CN218505201U - Light-transmitting decorative molded article - Google Patents

Abstract

A light-transmitting decorated molded article comprising: 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. Compared with the film manufactured by matching the printing layer with a plurality of anti-impact layers and the film of the INS printing layer attached to the base material in the conventional IML, the composite layer structure of the embodiment 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. In addition, the present disclosure further forms a protective layer locally in the groove formed after the laser engraving to protect the texture after the laser engraving from being damaged.

Description

Light-transmitting decorative molded article

Technical Field

The utility model relates to a printing opacity adds ornaments finished product.

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 for forming the case is to apply a hardening layer on the surface of the case by spraying after the case of the related product is completed, which is tedious, has a poor yield, and causes pollution of organic solvent gas, thereby causing many pollution problems. On the other hand, since the spraying process has the disadvantages of time consumption, complex process, low thickness uniformity, etc., the overall production yield and cost are to be improved. 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 been another option for forming surface patterns of objects.

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 substrate composed of PC and ABS has low hardness 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 press process.

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), as another option for forming patterns 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 IML process flow is as follows:

(1) Cutting: a roll of film substrate (typically PMMA/PC or PET or PC substrate coated with a protective material) is cut into a size designed for printing and vacuum forming.

(2) Plane printing: generally, screen printing (silk screen printing) and spray printing processes are used for providing icons, character effects and final anti-adhesion materials, printing passes are generally designed according to the product design drawing effects, and especially, the anti-adhesion materials are usually required to be printed for multi-pass stacking due to the need of matching with high-temperature and high-pressure molding injection molding plastic materials (generally, the injection molding temperature is about more than 200 ℃), so that the cost is increased, the use efficiency of adhesive films and the overall yield are reduced.

(3) Drying the ink: the printed ink is baked and dried at high temperature to ensure the physical properties of the ink.

(4) Pasting a protective film: the surface of the printed film is prevented from being damaged by the positioning hole of the back punch, and a protective film is adhered to protect the surface.

(5) Punching a positioning hole: because the film shrinks during the forming and heating process, a positioning hole needs to be punched, which ensures the positioning precision of the printed film and the matched product.

(6) High-temperature high-pressure forming: after the printed film is heated at high temperature, the plastic uptake is carried out by a forming machine under the condition of preheating.

(7) Cut shape: and cutting off the waste materials by cutting or laser cutting the three-dimensional film after plastic uptake.

(8) Injection molding: and finally, placing the cut three-dimensional film in an injection molding machine for injection molding to form a finished part and the physical property inspection of related goods.

The in-mold transfer printing (IMR) process is to print a pattern on a 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 film after the injection molding, and leave the ink layer on the 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 greatest difference between in-mold labeling (IML) and in-mold transfer (IMR) is whether a transparent protective film is provided 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 pattern is printed on the transparent film, the pattern is 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

SUMMERY OF THE UTILITY MODEL

The utility model provides a decorative molding article, include: the film forming device comprises a workpiece and a forming film attached to the outer surface of the workpiece. The above-mentioned 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; the optical hardening layer is arranged on the second decoration layer, wherein the first decoration layer, the second decoration layer and the optical hardening layer respectively comprise a protection material, an ink material and a bonding material; and the protective layer extends downwards from the top surface of the optical hardening layer to the second decoration layer.

In an embodiment of the present invention, the protection layer further extends to cover a top surface of the optical hardening layer.

The utility model provides a decorative molding article, include: the film forming device comprises a workpiece and a forming film attached to the outer surface of the workpiece. The above-mentioned formed film comprises: a substrate having a first surface and a second surface opposite to each other; an optical hardening layer disposed on the first surface of the substrate; a plurality of decorative layers disposed on the second surface of the substrate; an impact-resistant adhesion layer disposed between the plurality of decorative layers and an outer surface of the workpiece; and a protective layer disposed in the anti-impingement layer and extending into the plurality of decorative layers.

The utility model provides a decorative molding article, include: the film forming device comprises a workpiece and a forming film attached to the outer surface of the workpiece. The above-mentioned formed film comprises: a substrate having a first surface and a second surface opposite to each other; a first composite layer structure disposed on the first surface of the substrate, wherein the first composite layer structure includes a light-transmitting layer and an optical hardening layer; the second composite layer structure is arranged on the second surface of the substrate, wherein the second composite layer structure comprises a decorative layer and an anti-impact adhesion layer, and the anti-impact adhesion layer is in contact with the outer surface of the workpiece; and the protective layer extends downwards from the top surface of the optical hardening layer to the light-transmitting layer.

The utility model provides a decorative molding article, include: a workpiece and a formed film attached to an outer surface of the workpiece. The above-mentioned formed film comprises: a substrate having a first surface and a second surface opposite to each other; a decorative layer disposed on the first surface of the substrate; an optical hardening layer disposed on the decorative layer, wherein the second surface of the substrate contacts an outer surface of the workpiece; and a protective layer extending from the top surface of the optically hardened layer down into the decorative layer.

The utility model provides a decorative molding article, include: a workpiece and a formed film attached to an outer surface of the workpiece. The above-mentioned 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 between the first decorative layer and the first surface of the substrate; an optical hardening layer disposed on the first decoration layer; the anti-impact adhesion layer is arranged on the second surface of the base material and is contacted with the outer surface of the workpiece; the first protective layer extends downwards from the top surface of the optical hardening layer to the first decorative layer; and a second protective layer disposed in the anti-impingement layer.

The utility model provides a decorative molding article, include: a workpiece and a formed film attached to an inner surface of the workpiece. The above-mentioned 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; the anti-impact bonding layer is arranged on the second decoration layer, wherein the first decoration layer, the second decoration layer and the anti-impact bonding layer respectively comprise a protection material, an ink material and a bonding material; and the protective layer extends downwards from the top surface of the anti-impact adhesion layer to the second decoration layer.

The utility model provides a decorative molding article, include: a workpiece and a formed film attached to an inner surface of the workpiece. The above-mentioned formed film comprises: a substrate having first and second opposing surfaces, the first surface of the substrate contacting an inner surface of the workpiece; a first decorative layer disposed on the second surface of the substrate; a second decorative layer disposed between the first decorative layer and the substrate; and a protective layer disposed in the first decoration layer.

The utility model provides a decorative molding article, include: the film forming device comprises a workpiece and a forming film attached to the inner surface of the workpiece. The above-mentioned 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 between the first decorative layer and the first surface of the substrate; the anti-impact adhesion layer is arranged on the first decoration layer, so that the top surface of the anti-impact adhesion layer contacts the inner surface of the workpiece; the first protective layer is arranged in the anti-impact adhesion layer and the first decorative layer; and a second protective layer disposed in the substrate.

The utility model provides a decorative molding article, include: the film forming device comprises a workpiece and a forming film attached to the outer surface of the workpiece. The above-mentioned 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 decoration layer; a groove extending from the top surface of the optically hardened layer down into the second decorative layer; the coating layer is filled into the groove and is in contact with the first decorative layer; and a protective layer filled in the groove and disposed on the plating layer.

Based on the foregoing, the utility model discloses to unify coating formation more and carry out the solidification step on the substrate to form the composite bed structure that has protection effect, color effect and laminating 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. Additionally, the utility model discloses further form the protective layer part in the recess to the texture after the protection laser engraving avoids damaging, and then promotes composite bed structure's protecting effect and increase life. Furthermore, the utility model discloses a carry out laser engraving process before the plastic uptake forming technology after, consequently, the utility model discloses can solve prior art's counterpoint problem, and then promote the yield and reduce manufacturing cost.

On the other hand, compared with the conventional INS in which the ink layer or the printing layer is matched with the substrate bonding process, the stacked decorative layers of the present embodiment not only provide a variety of color effects, but also have a protection effect and a bonding effect, and do not need to perform an additional bonding process. In addition, compared to the conventional IML technique that an additional 3-10 layers of adhesive layers are required to be attached to the workpiece, the present embodiment does not require an additional adhesive layer. That is to say, the utility model discloses composite bed structure's manufacturing step can be effectively simplified to the composite bed structure that protective effect and laminating effect are better is provided. Furthermore, compared with the existing spraying technology, INS technology or IML technology, the manufacturing steps of the decorative molded product of the utility model are simplified, and the manufacturing cost is also effectively reduced.

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

Drawings

Fig. 1 is a schematic flow chart illustrating a method for manufacturing a decorated article according to a first embodiment of the present invention;

fig. 2A is a schematic cross-sectional view of a decorative molded article according to a first embodiment of the present invention;

fig. 2B is a schematic cross-sectional view of another decorative molded article according to the first embodiment of the present invention;

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

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

fig. 5 is a schematic flow chart illustrating 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 cross-sectional view of a decorative molded article according to a fourth embodiment of the present invention;

fig. 8 is a schematic cross-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 schematic flow chart of an off-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 cross-sectional view of a decorative molded article according to an eighth embodiment of the present invention;

FIGS. 13B and 13C are schematic top views of the structure of FIG. 13A without turning on the light source and turning on the light source, respectively;

fig. 14 is a schematic flow chart illustrating a method of manufacturing a decorated article according to a ninth embodiment of the present invention;

fig. 15A to 15E are schematic cross-sectional views illustrating a manufacturing process of a decorative molded article according to a ninth embodiment of the present invention.

Detailed Description

The present invention is described more fully hereinafter with reference to the accompanying drawings. The 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 illustrating a method for manufacturing a decorated article according to a first embodiment of the present invention. Fig. 2A is a schematic cross-sectional view of a decorative molded article according to a first embodiment of the present invention.

Referring to fig. 1 and 2A, a first embodiment of the present invention provides a manufacturing method S10 of a decorated molded article 10 as follows. Step S100 is performed to form a composite layer structure 110 (as shown in fig. 2A). Specifically, forming the composite layer structure 110 includes: step S102 is performed to form a first coating on the substrate 102 (as shown in fig. 2A) 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, an extrusion molding method may be used to heat melt, extrude, and cool the ABS solid plastic to form the ABS substrate 102. 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 using 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 matte surface and the like. In alternative embodiments, the material of the substrate 102 may also be wood veneer, aluminum sheet, steel plate, or the like, or a combination thereof.

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 (gravure printing) method, a screen printing (screen printing) method, a offset printing (offset printing) method, a reverse printing (reverse printing) method, a transfer 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 polymethyl methacrylate (PMMA), aliphatic Urethane acrylate (Aliphatic Urethane Diacrylate), 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 present 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. 2A) has different visual effects such as matting and pearling.

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 bonding material have been described in detail in the above paragraphs, and are not described in detail 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. 2A. 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 metallized 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. 2A, the composite layer structure 110 includes a first decoration layer 104, a second decoration layer 106, and an optical hardening 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. 2A, 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 addition, the optical hardening layer 108 may be formed on the second decoration layer 106 using a shower method, an imprint method, a 3D printing method, or an inkjet method, in addition to the coating method. In alternative embodiments, the optical hardening layer 108 material may be a UV material or a thermal curing material.

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. This first curing step may cause the conformable material to undergo a cross-linking reaction and conform to the substrate 102. In this embodiment, the coating can 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 step of purchasing a protective layer and forming the adhesive film structure through printing and laminating processes in the prior art, the utility model discloses can simplify manufacturing steps effectively, reduce manufacturing cost and prevent the produced pollution problem of adhesive film.

Compared with the existing INS technology that the ink layer or the printing layer is matched with the substrate, the stacked decorative layers of the embodiment not only provide a plurality of color effects, but also have a protection effect and a bonding effect, and do not need to be additionally bonded. That is to say, the utility model discloses composite bed structure's manufacturing step can be effectively simplified to the composite bed structure that protective effect and laminating effect are better is provided. Furthermore, compared with the existing spraying technology or INS technology, the manufacturing steps of the composite layer structure of the present invention are simplified, and the manufacturing cost can be effectively reduced.

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. 2A. In one embodiment, the substrate 102 has a first surface 102a and a second surface 102b opposite to each other. As shown in fig. 2A, the second surface 102b of the substrate 102 contacts the outer surface 200a of the workpiece 200, the first surface 102A of the substrate 102 contacts the first decorative layer 104, and the top surface 110a of the composite layer structure 110 is exposed upward. 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 schematic flow chart of an in-mold decoration technique according to an embodiment of the present invention. Fig. 10 is a schematic flow chart illustrating an exterior molding 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, the description thereof is omitted.

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 panel, a touch front, etc.), a car exterior trim panel (e.g., an exterior handle, a back door trim panel, a welcome pedal, 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 the shape and structure of the workpiece 200 that can be completed by the in-mold decoration technique are all the scope of the present invention.

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

On the other hand, the decorated article 10 may be manufactured by an outside 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 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. 2A 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 step of heating and softening 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 also 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 108a. That is, the hardness of the top surface 108a of the optical hardening layer 108 may be greater than the hardness of the bottom surface 108b of the optical hardening 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. 2A, recess 105 may extend downward from top surface 110a of composite layer structure 110 until top surface 104t of first decorative layer 104 is exposed. However, the present invention is not limited thereto, and in other embodiments, the groove 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. 2A 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 the consumer.

Thereafter, step S160 is performed to form a protective layer 112A in the groove 105. Specifically, the protective layer 112A may be formed using a three-dimensional (3D) printing technique. In one embodiment, the 3D Printing technique includes an Aerosol Jet Printing process. The aerosol spray printing process uses an aerosol jet deposition head (aerosol jet deposition head) to form an annular propagation nozzle consisting of an outer sheath flow (outer sheath flow) and an inner aerosol-laden carrier flow (inner aerosol-laden carrier flow). In the circular aerosol spray process, an aerosol stream (aerosol stream) of the material to be deposited is focused and deposited on the surface to be formed. The above steps may be referred to as Maskless Mesoscale Material Deposition (M3D), that is, they may be deposited without the use of a mask. In an alternative embodiment, the protective layer 112A may also be formed using inkjet Printing (Ink Jet Printing) techniques.

In the present embodiment, as shown in fig. 2A, the filling ink is filled into the groove 105 by the head of the 3D printing apparatus. In an embodiment, the filling ink may be similar to the third paint, and at least includes a protective material, an ink material and a bonding material, which are uniformly mixed, and a content of the protective material in the filling ink may be higher than a content of the protective material in the first paint or the second paint. In addition, after the filling ink is filled into the groove 105, an additional curing step may be performed to perform a cross-linking reaction on the protective material filled in the ink, thereby increasing the hardness of the protective layer 112A. In this case, the protection layer 112A can locally protect the laser-engraved texture, i.e., the first decoration layer 104 and the second decoration layer 106 exposed in the groove 105 from being damaged, so as to further enhance the protection effect of the composite layer structure 110 and increase the service life.

It should be noted that the nozzle used in the 3D printing technology of the present embodiment is small enough, so that the filling ink can be accurately filled in the groove to form a protection layer locally, thereby protecting the texture after laser engraving. Compared with the condition that the coating is greatly volatilized into the air by the common spraying technology, the 3D printing technology can effectively reduce the material consumption and reduce the manufacturing cost. In addition, the spray head of the general spraying technology is large, so that the spraying layer is in a dotted and discontinuous distribution, and the spraying effect is rough and uneven. Conversely, the nozzle of the 3D printing technology of the present embodiment is small enough, and the filling ink can be completely filled in the narrow groove and continuously distributed on the surface of the object, so that the protection layer is more flat and beautiful. In addition, the 3D printing technique of the present embodiment can also perform partial toning. That is, the present embodiment can fill different color protection layers in different groove positions according to the customer's requirement to increase the visual perception of the viewer.

In addition, although the protection layer 112A shown in fig. 2A is only located in the groove 105, that is, the top surface of the protection layer 112A is coplanar with the top surface 108a of the optical hardening layer 108, the present invention is not limited thereto. In other embodiments, as shown in FIG. 2B, the protective layer 112B may also extend from the groove 105 and cover the top surface 108a of the optical hardening layer 108. The extent or area of the extension portion of the protection layer 112B may be adjusted according to design requirements.

Referring back to fig. 2A, the decorative molded article 10 can be disposed on the light source 300 to emit light of different colors through the protection layer 112A in the groove 105. For example, the light source 300 may be blue light, the protection layer 112A is white transparent material, and the second decoration layer 106 may be a wood layer. When the light source 300 is not turned on, the consumer can see the laser engraved pattern with white light transmission and wood grain layer as the base from the visual surface 110a. On the other hand, when the light source 300 is turned on, the consumer can see the laser engraved pattern having the blue light effect from the viewing surface 110a through the protective layer 112A in the groove 105. In one embodiment, the light source 300 may include an LED point light source, an LED light bar, a mini LED, and the like. In addition, the protection layer 112A may have various colors to generate different color mixing effects in combination with the light source 300. For example, when the light source 300 is blue light and the protection layer 112A is red light-transmitting material, when the light source 300 is turned on, the consumer can see the laser engraved pattern with the purple light effect from the viewing surface 110a through the protection layer 112A in the groove 105. In alternative embodiments, the protection layer 112A may also be a semi-transparent material or an opaque material.

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 multi-color thin film is 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 if the post-laser engraving treatment is performed, the laser engraved film is peeled off or damaged due to poor surface properties, and thus an additional protective coating needs to be formed to protect the film, which leads to an increase in cost.

In order to solve the above problem, the embodiment of the utility model provides a to unify coating more and form and carry out the solidification step on the substrate to form the composite bed structure that has protection effect, color effect and laminating 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. In addition, compare in current spraying technique or INS technique, the utility model discloses a composite bed structure's manufacturing step is more simplified, also can effectively reduce manufacturing cost. Therefore, the formed film of the embodiment can be applied to the laser engraving process to form various light-transmitting decorative formed products. Furthermore, the present invention further forms the protection layer 112A or 112B locally in the groove 105 to protect the texture from being damaged after laser engraving, thereby improving the protection effect of the composite layer structure 110 and increasing the service life.

In addition, in the conventional in-mold labeling (IML) technique, a decorative layer of 3 to 5 layers is formed by screen printing on the back surface of a substrate (e.g., PC, PMMA, ABS, etc.), and then an adhesive layer of 3 to 10 layers is formed to be attached to a workpiece. Compared to the conventional IML technology, the substrate 102 of the present embodiment is melted by high temperature and high pressure during the injection molding process, and thus can be directly adhered to a portion of the outer surface 200a of the workpiece 200. That is, compared with the conventional IML technology, the present invention does not need to form an additional adhesion layer, so that the manufacturing steps of the decorated molded article are simplified and the manufacturing cost is reduced.

Fig. 3 is a schematic flow chart illustrating 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 present invention provides a method S20 for manufacturing 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 paint on the substrate 102 (as shown in fig. 4) by a coating method, a printing method, or a 3D printing method. Next, step S104 is performed to form a second paint on the first paint by a coating method, a printing method, or a 3D printing method. Then, step S107 is performed to form a fourth paint on the second paint by a coating method, a printing method, or a 3D 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 bonding material have been described in detail in the above paragraphs, and are not described in detail 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 paint may be higher than the content of the bonding material in the first paint or the second paint, so as to increase the adhesion between the composite layer structure 120 and the subsequently formed workpiece 200. 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. In addition to the coating method, the anti-adhesion layer 118 may be formed on the second decoration layer 106 by using a shower method, an embossing method, a 3D printing method, or an inkjet method. Compared with the existing INS printing ink layer or printing layer which needs to be matched with the bonding substrate process and the existing IML technology which needs to form 3-10 layers of bonding layers, the scour prevention bonding layer 118 of the embodiment not only provides a color effect, but also has high temperature resistance, a protection effect and a bonding effect, and does not need to form an additional bonding layer. That is to say, the utility model discloses can effectively simplify composite bed structure 120's manufacturing step to provide high temperature resistant, protection effect and the better composite bed structure 120 of laminating effect. Furthermore, compare in current spraying technique, INS or IML technique, the utility model discloses a manufacturing step of composite bed structure is more simplified, also can effectively reduce manufacturing cost.

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 present invention is not limited thereto, and in other embodiments, the groove 105 may have different depths.

Next, step S160 is performed to form a protection layer 212 in the groove 105. In one embodiment, the protection layer 212 may be formed using 3D printing techniques. Specifically, the filling ink is filled into the groove 105 by a nozzle of the 3D printing apparatus. In an embodiment, the filling ink may be similar to the fourth paint, and at least includes a protective material, an ink material and a bonding material, which are uniformly mixed, and a content of the bonding material in the filling ink may be higher than a content of the bonding material in the first paint or the second paint. Additionally, after filling the filling ink into the groove 105, an additional curing step may be performed to increase adhesion between the composite layer structure 120 and the subsequently formed workpiece 200. In this case, the protection layer 212 may locally protect the laser-engraved texture, i.e., the first decoration layer 104 and the second decoration layer 106 exposed in the groove 105 from being damaged, so as to further enhance the protection effect of the composite layer structure 120 and increase the service life. In an alternative embodiment, the protective layer 212 may also be formed using jet printing techniques.

In an alternative embodiment, the protective layer can be backfilled into the laser engraved transparent region (e.g., the groove 105) by using a 3D printing technique, and the 3D printing technique can also make different effects in the non-laser engraved transparent region, such as forming a logo or a gradient layer, and the like opaque film effect. Thereafter, an additional optical hardening layer is formed selectively using a shower method, an imprint method, a 3D printing method, or an inkjet method as appropriate.

Thereafter, step S170 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 may contact the top surface 120a of the composite layer structure 120 and the top surface of the protective layer 212. 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 deep crystal-like thickness texture. 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 present invention provides a method S30 for manufacturing 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 vacuum forming process to form a formed 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 present invention is not limited thereto, and in other embodiments, the groove 105 may have different depths.

Next, step S160 is performed to form a protection layer 312 in the groove 105. In one embodiment, the protection layer 312 may be formed using a 3D printing technique. Specifically, the filling ink is filled into the groove 105 by a nozzle of the 3D printing apparatus. In an embodiment, the filling ink may be similar to the fourth paint, and at least includes a protective material, an ink material and a bonding material, which are uniformly mixed, and a content of the bonding material in the filling ink may be higher than a content of the bonding material in the first paint or the second paint. In addition, after filling the filling ink into the groove 105, an additional curing step may be performed to increase the adhesion between the composite layer structure 130 and the light source 300. In this case, the protection layer 312 can locally protect the laser-engraved texture, i.e., the first decoration layer 104 and the second decoration layer 106 exposed in the groove 105 from being damaged, so as to further enhance the protection effect of the composite layer structure 130 and increase the service life. In an alternative embodiment, protective layer 312 may also be formed using jet printing techniques.

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 may contact the bottom surface 130b of the composite layer structure 130 and the bottom surface of the protection layer 312. 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 this embodiment, as shown in fig. 6, the decorative molded article 30 can emit light of different colors through the protection layer 312 in the groove 105. For example, the light source 300 may be blue light, the protection layer 312 is white transparent material, and the second decoration 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 geometric pattern from the viewing surface 200a through the protective layer 312 in the groove 105. In addition, the protection layer 312 may have various colors to generate different color mixing effects in combination with the light source 300.

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 decorative 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 optical hardening 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 optically hardened 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 optical hardening layer 108 may be formed on the first surface 102a of the substrate 102 using a shower method, an imprint method, a 3D printing method, or an inkjet method, in addition to the coating method.

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, from bottom to top, an anti-impact adhesion layer 118, a buffer layer (or decoration layer) 142, a third decoration layer 144, and a fourth decoration layer 146. 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 addition to the coating method, the impact-resistant layer 118 may be formed by a shower method, an imprint method, a 3D printing method, or an inkjet method. 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 of the second paint, and 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, or the like. 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 present invention is not limited thereto, and in other embodiments, a plurality of decoration layers stacked alternately may be formed 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, and the groove 105 can be filled with the protection layer 412 by using a 3D printing technique or a jet printing technique. The material and formation method of the protection layer 412 are the same as those of the protection layers 212 and 312, and thus are not described herein again. In other embodiments, the protective layer 412 may also have different depths. That is, protective layer 412 may also extend up into third decorative layer 144 and/or fourth decorative layer 146. The outer surface 200a of the workpiece 200 may contact the bottom surface 140b of the composite layer structure 140 and the bottom surface of the protective layer 412.

In this embodiment, as shown in fig. 7, the decorative molded article 40 can emit light of different colors through the protective layer 412 in the groove 105. For example, the light source 300 may be blue light, the protection layer 412 may be white transparent material, and the fourth decoration layer 146 may be an evaporated metal layer with 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 108a. 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 protective layer 412 in the groove 105. In addition, the protection layer 412 may have various colors to generate different color mixing effects in combination with the light source 300.

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 decorated 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. In addition to the coating method, the optical cured layer 108 may be formed by a shower method, an imprint method, a 3D printing method, or an inkjet method.

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 anti-impact 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 can be formed by the second paint, and can 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%. In addition to the coating method, the impact-resistant layer 118 may be formed by a shower method, an imprint method, a 3D printing method, or an inkjet method.

It is noted that the decorative molded article 50 further includes a groove 105 formed in the first composite layer structure 150, and the groove 105 can be filled with the protection layer 512 by using a 3D printing technique or a jet printing technique. The material and formation method of the protection layer 512 are the same as those of the protection layers 112A and 112B, and thus are not described herein again. In the present embodiment, the protection layer 512 may extend from the top surface 108a of the optical hardening layer 108 down to 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 can 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 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 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. In addition to the coating method, the optical hardening layer 108 may be formed by a shower method, an imprint method, a 3D printing method, or an inkjet method.

It is noted that the decorative molding 60 further includes a groove 105 formed in the composite layer structure 170, and the groove 105 may be filled with the protective layer 612 by using a 3D printing technique or a jet printing technique. The material and formation method of the protection layer 612 are the same as those of the protection layers 112A and 112B, and thus are not described again. In the present embodiment, the protective layer 612 may extend from the top surface 108a of the optical hardening layer 108 down into the fourth decoration 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 of the structure of fig. 12A without turning on the light source and turning on the light source, respectively.

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 optically hardened 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 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 100G from the top surface 108a of the optically hardening layer 108 downward. In the present embodiment, the third decoration layer 144 can be formed by the first paint, which can be printed one or more times to present different decoration patterns such as wood grain, geometric pattern, etc. Fourth decorative layer 146 may be formed of the second paint, 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 via the impact resistant layer 118. In addition to the coating method, the optical hardening layer 108 and the impact-resistant layer 118 may be formed by a shower method, an imprint method, a 3D printing method, or an inkjet method.

It is noted that the decorative molding 70 further includes a first groove 105a and a second groove 105B, and the first protection layer 712A is filled in the first groove 105a and the second protection layer 712B is filled in the second groove 105B by using a 3D printing technique or a jet printing technique. In one embodiment, the first protection layer 712A and the second protection layer 712B have different material compositions. Specifically, the material of the first protective layer 712A may be similar to the third paint described above, and the second protective layer 712B may be similar to the fourth paint described above. The content of the protective material in the first protective layer 712A may be higher than the content of the protective material in the second protective layer 712B, and the content of the bonding material in the second protective layer 712B may be higher than the content of the bonding material in the first protective layer 712A. As can be seen from fig. 12A, the first protective layer 712A is formed in the composite layer structure 180. That is, the first protective layer 712A extends from the top surface 108a of the optically hardening layer 108 down into the third decorative layer 144. The second protection layer 712B is formed in the landing layer 118. That is, the decorative molded article 70 of the present embodiment can form the first protection layer 712A and the second protection layer 712B on two opposite sides (i.e., the upper side and the lower side) respectively, so as to increase different light-transmitting areas and further enhance the visual perception of the consumer.

In the present embodiment, as shown in fig. 12B and 12C, the decorative molding product 70 can emit light of different colors through the first protective layer 712A and the second protective layer 712B in the grooves 105a and 105B. For example, the light source 300 may be blue light, the protection layers 712A and 712B may be white transparent materials, the third decoration layer 144 may be a wood-grain layer, and the fourth decoration layer 146 may be an evaporated metal layer with a transparency of 50%. When the light source 300 is not turned on, the consumer can see the wood grain layer with the metal edging from the viewing surface 108a through the first protective layer 712A in 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 metal edge strips and blue light characters from the visual surface 108a through the first protection layer 712A in the first groove 105a and the second protection layer 712B in the second groove 105B. In addition, the protection layers 712A and 712B may have different colors to generate different color mixing effects in combination with the light source 300.

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 of the structure of fig. 13A without turning on the light source and turning on the light source, respectively.

Referring to fig. 13A, the decorative 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 trim layer 144 may be disposed between fourth trim layer 146 and impact resistant 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. In addition to the coating method, the resist layer 118 may be formed by a shower method, an imprint method, a 3D printing method, or an inkjet method.

It is noted that the decorative molding 80 further includes a first groove 105a and a second groove 105B, and the first passivation layer 812A is filled in the first groove 105a and the second passivation layer 812B is filled in the second groove 105B by using a 3D printing technique or a jet printing technique. In one embodiment, the first protection layer 812A and the second protection layer 812B have the same material composition. Specifically, the materials of the first protection layer 812A and the second protection layer 812B may be similar to the fourth coating for forming the anti-impact layer, and thus are not described again. As can be seen from fig. 13A, a first protective layer 812A is formed in the composite layer structure 190. That is, first protective layer 812A extends from top surface 118a of impingement layer 118 down into third decorative layer 144. A second passivation layer 812B is formed in the substrate 102 to extend from the first surface 102a to the second surface 102B. That is to say, 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 consumers.

In this embodiment, as shown in fig. 13B and 13C, the decorative molding 80 can emit light of different colors through the first protective layer 812A and the second protective layer 812B in the grooves 105a and 105B. For example, the light source 300 may be blue light, the protection layers 812A and 812B may be white transparent materials, the third decoration layer 144 may be a wood-grain layer, and the fourth decoration 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 viewing surface 200a through the first protective layer 812A in the first groove 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 having the metal edge strips and the blue characters from the visual surface 200a through the first protection layer 812A in the first groove 105a and the second protection layer 812B in the second groove 105B. In addition, the protection layers 812A and 812B may have different colors to generate different color mixing effects in combination with the light source 300.

Fig. 14 is a schematic flow chart illustrating a method for manufacturing a decorative molded article according to a ninth embodiment of the present invention. Fig. 15A to 15E are schematic cross-sectional views illustrating a manufacturing process of a decorative molded article according to a ninth embodiment of the present invention.

Referring to fig. 14 and 15A, a ninth embodiment of the present invention provides a method S40 for manufacturing a decorated molded article 90 as follows. First, step S100 is performed to form a composite layer structure 110 (as shown in fig. 15A). Step S100 has already been described in detail in the above paragraphs, and is not described herein again. After the composite layer structure 110 is formed, a step S120 is performed to perform a vacuum forming process to form a formed film 100I.

Then, step S130 is performed to perform an in-mold decoration technique or an out-mold decoration technique so that the formed film 100I is attached to the outer surface 200a of the workpiece 200 to form the decorated formed article 90, as shown in fig. 15A. 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.

Referring back to fig. 14, 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.

Next, step S142 is performed to form a mask layer 902 on the composite layer structure 110. In one embodiment, as shown in fig. 15A, the mask layer 902 covers the top surface 110a of the composite layer structure 110.

Then, step S150 is performed to perform a laser engraving process to form a groove 905 in the mask layer 902 and the composite layer structure 110. As shown in fig. 15B, recess 905 may pass through masking layer 902 and extend downward from top surface 110a of composite layer structure 110 until top surface 104t of first decorative layer 104 is exposed. However, the present invention is not limited thereto, and in other embodiments, the groove 905 may have different depths. That is, bottom surface 905bt of recess 905 may be higher or lower than top surface 104t of first decorative layer 104, or bottom surface 905bt of recess 905 may be higher, equal or lower than top surface 106t of second decorative layer 106. In addition, although fig. 15B shows only a single groove 905, the present invention is not limited thereto, and in an alternative embodiment, the decorative molded article 90 may have a plurality of grooves to form various laser engraved patterns, so as to increase the visual perception of the consumer.

Thereafter, in step S152, a plating layer 904 is formed by evaporation or sputtering. Specifically, plating layer 904 may fill in recess 905 and cover the top surface of mask layer 902. Notably, the plating layer 904 does not fill the recess 905. That is, the plating layer 904 overlies the bottom 905bt of the groove 905, but exposes a portion of the sidewall 905sw of the groove 905, as shown in fig. 15C. In one embodiment, the material of the plating layer 904 comprises a metallic material. In this embodiment, the plating layer 904 may be a sputtered metal layer.

Then, in step S154, the mask layer 902 is removed. Specifically, the plating layer 904 over the mask layer 902 may also be removed at the same time as the mask layer 902 is removed. That is, after the mask layer 902 is removed, the remaining plating layer 904 is disposed only in the groove 905, as shown in fig. 15D.

Thereafter, step S160 is performed to form the protective layer 912 in the groove 905 such that the protective layer 912 covers and seals the plating layer 904. Specifically, the protective layer 912 may be formed using a 3D printing technique or a jet printing technique. The material and formation method of the protection layer 912 are the same as those of the protection layers 112A and 112B, and thus are not described again. It is noted that in the present embodiment, the protection layer 912 can locally protect the texture after laser engraving, i.e. the plating layer 904 exposed to the groove 905 and the second decoration layer 106 are protected from being damaged, so as to further enhance the protection effect of the composite layer structure 110 and increase the service life.

In addition, although the protection layer 912 is only located in the groove 905 as shown in fig. 15E, the present invention is not limited thereto. In other embodiments, a protective layer (not shown) may also extend from the recess 905 and cover the top surface 108a of the optical hardening layer 108. The range or area of the extension portion can be adjusted by the protection layer according to design requirements.

Referring back to fig. 15E, the decorative molded article 90 can be disposed on the light source 300 to emit light of different colors through the protection layer 912 in the recess 905. For example, the light source 300 may be blue light, the coating 904 is a sputtered silver layer with a transparency of 50%, the protection layer 912 is a white transparent material, and the second decoration layer 106 may be a wood-grain layer. When the light source 300 is not turned on, the consumer can see the laser engraved pattern with the metal silver color and with the wood-grain layer as the base from the visual surface 110a. On the other hand, when the light source 300 is turned on, the consumer can see the laser engraved pattern with the silver-blue metal effect from the visual face 110a through the protective layer 912 in the groove 905.

The process of performing steps S142 to S160 to form the plating layer and the protective layer in the groove may be applied to any one of the decorative moldings 20, 30, 40, 50, 60, 70, and 80. For example, after steps S142 to S160 are performed to form the plating layer and the protective layer in the groove, step S170 is performed, i.e., an in-mold decoration technique or an out-mold decoration technique is performed, so that the formed film is attached to the inner surface of the workpiece. In this embodiment, the protective layer is similar to the fourth paint used to form the anti-erosion layer because the protective layer is adhered to the inner surface of the workpiece. That is, the process of forming the plating layer and the passivation layer partially in the recess can be applied to various structures of the decorative molding product according to the product requirement.

Any of the decorative molded articles 10, 20, 30, 40, 50, 60, 70, 80, and 90 may be applied to a vehicle lamp. That is, any one of the decorative moldings 10, 20, 30, 40, 50, 60, 70, 80, 90 may be attached to a plastic housing of a vehicle lamp to present various color effects by laser engraving patterns (e.g., grooves 105). For example, the present invention can correspond the plurality of grooves 105 to the lamp bodies with different colors, so that the brake lamp presents red light through the first groove, the left-turn lamp presents yellow light through the second groove, and the headlight presents white light through the third groove.

Although the method of manufacturing S40 of fig. 14 is illustrated and described herein as a series of acts or events, it will be appreciated that the illustrated ordering of such acts or events are not to be interpreted in a limiting sense. That is, certain acts may occur in different orders and/or concurrently with other acts or events apart from those illustrated and/or described herein. For example, the formation of the mask layer, the laser engraving process and the 3D printing step are all the scope protected by the present invention regardless of the process sequence. Additionally, not all illustrated acts may be required to implement one or more aspects or embodiments described herein. Further, one or more of the acts illustrated herein may be performed in one or more separate acts and/or phases.

To sum up, the utility model discloses to unify coating formation more and carry out the solidification step on the substrate to form the composite bed structure that has protection effect, color effect and laminating 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. Additionally, the utility model discloses further form the local formation of protective layer in the recess to the texture after the protection laser engraving is avoided damaging, and then promotes composite bed structure's protecting effect and increase life. Furthermore, the utility model discloses a carry out laser engraving process after the plastic uptake forming process, consequently, the utility model discloses can solve prior art's counterpoint problem, and then promote the yield and reduce manufacturing cost.

On the other hand, compared with the existing INS in which the ink layer or the printing layer is matched with the substrate bonding process, the stacked decorative layers of the embodiment not only provide a plurality of color effects, but also have a protection effect and a bonding effect, and do not need to perform an additional bonding process. In addition, compared to the conventional IML technique that an additional 3-10 layers of adhesive layers are required to be attached to the workpiece, the present embodiment does not require an additional adhesive layer. That is to say, the utility model discloses composite bed structure's manufacturing step can be effectively simplified to the composite bed structure that protective effect and laminating effect are better is provided. Furthermore, compared with the existing spraying technology, INS technology or IML technology, the manufacturing steps of the decorative molded product of the utility model are simplified, and the manufacturing cost is also effectively reduced.

Although the present invention has been described with reference to the above embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention, and the scope of the invention is to be determined by the appended claims.

Claims (10)

1. 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 protective layer extending from a top surface of the optically hardened layer down into the second decorative layer.

2. The decorated article of claim 1, wherein the protective layer further extends over the top surface of the optically hardened layer.

3. A decorated molded article, comprising:

a workpiece; and

a formed film affixed 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;

an optical hardening layer disposed on the first surface of the substrate;

a plurality of decorative layers disposed on the second surface of the substrate;

an anti-impingement layer disposed between the plurality of decorative layers and the outer surface of the workpiece; and

and the protective layer is arranged in the anti-impact adhesion layer and extends into the decorative layers.

4. A decorated molded article, comprising:

a workpiece; and

a formed film affixed 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 composite layer structure disposed on the first surface of the substrate, wherein the first composite layer structure includes a light transmissive layer and an optically hardened layer;

a second composite layer structure disposed on the second surface of the substrate, wherein the second composite layer structure includes a decorative layer and an anti-impingement layer, and the anti-impingement layer contacts the outer surface of the workpiece; and

and the protective layer extends downwards from the top surface of the optical hardening layer to the light-transmitting layer.

5. 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 decorative layer disposed on the first surface of the substrate;

an optically hardening layer disposed on the decorative layer, wherein the second surface of the substrate contacts the outer surface of the workpiece; and

a protective layer extending from a top surface of the optically hardened layer down into the decorative layer.

6. A decorated molded article, comprising:

a workpiece; and

a formed film affixed 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 between the first decorative layer and the first surface of the substrate;

an optically hardened layer disposed on the first decorative layer;

an anti-impingement layer disposed on the second surface of the substrate and in contact with the outer surface of the workpiece;

a first protective layer extending from a top surface of the optically hardened layer down into the first decorative layer; and

and a second protective layer disposed in the anti-impingement layer.

7. A decorated molded article, comprising:

a workpiece; and

a formed film affixed to the inner 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 anti-impingement layer disposed on the second decorative layer, wherein the first decorative layer, the second decorative layer, and the anti-impingement layer each comprise a protective material, an ink material, and a bonding material; and

a protective layer extending downwardly from a top surface of the strike-resistant layer into the second decorative layer.

8. A decorated molded article, comprising:

a workpiece; and

a formed film affixed to the inner surface of the workpiece, wherein the formed film comprises:

a substrate having opposing first and second surfaces, the first surface of the substrate contacting the inner surface of the workpiece;

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

a second decorative layer disposed between the first decorative layer and the substrate; and

and a protective layer disposed in the first decorative layer.

9. A decorated molded article, comprising:

a workpiece; and

a formed film attached to the inner 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 between the first decorative layer and the first surface of the substrate;

an anti-impingement layer disposed on the first decorative layer such that a top surface of the anti-impingement layer contacts the inner surface of the workpiece;

a first protective layer disposed in the impact-resistant layer and the first decorative layer; and

a second protective layer disposed in the substrate.

10. A decorated molded article, comprising:

a workpiece; and

a formed film affixed 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 decoration layer;

a groove extending from a top surface of the optically hardened layer down into the second decorative layer;

the coating layer is filled in the groove and is in contact with the first decorative layer; and

and the protective layer is filled in the groove and is arranged on the plating layer.

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