WO2020023049A1

WO2020023049A1 - Surface decoration films

Info

Publication number: WO2020023049A1
Application number: PCT/US2018/044009
Authority: WO
Inventors: Chi-Hao Chang; Kuan-Ting Wu; Kuo-Chih Huang
Original assignee: Hewlett-Packard Development Company, L.P.
Priority date: 2018-07-27
Filing date: 2018-07-27
Publication date: 2020-01-30

Abstract

Examples of surface decoration films for devices are described. In an example, a surface decoration film includes a polymer substrate, a thermoplastic layer coated on the polymer substrate, a decorative mold layer disposed on the thermoplastic layer, and a vacuum-deposited layer coated on the decorative mold layer.

Description

SURFACE DECORATION FILMS

BACKGROUND

[0001] Devices, such as laptops, mobile phones, and display monitors, have a housing or an enclosure that may enclose a processor, a memory unit, motherboard, and an input/output device. Devices, such as spectacles holders, sunglasses holders, and card holders, have a housing or an enclosure that may enclose spectacles, sunglasses, and visiting cards. The outer surface of a housing or an enclosure, or other body parts, of such a device may be decorated to provide aesthetics to the device.

BRIEF DESCRIPTION OF DRAWINGS

[0002] The following detailed description references the drawings, wherein:

[0003] Fig. 1 illustrates a sectional view of a surface decoration film, according to an example of the present disclosure;

[0004] Fig. 2 illustrates a sectional view of a surface decoration film, according to another example of the present disclosure;

[0005] Fig. 3 illustrates a sectional view of a surface decoration film, according to another example of the present disclosure;

[0006] Fig. 4 illustrates an electronic device with a surface decoration film on a body part, according to an example of the present disclosure; and

[0007] Fig. 5 illustrates a method of fabrication of a surface decoration film for a device, according to an example of the present disclosure.

DETAILED DESCRIPTION

Definitions [0008] For convenience, before further description of the present disclosure, certain terms employed in the specification, and examples are described here. These definitions should be read in the light of the remainder of the present disclosure. The terms used herein have the meanings recognized and known to those of skilled in the art, however, for convenience and completeness, particular terms and their meanings are set forth below.

[0009] The articles“a”,“an” and“the” are used to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article.

[0010] The term“about” when referring to a numerical value is intended to encompass the values resulting from variations that can occur during the normal course of performing a method. Such variations are usually within plus or minus 5 to 10 percent of the stated numerical value.

[001 1] The term“weight percentage”, or“wt%”, of a component used herein refers to a percentage weight of that component relative to 100% weight of the composition.

[0012] The term“body part” or“body parts” of a device used herein refers to a part or parts, respectively, of the device that may be visible from outside and thus be decorated to provide aesthetics to the device. The term“body part” of a device used herein may refer to an enclosure or a housing of the device that may house a component therein. The term“body part” of a device used herein may also refer a body panel of the device.

[0013] The term“coat", and variations, such as“coating” and“coated”, used herein refer to deposition on a surface.

[0014] The term“paste”, and variations, such as“pasted” and“pasting”, used herein refer to attachment using an adhesive.

[0015] The term“dispose”, and variations, such as“disposed” and“disposing”, used herein refer to position, place, arrange, set, and the corresponding variations.

[0016] The term“pre-fabricate”, and variations, such as“pre-fabricated”,“pre- fabrication” and“pre-fabricating”, used herein refer to fabrication prior to use. [0017] The term “uniform surface profile” of a layer used herein refers to constant thickness of the layer with a deviation less than ±5%, or less than ±3%, or less than ±1%, or 0%.

[0018] The term“structurally stable” used herein refers to surface being averse to smudging and aberrations.

[0019] The term“quality of decoration of the surface decoration film” used herein refers appearance, or aesthetic appeal, of the surface decoration film.

[0020] Body parts of a device, such as a laptop, a mobile phone, a keyboard, a mouse, a spectacles holder, a sunglasses holder, and a card holder, may be decorated by coating a layer, or by pasting a film, thereon. Decoration on a body part of a device may provide aesthetics to the device.

[0021] Body parts of a device may be made of metals, glass, plastic, and composite materials. The body parts made of such materials are strong and light in weight. A decoration layer or film on a body part may be fabricated using tedious deposition techniques, which may increase the production time and cost. Further, the decoration layer or film may not be structurally stable, may include aberrations, and may smudge and get dirty with time, which may affect the look and feel of the decoration layer or film, and thus the quality of decoration.

[0022] The present disclosure describes examples of surface decoration films, electronic devices having the surface decoration films, and methods of fabrication of the surface decoration films. In an example, a surface decoration film includes a polymer substrate, and a thermoplastic layer coated on the polymer substrate. The polymer substrate may be made of polyethylene terephthalate, acrylic, polyamide, polycarbonate, polyurethane, or combinations thereof. The thermoplastic layer may be made of polycarbonate, polyacrylic, polyester, polycarbonate, acrylnitrile- butadiene-styrene, polyurethanes, polyamide, or combinations thereof. The surface decoration film also includes a decorative mold layer disposed on the thermoplastic layer. The decorative mold layer may be made of a chromium-molybdenum alloy or stainless steel. In an example, the chromium-molybdenum alloy may include chromium of about 70 wt% and molybdenum of about 30 wt%. The decorative mold layer may be prefabricated, using a molding process. The decorative mold layer includes a decorative pattern formed, for example, using a computer numerical control (CNC) machining process or an electrical discharge machining (EDM) process. The decorative mold layer is disposed on the thermoplastic layer prior to curing the thermoplastic layer. The thermoplastic layer may thermally be cured to harden or solidify the thermoplastic layer.

[0023] Further, the surface decoration film includes a vacuum-deposited layer coated on the decorative mold layer. The vacuum-deposited layer may be made of titanium, chromium, nickel, zinc, zirconium, manganese, copper, aluminum, tin, molybdenum, tantalum, tungsten, hafnium, gold, vanadium, silver, platinum, graphite, or combinations thereof. In an example, the vacuum-deposited layer may be coated using a physical vapor deposition (PVD) technique. In another example, the vacuum-deposited layer may be coated using a non-conductive vacuum metallization (NCVM) technique. The surface decoration film, as described above, may be pasted on a body part of a device to provide aesthetics to the device.

[0024] As described above, the decorative mold layer is disposed on the thermoplastic layer prior to curing the thermoplastic layer. Before curing, the thermoplastic layer shows characteristics of a plastic. The plastic nature of the thermoplastic layer enables a good adhesion of the decorative mold layer with the thermoplastic layer. Further, use of the prefabricated decorative mold layer, having a decorative pattern, in the surface decoration film may reduce the production time and cost of the surface decoration film. Further, the prefabricated decorative mold layer, used in the surface decoration film, may have a uniform surface profile and may be structurally stable in comparison to a decoration layer deposited using a deposition technique.

[0025] Further, the vacuum-deposited layer on the decorative mold layer, coated using the PVD technique or the NCVM technique is transparent, which allows reflection of light incident on the surface decoration film, thereby providing the aesthetic appeal to the surface decoration film. Also, the vacuum-deposited layer on the decorative mold layer prevents smudging and dirtying of the decorative pattern of the surface decoration film, which facilitates keeping the quality of decoration of the surface decoration film uniform for a longer time. The quality of decoration of the surface decoration film may be quantified by measuring a gloss value of the surface decoration film. In an example, the gloss value of the surface decoration film may be in a range of from 70 to 98 units as measured by American Society for Testing and Materials (ASTM) D523 at a viewing angle of about 60°. In another example, the gloss value of the surface decoration film may be in a range of from 85 to 95 units as measured by ASTM D523 at a viewing angle of about 60°.

[0026] The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar parts. While several examples are described in the description, modifications, adaptations, and other implementations are possible. Accordingly, the following detailed description does not limit the disclosed examples. Instead, the proper scope of the disclosed examples may be defined by the appended claims.

[0027] Fig. 1 illustrates a sectional view of a surface decoration film 100, according to an example of the present disclosure. The surface decoration film 100 includes a polymer substrate 102. The polymer substrate 102 is made of polyethylene terephthalate, acrylic, polyamide, polycarbonate, polyurethane, or combinations thereof. The polymer substrate 102 may be of a thickness in a range of from about 10 micrometer (pm) to about 100 pm. In an example, the polymer substrate 102 may be of a thickness in a range of from about 20 pm to about 90 pm, or in a range of from about 30 pm to about 80 pm, or in a range of from about 40 pm to about 70 pm, or in a range of from about 50 pm to about 60 pm.

[0028] The surface decoration film 100 also includes a thermoplastic layer 104 coated on the polymer substrate 102. The thermoplastic layer is made of polycarbonate, polyacrylic, polyester, polycarbonate, acrylnitrile-butadiene-styrene, polyurethanes, polyamide, or combinations thereof. The thermoplastic layer 104 is spray coated on the polymer substrate 102. The thermoplastic layer 104 may be of a thickness in a range of from about 30 pm to about 90 pm. in an example, the thermoplastic layer 104 may be of a thickness in a range of from about 40 pm to about 80 pm, or in a range of from about 50 pm to about 70 pm, or in a range of from about 55 pm to about 65 pm.

[0029] Further, the surface decoration film 100 includes a decorative mold layer 106 disposed on the thermoplastic layer 104. The decorative mold layer 106 is made of a chromium-molybdenum alloy or stainless steel. The decorative mold layer 106 may have a decorative pattern on one of the surfaces. In an example, the decorative pattern may be a fabric-type pattern, such that the surface decoration film 100 appears to have a design pattern like that of a fabric in an example, the decorative pattern may be a carbon fiber-like pattern, such that the surface decoration film 100 appears to have a design pattern like that of a carbon fiber sheet. The decorative mold layer 106 is disposed on the thermoplastic layer 104, such that the decorative pattern is visible from outside. The details of disposing the decorative mold layer on the thermoplastic layer is described with reference to Fig. 5.

[0030] The chromium-molybdenum alloy, used for making the decorative mold layer 106, may include chromium of about 70 wt% and molybdenum of about 30 wt%. in an example, the chromium-molybdenum alloy may include chromium in a range of from about 65 wt% to 75 wt% and molybdenum in a range of from about 25 wt% to 35 wt%. In another example, the chromium-molybdenum alloy may include chromium in a range of from about 67 wt% to 73 wt% and molybdenum in a range of from about 27 wt% to 37 wt%. In yet another example, the chromium-molybdenum alloy may include chromium in a range of from about 69 wt% to 71 wt% and molybdenum in a range of from about 29 wt% to 31 wt%.

[0031] In an example, the decorative mold layer 106 is made using an out-mold process, in which the chromium-molybdenum alloy or stainless steel, in liquid form, is poured in a mold. The liquid in the mold is allowed to cool and solidify, and then the solidified material is drawn out from the mold. The solidified material may be cleaned, washed, polished, degreased, and activated. The cleaning and washing may be performed using a buffer solution, which may help in removing foreign particles, if any, present on the surface of the solidified material. Further, the solidified material may be chemically polished using abrasives to remove irregularities that may be present on the surface of the solidified material. The solidified material may also be degreased through ultrasonic degreasing to remove impurities, such as fat, grease, or oil from the surface of the solidified material. Further, the solidified material may also be activated through acid treatment for removing the natural oxide layer, if any, present on the surface of the solidified material. Subsequently, the decorative pattern may be made using a CNC machining process or an EDM process to obtain the decorative mold layer 106.

[0032] The decorative mold layer 106 may have a thickness in a range of from about 100 pm to about 500 pm. In an example, the decorative mold layer 106 may be of a thickness in a range of from about 150 pm to about 450 pm, or in a range of from about 200 pm to about 400 pm, or in a range of from about 250 pm to about 350 pm, or in a range of from about 280 pm to about 320 pm.

[0033] The surface decoration film 100 further includes a vacuum-deposited layer 108 coated on the decorative mold layer 106. The vacuum-deposited layer 108 is made of titanium, chromium, nickel, zinc, zirconium, manganese, copper, aluminum, tin, molybdenum, tantalum, tungsten, hafnium, gold, vanadium, silver, platinum, graphite, or combinations thereof. In an example, the vacuum-deposited layer 108 is coated using a PVD technique in another example, the vacuum- deposited layer 108 is coated using a NCVM technique. The details of coating the vacuum-deposited layer on the decorative mold layer are described with reference to Fig. 5.

[0034] The vacuum-deposited layer 108 may have a thickness in a range of from about 30 nanometer (nm) to about 100 nm. In an example, the vacuum- deposited layer 108 may be of a thickness in a range of from about 40 nm to about 90 nm, or in a range of from about 50 nm to about 80 nm, or in a range of from about 60 nm to about 70 nm. The vacuum-deposited layer 108 of such a thickness coated using the PVD technique protects the decorative mold layer 106 from smudging and dirtying, which facilitates maintaining the quality of decoration of the surface decoration film uniform for a longer time. Also, the vacuum-deposited layer 108 of such a thickness coated using the PVD technique is clear, such that light incident on the surface decoration film is reflected from the decorative mold layer 106, thereby providing the aesthetic appeal to the surface decoration film. Further, vacuum- deposited layer 108 of such a thickness coated using the NCVM technique is a non- continuous coating. Such a non-continuous vacuum-deposited layer 108 in the surface decoration film 100 allows communication signals, associated with an electronic device on which the surface decoration film 100 is pasted, to pass through, thereby eliminating the antenna signal blocking issue which may otherwise be there with surface decoration films pasted on electronic devices.

[0035] The thermoplastic layer 104, as described above, is coated on a first surface of the polymer substrate 102. The first surface may be a planar surface of the polymer substrate 102. In an example, an optically clear adhesive layer is disposed on a second surface of the polymer substrate 102, as illustrated in a sectional view of a surface decoration film 200, shown in Fig. 2. The second surface is opposite to the first surface of the polymer substrate 102.

[0036] The optically clear adhesive layer, referenced as 202, is made of polyacrylic, polycarbonate, polyester, cyclic olefin co-polymer (COC), or combinations thereof. The optically clear adhesive layer 202 is spray coated on the second surface of the polymer substrate 102. The optically clear adhesive layer 202 may be of a thickness in a range of from about 30 pm to about 80 pm. In an example, the optically clear adhesive layer 202 may be of a thickness in a range of from about 40 pm to about 70 pm, or in a range of from about 50 pm to about 60 pm.

[0037] The optically clear adhesive layer 202 includes a release film 204. The release film is removable from the optically clear adhesive layer 202 to attach the surface decoration film 200 on a surface of a body part of a device to provide aesthetics to the device. The release film 204 is made of polyethylene terephthalate. The release film 204 has a thickness in a range of from about 5 pm to about 25 pm.

[0038] Fig. 3 illustrates a sectional view of a surface decoration film 300, according to another example of the present disclosure. The surface decoration film 300 include the polymer substrate 102, the thermoplastic layer 104, the decorative mo!d layer 106, and the vacuum-deposited layer 108, as shown and described with reference to Fig. 1. The surface decoration film 300 also includes the optically clear adhesive layer 202 and the release film 204, as shown and described with reference to Fig. 2. The surface decoration film 300 further includes an optically clear resin layer 302 coated on the vacuum-deposited layer 108. The optically clear resin layer 302 is a cover layer on the vacuum-deposited layer 108 to protect the vacuum- deposited layer 108 from scratches and aberrations, thereby increasing the robustness of the surface decoration film 300.

[0039] The optically clear resin layer 302 is made of polyacrylic, polycarbonate, cyclic olefin co-polymer (COC), or combinations thereof. The optically clear resin layer 302 is spray coated on the vacuum-deposited layer 108. The optically clear resin layer 302 may be of a thickness in a range of from about 10 pm to about 100 pm. In an example, the optically clear resin layer 302 may be of a thickness in a range of from about 20 pm to about 90 pm, or in a range of from about 30 pm to about 80 pm, or in a range of from about 40 pm to about 70 pm, or in a range of from about 50 pm to about 60 pm.

[0040] Fig. 4 illustrates an electronic device 400 with a surface decoration film 402 on a body part 404, according to an example of the present disclosure. Although, the electronic device 400 is shown to be a laptop in Fig. 4, the surface decoration film 402 can be pasted on a body part of other electronic devices, such as mobile phones, printers, monitors, keyboards, mice, and web-cameras. The body part 404 is an enclosure of the electronic device 400 that houses various components, such as a processor, a memory unit, a motherboard, and interfaces. In an example, the body part 404 may include a body panel of the electronic device 400, on a surface of which the surface decoration film 402 can be pasted for decorating the electronic device 400. The body part 404 may be made of metals, glass, plastic, carbon fiber and composite materials. The metals may include magnesium, aluminum, zinc, titanium, lithium, niobium, steel, copper, or combinations thereof. The composite materials may include carbon fiber/metal composite, metal/plastic composite, carbon fiber/plastic composite, glass/plastic composite, and carbon fiberglass composite. [0041] The surface decoration film 402 includes an optically clear adhesive layer 406 through which the surface decoration film 402 is attached to a surface 408 of the body part 404. The optically clear adhesive layer 406 may be the same as the optically clear adhesive layer 202, as described with reference to Fig. 2.

[0042] The surface decoration film 402 includes a polymer substrate 410 on the optically clear adhesive layer 406, a thermoplastic layer 412 coated on the polymer substrate 410, a decorative mold layer 414 disposed on the thermoplastic layer 412, a vacuum-deposited layer 416 coated on the decorative mold layer 414, and an optically clear layer 418 coated on the vacuum-deposited layer 416. The polymer substrate 410, the thermoplastic layer 412, the decorative mold layer 414, and the vacuum-deposited layer 416 may be the same as the polymer substrate 102, the thermoplastic layer 104, the decorative mold layer 106, and the vacuum-deposited layer 108, respectively, as described with reference to Fig. 1. The optically clear layer 418 may be the same as the optically clear resin layer 302, as described with reference to Fig. 3.

[0043] in an example, the surface decoration film 402 may include a hard layer (not shown in Fig. 4) coated on the optically clear layer 418. The hard layer is made of a polyacrylic resin. The hard layer is spray coated on the optically clear layer 418. The hard layer has a thickness in a range of from about 5 pm to about 15 pm. In an example, the hard layer has a thickness in a range of from about 6 pm to about 14 pm, or in a range of from about 7 pm to about 13 pm, or in a range of from about 8 pm to about 12 pm, or in a range of from about 9 pm to about 1 1 pm.

[0044] Although the description above is described with reference to an electronic device, the surface decoration film as disclosed herein can be pasted on other devices, such as spectacles holders, sunglasses holders, card holders, and bottles.

[0045] Fig. 5 illustrates a method 500 of fabrication of a surface decoration film for a device, according to an example of the present disclosure. While the method 500 is described in context of fabrication of the surface decoration film 100, the method 500 may be performed for fabrication of other surface decoration films. [0046] At block 502 of the method 500, a thermoplastic layer is coated on a first surface of a polymer substrate. The first surface may be a planar surface of the polymer substrate. The polymer substrate is the polymer substrate 102, as described with reference to Fig. 1 . The polymer substrate is made of polyethylene terephthalate, acrylic, polyamide, polycarbonate, polyurethane, or combinations thereof. The polymer substrate may be of a thickness in a range of from about 10 micrometer (pm) to about 100 pm. The thermoplastic layer is spray coated on the polymer substrate. The thermoplastic layer is the thermoplastic layer 104, as described with reference to Fig. 1. The thermoplastic layer is made of polycarbonate, polyacrylic, polyester, polycarbonate, acrylnitrile-butadiene-styrene, polyurethanes, polyamide, or combinations thereof. The thermoplastic layer 104 may be of a thickness in a range of from about 30 pm to about 90 pm.

[0047] At block 504, a decorative mold layer is disposed on the thermoplastic layer by exerting a physical force. The decorative mold layer is the decorative mold layer 106, as described with reference to Fig. 1. The decorative mold layer is made of a chromium-molybdenum alloy or stainless steel and has a decorative pattern thereon. The chromium-molybdenum alloy, used for making the decorative mold layer 106, may include chromium of 70 wt% and molybdenum of 30 wt%. The decorative mold layer is a pre-fabricated layer of a thickness in a range of from about 100 pm to about 500 pm. The decorative mold layer is made using an out-mold process, as described earlier. In an example, the decorative mold layer may be cleaned, washed, polished, degreased, and activated, as described earlier.

[0048] In an example, the decorative mold layer is placed on the thermoplastic layer and manually pressed. In another example, the decorative mold layer is placed on the thermoplastic layer and pressed using a pneumatic pressing machine. The physical force exerted on the decorative mold layer, while pressing, may be in a range of from about 100 N to about 500 N.

[0049] In an example, the thermoplastic layer is heated prior to disposing the decorative mold layer to remove moisture from the thermoplastic layer and dry the thermoplastic layer. The thermoplastic layer is heated at a temperature in a range of from about 40 °C to about 50 °C for a time duration in a range of from about 5 minutes to 10 minutes. In an example, the thermoplastic layer is heated at a temperature in a range of from about 42 °C to about 48 °C, or in a range of from about 44 °C to about 46 °C. In an example, the thermoplastic layer is heated for a time duration in a range of from about 6 minutes to 9 minutes, or in a range of from about 7 minutes to 8 minutes.

[0050] Further, in an example, the decorative mold layer is heated prior to disposing on the thermoplastic layer to adhesion of the decorative mold layer with the thermoplastic layer. The decorative mold layer is at a temperature in a range of from about 50 °C to about 60 °C when being disposed on the thermoplastic layer. In an example, the decorative mold layer is at a temperature in a range of from about 52 °C to about 58 °C, or in a range of from about 54 °C to about 56 °C.

[0051] Returning to Fig. 5, at block 506, the thermoplastic layer is cured at a temperature in a range of from about 55 °C to about 70 °C. Curing of the thermoplastic layer at a temperature in such a range hardens the thermoplastic layer. The thermoplastic layer is thermally cured. In an example, the thermoplastic layer is cured at a temperature in a range of from about 57 °C to about 67 °C, or in a range of from about 60 °C to about 65 °C, or in a range of from about 61 °C to about 63 °C.

[0052] At block 508, an over-layer is coating on the decorative mold layer by a PVD technique or a NCVM technique. The over-layer is the vacuum-deposited layer 108, as described with reference to Fig. 1. The over-layer is made of titanium, chromium, nickel, zinc, zirconium, manganese, copper, aluminum, tin, molybdenum, tantalum, tungsten, hafnium, gold, vanadium, silver, platinum, graphite, or combinations thereof. The over-layer has a thickness in a range of from about 30 nm to about 100 nm. The over-layer is coated at a vacuum pressure in a range of from about 10 ³ Torr to about 10^~4 Torr and at a temperature in a range of from about 25 °C to about 100 °C. In an example, the over-layer is coated at a vacuum pressure in a range of from about 2x1 O ³ Torr to about 0.8x1 O ⁴ Torr, or in a range of from about 4x1 O ³ Torr to about 0.6x1 O ⁴ Torr. In an example, the over-layer is coated at a temperature in a range of from about 35 °C to about 90 °C, or in a range of from about 45 °C to about 80 °C, or in a range of from about 55 °C to about 70 °C, or in a range of from about 60 °C to about 65 °C.

[0053] in an example, an optically clear adhesive layer is laminated on a second surface of the polymer substrate. The second surface is opposite to the first surface of the polymer substrate on which the thermoplastic layer is coated. The optically clear adhesive layer is made of polyacrylic, polycarbonate, polyester, cyclic olefin co-polymer (COC), or combinations thereof. The optically clear adhesive layer may be of a thickness in a range of from about 30 pm to about 80 pm.

[0054] Further, the optically clear adhesive layer has a removable release film. The release film is removed from the optically clear adhesive layer to attach the surface decoration film on a surface of a body part of a device. The release film is made of polyethylene terephthalate. The release film has a thickness in a range of from about 5 pm to about 25 pm.

EXAMPLES

[0055] The description hereinafter describes prophetic examples, which are intended to illustrate examples of the present disclosure and not intended to be taken restrictively to imply any limitations on the scope of the present disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. It is to be understood that this disclosure is not limited to the particular methods and experimental conditions described, as such methods and conditions may vary depending on the process and inputs used as will be easily understood by a person skilled in the art.

Prophetic Example 1

[0056] A thermoplastic layer of polycarbonate is spray coated on a surface of a polyethylene terephthalate substrate. The polyethylene terephthalate substrate is of a thickness of about 50 pm. The thermoplastic layer is of a thickness of about 50 pm.

[0057] After coating the polycarbonate thermoplastic layer, the polycarbonate thermoplastic layer is heated at a temperature of about 45 °C for a time duration of about 7 minutes to remove moisture from the thermoplastic layer and dry the thermoplastic layer.

[0058] Then, a decorative mold layer made of a chromium-molybdenum alloy and having a decorative pattern thereon is placed on the polycarbonate thermoplastic layer and pressed by exerting a physical force of 250 N using a pneumatic pressing machine. The chromium-molybdenum alloy, used for making the decorative mold layer, includes chromium of about 70 wt% and molybdenum of about 30 wt%. The decorative mold layer is of a thickness of about 200 pm. The decorative mold layer is heated to a temperature of about 55 °C prior to disposing on the thermoplastic layer.

[0059] After disposing the decorative mold layer, the thermoplastic layer is cured at a temperature of about 60 °C to harden the thermoplastic layer. After, curing the thermoplastic layer, an over-layer, or a vacuum-deposited layer, of copper is coating on the decorative mold layer by a PVD technique. The over-layer has a thickness of about 50 nm. The over-layer is coated at a vacuum pressure of about 5x1 O ³ Torr and at a temperature of 50 °C.

[0060] After coating the over-layer, an optically clear adhesive layer of cyclic olefin co-polymer (COC) is spray coated on another surface of the polyethylene terephthalate substrate, where the other surface is opposite to the surface of the polyethylene terephthalate substrate on which the thermoplastic layer is coated. The optically clear adhesive layer is of a thickness of about 50 pm.

[0061] Further, a release film of polyethylene terephthalate is pasted on the optically clear adhesive layer. The release film has a thickness of about 25 pm. The release film can be removed from the optically clear adhesive layer to attach the surface decoration film on a surface of a body part of a device.

Prophetic Example 2

[0062] A thermoplastic layer of polyacrylic is spray coated on a surface of a polyamide substrate. The polyamide substrate is of a thickness of about 60 pm. The thermoplastic layer is of a thickness of about 70 pm. [0063] After coating the polyacrylic thermoplastic layer, the polyacrylic thermoplastic layer is heated at a temperature of about 47 °C for a time duration of about 6 minutes to remove moisture from the thermoplastic layer and dry the thermoplastic layer.

[0064] Then, a decorative mold layer made of stainless steel and having a decorative pattern thereon is placed on the polyacrylic thermoplastic layer and pressed by exerting a physical force of 330 N using a pneumatic pressing machine. The decorative mold layer is of a thickness of about 300 pm. The decorative mold layer is heated to a temperature of about 52 °C prior to disposing on the thermoplastic layer.

[0065] After disposing the decorative mold layer, the thermoplastic layer is cured at a temperature of about 65 °C to harden the thermoplastic layer. After, curing the thermoplastic layer, an over-layer, or a vacuum-deposited layer, of silver is coating on the decorative mold layer by a NCVM technique. The over-layer has a thickness of about 70 nm. The over-layer is coated at a vacuum pressure of about 7x1 O ³ Torr and at a temperature of 60 °C.

[0066] After coating the over-layer, an optically clear adhesive layer of polyacrylic is spray coated on another surface of the polyamide substrate, where the other surface is opposite to the surface of the polyamide substrate on which the polyacrylic thermoplastic layer is coated. The optically clear adhesive layer is of a thickness of about 70 pm.

[0067] Further, a release film of polyethylene terephthalate is pasted on the optically clear adhesive layer. The release film has a thickness of about 15 pm. The release film can be removed from the optically clear adhesive layer to attach the surface decoration film on a surface of a body part of a device.

[0068] Although examples for the present disclosure have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not limited to the specific features or methods described herein. Rather, the specific features and methods are disclosed and explained as examples of the present disclosure.

Claims

We claim:

1. A surface decoration film for a device comprising:

a polymer substrate;

a thermoplastic layer coated on a first surface of the polymer substrate;

a decorative mold layer disposed on the thermoplastic layer; and

a vacuum-deposited layer coated on the decorative mold layer.

2. The surface decoration film as claimed in claim 1 , wherein the polymer substrate is made of polyethylene terephthalate, acrylic, polyamide, polycarbonate, polyurethane, or combinations thereof.

3. The surface decoration film as claimed in claim 1 , wherein the thermoplastic layer is cured at a temperature in a range of from about 55 °C to about 70 °C.

4. The surface decoration film as claimed in claim 1 , wherein the thermoplastic layer is made of polycarbonate, polyacrylic, polyester, polycarbonate, acrylnitrile- butadiene-styrene, polyurethanes, polyamide, or combinations thereof.

5. The surface decoration film as claimed in claim 1 , wherein the decorative mold layer is made of a chromium-molybdenum alloy or stainless steel.

6. The surface decoration film as claimed in claim 1 , wherein the vacuum-deposited layer is made of titanium, chromium, nickel, zinc, zirconium, manganese, copper, aluminum, tin, molybdenum, tantalum, tungsten, hafnium, gold, vanadium, silver, platinum, graphite, or combinations thereof.

7. The surface decoration film as claimed in claim 1 , further comprising:

an optically clear adhesive layer disposed on a second surface of the polymer substrate, the second surface being opposite to the first surface, and the optically clear adhesive layer comprising a release film removable from the optically clear adhesive layer to attach the surface decoration film on a surface of a body part of the device.

8. An electronic device comprising:

a body part; and

a surface decoration film including:

an optically clear adhesive layer through which the surface decoration film is attached to a surface of the body part;

a polymer substrate on the optically clear adhesive layer; a thermoplastic layer coated on the polymer substrate; a decorative mold layer disposed on the thermoplastic layer;

a vacuum-deposited layer coated on the decorative mold layer; and an optically clear layer coated on the vacuum-deposited layer.

9. The electronic device as claimed in claim 8, wherein the surface decoration film further comprises:

a hard layer coated on the optically clear layer, the hard layer being made of a polyacrylic resin.

10. The electronic device as claimed in claim 8, wherein:

the thermoplastic layer is made of polycarbonate, polyacrylic, polyester, polycarbonate, acrylnitrile-butadiene-styrene, polyurethanes, polyamide, or combinations thereof; and

the thermoplastic layer has a thickness in a range of from about 30 pm to about 90 pm.

11. The electronic device as claimed in claim 8, wherein:

the decorative mold layer is made of a chromium-molybdenum alloy or stainless steel, and the decorative mold layer has a decorative pattern thereon.

12. The electronic device as claimed in claim 8, wherein:

the vacuum-deposited layer is made of titanium, chromium, nickel, zinc, zirconium, manganese, copper, aluminum, tin, molybdenum, tantalum, tungsten, hafnium, gold, vanadium, silver, platinum, graphite, or combinations thereof; and the vacuum-deposited layer has a thickness in a range of from about 30 nm to about 100 nm.

13. A method of fabricating a surface decoration film for a device, the method comprising:

coating a thermoplastic layer on a first surface of a polymer substrate;

disposing a decorative mold layer on the thermoplastic layer by exerting a physical force;

curing the thermoplastic layer at a temperature in a range of from about 55 °C to about 70 °C; and

coating an over-layer on the decorative mold layer by a physical vapor deposition technique or a non-conductive vacuum metallization technique.

14. The method as claimed in claim 13, further comprising:

laminating an optically clear adhesive layer on a second surface of the polymer substrate, the second surface being opposite to the first surface, wherein the optically clear adhesive layer has a release film removable from the optically clear adhesive layer to attach the surface decoration film on a surface of a body part of the device.

15. The method as claimed in claim 13, further comprising:

heating the thermoplastic layer at a temperature in a range of from about 40 °C to about 50 °C for a time duration in a range of from about 5 minutes to 10 minutes, prior to disposing the decorative mold layer, wherein the decorative mold layer is at a temperature in a range of from about 50 °C to about 60 °C when being disposed on the thermoplastic layer.