TWI810082B - Method of fabricating light-transmitting decorated molding article - Google Patents

Abstract

A method of manufacturing a decorated molding article includes: forming an all-in-one coating on a substrate and performing a curing step, thereby forming a composite layer structure with a protective effect, a color effect, and a bonding effect. Compared with the printing layer in the conventional In Mold Label (IML) and InSert molding (INS) that is made by a plurality of anti-impact and bonding processes, the composite layer structure of the embodiment can form a molded film with better physical properties (e.g., higher hardness, better protection effect, etc.) after the blister molding process. Therefore, the molded film of the embodiment can be applied to a laser engraving process to form a variety of light-transmitting decorative molded products. Further, the present disclosure further forms a protective layer locally in the grooves formed after the laser engraving process, so as to protect the texture after the laser engraving process from damage.

Description

Manufacturing method of light-transmitting decorative molded article

The invention relates to a method for manufacturing a light-transmitting decorative molded article.

Generally speaking, decorations such as patterns or characters formed on the surface of the object shell are mainly formed through spraying or printing processes, so as to present specific visual effects and increase the variability of the appearance of the object. The traditional forming method is to apply a hardened layer on the surface of the shell by spraying after the shell of the related product is completed. This method is cumbersome, has poor yield and will cause pollution of organic solvent gas, thus causing many pollution problems. On the other hand, due to the time-consuming, complicated process, and low thickness uniformity of the spraying process, the overall production yield and cost need to be improved urgently. In order to solve the aforementioned problems, a variety of specific decoration processes using decorative films have been proposed, such as in-mold decoration (In-Mold Decoration, IMD) or out-mold decoration (Out Mold Decoration, OMD). Another option.

At present, the commonly used polymer substrate materials in in-mold decoration technology include polycarbonate (Polycarbonate, PC), polymethyl methacrylate, also known as polyacrylic. (Poly(methyl methacrylate), PMMA), polyhexene terephthalate (PET, Polyethylene Terephthalate) and acrylonitrile-butadiene-styrene copolymer (Acrylonitrile Butadiene Styrene, ABS). However, the hardness of the base material composed of PC and ABS is relatively low, which makes the surface of the base material prone to damage. Therefore, the hardness and scratch resistance of the base material surface are usually increased by coating a protective layer. On the other hand, the base material made of PMMA has high hardness, but it is easy to crack during molding, so it is not easy to carry out the hot pressing process.

In order to solve the aforementioned problems, a variety of specific decoration processes using decorative films have been proposed, such as in-mold decoration technology (In-Mold Decoration, IMD) or film out-of-film decoration technology (Out Mold Decoration, OMD). Another option.

Specifically, in-mold decoration technology (IMD) may include: In Mold Labeling (IML), In Mold Film (In Mold Film, IMF or INS) and In Mold Roller (IMR) , as shown in Table 1 below. The in-mold labeling (IML) process is characterized by a hardened transparent film on the surface, a printed pattern layer in the middle, and a plastic layer on the back. Because the ink is sandwiched between the hardened transparent film and the plastic layer, the product can prevent the surface from being scratched, wear-resistant, and can keep the color bright and not easy to fade for a long time. The IML process flow is as follows:

(1). Cutting: Take the roll-shaped film substrate (usually PMMA/PC or PET or PC substrate with hard coating), cut it into the designed size for printing and Blister molding use.

(2).Plane printing: usually screen printing (screen printing), spray printing process, providing icons and text The effect and the final anti-shock bonding material, and generally design the printing pass according to the effect of the product design diagram, especially the anti-shock bonding material needs to be matched with high-temperature and high-pressure injection molding plastic materials (generally, the injection molding temperature is about 200 degrees or more), usually requires Printing multi-pass stacking will lead to increased cost, lower film usage efficiency and lower overall yield.

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

(4).Pasting protective film: To prevent the post-punching positioning hole from damaging the surface of the printed film, a protective film must be attached to protect the surface.

(5). Punching positioning holes: Since the film will shrink during the forming and heating process, it is necessary to punch positioning holes to ensure the precision of the positioning of the printed film and matching products.

(6). High-temperature and high-pressure forming: After the printed film is subjected to high temperature and high heat, the forming machine is used for plastic absorption under preheating conditions.

(7). Cutting shape: Use cutting or laser cutting to cut off the waste after blistering.

(8).Injection molding: Finally, place the cut three-dimensional film on the injection molding machine for injection molding to form finished parts and physical inspection of related shipments.

The in-mold transfer (IMR) process is to print the pattern on the film, and then use the film feeder to attach the film to the mold cavity and perform injection molding. After injection, the ink layer with the pattern is separated from the film, and the ink layer is left in the film. A plastic part with a decorative pattern on the surface is obtained on the plastic part. Therefore, the surface of the final product of in-mold transfer does not have a layer of transparent protective film, and the film is only a carrier in the production process. In other words, the biggest difference between in-mold labeling (IML) and in-mold transfer (IMR) is whether there is a transparent protective film on the surface of the product. In addition, in-mold film (IMF) is the same as in-mold labeling (IML).

Out-of-film decoration technology (OMD), also known as high-pressure transfer printing. After printing the pattern on the transparent film, use high/medium/low pressure plus vacuum transfer printing to directly transfer the printing on the plastic casing. The main feature is the product with tactile sensation and it is used in 3C, home appliances and automobiles.

However, regardless of IMD or OMD film, if you want to make light-transmitting decorative products, you will make them by printing and stacking. After the client goes through the processes of blistering, cutting and injection molding, it will lead to difficult alignment and excessive material loss, which will lead to increased costs. And other shortcomings, and the difficulty of the laser engraving process in the later stage also makes it impossible to manufacture products such as transparent patterns.

Table 2 below shows the characteristics and disadvantages of various known decoration techniques.

Table 2

The invention provides a method for manufacturing a decorated molded product, comprising: providing a coating, wherein the coating at least includes: a protective material, an ink material, and a bonding material are uniformly mixed together; and the coating is formed on a substrate by a coating method or a printing method ; Carry out a first curing step to form a composite layer structure, wherein the composite layer structure includes at least an optically hardened layer disposed on a substrate; perform a blister molding process to form a shaped film; perform a second curing step to increase the shaped film the hardness; perform a laser engraving process to form grooves; form a protective layer in the grooves; and attach a molding film to the surface of the workpiece to form a decorative molded product.

In one embodiment of the present invention, the above-mentioned protective material includes polymethyl methacrylate, aliphatic urethane acrylate, epoxy acrylate, polyester polyol or a combination thereof, the ink material includes polyurethane, and the bonding material includes Thermoplastic polyurethane, aromatic polyurethane acrylate or combinations thereof.

In an embodiment of the present invention, the above protective layer is formed by using 3D printing technology or jet printing technology.

In one embodiment of the present invention, after performing the above-mentioned blister molding process, it further includes: performing in-mold decoration technology or out-of-mold decoration technology on the formed film, so that the formed film is attached to the outer surface of the workpiece to form Decorative moldings.

In one embodiment of the present invention, after performing the above-mentioned laser engraving process, it further includes: performing in-mold decoration technology or out-of-mold decoration technology on the formed film, so that the formed film is attached to the inner surface of the workpiece to form Decorative moldings.

The present invention provides a method for manufacturing a decorated molded product, comprising: providing a base material having opposite first and second surfaces; forming a second coating on the second surface of the base material by using a coating method or a printing method; The first coating is formed on the second coating by a coating method or a printing method; a first curing step is performed to form a composite layer structure, wherein the composite layer structure at least includes: a substrate; a first decorative layer configured on the substrate On the second surface; and the second decoration layer is disposed between the second surface of the base material and the first decoration; plastic forming process is performed to form a molded film; laser engraving process is performed to form grooves; forming a protective layer in the groove; and attaching a molding film to the surface of the workpiece to form a decorative molding.

In an embodiment of the present invention, each of the above-mentioned first coating and the second coating includes: a protective material, an ink material, and a bonding material are evenly mixed together.

In an embodiment of the present invention, the above protective layer is formed by using 3D printing technology or jet printing technology.

The invention provides a method for manufacturing a decorated molded product, comprising: providing a coated material, wherein the coating at least includes: a protective material, an ink material, and a bonding material are uniformly mixed together; the coating is formed on the substrate by a coating method or a printing method; the first curing step is performed to form a composite layer structure; Molding process to form a molded film; a second curing step to increase the hardness of the molded film; forming a mask layer on the composite layer structure; performing a laser engraving process to form recesses in the mask layer and the composite layer structure groove; forming a coating layer on the mask layer by evaporation or sputtering, wherein part of the coating layer is filled in the groove; removing the mask layer and the coating layer above it; forming a protection in the groove layer, wherein the protective layer covers the plating layer; and attaching a forming film to the surface of the workpiece to form a decorative molding.

In an embodiment of the present invention, the above protective layer is formed by using 3D printing technology or jet printing technology.

Based on the above, the present invention forms the all-in-one coating on the substrate and performs a curing step, thereby forming a composite layer structure with protection effect, color effect and lamination effect. The composite layer structure can form a molded film with better physical properties (such as higher hardness, better protection effect, etc.) after undergoing a blister molding process. Therefore, the molded film of this embodiment is suitable for laser engraving process, and then forms various light-transmitting decorative moldings. In addition, the present invention further partially forms the protective layer in the groove to protect the laser-engraved texture from damage, thereby improving the protective effect of the composite layer structure and increasing the service life. In addition, the present invention performs the laser engraving process before and after the blister forming process. Therefore, the present invention can solve the alignment problem of the prior art, thereby improving the yield rate and reducing the manufacturing cost.

On the other hand, compared with the ink layer or printing layer in the conventional INS, it needs to be matched In the lamination process of the base material, the multiple stacked decorative layers of this embodiment not only provide various color effects, but also have protective effects and lamination effects, without the need for an additional lamination process. In addition, compared with the conventional IML technology, which needs to form 3-10 additional layers of adhesive layer before it can be attached to the workpiece, this embodiment does not need to form an additional adhesive layer. That is to say, the present invention can effectively simplify the manufacturing steps of the composite layer structure, and provide a composite layer structure with better protection effect and bonding effect. Furthermore, compared with the conventional spraying technology, INS technology or IML technology, the manufacturing steps of the decorated molded article of the present invention are more simplified, and the manufacturing cost can be effectively reduced.

10, 20, 30, 40, 50, 60, 70, 80, 90: decorative molded products

100A, 100B, 100C, 100D, 100E, 100F, 100G, 100H, 100I: formed film

110, 120, 130, 140, 150, 160, 170, 180, 190: composite layer structure

102: Substrate

102a: first surface

102b: second surface

104: The first decorative layer

105, 105a, 105b, 905: groove

105bt, 106b, 108b, 130b, 140b, 160b, 905bt: Bottom

106: Second decorative layer

108: optical hardening layer

104t, 106t, 108a, 110a, 118a, 120a: top surface

112A, 112B, 212, 312, 412, 512, 612, 712A, 712B, 812A, 812B, 912: protective layer

118: Anti-shock bonding layer

142: buffer layer (decorative layer)

144: The third decorative layer

146: The fourth decorative layer

154: transparent layer

200: workpiece

200a: outer surface

200b: inner surface

300: light source

902: mask layer

904: Plating layer

905sw: side wall

S10, S20, S30, S40: manufacturing method

S100, S101, S102, S103, S104, S106, S107, S108, S120, S130, S140, S142, S150, S152, S154, S160, S170, S202, S204, S206, S208, S210, S302, S304, S3 06、 S308: step

S200, S300: step process

FIG. 1 is a schematic flowchart of a method for manufacturing a decorated molded article according to a first embodiment of the present invention.

2A is a schematic cross-sectional view of a decorated molded product according to the first embodiment of the present invention.

FIG. 2B is a schematic cross-sectional view of another decorated molded product according to the first embodiment of the present invention.

FIG. 3 is a schematic flowchart of a method for manufacturing a decorated molded article according to a second embodiment of the present invention.

4 is a schematic cross-sectional view of a decorated molded product according to a second embodiment of the present invention.

FIG. 5 is a schematic flowchart of a method for manufacturing a decorated molded article according to a third embodiment of the present invention.

6 is a schematic cross-sectional view of a decorated molded product according to a third embodiment of the present invention.

7 is a schematic cross-sectional view of a decorated molded product according to a fourth embodiment of the present invention.

8 is a schematic cross-sectional view of a decorated molded product according to a fifth embodiment of the present invention.

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

FIG. 10 is a schematic flow chart of the out-of-mold decoration technology according to an embodiment of the present invention.

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

12A is a schematic cross-sectional view of a decorated molded product according to a seventh embodiment of the present invention.

FIG. 12B and FIG. 12C are schematic top views of the structure in FIG. 12A with the light source turned off and the light source turned on, respectively.

13A is a schematic cross-sectional view of a decorated molded product according to the eighth embodiment of the present invention.

FIG. 13B and FIG. 13C are schematic top views of the structure in FIG. 13A with the light source turned off and the light source turned on, respectively.

FIG. 14 is a schematic flowchart of a method for manufacturing a decorated molded article according to a ninth embodiment of the present invention.

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

The present invention is described more fully hereinafter with reference to the accompanying drawings. However, the present invention may be practiced in many different forms and is not limited to the embodiments set forth herein. The directional terms mentioned in the following embodiments, such as "upper" and "lower", are only referring to the directions of the accompanying drawings, so the directional terms used are for the purpose of specifying rather than limiting the present invention. In addition, the thicknesses of layers and regions in the drawings may be exaggerated for clarity. The same or similar component numbers represent the same or similar components, as follows Paragraphs will not repeat them one by one.

FIG. 1 is a schematic flowchart of a method for manufacturing a decorated molded article according to a first embodiment of the present invention. 2A is a schematic cross-sectional view of a decorated molded product according to the first embodiment of the present invention.

Referring to FIG. 1 and FIG. 2A , the first embodiment of the present invention provides a manufacturing method S10 of a decorated molded product 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: performing step S102 , forming a first paint on the substrate 102 (as shown in FIG. 2A ) by using a coating method or a printing method. In one embodiment, the material of the substrate 102 includes acrylonitrile-butadiene-styrene copolymer (ABS), polycarbonate (PC), polymethyl methacrylate (PMMA) or a combination thereof, and the forming method thereof Including extrusion molding method, etc. For example, ABS solid plastic can be heated and melted, extruded and cooled to form the ABS substrate 102 by extrusion molding. In addition, it is also possible to firstly mix ABS solid plastic with color masterbatch, pigment, pearl powder and related additives to form a mixture. Next, the mixture is extruded by extrusion molding to form another ABS substrate, so that the ABS substrate has visual effects such as color, pearlescent, bright surface, mirror surface, and matte surface. In an alternative embodiment, the material of the base material 102 may also be wood veneer, aluminum sheet, steel plate, etc. or a combination thereof.

Specifically, the coating method is to distribute the paint in a coating device, and uniformly coat the paint on the substrate 102 through a coating head of the coating device. In one embodiment, the opening of the coating head may be flat, so that the coating coated on the substrate 102 has a glossy effect. In another embodiment, the coating The opening of the head may have a plurality of microstructures (such as micro-dimples), so that the paint coated on the substrate 102 has a matte effect. In an alternative embodiment, the opening of the coating head may have a plurality of concave-convex structures, so that the coating coated on the substrate 102 has a hairline effect. On the other hand, the printing method may include gravure printing, screen printing, offset printing, reverse printing, transfer printing or spray printing. Suitable printing methods such as ink printing. Compared with the coating method, the printing method can form a thinner film layer.

In one embodiment, the first coating at least includes: a protective material, an ink material, and a bonding material mixed uniformly together. The protective material may include polymethyl methacrylate (PMMA), aliphatic urethane acrylate (Aliphatic Urethane Diacrylate), epoxy acrylate (epoxy acrylate, EA), polyester polyol (polyester polyol) or a combination thereof; The ink material may include polyurethane (PU) and the like; and the bonding material may include thermoplastic polyurethane (TPU), aromatic urethane diacrylate (Aromatic Urethane Diacrylate) or a combination thereof. In addition, the first coating further includes: a heat-resistant material, a solvent, and a hardener. In one embodiment, the heat-resistant material may include polycarbonate (PC) and the like; the solvent may include ethyl acetate, methyl ethyl ketone, toluene, xylene, or a combination thereof; and the hardener may include polycarbonate (PC). Isocyanate (Aromatic Urethane Diacrylate) and similar materials. But the present invention is not limited thereto. In other embodiments, the first paint can also include other additives, such as matting powder, pearl powder, etc., so that the first decorative layer 104 formed subsequently (as shown in FIG. 2A ) Shown) has different visual effects such as matting and pearlescent.

Next, proceed to step S104 , forming the second paint on the first paint by coating method or printing method. In one embodiment, the second coating at least includes: a protective material, an ink material, and a bonding material mixed uniformly together. In addition, the coating method, printing method, protective material, ink material and laminating material have been described in detail in the above paragraphs, and will not be repeated here. It should be 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 paint and the second paint have different compositions to achieve different visual effects. In another embodiment, the first decoration layer 104 or the second decoration layer 106 can also use evaporation or sputtering to achieve a metallized decoration effect. For example, the first decorative layer 104 formed by the first paint can be a wood grain layer, and the second decorative layer 106 formed by the second paint can have a matte silver color, so that the composite layer structure 110 presents a matte silver color wood grain pattern.

Then, proceed to step S106 , forming a third coating on the second coating by using a coating method or a printing method. In one embodiment, the third coating at least includes: a protective material, an ink material, and a bonding material mixed uniformly together. In addition, the coating method, printing method, protective material, ink material and laminating material have been 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 paint may be higher than the content of the protective material in the first paint or the second paint.

Afterwards, step S108 is performed to perform a first curing step to form the 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 . The first decoration layer 104 can be configured on the base on the first surface 102a of the material 102. The second decoration layer 106 can be disposed on the first decoration layer 104 . The optical hardening layer 108 can be disposed on the second decoration layer 106 such that the second decoration layer 106 is disposed between the first surface 102 a of the substrate 102 and the optical hardening layer 108 . Although only two layers of the first decorative layer 104 and the second decorative layer 106 are shown in FIG. 2A, the present invention is not limited thereto. In other embodiments, the composite layer structure 110 may also have multiple layers (such as three layers, Four or more layers) of decorative layers stacked. In addition, in addition to the coating method, the optical hardening layer 108 can also be formed on the second decoration layer 106 by a coating method, an embossing method, a 3D printing method or a jet printing method. In alternative embodiments, the material of the optical hardening layer 108 can also 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 steps. The first curing step enables the bonding material to undergo a cross-linking reaction and bonded 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 protection effect, color effect and bonding effect at the same time. In this case, the composite layer structure 110 can also be called an all-in-one composite layer structure. Compared with the step of purchasing a protective layer and forming the film structure through printing and laminating processes in the prior art, the present invention can effectively simplify the manufacturing steps, reduce the manufacturing cost and prevent the pollution caused by the film.

Compared with the ink layer or printing layer in the conventional INS, which needs to be matched with the substrate bonding process, the multiple stacked decorative layers in this embodiment not only provide a variety of color effects, but also have both protective and bonding effects, without An additional bonding process is required. That is to say, the present invention can effectively simplify the manufacturing steps of the composite layer structure and provide protection Composite layer structure with better effect and fit. Furthermore, compared with the conventional spraying technology or INS technology, the manufacturing steps of the composite layer structure of the present invention are more simplified, and the manufacturing cost can also be effectively reduced.

After the composite layer structure 110 is formed, step S120 is performed to perform a blister forming process to form a molded film 100A. In one embodiment, the blister molding process includes: heating the composite layer structure 110 and the substrate 102 to soften the composite layer structure 110 and the substrate 102; putting the softened composite layer structure 110 and the substrate 102 into a mold And pressurize, so that the softened composite layer structure 110 and the substrate 102 are molded into a desired shape; a cooling step is performed; and excess parts are cut to form a molded film 100A.

Next, proceed to step S130, performing in-mold decoration technology or out-of-mold decoration technology, so that the forming film 100A is attached to the outer surface 200a of the workpiece 200 to form a decorated molded product 10, as shown in FIG. 2A. In one embodiment, the substrate 102 has a first surface 102 a and a second surface 102 b 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 decoration layer 104, and the top surface 110a of the composite layer structure 110 is exposed upward. . In this embodiment, the top surface 110 a of the composite layer structure 110 may be a visual surface, so that consumers can see the visual effect of the formed film 100A from the top surface 110 a of the composite layer structure 110 .

FIG. 9 is a schematic flow chart of the in-mold decoration technology according to an embodiment of the present invention. FIG. 10 is a schematic flow chart of the out-of-mold decoration technology according to an embodiment of the present invention.

Please refer to FIG. 9 , the step flow S200 of the in-mold decoration technology is as follows. Firstly, step S202 is performed to provide a molded film. The formed film can be, for example, a formed Film 100A. The composition of the formed film 100A has been described in the above paragraphs, and will not be repeated here.

Next, step S204 is performed, disposing the molded film 100A in the in-mold decoration mold. In detail, the in-mold decoration mold includes a hollow mold cavity. The cavity has a surface. Afterwards, the forming film 100A is attached to the surface of the cavity such that the forming film 100A covers at least a part of the surface of the cavity. In an alternative embodiment, before performing step S206 , preforming may be optionally performed by heating and excess film may be removed by die cutting, laser cutting or water jet cutting.

Then, proceed to step S206 , pour the molding material into the mold cavity of the in-mold decoration mold, so that the molding material and the molding film 100A are combined with each other. In an embodiment, the molding material may be, for example, plastic material, resin material, metal material, carbon fiber material, glass and other suitable molding materials.

Afterwards, step S208 is performed to cool the molding material to form the workpiece 200 . The workpiece 200 depends on the application of the decorative molded article of the present invention, which may be an electronic device casing or component, a vehicle casing or component, or a combination thereof. For example, the workpiece 200 may be, for example, 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 (globe position system, GPS) Devices, car monitors, navigation, displays, digital photo frames, DVD players, car interior trim panels (such as handles, trim strips, touch screens, etc.), car exterior trim panels (such as exterior handles, back door trim bars, welcome pedals, etc.), car dashboards, car logos, intelligent keys (intelligent key, I-key), engine start buttons, clocks, radios, toys, Cases or components used in watches or other electronic products that require power. However, the present invention does not limit the shape and structure of the workpiece 200 , as long as the shape and structure of the workpiece 200 can be completed by the in-mold decoration technology, it falls within the scope of the present invention.

Next, proceed to step S210, taking out the decorated molded product 10 from the in-mold decoration mold. The obtained decorative molded product 10 has been described in detail in the above-mentioned FIG. 2A , and will not be repeated here.

On the other hand, the decorated molded product 10 can also be manufactured by out-of-mold decoration technology. Please refer to FIG. 10 , the step flow S200 of the out-of-mold decoration technology is as follows. First, step S302 is performed to provide a workpiece 200 . In one embodiment, the workpiece 200 depends on the application of the decorative molded article of the present invention, which may be an electronic device casing or component, a vehicle casing or component, or a combination thereof. In an alternative embodiment, the material of the outer surface 200a of the workpiece 200 can be plastic, resin, metal, carbon fiber, glass or other formed various casing materials, and for example, it can be produced with the desired characteristics through appropriate pre-treatment processes. artifacts. For example, when the material of the workpiece is plastic, the plastic workpiece (such as a plastic casing, etc.) can be obtained after the injection molding process through the injection mold; or, when the material of the workpiece is metal, the metal can be processed first. Surface treatment to obtain metal workpieces (such as metal casings, etc.).

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

Afterwards, step S306 is performed to place the workpiece 200 and the molded film 100A in the jig. It is noted here that, before performing step S306, optionally Design the jig and prepare the jig according to the requirements of the final product.

Then, step S308 is performed to perform a high-pressure decoration molding process, so that the molding film 100A is attached to the outer surface 200 a of the workpiece 200 . In detail, the high-pressure decoration molding process is, for example, firstly performing a heating and softening step on the molding film 100A. In one embodiment, the temperature of the heating and softening step can be between 80° C. and 150° C.; the time of the heating and softening step can be between 30 seconds and 180 seconds. Next, the molded film 100A is brought into contact with the workpiece 200, and a pressing step is performed. Afterwards, a high-pressure vacuum forming step is performed on the formed film 100A, so that the formed film 100A is attached to the workpiece 200 . Finally, the remaining composite layer structure can be optionally removed by die cutting, laser cutting or water jet cutting. In short, in this embodiment, the molded film 100A can be closely adhered to the part of the outer surface 200a of the workpiece 200 by the out-of-mold decoration technology.

Referring back to FIG. 1 , after the decorative molding 10 is formed, step S140 is performed to perform a second curing step to increase the hardness of the composite layer structure 110 . In one embodiment, the second curing step may include a thermal curing step, an ultraviolet (UV) curing step, a combination thereof, or other suitable curing steps. In this embodiment, the first curing step is different from the second curing step. For example, the first curing step can be a thermal curing step and the second curing step can be a UV curing step; vice versa. 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 that of the first curing step. It is worth noting that the second curing step can make the protective material carry out a cross-linking reaction, so as to increase the hardness of the top surface 108 a of the optical hardening layer 108 , thereby improving the protective effect. That is to say, when performing in-mold decoration technology or out-of-mold decoration technology (that is, the steps In S130 ), the optical hardening layer 108 is not completely cured and has ductility, and is then completely attached to the outer surface 200 a of the workpiece 200 . After the second curing step (ie step S140 ), the optical hardening layer 108 is completely cured and has a complete protective 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 108a. That is, the hardness of the top surface 108 a of the optical hardening layer 108 may be greater than the hardness of the bottom surface 108 b of the optical hardening layer 108 . In addition, the second curing step can also increase the hardness of the first decoration layer 104 and the second decoration layer 106 to facilitate the subsequent laser engraving process (that is, step S150 ).

Then, step S150 is performed to perform a laser engraving process to form the groove 105 in the composite layer structure 110 . As shown in FIG. 2A , the groove 105 may extend downward from the top surface 110 a of the composite layer structure 110 until the top surface 104 t of the first decoration layer 104 is exposed. But the present invention is not limited thereto, and in other embodiments, the grooves 105 may also have different depths. That is to say, the bottom surface 105bt of the groove 105 can be higher than or lower than the top surface 104t of the first decoration layer 104, or the bottom surface 105bt of the groove 105 can be higher than, equal to or lower than the top of the second decoration layer 106. Surface 106t. In addition, although FIG. 2A only depicts a single groove 105, the present invention is not limited thereto. In an alternative embodiment, the decorative molding 10 may have multiple grooves to form various laser engraving patterns, and then Increase the visual experience of consumers.

Afterwards, step S160 is performed to form a protective layer 112A in the groove 105 . Specifically, the protection layer 112A can be formed by using a three-dimensional (3D) printing technique. In one embodiment, the 3D printing technique includes aerosol spraying Printing process (Aerosol Jet Printing process). The aerosol spray printing process uses an aerosol jet deposition head to form an outer sheath flow and an inner aerosol-laden carrier flow. Annular spread nozzle. In the annular aerosol spraying process, an aerosol stream of the material to be deposited is focused and deposited on the surface to be formed. The above steps can be called maskless mesoscale material deposition (M3D), that is, it can be deposited without using a mask. In an alternative embodiment, the protective layer 112A can also be formed by using ink jet printing technology.

In this embodiment, as shown in FIG. 2A , the filling ink is filled into the groove 105 through the nozzle of the 3D printing device. In one embodiment, the filling ink can be similar to the above-mentioned third paint, which at least includes a uniformly mixed protective material, ink material and bonding material, and the content of the protective material in the filling ink can be higher than that of the first paint or The content of the protective material in the second paint. In addition, after the filling ink is filled into the groove 105 , an additional curing step may be performed, so that the protective material in the filling ink undergoes a cross-linking reaction, thereby increasing the hardness of the protective layer 112A. In this case, the protection layer 112A can partially protect the laser-engraved texture, that is, 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 is worth noting that the nozzle used in the 3D printing technology of this embodiment is small enough, so the filling ink can be accurately filled in the groove to form a protective layer locally, thereby protecting the texture after laser engraving. Compared with general spraying technology, a large amount of paint will be volatilized In the case of being released into the air, the use of 3D printing technology in this embodiment can effectively reduce material consumption and reduce manufacturing costs. In addition, the nozzles of the general spraying technology are relatively large, which makes the sprayed layer distributed discontinuously in dots, which in turn leads to rough and uneven spraying effect. On the other hand, the 3D printing technology nozzle of this embodiment is small enough, it can completely fill the filling ink in the narrow groove and distribute it continuously on the surface of the object, so that the protective layer is more smooth and beautiful. In addition, the 3D printing technology of this embodiment can also perform partial color adjustment. That is to say, in this embodiment, protective layers of different colors can be filled in different groove positions according to customer requirements, so as to increase the visual experience of viewers.

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 108 a of the optical hardening layer 108 , the invention is not limited thereto. In other embodiments, as shown in FIG. 2B , the protection layer 112B can also extend from the groove 105 and cover the top surface 108 a of the optical hardening layer 108 . The protection layer 112B can adjust the range or area of the extension part 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 various colors through the protective layer 112A in the groove 105 . For example, the light source 300 may be a blue light, the protective layer 112A may be 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 white transparent laser engraved pattern with the wood grain layer as the background from the viewing surface 110a. On the other hand, when the light source 300 is turned on, the consumer can see the laser engraving pattern with blue light effect from the visual surface 110 a through the protective layer 112A in the groove 105 . In an 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 protective layer 112A can also have various colors, so as to be combined with the light source 300 Produce different color mixing effects. For example, when the light source 300 is blue light and the protective layer 112A is a red light-transmitting material, when the light source 300 is turned on, consumers can see the laser engraving with purple light effect through the protective layer 112A in the groove 105 from the visual surface 110a pattern. In an alternative embodiment, the protective layer 112A can also be made of a semi-transparent material or an opaque material.

In the conventional spraying technology, multiple spraying steps and multiple laser engraving steps are required to form a multi-color film. The disadvantages of this technology are: cumbersome manufacturing process, difficult processing, high cost and high degree of environmental pollution. In addition, in conventional decoration processes (such as IMD or OMD), multi-color thin films are usually formed by stencil printing. However, this technology will lead to disadvantages such as difficult alignment, low yield, excessive material consumption, and high cost after the client goes through processes such as blister forming, cutting, and injection molding. In addition, since the IMD film or the OMD film is relatively thin, it is not conducive to the laser engraving process. That is to say, even after laser engraving, the film after laser engraving will peel off or be damaged due to poor surface properties. Therefore, an additional protective coating needs to be formed to protect the film, which will increase the cost.

In order to solve the above problems, the embodiment of the present invention forms the all-in-one coating on the substrate and performs a curing step, thereby forming a composite layer structure with protection effect, color effect and bonding effect. The composite layer structure can form a molded film with better physical properties (such as higher hardness, better protection effect, etc.) after undergoing a blister molding process. In addition, compared with the conventional spraying technology or INS technology, the manufacturing steps of the composite layer structure of the present invention are more simplified, and the manufacturing cost can also be effectively reduced. Therefore, the formed film of this embodiment can be applied to the laser engraving process to form various light-transmitting decorative molded products. In addition, the present invention further partially forms the protective layer 112A or 112B in the groove 105 to protect the laser-engraved texture from damage, thereby improving the protective effect of the composite layer structure 110 and increasing the service life.

In addition, the traditional in-mold labeling (IML) technology is to perform screen printing on the back of the substrate (such as PC, PMMA, ABS, etc.) to form a 3-5-layer decorative layer, and then form 3-10 layers The adhesive layer can be attached to the workpiece. Compared with the conventional IML technology, the base material 102 of this embodiment will be melted due to high temperature and high pressure during the injection molding process, and then can be directly bonded to the part of the outer surface 200 a of the workpiece 200 . That is to say, compared with the conventional IML technology, the present invention does not need to form an additional adhesive layer, so that the manufacturing steps of the decorated molded article are simplified and the manufacturing cost is reduced.

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

Referring to FIG. 3 and FIG. 4 , the second embodiment of the present invention provides a manufacturing method S20 of a decorated 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: performing step S102 , forming a first paint on the substrate 102 (as shown in FIG. 4 ) by using a coating method or a printing method. Next, step S104 is performed, forming the second paint on the first paint by coating, printing or 3D printing. Then, proceed to step S107, forming a fourth coating on the second coating by using a coating method, a printing method or a 3D printing method. In one embodiment, the fourth paint at least includes: a protective material, an ink material, and a bonding material mixed uniformly together. In addition, the coating method, printing method, protective material, ink material and laminating material have been described in detail in the above paragraphs, and will not be repeated here. It should be noted that the fourth paint is used to form the impact-proof adhesive layer 118 (as shown in FIG. 4 ). In this embodiment, the content of the bonding material in the fourth paint can be higher than that 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 decoration layer 104 , a second decoration layer 106 and an impact-proof adhesive layer 118 . The first decoration layer 104 can be disposed on the first surface 102 a of the substrate 102 . The second decoration layer 106 can be disposed on the first decoration layer 104 . The impact-proof adhesive layer 118 can be disposed on the second decoration layer 106 such that the second decoration layer 106 is disposed between the first surface 102 a of the substrate 102 and the impact-proof adhesive layer 118 . In addition, in addition to the coating method, the anti-impact adhesive layer 118 can also be formed on the second decoration layer 106 by a coating method, an embossing method, a 3D printing method or a jet printing method. Compared with the ink layer or printing layer in the conventional INS, which needs to be matched with the bonding substrate process, and the conventional IML technology needs to form 3~10 layers of adhesive layers before it can be attached to the workpiece, the anti-impact adhesive layer of this embodiment 118 not only provides color effect, but also has high temperature resistance, protective effect and laminating effect, without the need to form an additional adhesive layer. That is to say, the present invention can effectively simplify the manufacturing steps of the composite layer structure 120 , and provide the composite layer structure 120 with better high temperature resistance, better protection effect and better bonding effect. Furthermore, compared with the conventional spraying technology, INS or IML technology, the manufacturing steps of the composite layer structure of the present invention are more simplified, and the manufacturing cost can also be effectively reduced.

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

Then, step S150 is performed to perform a laser engraving process to form the groove 105 in the composite layer structure 120 . As shown in Figure 4, the groove 105 can be formed from the composite layer structure The top surface 120 a of 120 extends downward until the top surface 104 t of the first decoration layer 104 is exposed. But the present invention is not limited thereto, and in other embodiments, the grooves 105 may also have different depths.

Next, step S160 is performed to form a protection layer 212 in the groove 105 . In one embodiment, the protective layer 212 can be formed by 3D printing technology. Specifically, the filling ink is filled into the groove 105 through the nozzle of the 3D printing device. In one embodiment, the filling ink can be similar to the above-mentioned fourth paint, which at least includes a uniformly mixed protective material, ink material and bonding material, and the content of the bonding material in the filling ink can be higher than that of the first coating. The content of the bonding material in the 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 120 and the subsequently formed workpiece 200 . In this case, the protective layer 212 can partially protect the laser-engraved texture, that is, the first decorative layer 104 and the second decorative layer 106 exposed in the groove 105 from being damaged, so as to further enhance the protective effect of the composite layer structure 120 And increase the service life. In an alternative embodiment, the protection layer 212 can also be formed by jet printing technology.

In an alternative embodiment, 3D printing technology can be used to backfill the protective layer into the laser-engraved light-transmitting area (such as the groove 105), and 3D printing technology can also make different effects in the non-laser-engraved light-transmitting area, such as forming a logo (logo) or gradient and other similar opaque film effects. Afterwards, an additional optically hardened layer is selectively formed by lamination, embossing, 3D printing or jet printing as appropriate.

Afterwards, step S170 is performed to perform in-mold decoration technology or out-of-mold decoration technology, so that the forming film 100B is attached to the inner surface 200b of the workpiece 200 to form a A decorative molded product 20 is formed, as shown in FIG. 4 . Specifically, the inner surface 200 b of the workpiece 200 can contact the top surface 120 a of the composite layer structure 120 and the top surface of the protection layer 212 . In this embodiment, the outer surface 200a of the workpiece 200 can be a visual surface, so that consumers can look down from the outer surface 200a of the workpiece 200 to see the visual effect of the formed film 100B and have a deep crystal-like thickness texture. In addition, the in-mold decoration technology and the out-of-mold decoration technology have been described in detail in the above paragraphs, and will not be repeated here.

FIG. 5 is a schematic flowchart of a method for manufacturing a decorated molded article according to a third embodiment of the present invention. 6 is a schematic cross-sectional view of a decorated molded product according to a third embodiment of the present invention.

Referring to FIG. 5 and FIG. 6 , the third embodiment of the present invention provides a manufacturing method S30 of a decorated 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: performing step S101 , coating the second paint on the substrate (as shown in FIG. 6 ) by using a coating method or a printing method. Next, proceed to step S103, using a coating method or a printing method to coat the first paint on the second paint. 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 this embodiment, the first paint and the second paint can form the first decoration layer 104 and the second decoration layer 106 without additional curing steps (ie, at room temperature), thereby forming the composite layer structure 130 . As shown in FIG. 6 , the composite layer structure 130 includes the first decoration layer 104 and the second decoration layer 106 . The second decoration layer 106 can be disposed on the second surface 102 b of the substrate 102 . The first decoration layer 104 can be disposed under the second decoration layer 106 such that the second decoration layer 106 is interposed between the second surface 102 b of the substrate 102 and the first decoration layer 104 .

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

Then, step S150 is performed to perform a laser engraving process to form the groove 105 in the composite layer structure 130 . As shown in FIG. 6 , the groove 105 may extend upward from the bottom surface 130 b of the composite layer structure 130 until the bottom surface 106 b of the second decoration layer 106 is exposed. But the present invention is not limited thereto, and in other embodiments, the grooves 105 may also 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 can be formed by 3D printing technology. Specifically, the filling ink is filled into the groove 105 through the nozzle of the 3D printing device. In one embodiment, the filling ink can be similar to the above-mentioned fourth paint, which at least includes a uniformly mixed protective material, ink material and bonding material, and the content of the bonding material in the filling ink can be higher than that of the first coating. The content of the bonding material in the 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 partially protect the laser-engraved texture, that is, 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, the protective layer 312 can also be formed by jet printing technology.

Afterwards, step S160 is performed, performing in-mold decoration technology or out-of-mold decoration technology, so that the molded film 100C is attached to the inner surface 200b of the workpiece 200 to form a decorated molded product 30 , as shown in FIG. 6 . Specifically, the inner surface 200b of the workpiece 200 In contact with the first surface 102a of the substrate 102 . The light source 300 can contact the bottom surface 130 b 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 consumers can see the visual effect of the formed film 100C from the outer surface 200a of the workpiece 200 . In addition, the in-mold decoration technology and the out-of-mold decoration technology have been described in detail in the above paragraphs, and will not be repeated here.

In this embodiment, as shown in FIG. 6 , the decorative molded product 30 can emit light of various colors through the protective layer 312 in the groove 105 . For example, the light source 300 may be a blue light, the protective layer 312 may be a white transparent material, and the second decoration layer 106 may be a geometric pattern layer. When the light source 300 is not turned on, consumers can see the entire geometric pattern from the viewing surface 200a. On the other hand, when the light source 300 is turned on, the consumer can see the laser engraved pattern with blue light geometric pattern effect from the viewing surface 200 a through the protective layer 312 in the groove 105 . In addition, the protective layer 312 can also have various colors to combine with the light source 300 to produce different color mixing effects.

7 is a schematic cross-sectional view of a decorated molded product according to a fourth embodiment of the present invention.

Please refer to FIG. 7 , the decorated molded product 40 of the fourth embodiment may include: a workpiece 200 and a molded film 100D. The forming film 100D may be disposed on the outer surface 200 a of the workpiece 200 , and the light source 300 may be disposed on the inner surface 200 b 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 can be disposed on the first surface 102 a of the substrate 102 . In this embodiment, the optical hardening layer 108 can be formed by the above-mentioned third paint, and the content of its protective material can be higher than that of the above-mentioned first paint or the protective material in the above-mentioned second paint. content. In this embodiment, the optical hardening layer 108 can also be called an all-in-one hard coating. In this embodiment, the top surface 108 a of the optical hardening layer 108 may be a viewing surface, so that consumers can see the visual effect of the formed film 100D from the top surface 108 a of the optical hardening layer 108 . In addition, in addition to the coating method, the optical hardening layer 108 can also be formed on the first surface 102 a of the substrate 102 by a coating method, an embossing method, a 3D printing method or a jet printing method.

In addition, the composite layer structure 140 can be disposed on the second surface 102 b of the substrate 102 . Specifically, the composite layer structure 140 may sequentially include an impact-proof adhesive layer 118 , a buffer layer (or decoration layer) 142 , a third decoration layer 144 and a fourth decoration layer 146 from bottom to top. In this embodiment, the anti-shock adhesive layer 118 may be formed by the fourth paint, and the content of the bonding material thereof may be higher than that of the bonding material in the first paint or the second paint. In addition, in addition to the coating method, the anti-impact adhesive layer 118 can also be formed by a coating method, an embossing method, a 3D printing method or a jet printing method. In one embodiment, the material of the buffer layer 142 includes polyurethane (PU) and polymethyl methacrylate (PMMA), which function to prevent ink washout and improve laser engraving resolution. In one embodiment, the third decoration layer 144 can be formed by the above-mentioned first paint, which can be printed once or multiple times to present different decorative patterns such as wood grain and geometric patterns. In one embodiment, the fourth decoration layer 146 can be formed by the above-mentioned second paint, which can be formed on the second surface of the substrate 102 by physical vapor deposition (such as vapor deposition, sputtering, etc.), electroplating, etc. surface 102b. For example, the third decorative layer 144 can be a wood grain layer, and the fourth decorative layer 146 can have a vapor-deposited metal layer with a transparency of 50%, so that the composite layer structure 140 presents a metal-colored wood grain with a transparency of 50%. pattern. also, Although there are only two third decoration layers 144 and fourth decoration layers 146 in FIG. 7 , the present invention is not limited thereto. In other embodiments, multiple decoration layers stacked alternately can be formed according to the requirements of different effects.

It is worth noting that the decorative molded product 40 further includes a groove 105 formed in the anti-shock adhesive layer 118 and the buffer layer 142, and 3D printing technology or jet printing technology can be used to fill the groove 105 with a protective layer. 412. The material and formation method of the protective layer 412 are the same as those of the protective layers 212 and 312 described above, and will not be repeated here. In other embodiments, the protection layer 412 may also have different depths. That is to say, the protective layer 412 can also extend upwards into the third decoration layer 144 and/or the fourth decoration layer 146 . The outer surface 200 a of the workpiece 200 may contact the bottom surface 140 b 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 product 40 can emit light of various colors through the protective layer 412 in the groove 105 . For example, the light source 300 can be a blue light, the protective layer 412 can be a white transparent material, and the fourth decoration layer 146 can be an evaporated metal layer with a transparency of 50%. When the light source 300 is not turned on, consumers can see the entire evaporated metal layer 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 blue metallic effect from the viewing surface 108 a through the protective layer 412 in the groove 105 . In addition, the protective layer 412 can also have various colors to combine with the light source 300 to produce different color mixing effects.

8 is a schematic cross-sectional view of a decorated molded product according to a fifth embodiment of the present invention.

Referring to FIG. 8 , the decorated molded product 50 of the fifth embodiment may include: a workpiece 200 and a molded film 100E. The forming film 100E can be disposed on the outer surface of the workpiece 200 200a, 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 can be disposed on the first surface 102 a of the substrate 102 . The first composite layer structure 150 may include the optical hardening layer 108 and the light-transmitting layer 154 . The material of the light-transmitting layer 154 includes polymethacrylic resin, which has a chemical-resistant decorative layer effect. The transparent layer 154 can contact the first surface 102 a of the substrate 102 , and the optical hardening layer 108 is disposed on the transparent layer 154 . In this embodiment, the top surface 108 a of the optical hardening layer 108 may be a viewing surface, so that consumers can see the visual effect of the formed film 100E from the top surface 108 a of the optical hardening layer 108 . In addition, in addition to the coating method, the optical hardening layer 108 can also be formed by a coating method, an embossing method, a 3D printing method or a jet printing method.

In addition, the second composite layer structure 160 can be disposed on the second surface 102 b of the substrate 102 . Specifically, the second composite layer structure 160 may include the impact-proof adhesive layer 118 and the fourth decoration layer 146 . The fourth decoration layer 146 can be in contact with the second surface 102b of the base material 102, and the anti-shock adhesive layer 118 can be disposed under the fourth decoration layer 146, so that the fourth decoration layer 146 is sandwiched on the second surface of the base material 102. 102b and the anti-shock adhesive layer 118. In this embodiment, the fourth decorative layer 146 can be formed by the above-mentioned second paint, which can be formed on the second surface of the substrate 102 by physical vapor deposition (such as vapor deposition, sputtering, etc.), electroplating, etc. surface 102b. For example, the light-transmitting layer 154 may be a semi-transparent black layer, and the fourth decoration layer 146 may have an evaporated metal layer with a transparency of 25%, so that the molded film 100E presents a black metallic color with a transparency of 25%. Other In addition, in addition to the coating method, the anti-impact adhesive layer 118 can also be formed by a coating method, an embossing method, a 3D printing method or a jet printing method.

It is worth noting that the decorative molding 50 further includes a groove 105 formed in the first composite layer structure 150 , and the protective layer 512 can be filled in the groove 105 by using 3D printing technology or jet printing technology. The material and formation method of the protection layer 512 are the same as those of the above protection layers 112A and 112B, and will not be repeated here. In this embodiment, the protection layer 512 may extend downward from the top surface 108 a of the optical hardening layer 108 into the light-transmitting layer 154 . The bottom surface 160b of the second composite layer structure 160 can contact the outer surface 200a of the workpiece 200 so as to be adhered to the outer surface 200a of the workpiece 200 through the anti-shock adhesive layer 118 .

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

Please refer to FIG. 11 , the decorative molded product 60 of the sixth embodiment may include: a workpiece 200 and a molded film 100F. The forming film 100F may be disposed on the outer surface 200 a of the workpiece 200 , and the light source 300 may be disposed on the inner surface 200 b 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 can be disposed on the first surface 102 a 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 can contact the first surface 102 a of the substrate 102 , and the optical hardening layer 108 is disposed on the fourth decoration layer 146 . In this embodiment, the top surface 108 a of the optical hardening layer 108 may be a visual surface, so that consumers can see the visual effect of the formed film 100F from the top surface 108 a of the optical hardening layer 108 . In this embodiment, the fourth decorative layer 146 can be formed by the above-mentioned second paint, which can be formed by physical vapor deposition (such as vapor deposition, sputtering, etc.), electroplating method etc. are formed on the first surface 102a of the substrate 102 . The optical hardening layer 108 can have a protective function to prevent the fourth decoration layer 146 from being scratched or damaged. In addition, in addition to the coating method, the optical hardening layer 108 can also be formed by a coating method, an embossing method, a 3D printing method or a jet printing method.

It is worth noting that the decorative molded product 60 further includes the groove 105 formed in the composite layer structure 170 , and the protective layer 612 can be filled in the groove 105 by using 3D printing technology or jet printing technology. The material and formation method of the protection layer 612 are the same as those of the above protection layers 112A and 112B, and will not be repeated here. In this embodiment, the protection layer 612 may extend downward from the top surface 108 a of the optical hardening layer 108 into the fourth decoration layer 146 .

12A is a schematic cross-sectional view of a decorated molded product according to a seventh embodiment of the present invention. FIG. 12B and FIG. 12C are schematic top views of the structure in FIG. 12A with the light source turned off and the light source turned on, respectively.

Please refer to FIG. 12A , the decorative molded product 70 of the seventh embodiment may include: a workpiece 200 and a molded film 100G. The forming film 100G may be disposed on the outer surface 200 a of the workpiece 200 , and the light source 300 may be disposed on the inner surface 200 b of the workpiece 200 . Specifically, the formed film 100G may include a substrate 102 , a composite layer structure 180 and an impact-resistant adhesive layer 118 . The substrate 102 has a first surface 102a and a second surface 102b opposite to each other. The composite layer structure 180 can be disposed on the first surface 102 a of the substrate 102 . The composite layer structure 180 may include the third decorative layer 144 , the fourth decorative layer 146 and the optical hardening layer 108 . The fourth decoration layer 146 can contact the first surface 102 a of the substrate 102 . The optical hardening layer 108 can be disposed on the fourth decoration layer 146 . The third decorative layer 144 can be equipped with placed between the fourth decoration layer 146 and the optical hardening layer 108 . In this embodiment, the top surface 108 a of the optical hardening layer 108 may be a visual surface, so that consumers can see the visual effect of the molded film 100G from the top surface 108 a of the optical hardening layer 108 . In this embodiment, the third decoration layer 144 can be formed by the above-mentioned first paint, which can be printed once or multiple times to present different decorative patterns such as wood grain and geometric patterns. The fourth decoration layer 146 can be formed by the above-mentioned second paint, which can be formed on the first surface 102 a of the substrate 102 by physical vapor deposition (such as vapor deposition, sputtering, etc.), electroplating, and the like. The optical hardening layer 108 can have a protective function to prevent the third decoration layer 144 from being scratched or damaged. On the other hand, the impact-proof adhesive layer 118 can be disposed on the second surface 102 b of the substrate 102 and be in contact with the second surface 102 b of the substrate 102 . In this embodiment, the forming film 100G can be adhered to the outer surface 200 a of the workpiece 200 through the anti-shock adhesive layer 118 . In addition, in addition to the coating method, the optical hardening layer 108 and the impact-proof adhesive layer 118 can also be formed by a coating method, an embossing method, a 3D printing method or a jet printing method.

It is worth noting that the decorative molded product 70 further includes a first groove 105a and a second groove 105b, and 3D printing technology or jet printing technology can be used to fill the first protective layer in the first groove 105a 712A and fill the second protective layer 712B in the second groove 105b. In one embodiment, the first passivation layer 712A and the second passivation layer 712B have different material compositions. Specifically, the material of the first protective layer 712A may be similar to the above-mentioned third paint, and the second protective layer 712B may be similar to the above-mentioned fourth paint. The content of the protective material in the first protective layer 712A can 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 The content may be higher than that of the bonding material in the first protective layer 712A. It can be seen from FIG. 12A that the first protection layer 712A is formed in the composite layer structure 180 . That is, the first protection layer 712A extends downward from the top surface 108 a of the optical hardening layer 108 into the third decoration layer 144 . The second protective layer 712B is formed in the anti-shock adhesive layer 118 . That is to say, the decorative molded article 70 of this embodiment can form the first protective layer 712A and the second protective layer 712B on the opposite sides (ie, the upper side and the lower side) respectively, so as to increase different light-transmitting areas, thereby improving consumer perception.

In this embodiment, as shown in FIG. 12B and FIG. 12C , the decorated molded product 70 can emit light of various colors through the first protective layer 712A and the second protective layer 712B in the grooves 105 a and 105 b. For example, the light source 300 can be a blue light, the protective layers 712A and 712B can be made of a white light-transmitting material, the third decorative layer 144 can be a wood grain layer, and the fourth decorative layer 146 can 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 edge 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, consumers can see through the first protective layer 712A in the first groove 105a and the second protective layer 712B in the second groove 105b from the viewing surface 108a that there are metal side strips and Wood grain layer for blu typeface. In addition, the protective layers 712A and 712B can also have various colors, so as to combine with the light source 300 to produce different color mixing effects.

13A is a schematic cross-sectional view of a decorated molded product according to the eighth embodiment of the present invention. FIG. 13B and FIG. 13C are schematic top views of the structure in FIG. 13A with the light source turned off and the light source turned on, respectively.

Please refer to FIG. 13A , the decorative molded product 80 of the eighth embodiment may include: a workpiece 200 and a molded film 100H. The forming film 100H may be disposed on the inner surface 200b of the workpiece 200, and the light source 300 may be disposed below the forming film 100H such that the forming film 100H is sandwiched between the workpiece 200 and the forming 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 can be disposed on the first surface 102 a of the substrate 102 . The composite layer structure 190 may include the third decoration layer 144 , the fourth decoration layer 146 and the impact-proof adhesive layer 118 . The fourth decoration layer 146 can contact the first surface 102 a of the substrate 102 . The impact-proof adhesive layer 118 can be disposed on the fourth decoration layer 146 . The third decoration layer 144 can be disposed between the fourth decoration layer 146 and the impact-proof adhesive layer 118 . In this embodiment, the outer surface 200 a of the workpiece 200 may be a visual surface, so that consumers can see the visual effect of the formed film 100H from the outer surface 200 a of the workpiece 200 . In this embodiment, the third decoration layer 144 can be formed by the above-mentioned first paint, which can be printed once or multiple times to present different decorative patterns such as wood grain and geometric patterns. The fourth decoration layer 146 can be formed by the above-mentioned second paint, which can be formed on the first surface 102 a of the substrate 102 by physical vapor deposition (such as vapor deposition, sputtering, etc.), electroplating, and the like. The anti-shock adhesive layer 118 can have an adhesive function, so that the formed film 100H can be adhered to the inner surface 200 b of the workpiece 200 through the anti-shock adhesive layer 118 . In addition, in addition to the coating method, the anti-impact adhesive layer 118 can also be formed by a coating method, an embossing method, a 3D printing method or a jet printing method.

It is worth noting that the decorative molded product 80 further includes a first groove 105a and a second groove 105b, and 3D printing technology or jet printing technology can be used to print A first protection layer 812A is filled in a groove 105a and a second protection layer 812B is filled in a second groove 105b. In one embodiment, the first passivation layer 812A and the second passivation layer 812B have the same material composition. Specifically, the materials of the first protective layer 812A and the second protective layer 812B may be similar to the fourth paint used to form the anti-shock adhesive layer, which will not be repeated here. It can be seen from FIG. 13A that the first protection layer 812A is formed in the composite layer structure 190 . That is to say, the first protection layer 812A extends downward from the top surface 118 a of the impact-proof adhesive layer 118 into the third decoration layer 144 . The second protective 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 this embodiment can form grooves on opposite sides (ie, the upper side and the lower side) respectively, so as to increase different light-transmitting areas, thereby enhancing consumers' visual experience.

In this embodiment, as shown in FIG. 13B and FIG. 13C , the decorated molded product 80 can emit light of various colors through the first protective layer 812A and the second protective layer 812B in the grooves 105 a and 105 b. For example, the light source 300 can be blue light, the protective layers 812A, 812B can be white light-transmitting materials, the third decorative layer 144 can be a wood grain layer, and the fourth decorative layer 146 can 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 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, consumers can see through the first protective layer 812A in the first groove 105a and the second protective layer 812B in the second groove 105b from the viewing surface 200a that there are metal side strips and Wood grain layer for blu typeface. In addition, the protective layers 812A, 812B can also have various colors, so as to combine with the light source 300 to produce different color mixing effects.

FIG. 14 is a schematic flowchart of a method for manufacturing a decorated molded article according to a ninth embodiment of the present invention. 15A to 15E are schematic cross-sectional views of the manufacturing process of the decorated molded article according to the ninth embodiment of the present invention.

Referring to FIG. 14 and FIG. 15A , the ninth embodiment of the present invention provides a manufacturing method S40 of a decorated molded product 90 as follows. First, step S100 is performed to form a composite layer structure 110 (as shown in FIG. 15A ). Step S100 has been described in detail in the above paragraphs, and will not be repeated here. After the composite layer structure 110 is formed, step S120 is performed to perform a blister forming process to form a molded film 100I.

Then, proceed to step S130, performing in-mold decoration technology or out-of-mold decoration technology, so that the forming film 100I is attached to the outer surface 200a of the workpiece 200 to form a decorated molded product 90, as shown in FIG. 15A. The in-mold decoration technology and the out-of-mold decoration technology have been described in detail in the above paragraphs, and will not be repeated here.

Referring back to FIG. 14 , after the decorative molding 10 is formed, step S140 is performed to perform a second curing step to increase the hardness of the composite layer structure 110 .

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 110 a of the composite layer structure 110 .

Then, step S150 is performed to perform a laser engraving process to form grooves 905 in the mask layer 902 and the composite layer structure 110 . As shown in FIG. 15B , the groove 905 can pass through the mask layer 902 and extend downward from the top surface 110 a of the composite layer structure 110 until exposing the top surface 104 t of the first decoration layer 104 . But the present invention is not limited thereto, and in other embodiments, the groove 905 may also have different depths. That is, groove 905 The bottom surface 905bt of the groove 905 can be higher than or lower than the top surface 104t of the first decoration layer 104 , or the bottom surface 905bt of the groove 905 can be higher than, equal to or lower than the top surface 106t of the second decoration layer 106 . In addition, although FIG. 15B only depicts a single groove 905, the present invention is not limited thereto. In an alternative embodiment, the decorative molding 90 may have multiple grooves to form various laser engraving patterns, and then Increase the visual experience of consumers.

Afterwards, step S152 is performed, and the plating layer 904 is formed by vapor deposition or sputtering. Specifically, the plating layer 904 can be filled into the groove 905 and cover the top surface of the mask layer 902 . It should be noted that the plating layer 904 does not fill the groove 905 . That is to say, the plating layer 904 covers the bottom surface 905bt of the groove 905 , but exposes part of the sidewall 905sw of the groove 905 , as shown in FIG. 15C . In one embodiment, the material of the plating layer 904 includes a metal material. In this embodiment, the plating layer 904 may be a sputtered metal layer.

Then, step S154 is performed to remove the mask layer 902 . Specifically, when the mask layer 902 is removed, the plating layer 904 above the mask layer 902 can also be removed. That is, after removing the mask layer 902, the remaining plating layer 904 is only disposed in the groove 905, as shown in FIG. 15D.

Afterwards, step S160 is performed to form a protection layer 912 in the groove 905 such that the protection layer 912 covers and seals the plating layer 904 . Specifically, the protective layer 912 can be formed by using 3D printing technology or jet printing technology. The material and formation method of the protection layer 912 are the same as those of the above protection layers 112A and 112B, and will not be repeated here. It is worth noting that in this embodiment, the protective layer 912 can partially protect the laser-engraved texture, that is, the plating layer 904 exposed in the groove 905 and the second decorative layer 106 from being damaged, so as to further enhance the composite layer The protective effect of the structure 110 and increase the service life.

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

Referring back to FIG. 15E , the decorative molded product 90 can be disposed on the light source 300 to emit light of various colors through the protective layer 912 in the groove 905 . For example, the light source 300 can be blue light, the plating layer 904 is a sputtered silver layer with a transparency of 50%, the protective layer 912 is a white transparent material, and the second decoration layer 106 can be a wood grain layer. When the light source 300 is not turned on, the consumer can see the metal silver laser engraved pattern with the wood grain layer as the background from the viewing surface 110a. On the other hand, when the light source 300 is turned on, consumers can see the laser-engraved pattern with a silver-blue metallic effect through the protective layer 912 in the groove 905 from the visual surface 110a.

The above process of performing steps S142 to S160 to partially form the plating layer and the protective layer in the groove can also be applied to any one of the above-mentioned decorative molded products 20, 30, 40, 50, 60, 70, and 80 . For example, after step S142 to step S160 are performed to form the coating layer and the protective layer in the groove, step S170 is performed, that is, the in-mold decoration technology or the out-of-mold decoration technology is performed, so that the molded film is attached to the inner surface of the workpiece. On the surface. In this embodiment, since the protective layer will be attached to the inner surface of the workpiece, the material of the protective layer is similar to the fourth paint used to form the anti-scourrence bonding layer. That is to say, the process of partially forming the plating layer and the protective layer in the groove can be applied to the structures of various decorative moldings according to product requirements.

In addition, the above-mentioned decorative molded products 10, 20, 30, 40, 50, 60, 70, Any one of 80,90 can be applied on the car light. That is to say, any one of the decorative moldings 10, 20, 30, 40, 50, 60, 70, 80, 90 can be attached to the plastic housing of the car lamp to engrave patterns (such as concave holes) through laser light. Groove 105) to present a variety of different color effects. For example, in the present invention, a plurality of grooves 105 can be corresponding to lamp bodies of different colors, so that the brake light presents a red light through the first groove, the left turn lamp presents a yellow light through the second groove, and The headlights present white light etc. through the third groove.

Although the manufacturing method S40 of FIG. 14 is shown and described herein as a series of actions or events, it should be understood that the illustrated order of these actions or events should not be construed as limiting. That is, certain acts may occur in different orders and/or concurrently with other acts or events than those shown and/or described herein. For example, the formation of the mask layer, the laser engraving process, and the 3D printing steps are all within the protection scope of the present invention regardless of the process sequence. In addition, not all illustrated acts may be required to implement one or more aspects or embodiments described herein. Furthermore, one or more of the acts depicted herein may be performed in one or more separate acts and/or stages.

To sum up, the present invention forms the all-in-one coating on the substrate and performs a curing step to form a composite layer structure with protective effect, color effect and bonding effect. The composite layer structure can form a molded film with better physical properties (such as higher hardness, better protection effect, etc.) after undergoing a blister molding process. Therefore, the molded film of this embodiment is suitable for laser engraving process, and then forms various light-transmitting decorative moldings. In addition, the present invention further partially forms the protective layer in the groove to protect the laser-engraved texture from damage, thereby improving the composite layer structure. Protective effect and increase service life. In addition, the present invention performs the laser engraving process after the blister forming process, therefore, the present invention can solve the alignment problem of the prior art, thereby improving the yield rate and reducing the manufacturing cost.

On the other hand, compared with the ink layer or printing layer in the conventional INS, which needs to be matched with the substrate bonding process, the multiple stacked decorative layers in this embodiment not only provide a variety of color effects, but also have protective effects and bonding effect without the need for an additional bonding process. In addition, compared with the conventional IML technology, which needs to form 3-10 additional layers of adhesive layer before it can be attached to the workpiece, this embodiment does not need to form an additional adhesive layer. That is to say, the present invention can effectively simplify the manufacturing steps of the composite layer structure, and provide a composite layer structure with better protection effect and bonding effect. Furthermore, compared with the conventional spraying technology, INS technology or IML technology, the manufacturing steps of the decorated molded article of the present invention are more simplified, and the manufacturing cost can be effectively reduced.

S40: Manufacturing method

S100, S102, S104, S106, S108, S120, S130, S140, S142, S150, S152, S154, S160: steps

Claims (10)

A method for manufacturing a decorative molded article, comprising: providing a coating, wherein the coating at least includes: a protective material, an ink material, and a bonding material are uniformly mixed together; and forming the coating on a substrate by using a coating method or a printing method On; performing a first curing step to form a composite layer structure, wherein the composite layer structure includes at least an optically hardened layer disposed on the substrate; performing a blister forming process to form a molded film; performing a second curing step , to increase the hardness of the forming film; perform a laser engraving process to form grooves; form a protective layer in the grooves, wherein the content of the protective material in the protective layer is higher than that of the coating content of the protective material; and attaching the forming film to the surface of the workpiece to form a decorative molding. The method for manufacturing a decorated molded article according to claim 1, wherein the protective material includes polymethyl methacrylate, aliphatic urethane acrylate, epoxy acrylate, polyester polyol or a combination thereof, and the ink The material includes polyurethane, and the conforming material includes thermoplastic polyurethane, aromatic urethane acrylate, or combinations thereof. The method for manufacturing a decorated molded article according to Claim 1, wherein the protective layer is formed by 3D printing technology or jet printing technology. The method for manufacturing a decorated molded article according to claim 1, wherein the step of attaching the molded film to the surface of the workpiece comprises: After performing the blister forming process, the molded film is subjected to in-mold decoration technology or out-of-mold decoration technology, so that the molded film is attached to the outer surface of the workpiece to form the decorated molded product . The method for manufacturing a decorated molded article according to claim 1, wherein the step of attaching the molded film to the surface of the workpiece comprises: after performing the laser engraving process, The film is subjected to an in-mold decoration technique or an out-of-mold decoration technique, so that the formed film is attached to the inner surface of the workpiece to form the decorated molded article. A method for manufacturing a decorated molded product, comprising: providing a substrate having opposite first and second surfaces; forming a second paint on the second surface of the substrate by using a coating method or a printing method ; Utilizing a coating method or a printing method to form the first coating on the second coating; performing a first curing step to form a composite layer structure, wherein the composite layer structure includes at least: the base material; the first decoration a layer configured on the second surface of the substrate; and a second decorative layer configured between the second surface of the substrate and the first decorative layer; performing a blister molding process, To form a molded film; perform a laser engraving process to form a groove; form a protective layer in the groove, wherein the content of the bonding material in the protective layer The content of the pasting material is higher than that in the first paint or the second paint; and attaching the molded film to the surface of the workpiece to form a decorated molded article. The method of manufacturing a decorated molded article according to claim 6, wherein each of the first paint and the second paint includes: a protective material, an ink material, and the bonding material are uniformly mixed together. The method for manufacturing a decorated molded article as claimed in claim 6, wherein the protective layer is formed by 3D printing technology or jet printing technology. A method for manufacturing a decorative molded article, comprising: providing a coating, wherein the coating at least includes: a protective material, an ink material, and a bonding material are uniformly mixed together; and forming the coating on a substrate by using a coating method or a printing method On; performing a first curing step to form a composite layer structure; performing a blister forming process to form a molded film; performing a second curing step to increase the hardness of the molded film; forming a mask on the composite layer structure layer; perform a laser engraving process to form grooves in the mask layer and the composite layer structure; use evaporation or sputtering to form a coating layer on the mask layer, part of which filling the plating layer into the groove; removing the mask layer and the plating layer above it; forming a protection layer in the groove, wherein the protection layer covers the plating layer, wherein the content of the protective material in the protective layer is higher than that in the paint The content of the protective material; and attaching the forming film to the surface of the workpiece to form a decorative molding. The method for manufacturing a decorated molded article as claimed in claim 9, wherein the protective layer is formed by 3D printing technology or jet printing technology.