CN115366449A

CN115366449A - Light-transmitting decorative molded article and method for producing same

Info

Publication number: CN115366449A
Application number: CN202111142433.7A
Authority: CN
Inventors: 应国良
Original assignee: Jin Ya Dian Technology Co ltd
Current assignee: Jin Ya Dian Technology Co ltd
Priority date: 2021-05-21
Filing date: 2021-09-28
Publication date: 2022-11-22

Abstract

The invention provides a method for manufacturing a light-transmitting decorative molding, which comprises the following steps: and forming the all-in-one coating on the substrate and carrying out a curing step, thereby forming a composite layer structure with a protection effect, a color effect and a bonding effect. The composite layer structure can form a formed film with better physical properties (such as higher hardness, better protection effect and the like) after a plastic suction forming process. Therefore, the formed film of the embodiment can be applied to the laser engraving process to form various light-transmitting decorative formed products.

Description

Light-transmitting decorative molded article and method for producing same

Technical Field

The invention relates to a light-transmitting decorative molding and a manufacturing method thereof.

Background

Generally, decorations such as patterns or letters formed on the surface of the housing of the object are mainly formed through a spraying (spraying) or printing (printing) process so as to present a specific visual effect, thereby adding variability in the appearance of the object. The conventional method of forming the case is to apply a hardened layer on the surface of the case by spraying after the case of the related product is completed, which is complicated in process, poor in yield, and causes pollution of organic solvent gas, thereby causing many pollution problems. On the other hand, the spray coating process is not suitable for mass production because it has disadvantages of time consumption, complicated process, low thickness uniformity, etc.

In order to solve the above problems, various specific Decoration processes using a Decoration film have been proposed, such as In-Mold Decoration (IMD) or Out-of-film Decoration (OMD) have become another option for forming an image on the surface of an object.

The materials of the polymer substrate commonly used in the in-mold decoration technology at present include Polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene Terephthalate (PET), and Acrylonitrile-Butadiene-Styrene (ABS). However, since the hardness of the substrate composed of PC and ABS is low and the surface of the substrate is easily damaged, the hardness and scratch resistance of the surface of the substrate are often increased by coating a protective layer. On the other hand, the base material made of PMMA has high hardness, but is easily cracked at the time of molding, and thus is not easily subjected to the hot pressing process.

In order to solve the above problems, various specific Decoration processes using a Decoration film, such as In-Mold Decoration (IMD) or Out-Mold Decoration (OMD), have been proposed as another option for forming an image on the surface of an object.

In particular, in-mold decoration (IMD) techniques may include: in-Mold Labeling (IML), in-Mold Film (IMF or INS), and In-Mold transfer (IMR) as shown In Table 1 below. The in-mold labeling (IML) process features that the surface is one layer of hardened transparent film, the middle layer is printed pattern layer and the back layer is plastic layer. The ink is sandwiched between the hardened transparent film and the plastic layer, so that the product has no surface scratch, high friction resistance, long color keeping and less fading. The in-mold transfer printing (IMR) process is to print a pattern on a thin film, attach a membrane to a plastic mold cavity through a film feeding machine and perform injection molding, separate an ink layer with the pattern from the thin film after the injection molding, and leave the ink layer on a plastic part to obtain the plastic part with the decorative pattern on the surface. Therefore, the surface of the final product of the in-mold transfer printing is not provided with a transparent protective film, and the membrane is only a carrier in the production process. That is, the biggest difference between in-mold labeling (IML) and in-mold transfer (IMR) is whether a transparent protective film is present on the surface of the product. The in-mold film (IMF) is similar to the in-mold label (IML).

TABLE 1

The outside film decoration technique (OMD), also known as high pressure transfer. After the patterns are printed on the transparent film, the patterns are directly transferred to the plastic shell by adopting high/medium/low pressure and vacuum transfer printing, and the plastic shell is mainly characterized in that the plastic shell is a product with touch and is applied to 3C, household appliances and automobiles.

However, no matter the IMD or the OMD film is used, if a transparent decoration product is to be manufactured, the transparent decoration product is manufactured in a printing and stacking manner, and the client side has the disadvantages of difficult alignment, excessive material loss, cost increase and the like after the processes of plastic suction, cutting and injection molding, and the subsequent laser engraving process is difficult and cannot manufacture the transparent pattern and other products.

Table 2 below illustrates the characteristics and disadvantages of various prior art decorating techniques.

TABLE 2

Disclosure of Invention

The invention provides a method for manufacturing a decorated molded article, comprising: providing a coating, wherein the coating comprises at least: uniformly mixing the protective material, the ink material and the jointing material together; forming the coating on a substrate by using a coating method or a printing method; performing a first curing step to form a composite layer structure, wherein the composite layer structure comprises at least an optically hardened layer disposed on the substrate; carrying out a plastic suction molding process to form a molded film; performing a second curing step to increase the hardness of the formed film; and carrying out a laser engraving process.

In an embodiment of the invention, the protective material includes polymethyl methacrylate, aliphatic urethane acrylate, epoxy acrylate, polyester polyol or a combination thereof, the ink material includes polyurethane, and the bonding material includes thermoplastic polyurethane, aromatic urethane acrylate or a combination thereof.

In an embodiment of the invention, the paint further includes: a heat resistant material, a solvent, and a hardener.

In an embodiment of the invention, after the above-mentioned blister forming process, the method further includes: and carrying out in-mold decoration technology or out-mold decoration technology on the formed film, so that the formed film is attached to the outer surface of the workpiece to form a decorated formed product.

In an embodiment of the invention, after performing the laser engraving process, the method further includes: and carrying out an in-mold decoration technology or an out-mold decoration technology on the formed film, so that the formed film is attached to the inner surface of the workpiece to form a decorated formed product.

The invention provides a manufacturing method of a decorative molding product, which comprises the following steps: providing a substrate having a first surface and a second surface opposite to the first surface; forming a second coating on the second surface of the substrate by using a coating method or a printing method; forming a first coating material on the second coating material by using a coating method or a printing method; performing a first curing step to form a composite layer structure, wherein the composite layer structure comprises at least: the substrate; a first decorative layer disposed on the second surface of the substrate; and a second decorative layer disposed between the second surface of the substrate and the first decoration; carrying out a plastic suction forming process to form a formed film; and carrying out a laser engraving process.

In an embodiment of the invention, each of the first paint and the second paint includes: the protective material, the ink material and the bonding material are uniformly mixed together.

In an embodiment of the present invention, after performing the laser engraving process, the method further includes: and carrying out an in-mold decoration technology or an out-mold decoration technology on the formed film, so that the formed film is attached to the inner surface of the workpiece to form a decorated formed product.

The invention provides a decorative molded article, comprising: a workpiece and a formed film attached to an outer surface of the workpiece. The formed film includes: a substrate having a first surface and a second surface opposite to each other; a first decorative layer disposed on the first surface of the substrate; the second decorative layer is arranged on the first decorative layer, and the decorative layer can achieve different effects by stacking different layers; an optical hardening layer disposed on the second decorative layer, wherein the first decorative layer, the second decorative layer, and the optical hardening layer each include a protective material, an ink material, and a bonding material; and a groove extending from the top surface of the optically hardened layer down into the second decorative layer.

Based on the above, the invention forms the all-in-one coating on the substrate and carries out the curing step, thereby forming the composite layer structure with the protection effect, the color effect and the attaching effect. The composite layer structure can form a formed film with better physical properties (such as higher hardness, better protection effect and the like) after a plastic suction forming process. Therefore, the formed film of the present embodiment can be applied to a laser engraving process to form various light-transmissive decorative products. In addition, the invention carries out the laser engraving process before and after the plastic suction molding process, thereby solving the alignment problem in the prior art, further improving the yield and reducing the manufacturing cost.

In order to make the aforementioned and other features and advantages of the invention more comprehensible, embodiments accompanied with figures are described in detail below.

Drawings

FIG. 1 is a schematic flow chart showing a method for producing a decorated article according to a first embodiment of the present invention;

FIG. 2 is a schematic cross-sectional view of a decorated article according to a first embodiment of the present invention;

FIG. 3 is a schematic flow chart showing a method of manufacturing a decorated article according to a second embodiment of the present invention;

FIG. 4 is a schematic cross-sectional view of a decorative molded article according to a second embodiment of the present invention;

FIG. 5 is a schematic flow chart showing a method of manufacturing a decorated article according to a third embodiment of the present invention;

FIG. 6 is a schematic cross-sectional view of a decorative molded article according to a third embodiment of the present invention;

FIG. 7 is a schematic sectional view of a decorative molded article according to a fourth embodiment of the present invention;

FIG. 8 is a schematic sectional view of a decorative molded article according to a fifth embodiment of the present invention;

FIG. 9 is a schematic flow chart of an in-mold decoration technique according to an embodiment of the present invention;

FIG. 10 is a flow chart illustrating an exterior mold decoration technique according to an embodiment of the present invention;

FIG. 11 is a schematic cross-sectional view of a decorative molded article according to a sixth embodiment of the present invention;

FIG. 12A is a schematic cross-sectional view of a decorative molded article according to a seventh embodiment of the present invention;

FIGS. 12B and 12C are schematic top views of the structure of FIG. 12A without and with the light source turned on, respectively;

FIG. 13A is a schematic sectional view of a decorative molded article according to an eighth embodiment of the present invention;

fig. 13B and 13C are schematic top views respectively illustrating turning on and off the light source for the structure of fig. 13A.

Detailed Description

The present invention is described more fully hereinafter with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Directional phrases used in the following embodiments, such as "upper", "lower", etc., refer only to the direction of the attached drawings and are, therefore, used in the detailed description and should not be construed as limiting the present invention. In addition, the thickness of layers and regions in the drawings may be exaggerated for clarity. The same or similar element numbers refer to the same or similar elements, and the description thereof will not be repeated in the following paragraphs.

Fig. 1 is a schematic flow chart of a method for manufacturing a decorated molded article according to a first embodiment of the present invention. Fig. 2 is a schematic cross-sectional view of a decorated article according to a first embodiment of the present invention.

Referring to fig. 1 and 2, a first embodiment of the invention provides a method S10 for manufacturing a decorated molded article 10 as follows. Step S100 is performed to form a composite layer structure 110 (shown in fig. 2). Specifically, forming the composite layer structure 110 includes: step S102 is performed to form a first coating material on the substrate 102 (shown in fig. 2) by a coating method or a printing method. In one embodiment, the material of the substrate 102 includes Acrylonitrile Butadiene Styrene (ABS), polycarbonate (PC), polymethyl methacrylate (PMMA), or a combination thereof, and the forming method thereof includes an extrusion molding method, and the like. For example, the ABS solid plastic may be heated to melt, extruded and cooled to form the ABS substrate 102 by extrusion molding. In addition, the ABS solid plastic, color master batch, pigment, pearl powder and related addition additives can be mixed to form a mixture. And then, extruding the mixture by an extrusion molding method to form another ABS substrate, so that the ABS substrate has visual effects of color, pearlescence, bright surface, mirror surface, extinction haze surface and the like.

Specifically, the coating method is to distribute the coating material in a coating apparatus and uniformly coat the coating material on the substrate 102 through a coating head of the coating apparatus. In one embodiment, the opening of the coating head may be flat to provide a bright finish to the coating applied to the substrate 102. In another embodiment, the opening of the coating head may have a plurality of microstructures (e.g., dimples) to provide a matte effect to the coating applied to the substrate 102. In an alternative embodiment, the opening portion of the coating head may have a plurality of concave-convex structures to provide hairline effect to the coating material coated on the substrate 102. On the other hand, the printing method may include a suitable printing method such as a gravure (printing) method, a screen printing (screen printing) method, an offset printing (offset printing) method, a reverse printing (reverse printing) method, or an inkjet printing method. The printing method can form a thinner film layer than the coating method.

In one embodiment, the first coating includes at least: the protective material, the ink material and the bonding material are uniformly mixed together. The protective material may include Polymethylmethacrylate (PMMA), aliphatic Urethane acrylate (Aliphatic Urethane acrylate), epoxy Acrylate (EA), polyester polyol (polyester polyol), or a combination thereof; the ink material may include Polyurethane (PU) and the like; and the conformable material may comprise Thermoplastic Polyurethane (TPU), aromatic Urethane acrylate (Aromatic Urethane Diacrylate), or a combination thereof. In addition, the first dope further includes: a heat resistant material, a solvent, and a hardener. In one embodiment, the heat resistant material may comprise Polycarbonate (PC) or the like; the solvent may include ethyl acetate, butanone, toluene, xylene, or a combination thereof; and the hardener may include polyisocyanate (Aromatic Urethane Diacrylate) and the like. However, the invention is not limited thereto, and in other embodiments, the first coating may further include other additives, such as matting powder, pearl powder, etc., so that the subsequently formed first decoration layer 104 (as shown in fig. 2) has different visual effects such as matting, pearling, etc.

Next, step S104 is performed to form a second paint on the first paint by a coating method or a printing method. In one embodiment, the second coating comprises at least: the protective material, the ink material and the bonding material are uniformly mixed together. In addition, the coating method, the printing method, the protective material, the ink material and the laminating material have been described in detail in the above paragraphs, and are not repeated herein. It is noted that the first paint is used to form the first decoration layer 104, and the second paint is used to form the second decoration layer 106, as shown in fig. 2. In this embodiment, the first coating and the second coating have different compositions to achieve different visual effects. In another embodiment, the

decoration layer

104 or 106 can be formed by evaporation or sputtering to achieve a metalized decoration effect. For example, the first decorative layer 104 formed by the first paint may be a wood grain layer, and the second decorative layer 106 formed by the second paint may have a dull silver color, so that the composite layer structure 110 may have a dull silver wood grain pattern.

Then, step S106 is performed to form a third paint on the second paint by a coating method or a printing method. In one embodiment, the third coating comprises at least: the protective material, the ink material and the bonding material are uniformly mixed together. In addition, the coating method, the printing method, the protective material, the ink material and the bonding material have been described in detail in the above paragraphs, and are not described in detail herein. It is noted that the third coating is used to form the optical hardening layer 108. In this embodiment, the content of the protective material in the third paint may be higher than the content of the protective material in the first paint or the second paint.

Thereafter, step S108 is performed to perform a first curing step to form a composite layer structure 110. As shown in fig. 2, the composite layer structure 110 includes a first decoration layer 104, a second decoration layer 106, and an optically hardened layer 108. First decorative layer 104 may be disposed on first surface 102a of substrate 102. Second trim layer 106 may be disposed on first trim layer 104. The optical hardening layer 108 may be disposed on the second decoration layer 106 such that the second decoration layer 106 is disposed between the first surface 102a of the substrate 102 and the optical hardening layer 108. Although only two

decorative layers

104, 106 are shown in fig. 2, the present invention is not limited thereto, and in other embodiments, the composite layer structure 110 may have multiple (e.g., three, four or more) stacked decorative layers.

In an embodiment, the first curing step may include a thermal curing step, an Ultraviolet (UV) curing step, a combination thereof, or other suitable curing step. The first curing step can cause the bonding material to undergo a cross-linking reaction and bond to the substrate 102. In this embodiment, the coating may be regarded as an all-in-one coating, which can make the cured composite layer structure 110 have the protection effect, the color effect and the adhesion effect at the same time. In this case, the composite layer structure 110 may also be referred to as an all-in-one composite layer structure. Compared with the steps of purchasing a protective layer and forming the adhesive film structure through printing and laminating processes in the prior art, the method can effectively simplify the manufacturing steps, reduce the manufacturing cost and prevent the pollution problem caused by the adhesive film.

After the composite layer structure 110 is formed, a step S120 is performed to perform a vacuum forming process to form a formed film 100A. In one embodiment, the blister process comprises: heating the composite layer structure 110 and the substrate 102 to soften the composite layer structure 110 and the substrate 102; placing the softened composite layer structure 110 and the substrate 102 into a mold and pressurizing to form the softened composite layer structure 110 and the substrate 102 into a desired shape; carrying out a cooling step; and cutting the excess portion to form a formed film 100A.

Next, step S130 is performed to perform an in-mold decoration technique or an out-mold decoration technique, so that the formed film 100A is attached to the outer surface 200A of the workpiece 200 to form the decorated formed article 10, as shown in fig. 2. In one embodiment, the substrate 102 has a first surface 102a and a second surface 102b opposite to each other. As shown in fig. 2, second surface 102b of substrate 102 contacts outer surface 200a of workpiece 200, first surface 102a of substrate 102 contacts first decorative layer 104, and top surface 110a of composite layer structure 110 is exposed upwardly. In this embodiment, the top surface 110A of the composite layer structure 110 may be a visual surface, so that the consumer can see the visual effect of the formed film 100A from the top surface 110A of the composite layer structure 110.

FIG. 9 is a flow chart of an in-mold decoration technique according to an embodiment of the present invention. Fig. 10 is a flow chart illustrating an exterior mold decoration technique according to an embodiment of the present invention.

Referring to fig. 9, a process flow S200 of the in-mold decoration technique is as follows. First, step S202 is performed to provide a molded film. The formed film may be, for example, formed film 100A. The composition of the formed film 100A is described in the above paragraphs, and thus is not described in detail.

Next, in step S204, the molded film 100A is placed in an in-mold decoration mold. In detail, the in-mold decoration mold includes a hollow mold cavity. The mold cavity has a surface. Then, the molding film 100A is attached to the surface of the mold cavity such that the molding film 100A covers at least a portion of the surface of the mold cavity. In an alternative embodiment, before performing step S206, heat pre-forming and removing the excess film by using knife cutting, laser cutting or water jet cutting may be performed optionally.

Then, step S206 is performed to fill the molding material into the cavity of the in-mold decoration mold, so that the molding material and the molding film 100A are bonded to each other. In one embodiment, the molding material may be, for example, a plastic material, a resin material, a metal material, a carbon fiber material, glass, or other suitable molding material.

Thereafter, step S208 is performed to cool the molding material to form the workpiece 200. The workpiece 200 is an application of the decorated article according to the present invention, and may be an electronic device housing or component, a vehicle housing or component, or a combination thereof. For example, the workpiece 200 may be a housing or a component used in a mobile phone, a digital camera, a Personal Digital Assistant (PDA), a notebook computer, a desktop computer, a touch panel, a television, a satellite positioning system (GPS) device, a car monitor, a navigation device, a display, a digital photo frame, a DVD player, a car interior trim panel (e.g., a handle, a trim strip, a touch front, etc.), a car exterior trim panel (e.g., an exterior handle, a back door trim strip, etc.), a car dashboard, a car logo, an intelligent key (I-key), an engine start button, a clock, a radio, a toy, a watch, or other electronic products requiring electric power. However, the present invention is not limited to the shape and structure of the workpiece 200, and any shape and structure of the workpiece 200 that can be finished by the in-mold decoration technique is within the scope of the present invention.

Next, step S210 is performed to take out the decorated molded article 10 from the in-mold decoration mold. The obtained decorated molded article 10 is described in detail in fig. 2, and is not described herein again.

On the other hand, the decorated article 10 may be manufactured by an in-mold decoration technique. Referring to fig. 10, the process flow S200 of the mold exterior decoration technique is as follows. First, step S302 is performed to provide the workpiece 200. In one embodiment, the workpiece 200 is an application of a decorated article according to the present invention, which may be an electronic device housing or component, a vehicle housing or component, or a combination thereof. In alternative embodiments, the material of the outer surface 200a of the workpiece 200 may be plastic, resin, metal, carbon fiber, glass, or other various formed housing materials, and may be subjected to appropriate pre-processing processes to produce a workpiece having desired characteristics, for example. For example, when the workpiece is made of plastic, the plastic workpiece (such as a plastic housing) can be obtained by an injection molding process using an injection molding mold; alternatively, when the workpiece is made of metal, the metal may be first subjected to surface treatment to obtain a metal workpiece (e.g., a metal housing).

Then, step S304 is performed to provide a molded film. The formed film may be, for example, the formed film 100A shown in FIG. 2 and described above. The composition of the formed film 100A is described in the above paragraphs, and thus, the description thereof is omitted.

Then, step S306 is performed to place the workpiece 200 and the formed film 100A in the fixture. It is noted that before performing step S306, a jig may be optionally designed according to the requirement of the final product and the jig is prepared.

Then, step S308 is performed to perform a high pressure decoration molding process so as to attach the molded film 100A to the outer surface 200A of the workpiece 200. Specifically, the high-pressure decoration forming process is, for example, a heating softening step of the formed film 100A. In one embodiment, the temperature of the heat softening step may be between 80 ℃ and 150 ℃; the time for the heat softening step may be between 30 seconds and 180 seconds. Next, the formed film 100A is brought into contact with the workpiece 200, and a pressing step is performed. Then, the formed film 100A is subjected to a high pressure vacuum forming process to attach the formed film 100A to the workpiece 200. Finally, the remaining composite layer structure can be selectively removed by die cutting, laser cutting or water jet cutting. In short, the present embodiment can closely adhere the formed film 100A to a portion of the outer surface 200A of the workpiece 200 by the mold decoration technique.

Referring back to fig. 1, after the decorative molded article 10 is formed, a second curing step is performed to increase the hardness of the composite layer structure 110 in step S140. In an embodiment, the second curing step may include a thermal curing step, an Ultraviolet (UV) curing step, a combination thereof, or other suitable curing step. In this embodiment, the first curing step is different from the second curing step. For example, the first curing step may be a thermal curing step, and the second curing step may be a UV curing step; the reverse is true. In an alternative embodiment, when both the first curing step and the second curing step are thermal curing steps, the curing temperature of the second curing step may be higher than the curing temperature of the first curing step. It is noted that the second curing step can perform a cross-linking reaction on the protective material to increase the hardness of the top surface 108a of the optical hardening layer 108, thereby enhancing the protection effect. That is, when the in-mold decoration or the out-mold decoration (i.e., step S130) is performed, the optical cured layer 108 is still not completely cured and has ductility, and is completely attached to the outer surface 200a of the workpiece 200. After the second curing step (i.e., step S140), the optical hardening layer 108 is completely cured and has a complete protection effect. In the present embodiment, the hardness of the optically hardened layer 108 may have a gradient change. Specifically, the hardness of the optically hardening layer 108 may increase from the bottom surface 108b toward the top surface 108 a. That is, the hardness of the top surface 108a of the optically hardened layer 108 may be greater than the hardness of the bottom surface 108b of the optically hardened layer 108. In addition, the second curing step may also increase the hardness of the first decoration layer 104 and the second decoration layer 106 to facilitate the subsequent laser engraving process (i.e., step S150).

Then, step S150 is performed, and a laser engraving process is performed to form the groove 105 in the composite layer structure 110. As shown in fig. 2, recess 105 may extend downwardly from top surface 110a of composite layer structure 110 until top surface 104t of first decorative layer 104 is exposed. However, the invention is not limited thereto, and in other embodiments, the grooves 105 may have different depths. That is, bottom surface 105bt of recess 105 may be higher or lower than top surface 104t of first decorative layer 104, or bottom surface 105bt of recess 105 may be higher, equal or lower than top surface 106t of second decorative layer 106. Furthermore, although fig. 2 only shows a single groove 105, the present invention is not limited thereto, and in an alternative embodiment, the decorative molded article 10 may have a plurality of grooves to form various laser engraved patterns, so as to increase the visual perception of consumers.

Referring to fig. 2, the decorative molding 10 can be disposed on the light source 300 to emit light of different colors through the groove 105. For example, light source 300 may be blue light and first decorative layer 104 may be a wood layer. When the light source 300 is not turned on, the consumer can see the laser engraved pattern having the wood grain effect through the groove 105 from the viewing surface 110 a. On the other hand, when the light source 300 is turned on, the consumer can see the laser engraved pattern having the blue wood grain effect through the groove 105 from the viewing surface 110 a. In one embodiment, the light source 300 may include an LED point light source, an LED light bar, a mini LED, or the like.

In the prior art, multiple spraying steps and multiple laser engraving steps are required to form a multicolor film. The disadvantages of this technique are: complex process, difficult processing, high cost and high environmental pollution degree. In addition, in the existing decoration process (such as IMD or OMD), a multicolor film is usually formed by stencil printing. However, after the client is subjected to the processes of plastic-sucking molding, cutting, injection molding, etc., the technique has the disadvantages of difficult alignment, low yield, excessive material consumption, high cost, etc. In addition, because the IMD film or the OMD film is thinner, the laser engraving process is not favorable. That is, even when the post-laser engraving treatment is performed, the laser engraved film is peeled or damaged due to poor surface physical properties, and thus it is necessary to additionally form a protective coating layer to protect the film, which leads to an increase in cost.

In order to solve the above problems, in the embodiments of the present invention, an all-in-one coating is formed on a substrate and cured to form a composite layer structure having a protection effect, a color effect, and a bonding effect. The composite layer structure can form a formed film with better physical properties (such as higher hardness, better protection effect and the like) after a plastic suction forming process. Therefore, the formed film of the present embodiment can be applied to a laser engraving process to form various light-transmissive decorative products.

Fig. 3 is a schematic flow chart of a method for manufacturing a decorated article according to a second embodiment of the present invention. FIG. 4 is a schematic cross-sectional view of a decorative molded article according to a second embodiment of the present invention.

Referring to fig. 3 and 4, a second embodiment of the invention provides a manufacturing method S20 of a decorated molded article 20 as follows. Step S100 is performed to form a composite layer structure 120 (shown in fig. 4). Specifically, forming the composite layer structure 120 includes: step S102 is performed to form a first coating material on the substrate 102 (as shown in fig. 4) by a coating method or a printing method. Next, in step S104, a second paint is formed on the first paint by a coating method or a printing method. Then, step S107 is performed to form a fourth paint on the second paint by a coating method or a printing method. In one embodiment, the fourth dope includes at least: the protective material, the ink material and the bonding material are uniformly mixed together. In addition, the coating method, the printing method, the protective material, the ink material and the laminating material have been described in detail in the above paragraphs, and are not repeated herein. It is noted that the fourth coating is used to form the landing prevention layer 118 (as shown in FIG. 4). In the embodiment, the content of the bonding material in the fourth coating material may be higher than the content of the bonding material in the first coating material or the second coating material, so as to increase the adhesion between the composite layer structure 120 and the subsequently formed workpiece 200. To form a composite layer structure 120. As shown in fig. 4, the composite layer structure 120 includes a first decorative layer 104, a second decorative layer 106, and an anti-adhesion layer 118. First decorative layer 104 may be disposed on first surface 102a of substrate 102. Second trim layer 106 may be disposed on first trim layer 104. Impact resistant layer 118 may be disposed on second decorative layer 106 such that second decorative layer 106 is disposed between first surface 102a of substrate 102 and impact resistant layer 118.

After the composite layer structure 120 is formed, a step S120 is performed to perform a vacuum forming process to form a formed film 100B.

Then, step S150 is performed, and a laser engraving process is performed to form the groove 105 in the composite layer structure 120. As shown in fig. 4, recess 105 may extend downwardly from top surface 120a of composite layer structure 120 until top surface 104t of first decorative layer 104 is exposed. However, the invention is not limited thereto, and in other embodiments, the grooves 105 may have different depths.

Thereafter, step S160 is performed to perform an in-mold decoration technique or an out-mold decoration technique so that the formed film 100B is attached to the inner surface 200B of the workpiece 200 to form the decorated formed article 20, as shown in fig. 4. Specifically, the inner surface 200b of the workpiece 200 contacts the top surface 120a of the composite layer structure 120 to seal the groove 105. In this embodiment, the outer surface 200a of the workpiece 200 may be a visual surface, so that a consumer can see the visual effect of the formed film 100B from the outer surface 200a of the workpiece 200 and has a thickness texture similar to that of crystal in a deep layer. In addition, the in-mold decoration technique and the out-mold decoration technique have been described in detail in the above paragraphs, and are not described herein again.

Fig. 5 is a schematic flow chart illustrating a method for manufacturing a decorated article according to a third embodiment of the present invention. FIG. 6 is a schematic cross-sectional view of a decorative molded article according to a third embodiment of the present invention.

Referring to fig. 5 and 6, a third embodiment of the invention provides a manufacturing method S30 of a decorated molded article 30 as follows. Step S100 is performed to form a composite layer structure 130 (shown in fig. 6). Specifically, forming the composite layer structure 130 includes: step S101 is performed to apply the second coating material on the substrate (as shown in fig. 6) by a coating method or a printing method. Next, step S103 is performed to coat the first paint on the second paint by a coating method or a printing method. In one embodiment, the first paint is used to form the first decoration layer 104, and the second paint is used to form the second decoration layer 106, as shown in fig. 6. In the present embodiment, the first paint and the second paint do not require an additional curing step (i.e., at room temperature) to form the first decoration layer 104 and the second decoration layer 106, thereby forming the composite layer structure 130. As shown in fig. 6, the composite layer structure 130 includes a first decoration layer 104 and a second decoration layer 106. Second decorative layer 106 may be disposed on second surface 102b of substrate 102. First decorative layer 104 may be disposed below second decorative layer 106 such that second decorative layer 106 is sandwiched between second surface 102b of substrate 102 and first decorative layer 104.

After the composite layer structure 130 is formed, a step S120 is performed to perform a plastic molding process to form a molded film 100C.

Then, step S150 is performed, and a laser engraving process is performed to form the groove 105 in the composite layer structure 130. As shown in fig. 6, the recess 105 may extend upwardly from the bottom surface 130b of the composite layer structure 130 until the bottom surface 106b of the second decorative layer 106 is exposed. However, the invention is not limited thereto, and in other embodiments, the grooves 105 may have different depths.

Thereafter, step S160 is performed to perform an in-mold decoration technique or an out-mold decoration technique so that the formed film 100C is attached to the inner surface 200b of the workpiece 200 to form the decorated formed article 30, as shown in fig. 6. Specifically, the inner surface 200b of the workpiece 200 is in contact with the first surface 102a of the substrate 102. The light source 300 contacts the bottom surface 130b of the composite layer structure 130 to seal the groove 105. In this embodiment, the outer surface 200a of the workpiece 200 may be a visual surface so that a consumer can see the visual effect of the formed film 100C from the outer surface 200a of the workpiece 200 down. In addition, the in-mold decoration technique and the out-mold decoration technique have been described in detail in the above paragraphs, and are not described herein again.

In the present embodiment, as shown in fig. 6, the decorative molding 30 can emit light of different colors through the groove 105. For example, light source 300 may be blue light and second decorative layer 106 may be a geometric pattern layer. When the light source 300 is not turned on, the consumer can see the geometric pattern of the whole piece from the visual surface 200 a. On the other hand, when the light source 300 is turned on, the consumer can see the laser engraved pattern having the effect of the blue light geometric pattern from the viewing surface 200a through the groove 105.

FIG. 7 is a schematic cross-sectional view of a decorative molded article according to a fourth embodiment of the present invention.

Referring to fig. 7, the decorated molded article 40 of the fourth embodiment may include: workpiece 200 and formed film 100D. The formed film 100D may be disposed on the outer surface 200a of the workpiece 200 and the light source 300 may be disposed on the inner surface 200b of the workpiece 200. Specifically, the formed film 100D may include a substrate 102, an optically hardened layer 108, and a composite layer structure 140. The substrate 102 has a first surface 102a and a second surface 102b opposite to each other. The optically hardened layer 108 may be disposed on the first surface 102a of the substrate 102. In this embodiment, the optical hardening layer 108 may be formed by the third paint, and the content of the protective material may be higher than the content of the protective material in the first paint or the second paint. In this embodiment, the optical hardening layer 108 may also be referred to as an all-in-one hard coating. In the present embodiment, the top surface 108a of the optically hardening layer 108 may be a visual surface, so that the consumer can see the visual effect of the formed film 100D from the top surface 108a of the optically hardening layer 108.

In addition, the composite layer structure 140 may be disposed on the second surface 102b of the substrate 102. Specifically, the composite layer structure 140 may sequentially include an anti-adhesion layer 118, a buffer layer (or decoration layer) 142, a third decoration layer 144, and a fourth decoration layer 146 from bottom to top. In this embodiment, the anti-adhesion layer 118 may be formed by the fourth paint, and the content of the bonding material thereof may be higher than the content of the bonding material in the first paint or the second paint. In one embodiment, the material of the buffer layer 142 includes Polyurethane (PU) and polymethyl methacrylate (PMMA), which has the effects of preventing ink wash and improving laser engraving resolution. In one embodiment, the third decorative layer 144 can be formed by the first coating, which can be printed one or more times to present different decorative patterns such as wood grain, geometric patterns, etc. In an embodiment, the fourth decoration layer 146 may be formed by the second paint, which may be formed on the second surface 102b of the substrate 102 by a physical vapor deposition method (e.g., evaporation method, sputtering method, etc.), an electroplating method, etc. For example, third decorative layer 144 may be a wood grain layer, and fourth decorative layer 146 may have a vapor deposited metal layer having a transparency of 50%, thereby causing composite layer structure 140 to exhibit a wood grain pattern having a metallic color with a transparency of 50%. In addition, although fig. 7 shows only two

decoration layers

144 and 146, the invention is not limited thereto, and in other embodiments, a plurality of decoration layers can be alternately stacked according to different requirements.

It is noted that the decorative molding 40 further includes a groove 105 formed in the impact-resistant layer 118 and the buffer layer 142. However, the invention is not limited thereto, and in other embodiments, the grooves 105 may have different depths. That is, recess 105 may also extend upwardly into third decorative layer 144 and/or fourth decorative layer 146. The bottom surface 140b of the composite layer structure 140 may contact the outer surface 200a of the workpiece 200 to seal the groove 105.

In this embodiment, as shown in fig. 7, the decorative molded article 40 can emit light of various colors through the groove 105. For example, light source 300 may be blue light and fourth decorative layer 146 may be a layer of evaporated metal having a transparency of 50%. When the light source 300 is not turned on, the entire evaporated metal layer is visible to the consumer from the viewing surface 108 a. On the other hand, when the light source 300 is turned on, the consumer can see the laser engraved pattern with the blue metal effect from the viewing surface 108a through the groove 105.

Fig. 8 is a schematic cross-sectional view of a decorative molded article according to a fifth embodiment of the present invention.

Referring to fig. 8, the decorative molded article 50 of the fifth embodiment may include: workpiece 200 and formed film 100E. The formed film 100E may be disposed on the outer surface 200a of the workpiece 200 and the light source 300 may be disposed on the inner surface 200b of the workpiece 200. Specifically, the formed film 100E may include a substrate 102, a first composite layer structure 150, and a second composite layer structure 160. The substrate 102 has a first surface 102a and a second surface 102b opposite to each other. The first composite layer structure 150 may be disposed on the first surface 102a of the substrate 102. The first composite layer structure 150 may include an optically hardened layer 108 and a light transmissive layer 154. The material of the light-transmitting layer 154 includes polymethacrylic resin, which has a decorative effect of chemical resistance. The transparent layer 154 may contact the first surface 102a of the substrate 102, and the optical hardening layer 108 is disposed on the transparent layer 154. In this embodiment, the top surface 108a of the optically hardening layer 108 may be a visual surface, so that a consumer can see the visual effect of the formed film 100E from the top surface 108a of the optically hardening layer 108 downward.

Additionally, a second composite layer structure 160 may be disposed on the second surface 102b of the substrate 102. Specifically, second composite layer structure 160 may include impact resistant layer 118 and fourth decorative layer 146. Fourth decorative layer 146 may contact second surface 102b of substrate 102, and anti-impingement layer 118 may be disposed below fourth decorative layer 146 such that fourth decorative layer 146 is sandwiched between second surface 102b of substrate 102 and anti-impingement layer 118. In the present embodiment, the fourth decoration layer 146 may be formed by the second paint, which may be formed on the second surface 102b of the substrate 102 by a physical vapor deposition method (e.g., an evaporation method, a sputtering method, etc.), an electroplating method, or the like. For example, the transparent layer 154 may be a semi-transparent black layer, and the fourth decoration layer 146 may have a vapor-deposited metal layer with a transparency of 25%, so that the formed film 100E exhibits a black metal color with a transparency of 25%.

It is noted that the decorative molding 50 further includes a groove 105 formed in the first composite layer structure 150. That is, the groove 105 extends downward from the top surface 108a of the optically hardened layer 108 into the light transmissive layer 154. The bottom surface 160b of the second composite layer structure 160 can contact the outer surface 200a of the workpiece 200 to adhere to the outer surface 200a of the workpiece 200 through the anti-impact adhesive layer 118.

FIG. 11 is a schematic cross-sectional view of a decorative molded article according to a sixth embodiment of the present invention.

Referring to fig. 11, the decorative molded article 60 of the sixth embodiment may include: workpiece 200 and formed film 100F. The formed film 100F may be disposed on the outer surface 200a of the workpiece 200 and the light source 300 may be disposed on the inner surface 200b of the workpiece 200. Specifically, the formed film 100F may include a substrate 102 and a composite layer structure 170. The substrate 102 has a first surface 102a and a second surface 102b opposite to each other. The composite layer structure 170 may be disposed on the first surface 102a of the substrate 102. The composite layer structure 170 may include the fourth decoration layer 146 and the optical hardening layer 108. The fourth decoration layer 146 may contact the first surface 102a of the substrate 102, and the optical hardening layer 108 is disposed on the fourth decoration layer 146. In the present embodiment, the top surface 108a of the optically hardening layer 108 may be a visual surface, so that the consumer can see the visual effect of the formed film 100F from the top surface 108a of the optically hardening layer 108 downward. In the present embodiment, the fourth decoration layer 146 can be formed by the second paint, and can be formed on the first surface 102a of the substrate 102 by a physical vapor deposition method (e.g., an evaporation method, a sputtering method, etc.), an electroplating method, or the like. The optical hardening layer 108 can have a protective effect to prevent the fourth decoration layer 146 from being scratched or damaged.

It is noted that the decorative molding 60 further includes a groove 105 formed in the composite layer structure 170. That is, the groove 105 extends from the top surface 108a of the optically hardening layer 108 down into the fourth decorative layer 146.

Fig. 12A is a schematic cross-sectional view of a decorative molded article according to a seventh embodiment of the present invention. Fig. 12B and 12C are schematic top views illustrating turning off and turning on the light source, respectively, for the structure of fig. 12A.

Referring to fig. 12A, the decorated molded article 70 of the seventh embodiment may include: work 200 and formed film 100G. The formed film 100G may be disposed on the outer surface 200a of the workpiece 200 and the light source 300 may be disposed on the inner surface 200b of the workpiece 200. Specifically, the formed film 100G can include a substrate 102, a composite layer structure 180, and an impact resistant layer 118. The substrate 102 has a first surface 102a and a second surface 102b opposite to each other. The composite layer structure 180 may be disposed on the first surface 102a of the substrate 102. The composite layer structure 180 may include a third decorative layer 144, a fourth decorative layer 146, and an optically hardened layer 108. Fourth decorative layer 146 may contact first surface 102a of substrate 102. The optical hardening layer 108 may be disposed on the fourth decorative layer 146. The third decorative layer 144 may be disposed between the fourth decorative layer 146 and the optically hardening layer 108. In the present embodiment, the top surface 108a of the optically hardening layer 108 may be a visual surface, so that the consumer can see the visual effect of the formed film 100G from the top surface 108a of the optically hardening layer 108. In the present embodiment, the third decoration layer 144 can be formed by the first paint, which can be printed once or multiple times to present different decoration patterns such as wood grain, geometric patterns, etc. Fourth decorative layer 146 may be formed of the second coating material, and may be formed on first surface 102a of substrate 102 by a physical vapor deposition method (e.g., evaporation method, sputtering method, etc.), an electroplating method, or the like. The optical hardening layer 108 can have a protective effect to prevent the third decoration layer 144 from being scratched or damaged. On the other hand, the anti-impact layer 118 can be disposed on the second surface 102b of the substrate 102 and in contact with the second surface 102b of the substrate 102. In this embodiment, the formed film 100G may be attached to the outer surface 200a of the workpiece 200 through the impact resistant layer 118.

It is noted that the decorative molded article 70 further includes a first groove 105a and a second groove 105b. The first groove 105a is formed in the composite layer structure 180. That is, the first groove 105a extends from the top surface 108a of the optically hardening layer 108 down into the third decoration layer 144. A second recess 105b is formed in the anti-impingement layer 118. That is, the decorative molded article 70 of the present embodiment can be formed with grooves on two opposite sides (i.e., the upper side and the lower side) to increase different light-transmitting areas, thereby improving the visual perception of the consumer.

In this embodiment, as shown in fig. 12B and 12C, the decorative molded article 70 can emit light of different colors through the grooves 105a and 105B. For example, light source 300 may be blue light, third decorative layer 144 may be a wood layer, and fourth decorative layer 146 may be a vapor-deposited metal layer having a transparency of 50%. When the light source 300 is not turned on, the consumer can see the wood-grain layer with the metal edge strips from the visual surface 108a through the first groove 105a, as shown in fig. 12B. On the other hand, when the light source 300 is turned on, the consumer can see the wood grain layer with the metal edge strips and the blue characters from the visual surface 108a through the first groove 105a and the second groove 105b.

Fig. 13A is a schematic cross-sectional view of a decorative molded article according to an eighth embodiment of the present invention. Fig. 13B and 13C are schematic top views respectively illustrating turning on and off the light source for the structure of fig. 13A.

Referring to fig. 13A, the decorated molded article 80 of the eighth embodiment may include: workpiece 200 and formed film 100H. The formed film 100H may be disposed on the inner surface 200b of the workpiece 200, and the light source 300 may be disposed below the formed film 100H with the formed film 100H interposed between the workpiece 200 and the formed film 100H. Specifically, formed film 100H may include substrate 102 and composite layer structure 190. The substrate 102 has a first surface 102a and a second surface 102b opposite to each other. The composite layer structure 190 may be disposed on the first surface 102a of the substrate 102. Composite layer structure 190 may include third trim layer 144, fourth trim layer 146, and impact resistant layer 118. Fourth decorative layer 146 may contact first surface 102a of substrate 102. Impact resistant layer 118 may be disposed on fourth decorative layer 146. Third decorative layer 144 may be disposed between fourth decorative layer 146 and impingement layer 118. In this embodiment, the outer surface 200a of the workpiece 200 may be a visual surface so that a consumer can see the visual effect of the formed film 100H from the outer surface 200a of the workpiece 200 down. In the present embodiment, the third decoration layer 144 can be formed by the first paint, which can be printed once or multiple times to present different decoration patterns such as wood grain, geometric patterns, etc. Fourth decorative layer 146 may be formed of the second coating material, and may be formed on first surface 102a of substrate 102 by a physical vapor deposition method (e.g., evaporation method, sputtering method, etc.), an electroplating method, or the like. The anti-adhesion layer 118 can have an adhesion function, so that the formed film 100H can be adhered to the inner surface 200b of the workpiece 200 through the anti-adhesion layer 118.

It is noted that the decorative molding 80 further includes a first groove 105a and a second groove 105b. The first groove 105a is formed in the composite layer structure 190. That is, first recess 105a extends downwardly from top surface 118a of impact resistant layer 118 into third decorative layer 144. A second groove 105b is formed in the substrate 102 to extend from the first surface 102a to the second surface 102b. That is, the decorative molded article 80 of the present embodiment can be formed with grooves on two opposite sides (i.e., the upper side and the lower side) respectively to increase different light-transmitting areas, thereby improving the visual perception of the consumer.

In the present embodiment, as shown in fig. 13B and 13C, the decorative molded article 80 can emit light of different colors through the grooves 105a and 105B. For example, light source 300 may be blue light, third decorative layer 144 may be a wood-grain layer, and fourth decorative layer 146 may be an evaporated metal layer having a transparency of 50%. When the light source 300 is not turned on, the consumer can see the wood-grain layer with the metal edge strips from the viewing surface 200a through the first grooves 105a, as shown in fig. 13B. On the other hand, when the light source 300 is turned on, the consumer can see the wood grain layer with the metal edge strips and the blue characters from the visual surface 200a through the first groove 105a and the second groove 105b.

Any of the decorative molded

articles

10, 20, 30, 40, 50, 60, 70, and 80 may be applied to a vehicle lamp. That is, any one of the

decorative moldings

10, 20, 30, 40, 50, 60, 70, 80 may be attached to a plastic housing of a vehicle lamp to present various color effects by laser-engraving patterns (e.g., the grooves 105). For example, the present invention can correspond the plurality of grooves 105 to different color lamp bodies, such that the brake light can show red light through the first groove, the left turn light can show yellow light through the second groove, and the headlight can show white light through the third groove.

In summary, the present invention forms the all-in-one coating on the substrate and performs the curing step, thereby forming the composite layer structure having the protection effect, the color effect and the bonding effect. The composite layer structure can form a formed film with better physical properties (such as higher hardness, better protection effect and the like) after a plastic suction forming process. Therefore, the formed film of the present embodiment can be applied to a laser engraving process to form various light-transmissive decorative products. In addition, the invention carries out the laser engraving process after the plastic suction molding process, thereby solving the alignment problem in the prior art, further improving the yield and reducing the manufacturing cost.

Although the present invention has been described with reference to the above embodiments, it should be understood that various changes and modifications can be made therein by those skilled in the art without departing from the spirit and scope of the invention.

Claims

1. A method for manufacturing a decorated molded article, comprising:

providing a coating, wherein the coating comprises at least: uniformly mixing the protective material, the printing ink material and the jointing material together;

forming the coating on a substrate by using a coating method or a printing method;

performing a first curing step to form a composite layer structure, wherein the composite layer structure comprises at least an optically hardened layer disposed on the substrate;

carrying out a plastic suction molding process to form a molded film;

performing a second curing step to increase the hardness of the formed film; and

and carrying out a laser engraving process.

2. The method of manufacturing a decorated molded article according to claim 1, wherein the protective material includes polymethyl methacrylate, aliphatic urethane acrylate, epoxy acrylate, polyester polyol, or a combination thereof, the ink material includes polyurethane, and the conformable material includes thermoplastic polyurethane, aromatic urethane acrylate, or a combination thereof.

3. The method of producing a decorated molded article according to claim 1, wherein the paint further comprises: a heat resistant material, a solvent, and a hardener.

4. The method of manufacturing a decorated article according to claim 1, further comprising, after the blister forming process is performed:

and carrying out in-mold decoration technology or out-mold decoration technology on the formed film, so that the formed film is attached to the outer surface of the workpiece to form a decorated formed product.

5. The method of manufacturing a decorated molding according to claim 1, further comprising, after the laser engraving process is performed:

and carrying out in-mold decoration technology or out-mold decoration technology on the formed film, so that the formed film is attached to the inner surface of the workpiece to form a decorated formed product.

6. A method for manufacturing a decorated molded article, comprising:

providing a substrate with a first surface and a second surface which are opposite;

forming a second coating on the second surface of the substrate by using a coating method or a printing method;

forming a first coating material on the second coating material by using a coating method or a printing method;

performing a first curing step to form a composite layer structure, wherein the composite layer structure comprises at least:

the substrate;

a first decorative layer disposed on the second surface of the substrate; and

a second decorative layer disposed between the second surface of the substrate and the first decoration;

carrying out a plastic suction forming process to form a formed film; and

and carrying out a laser engraving process.

7. The method of manufacturing a decorated molded article according to claim 6, wherein the first paint and the second paint each include: the protective material, the ink material and the bonding material are uniformly mixed together.

8. The method of manufacturing a decorated molded article according to claim 7, wherein the protective material includes polymethyl methacrylate, aliphatic urethane acrylate, epoxy acrylate, polyester polyol, or a combination thereof, the ink material includes polyurethane, and the conformable material includes thermoplastic polyurethane, aromatic urethane acrylate, or a combination thereof.

9. The method of manufacturing a decorated molded article according to claim 7, wherein after the laser engraving process is performed, the method further comprises:

10. A decorated molded article comprising:

a workpiece; and

a formed film attached to the outer surface of the workpiece, wherein the formed film comprises:

a substrate having a first surface and a second surface opposite to each other;

a first decorative layer disposed on the first surface of the substrate;

a second decorative layer disposed on the first decorative layer;

an optical hardening layer disposed on the second decorative layer, wherein the first decorative layer, the second decorative layer, and the optical hardening layer each include a protective material, an ink material, and a bonding material; and

a recess extending downwardly from a top surface of the optically hardened layer into the second decorative layer.