CN219446372U

CN219446372U - Decorative molded article

Info

Publication number: CN219446372U
Application number: CN202222854741.9U
Authority: CN
Inventors: 余泽民; 应国良
Original assignee: Jin Ya Dian Technology Co ltd
Current assignee: Jin Ya Dian Technology Co ltd
Priority date: 2022-08-30
Filing date: 2022-10-28
Publication date: 2023-08-01
Anticipated expiration: 2032-10-28
Also published as: CN117656625A

Abstract

The present utility model provides an ornamental molded article comprising: the workpiece and the forming film attached to the outer surface or the indoor surface of the workpiece. Compared with the film products manufactured by matching the printing layers in the existing IML and INS with a plurality of anti-impact and bonding processes, the plurality of stacked decorative layers of the embodiment not only provide various color effects, but also can be directly combined with injection molding materials to form part products, and also has the protection effect and the bonding effect. In addition, the utility model can effectively simplify the manufacturing steps of the composite layer structure and reduce the manufacturing cost.

Description

Decorative molded article

Technical Field

The present utility model relates to an ornamental molded article.

Background

In general, decoration such as patterns or characters formed on the surface of an object housing is mainly formed through spraying (painting) or printing (printing) processes so as to present a specific visual effect and add variability to the appearance of the object. The traditional forming method is to coat a hardening layer on the surface of the shell by using a spraying mode after the shell of the related product is finished, and the method has complex process, poor yield and causes pollution of organic solvent gas, thus causing a plurality of pollution problems. On the other hand, the spraying process is not suitable for mass production because of the disadvantages of time consumption, complicated process, low thickness uniformity, etc.

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

Materials for polymeric substrates commonly used in-mold decoration technology today include Polycarbonate (PC), polymethyl methacrylate, also known as poly-acrylic (Poly (methyl methacrylate), PMMA), polyhexene terephthalate (PET, polyethylene Terephthalate), and acrylonitrile-butadiene-styrene copolymer (Acrylonitrile Butadiene Styrene, ABS). However, the hardness of the substrate composed of PC and ABS is low, so that the surface of the substrate is easily damaged, and thus the hardness and scratch resistance of the substrate surface are mostly increased by coating a protective layer. On the other hand, a substrate made of PMMA has high hardness, but is likely to crack during molding, and thus it is difficult to perform a hot pressing process.

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

In particular, in-mold decoration techniques (IMDs) may include: in Mold Labeling (IML), in Mold Film (IMF or INS), in Mold Roller (IMR), as shown In table 1 below. The in-mold labeling (IML) process features that the surface is one hardened transparent film, the middle printed pattern layer and the back plastic layer. The ink is clamped between the hardened transparent film and the plastic layer, so that the product can prevent the surface from being scratched, is wear-resistant, and can keep the vividness of the color for a long time and is not easy to fade. The IML process flow is as follows:

(1) Cutting: a roll-like film substrate (typically PMMA/PC or PET or PC substrate with a protective coating) is cut to a size designed for printing and suction molding.

(2) Plane printing: in general, screen printing (silk screen printing) and spray printing processes are used to provide icon and text effects and finally anti-impact adhesive materials, and printing passes are generally designed according to the design pattern effect of the product, and particularly, the anti-impact adhesive materials are required to be matched with high-temperature and high-pressure molding injection molding plastic materials (generally, the injection molding temperature is more than about 200 degrees), so that multiple stacking printing processes are generally required, and the cost is increased, the use efficiency of adhesive films is reduced, and the overall yield is reduced.

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

(4) Sticking a protective film: the surface of the printed film is prevented from being damaged by punching positioning holes at the rear section, and a protective film is required to be attached to protect the surface.

(5) Punching positioning holes: because the film has shrinkage condition in the molding and heating process, the design of punching positioning holes is needed, so that the precision of positioning the printed film and matched products is ensured.

(6) High temperature and high pressure molding: after the printed film is subjected to high temperature and high heat, a forming machine is used for carrying out plastic suction under the preheating condition.

(7) Cutting shape: cutting the three-dimensional film after plastic suction by cutting or laser cutting to cut off the waste material.

(8) Injection molding: and finally, placing the cut three-dimensional film on an injection molding machine for injection molding to form a finished part and inspecting physical properties of related shipment.

The in-mold transfer printing (IMR) process is to print a pattern on a film, attach a film to a mold cavity by a film feeder, perform injection molding, separate an ink layer with the pattern from the film after injection molding, and leave the ink layer on the molded part to obtain the molded part with a decorative pattern on the surface. Thus, the surface of the final product is free of a transparent protective film, and the film 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 the product surface has a transparent protective film. In addition, in-mold films (IMFs) are similar to in-mold labeling (IMLs).

TABLE 1

Disclosure of Invention

The present utility model provides an ornamental molded article comprising: 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; the second decorative layer is configured on the first decorative layer; and an optical hardening layer disposed on the second decorative layer. The first decorative layer, the second decorative layer and the optical hardening layer respectively comprise a protective material, an ink material and a bonding material, and the optical hardening layer has a flat top surface.

In an embodiment of the utility model, a content of the protective material of the optical hardening layer is higher than a content of the protective material of the first decorative layer and higher than a content of the protective material of the second decorative layer.

The present utility model provides an ornamental molded article comprising: 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; 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; and an anti-impact adhesive layer disposed between the plurality of decorative layers and the outer surface of the workpiece. The adhesive material content of the anti-impact adhesive layer is higher than that of the plurality of decorative layers.

The present utility model provides an ornamental molded article comprising: 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; the first composite layer structure is configured on the first surface of the substrate, and comprises a light-transmitting layer and an optical hardening layer, wherein the optical hardening layer is provided with a flat top surface; and a second composite layer structure disposed on the second surface of the substrate, wherein the second composite layer structure comprises a decorative layer and an anti-impact bonding layer, and the anti-impact bonding layer contacts the outer surface of the workpiece. The adhesive material content of the anti-impact adhesive layer is higher than that of the decorative layer.

The present utility model provides an ornamental molded article comprising: 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; and an optical hardening layer disposed on the decoration layer, wherein the second surface of the substrate contacts the outer surface of the workpiece. The optical hardening layer has a flat top surface, and the content of the protective material of the optical hardening layer is higher than that of the decorative layer.

The present utility model provides an ornamental molded article comprising: 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 decorative layer, wherein the optical hardening layer has a flat top surface; and an anti-impact bonding layer which is configured on the second surface of the base material and is contacted with the outer surface of the workpiece. The adhesive material of the anti-impact adhesive layer is higher than the adhesive material of the first decorative layer and higher than the adhesive material of the second decorative layer.

The present utility model provides an ornamental molded article comprising: 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; the second decorative layer is configured on the first decorative layer; the anti-impact bonding layer is arranged on the second decorative layer. The first decorative layer, the second decorative layer and the anti-impact adhesive layer respectively comprise a protective material, an ink material and a bonding material. The adhesive material of the anti-impact adhesive layer is higher than the adhesive material of the first decorative layer and higher than the adhesive material of the second decorative layer.

The present utility model provides an ornamental molded article comprising: a workpiece and a formed film attached to an inner surface of the workpiece. The above-mentioned formed film comprises: a substrate having opposing first and second 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; and a second decorative layer disposed between the first decorative layer and the substrate. The first decorative layer has a flat bottom surface.

In an embodiment of the utility model, the first decorative layer and the second decorative layer have different ink materials.

The present utility model provides an ornamental molded article comprising: 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 between the first decorative layer and the first surface of the substrate; and an anti-impact bonding layer arranged on the first decorative layer so that the top surface of the anti-impact bonding layer contacts the inner surface of the workpiece. The adhesive material of the anti-impact adhesive layer is higher than the adhesive material of the first decorative layer and higher than the adhesive material of the second decorative layer.

Based on the above, the utility model forms the all-in-one coating on the substrate and carries out the curing step, thereby forming the composite layer structure with the protection effect, the color effect and the attaching effect. The composite layer structure can form a formed film with better physical properties (such as higher hardness, better protection effect and the like) after the plastic sucking forming process. In addition, compared with the existing INS in which the ink layer or the printing layer is matched with the substrate laminating process, the plurality of stacked decorative layers of the embodiment not only provide various color effects, but also have the protection effect and the laminating effect, and do not need to carry out additional laminating processes. In addition, compared with the existing IML technology, 3-10 layers of anti-impact adhesive layers are required to be formed additionally to be attached on the workpiece, and the embodiment does not need to form additional adhesive layers. That is, the utility model can effectively simplify the manufacturing steps of the composite layer structure and provide the composite layer structure with better protection effect and bonding effect. Furthermore, compared with the prior 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 can be effectively reduced.

In order to make the above features and advantages of the present utility model more comprehensible, embodiments accompanied with figures are described in detail below.

Drawings

FIG. 1 is a schematic flow chart of a method for producing an decorated molded article according to a first embodiment of the utility model;

FIG. 2 is a schematic cross-sectional view of an decorated molded article according to the first embodiment of the utility model;

FIG. 3 is a schematic flow chart of a method for producing an decorated molded article according to a second embodiment of the utility model;

FIG. 4 is a schematic cross-sectional view of an decorated molded article according to the second embodiment of the utility model;

FIG. 5 is a schematic flow chart of a method for producing an decorated molded article according to a third embodiment of the utility model;

FIG. 6 is a schematic cross-sectional view of an decorated molded article according to the third embodiment of the utility model;

FIG. 7 is a schematic cross-sectional view of an decorated molded article according to the fourth embodiment of the utility model;

FIG. 8 is a schematic cross-sectional view of an decorated molded article in accordance with the fifth embodiment of the utility model;

FIG. 9 is a flow chart of an in-mold decoration technique according to an embodiment of the utility model;

FIG. 10 is a schematic flow chart of an out-mold decoration technique according to an embodiment of the utility model;

FIG. 11 is a schematic cross-sectional view of an decorated molded article according to the sixth embodiment of the utility model;

FIG. 12 is a schematic cross-sectional view of an decorated molded article according to the seventh embodiment of the utility model;

fig. 13 is a schematic cross-sectional view of an decorated molded article according to the eighth embodiment of the utility model.

Detailed Description

The present utility model will be described more fully hereinafter with reference to the accompanying drawings. This utility model may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. The directional terms mentioned in the following embodiments, such as "upper", "lower", etc., are only with reference to the directions of the attached drawings, and thus the directional terms are used for the detailed description, not for limiting the present utility model. In addition, the thickness of layers and regions in the drawings may be exaggerated for clarity. The same or similar elements are denoted by the same or similar element numbers, and the following paragraphs will not be repeated.

Fig. 1 is a schematic flow chart of a method for producing an decorated molded article according to a first embodiment of the utility model. Fig. 2 is a schematic cross-sectional view of an decorated molded article according to the first embodiment of the utility model.

Referring to fig. 1 and 2, a first embodiment of the present utility model provides a method S10 for manufacturing an ornamental molded product 10 as follows. Step S100 is performed to form a composite layer structure 110 (shown in fig. 2). Specifically, forming the composite layer structure 110 includes: step S102 is performed to form a first coating material on the substrate 102 (shown in fig. 2) by a coating method or a printing method. In one embodiment, the material of the substrate 102 comprises Acrylonitrile Butadiene Styrene (ABS), polycarbonate (PC), polymethyl methacrylate (PMMA), or a combination thereof, and the forming method comprises extrusion molding or the like. For example, an ABS solid plastic may be heated to melt, extruded, and cooled to shape the ABS substrate 102 using an extrusion molding process. In addition, ABS solid plastic, color masterbatch, pigment, pearl powder and relevant additives can be firstly mixed to form a mixture. Then, the mixture is extruded by an extrusion molding method to form another ABS substrate, so that the ABS substrate has the visual effects of color, pearlescence, bright surface, mirror surface, extinction fog surface and the like. In alternative embodiments, the material of the substrate 102 may be wood veneer, aluminum sheet, steel sheet, or the like, or a combination thereof.

Specifically, the coating method is to dispense the coating material in a coating apparatus and uniformly coat the coating material on the substrate 102 by a coating head of the coating apparatus. In one embodiment, the opening of the coating head may be planar to provide a shiny 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., micro-dents) to provide a matting effect to the coating applied to the substrate 102. In an alternative embodiment, the opening of the coating head may have a plurality of concave-convex structures so that the coating applied on the substrate 102 has a hairline effect. On the other hand, the printing method may include a suitable printing method such as a gravure printing method, a screen printing method, a offset printing method, a reverse printing method, a transfer printing method, or an inkjet printing method. The printing process may form a thinner film layer than the coating process.

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 paint further includes: heat resistant material, solvent and hardening agent. 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 a polyisocyanate (Aromatic Urethane Diacrylate) and the like. However, the present utility model is not limited thereto, and in other embodiments, the first coating may further include other additives, such as matting agents, pearl powder, etc., so that the subsequently formed first decorative layer 104 (shown in fig. 2) has different visual effects such as matting, pearlescence, etc.

Next, step S104 is performed to form a second coating material on the first coating material by a coating method or a printing method. In one embodiment, the second coating includes at least: the protective material, the ink material and the bonding material are uniformly mixed together. In addition, the coating method, printing method, protective material, ink material and adhesive material are described in detail in the above paragraphs, and will not be repeated here. It should be noted that the first coating is used to form the first decorative layer 104, and the second coating is used to form the second decorative layer 106, as shown in fig. 2. In this embodiment, the first coating and the second coating have different compositions to achieve different visual effects. In another embodiment, the decorative layer 104 or 106 may also be vapor deposited or sputtered to achieve a metallized decorative 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 matt silver color, such that the composite layer structure 110 presents a matt silver wood grain pattern.

Then, step S106 is performed to form a third coating material on the second coating material by a coating method or a printing method. In one embodiment, the third coating includes at least: the protective material, the ink material and the bonding material are uniformly mixed together. In addition, the coating method, printing method, protective material, ink material and adhesive material are described in detail in the above paragraphs, and will not be repeated here. It should be 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 coating may be higher than the content of the protective material in the first coating or the second coating.

After that, step S108 is performed, and a first curing step is performed to form the composite layer structure 110. As shown in fig. 2, the composite layer structure 110 includes a first decorative layer 104, a second decorative layer 106, and an optical hardening layer 108. The first decorative layer 104 may be disposed on the first surface 102a of the substrate 102. The second decorative layer 106 may be disposed on the top surface 104t of the first decorative layer 104. The optical hardening layer 108 may be disposed on the top surface 106t of 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 bottom surface 108b of the optical hardening layer 108. Although only two decorative layers 104, 106 are shown in fig. 2, the utility model is not limited thereto, and in other embodiments, the composite layer structure 110 may also have a plurality of (e.g., three, four or more) stacked decorative layers. In addition, the optical hardening layer 108 may be formed on the top surface 106t of the second decoration layer 106 by a film coating method, an embossing method, a 3D printing method, or a spray printing method. In alternative embodiments, the material of the optical hardening layer 108 may also be a UV material or a thermally cured 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 allow the bonding material to crosslink and bond to the substrate 102. In this embodiment, the coating can be regarded as an all-in-one (all-in-one) coating, which can allow the cured composite layer structure 110 to have a protective effect, a color effect and a bonding effect. In this case, the composite layer structure 110 may also be referred to as an all-in-one composite layer structure. Compared with the prior art, which needs to purchase a protective layer and form a glue film structure through printing and attaching processes, the utility model can effectively simplify the manufacturing steps, reduce the manufacturing cost and prevent the pollution problem caused by the glue film.

Compared with the existing INS in which the ink layer or the printing layer is matched with the substrate laminating process, the stacked decorative layers of the embodiment not only provide various color effects, but also have the protection effect and the laminating effect, and do not need to carry out additional laminating process. That is, the utility model can effectively simplify the manufacturing steps of the composite layer structure and provide the composite layer structure with better protection effect and bonding effect. Furthermore, compared with the prior spraying technology or INS technology, the manufacturing steps of the composite layer structure of the utility model are simplified, and the manufacturing cost can be effectively reduced.

In alternative embodiments, after one or more decorative layers are formed on the substrate 102 using a coating process, 3D printing, the 3D printing may be subsequently reused to effect, such as forming a logo (logo) or a gradient. Then, the optically hardened layer is formed by selectively using a film coating method, an embossing method, a 3D printing method, or a spray printing method as appropriate.

After forming the composite layer structure 110, a step S120 is performed, and a plastic suction forming process is performed to form the formed film 100A. In one embodiment, the suction molding 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 shape the softened composite layer structure 110 and the substrate 102 into a desired shape; a cooling step is carried out; and cutting the excess portion to form the formed film 100A.

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

FIG. 9 is a flow chart of an in-mold decoration technique according to an embodiment of the utility model. FIG. 10 is a flow chart of an out-mold decoration technique according to an embodiment of the utility model.

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

Next, step S204 is performed to dispose the molded film 100A in the in-mold decoration mold. In detail, the in-mold decoration mold comprises a hollow mold cavity. The mold cavity has a surface. Then, the molding film 100A is attached to the surface of the mold cavity, so that the molding film 100A covers at least a portion of the surface of the mold cavity. In alternative embodiments, the heating preform may be optionally performed and the excess film removed by die cutting, laser cutting or water knife cutting prior to step S206.

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 combined with 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 the like.

After that, step S208 is performed to cool the molding material to form the workpiece 200. The workpiece 200 is an application of the decorative molding according to the present utility model, which may be an electronic device housing or component, a vehicle housing or component, or a combination thereof. For example, the work piece 200 may be, for example, a housing or component used by a cell phone, a digital camera, a personal digital assistant (personal digital assistant, PDA), a notebook computer, a desktop computer, a touch panel, a television, a satellite positioning system (globe position system, GPS) device, a car monitor, a navigation, a display, a digital photo frame, a DVD player, a car interior trim panel (e.g., a handle, a trim strip, a touch front stop, etc.), a car exterior trim panel (e.g., an exterior trim handle, a back door trim strip, 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 power. However, the present utility model is not limited to the shape and structure of the work 200, and any shape and structure of the work 200 that can be achieved by in-mold decoration technology is within the scope of the present utility model.

Next, step S210 is performed, and the decorated molded article 10 is taken out of the in-mold decoration mold. The obtained decorated molded article 10 is already described in detail in fig. 2, and will not be described again here.

On the other hand, the decorated molded article 10 may be produced by an out-mold decoration technique. Referring to fig. 10, a step flow S200 of the out-mold decoration technology is as follows. First, step S302 is performed to provide the workpiece 200. In one embodiment, the workpiece 200 is an application of the decorative molding according to the present utility model, 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 shaped housing materials, and may be, for example, subjected to a suitable pretreatment process to produce a workpiece having the desired characteristics. For example, when the workpiece is made of plastic, the plastic workpiece (such as a plastic housing) can be obtained through an injection molding process by using an injection molding die; alternatively, when the material of the workpiece is metal, the metal may be first subjected to surface treatment to obtain a metal workpiece (e.g., a metal casing, etc.).

Next, step S304 is performed to provide a molded film. The formed film may be, for example, the formed film 100A shown in fig. 2. The composition of the formed film 100A is described in the above paragraphs, and will not be described again here.

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

Then, step S308 is performed to perform a high-pressure decoration molding process to attach the molded film 100A to the outer surface 200A of the work 200. In detail, the high-pressure decoration molding process is, for example, a heat softening step is performed on the molded film 100A. In an embodiment, the temperature of the heat softening step may be between 80 ℃ and 150 ℃; the time of the heat softening step may be between 30 seconds and 180 seconds. Next, the molded film 100A is brought into contact with the work 200, and a pressurizing step is performed. Thereafter, the high-pressure vacuum forming step is performed on the formed film 100A to attach the formed film 100A to the work 200. Finally, the remaining composite layer structure can be selectively removed by using a cutting die cutting, a laser cutting or a water jet cutting mode. In short, the present embodiment can tightly adhere the formed film 100A to a part of the outer surface 200A of the work 200 by the out-mold decoration technique.

Referring back to fig. 1, after the decorative molded article 10 is formed, step S140 may optionally be performed to perform a second curing step to increase the stiffness of the composite layer structure 110. That is, the customer may choose to implement the step S140 or not implement the step S140 according to the requirement. 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 which case the first curing step is different from the second curing step. For example, the first curing step may be a thermal curing step, while the second curing step may be a UV curing step; the opposite is true. In an alternative embodiment, when the first curing step and the second curing step are both thermal curing steps, the curing temperature of the second curing step may be higher than the curing temperature of the first curing step. It should be noted that the second curing step can crosslink the protective material to increase the hardness of the top surface 108a of the optical hardening layer 108, thereby improving the protection effect. That is, when the in-mold decoration technique or the out-mold decoration technique is performed (i.e., step S130), the optical hardening layer 108 is still not completely cured and has ductility, and is then completely adhered 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 to have a complete protection effect. In this embodiment, the hardness of the optical hardening layer 108 may have a gradient change. Specifically, the hardness of the optical hardening layer 108 may increase from the bottom surface 108b toward the top surface 108 a. That is, the top surface 108a of the optical hardening layer 108 may have a hardness greater than that of the bottom surface 108b of the optical hardening layer 108. In addition, since the present utility model does not perform the laser engraving process, the optical hardening layer 108 has a flat top surface 108a without grooves. In addition, the second curing step may also increase the hardness of the first decorative layer 104 and the second decorative layer 106.

In the prior art, multiple spraying steps and multiple laser engraving steps are required to form a multi-color film. The disadvantage of this technique is that: complex process, difficult processing, high cost and high environmental pollution. In addition, in the existing decoration process (such as IMD or OMD), the multicolor film is usually formed by the stencil printing method. However, the technology can cause the defects of difficult alignment, low yield, overlarge material consumption, high cost and the like after the client is subjected to the processes of plastic suction molding, cutting, injection molding and the like. In order to solve the above problems, the embodiment of the utility model forms the all-in-one coating on the substrate and performs the curing step, thereby forming the composite layer structure with the protection effect, the color effect and the bonding effect. The composite layer structure can form a formed film with better physical properties (such as higher hardness, better protection effect and the like) after the plastic sucking forming process. In addition, compared with the existing spraying technology or INS technology, the manufacturing steps of the composite layer structure of the utility model are simplified, and the manufacturing cost can be effectively reduced.

In addition, in the conventional in-mold labeling (IML) technology, screen printing is performed on the back surface of a substrate (for example, PC, PMMA, ABS substrate) to form 3 to 5 decorative layers, and then 3 to 10 adhesive layers are formed to adhere the decorative layers to a workpiece. Compared with the conventional IML technique, the substrate 102 of the present embodiment is melted due to high temperature and high pressure during the injection molding process, and further 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 utility model does not require the formation of an additional adhesive layer, thereby simplifying the manufacturing steps of the decorative molded article and reducing the manufacturing cost.

Fig. 3 is a schematic flow chart of a method for producing an decorated molded article according to a second embodiment of the utility model. Fig. 4 is a schematic cross-sectional view of an decorated molded article according to the second embodiment of the utility model.

Referring to fig. 3 and 4, a second embodiment of the present utility model provides a method S20 for manufacturing an ornamental molded product 20 as follows. Step S100 is performed to form a composite layer structure 120 (as shown in fig. 4). Specifically, forming the composite layer structure 120 includes: step S102 is performed to form a first coating material on the substrate 102 (as shown in fig. 4) by a coating method, 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 or a printing method. In one embodiment, the fourth coating includes at least: the protective material, the ink material and the bonding material are uniformly mixed together. In addition, the coating method, printing method, protective material, ink material and adhesive material are described in detail in the above paragraphs, and will not be repeated here. It is noted that the fourth coating is used to form the anti-impact adhesive layer 118 (as shown in fig. 4). In this embodiment, the content of the bonding material in the fourth coating may be higher than that in the first coating or the second coating to increase the adhesion of the composite layer structure 120 to the workpiece 200 formed later. As shown in fig. 4, the composite layer structure 120 includes a first decorative layer 104, a second decorative layer 106, and an anti-impact layer 118. The first decorative layer 104 may be disposed on the first surface 102a of the substrate 102. The second decorative layer 106 may be disposed on the top surface 104t of the first decorative layer 104. The anti-impact layer 118 may be disposed on the second decorative layer 106 such that the second decorative layer 106 is disposed between the first surface 102a of the substrate 102 and the anti-impact layer 118. In addition, besides the coating method, the anti-impact layer 118 may be formed on the second decorative layer 106 by using a shower method, an imprinting method, a 3D printing method, or a spray printing method. Compared with the conventional INS in which the ink layer or the printing layer is bonded to the substrate by the process and the conventional IML technology requires forming 3-10 bonding layers to be bonded to the workpiece, the anti-impact bonding layer 118 of the present embodiment not only provides color effects, but also has high temperature resistance, protection effect and bonding effect, and does not require performing additional bonding process or forming additional bonding layers. That is, the present utility model can effectively simplify the manufacturing steps of the composite layer structure 120, and provide a composite layer structure 120 with better high temperature resistance, protection effect and bonding effect. Furthermore, compared with the prior spraying technology, INS or IML technology, the manufacturing steps of the composite layer structure of the utility model are simplified, and the manufacturing cost can be effectively reduced.

After the composite layer structure 120 is formed, a step S120 is performed, and a plastic suction molding process is performed to form the molded film 100B.

After that, step S160 is performed, and an in-mold decoration technique or an out-mold decoration technique is performed so that the molding film 100B is attached to the inner surface 200B of the work 200 to form the decorated molded article 20, as shown in fig. 4. Specifically, the inner surface 200b of the workpiece 200 is in contact with the top surface 120a of the composite layer structure 120. In this embodiment, the outer surface 200a of the workpiece 200 may be a visual surface so that the consumer can see the visual effect of the formed film 100B down 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 are described in detail in the above paragraphs, and will not be repeated here.

Fig. 5 is a schematic flow chart of a method for producing an decorated molded article according to the third embodiment of the utility model. FIG. 6 is a schematic cross-sectional view of an decorated molded article according to the third embodiment of the utility model.

Referring to fig. 5 and 6, a third embodiment of the present utility model provides a method S30 for manufacturing an ornamental molded product 30 as follows. Step S100 is performed to form a composite layer structure 130 (as shown in fig. 6). Specifically, forming the composite layer structure 130 includes: step S101 is performed to apply a second coating material to the substrate (as shown in fig. 6) by a coating method or a printing method. Next, step S103 is performed to apply the first paint to the second paint by a coating method or a printing method. In one embodiment, the first coating is used to form the first decorative layer 104, and the second coating is used to form the second decorative layer 106, as shown in FIG. 6. In the present embodiment, the first coating and the second coating do not require an additional curing step (i.e., at room temperature) to form the first decorative layer 104 and the second decorative layer 106, thereby forming the composite layer structure 130. As shown in fig. 6, the composite layer structure 130 includes a first decorative layer 104 and a second decorative layer 106. The second decorative layer 106 may be disposed on the second surface 102b of the substrate 102. The first decorative layer 104 may be disposed on the bottom surface 106b of the second decorative layer 106, such that the second decorative layer 106 is sandwiched between the second surface 102b of the substrate 102 and the first decorative layer 104. In addition, since the present utility model does not perform the laser engraving process, the first decorative layer 104 has a flat bottom surface without grooves.

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

After that, step S160 is performed, and an in-mold decoration technique or an out-mold decoration technique is performed so that the molded film 100C is attached to the inner surface 200b of the work 200 to form the decorated molded 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. In this embodiment, the outer surface 200a of the work piece 200 may be a visual surface so that the consumer can see the visual effect of the formed film 100C down from the outer surface 200a of the work piece 200. In addition, the in-mold decoration technique and the out-mold decoration technique are described in detail in the above paragraphs, and will not be repeated here.

Fig. 7 is a schematic cross-sectional view of an decorated molded article according to the fourth embodiment of the utility model.

Referring to fig. 7, the decoration molding 40 of the fourth embodiment may include: the workpiece 200 and the formed film 100D. The formed film 100D may be disposed on the outer surface 200a of the workpiece 200. Specifically, the shaped 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 coating material, and the content of the protective material may be higher than that of the first coating material or the second coating material. In this embodiment, the optical hardening layer 108 may also be referred to as an all-in-one hard coating. In this embodiment, the top surface 108a of the optical hardening layer 108 may be a visual surface so that the consumer can see the visual effect of the molding film 100D downward from the top surface 108a of the optical hardening layer 108. In addition, the optical hardening layer 108 may be formed on the first surface 102a of the substrate 102 by a shower method, an imprinting method, a 3D printing method, or a spray printing 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 include, in order from bottom to top, an anti-impact 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-impact layer 118 may be formed by the fourth coating material, and the content of the bonding material may be higher than that of the first coating material or the second coating material. In addition, the anti-impact layer 118 may be formed by a shower method, an imprint method, a 3D printing method, or a spray printing method, in addition to the coating method. In one embodiment, the material of the buffer layer 142 includes Polyurethane (PU) and polymethyl methacrylate (PMMA), which have the effects of preventing ink-flushing and improving laser engraving resolution. In one embodiment, the third decorative layer 144 may be formed by the first coating, which may be printed in one or more times to present different decorative patterns such as wood grain, geometric patterns, etc. In one embodiment, the fourth decorative layer 146 may be formed by the second coating material, which may be formed on the second surface 102b of the substrate 102 by physical vapor deposition (e.g., evaporation, sputtering, etc.), electroplating, etc. For example, the third decorative layer 144 may be a wood grain layer, and the fourth decorative layer 146 may have an evaporated metal layer with a transparency of 50%, so that the composite layer structure 140 presents a wood grain pattern with a metal color with a transparency of 50%. In addition, although fig. 7 shows only two decorative layers 144 and 146, the present utility model is not limited thereto, and in other embodiments, a plurality of decorative layers can be formed alternately according to different effects.

Fig. 8 is a schematic cross-sectional view of an decorated molded article according to the fifth embodiment of the utility model.

Referring to fig. 8, the decorative molded article 50 of the fifth embodiment may include: the workpiece 200 and the formed film 100E. The formed film 100E may be disposed on the outer surface 200a 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 optical hardened layer 108 and a light-transmitting layer 154. The material of the light-transmitting layer 154 includes a polymethacrylate resin, which has a decorative layer effect of chemical resistance. The light-transmitting layer 154 may contact the first surface 102a of the substrate 102, and the optical hardening layer 108 is disposed on the light-transmitting layer 154. In this embodiment, the top surface 108a of the optical hardening layer 108 may be a visual surface so that the consumer can see the visual effect of the molding film 100E downward from the top surface 108a of the optical hardening layer 108. In addition, since the present utility model does not perform the laser engraving process, the optical hardening layer 108 has a flat top surface 108a without grooves. In addition, the optical hardening layer 108 may be formed by a shower method, an imprinting method, a 3D printing method, or a spray printing method, in addition to the coating method.

In addition, the second composite layer structure 160 may be disposed on the second surface 102b of the substrate 102. Specifically, the second composite layer structure 160 may include the anti-impact adhesive layer 118 and the fourth decorative layer 146. The fourth decorative layer 146 may contact the second surface 102b of the substrate 102, and the anti-impact adhesive layer 118 may be disposed under the fourth decorative layer 146 such that the fourth decorative layer 146 is sandwiched between the second surface 102b of the substrate 102 and the anti-impact adhesive layer 118. In the present embodiment, the fourth decorative layer 146 may be formed by the second coating material, which may be formed on the second surface 102b of the substrate 102 by physical vapor deposition (e.g., evaporation, sputtering, etc.), electroplating, etc. For example, the light-transmitting layer 154 may be a semi-transparent black layer, and the fourth decorative layer 146 may have an evaporated 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, the anti-impact layer 118 may be formed by a shower method, an imprint method, a 3D printing method, or a spray printing method, in addition to the coating method.

Fig. 11 is a schematic cross-sectional view of an decorated molded article according to the sixth embodiment of the utility model.

Referring to fig. 11, the decoration molding 60 of the sixth embodiment may include: the workpiece 200 and the formed film 100F. The formed film 100F may be disposed on the outer surface 200a of the workpiece 200. Specifically, the formed film 100F may include a substrate 102 and a composite layer structure 170. The substrate 102 has a first surface 102a and a second surface 102b opposite to each other. The composite layer structure 170 may be disposed on the first surface 102a of the substrate 102. The composite layer structure 170 may include the fourth decorative layer 146 and the optical hardening layer 108. The fourth decorative layer 146 may contact the first surface 102a of the substrate 102, and the optical hardening layer 108 is disposed on the fourth decorative layer 146. In this embodiment, the top surface 108a of the optical hardening layer 108 may be a visual surface so that the consumer can see the visual effect of the molding film 100F downward from the top surface 108a of the optical hardening layer 108. In addition, since the present utility model does not perform the laser engraving process, the optical hardening layer 108 has a flat top surface 108a without grooves. In the present embodiment, the fourth decorative layer 146 may be formed by the second coating material, which may be formed on the first surface 102a of the substrate 102 by physical vapor deposition (e.g., evaporation, sputtering, etc.), electroplating, etc. The optical hardening layer 108 may have a protection effect to prevent the fourth decorative layer 146 from being scratched or damaged. In addition, the optical hardening layer 108 may be formed by a shower method, an imprinting method, a 3D printing method, or a spray printing method, in addition to the coating method.

Fig. 12 is a schematic cross-sectional view of an decorated molded article according to the seventh embodiment of the utility model.

Referring to fig. 12, the decoration molding 70 of the seventh embodiment may include: the workpiece 200 and the formed film 100G. The formed film 100G may be disposed on the outer surface 200a of the work 200. Specifically, the formed film 100G may include a substrate 102, a composite layer structure 180, and an anti-impact 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. The fourth decorative layer 146 may contact the first surface 102a of the substrate 102. The optical hardening layer 108 may be disposed on the fourth decorative layer 146. The third decorative layer 144 may be disposed between the fourth decorative layer 146 and the optical hardening layer 108. In this embodiment, the top surface 108a of the optical hardening layer 108 may be a visual surface so that the consumer can see the visual effect of the molding film 100G downward from the top surface 108a of the optical hardening layer 108. In addition, since the present utility model does not perform the laser engraving process, the optical hardening layer 108 has a flat top surface 108a without grooves. In the present embodiment, the third decorative layer 144 may be formed by the first coating material, which may be printed in a single or multiple times to present different decorative patterns such as wood grain, geometric patterns, etc. The fourth decorative layer 146 may be formed of the second coating material, and may be formed on the first surface 102a of the substrate 102 by physical vapor deposition (e.g., evaporation, sputtering, etc.), electroplating, etc. The optical hardening layer 108 can have a protection effect to prevent the third decoration layer 144 from being scratched or damaged. On the other hand, the anti-impact layer 118 may be disposed on the second surface 102b of the substrate 102 and in contact with the second surface 102b of the substrate 102. It is noted that the anti-impact layer 118 may also have different effects by printing a plurality of stacks (such as wood grain or geometric patterns) or by matching with anti-impact layers of different colors, and in this embodiment, the formed film 100G may be adhered to the outer surface 200a of the workpiece 200 through the anti-impact layer 118. In addition, the optical hardening layer 108 and the anti-impact layer 118 may be formed by a shower method, an imprinting method, a 3D printing method, or a spray printing method, in addition to the coating method.

Referring to fig. 13, an ornamental molded article 80 according to an eighth embodiment may include: the workpiece 200 and the formed film 100H. The formed film 100H may be disposed on the inner surface 200b of the workpiece 200. Specifically, the formed film 100H may include a substrate 102 and a 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. The composite layer structure 190 may include a third decorative layer 144, a fourth decorative layer 146, and an anti-impact layer 118. The fourth decorative layer 146 may contact the first surface 102a of the substrate 102. The anti-impact adhesive layer 118 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 anti-impact layer 118. In this embodiment, the outer surface 200a of the work piece 200 may be a visual surface so that the consumer can see the visual effect of the formed film 100H down from the outer surface 200a of the work piece 200. In the present embodiment, the third decorative layer 144 may be formed by the first coating material, which may be printed in a single or multiple times to present different decorative patterns such as wood grain, geometric patterns, etc. The fourth decorative layer 146 may be formed of the second coating material, and may be formed on the first surface 102a of the substrate 102 by physical vapor deposition (e.g., evaporation, sputtering, etc.), electroplating, etc. The anti-impact adhesive layer 118 having a transparent or different transmittance may have an adhesive function so that the molding film 100H may be adhered to the inner surface 200b of the work 200 through the anti-impact adhesive layer 118. In addition, the anti-impact layer 118 may be formed by a shower method, an imprint method, a 3D printing method, or a spray printing method, in addition to the coating method.

In summary, the present utility model forms the all-in-one coating on the substrate and performs the curing step, thereby forming the composite layer structure with the protection effect, the color effect and the bonding effect. The composite layer structure can form a formed film with better physical properties (such as higher hardness, better protection effect and the like) after the plastic sucking forming process. Therefore, the formed film of the present embodiment is suitable for performing a laser engraving process, thereby forming various light-transmitting decorative molded articles. In addition, compared with the existing INS in which the ink layer or the printing layer is matched with the substrate laminating process, the plurality of stacked decorative layers of the embodiment not only provide various color effects, but also have the protection effect and the laminating effect, and do not need to carry out additional laminating processes. In addition, compared with the conventional IML technology, the present embodiment requires 3-10 additional adhesive layers to be formed to adhere to the workpiece, and the present embodiment does not require the formation of additional adhesive layers. That is, the utility model can effectively simplify the manufacturing steps of the composite layer structure and provide the composite layer structure with better protection effect and bonding effect. Furthermore, compared with the prior 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 can be effectively reduced.

Although the present utility model has been described with reference to the above embodiments, it should be understood that the utility model is not limited thereto, but rather may be modified or altered somewhat by those skilled in the art without departing from the spirit and scope of the present utility model.

Claims

1. A decorated molded article, comprising:

a workpiece; and

a shaped film attached to an outer surface of the workpiece, wherein the shaped 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; and

and an optical hardening layer disposed on the second decorative layer, wherein the optical hardening layer has a flat top surface.

2. A decorated molded article, comprising:

a workpiece; and

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 base material;

A plurality of decorative layers disposed on the second surface of the substrate; and

and an anti-impact adhesive layer arranged between the plurality of decorative layers and the outer surface of the workpiece.

3. A decorated molded article, comprising:

a workpiece; and

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 comprises a light-transmitting layer and an optical hardening layer, wherein the optical hardening layer has a flat top surface; and

and a second composite layer structure configured on the second surface of the substrate, wherein the second composite layer structure comprises a decorative layer and an anti-impact bonding layer, and the anti-impact bonding layer contacts the outer surface of the workpiece.

4. A decorated molded article, comprising:

a workpiece; and

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; and

An optical hardened layer disposed on the decorative layer, wherein the second surface of the substrate contacts the outer surface of the workpiece, wherein the optical hardened layer has a planar top surface.

5. A decorated molded article, comprising:

a workpiece; and

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 decorative layer, wherein the optical hardening layer has a flat top surface; and

and an anti-impact bonding layer which is configured on the second surface of the base material and is contacted with the outer surface of the workpiece.

6. A decorated molded article, comprising:

a workpiece; and

a shaped film attached to an inner surface of the workpiece, wherein the shaped 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; and

and the anti-impact bonding layer is arranged on the second decorative layer.

7. A decorated molded article, comprising:

a workpiece; and

a substrate having opposed 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; and

and the second decorative layer is arranged between the first decorative layer and the base material, wherein the first decorative layer is provided with a flat bottom surface.

8. A decorated molded article, comprising:

a workpiece; and

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; and

and the anti-impact bonding layer is configured on the first decorative layer, so that the top surface of the anti-impact bonding layer contacts the inner surface of the workpiece.