Patent Description:
In general, patterns or texts formed on an outer surface of a housing of an object are mainly formed by a spraying or printing process, so as to present specific visual effects and add variability to the appearance of the object. The conventional method for forming such patterns or texts is to apply a hardened layer on the outer surface of the housing by spraying after a housing of a related product has been accomplished. This method is cumbersome, has poor yields, and causes pollutions of gaseous organic solvents, thus resulting in numerous environmental issues. On the other hand, since the spraying process has disadvantages such as time consumption, complicate processing, and low thickness uniformity, it is not suitable for application in large scale production.

<CIT> relates to a multilayer composite foil substantially free from polyvinyl chloride and polyolefins, more particularly a furniture foil, comprising ABS, especially ABS with admixtures, and/or polystyrene, especially polystyrene with admixtures and/or high shock-resistant polystyrene, and/or polyester, especially amorphous polyester copolymer, wherein a maximum tensile force ranging between <NUM> and <NUM> Newton is attained during a uniaxial tensile test of one test body consisting of the composite foil, wherein the uniaxial tensile test complies with special test regulations.

<CIT> A discloses a decorative film which can be adhesively bonded firmly to any underlying surfaces and having a glossy, abrasion-resistant and tough surface comprises a clear layer (a) of polycarbonate plastic or an impact-resistant PMMA plastic and a layer (b), adhesively bonded to the latter, of an ABS plastic, the side of the layer a bonded to the ABS plastic or one of the surfaces of the layer b bearing a decoration of a diffused-in dye. The layers a and b may be bonded by coextrusion or - if appropriate after transfer printing - by compressing between heated rolls.

<CIT> discloses an acrylic resin film, a laminate film comprising the acrylic resin film and a thermoplastic resin layer placed on one surface of the acrylic resin film, and an injection molded article using the acrylic resin film are provided. The acrylic resin film laminate film have little white turbidity even if being heated in molding and maintains excellent design properties, and the injection molded article having the acrylic resin film on its surface is excellent in design properties such as color depth.

To address the aforementioned issues, various decoration processes using decorative films are proposed. For example, in-mold decoration (IMD) or out mold decoration (OMD) has become another choice to form the patterns or texts on a surface of an object.

At present, polymeric materials commonly used in IMD include polycarbonate (PC), poly (methyl methacrylate) (PMMA), also known as polyacrylate, polyethylene terephthalate (PET), and acrylonitrile butadiene styrene copolymer (ABS). However, the hardness of a base material composed of PC and ABS is low, so that a surface of the substrate is liable to be damaged. A protective layer is therefore applied thereon to enhance the hardness and scratch resistance of the surface of the base material. On the other hand, a base material composed of PMMA has high hardness but is easily cracked during molding. Thus, it is difficult to perform a heat pressurizing process thereto.

The invention provides a decorated molding article including a composite layer structure which has both high hardness and high tensile properties according to the claims. The composite layer structure provides the appearance of highlight gloss, lusterless matte and various geometrically textured effects and is suitable for subsequent in-mold decoration or out mold decoration.

The invention provides a method for fabricating a decorated molding article, which may conduct a dyeing process during the formation of the composite layer structure according to the claims. Therefore, the composite layer structure may achieve decorative effects without an additional printing process, so as to reduce the costs and improve the yields.

In an embodiment of the invention, the first layer, the second layer or both of the layers further include a color concentrate, a pigment, a pearl powder or a combination thereof, so that the composite layer structure has colorful, pearlescent, glossy, mirror-like or other visual effects.

In an embodiment of the invention, the composite layer structure is a transparent composite layer structure.

In an embodiment of the invention, a material of the outer surface of the workpiece comprises plastics, resin, metal, carbon fiber, glass, or a combination thereof.

In an embodiment of the invention, the method further includes, prior to performing the co-extrusion molding film process, providing a third material to a third screw of the co-extrusion blow molding machine, wherein the third material includes a color concentrate, a pigment, a pearl powder, or a combination thereof.

In an embodiment of the invention, the method further includes, prior to performing the co-extrusion molding film process, providing a fourth material to a fourth screw of the co-extrusion blow molding machine, wherein the fourth material includes an additive.

In an embodiment of the invention, the first material and a color concentrate, a pigment, a pearl powder, and additional additive auxiliaries may be blended prior to performing the co-extrusion molding film process, then they are subjected to a co-extrusion molding film process with the second material to form the composite layer structure.

In an embodiment of the invention, the performing the in-mold decoration on the composite layer structure includes: disposing the composite layer structure in an in-mold decoration mold having a mold cavity where the composite layer structure covers at least a portion of a surface of the mold cavity, heating for pre-molding and cutting excessive film materials; injecting a molding material into the in-mold decoration mold, so that the molding material and the composite layer structure are combined with each other; cooling the molding material; and taking the decorated molding article out from the in-mold decoration mold.

In an embodiment of the invention, the performing the out mold decoration on the composite layer structure includes: providing a workpiece; placing the workpiece and the composite layer structure in a fixture; performing a high pressure decorative molding process, so that the composite layer structure is attached onto the outer surface of the workpiece via the adhesive layer.

In an embodiment of the invention, the high pressure decorative molding process includes: performing a heating and softening step on the composite layer structure and cutting excessive film materials; contacting the composite layer structure with the workpiece and performing a pressurizing step; performing a high pressure vacuum molding step on the composite layer structure and the workpiece, so that the composite layer structure is attached onto the outer surface of the workpiece.

In view of the foregoing, the present invention provides a decorated molding article comprising a composite layer structure as defined in the appended claim <NUM>, wherein the composite layer structure is formed by combining a first layer and a second layer which have different materials, so that the composite layer structure has both high hardness and high tensile properties. Various surface treatments, such as for adding gloss, matt, and geometric texture, may be performed on the composite layer structure by the pressure roller in the back end of the extrusion process, such that the composite layer structure is suitable for subsequent IMD or OMD. Further, the present invention provides a method for fabricating a decorated molding article, which may perform a dyeing treatment during the formation of the composite layer structure. Therefore, the composite layer structure may achieve decorative effects without an additional printing process, so as to reduce the costs and improve the yields.

The features and advantages of the present invention set forth above will be described in view of the following examples with reference to the accompanying drawings.

The present invention is described more detailed hereinafter with reference to the accompanying drawings. However, the present invention may be embodied in a variety of ways and is not limited to the examples set forth herein. Spatially related terms used in the following examples, such as "upper," "lower," and the like, may refer to the orientations of the attached drawings, and are therefore intended for the purposes of illustration rather than limitation. Furthermore, thicknesses of layers and regions in the drawings will be exaggerated for clarity. Same or like numeral references denote same or like elements, and the descriptions thereof will be omitted hereinafter.

<FIG> is a schematic cross-sectional view showing a composite layer structure.

Referring to <FIG>, a composite layer structure <NUM> is provided which includes a first layer <NUM> and a second layer <NUM>. The material of the first layer <NUM> is different from the material of the second layer <NUM>. More specifically, the material of the first layer <NUM> is acrylonitrile butadiene styrene copolymer (ABS) and the material of the second layer <NUM> is poly(methyl methacrylate) (PMMA).

The composite layer structure <NUM> is formed by a co-extrusion molding film process. Thus, a mixed region <NUM> is included between the first layer <NUM> and the second layer <NUM>. The mixed region <NUM> includes a portion of the first layer <NUM> and a portion of the second layer <NUM>. That is to say, the mixed region <NUM> includes both the material of the first layer <NUM> and the material of the second layer <NUM>. More specifically, the mixed region <NUM> includes acrylonitrile butadiene styrene copolymer (ABS) and poly(methyl methacrylate) (PMMA). In some embodiments, acrylonitrile butadiene styrene copolymer and poly(methyl methacrylate) in the mixed region <NUM> may be mixed together. In an alternate embodiment, poly(methyl methacrylate) in the mixed region <NUM> may be disposed on the acrylonitrile butadiene styrene copolymer as well. A method for fabricating the composite layer structure <NUM> will be described in more details hereinafter and thus the related descriptions will be omitted.

In an embodiment, the first layer <NUM> of the composite layer structure <NUM> further includes a color concentrate, a pigment, a pearl powder or a combination thereof, such that the composite layer structure <NUM> has colorful, pearlescent, glossy, mirror-like or other visual effects. For example, the composite layer structure <NUM> may have decorative effects such as glossy black and electroplating silver. In other embodiments, the second layer <NUM> of the composite layer structure <NUM> may also include a color concentrate, a pigment, a pearl powder, or a combination thereof. In an alternate embodiment, both of the first layer <NUM> and the second layer <NUM> of the composite layer structure <NUM> may include a color concentrate, a pigment, a pearl powder, or a combination thereof. In another embodiment, the composite layer structure <NUM> may be a transparent composite layer structure as well.

The composite layer structure <NUM> has a thickness of between <NUM> and <NUM>. In an embodiment, the apparent surface gloss (i.e., the surface gloss measured by using a surface gloss meter at an angle of <NUM> degrees) of the composite layer structure <NUM> is about <NUM>% or more. In other embodiments, the composite layer structure <NUM> has a density of about <NUM>/ml or more.

<FIG> is a process chart showing a method for fabricating a composite layer structure. <FIG> is a schematic side view of a first screw of <FIG>. The composite layer structure <NUM> may be formed by a bi-layered or multi-layered co-extrusion blow molding machine.

Referring to <FIG>, a first material is provided to a first screw <NUM> of the co-extrusion blow molding machine and a second material is provided to a second screw <NUM> of the co-extrusion blow molding machine. The first material is used to form the first layer <NUM> of <FIG>. The second material is used to form the second layer <NUM> of <FIG>. The first material is different from the second material. More specifically, the first material is acrylonitrile butadiene styrene copolymer (ABS) and the second material is poly(methyl methacrylate) (PMMA). In some embodiments, the first material is included in an amount of <NUM> wt% to <NUM> wt% and the second material is included in an amount of <NUM> wt% to <NUM> wt%.

In an embodiment, the screw is a supply unit for melting the plastics in the extrusion process, and plays an essential role in the quality of the melted plastics. That is to say, the main functions of the screw are to melt the solid plastics, transfer the melted plastics, homogenize the plastics and provide the pressure required for the melted plastics extruding out of the die head. Specifically, as shown in <FIG>, the first screw <NUM> may include a feeding section <NUM>, a compression section <NUM>, and a metering section <NUM> depending on the functions. Other screws <NUM>, <NUM>, <NUM> (as shown in <FIG>) have the same functions, thus the descriptions thereof will be omitted.

In an embodiment, the feeding section <NUM> (also referred to as a solids transport section) is used to compress the solid plastic particles and push them forward smoothly. The conveying method in this section is transported by the drag and the guide of the screw. In other words, the difference between a frictional force of the plastics against the casing and a frictional force of the plastics against the surface of the screw is used to push the solid plastic particles (referred to the first material here) forward. The greater the difference between the frictional force of the plastics against the inner side of the casing and the frictional force of the plastics against the surface of the screw is, the greater the transportability is. In order to increase the frictional force of the plastics against the casting, the surface of the casting may be engraved with a plurality of longitudinal grooves parallel to the screw, such that the frictional force is significantly increased and the first material is pushed forward along the axial direction of the screw rather than twisted surrounding the screw, thereby improving the capability of the solids transport section.

In an embodiment, the compression section (also referred to as a melt section) <NUM> is located at the end of the feeding section <NUM> where the groove depth of the longitudinal groove gradually decreases along the direction of the screw. When the first material is transferred from the feeding section <NUM> to the compression section <NUM>, the frictional heat of the solid particles of the first material and external heating cause the plastics begin to melt. The volume of the plastics is decreased while melting, so the depth of the groove needs to be reduced as well to match the decreased volume of the plastics. In addition, as the depth of the groove is reduced, the flow is constrained, so that the pressure in this area is gradually increased, thereby generating a pressurized effect on the first material.

In an embodiment, the metering section (also referred to as a melt transfer section) <NUM> is the last section in the first screw <NUM> that controls the flow. When the melt enters this section, it is thoroughly mixed and pressurized, so as to resist the back pressure of the die head at the front end of the first screw <NUM>.

Referring back to <FIG>, after providing the first material to the first screw <NUM> and providing the second material to the second screw <NUM>, a co-extrusion molding film process <NUM> is performed, so that the first material and the second material are joined at the confluence section <NUM> and form a composite material. Next, the composite material may be formed into a composite layer structure 100a after stretching longitudinally and/or laterally through the stretching section <NUM>. The configuration and material of the composite layer structure 100a are similar to those of the composite layer structure <NUM> of <FIG>, thus the descriptions thereof will be omitted. In an embodiment, a further step between the confluence section <NUM> and the stretching section <NUM> includes a cooling and molding step.

In this case, the composite layer structure 100a of the first embodiment may be a transparent composite layer structure. In other embodiments, prior to the co-extrusion molding film process <NUM>, the first material and a color concentrate, a pigment, a pearl powder, and additional additives may be blended to form a mixture. Next, the mixture and the second material are subjected to the co-extrusion molding film process <NUM> to form another composite layer structure, such that the composite layer structure has colorful, pearlescent, glossy, mirror-like, lusterless matte or other visual effects.

Further, after performing co-extrusion molding film process <NUM>, various surface treatments (such as gloss, matt, and geometric texture) may be performed by the pressure roller in the back end of the extrusion process.

<FIG> is a flow chart showing a method for fabricating a composite layer structure according to a second embodiment. The composite layer structure 100b of the second embodiment may have colouring effects. Detailed fabricating method thereof is set forth below.

Referring to <FIG>, a first material is provided to a first screw <NUM> of a co-extrusion blow molding machine, and a second material is provided to a second screw <NUM> of the co-extrusion blow molding machine. The types and contents of first material and second material are described above, thus the descriptions thereof will be omitted. Further, the fabricating method of the second embodiment further includes providing a third material to a third screw <NUM> of the co-extrusion blow molding machine and providing a fourth material to a fourth screw <NUM> of the co-extrusion blow molding machine. In an embodiment, the third material includes a color concentrate, a pigment, a pearl powder or a combination thereof, to provide colorful, pearlescent, glossy, mirror-like or other visual effects. The fourth material may include an additive, such as a lubricant, a dispersant, an ultraviolet light absorber, an oxidation inhibitor, or a combination thereof.

As shown in <FIG>, the first material, the second material, the third material, and the fourth material are subjected to a co-extrusion molding film process <NUM> to join at the confluence section <NUM> and form a composite material. Next, the composite material is formed into a composite layer structure 100b after stretching longitudinally and/or laterally through the stretching section <NUM>. The configuration and material of the composite layer structure 100b are similar to those of the composite layer structure <NUM> of <FIG>, thus the descriptions thereof will be omitted. It should be noted that, in the second embodiment, a dyeing process may be performed on the first layer (i.e. the first material) of the composite layer structure 100b during the co-extrusion molding film process <NUM>, such that the composite layer structure 100b has colorful, pearlescent, glossy, mirror-like or other visual effects. Therefore, the composite layer structure 100b of this embodiment may achieve decorative effects without an additional printing process, so as to reduce the costs and improve the yields.

Although the embodiments of <FIG> and <FIG> show methods for fabricating a composite layer structure with two layers, in other embodiments, bi-layered or multi-layered co-extrusion blow molding machines may be used to form a composite layer structure with two or more layers.

<FIG> is a schematic cross-sectional view showing a decorated molding article according to an embodiment of the present invention.

Referring to <FIG>, this embodiment provides a decorated molding article <NUM>, which includes a composite layer structure <NUM>, a decorative layer <NUM>, an adhesive layer <NUM>, and a workpiece <NUM>. The configuration and materials of the composite layer structure <NUM> have been described above and will be omitted hereinafter.

As shown in <FIG>, the decorative layer <NUM> may be disposed on a surface 102a of the first layer <NUM> of the composite layer structure <NUM> to form a composite layer structure <NUM>' which has the decorative layer <NUM>. In an embodiment, when the composite layer structure <NUM> is a transparent composite layer structure, various visual effects may be attained by the decorative layer <NUM>. However, the present invention is not limited thereto.

The decorative layer <NUM> may be formed by printing, spraying, electroplating, evaporation deposition, sputtering, or a combination thereof. For example, the decorative layer <NUM> may be composed of a printing ink or a printable material, which may be a single ink layer, multiple ink layers, or a patterned ink layer for example, so as to present a single color, multiple colors or desired patterns respectively. The decorative layer <NUM> may increase the diversity of patterns and colors of the composite layer structure <NUM>, so as to enrich the visual effects of the user or the viewer. In an alternate embodiment, the decorative layer <NUM> may be formed by gravure printing, screen printing, offset printing, reverse printing, inkjet printing, or any suitable printing method. In other embodiments, a material of the decorative layer <NUM> may include polyurethane (PU), polyacrylate, polyethylene terephthalate (PET), ethylene, propylene, polymer of higher olefins (polyolefin, PO), poly(methyl methacrylate) (PMMA), acrylonitrile styrene acrylic rubber copolymer (ASA), acrylonitrile-styrene copolymer (SAN), methyl methacrylate acrylonitrile butadiene styrene copolymer (MABS), polystyrene (PS), methyl methacrylate styrene copolymer (MS), or any suitable material, which may be mixed with an inorganic material.

As shown in <FIG>, the composite layer structure <NUM>' is attached onto an outer surface 200a of the workpiece <NUM> via the adhesive layer <NUM> to form the decorated molding article <NUM>. In an embodiment, the adhesive layer <NUM> may be a hot melt adhesive, a UV-curing type adhesive, a light-curing type adhesive, an electron-curing type adhesive, or a combination thereof, for example. For example, a material of the adhesive layer <NUM> may include at least one of polyacrylate, polymethacrylate, polycarbonate, polyurethane, polyester, polyamide, epoxy resin, ethylene vinyl acetate copolymer (EVA), acrylonitrile butadiene styrene copolymer (ASA), acrylonitrile-styrene copolymer (SAN), methyl methacrylate acrylonitrile butadiene styrene copolymer (MABS), polystyrene (PS), methyl methacrylate styrene copolymer (MS), or a thermoplastic elastomer, or a copolymer, mixture or composite thereof.

<FIG> is a flow chart showing the steps of a method for fabricating a decorated molding article in accordance with an embodiment of the present invention. <FIG> is a flow chart showing the steps of a method for fabricating a decorated molding article in accordance with another embodiment of the present invention.

<FIG> shows that the composite layer structure <NUM> is attached onto the outer surface 200a of the workpiece <NUM> via the adhesive layer <NUM> to form the decorated molding article <NUM>. The decorated molding article <NUM> may be manufactured by the fabricating method of <FIG> (which may be IMD, for example) or the fabricating method of <FIG> (which may be OMD, for example).

In detail, referring to <FIG>, a flow chart of the steps S100 of a method for fabricating a decorated molding article of the first embodiment is as below. First, in the step S102, a composite layer structure is provided. The composite layer structure may be the composite layer structure <NUM> of <FIG> or the composite layer structure <NUM>' having the decorative layer <NUM> (hereinafter simply referred to the composite layer structure <NUM>). The composition of the composite layer structure <NUM> is described above, thus the descriptions thereof will be omitted.

Next, in the step S104, the composite layer structure <NUM> is disposed in an in-mold decoration mold. In detail, the in-mold decorative mold includes a hollow molding cavity. The molding cavity has a surface. Thereafter, the composite layer structure <NUM> is attached onto the surface of the molding cavity, such that the composite layer structure <NUM> covers at least a portion of the surface of the molding cavity. In an alternate embodiment, prior to step S106, a heating and pre-molding step may be optionally performed, and an excessive portion of the composite layer structure is removed by using die cutting, laser cutting, or water jet cutting.

Then, in the step S106, a molding material is injected into the molding cavity of the in-mold decorative mold, such that the molding material and the composite layer structure <NUM> are combined with each other. In an embodiment, the molding material may be a plastic material, a resin material, a metal material, a carbon fiber material, glass, or any suitable molding material.

Thereafter, in the step S108, the molding material is cooled to form the workpiece <NUM>. Depending on the applications of the decorated molding article of the present invention, the workpiece <NUM> may be a housing or component of an electronic device, a housing or component of a vehicle, or a combination thereof. For example, the workpiece <NUM> may be a housing or component used in an electronic device, such as a mobile phone, a digital camera, a personal digital assistant (PDA), a laptop computer, a desktop computer, a touch panel, a television, a global positioning system (GPS) device, a car monitor, a navigator, a display, a digital photo frame, a DVD player, automotive interior trim panels (e.g., handles, trims, touchable front bumpers and the like), automotive exterior trim panels (e.g., exterior handles, back door trim strips and the like), an automotive dashboard, an automotive logo, an intelligent key (I-key), an engine start button, a clock, a radio, a toy, a watches, or other electronic devices that require electricity. However, the present invention is not limited to the shape and structure of the workpiece <NUM>. Any workpiece <NUM> of which the shape and structure may be accomplished by IMD falls within the scope of this invention.

Next, in step S110, the decorated molding article <NUM> is taken out from the in-mold decorative mold. The obtained decorated molding article <NUM> is described above in <FIG> above, and will be omitted hereinafter.

On the other hand, the decorated molding article <NUM> may also be manufactured by OMD. Referring to <FIG>, a flow chart of the steps S200 of a method for fabricating a decorated molding article of the second embodiment is as below. First, in the step S202, a workpiece <NUM> is provided. In an embodiment, depending on the applications of the decorated molding article of the present invention, the workpiece <NUM> may be a housing or component of an electronic device, a housing or component of a vehicle, or a combination thereof. In an alternate embodiment, a material of the outer surface 200a of the workpiece <NUM> may be plastics, resin, metal, carbon fiber, glass, or other molded casing material, and the workpiece <NUM> may be a workpiece which is suitably pre-treated to have the desired properties, for example. For example, when the material of the workpiece is plastics, a plastic workpiece (e.g., a plastics casing) may be obtained by an injecting process via an injecting mold; or, when the material of the workpiece is metal, a metal workpiece (e.g., a metal casing or the like) may be obtained by a metal surface treatment.

Next, in step S204, a composite layer structure is provided. The composite layer structure may be the composite layer structure <NUM> or the composite layer structure <NUM>' having the decorative layer <NUM> as shown in <FIG> (hereinafter simply referred to as the composite layer structure <NUM>), for example. The composition of the composite layer structure <NUM> is described above, thus the description thereof will be omitted.

Thereafter, in step S206, the workpiece <NUM> and the composite layer structure <NUM> are placed in a fixture. It should be noted that, prior to step S206, the fixture may optionally be tailored depending on the demands of the final products and manufactured accordingly.

Claim 1:
A decorated molding article (<NUM>) comprising:
a workpiece (<NUM>), being a housing or component of an electronic device, a housing or component of a vehicle, or a combination thereof; and the housing or component of the vehicle being an automotive interior decoration, an automotive exterior decoration, an automotive logo, an automotive dashboard, an intelligent key, an engine start button or a combination thereof;
wherein the decorated molding article (<NUM>) is characterized by comprising:
a composite layer structure (<NUM>), attached onto an outer surface (200a) of the workpiece (<NUM>) via an adhesive layer (<NUM>), comprising:
a first layer (<NUM>), wherein the material of the first layer (<NUM>) is acrylonitrile butadiene styrene copolymer; and
a second layer (<NUM>), wherein the material of the second layer (<NUM>) is poly(methyl methacrylate) and wherein the second layer (<NUM>) is disposed on the first layer (<NUM>),
wherein the composite layer structure (<NUM>) is formed by a co-extrusion molding film process (<NUM>), and the composite layer structure (<NUM>) has a thickness of between <NUM> and <NUM>; and
a decorative layer (<NUM>) disposed between the composite layer structure (<NUM>) and the adhesive layer (<NUM>).