Patent Publication Number: US-2013248095-A1

Title: Decoration film, method of fabricating a decoration film, and method of fabricating a decoration device

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to a decoration film, a method of fabricating a decoration film, and a method of fabricating a decoration device, in particular, to a decoration film having a relief surface and fabricating by an embossing process, a method of fabricating a decoration film having a relief surface, and a method of fabricating a decoration device by using a decoration film having a relief surface. 
     2. Description of Related Art 
     The illustrations or decorations formed on the surface of the plastic or the metal housing can be fabricated by a decoration process using a decoration film which has predetermined decoration layers formed on the substrate. Conventionally, the process for decorating a metal housing is performed after the metal housing is stamped to have a predetermined shape. The decoration processes include an in-mold decoration (IMD) technique, a heat transfer printing process, a sublimation heat transfer process, a hot stamping process, an ink-jet printing process, a water transfer printing process, and the like. 
     For example, the process of the IMD technique includes placing the decoration film into a mold of the injection machine, injecting a melted resin or plastic material at a side of the decoration film in the mold so that the melted resin and the decoration layers of the decoration film are combined to form a decoration device, and thereafter ejecting the decoration device from the mold. Accordingly, the in-mold decoration process is completed. 
     With the variety of the requirements on the decoration device, the predetermined decoration layers must have various properties such as specific sense of touch. For example, the decoration device may be required to provide a relief outer surface such that a user can feel the roughness of the decoration device when touching thereon. Particularly, the portion capable of providing the roughness feeling in the decoration device can be further requested to be aligned to the illustration patterns formed on the decoration device. However, the portion capable of providing the roughness feeling in the decoration device and the illustration patterns are formed in different layers so that the alignment between the illustration patterns and the portion capable of providing the roughness feeling in the decoration device may be difficult. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention is directed to a decoration film having relief pattern layer with a relief marker for position alignment. 
     The present invention is directed to a method for fabricating a decoration film having relief pattern layer with a relief marker for position alignment. 
     The present invention is directed to a method for fabricating a decoration device having relief pattern on the outer surface thereof and the method uses a decoration film having a relief pattern layer with a relief marker for position alignment. 
     The present invention is directed to a decoration film for in-mold decoration process. The decoration film includes a substrate and a relief pattern layer disposed on the substrate. The relief pattern layer has a relief surface away from the substrate and includes a decoration relief portion and a marker relief portion located around the decoration relief portion, wherein the relief pattern layer is remained on the substrate after the in-mold decoration process. 
     According to an embodiment of the present invention, a material of the relief pattern layer comprises a rapid-cured material. For example, the rapid-cured material includes a UV-curable gum suitable for being cured immediately during an embossing process. The material of the relief pattern layer can further includes a dye, a pigment, a filler, or a combination thereof. 
     According to an embodiment of the present invention, the decoration film further includes a hard coat layer disposed on the relief surface of the relief pattern layer, wherein the hard coat layer has a decoration relief and a marker relief respectively corresponding to the decoration relief portion and the marker relief portion. The decoration relief and the marker relief are substantially conformed to the decoration relief portion and the marker relief portion, respectively. In an alternate example, a space is defined between the hard coat layer and a part of the decoration relief portion such that the decoration relief is substantially conformed to the other part of the decoration relief portion. Furthermore, the decoration film further includes an adhesion layer disposed on the hard coat layer away from the relief pattern layer. Alternately, the decoration film further includes a function layer disposed between the hard coat layer and the adhesion layer, wherein the function layer can include an ink layer, a metal layer, or a combination thereof. The decoration film can further include a releasing layer disposed between the hard coat layer and the relief pattern layer. 
     According to an embodiment of the present invention, a relief depth of the marker relief portion in the relief pattern layer is from 3 μm to 25 μm. 
     The present invention is further directed to a method for fabricating a decoration film. A rapid-cured material is applied on a substrate. An embossing process is performed on the rapid-cured material and the rapid-cured material is immediately cured to form a relief pattern layer having a relief surface away from the substrate, wherein the relief pattern layer can include a decoration relief portion and a marker relief portion located around the decoration relief portion. 
     According to an embodiment of the present invention, the rapid-cured material comprises a UV-curable gum. 
     According to an embodiment of the present invention, the method for fabricating a decoration film further includes forming a hard coat layer on the relief surface of the relief pattern layer, wherein the hard coat layer has a decoration relief and a marker relief respectively corresponding to the decoration relief portion and the marker relief portion. 
     According to an embodiment of the present invention, the decoration relief and the marker relief are substantially conformed to the decoration relief portion and the marker relief portion, respectively. 
     According to an embodiment of the present invention, the method of forming the hard coat layer includes applying a hard coat material on the relief pattern layer; adjusting an amount of the hard coat material on the relief pattern layer such that a space is defined between the hard coat material and a part of the decoration relief portion; and curing the hard coat material such that the decoration relief of the hard coat layer is substantially conformed to the other part of the decoration relief portion. In an example, the method for fabricating a decoration film further includes forming an adhesion layer on the hard coat layer away from the relief pattern layer. The method for fabricating a decoration film can further include forming a function layer disposed between the hard coat layer and the adhesion layer, wherein the function layer comprises an ink layer, a metal layer, or a combination thereof. In another example, the method for fabricating a decoration film can further include forming a releasing layer disposed between the hard coat layer and the relief pattern layer. 
     The present invention is also directed to a method for fabricating a decoration device. A decoration film is provided and the decoration film includes a substrate, a relief pattern layer, a hard coat layer, and an adhesion layer. The relief pattern layer is disposed on the substrate and has a relief surface away from the substrate. The relief layer includes a decoration relief portion and a marker relief portion located around the decoration relief portion. The hard coat layer is disposed on the relief surface of the relief pattern layer, wherein the hard coat layer has a decoration relief and a marker relief respectively corresponding to the decoration relief portion and the marker relief portion. The adhesion layer is disposed on the hard coat layer away from the relief pattern layer. Subsequently, the decoration film is adhered on a body and the substrate and the relief pattern layer are subsequently removed from the body to form a decoration device, wherein the relief pattern layer is remained on the substrate and the hard coat layer is exposed. 
     According to an embodiment of the present invention, the method of adhering the decoration film on the body comprises an in-mold decoration process. 
     According to an embodiment of the present invention, the decoration film further includes a releasing layer between the hard coat layer and the relief pattern layer, and the releasing is further removed during removing the substrate and the relief pattern layer from the body. 
     In light of the foregoing descriptions, in the decoration film according to an embodiment of the invention, the relief pattern layer formed on the substrate is fabricated by an embossing process and includes both a decoration relief portion and a marker decoration portion. Accordingly, the relief pattern layer on the substrate can be properly aligned to the pattern of the decoration layers subsequently formed on the substrate. The decoration device fabricated by the decoration film can provide certain roughness touching feeling at a part of the outer surface corresponding to the pattern and complies with the requirement of the user. 
     In order to make the aforementioned and other features and advantages of the invention more comprehensible, embodiments accompanying figures are described in detail below. 
     Herein, the same or similar reference numbers used in the drawings and the descriptions are referred as the same or similar elements. For clearly describing the concept of the invention, the shapes and the thickness of the elements in the embodiments accompanying with the drawings may not definitely comply with the real circumstance. In addition, the following descriptions are directed to the elements or the combinations thereof, but the elements are not particularly restricted in the contents or the descriptions. Any form or shape known by one skilled in the art is applicable in the invention. Moreover, the description that a material layer disposed on a substrate or disposed on another material layer means that the material layer is directly located on the substrate or the another material layer, and may also mean that some interlayer is interrupted between the material layer and the substrate or between the material layer and the another material layer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
         FIG. 1  schematically shows a method for fabricating a decoration film according to an embodiment of the present invention. 
         FIG. 2  schematically illustrates a decoration film according to the present invention. 
         FIG. 3  is a cross-sectional view of the decoration film of  FIG. 1  taking along line I-I′. 
         FIG. 4  schematically illustrates a decoration film according to a first embodiment of the present invention. 
         FIG. 5  schematically illustrates a decoration device fabricated by using the decoration film of  FIG. 4  according to the first embodiment of the present invention. 
         FIG. 6  schematically illustrates a decoration film according to a second embodiment of the present invention. 
         FIG. 7  schematically illustrates a decoration device fabricated by using the decoration film of  FIG. 6  according to the second embodiment of the present invention. 
         FIG. 8  schematically illustrates a decoration film according to a third embodiment of the present invention. 
         FIG. 9  schematically illustrates a decoration device fabricated by using the decoration film of  FIG. 8  according to the third embodiment of the present invention. 
         FIG. 10  schematically illustrates a decoration film according to a fourth embodiment of the present invention. 
         FIG. 11  schematically illustrates a pattern roll using in the embossing process according to another embodiment of the invention. 
         FIG. 12  schematically illustrates a decoration film fabricated by the pattern roll of  FIG. 11 . 
         FIG. 13  schematically illustrates a decoration film fabricated by using the pattern roll  10 A of  FIG. 11 . 
     
    
    
     DESCRIPTION OF THE EMBODIMENTS 
     Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts. 
     For achieving a required touching feeling in a decoration device, the following descriptions exemplified depict a decoration film and the application thereof. Several decoration processes such as an in-mold decoration (IMD) technique, a heat transfer printing process, a sublimation heat transfer process, a hot stamping process, an ink-jet printing process, a water transfer printing process, and the like are provided for forming the decoration device, wherein the IMD technique substantially includes an in-mold labelling (IML) process, an in-mold film (IMF) process, an in-mold roller (IMR) process, or the like. It is noted that the decoration film described hereinafter can be applied in any of the aforesaid decoration processes, but the invention is not limited thereto. 
       FIG. 1  schematically shows a method for fabricating a decoration film according to an embodiment of the present invention,  FIG. 2  schematically illustrates a decoration film according to the present invention, and  FIG. 3  is a cross-sectional view of the decoration film of  FIG. 1  taking along line IT. Referring to  FIGS. 1 to 3 , an apparatus at least including a pattern roll  10 , a pressing roll  20 , and energy source  30  is provided. The pattern roll  10  and the pressing roll  20  are leant against with each other. A substrate  110  is placed between the pattern roll  10  and the pressing roll  20  and the substrate  110  can be transmitted in the predetermined direction D. Herein, the energy source  30  is located at the downstream of the pattern roll  10  in the predetermined direction D. 
     During performing the embossing process, a rapid-cured material  120 ′ is applied on the substrate  110  at the upstream of the pattern roll  10  in the predetermined direction D. The rapid-cured material  120 ′ on the substrate  110  can be squeezed by the pattern roll  10  and the pressing roll  20  when the substrate  110  is transmitted in the direction D. In addition, the rapid-cured material  120 ′ can be cured immediately by the energy source  30  after squeezing of the pattern roll  10  and the pressing roll  20  and the cured rapid-cured material  120 ′ can be separated from the pattern roll  10  to form the decoration film  100  including the relief pattern layer  120  formed on the substrate  110  as shown in  FIG. 1  and  FIG. 2 . 
     It is noted that the surface of the pattern roll  10  can have a predetermined concave-convex structure  12  thereon and thus the relief pattern layer  120  can have a relief surface  122 . Specifically, the relief surface  122  is configured away from the substrate  110  and the relief pattern layer  120  includes a decoration relief portion  126  and a marker relief portion  124  located around the decoration relief portion  126 . 
     In the present embodiment, the substrate  110  can be a flexible substrate and a material of the substrate  110  can be polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyethylene glycol-co-cyclohexane-1,4 dimethanol terephthalate (PETG), thermalplastic polyurethane (TPU), polyurethane (PU), polypropylene (PP), polycarbonate (PC), amorphous polyethylene terephthalate (A-PET), polyvinyl chloride (PVC), Polystyrene (PS), triacetyl cellulose (TAC), polymethylmethacrylate (PMMA), methylmethacrylate-styrene (MMA-st, MS) copolymer, cyclo olefin copolymer (COC) and a combination thereof, but the invention is not restricted herein. 
     In addition, a material of the rapid-cured material  120 ′ can include a UV-curable gum suitable for being cured immediately during the embossing process. Therefore, the energy source  30  according to the present embodiment can be a UV source. Certainly, the rapid-cured material  120 ′ can be other materials capable of being cured immediately during the embossing process. In one example, the rapid-cured material  120 ′ can be a thermal curable material and the energy source  30  can be correspondingly a heater. In addition, the material of the relief pattern layer  120  can further includes a dye, a pigment, a filler, or a combination thereof such that the relief pattern layer  120  can represent certain color. In an example, the pigment can be carbon black, titanium white, or the like and the filler can include the materials such as CaCO 3 , ZnO, Al 2 O 3 , BaSO 4 , or the like. When the marker relief portion  124  provides the position alignment function in the subsequent process, the colored marker relief portion  124  can be detected easily. However, the invention is not restricted thereto and the relief pattern layer  120  can be colorless when the marker relief portion  124  has suitable dimension for detecting by the position alignment apparatus. For example, the relief depth of the marker relief portion  124  in the relief pattern layer  120  can be designed according to the detecting limitation of the position alignment apparatus and can be from 3 μm to 25 μm in an exemplary example. 
     It is noted that other function layers or decoration layers can be further formed on the substrate  110  and the decoration film  100  can be used in an IMD process for forming a decoration device. The following descriptions provide several designs of the decoration film and several decoration device fabricated thereby according to the present invention for clearly pointing out the scope of the invention, but it should be noted that the following descriptions are not intent to be construe as a limitation of the invention. 
       FIG. 4  schematically illustrates a decoration film according to a first embodiment of the present invention. Referring to  FIG. 4 , the decoration film  200  includes the substrate  110  and the relief pattern layer  120  and further includes a releasing layer  130 , a hard coat layer  140 , and an adhesion layer  150 . The substrate  110  and the relief pattern layer  120  is similar to those described in  FIG. 2  and  FIG. 3  and the relief pattern layer  120  can be fabricated by the method depicted in  FIG. 1 . In the present embodiment, the releasing layer  130 , the hard coat layer  140 , and the adhesion layer  150  can be sequentially formed on the relief surface  122  of the relief pattern layer  120 . The releasing layer  130  can be conformed to the relief surface  122 . In addition, the hard coat layer  140  has a decoration relief  142  and a marker relief  144  respectively corresponding to the decoration relief portion  124  and the marker relief portion  126 . 
       FIG. 5  schematically illustrates a decoration device fabricated by using the decoration film of  FIG. 4  according to the first embodiment of the present invention. Referring to  FIG. 4  and  FIG. 5 , the decoration film  200  as shown in  FIG. 4  is adhered on a body  2100  and thereafter, the substrate  110  is separated from the body  2100  to form a decoration device  2000 , wherein the relief pattern layer  120  and the releasing layer  130  are remained on the substrate  100  when the substrate  100  is separated from the body  110 . 
     In the present embodiment, the method for adhering the decoration film  100  on the body  2100  includes the IMD process or any decoration process mentioned in above. Specifically, when the body  2100  is formed by an in-mold ejection process, the decoration film  100  can be adhered on the body  2100  by performing the in-mold decoration process and the body  2100  can be made of plastic material. Alternately, when the body  2100  is formed by a punching process of a metal piece, the decoration film  100  can be adhered on the body  2100  during the punching process and the body  2100  can be made of metal. The decoration relief  142  and the marker relief  144  are substantially conformed to the decoration relief portion  124  and the marker relief portion  126 , respectively. Accordingly, the hard coat layer  140  has a rough surface away from the adhesion layer  150  corresponding to the relief surface  122  of the relief pattern layer  120 . The rough surface of the hard coat layer  140  is exposed after the substrate  110  and the relief pattern layer  120  formed thereon are separated from the body  2100 . 
     It is noted that the decoration relief  142  is located at a part of the outer surface of the hard coat layer  140  so as to provide specific roughness touching feeling at certain location for a user. It may be requested that the location of the decoration relief  142  is well-aligned to other pattern or structures of the decoration device  2000  for satisfying the design purpose. In the present embodiment, the marker relief portion  126  of the relief pattern layer  120  can provide the position alignment function so that the alignment of the decoration relief  142  can be desirable, which is conducive to improve the quality of the decoration device  2000 . 
       FIG. 6  schematically illustrates a decoration film according to a second embodiment of the present invention and  FIG. 7  schematically illustrates a decoration device fabricated by using the decoration film of  FIG. 6  according to the second embodiment of the present invention. Referring to  FIG. 6  and  FIG. 7 , the present embodiment is substantially similar to the first embodiment and thus the identical components are referred to identical reference numbers. Specifically, the difference between the present embodiment and the first embodiment lies in that the decoration film  300  of the present embodiment further includes a function layer  160  disposed between the hard coat layer  140  and the adhesion layer  150 , wherein the function layer  160  can include an ink layer, a metal layer, or a combination thereof. Accordingly, in addition to the roughness touch feeling, the decoration device  3000  fabricated by the decoration film  300  can further provide certain vision effect. For example, the function layer  160  can present a specific pattern such as an icon, a trademark, a pattern, and the like on the decoration device  3000 . 
     It is noted that the specific function provided by the function layer  160  may be required to corresponds to the location having the roughness touching feeling. Therefore, the function layer  160  and the hard coat layer  140  must be well-aligned to each other. In the present embodiment, the configuration of the marker relief portion  126  provides the alignment reference to the function layer  160 , which is conducive to render the decoration device  3000  having desirable quality. 
       FIG. 8  schematically illustrates a decoration film according to a third embodiment of the present invention and  FIG. 9  schematically illustrates a decoration device fabricated by using the decoration film of  FIG. 8  according to the third embodiment of the present invention. Referring to  FIG. 8  and  FIG. 9 , the present embodiment is substantially similar to the first embodiment and thus the identical components are referred to identical reference numbers. Specifically, the difference between the present embodiment and the first embodiment lies in that the decoration film  400  does not include the releasing layer  120  as shown in  FIG. 4 . Accordingly, the hard coat layer  140  can directly contact the relief pattern layer  120  in the present embodiment. 
     It is noted that the hard coat layer  140  can have the releasing function for applying in the decoration process. Specifically, the substrate  110  and the relief pattern layer  120  of the decoration film  400  must be separated from the body  2100  of the decoration device  2000  such that the hard coat layer  140  can be exposed to provide the roughness touching feeling. Accordingly, the hard coat layer  140  in contact with the relief pattern layer  120  preferably has the releasing function. In an example, the hard coat layer  140  can be fabricated by a material having better adhesion property with the adhesion layer  150  than with the relief pattern layer  120  and such material can include silicon acrylate, fluoro acrylate, or some of additives having release property. 
       FIG. 10  schematically illustrates a decoration film according to a fourth embodiment of the present invention. Referring to  FIG. 10 , the decoration film  500  in the present embodiment is substantially similar to that in the third embodiment and thus the identical components are referred to identical reference numbers. Specifically, the difference between the present embodiment and the third embodiment lies in that the decoration film  500  can further include a function layer  160  disposed between the adhesion layer  150  and the relief pattern layer  120 . Herein, similar to the third embodiment, the hard coat layer  140  can have the releasing function such that the decoration film  500  can be configured without a releasing layer as shown in  FIG. 6 , which is conducive to simplify the fabricating the decoration film  500  and reduce the fabrication cost. 
     In the foregoing embodiments, the outline of the decoration relief portion  126  on the relief pattern layer  120  can be determined by the concave-convex structure  12  of the pattern roll  10  depicted in  FIG. 1 . In the first embodiment as shown in  FIG. 2 , the outline of the decoration relief portion  126  is an irregular pattern such as a cloud, but the invention is not limited thereto. In an alternate embodiment, the design of the concave-convex structure  10  of the pattern roll  10  can have regular patterns. For example,  FIG. 11  schematically illustrates a pattern roll using in the embossing process according to another embodiment of the invention and  FIG. 12  schematically illustrates a decoration film fabricated by the pattern roll of  FIG. 11 . Referring to  FIG. 11  and  FIG. 12 , a pattern roll  10 A can have a regular concave-convex structure  12 A. It is noted that the concave-convex structure  12 A includes a marker point M and a plurality of linear traces H having gradually increasing width in a particular direction. When the pattern roll  10 A is applied in fabricating a decoration film by using the method depict in  FIG. 1 , a decoration film  600  shown in  FIG. 12  can be formed. The decoration film  600  includes the substrate  610  and the relief pattern layer  620 , wherein the relief pattern layer  620  includes a decoration relief potion  622  and a marker relief portion  624  corresponding to the hairline traces H and the marker point M of the pattern roll  10 A, respectively. 
     When the decoration film  600  is applied in fabricating a decoration device, the decoration device can have hairline relief on the hard coat layer. Accordingly, the roughness touching feeling can correspond to the hairline distribution. When compared to the recent design of the decoration device which merely have the hairline vision effect, the design of the present embodiment can further provide the hairline touching feeling, which improves the variety of the design of the decoration device. 
     It is noted that the hairline relief on the decoration device is usually determined by the concave-convex structure  12 A of the pattern roll  10 A. However, in certain circumstances, the designer may want to modify the distribution of the hairline relief on the decoration device. As such, the designer may need to buy or fabricate a new pattern roll, which is time consumption and cost increasing. Therefore, a decoration film fabricated by using the pattern roll  10 A is provided in  FIG. 13 , wherein a new pattern roller is not required for modifying the distribution of the hairline relief on the decoration device made by the decoration film. 
     Referring to  FIG. 13 , a decoration film  700  includes the substrate  610  and the relief pattern layer  620  depicted in  FIG. 12  and further includes a releasing layer  710 , a hard coat layer  720 , and an adhesion layer  730 . In the present embodiment, the relief pattern layer  620  is fabricated by using the pattern roll  10 A depicted in  FIG. 11  and thus the relief pattern layer  620  can construct the hairlines in top view vision (not shown). 
     In the present embodiment, a portion of the hairlines of the relief pattern layer  620  may not be required to form in the end product according particular design and thus the method of fabricating the decoration film  700  can include applying a hard coat material on the relief pattern layer  620 ; adjusting an amount of the hard coat material on the relief pattern layer  620  such that a space S can be defined between the hard coat material and a part of the decoration relief portion  622 ; and curing the hard coat material such that the decoration relief  722  of the hard coat layer  720  is substantially conformed to the other part of the decoration relief portion  622 . That is to say, a part of the concaves defined by the decoration relief portion  622  of the relief pattern layer  620  is not completely filled by the hard coat material so that the pattern of the decoration relief portion  622  is not completely transformed onto the hard coat layer  720 . A decoration device made by the decoration film  700  can have the hairline roughness which is not completely the same to the hairline traces H of the pattern roll  10 A, which satisfies the requirement of the designer without increase the fabrication cost. 
     In view of the above, the decoration film according to the present invention can have the relief pattern layer for fabricating the decoration device with roughness touching feeling and the relief pattern layer has the design for alignment. Accordingly, the relief structure and other patterns in the decoration film can be well-aligned to each other, which is conducive to improve the quality of the decoration device made by the decoration film. Furthermore, the relief structure on the decoration device fabricated by using the decoration film of the present embodiment can be modified through adjusting the hard coat material and can be different from the relief pattern layer of the decoration film, which provides better variety of the design of the decoration device. 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.