Patent Publication Number: US-2016229092-A1

Title: Textured film on substrate

Description:
BACKGROUND 
     During in-mold decoration (IMD), a textured film can be located in a plastic injection mold. Plastic resin is injected into the mold, fixing the film in the molded product. 
     Using out-side mold decoration (OMD), a molded part is formed and then a textured film can be transferred onto the molded part to form a molded product. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       By way of non-limiting examples, methods and apparatus according to the present disclosure are described with reference to the following drawings, in which: 
         FIGS. 1 a  to 1 e    illustrate an example method of molding according to the present disclosure; 
         FIGS. 2 a  to 2 c    illustrate another example method of molding according to the present disclosure; 
         FIGS. 3 a  to 3 c    illustrate yet another example method of molding according to the present disclosure; 
         FIGS. 4 a  to 4 c    illustrate another example method of molding according to the present disclosure; 
         FIG. 5  illustrates yet another example method of molding according to the present disclosure; 
         FIG. 6  illustrates another example method of molding according to the present disclosure; 
         FIG. 7  illustrates an alternative example of a preform that may be used in example methods of molding according to the present disclosure; 
         FIG. 8  illustrates another example method of molding according to the present disclosure; 
         FIG. 9  illustrates yet another example method of molding according to the present disclosure; and 
         FIGS. 10 a  to 10 c    illustrate another example method of molding according to the present disclosure. 
     
    
    
     DESCRIPTION OF EXAMPLES 
     In some examples disclosed herein, as film and a substrate are positioned between first and second mold parts. The first mold part is compressed against the film and the second mold part is compressed against the substrate to form the film and substrate into a molded product. The compressing forms a texture in a surface of the film. The compressing can also change the shape of the substrate. In some examples disclosed herein, a substrate having film connected to the substrate is compressed, wherein the compressing shapes the substrate and forms a texture in a surface of the film substantially at the same time. In some examples disclosed herein, molding apparatus includes a first mold part and a second mold part. The first and second mold parts are adapted to receive a film and a substrate therebetween and compress the film and the substrate to form a molded product. The first mold part includes a texture mold form such that, when the first and second mold parts compress the film and the substrate, a texture is formed in a surface of the film by the texture mold form. The second mold part can include a shape mold form such that, when the first and second mold parts compress the film and the substrate, a shape is formed in the substrate. 
     In some examples disclosed herein, by forming a texture in a surface of a film substantially at the same time as forming a molded product, the number of processing steps required to form a finished product may be reduced, a shorter production cycle time may be achieved and/or production costs may be lowered. 
       FIGS. 1 a  to 1 e    illustrate an example method of molding according to the present disclosure. With reference to  FIG. 1   a,  as part of a pre-heating stage, heat  13  is applied to a film  11 . Pre-heating of the film may be at a temperature of between about 80 to 300° C., for example. During or immediately after pre-heating, the film  11  is brought into contact with a surface of a substrate  12  to form a preform  10 . The preform  10  therefore includes a layer of film  11  at a first side  101  and a layer of substrate  12  at a second side  102 . By pre-heating the film  11 , flexibility and/or adhesive properties of the film  11  can be increased to provide a reliable engagement between the film  11  and the substrate  12 . 
     Next, with reference to  FIG. 1   b,  the preform  10  is located between first and second mold parts  21 ,  22  of a compression mold  20 , with the first side  101  of the perform  10  facing the first mold part  21  and the second side  102  of the preform  10  facing the second mold part  22 . The first mold part  21  includes a texture mold form, represented by protrusions  211 , and the second mold part  22  includes a shape mold form  221 . 
     Subsequently, with reference to  FIG. 1   e,  pressure is applied to one or both of the mold parts  21 ,  22  such as to press the mold parts  21 ,  22  towards each other and compress the preform  10  therebetween. Mechanical pressure and/or vacuum pressure may be applied, for example. Immediately before and/or during the compression, heat  13  can be applied to the preform  10 . Heating of the preform  10  may be at a temperature of between about 80 to 300° C., for example. By applying pressure, or by applying pressure and heating, the film and the substrate may be fixed together, e.g., substantially fused and/or irremovably connected together. 
     During compression, the texture mold form  211  is adapted to press into the film  11  in order to mold a corresponding (negative) texture in the film  11  and, substantially at the same time, the shape mold form  221  is adapted to press into the substrate  12  in order to mold a corresponding (negative) shape in the substrate  12 . The compression results in formation of a molded product  14  as represented in  FIG. 1 d    in this example. To assist with removal of the molded product  14  from the mold  20 , heat may be applied to the mold  20  and/or molded product  14 . The molded product  14  may be trimmed, e.g., using a laser cutting or a computer numerical control (CNC) process. 
     A flowchart representing the method described above with reference to  FIGS. 1 a  to 1 d    is illustrated in  FIG. 1   e,  and is designated generally by reference numeral  1000 . At  1001 , the film is preheated. At  1002 , the film is brought into contact with a surface of the substrate to form a preform. At  1003 , the preform is located in the mold. At  1004 , during or after heating, pressure is applied to the preform by the mold to form a molded product with texture in the film. At  1005 , the molded product is removed from the mold. At  1006 , the molded product is trimmed. Not all of these features are necessarily required. 
       FIGS. 2 a  to 2 c    illustrate a modification to the method described above with reference to  FIGS. 1 a    to  1   e.  In this modified example, a preform is not formed prior to insertion of the film  11  and the substrate  12  into the mold. Rather, the film  11  and substrate  12  are independently inserted into the mold  20  as represented in  FIG. 2   a,  and engagement between the film  11  and the substrate  12  takes place through the application of pressure by the first and second mold parts  21 ,  22  during the compression molding process as represented in  FIG. 2   b.    
     A flowchart representing the method described above with reference to  FIGS. 2 a  and 2 b    is illustrated in  FIG. 2 c   , and is designated generally by reference numeral  2000 . At  2001 , the film and the substrate are located in the mold. At  2002 , during or after heating pressure is applied to the film and the substrate by the mold to form a molded product with texture in the film. At  2003 , the molded product is removed from the mold. At  2004 , the molded product is trimmed. Not all of these features are necessarily required. 
       FIGS. 3 a  to 3 c    illustrate yet another modification to the method described above with reference to  FIGS. 1 a    to  1   e.  In this modified example, again preform is not formed prior to insertion of the film  11  and the substrate  12  into a mold  23  as represented in  FIG. 3 a   . Further, a second mold part  24  is provided that does not include a shape mold form in this instance. Rather, the mold  23  is adapted to fix the film  11  to the substrate  12  as part of the compression molding process as represented in  FIG. 3 b   , and than the texture in the film  11 , but provide substantially no reshaping of the substrate  12 , in order to provide a molded product  15  as represented in  FIG. 3   c.    
       FIGS. 4 a  to 4 c    illustrate another modification to the method described above with reference to  FIGS. 1 a    to  1   e.  In this modified example, a mold  25  is provided that includes first and second mold parts  26 ,  27  that both have shape mold forms. In particular, as can be seen in  FIG. 4 a   , the first mold span  26  is provided with a recessed shape mold form  261 , in addition to a texture mold form  262 , and the second mold  27  is provided with the a protecting mold form  271 . In this example, during compression as represented in  FIG. 4 b   , both the film  11  and the substrate  12  are substantially re-shaped by the mold  25 , and a texture is formed in the surface of the film, resulting to a molded product  16  as represented in  FIG. 4   c.    
       FIGS. 5 and 6  illustrate examples in which a continuous production process is used to form a molded product. Similar molding techniques may be used as described with reference to previous examples. For example, in  FIG. 5 , a mold  30  is provided having first and second mold parts  31 ,  32  (e.g. a core mold  31  and a cavity mold  32 ), which are arranged to press either side of the film  11  and substrate  12 . The first and second mold parts  31 ,  32  each included shape mold forms  311 ,  321  and the first mold part  31  includes a texture mold form  312 . In  FIG. 6 , a mold  33  is provided having first and second mold parts  34 ,  35 , which are arranged to press either side of the film  11  and substrate  12 . The first mold part  34  includes a texture mold form  341 . In these examples, the film  11  and substrate  12  are introduced into the mold  30 ,  33  by a continuous feed system  34 . Accordingly, a continuous manufacturing process can be applied, e.g., in contrast to a batch manufacturing process. 
       FIG. 7  illustrates another example of a preform  17  according to the present disclosure. In this example, the preform  17  includes a film  11 , a substrate  12  and a bonding layer  18  between the film  11  and substrate  12 . The bonding layer  18  is adapted to enhance interfacial bonding between the film  11  and the substrate  12 . The bonding layer  18  may include an adhesive or thermoplastic resin film, for example. As part of a pre-heating step, heat  13  may be applied to the film  11 , substrate  12  and/or bonding layer  18 , e.g., at a temperature of between about 80 to 300° C., to further enhance engagement and bonding between these elements. The preform may be located in a mold and molded in accordance with methods discussed above, e.g., with reference to  FIGS. 1 b    and  1   c,  or  FIGS. 4 a    and  4   b.    
     In an alternative example, the preform  17  may not be formed prior to location of the film  11 , substrate  12  and bonding layer  18  into the mold. For example, the film  11 , substrate  12  and bonding layer  18  may be independently inserted into a mold  20  as illustrated in  FIG. 8 , and engagement between the film  11  and the substrate  12  can take place through the application of pressure by the first and second mold parts  21 ,  22 . Alternatively, as illustrated in  FIG. 9 , the bonding layer  18  may be engaged with only one of the film  11  and the substrate  12 , prior to location in the mold  20 . In this instance, engagement between the substrate  12  and the already-engaged film  11  and building layer  18 , or between the film  11  and the already-engaged bonding layer  18  and substrate  12 , can take place through the application of pressure by the first and second mold parts  21 ,  22 . 
       FIGS. 10 a  to 10 c    illustrate another modification to the method described above with reference to  FIGS. 1 a    to  1   e.  In this modified example, a substrate  120  is provided that includes a textured surface  121 . The textured surface  121  may have been formed by molding of the substrate. 
     The film  11  is configured to locate on a side of the substrate  120  that has the textured surface  121 . The texture of the textured surface  121  of the substrate  120  may have a similar or identical scale, shape, pattern and/or depth to the texture of the textured surface formed in the film  11 . The textured surface  121  of the substrate  120  is formed prior to locating the film  11  and the substrate  120  in the mold  20 . The film  11  and the substrate  120  can be connected together as a preform prior to location in the mold  20  as represented in  FIG. 10   a,  or located at the mold  20  separately. Molding of the film  11  and substrate  120  to form a molded product with a film  11  having a textured surface can take place as represented in  FIG. 10   b,  and substantially in accordance with previous discussions. A bonding layer may be used between the film  11  and substrate  120  e.g. as described with reference to  FIG. 7, 8 or 9 . 
     By providing the substrate  120  with a textured surface  121 , a molded product  19  can be formed as represented in  FIG. 10   c,  in which texture is provided in both the film  11  and the substrate  120 . This may modify a visual effect provided at a surface of the molded product. For example, it may be beneficial to a pattern design and/or may enhance a metal-like effect (e.g., metal luster). The film  11  may be transparent or see-through to some extent. 
     While in the examples described, the texture mold forms are illustrated using conspicuous protrusions  211 ,  262 ,  312 ,  341 , in practice a texture mold form, and the texture formed in the film by the texture mold form, may be hard to see or invisible with the naked eye. This may contrast with the shape mold forms  221 ,  271 ,  311 ,  321 , and the shapes formed in the substrates by the shape mold forms, which may be clearly visible to the naked eye. In some examples, the shape formed in the substrate may be considered macroscopic and the texture formed in the film may be considered microscopic, or otherwise. 
     Further, while the film  11  is illustrated in the Figures as having a reasonably similar thickness to the substrate  12 ,  120 , in practice the film  11  may have a thickness that is significantly shorter than the thickness of the substrate  12 ,  120 . For example, the film  11  may have a thickness that is less than 50%, less than 20%, less than 10%, less than 5% less than 2% or otherwise, of the thickness of the substrate  12 ,  120 . 
     Further, the thickness of the texture mold form, and/or the depth of portion of the texture mold form that is configured to press into the film  11 , may be configured to be shorter than the thickness of the film  11 . Accordingly, exposure of the substrate  12 ,  120  through the film  11  may be prevented during the molding process. 
     In the examples, the texture in the film  11  formed by the molding may include a pattern, an array, letters, numbers, symbols and/or other features. The molded texture in the film  11  may provide for decoration of the film and the molded product in general. The molded texture in the film  11  may provide a cosmetic and/or technical effect. For example, it may provide anti-fingerprint, antibacterial, anti-scratch, metal-like, matt, visual and/or tactual effect to a surface of the molded product. 
     In this and other examples, the molded product may take a variety of different shapes and configurations and be used for a variety of different applications. For example, the molded product may be a casing or part of a casing for an electrical device such as a notebook, laptop, tablet PC or smartphone, and the molded texture may provide anti-fingerprint and metal-like properties to the casing. 
     The film  11  may be formed of a variety of different materials. For example, the film may include polymeric material, metal, rubber, combinations thereof or otherwise. 
     The substrate may be formed of a variety of different materials. For example, the substrate may include metal, plastic, carbon fibers, ceramics or composites, combinations thereof or otherwise. 
     Throughout this specification the words “comprising”, “having” and “including” or variations such as “comprise”, “comprises, “have,” “has”, “include”, or “includes”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. 
     It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described examples, without departing from the broad general scope of the present disclosure. For example, the molds, mold parts, texture mold forms and/or shape mold forms may take a variety of different shapes and configurations, which may differ considerably from those represented in the Figures. Further, while the substrate is illustrated in Figures as including one layer only, the substrate may include multiple layers or components. Still further, while the film is shown in Figures on one side of the substrate only, the film may be applied to more than one side and/or around the entire substrate. The present examples are, therefore, to be considered in all respects as illustrative and not restrictive.