第二表面的表面图案可以具有凹槽和脊,其中凹槽可以形成为距第二表面100μm至250μm深。
树脂层可包括选自聚氨酯丙烯酸酯、丙烯酸丙烯酸酯、聚酯丙烯酸酯及其组合的组中的至少一种。
复制膜可以进一步包括沉积层,该沉积层设置在树脂层上并且包括下列项的至少任何一种:选自铝(Al)、铬(Cr)、镍铬(Ni-Cr)、锡(Sn)及其组合的组的金属;以及选自二氧化钛(TiO2)、二氧化硅(SiO2)及其组合的组的陶瓷。
沉积层可以沿着树脂层的第二表面的表面图案形成。
基材层的透射率可以为20%至80%。
复制膜可以进一步包括布置在沉积层上并且包括选自氨基甲酸酯基墨、聚氯乙烯基墨及其组合的组中的至少一种的印刷层。
根据本公开的一种形式的生产真实材料的复制膜的方法包括:制造压模,压模包括具有与真实材料的表面图案相对应的形状的表面图案;在基材层上形成树脂层,树脂层具有面对基材层的第一表面和与第一表面相对的第二表面;以及使用压模在第二表面上形成与真实材料的表面图案相同的表面图案。
可以通过在真实材料的表面上镀覆金属,并且然后去除真实材料,来形成具有与真实材料的表面图案相对应的形状的表面图案的压模。
通过将压模围绕辊缠绕并且将树脂层供应到辊,可以在树脂层的第二表面上形成与真实材料的表面图案相同的表面图案。
该方法可以进一步包括通过沉积以下项中的至少任何一种形成沿着树脂层的第二表面的表面图案设置在树脂层上的沉积层:选自铝(Al)、铬(Cr)、镍铬(Ni-Cr)、锡(Sn)及其组合的组的金属;以及选自二氧化钛(TiO2)、二氧化硅(SiO2)及其组合的组的陶瓷。
复制膜可以进一步包括通过在沉积层上印刷选自氨基甲酸酯基墨、聚氯乙烯基墨及其组合的组中的至少一种来形成印刷层。
根据本公开的一种形式的汽车零件可以包括基层和设置在该基层上的复制膜。
基层的至少一部分的曲率可以是0.5或更大。
根据本公开,可以通过精确地复制真实材料来获得具有真实材料的特定特性的复制膜。
根据本公开,可以实现具有优异的成型性并且甚至可以应用于具有复杂的非平坦形状的汽车零件的复制膜。
根据本公开,可以实现具有与真实材料相同水平的外观并且具有优异的价格竞争力的复制膜,因为其可以以真实材料的成本的1/10制造。
根据本公开,由于其实现了与真实材料不同的颜色,因此可以实现具有高商业价值的复制膜。
根据本文提供的描述,其他应用领域将变得显而易见。应当理解,描述和特定示例仅旨在用于说明的目的,并不旨在限制本公开的范围。
附图说明
为了使本公开易于理解,现在将通过示例的方式描述本公开的各种形式,并参考附图,其中:
图1A是示意性示出真实碳膜的结构的截面图;
图1B是示出使用光学显微镜观察图1A的真实碳膜的表面图案的结果的图;
图2A是示意性示出现有技术的真实碳的复制膜的截面图;
图2B是示出使用光学显微镜观察图2A的真实碳膜的表面图案的结果的图;
图3是示意性地示出根据本公开的一种形式的真实材料的复制膜的截面图;
图4是示出根据本公开的制造真实材料的复制膜的方法的一种形式的流程图;
图5A至图5C是示出根据本公开制造用于制造真实材料的复制膜的方法的一种形式的压模的步骤的参考图,其中,图5A是示出真实材料的截面图,图5B是示出使用真实材料制造压模的方法的参考图,并且图5C是示出当分离真实材料和压模时的状态的参考图;
图6是说明步骤的参考视图,其中,使用压模(用于生产根据本公开的一种形式的真实材料的复制膜)在树脂层的表面上施加与真实材料的表面图案相同的表面图案;
图7是示出使用光学显微镜观察根据本公开的真实材料的复制膜的表面图案的结果的图;以及
图8A至图8C是示意性地示出根据本公开的制造汽车零件的方法的参考视图,其中,图8A示出了将复制膜放入模具中的步骤,图8B示出了将基础树脂注入复制膜的后表面的步骤,以及图8C示出了将汽车零件从模具中取出的步骤。
图9是示出根据本公开的应用于汽车零件的真实材料的复制膜视图。
本文描述的附图仅出于说明目的,并且无意以任何方式限制本公开的范围。
具体实施方式
以下描述本质上仅是示例性的,并且无意于限制本公开、应用或用途。应当理解,在所有附图中,相应的附图标记表示相同或相应的部件和特征。
通过以下与附图有关的示例性形式,可以容易地理解本公开的上述目的、其他目的、特征和优点。本公开不限于本文描述的形式,并且可以以其他方式来实现。提供本文公开的变型,以便可以使公开的内容透彻和完整,并且可以将本公开的精神充分传达给本领域技术人员。
在下面的附图描述中,相似的附图标记被分配给相似的组件。在附图中,尺寸和结构大于实际尺寸,以使本公开清楚。说明书中使用的术语“第一”、“第二”等可以用来描述各种组件,但是这些组件不应解释为仅限于这些术语。这些术语仅用于区分一个组件和另一组件。例如,在不脱离本公开的范围的情况下,“第一”组件可以被命名为“第二”组件,反之亦然。除非上下文另外明确指出,否则单数形式旨在包括复数形式。
将进一步理解,在本说明书中使用的术语“包括”或“具有”指定存在所述特征、步骤、操作、组件、部件或其组合,但不排除一个或多个其他特征、数字、步骤、操作、组件、部件或其组合的存在或增加。当诸如层、膜、区域和板的元件“在”另一组件“上”时,它可以直接在另一元件上,也可以在其间具有其他居间元件。当诸如层、膜、区域和板的元件在另一个组件“之下”时,它可以直接位于另一个元件之下,也可以在它们之间具有其他居间元件。
除非另有说明,否则显示本文中使用的组分、反应条件以及聚合物组合物和混合物的量的所有数字、值和/或表达式均为近似值,反映了测量中的各种不确定性,当这些数字基本上从其他数字获得这些值时,将生成这些量,因此应将其解释为由术语“大约”修饰。此外,当在此公开数字范围时,该范围是连续的,并且包括该范围中的从最小值到包括最大值的最大值的所有值,除非另有说明。此外,当该范围表示整数时,除非另外说明,否则包括从最小值到包括最大值的最大值的所有整数值。
图1A是示意性示出真实碳膜的结构的截面图。参照图1A,真实碳膜包括一种支撑层50,设置在支撑层50上的机织碳纤维织物60以及设置在碳纤维织物60上的涂层70。因此,如图1B所示,碳纤维织物60的特定图案暴露于外部,从而产生一定的美学外观。
图2A是示意性示出现有技术的真实碳的复制膜的截面图。参照图2A,现有技术的复制膜包括一种支撑层50',印刷在支撑层上的黑色印刷层80,以及在印刷层上具有预定形状的表面图案的膜层90。取决于膜层90的表面图案,印刷层80的颜色暴露于外部。因此,如图2B所示,类似于真实碳的图案暴露于外部。真实碳膜的图案的线宽为约5μm,而现有技术的复制膜的线宽为约50μm。即,相关技术的复制膜的线宽太大,从而与真实碳膜相比大大降低了外观质量。这是因为通过在复制膜中的膜层90实现图案,在复制膜中通过模具制造膜层90,这在减小压纹间隙方面产生了物理限制。
在下文中,详细描述根据本公开的真实材料的复制膜。
图3是示意性地示出根据本公开的真实材料的复制膜1的截面图。参照图3,复制膜1可以包括:基材层10;树脂层20,其设置在基材层10上,并且具有面对基材层10的第一表面21和与第一表面21相对的第二表面22;在树脂层上的沉积层30;以及设置在沉积层上的印刷层40。
可以使用真实材料而没有特别限制,只要其具有特定的表面纹理即可。详细地,真实材料可以选自真实碳、真实木材、天然软木、真实石材、薄金属、韩纸及其组合的组。优选地,真实材料可以是真实碳。根据本公开,可以实现具有与真实材料的表面图案相同并且暴露于外部的表面图案的复制膜。
基材层10可以包括透明材料,包括但不限于选自聚碳酸酯(PC)、聚甲基丙烯酸甲酯(PMMA)、聚对苯二甲酸乙二醇酯(PET)及其组合的组中的至少一种材料。
基材层10的厚度可以为0.125mm至0.5mm。当厚度小于0.125mm时,不能实现复制膜1的深度感,而当厚度超过0.5mm时,可成形性可能劣化。
树脂层20可以具有第二表面22,该第二表面具有与真实材料的表面图案相同的表面图案。下面描述形成第二表面22的方法。尽管图3所示的第二表面22的表面图案具有不平坦的结构,但是该表面图案不限于此,并且应被解释为与根据目的选择的真实材料的表面图案相同。
第二表面22的表面图案具有凹槽22a和脊22b。凹槽22a可以形成为距第二表面22深100μm至250μm。用于测量凹槽22a的深度的参考可以是第二表面22的脊22b的平坦表面。当厚度小于100μm时,可能无法获得三维感。另一方面,当厚度超过250μm时,可成形性可能劣化并且来自印刷层40的不明显性可能劣化。
在第二表面22的表面图案中,凹槽22a和脊22b可以显示为彼此交替。间隙可以是规则的或不规则的。如图3所示,凹槽22a可以垂直地或接近垂直地凹陷,或者可以与脊22b以预定角度凹陷。
树脂层20可以通过UV固化形成,这将在下面描述。因此,树脂层20可以包括UV可固化树脂。详细地,树脂层20可以包括选自聚氨酯丙烯酸酯、丙烯酸丙烯酸酯、聚酯丙烯酸酯及其组合的组的UV固化树脂。
可以根据目的适当地调节和混合树脂层20中包含的组分的含量,但是,当将复制膜应用于汽车零件时,可以包含40wt%至70wt%的聚氨酯丙烯酸酯以确保伸长率。
考虑到树脂层20的物理化学性质、可成形性、图案保持等,可以调节树脂层20中包括的每种UV固化树脂的分子量或添加功能添加剂。
沉积层30设置在树脂层20上,并且可以沿树脂层20的第二表面22的表面图案形成而不会损坏表面图案。不破坏第二表面22的表面图案的意思是沉积层30沿着表面图案以非常薄的层沉积,并且沉积层30的表面也形成为基本上与树脂层20的表面图案相同的形状。
根据包含在沉积层30中的沉积源来实现复制膜1的光泽。详细地,沉积层30可以包括下列项的至少任何一种:选自铝(Al)、铬(Cr)、镍铬(Ni-Cr)、锡(Sn)及其组合的组的金属;以及选自二氧化钛(TiO2)、二氧化硅(SiO2)及其组合的组的陶瓷。
另外,复制膜1的颜色取决于形成沉积层30时使用的沉积源。沉积源显示的颜色与印刷层40的颜色相互作用,从而实现了新的颜色和饱和度,而这种饱和度不是由真实的碳实现的。
沉积层30的透射率可以为20%至80%。当透射率小于20%时,沉积层30形成得太厚,在这种情况下,印刷层40的颜色可能不会露出到外部。另一方面,当透射率超过80%时,沉积层30太透明,在这种情况下可能无法实现光泽。
印刷层40是设置在沉积层30上的部件,其实现整个复制膜1的总体颜色并保护树脂层20和沉积层30。
印刷层40不限于此,并且可通过以预定程度在沉积层上印刷选自氨基甲酸酯基墨、聚氯乙烯基墨及其组合的组的墨来形成。
墨可以是单流体类型或双流体类型墨。当为双流体类型墨时,可以使用例如HDI、MDI、TDI和IPDI的异氰酸酯基固化剂作为固化剂,且其含量可以为墨组合物总重量的10wt%至20wt%。当固化剂的含量小于10wt%时,印刷层20的性能劣化并因此可能发生墨洗出,而当含量超过20wt%时,印刷性可能劣化。
当形成印刷层40时,程度没有特别限制,但是在印刷中可以为4度或以上。当印刷层40被印刷小于4度时,当将复制膜1施加到汽车零件上时,可能会发生墨洗出。
以下,详细描述根据本公开的用于制造真实材料的复制膜的方法。
图4是示出根据本公开的制造真实材料的复制膜的方法的一种形式的流程图。参照图4,该方法可以包括:制造压模,该压模包括具有与真实材料的表面图案相对应的形状的表面图案(S1);在基材层上形成树脂层(S2);使用压模在树脂层的第二表面上形成与真实材料的表面图案相同的表面图案(S3);在树脂层上形成沉积层(S4);以及在沉积层上形成印刷层(S5)。
图5A至图5C是示出压模的制造(S1)的参考视图。简而言之,图5A是示出真实材料A的截面图,图5B是示出使用真实材料A制造压模B的方法的参考图,以及图5C是示出当真实材料A和压模B分离时的状态的参考图。
首先,如图5A所示,制备具有特定表面图案的真实材料A。此后,可以使用真实材料A通过电成型来形成压模B,如图5B所示。详细地,具有预定厚度的压模B可以通过电解金属C以使金属离子(M+)附着(电镀)到真实材料A的表面图案上而获得。压模B的厚度不受特别限制,并且可以根据目的适当调整。当真实材料A和压模B分离时,如图5C所示,可以获得具有与真实材料A的表面图案相对应的形状的表面图案的压模B。
树脂层可以通过以预定的厚度在上述基材层上施加UV固化树脂来形成(S2)。该状态下的树脂层不具有表面图案。
图6是示出使用压模B在树脂层上形成与真实材料的表面图案相同的表面图案(S3)的参考图。
参照图6,将如上所述获得的压模B缠绕在辊D上,并且将树脂层20供应到旋转的辊D,使得缠绕在辊D上的压模B按压树脂层20。因此,压模B的表面图案被转印到树脂层20的表面。因此,在树脂层20的表面上形成了与真实材料的表面图案相同的表面图案。
同时或在不同时间,紫外线照射到树脂层以固化树脂层,使得在树脂层上形成的表面层不被破坏。紫外线的照射方式、位置和强度没有特别限制并且可以适当地调节。
如上所述,在树脂层上形成了表面图案之后,可以在树脂层上形成沉积层(S4)。形成沉积层的方法没有特别限制,但是可以通过在真空室中沉积上述沉积源或通过使用卷对卷沉积、大气压沉积等来形成沉积层。
此后,可以在沉积层上形成印刷层(S5)。形成印刷层的方法没有特别限制,可以使用丝网印刷。
图7示出了使用光学显微镜观察通过上述方法制造的复制膜的表面的结果。将真实碳(图1B)的表面图案与图7进行比较,可以看出,根据本公开的复制膜显示的图案具有与外部所示的真实碳基本相同的形状。此外,将现有技术的复制膜(图2B)与图7进行比较,可以看出,与现有技术的复制膜相比,本公开的复制膜显示出与真实碳的光泽和深度感觉更相似的光泽和深度感。
根据本公开的汽车零件可以包括基层和设置在该基层上的复制膜。
汽车零件的制造方法不受特别限制,但是可以使用嵌件注射。
图8A至图8C是示意性地示出根据本公开的制造汽车零件的方法的参考图。详细地,如图8A所示,将上述复制膜1放入模具E中,如图8B所示,将基础树脂注入复制膜1的后表面,从而形成基层2。之后,如图8C所示,将复制膜1和基层2从模具E中取出,从而可以获得汽车零件。
在将复制膜1放入模具E中之前,可以预热复制膜1,执行热压成型或真空成型以形成零件的形状,并且然后进行修整。
对基础树脂没有特别限制,但是可以包括选自丙烯腈丁二烯苯乙烯(ABS)、聚碳酸酯及其组合的组中的至少一种。
此外,可以看出,基层在至少任何一部分处,具体地在端部处具有0.5或更大的曲率。根据本公开的复制膜甚至可以应用于具有复杂的非平坦形状的汽车零件。
图9是示出根据本公开的应用于汽车零件的材料的复制膜视图。如图9所示,汽车零件可以是门装饰、中心装饰、车顶、引擎盖等。
尽管已经结合当前被认为是实用的示例性形式描述了本公开,但是应当理解,本公开不限于所公开的形式,相反,其意图是覆盖本公开的精神和应对之内的包括的各种修改和等效布置。
Claims (20)
1.一种真实材料的复制膜,包括:
基材层;以及
设置在所述基材层上的树脂层,
其中,所述树脂层具有面对所述基材层的第一表面和与所述第一表面相对的第二表面,
其中,所述第二表面具有与所述真实材料的表面图案相同的表面图案。
2.根据权利要求1所述的复制膜,其中,所述基材层包括选自聚碳酸酯、聚甲基丙烯酸甲酯、聚对苯二甲酸乙二醇酯及其组合的组中的至少一种。
3.根据权利要求1所述的复制膜,其中,所述基材层具有0.125mm至0.5mm的厚度。
4.根据权利要求1所述的复制膜,其中,所述真实材料包括选自真实碳、真实木材、天然软木、真实石材、薄金属、韩纸及其组合的组中的至少一种。
5.根据权利要求1所述的复制膜,其中,所述第二表面的所述表面图案具有凹槽和脊,并且
所述凹槽形成为距所述第二表面100μm至250μm深。
6.根据权利要求1所述的复制膜,其中,所述树脂层包括选自聚氨酯丙烯酸酯、丙烯酸丙烯酸酯、聚酯丙烯酸酯及其组合的组中的至少一种。
7.根据权利要求1所述的复制膜,还包括沉积层,所述沉积层设置在所述树脂层上并且包括下列项的至少任何一种:选自铝、铬、镍铬、锡及其组合的组的金属;以及选自二氧化钛、二氧化硅及其组合的组的陶瓷。
8.根据权利要求7所述的复制膜,其中,所述沉积层沿着所述树脂层的所述第二表面的所述表面图案形成。
9.根据权利要求7所述的复制膜,其中,所述基材层的透射率为20%至80%。
10.根据权利要求7所述的复制膜,还包括设置在所述沉积层上的印刷层,所述印刷层包括选自氨基甲酸酯基墨、聚氯乙烯基墨及其组合的组中的至少一种。
11.一种生产真实材料的复制膜的方法,包括:
制造压模,所述压模包括具有与所述真实材料的表面图案相对应的形状的表面图案;
在所述基材层上形成树脂层,所述树脂层具有面对所述基材层的第一表面和与所述第一表面相对的第二表面;以及
使用所述压模在所述第二表面上形成与所述真实材料的所述表面图案相同的表面图案。
12.根据权利要求11所述的方法,其中,通过在所述真实材料的表面上镀覆金属,并且然后去除所述真实材料,来形成具有表面图案的压模,所述表面图案具有与所述真实材料的所述表面图案相对应的形状。
13.根据权利要求11所述的方法,其中,所述真实材料包括选自真实碳、真实木材、天然软木、真实石材、薄金属、韩纸及其组合的组中的至少一种。
14.根据权利要求11所述的方法,其中,所述基材层包括选自聚碳酸酯、聚甲基丙烯酸甲酯、聚对苯二甲酸乙二醇酯及其组合的组中的至少一种。
15.根据权利要求11所述的方法,其中,所述树脂层包括选自聚氨酯丙烯酸酯、丙烯酸丙烯酸酯、聚酯丙烯酸酯及其组合的组中的至少一种。
16.根据权利要求11所述的方法,其中,通过将所述压模围绕辊缠绕并将所述树脂层供应到所述辊,在所述树脂层的所述第二表面上形成与所述真实材料的所述表面图案相同的表面图案。
17.根据权利要求11所述的方法,还包括通过沉积以下项中的至少任何一种形成沿着所述树脂层的所述第二表面的所述表面图案设置的所述沉积层:选自铝、铬、镍铬、锡及其组合的组的金属;以及选自二氧化钛、二氧化硅及其组合的组的陶瓷。
18.根据权利要求17所述的方法,其中,所述基材层的透射率为20%至80%。
19.根据权利要求11所述的方法,还包括通过印刷选自氨基甲酸酯基墨、聚氯乙烯基墨及其组合的组中的至少一种来在沉积层上形成印刷层。
20.一种汽车零件,包括:
具有预定形状的基层;以及
设置在所述基层上的权利要求1所述的复制膜,
其中,所述基层的至少一部分的曲率是0.5或以上。
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