TW201509676A - Decoration film, composite article decorated by such decoration film and method of fabricating the same - Google Patents

Abstract

The invention discloses a decoration film, a composite article decorated by such decoration film and a method of fabricating the composite article. The method according to a preferred embodiment of the invention is, firstly, to stack a plurality of fiber layers. Next, the method is to mold the plurality of fiber layers into a main body. Then, the method is to cover an outer surface of the main body with a decoration film. Next, the method is to place the main body together with the decoration film within a chamber, and to dispose the main body and the decoration film between an inlet and an outlet of the chamber. Then, the method is to vacuumize from the outlet and/or to pressurize highly from the inlet such that the decoration film is attached on the outer surface of the main body due to the vacuum action and/or the high-pressure action. Finally, the method is to teat off a base layer and a release layer of the decoration film and to remain an adhesion layer and a structural pattern layer of the decoration film bonded on the outer surface of the main body to finish the composite article.

Description

Decorative film, composite material decorated by the decorative film and manufacturing method thereof

The present invention relates to a decorative film, a composite article decorated from the decorative film, and a method of manufacturing the same. And in particular, the present invention relates to a composite article made by in-mold decoration (IMD) or out-side mold decoration (OMD) and a method of manufacturing the same.

Composite materials based on glass fiber and carbon fiber have been widely developed into a variety of articles, including housings for information products, due to their excellent mechanical properties.

However, the appearance and color of the articles formed only by the above composite materials are monotonous. At present, composite material articles made by in-mold decoration technology or mold-out decoration technology and a manufacturing method thereof have not been proposed.

In addition, the carbon fiber composite housing blocks the reception of the antenna of the communication electronic product only by the casing of the communication electronic product (for example, notebook computer, mobile communication device, etc.) formed by the composite material of the carbon fiber substrate. It has not been found that a molded article retaining excellent mechanical properties of a carbon fiber-based composite material and which does not block antenna reception and a method of manufacturing the same have been proposed.

Therefore, the technical problem to be solved by the present invention is to provide a composite material article and a method of manufacturing the same, which are combined with an in-mold decoration technique or an exterior molding technique. In addition, the present invention also provides a molded article that retains excellent mechanical properties of a carbon fiber-based composite material and does not block antenna reception and Production method.

A composite article of a preferred embodiment of the invention comprises a body, an adhesive layer, and a structural layer. The main system is formed by stacking and molding a plurality of layers of fibrous material and has a body outer surface. The adhesive layer is coated on the outer surface of the body of the body. The structural layer is coated on the adhesive layer. The bonding process between the adhesive layer and the structural layer and the outer surface of the main body of the main body comprises the following steps: (1) providing a decorative film, wherein the decorative film sequentially comprises an adhesive layer, a structural layer, a release layer and a base layer; 2) first attaching the decorative film to the outer surface of the body through the adhesive layer; and (3) then tearing off the base layer and the release layer, leaving the adhesive layer and the structural layer bonded to the outer surface of the body of the body.

The method of manufacturing a composite article of the first preferred embodiment of the present invention, first, stacks a plurality of layers of fibrous material. Next, the method is to form the multilayer fibrous material into a body, wherein the body has a body outer surface. Next, the method covers the decorative film on the outer surface of the body of the formed body, wherein the decorative film sequentially comprises an adhesive layer, a structural layer, a release layer and a base layer from adjacent the outer surface of the body. Next, the method places the decorative film and the main body in the chamber, and is located between the air inlet hole and the air outlet hole of the chamber. Next, the method is to evacuate from the vent and/or apply high pressure from the vent, such that the decorative film is subjected to vacuum and/or high pressure to adhere to the outer surface of the body of the body. Finally, the method tears off the base layer and the release layer, leaving the adhesive layer and the structural layer bonded to the outer surface of the body of the body to complete the composite article.

A method of manufacturing a composite article according to a second preferred embodiment of the present invention, first, provides a mold in which the mold has an inner wall of the mold. Next, the method is to place a decorative film on the inner wall of the mold of the mold, wherein the decorative film sequentially includes a base layer, a release layer, a structural layer and an adhesive layer from the inner wall of the mold. Next, the method is to stack a plurality of layers of fibrous material within a mold. Next, the method pressurizes and heats the multilayered fibrous material and the decorative film by a mold to form the multilayered fibrous material into a main body, and at the same time causes the decorative film to be attached to the outer surface of the main body of the main body. Next, the method takes the body out of the mold and A decorative film attached to the outer surface of the body. Finally, the method tears off the base layer and the release layer, leaving the adhesive layer and the structural layer bonded to the outer surface of the body of the body to complete the composite article.

In one embodiment, each layer of fibrous material is generally comprised of a plurality of unidirectional fibers and comprises a thermosetting resin. Each fiber can be carbon fiber or fiberglass.

In one embodiment, each layer of fibrous material is substantially woven from a plurality of carbon fibers and a plurality of glass fibers and comprises a thermosetting resin.

In one embodiment, the structural layer may be formed of an ultraviolet curable resin, an electron beam curable resin, a thermosetting resin, or other commercially similar resin. The structural layer bonded to the outer surface of the main body of the main body is further subjected to a curing process to be cured

The composite article of the present invention can have a good color and appearance as compared to the prior art. The composite article of the present invention can also retain the excellent mechanical properties of the carbon fiber matrix composite and does not block the antenna reception.

The advantages and spirit of the present invention will be further understood from the following detailed description of the invention.

1‧‧‧Composite objects

2‧‧‧ Subject

20‧‧‧External surface of the main body

22‧‧‧a layer of fiber material

24‧‧‧Bottom edge surface

3‧‧‧Decorative film

32‧‧‧Adhesive layer

34‧‧‧Structural layer

36‧‧‧ release layer

38‧‧‧ basal layer

39‧‧‧Ink layer

4‧‧‧ chamber

42‧‧‧Air intake

44‧‧‧ Vents

46‧‧‧Support column

5‧‧‧Template

50‧‧‧Mold inner wall

52‧‧‧Male model

54‧‧‧Female mold

56‧‧‧roller

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a partial cross-sectional view of a composite article of a preferred embodiment of the present invention.

Figure 2 is a partial cross-sectional view of a decorative film used in the manufacture of the composite article of the present invention.

3A to 3E are schematic cross-sectional views showing a first preferred embodiment of the method of manufacturing a composite article of the present invention.

4A to 4D are schematic cross-sectional views showing the manufacturing process of the present invention A second preferred embodiment of the method of combining materials.

Please refer to Figure 1 and Figure 2. 1 is a partial cross-sectional view schematically showing a composite article 1 of a preferred embodiment of the present invention. Figure 2 is a partial cross-sectional view schematically showing the decorative film 3 used in the manufacture of the composite article 1 of the present invention.

The composite article 1 of a preferred embodiment of the present invention comprises a body 2, an adhesive layer 32 and a structural layer 34. The body 2 is stacked and formed from a plurality of layers of fibrous material 22 and has a body outer surface 20.

As shown in FIG. 2, the decorative film 3 sequentially includes an adhesive layer 32, a structural layer 34, a release layer 36, and a base layer 38. The adhesive layer 32 is coated on the outer surface 20 of the body of the body 2. The structural layer 34 is coated on the adhesive layer 32. The structural layer 34 is used to decorate the outer surface of the composite article 1 of the present invention, and the structural layer 34 is firmly adhered to the outer surface 20 of the body through the adhesive layer 32. The release layer 36 is coated on the structural layer 34, and the bonding strength between the release layer 36 and the structural layer 34 is less than the bonding strength between the adhesive layer 32 and the structural layer 34, so when subjected to an external force, the release layer 36 The structural layer 34 is first detached from the structural layer 34 to expose the structural layer 34. The base layer 38 is bonded to the release layer 36. When the release layer 36 is detached from the structural layer 34, the substrate layer 38 is simultaneously removed from the outer surface of the body along with the release layer 36.

The bonding process between the adhesive layer 32 and the structural layer 34 and the outer surface 20 of the main body 2 comprises the following steps: (1) providing a decorative film 3; (2) first attaching the decorative film 3 to the main body through the adhesive layer 32. The body outer surface 20 of the body 2; and (3) the base layer 38 and the release layer 36 are then removed, leaving the adhesive layer 32 and the structural layer 34 bonded to the body outer surface 20 of the body 2. Preferred embodiments of the method of making the composite article 1 of the present invention are described in detail below.

In a specific embodiment, the base layer 38 can be made of PET (poly pair) Polyethylene terephthalate resin, amorphous PET (A-PET) resin, PEN (Polyethylene Naphthalate) resin, PI (Polyimide) Resin, PO (Polyolefine) resin, ABS (Acrylonitrile Butadiene Styrene) resin or other commercially similar resin.

In one embodiment, the release layer 36 can be formed from silicone, fluororesin, melamine, or other commercially similar resins.

In one embodiment, the adhesive layer 32 may be formed of a thermoplastic resin.

In one embodiment, the structural layer 34 may be formed of a thermosetting resin, an ultraviolet curing resin, or an electron beam curing resin, and the structural layer bonded to the outer surface of the body is further subjected to a curing process to be cured. The upper surface of the structural layer 34 has a first embossed grain 35, and the lower surface of the release layer 36 has a second embossed line 37. As shown in FIG. 2, the first embossed grain 35 and the second embossed track 37 are periodically repeated square-bump lines which complement each other and are engaged with each other.

In a specific embodiment, the decorative film 3 may also optionally include an ink layer 39. The ink layer 39 is formed between the structural layer 34 and the adhesive layer 32. The ink layer 39 is used to provide the color exhibited by the appearance of the composite article 1 of the present invention. The ink layer 39 may be formed of a thermosetting resin, an ultraviolet curing resin, an electron beam curing resin, or other commercially similar resin.

The layer structure of the decorative film 3 can be formed by various printing and coating processes, for example, relief printing, lithography, gravure printing, screen printing, spray coating, and the like.

Referring to Figures 3A through 3F, a method of manufacturing a composite material article 1 in accordance with a first preferred embodiment of the present invention is schematically illustrated in a cross-sectional view.

First, as shown in FIG. 3A, the method of the first preferred embodiment of the present invention stacks a plurality of layers of fibrous material 22.

Next, as shown in FIG. 3B, the method of the first preferred embodiment of the present invention forms the multilayer fibrous material 22 into a body 2, wherein the body 2 has a body outer surface 20.

Next, as shown in FIG. 3C, the method of the first preferred embodiment of the present invention covers the decorative film 3 on the outer surface 20 of the body of the molded body 2, wherein the decorative film 3 is sequentially adjacent to the outer surface 20 of the body. An adhesive layer 32, a structural layer 34, a release layer 36, and a base layer 38 are included.

Next, as shown in FIG. 3C, the method of the first preferred embodiment of the present invention places the decorative film 3 and the main body 2 in the chamber 4, and is located at the air inlet 42 and the air outlet 44 of the chamber 4. between.

Next, as shown in FIG. 3D, the method of the first preferred embodiment of the present invention draws a vacuum from the air outlet 44 and/or applies a high air pressure from the air inlet 42 to cause the decorative film 3 to be subjected to vacuum and/or high. The air pressure is then attached to the outer surface 20 of the body 2 of the body 2. Further, the main body 2 can be overhead in the chamber 4 by means of an auxiliary tool such as a support post 46, as shown in Figs. 3C and 3D. The decorative film 3 can be further attached to the lower edge surface 24 of the outer edge of the body 2 by a suitable vacuum and/or high air pressure.

Finally, as shown in FIG. 3E, the method of the first preferred embodiment of the present invention tears off the base layer 38 and the release layer 36, leaving the adhesive layer 32 and the structural layer 34 bonded to the outer surface of the body of the body 2. 20 to complete the composite article 1 as shown in FIG. 3E schematically illustrates a process of tearing the base layer 38 and the release layer 36 from the outer surface 20 of the body of the body 2 in a partial cross-sectional view.

Referring to FIG. 4A to FIG. 4F, a method of manufacturing a composite material article 1 according to a second preferred embodiment of the present invention is schematically illustrated in a cross-sectional view.

First, as shown in FIG. 4A, the method of the second preferred embodiment of the present invention provides a mold 5 in which the mold 5 has a mold inner wall 50.

Next, as also shown in FIG. 4A, the method of the second preferred embodiment of the present invention places a decorative film 3 on the inner wall 50 of the mold 5, wherein the decorative film 3 sequentially includes the base layer from the inner wall of the mold. 38. Release layer 36, structural layer 34, and adhesive layer 32. For example, the mold 5 is composed of a male mold core 52 and a female mold core 54. In the case shown in Fig. 4A, the decorative film 3 is attached to the mold inner wall 50 of the female mold core 54.

In practice, the method of the second preferred embodiment of the present invention may employ a roll-to-roll continuous process for the decorative film 3. For example, as shown in FIG. 4A, the decorative film 3 is rolled up to a proper position by a pair of rollers 56.

Next, as shown in FIG. 4B, the method of the second preferred embodiment of the present invention is to stack a plurality of layers of fibrous material 22 within the mold 5. In practice, the multilayer fibrous material 22 is stacked on the decorative film 3.

Next, as shown in FIG. 4C, the method of the second preferred embodiment of the present invention pressurizes and heats the multilayer fiber material 22 and the decorative film 3 by the mold 5, that is, the male mold 52 and the female mold core. The 54-mesh pressurizes and heats the multilayered fibrous material 22 and the decorative film 3 to form the multilayered fibrous material 22 into the main body 2, and at the same time causes the decorative film 3 to be attached to the main body outer surface 20 of the main body 2.

Next, as shown in Fig. 4D, the method of the second preferred embodiment of the present invention takes out the main body 2 and the decorative film 3 attached to the outer surface 20 of the main body from the mold 5.

Finally, as also shown in FIG. 4D, the method of the second preferred embodiment of the present invention tears off the base layer 38 and the release layer 36, leaving the adhesive layer 32 and the structural layer 34 bonded outside the body of the body 2. Surface 20 is formed to complete composite article 1 as shown in FIG. 4D is a partial cross-sectional view schematically showing the removal of the base layer 38 and the release layer from the outer surface 20 of the body 2 of the body 2. 36 process.

In one embodiment, each layer of fibrous material 22 is generally comprised of a plurality of unidirectional fibers and comprises a thermosetting resin. Each fiber can be carbon fiber or fiberglass.

In one embodiment, each layer of fibrous material 22 is substantially woven from a plurality of carbon fibers and a plurality of glass fibers and comprises a thermosetting resin. The composite material article 1 of the present invention as a casing of a communication electronic product can retain the excellent mechanical properties of the carbon fiber matrix composite material and does not block the antenna reception.

In one embodiment, the structural layer 34 can be formed from an ultraviolet curable resin, an electron beam curable resin, a thermosetting resin, or other commercially similar resin. The structural layer 34 bonded to the outer surface 20 of the body 2 is further subjected to a curing process, for example, by ultraviolet irradiation, and the structural layer 34 is thereby hardened.

The features and spirit of the present invention are intended to be more apparent from the detailed description of the preferred embodiments. On the contrary, the intention is to cover various modifications and equivalents that are within the scope of the invention as claimed. Therefore, the scope of the patent application of the present invention should be construed broadly in the light of the above description, so that it covers all possible changes and arrangements.

2‧‧‧ Subject

20‧‧‧External surface of the main body

22‧‧‧a layer of fiber material

3‧‧‧Decorative film

32‧‧‧Adhesive layer

34‧‧‧Structural layer

36‧‧‧ release layer

38‧‧‧ basal layer

39‧‧‧Ink layer

Claims (19)

A method of making a composite article comprising the steps of: providing a body having a body outer surface; covering a decorative film on the outer surface of the body, wherein the decorative film is sequentially contained adjacent the outer surface of the body An adhesive layer, a structural layer, a release layer and a base layer; the decorative film and the body are placed in a chamber and located between an air inlet and an air outlet of the chamber; The vent is evacuated and/or a high pressure is applied from the air inlet to cause the decorative film to be attached to the outer surface of the body by the vacuum and/or the high pressure; and the base layer is peeled off and The release layer leaves the adhesive layer and the structural layer on the outer surface of the body to complete the composite article. The method of claim 1, wherein the primary system is formed by first stacking a plurality of layers of fibrous material, each layer of fibrous material consisting essentially of a plurality of unidirectional fibers and comprising a thermosetting resin. The method of claim 1, wherein the main system is formed by first stacking a plurality of layers of fiber material, and each layer of fiber material is substantially woven from a plurality of carbon fibers and a plurality of glass fibers, and comprises a thermosetting property. Resin. The method of claim 1, wherein the structural layer is formed of a thermosetting resin, an ultraviolet curing resin or an electron beam curing resin, and the structural layer bonded to the outer surface of the body is further subjected to a curing process. Processed and solidified. A method of making a composite article comprising the following steps: Providing a mold having a mold inner wall; and placing a decorative film on the inner wall of the mold, wherein the decorative film sequentially comprises a base layer, a release layer, a structural layer and an adhesive layer from the inner wall of the mold a layer; stacking a plurality of layers of fiber material in the mold; pressurizing and heating the multilayer fiber material and the decorative film by the mold to form the multilayer fiber material into a body having a body outer surface and simultaneously The decorative film is attached to the outer surface of the main body; the main body and the decorative film attached to the outer surface of the main body are taken out from the mold; and the base layer and the release layer are peeled off to leave the adhesive A layer and the structural layer are bonded to the outer surface of the body to complete the composite article. The method of claim 5, wherein each layer of fibrous material consists essentially of a plurality of unidirectional fibers and comprises a thermosetting resin. The method of claim 5, wherein each layer of the fibrous material is substantially woven from a plurality of carbon fibers and a plurality of glass fibers, and comprises a thermosetting resin. The method of claim 5, wherein the structural layer is formed of a thermosetting resin, an ultraviolet curing resin or an electron beam curing resin, and the structural layer bonded to the outer surface of the body is further subjected to a curing process. Processed and solidified. A composite material comprising: a body formed by stacking and molding a plurality of layers of fibrous material, and having a body outer surface; An adhesive layer is coated on the outer surface of the body; and a structural layer is coated on the adhesive layer; wherein the bonding process between the adhesive layer and the structural surface and the outer surface of the body comprises the following steps (1) providing a decorative film, the decorative film sequentially comprises the adhesive layer, the structural layer, a release layer and a base layer; (2) first attaching the decorative film to the body through the adhesive layer And (3) then peeling off the base layer and the release layer, leaving the adhesive layer and the structural layer bonded to the outer surface of the body. The composite article of claim 9 wherein each layer of fibrous material consists essentially of a plurality of unidirectional fibers and comprises a thermosetting resin. The composite article of claim 9 wherein each layer of fibrous material is substantially woven from a plurality of carbon fibers and a plurality of glass fibers and comprises a thermosetting resin. The composite article of claim 9, wherein the structural layer is formed of a thermosetting resin, an ultraviolet curing resin or an electron beam curing resin, and the structural layer bonded to the outer surface of the body is further passed through a Curing process, and then curing. The composite article of claim 9, further comprising an ink layer formed between the structural layer and the adhesive layer. The composite article of claim 9, wherein the step (2) further comprises the following steps: (2a) placing the decorative film and the main body in a chamber between an air inlet hole and an air outlet of the chamber; (2b) evacuating from the air outlet hole and/or from the air inlet hole A high pressure is applied such that the decorative film is attached to the outer surface of the body by the vacuum and/or the high air pressure. The composite article of claim 9, wherein the step (2) further comprises the steps of: (2a) providing a mold having a mold inner wall; (2b) placing the decorative film on the inner wall of the mold, and Stacking the multilayer fiber material in the mold; (2c) pressing and heating the multilayer fiber material and the decorative film by the mold to form the multilayer fiber material into the body, and simultaneously attaching the decorative film to the film Onto the outer surface of the body. A decorative film for decorating an outer surface of a main body of the main body, the decorative film comprising: an adhesive layer; a structural layer covering the adhesive layer, wherein the structural layer can be firmly attached through the adhesive layer On the outer surface of the body; a release layer is coated on the structural layer, the bonding strength between the release layer and the structural layer is less than the bonding strength between the adhesive layer and the structural layer, when subjected to an external force The release layer is detached from the structural layer to expose the structural layer; A substrate layer is bonded to the release layer, and when the release layer is detached from the structural layer, the substrate layer is simultaneously removed from the outer surface of the body along with the release layer. The decorative film of claim 16, further comprising an ink layer formed between the structural layer and the adhesive layer, the ink layer providing a color exhibited by an outer surface of the body. The decorative film of claim 16, wherein an upper surface of the structural layer has a first concave and convex grain, and a lower surface of the release layer has a second concave and convex grain, the first concave and convex lines and the second concave and convex The lines complement each other and bite each other. The decorative film of claim 18, wherein the first embossed grain and the second embossed grain are periodically repeating lines.