Abstract:
Disclosed are a dual surface-treated injection molding article, which is manufactured by dually surface-treating an injection molding substrate formed of a light-transmissive semi-transparent or transparent material in such a manner that a metallic appearance is expressed or any of a logo, a pattern, an ornamental design, and a picture is formed on each of inner and outer surfaces of the injection molding substrate, and a method of manufacturing the same.

Description:
CLAIM OF PRIORITY 
       [0001]    This application claims the priority under 35 U.S.C. §119 of an application entitled “Dual Surface Treated Injection Molding Article And Method Of Manufacturing The Same” filed in the Korean Intellectual Property Office on Apr. 15, 2010 and assigned Serial No. 10-2010-0034688, the contents of which are hereby incorporated by reference. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to a dual surface-treated injection molding article and a method of manufacturing the same. 
         [0004]    2. Description of the Related Art 
         [0005]    In general, an injection molding article comprises a synthetic resin article manufactured in a shape corresponding to a mold by pouring a molten resin into the mold. Since it is easy to mass-produce such injection molding articles, they are widely utilized as casings for many consumer electronic appliances. 
         [0006]    For example, injection molding articles are employed for producing cosmetic containers, game machines, portable terminals, such as mobile phones, etc. The evolving trend in modern portable products is that they serve as fashionable items for users. Due to this trend, portable terminal users sometimes decorate their portable terminals using a third party portable pouch, or a case directly mountable to the terminal. 
         [0007]    According to various demands of such users, efforts are being made so as to diversify the cases&#39; external appearances of portable appliances by phone manufacturers. For example, such efforts include: merely diversifying products&#39; colors; performing post-processing surface treatment, such as painting, vapor deposition, printing, or plating, etc. to vary the color of casing; and performing insert mold labeling (IML) so as to coat a separate film onto a product when the product is molded. Further, separately manufactured pattern stickers are available to attach onto the injection molding articles. 
         [0008]    By providing ornamental elements as mentioned above, new visual effects can be provided to the external appearances of portable appliances. 
         [0009]    As shown in  FIG. 1 , a conventional surface-treated injection molding article has a paint layer  2  formed on a main surface of an injection molding substrate  1  formed from an opaque material, and a colored area, a logo, a pattern, an ornamental design, and a picture  3  formed in the paint layer  2 . However, such a conventional injection molding article formed from an opaque material exhibits a poor durability without the use of paint layer (protection layer)  2 , and has a limitation in implementing a stereographic appearance of designed ornamental elements, such as a colored area, a logo, a pattern, an ornamental design, and a picture  3 . 
         [0010]    The conventional injection molding article is formed with a pattern on one side thereof by processing an injection molding substrate, using a mold having a corresponding pattern, and then surface-treating the injection molding substrate by forming a paint layer once only. As a result, there is a limitation in implementing such a pattern in depth, and also it is difficult to form a logo, a pattern, an ornamental design, a picture, etc. precisely. 
         [0011]    Therefore, what is needed is to provide a method which can implement a metallic appearance or a stereographic appearance of a logo, a pattern, an ornamental design, a picture or the like more in depth on the final injection molding article. 
       SUMMARY OF THE INVENTION 
       [0012]    Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art and provides additional advantages, by providing a dual surface-treated injection molding article and a method of manufacturing the same, wherein the dual surface-treated injection molding article is manufactured by dually surface-treating an injection molding substrate formed from a light-transmissive semi-transparent or transparent material in such a manner that a metallic appearance is expressed or any of a logo, a pattern, an ornamental design and a picture is formed on each of the inner and outer surfaces of the injection molding substrate, so that a metallic appearance or a stereographic appearance of the logo, the pattern, the ornamental design and the picture can be implemented more deeply, thereby enhancing stereographic visual effects on the resultant final injection molding article. 
         [0013]    In accordance with an aspect of the present invention, a dual surface-treated injection molding article includes: a first physical vapor deposition layer formed on the inner surface of an injection molding substrate which is formed from a light-transmissive semi-transparent or transparent material; a first physical vapor deposition layer formed on the inner surface of the injection molding substrate; a first print layer formed by etching or removing the first physical vapor deposition layer; a first paint layer formed on the inner surface of the injection molding substrate; a masking layer formed on the outer surface of the injection molding substrate; a second physical vapor deposition layer formed on the outer surface of the injection molding substrate at an area exposed through the masking layer; a second print layer formed by etching or removing the masking layer; and a second paint layer formed on the outer surface of the injection molding substrate. 
         [0014]    In accordance with another aspect of the present invention, a method of manufacturing a dual surface-treated article includes: forming a first physical vapor deposition layer on the inner surface of an injection molding substrate which is formed from a light-transmissive semi-transparent or transparent material; forming a first print layer by etching or removing the first physical vapor deposition layer; forming a first paint layer on the inner surface of the injection molding substrate; forming a masking layer on the outer surface of the injection molding substrate; forming a second physical vapor deposition layer on the outer surface of the injection molding substrate at an area exposed though the masking layer; forming a second print layer at an area by etching or removing the masking layer; and forming a second paint layer on the outer surface of the injection molding substrate. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    The above and other aspects, features and advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which: 
           [0016]      FIG. 1  is a cross-sectional view showing a conventional dual surface-treated injection molding article; 
           [0017]      FIG. 2  shows a process for manufacturing a dual surface-treated injection molding article in accordance with an embodiment of the present invention; 
           [0018]      FIG. 3  shows a dual surface-treated injection molding article in accordance with an embodiment of the present invention; and 
           [0019]      FIG. 4  is a flowchart showing a process of manufacturing a dual surface-treated injection molding article in accordance with an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In this regards, it shall be appreciated that the embodiments described herein and the constructions show in the accompanying drawings merely illustrate the most desired embodiments of the present invention, and various modified embodiments can be made within the scope of the present invention. 
         [0021]    Referring to  FIGS. 2 and 3 , a dual surface-treated injection molding article  10  includes: an injection molding substrate  11  formed of a light-transmissive semi-transparent or transparent material; first and second PVD (Physical Vapor Deposition) layers  12  and  16 ; first and second print layers  13  and  17 ; first and second paint layers  14  and  18 ; and a masking layer  15 , wherein the injection molding substrate  11  is formed by injection-molding the light-transmissive semi-transparent or transparent material to an external appearance of a portable communication device  20 . 
         [0022]    As shown in  FIGS. 2 and 3 , the first PVD layer  12  is formed on the inner surface of the injection molding substrate  11  so as to form the first print layer  13  on the injection molding substrate  11 , the first print layer  13  is adapted to be formed by etching or removing the first PVD layer  12  through an etching process or by using a laser (not shown). The first paint layer  14  is formed on the inner surface of the injection molding substrate  11  so as to protect the first print layer  13 . 
         [0023]    The masking layer  15  is formed on the outer surface of the injection molding substrate  11  so as to form the second PVD layer  16 . The second PVD layer  16  is formed at an area exposed through the masking layer  15  so as to form the second print layer  17 , wherein the second print layer  17  is adapted to be formed by etching or removing the masking layer  15  through an etching process or by using a laser (not shown). The second paint layer  18  is formed on the outer surface of the injection molding substrate  11  so as to protect the second print layer  17 . 
         [0024]    Each of the first and second PVD layers  12  and  16  is preferably formed by depositing tin (Sn) or aluminum (Al) so as to provide a metallic appearance. However, in addition to Sn and Al, the first and second PVD layers  12  and  16  may be formed by other metal (e.g., nickel (Ni) and silicon (Si)). 
         [0025]    The first and second print layers  13  and  17  may include any of a logo (A 1 ) and a pattern (A 2 ) as show in  FIG. 3 , and may include other forms of logos, patterns, ornamental designs, and pictures (e.g., symbols and numeric characters), thus providing a three-dimensional or depth perception. 
         [0026]    In the embodiment, the first paint layer  14  may be formed by a black-series color so as to hide the internal parts of the final product, and the second paint layer  18  may be formed from a transparent color so as to show the stereographic appearance of the first and second print layers  13  and  17 . 
         [0027]    The masking layer  15  is formed to expose an area opposite to the first print layer  13 , wherein the second PVD layer  16  is formed at the area exposed through the masking layer  15  to correspond to the first print layer  13 . 
         [0028]    As shown in  FIG. 3 , the inventive dual surface-treated injection molding article  10  according to the teachings of the present invention described above may be applicable to the portable communication device  20 . However, the portable communication device  20  is not necessarily limited to a mobile communication terminal, and the inventive dual surface-treated injection molding article  10  is applicable to various types of terminals (e.g., bar-type, folder type and slide-type terminals). 
         [0029]    Further, in addition to all types of mobile communication terminals operated by various communication protocols to which the present invention is applicable, the teachings of the present invention may be applicable to other portable communication  25  devices which include ding information communication appliances, multimedia appliances and their applications, such as digital cameras, PMPs (Portable Multimedia players), MP3 players, navigation units, game machines, notebook personal computers, sign boards, TV sets, digital broadcasting players, PDAs (Personal Digital Assistants), and smart phones. 
         [0030]    Now, a process of manufacturing a dual surface-treated injection molding article having the above-mentioned construction will be described in more detail with reference to  FIGS. 2 and 3 . 
         [0031]    As shown in  FIGS. 2 and 3 , an injection molding substrate  11  is injection-molded to be suitable for the external appearance of a portable communication device  20  using a light-transmissive semi-transparent or transparent material. 
         [0032]    In this state, a first PVD layer  12  is formed on the inner surface of the injection molding substrate  11  so as to provide a metallic appearance of the injection molding article, wherein the first PVD layer  12  is formed by depositing tin (Sn) or aluminum (Al). 
         [0033]    In this state, the first PVD layer  12  is etched or removed through an etching process or by using a laser, so as to form a first print layer  13  on the inner surface of the injection molding substrate  11 . 
         [0034]    The first print layer  13  may include any of a logo A 1 , a pattern A 2 , an ornamental design, and a picture.  FIG. 3  shows the logo A 1  and the pattern A 2 . 
         [0035]    Then, a first paint layer  14  is formed on the inner surface of the injection molding substrate  11  so as to protect the first print layer  13 . 
         [0036]    The first paint layer  14  is formed by a black-series color. 
         [0037]    At this time, the metallic appearance or stereographic appearance of the first print layer  14  is visually seen primarily through the injection molding substrate  11  which is formed from the semi-transparent or transparent material. 
         [0038]    In this state, a masking layer  15  is formed on the outer surface of the injection molding substrate to expose an area opposite to the first print layer  13 , as shown in  FIG. 2 . 
         [0039]    On the outer surface of the injection molding substrate  11 , a second PVD layer  16  is formed at the area exposed through the masking layer  15 . 
         [0040]    The second PVD layer  16  is formed to correspond to the first print layer  13 . 
         [0041]    Then, the masking layer  15  is etched or removed through an etching process or by using a laser (not shown), and a second print layer  17  is formed on the outer surface of the injection molding substrate  11 . 
         [0042]    The second print layer  17  may include any of a logo A 1 , a pattern A 2 , an ornamental design and a picture.  FIG. 3  shows a logo A 1  and a pattern A 2 . 
         [0043]    In this state, a second paint layer  18  is formed on the outer surface of the injection molding substrate  11  so as to protect the second print layer  17 . 
         [0044]    The second paint layer  18  is formed by a transparent color so that the first and second print layers  13  and  17  are visible to the outside. 
         [0045]    In a state in which the metallic appearance or stereographic appearance of the first print layer  13  is visually seen primarily through the injection molding substrate formed from a semi-transparent or transparent material, the metallic appearance or stereographic appearance of the second print layer  17  is visually seen secondarily through the second paint layer  18 . 
         [0046]    By performing dual surface-treatment on an injection molding substrate formed from a light-transmissive semi-transparent or transparent material as described above, it should be apparent to those skilled in the art that the inventive process provides an enhanced metallic appearance or a stereographic appearance of a logo, pattern, an ornamental design, and a picture in more depth in the final product. 
         [0047]    Hereinafter, a method of manufacturing a dual surface-treated injection molding article as described above will be described in more detail with reference to  FIG. 4 . 
         [0048]    As shown in  FIG. 4 , an injection molding substrate  11  is injection-molded to correspond to an external appearance of a portable communication device  20  using a light transmissive semi-transparent or transparent material (Si). 
         [0049]    Then, a first PVD layer  12  is formed on the inner surface of the injection molding substrate  11  so as to provide a metallic appearance of the injection molding substrate  11  (S 2 ). 
         [0050]    The first PVD layer  12  is formed by depositing tin (Sn) or aluminum (Al). 
         [0051]    Then, the first PVD layer  12  is etched or removed through an etching process or by using a laser, so as to form a first print layer  13  on the inner surface of the injection molding substrate  11  (S 3 ). 
         [0052]    The first print layer  13  may include any of a logo A 1 , a pattern A 2 , an ornamental design and a picture.  FIG. 3  shows the logo A 1  and the pattern A 2 . 
         [0053]    Then, a first paint layer  14  is formed on the inner surface of the injection molding substrate  11  so as to protect the first print layer  13  (S 4 ). 
         [0054]    The first paint layer  14  is formed by a black-series color. 
         [0055]    At this time, the metallic appearance or the stereographic appearance of the first print layer  14  is visually seen primarily through the injection molding substrate  11  which is formed from a semi-transparent or transparent material. 
         [0056]    Then, a masking layer  15  is formed on the outer surface of the injection molding substrate at an area exposed through the first print layer  13  (S 5 ). 
         [0057]    On the outer surface of the injection molding substrate  11 , a second PVD layer  16  is formed at an area exposed through the masking layer  15  (S 6 ). 
         [0058]    The second PVD layer  16  is formed to correspond to the first print layer  13 . 
         [0059]    Then, the masking layer  15  is etched or removed through an etching process or by using a laser (not shown), and a second print layer  17  is formed on the outer surface of the injection molding substrate  11  (S 7 ). 
         [0060]    The second print layer  17  may include any of a logo Al, a pattern A 2 , an  ornamental design and a picture.  FIG. 3  shows a logo Al and a pattern A 2 . 
         [0061]    Then, a second paint layer  18  is formed on the outer surface of the injection molding substrate  11  so as to protect the second print layer  17  (S 8 ). 
         [0062]    The second paint layer  18  is formed by a transparent color so that the first and second print layers  13  and  17  are visible to the outside. 
         [0063]    In a state in which the metallic appearance or stereographic appearance of the first print layer  13  is visually seen primarily through the injection molding substrate formed from a semi-transparent or transparent material, the metallic appearance or stereographic appearance of the second print layer  17  is visually seen secondarily through the second paint layer  18 . 
         [0064]    By performing dual surface-treatment on an injection molding substrate formed from a light-transmissive semi-transparent or transparent material as described above, it is possible to implement an enhanced metallic appearance or a stereographic appearance of a logo, pattern, an ornamental design, and a picture in more depth in the final product. 
         [0065]    While the invention has been shown and described with reference to certain embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.