CN114905828A - Composite membrane, formed part and IML forming process - Google Patents
Composite membrane, formed part and IML forming process Download PDFInfo
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- CN114905828A CN114905828A CN202110175215.7A CN202110175215A CN114905828A CN 114905828 A CN114905828 A CN 114905828A CN 202110175215 A CN202110175215 A CN 202110175215A CN 114905828 A CN114905828 A CN 114905828A
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Images
Classifications
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- B32B27/00—Layered products comprising a layer of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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Abstract
The invention relates to the technical field of product decoration, and provides a composite membrane, a formed part and an IML (in-mold labeling) forming process. This composite film's thin layer has plasticity, the decorative layer is for having flexible non-plastic thin slice, after laminating the decorative layer on the thin layer, the decorative layer can suit with the structure of thin layer, in order closely to laminate on the thin layer, and, when the thin layer shape changes, the decorative layer can be along with the corresponding change of shape of thin layer, the decorative layer forms composite film through cutting apart after laminating on the thin layer, the decorative layer is high with the uniformity of thin layer in the composite film piece that so obtains, be convenient for mass production, this composite film piece is being arranged in on the formed part, and after the follow-up is used to the product on, the user is when using, can touch the decorative layer, thereby bring different use impression, satisfy the more hobby the user.
Description
Technical Field
The invention relates to the technical field of product decoration, in particular to a composite membrane, a formed part and an IML (in-mold labeling) forming process.
Background
The technology of In-mold insert injection Molding (IML for short) has the very obvious characteristics that: the surface of a product produced by the in-mold insert injection molding process is a hardened transparent film, the middle of the product is a printing pattern layer, the back of the product is a plastic layer, and the transparent film covers the printing pattern layer, so that the transparent film is firstly contacted in the using process, the transparent film can protect the product, the wear resistance of the surface of the product is improved, the surface of the product is prevented from being scratched, and meanwhile, the printing ink on the printing pattern layer is clamped in the middle of the product, so that the printing ink is prevented from being scratched, and the vivid color of the printing ink can be kept for a long time.
At present, more and more electronic products are made of shells by adopting an in-mold insert injection molding process, and with the improvement of the consumption level of substances of people, the selection of some consumers on the electronic products is not limited to the functions of the consumers, and more consumers put higher requirements on the appearance of the products.
The appearance of a product is enhanced mainly by a pattern layer or an ink layer in a film in the traditional IML, but with the development of science and technology and the progress of technology, the traditional plastic decorative layer can not meet the requirements of customers, particularly for high-end products, the customers not only require the product to be attractive, but also require the product to have various other use requirements, such as good touch feeling, and the like, so that new requirements are provided for the traditional IML production.
Disclosure of Invention
The invention aims to provide a composite membrane, and aims to solve the problem of poor user experience caused by process defects of the conventional IML membrane.
In order to achieve the purpose, the invention adopts the technical scheme that: the utility model provides a composite membrane for combine in order to form the formed part with the substrate layer, composite membrane including have plasticity thin layer and laminate in decorative layer on the thin layer, the decorative layer is for having flexible thin slice, the thin layer with form after cutting apart at least after the decorative layer laminating composite membrane.
In one embodiment, the decorative layer is a sheet made of a non-plastic material, or the decorative layer is a sheet made of a PU material.
In one embodiment, the decorative layer and the film layer are bonded after hot pressing, and/or the decorative layer and the film layer are bonded through an adhesive.
In one embodiment, the composite film further comprises a pattern layer arranged on the thin film layer, and the decorative layer is provided with a viewing window hole for observing the pattern layer.
In one embodiment, the film layer protrudes into the window hole at a position corresponding to the window hole to form a protrusion, and the outer side surface of the protrusion and one side of the decorative layer, which is far away from the film layer, are in smooth transition or are in stepped arrangement.
In one embodiment, a light transmitting layer attached to the thin film layer is arranged at a position, corresponding to the viewing window hole, of the thin film layer, and one side, far away from the thin film layer, of the light transmitting layer and one side, far away from the thin film layer, of the decorative layer are in smooth transition or are in stepped arrangement.
The application also provides a formed part, including the substrate layer and as before compound diaphragm, compound diaphragm cover in on the substrate layer, the decorative layer of compound diaphragm is located keeps away from one side of substrate layer.
In one embodiment, the substrate layer and the composite membrane are subjected to injection molding, or/and the substrate layer and the composite membrane are subjected to hot press molding.
In one embodiment, the substrate layer is of a light-transmitting structure, and/or the position of the substrate layer corresponding to the viewing window hole of the composite membrane is a hollow structure.
In one embodiment, the substrate layer is of a light-transmitting structure, and/or the position of the substrate layer corresponding to the viewing window hole of the composite membrane is of a thin-wall structure.
In one embodiment, the forming member is provided with a functional hole, and the functional hole at least penetrates through the film layer and the substrate layer of the composite membrane.
The application also provides an IML forming process, which comprises the following steps:
s1: the film layer is attached to the decorative layer to prepare a composite film with the decorative layer;
s2: cutting the composite membrane into a composite membrane for combining with a base material layer;
s3: and placing the composite membrane into a mold so that the composite membrane is combined with the base material layer to form a formed piece.
In an embodiment, the step S1 specifically includes:
s1: coating glue and/or carrying out hot melting treatment on one side of the thin film layer to form an adhesive surface with an adhesive effect on one side of the thin film layer, flatly attaching the decorative layer to the adhesive surface, and flattening to form the composite film; and carrying out hot pressing on the composite film to ensure that at least part of the outline of the composite film is matched with the outline of the substrate layer to be combined.
In one embodiment, before the step S1, the method further includes the following steps:
the decorative layer is provided with a first positioning hole, the thin film layer is provided with a second positioning hole opposite to the first positioning hole, the thin film layer is provided with a pattern layer, the decorative layer is provided with a window hole corresponding to the pattern layer, and the relative position of the window hole and the first positioning hole is determined according to the relative position of the pattern layer and the second positioning hole.
In one embodiment, the method further comprises the following steps:
before the step S1, forming a third positioning hole in the thin film layer, and providing a first insert pin adapted to the third positioning hole on a device for hot-pressing the composite film; a second insert pin matched with the third positioning hole is arranged on a device for dividing the composite film; arranging a third insert pin matched with the third positioning hole on the die for combining the composite membrane with the substrate layer;
in the step S1, the third positioning hole is engaged with the first insert pin to position the composite film, and then hot-pressing is performed;
in step S2, the third positioning hole is engaged with the second insert pin to position the composite film, and then a cutting operation is performed;
in step S3, the composite film is placed in the mold, so that the third positioning hole is engaged with the third insert pin, and the third positioning hole is blocked by the third insert pin, and the composite film is positioned at the same time, and then the substrate layer is formed by injection molding in the mold, and the substrate layer is drawn out by the third insert pin after the composite film is combined with the substrate layer to obtain the molded article, and the functional hole penetrating through the substrate layer and the film layer is formed on the molded article.
The invention has the beneficial effects that: the thin film layer has plasticity, the decorative layer is a flexible non-plastic sheet or a PU material sheet, after the decorative layer is attached to the thin film layer, the decorative layer can adapt to the structure of the thin film layer so as to be closely attached to the thin film layer, and when the shape of the thin film layer is changed, the decorative layer can correspondingly change along with the shape of the thin film layer, and the decorative layer is attached to the thin film layer and then is divided into composite films, so that the consistency of the decorative layer and the thin film layer in the obtained composite films is high, the mass production is convenient, the attaching position between the decorative layer and the thin film layer is more neat, the situation that manual cutting cannot be performed to be neat and consistent as the traditional covering cloth or covering cloth is avoided, meanwhile, the problems that the batch production cannot be realized due to the fact that the traditional covering cloth or covering cloth process group needs single attaching and cutting operation, and the production efficiency and the size precision cannot be improved are solved, the composite membrane can better meet the requirements of users and industrial production, and after the composite membrane is used on a formed part and is subsequently applied to a product, the users can touch the decorative layer when using the composite membrane, so that different use feelings are brought, and more preferences of the users are met.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed for the embodiments or the prior art descriptions will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
Fig. 1 is a schematic structural diagram of a composite membrane provided in an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a composite membrane having a pattern layer according to an embodiment of the present invention;
FIG. 3 is a first schematic structural diagram of a composite membrane having a viewing aperture and a pattern layer according to an embodiment of the present invention;
FIG. 4 is a second schematic structural diagram of a composite membrane having a viewing aperture and a pattern layer according to an embodiment of the present invention;
fig. 5 is a schematic structural diagram three of a composite membrane having a viewing aperture and a pattern layer according to an embodiment of the present invention;
FIG. 6 is a schematic view of a molding member without a viewing aperture according to an embodiment of the present invention;
fig. 7 is a first structural diagram of a molding member with a viewing window according to an embodiment of the present invention;
fig. 8 is a second schematic structural view of a molding member with a viewing window according to an embodiment of the present invention;
fig. 9 is a third schematic structural view of a molding member with a viewing window according to an embodiment of the present invention;
fig. 10 is a first schematic structural diagram of a molding member with functional holes according to an embodiment of the present invention;
fig. 11 is a second schematic structural diagram of a molding member with a functional hole according to an embodiment of the present invention;
fig. 12 is a third schematic structural view of a molding member with a functional hole according to an embodiment of the present invention;
fig. 13 is a fourth schematic structural diagram of a molding member with functional holes according to an embodiment of the present invention;
fig. 14 is a schematic structural diagram of a molding member with functional holes according to an embodiment of the present invention;
fig. 15 is a schematic structural diagram six of a molding member with functional holes according to an embodiment of the present invention;
fig. 16 is a seventh schematic structural diagram of a molding member with a functional hole according to an embodiment of the present invention.
Description of the main element symbols:
composite membrane sheet-100; molding piece-200; decorative layer-10; film layer-20; a boss-21; a light-transmitting layer-22; a pattern layer-30; a substrate layer-40; functional pore-50; a viewing aperture-11; a hollow structure-41; thin-walled structure-42.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.
In the description of the present invention, it is to be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on the orientations or positional relationships illustrated in the drawings, and are used merely for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed in a particular orientation, and be operated, and thus, are not to be construed as limiting the present invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or to implicitly indicate the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless specifically defined otherwise.
In the present invention, unless otherwise expressly stated or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; they may be directly connected or indirectly connected through intervening media, or may be connected through the use of two elements or the interaction of two elements. The specific meanings of the above terms in the present invention can be understood according to specific situations by those of ordinary skill in the art.
Referring to fig. 1 to 5, a composite film 100 of the present application is shown, which is used to combine with a substrate layer 40 to form a formed part 200, the composite film 100 includes a plastic film layer 20 and a decorative layer 10 attached on the film layer 20, the decorative layer 10 is a flexible sheet, the film layer 20 and the decorative layer 10 are attached and then at least divided to form the composite film 100, in this embodiment, the outline of the composite film 100 is adapted to the outline of the substrate layer 40; the dividing method may be punching, shearing, or other feasible dividing methods as long as the composite film 100 for bonding with the substrate layer 40 can be separated from the composite film.
In this embodiment, the thin film layer 20 has plasticity, the decoration layer 10 is a flexible sheet, after the decoration layer 10 is attached to the thin film layer 20, the decoration layer 10 can adapt to the structure of the thin film layer 20 to be closely attached to the thin film layer 20, and when the shape of the thin film layer 20 changes, the decoration layer 10 can correspondingly change along with the shape of the thin film layer 20, and the decoration layer 10 is attached to the thin film layer 20 and then is divided into the composite films 100, so that the obtained composite films 100 have high consistency between the decoration layer 10 and the thin film layer 20, which is convenient for mass production, and the positions of attachment between the decoration layer 10 and the thin film layer 20 are more orderly, which cannot be orderly and consistently achieved by manual cutting like the conventional masking cloth or skin, and meanwhile, the problem that the conventional masking cloth or skin process set needs single attachment and cutting operation, which results in that mass production cannot be achieved is overcome, the problems of improving the production efficiency and the size precision are not facilitated, and the requirements of users and industrial production can be better met.
In an alternative embodiment, the decorative layer is a sheet made of a non-plastic material, or the decorative layer is a sheet made of a PU material.
Specifically, the decoration layer 10 in this embodiment may be any flexible non-plastic material that can be attached to the thin film layer 20, such as at least any one of cloth, leather, plant sheets, synthetic plant sheets, non-woven fabrics, paper sheets, and metal sheets, where the plant sheets at least include wood sheets, bamboo sheets, bark, and leaves, and after the decoration layer 10 is attached to the thin film layer 20, the decoration layer 10 can modify the thin film layer 20, and the decoration layer 10 is located on one side of the thin film layer 20, and after the decoration layer is subsequently applied to a product, a user can touch the decoration layer 10 during use, thereby bringing about different use feelings, and satisfying more preferences of the user, and the decoration layer 10 may be a single-material sheet, or may be a flexible sheet formed by arranging or/weaving multiple sheets of different materials according to a certain rule.
Further, decorative layer 10 in this embodiment can be the thin slice that the flexible PU material that can laminate with thin layer 20 made, and decorative layer 10 that the PU material that has flexibility made can be good laminate to thin layer 10 on to play the decorative effect to the product, bring more different use experience for the user.
In an alternative embodiment, decorative layer 10 is attached to film layer 20 after heat pressing, or/and decorative layer 10 is attached to film layer 20 by an adhesive. In this embodiment, decorative layer 10 may be adhered to film layer 20 by hot pressing one side of film layer 20 to form an adhesive surface, and then covering decorative layer 10 over the adhesive surface. Or/and the adhesive can be coated between the film layer 20 and the decorative layer 10, so that the film layer 20 and the decorative layer 10 are tightly attached, and in any way, the tight attachment of the decorative layer 10 and the film layer 20 can be realized, which is more convenient compared with the existing covering or fabric covering way, and the attachment between the two layers can be more tightly fixed through pressing in the attachment process or after the attachment; alternatively, the two layers may be pressed together by an embossing roller to firmly adhere the two layers according to a certain pattern, thereby further enhancing the local adhesion strength of some of the decorative layers 10 having patterns and the film layer 20.
Referring to fig. 2, as another specific embodiment of the composite membrane 100 provided in the present application, the composite membrane 100 further includes a pattern layer 30 disposed on the thin film layer 20, an ink layer is disposed in the conventional IML membrane, the pattern layer 30 in this embodiment may be a portion having a special shape and/or color in the conventional ink layer, or a hollow portion disposed in the ink layer, and the pattern layer 30 may be a double-sided transparent or one-sided transparent pattern layer 30. In the present embodiment, the decorative layer 10 is made of a transparent material, so that a user can directly observe the pattern layer 30 through the decorative layer 10.
Referring to fig. 3, as another embodiment of the composite film 100 provided in the present application, the composite film 100 further includes a pattern layer 30 disposed on the thin film layer 20, and the decorative layer 10 is provided with a window 11 for observing the pattern layer 30. In the present embodiment, decorative layer 10 is made of a material having no good light transmittance, thin film layer 20 has good light transmittance, and when pattern layer 30 is provided on thin film layer 20, the pattern can be observed and seen through viewing hole 11 provided in decorative layer 10.
In the embodiment, the pattern layer 30 is arranged and the window hole 11 is formed in the decoration layer 10, so that on one hand, the attractive appearance and the good touch of the product are ensured, on the other hand, the characteristic of the traditional IML membrane product that the pattern layer 30 is not easy to damage is kept, and the attractive appearance and the interestingness of the product are enhanced.
Referring to fig. 4, as an embodiment of the composite film 100 provided by the present application, a protrusion 21 is formed by protruding the thin film layer 20 into the window hole 11 corresponding to the position of the window hole 11, and the outer side surface of the protrusion 21 is flush with the side of the decorative layer 10 away from the thin film layer 20. In this embodiment, seted up on decorative layer 10 and looked fenestra hole 11, decorative layer 10 has certain thickness, after seting up and looking fenestra hole 11, just there is one between decorative layer 10 and the thin layer 20 sunken, can influence when the user uses and feel, therefore, after setting up bellying 21, the shape and the window hole 11 full adaptation of bellying 21, and the lateral surface of bellying 21 and decorative layer 10 keep away from one side parallel and level of thin layer 20, make the user when using, can not touch the depressed part on the surface of composite film 100, feel better. The film layer 20 in this embodiment is a transparent structure, so the arrangement of the protruding portion 21 does not affect the user to observe the pattern layer 30 through the viewing window 11; of course, in some embodiments, the protrusions 21 may be only smooth transitions between the outer edges and the decorative layer 10, or the protrusions may be arranged in a step arrangement with the outer side of the decorative layer 10.
Furthermore, in the present embodiment, a recess is disposed on a side of the film layer 20 opposite to the decoration layer 10, the position of the recess corresponds to the position of the window hole 11, and the pattern layer 30 is disposed in the recess, so that the finished pattern layer 30 can be observed through the portion of the film layer 20 protruding out of the window hole 11.
Referring to fig. 5, as an embodiment of the composite film 100 provided by the present application, a transparent layer 22 attached to the thin film layer 20 is disposed at a position of the thin film layer 20 corresponding to the window hole 11, and a side of the transparent layer 22 away from the thin film layer 20 is flush with a side of the decorative layer 10 away from the thin film layer 20. In this embodiment, the shape of the light-transmitting layer 22 is completely matched with the shape of the window hole 11, and after the light-transmitting layer 22 is attached to the thin film layer 20, one side of the light-transmitting layer 22, which is far away from the thin film layer 20, is flush with one side of the decorative layer 10, which is far away from the thin film layer 20, so that a user feels better when using the decorative layer.
Referring to fig. 6 to 16, a molded article 200 according to the present invention is shown, which includes a substrate layer 40 and a composite film 100, wherein the composite film 100 covers the substrate layer 40, and the decorative layer 10 of the composite film 100 is located on a side away from the substrate layer 40. In this embodiment, the composite film 100 has a thin film layer 20 and a decorative layer 10 attached to the thin film layer 20, a pattern layer 30 is disposed on a side of the thin film layer 20 opposite to the decorative layer 10, and a substrate layer 40 is attached to a side of the thin film layer 20 having the pattern layer 30. The substrate layer 40 is made of a material that can be attached to the thin film layer 20 or the pattern layer 30 of the composite film 100, and is specifically an injection or/and hot-pressing material, for example, a plastic material, a silica gel material, or a rubber material, and the like, and the substrate layer 40 and the composite film 100 can be directly attached in the molding process, or attached in the molding process by using an adhesive, or attached by using a process that can enhance the bonding surface and/or the bonding degree between the substrate layer 40 and the composite film 100, which are not described in detail herein.
As a specific embodiment, in this embodiment, the decorative layer 10 is made of a material having a certain light transmittance, the substrate layer 40 has a light transmittance, when the molded article 200 is applied to an electronic product, light of the electronic product is irradiated onto the substrate layer 40, because the substrate layer 40 has a light transmittance, the pattern layer 30 located between the substrate layer 40 and the thin film layer 20 is illuminated, and the decorative layer 10 has a certain light transmittance, so that a user can still observe the pattern of the pattern layer 30 even though the viewing window hole 11 is not formed in the decorative layer 10 in this embodiment.
In an optional embodiment, injection molding is performed between the substrate layer 40 and the composite membrane 100, and the bonding between the substrate layer 40 and the composite membrane 100 is performed in a mold, specifically, the substrate layer 40 in this embodiment is made of a material that can be subjected to flowable injection molding, when the substrate layer 40 is bonded to the composite membrane 100, the composite membrane 100 is first placed into the mold, the mold has a processing cavity for bonding the substrate layer 40 to the composite membrane 100, a high-temperature and high-pressure material for manufacturing the substrate layer 40 is injected into the processing cavity, and after solidification, the composite membrane 100 and the substrate layer 40 are bonded together.
In an alternative embodiment, the substrate layer 40 and the composite membrane 100 are hot-pressed. The substrate layer 40 in this embodiment is made of a heat-pressable material, and after the composite film 100 is placed in a mold, the heat-pressable material in the mold is heated and pressed, so that the substrate layer 10 attached to the composite film 100 is formed on the side away from the decorative layer 10.
As shown in fig. 6, as an embodiment of the molded part 200 provided in the present application, the substrate layer 40 is a light-transmitting structure. In this embodiment, the light irradiated to the substrate layer 40 can illuminate the pattern layer 30 through the substrate layer 40, so that the user can clearly see the pattern of the pattern layer 30 through the viewing window hole 11.
As shown in fig. 7, as a specific embodiment of the molding member 200 provided by the present application, the position of the substrate layer 40 corresponding to the window hole 11 of the composite membrane 100 is a hollow structure 41, in this embodiment, the substrate layer 40 is made of an opaque material, in this case, light can directly illuminate the pattern layer 30 through the hollow position, so that a user can clearly see the pattern of the pattern layer 30 through the window hole 11.
In an alternative embodiment, the substrate layer 40 is a light-transmitting structure, and the position of the substrate layer 40 corresponding to the window hole 11 of the composite film 100 is a hollow structure 41. In this embodiment, the substrate layer 40 is made for the printing opacity material, and the substrate layer 40 is corresponding to the position fretwork of looking at fenestra 11, light can see through fretwork position and illuminate pattern layer 30 under this kind of circumstances, can see through substrate layer 40 and illuminate other parts except pattern layer 30 simultaneously, the luminance in pattern layer 30 position is the highest only, also see the luminance in fenestra 11 position the highest, other position luminance is slightly low, this is mainly because the substrate layer 40 of printing opacity material can reflect some light, lead to actual luminousness to be less than the fretwork layer luminousness, thereby make the light intensity that passes substrate layer 40 and shine other positions except pattern layer 30 be less than the light intensity who shines pattern layer 30 position. In this embodiment, the user can see the pattern of the pattern layer 30 clearly through the viewing window 11, and can see that the peripheral side of the pattern has a layer of hazy light, thereby further improving the visual experience.
As shown in fig. 8, as a specific embodiment of the molding member 200 provided by the present application, a thin-wall structure 42 is disposed at a position of the substrate layer 40 corresponding to the window hole 11 of the composite film 100, in this embodiment, the substrate layer 40 is made of an opaque material, but due to the existence of the thin-wall structure 42, the wall thickness of the thin-wall structure 42 is very thin, and when light irradiates the thin-wall structure 42 from one side of the thin-wall structure 42, the brightness of the other side of the thin-wall structure 42 is increased, so as to form an effect similar to that when gel is lighted, so that the light can directly illuminate the thin-wall structure 42, and the pattern layer 30 can be lighted by the lighted light on the thin-wall structure 42, so that a user can observe the pattern layer 30 through the window hole 11. Thin-walled structure 42 is light transmissive, and when a light source is applied to thin-walled structure 42, the light source illuminates patterned layer 30 through thin-walled structure 42.
As shown in fig. 9, as a specific embodiment of the molded article 200 provided in the present application, the substrate layer 40 is of a light-transmitting structure, and the position of the substrate layer 40 corresponding to the window hole 11 of the composite film 100 is the thin-wall structure 42, in this embodiment, light can illuminate the pattern layer 30 and other parts except the pattern layer 30, but the luminance of the pattern layer 30 is the highest, that is, the luminance of the window position is the highest, and the luminance of the other positions is slightly lower, mainly because the light-transmitting material can reflect a part of light, the thicker the thickness of the light-transmitting material is, the lower the light transmittance is, so that the actual light transmittance of the other positions of the substrate layer 40 is lower than the light transmittance of the thin-wall structure 42, and thus the intensity of light passing through the substrate layer 40 and irradiating other positions except the pattern layer 30 is lower than the intensity of light irradiating the position of the pattern layer 30. In this embodiment, the user can see the pattern of the pattern layer 30 clearly through the viewing window 11, and can see that the peripheral side of the pattern has a layer of hazy light, thereby further improving the visual experience.
In an alternative embodiment, the molding member 200 is provided with a functional hole 50, and the functional hole 50 at least penetrates through the film layer 20 and the substrate layer 40 of the composite membrane 100. The functional holes 50 in this embodiment are used for realizing various different specific functions after the molding member 200 is mounted on the product, and for example, the functional holes 50 may be sound holes for sound to pass through, may be heat dissipation holes for heat dissipation of the product, may be light transmission holes for light to pass through, may be air holes for gas to pass through, may be atomization holes for atomization, and the like. The specific function of the functional hole 50 is determined according to the specific environment of the electronic product to which the molding member 200 is applied.
As shown in fig. 10, as a specific embodiment of the molded article 200 provided by the present application, the functional hole 50 penetrates through the substrate layer 40 and the thin film layer 20 of the composite film 100, the substrate layer 40 is made of a light-transmitting material, the decorative layer 10 has a certain light-transmitting property, when the molded article 200 is applied to an electronic product, the electronic product emits light onto the substrate layer 40, and a user can directly observe the pattern layer 30 from one side of the decorative layer 10. Specifically, the functional hole 50 in this embodiment may be a light-transmitting hole, so that when the electronic product emits light, the light can be irradiated onto the decoration layer 10 through the functional hole 50, and since the decoration layer 10 is a light-transmitting structure, the electronic product can perform an illumination function due to the arrangement of the functional hole 50. The functional holes 50 in this embodiment may also have more functions according to specific application scenarios.
As shown in fig. 11, as a specific embodiment of the molded article 200 provided by the present application, the functional hole 50 penetrates through the substrate layer 40 and the entire composite film 100, the substrate layer 40 is made of a light-transmitting material, the viewing hole 11 is provided on the decorative layer 10, when the molded article 200 is applied to a product, a light source of the product is irradiated onto the substrate layer 40, and a user can observe the pattern layer 30 through the viewing hole 11. Specifically, the functional holes 50 in the present embodiment may be light holes, heat dissipation holes, air holes, sound holes, and the like, and even the functional holes 50 may have multiple functions. Through the functional holes 50 penetrating through the whole composite membrane 100 and the substrate layer 40, the environment inside the molding member 200 and the environment outside the molding member 200 in the product can be communicated, thereby satisfying various functions required in application.
As shown in fig. 12, as a specific embodiment of the molding member 200 provided in the present application, the functional hole 50 penetrates through the substrate layer 40 and the entire composite film 100, the viewing hole 11 is provided on the decorative layer 10, the hollow structure 41 is provided on the substrate layer 40 at a position corresponding to the viewing hole 11, both the substrate layer 40 and the decorative layer 10 can be made of opaque materials, the light source irradiates the pattern layer 30 from the hollow structure 41 of the substrate layer 40, and the user can observe the pattern layer 30 through the viewing hole 11. Specifically, the functional hole 50 in the present embodiment may be a light-transmitting hole, and when the substrate layer 40 and the decoration layer 10 are not light-transmitting, light can be irradiated from the inside of the molded article 200 to the outside of the molded article 200 through the functional hole 50, thereby performing an illumination function. The functional holes 50 may also be used to perform various other functions depending on the particular application.
As shown in fig. 13, as an embodiment of the molded article 200 provided by the present application, the functional hole 50 penetrates through the substrate layer 40 and the entire composite film 100, the viewing hole 11 is provided on the decorative layer 10, and the thin-walled structure 42 is provided on the substrate layer 40 at a position corresponding to the viewing hole 11, and the thin-walled structure 42 has a certain light transmittance, so that a user can observe the pattern layer 30 through the viewing hole 11. In this embodiment, the functional hole 50 penetrating through the whole composite membrane 100 and the substrate layer 40 can communicate between the environment inside the molded part 200 and the environment outside the molded part 200 in the product, so as to satisfy various functions required in application. Specifically, the functional holes 50 in the present embodiment may be light holes, heat dissipation holes, air holes, sound holes, and the like, and even the functional holes 50 may have multiple functions.
As shown in fig. 14, as an embodiment of the formed part 200 provided in the present application, the functional holes 50 penetrate through the substrate layer 40 and the thin film layer 20 of the composite film 100, the viewing hole 11 is provided on the decorative layer 10, the decorative layer 10 is made of opaque material, the substrate layer 40 is made of transparent material, and the light source can irradiate onto the pattern layer 30 through the substrate layer 40, so that the user can observe the pattern of the pattern layer 30 through the viewing hole 11. Specifically, the functional holes 50 in the present embodiment may be sound holes, and the material of the decorative layer 10 has little obstruction to sound, so that the sound emitted from the product can be transmitted through the functional holes 50 after the molded article 200 is applied to the product. The functional holes 50 in this embodiment may also be heat dissipation holes for dissipating heat from the product.
As shown in fig. 15, as an embodiment of the molded article 200 provided in the present application, the functional hole 50 penetrates through the substrate layer 40 and the thin film layer 20 of the composite film 100, the viewing window hole 11 is provided on the decorative layer 10, the hollow structure 41 is provided on the substrate layer 40 at a position corresponding to the viewing window hole 11, and when light is irradiated from the substrate layer 40 side to the composite film 100, a user can see the pattern layer 30 through the viewing window hole 11. In this embodiment, substrate layer 40 can be made of a transparent material or an opaque material, and decorative layer 10 is made of an opaque material. The functional holes 50 in this embodiment can be heat dissipation holes, sound holes, air holes, and the like, and can be specifically set according to the requirements of the product, and meanwhile, according to the function of the functional holes 50, the material of the decorative layer 10 can be correspondingly adjusted when the composite film 100 is manufactured, for example, when the functional holes 50 are air holes, the material of the decorative layer 10 needs to be made of a material with good air permeability.
As shown in fig. 16, as an embodiment of the molded article 200 provided by the present application, the functional hole 50 penetrates through the substrate layer 40 and the thin film layer 20 of the composite film 100, the viewing hole 11 is provided on the decorative layer 10, and the thin-walled structure 42 is provided on the substrate layer 40 at a position corresponding to the viewing hole 11, and the thin-walled structure 42 has a certain light transmittance, so that a user can observe the pattern layer 30 through the viewing hole 11. In this embodiment, the decoration layer 10 is made of opaque material, and the functional holes 50 can be heat dissipation holes, sound holes, air holes, etc., and can be specifically configured according to the requirements of the product. Meanwhile, according to the function of the functional hole 50, when the composite membrane 100 is manufactured, the material of the decorative layer 10 may be adjusted accordingly, for example, when the functional hole 50 is a sound hole, the decorative layer 10 needs to be made of a material with poor sound insulation performance.
The application also provides an IML forming process, which comprises the following steps:
s1: attaching the thin film layer to the decorative layer 10 to obtain a composite film with the decorative layer 10;
s2: cutting the composite membrane into composite membranes 100 used for being combined with the base material layer;
s3: the composite membrane 100 is placed in a mold such that the composite membrane 100 is bonded to the substrate layer 40 to form the molded part 200.
In this embodiment, the decoration layer 10 is first attached to the thin film layer 20 to obtain a composite film with the decoration layer 10, then at least the composite film is cut to obtain a composite film 100 adapted to the profile of the substrate layer 40, the composite film 100 has the same thickness as the composite film, only the size of the composite film 100 is smaller than that of the composite film, and then the substrate layer 40 and the composite film 100 are combined in a mold to obtain the molded part 200. The formed part 200 finally manufactured in the embodiment has the decoration layer 10, and can meet the requirements of some high-end products or customers with higher requirements.
Further, the in-process that composite film 100 and substrate layer 40 combine in the mould, injection moulding between substrate layer 40 and the composite film 100, the combination between substrate layer 40 and the composite film 100 goes on in the mould, specifically speaking, substrate layer 40 in this embodiment is made for flowable injection moulding's material, when combining substrate layer 40 with composite film 100, put composite film 100 into the mould earlier, have the process chamber that is used for combining substrate layer 40 and composite film 100 in the mould, inject the high temperature high pressure material that is used for making substrate layer 40 into the process chamber, after waiting to solidify, just combine together between composite film 100 and the substrate layer 40.
In an alternative embodiment, the substrate layer 40 and the composite membrane 100 are hot-pressed. The substrate layer 40 in this embodiment is made of a material that can be hot-pressed, and after the composite film 100 is placed in a mold, the material that can be hot-pressed in the mold is heated and pressurized, so that the substrate layer 10 attached to the composite film 100 is formed on the side away from the decorative layer 10.
In an alternative embodiment, after preparing film layer 20 and decorative layer 10, one side of the film layer is coated with glue and/or hot-melted to form an adhesive surface with adhesive effect on one side of the film layer, and the decorative layer is flatly adhered to the adhesive surface; the composite membrane is hot-pressed, so that at least partial outline of the composite membrane is matched with the outline of the substrate layer 40 to be combined, one composite membrane can be finally divided into a plurality of composite membranes 100, the outline of each composite membrane 100 can be matched with the outline of the substrate layer 40 to be combined, and the composite membrane is also provided with a plurality of parts matched with the outlines of the substrate layer 40 to be combined.
In the present embodiment, two ways of attaching decorative layer 10 to film layer 20 are proposed, one way is to use an adhesive between decorative layer 10 and film layer 20 so as to attach decorative layer 10 to film layer 20, and the other way is to form an adhesive surface by hot melting one side of film layer 20, and then cover decorative layer 10 on the adhesive surface so as to attach decorative layer 10 to film layer 20. No matter which mode is used to laminate decorative layer 10 to thin film layer 20, for traditional cloth or covering operation, the roughness and the glue effect on decorative layer 10 surface are guaranteed more easily to this kind of mode to be favorable to improving the product quality and the outward appearance effect that finally make, can also improve the life of product simultaneously.
Specifically, thin layer 20 in this embodiment is planar structure before laminating with decorative layer 10, therefore, in the in-process with decorative layer 10 attached to thin layer 20, can make decorative layer 10 can be simply and smoothly attached to thin layer 20, can not receive the problem that leads to inconvenient pasting or laminating not tight because the restraint of product corner position space leads to like in the process of cloth or covering technology, after laminating decorative layer 10 to thin layer 20, carry out hot pressing to thin layer 20 again and make its profile that forms with substrate layer 40 looks adaptation, then cut apart the composite membrane 100 that is used for combining with substrate layer 40. In this way, in the production process, a plurality of composite films 100 can be cut on a group of attached decorative layers 10 and thin film layers 20 in batch, and before the cutting, the decorative layers 10 and the thin film layers 20 are attached directly or/and form a contour matched with the substrate layer 40 after hot pressing, so that the decorative layers 10 and the thin film layers 20 in the obtained composite films 100 after the cutting are always closely attached and have completely consistent corners, and the composite films can be matched and combined with the substrate layer 40.
In a specific embodiment, before attaching decorative layer 10 to film layer 20, a first positioning hole is formed in decorative layer 10, a second positioning hole is formed in film layer 20 opposite to the first positioning hole, pattern layer 30 is disposed on film layer 20, viewing window 11 is formed in decorative layer 10 corresponding to pattern layer 30, and the relative position of viewing window 11 and the first positioning hole is determined according to the relative position of pattern layer 30 and the second positioning hole.
In this embodiment, the decorative layer 10 is made of an opaque material, the viewing window hole 11 needs to be formed in the decorative layer 10 to observe the pattern layer 30 inside the thin film layer 20, before the decorative layer 10 is attached to the thin film layer 20, the first positioning hole and the second positioning hole are formed in the decorative layer 10 and the thin film layer 20, respectively, and the relative position between the pattern layer 30 and the second positioning hole is determined, because the first positioning hole is opposite to the second positioning hole, the position of the viewing window hole 11 can be determined on the decorative layer 10 according to the relative position between the pattern layer 30 and the second positioning hole, and then the viewing window hole 11 is formed in the decorative layer 10, so that the viewing window hole 11 formed in the decorative layer 10 can be ensured to accurately observe the pattern layer 30, and simultaneously, the subsequent steps of molding, cutting and combining with the substrate layer 40 are facilitated, the positioning of the composite film is performed, and the relative position of the viewing window hole 11 in each step is ensured, ensuring the precision of the viewing aperture 11 in the final product.
In a specific embodiment, the molding member 200 has a functional hole 50 penetrating through the substrate layer 40 and the thin film layer 20, specifically, in the present embodiment:
before the thin film layer 20 is attached to the decoration layer 10, a third positioning hole is formed in the thin film layer 20, and a first insert pin matched with the third positioning hole is arranged on a device for hot-pressing the composite film; a second insert pin matched with the third positioning hole is arranged on the device for dividing the composite film; a third insert pin matched with the third positioning hole is arranged on the die for combining the composite membrane 100 and the substrate layer 40;
in the hot-press molding process, the third positioning hole is matched with the first insert pin to position the composite membrane 100, and then the composite membrane is subjected to hot-press molding;
in the cutting process, the third positioning hole is matched with the second insert pin to position the composite membrane 100, and then cutting operation is carried out;
in the process of combining the composite membrane 100 and the substrate layer 40, after the composite membrane 100 is placed in a mold, a third positioning hole is matched with a third insert pin, the third positioning hole is blocked by the third insert pin, the composite membrane 100 is positioned at the same time, then the substrate layer 40 is formed by injection molding in the mold, the third insert pin is pulled out after the substrate layer 40 is combined with the composite membrane 100 to obtain a formed part 200, and meanwhile, a functional hole 50 penetrating through the substrate layer 40 and the thin film layer 20 is formed in the formed part 200.
In this embodiment, the decorative layer 10 does not need to have the viewing window 11.
In one embodiment, the decorative layer 10 is provided with a visible window, and the molded part 200 is provided with a functional hole 50 penetrating through the composite film 100 and the substrate layer 40.
In this embodiment, before the decorative layer 10 is attached to the thin film layer 20, a fourth positioning hole and a fifth positioning hole are respectively formed in the decorative layer 10 and the thin film layer 20, the fourth positioning hole is aligned with the fifth positioning hole, and in the process of bonding the composite film 100 to the substrate layer 40, holes aligned with the fourth positioning hole and the fifth positioning hole are formed in the substrate layer 40 by means of an insert pin, so that the functional hole 50 penetrating through the whole molded part 200 is formed in the molded part 200.
In a specific embodiment, the viewing window 11 does not need to be formed on the decorative layer 10, and after the decorative layer 10 is attached to the thin film layer 20 and is divided into the composite film 100, a sixth positioning hole is formed in the composite film 100, and the sixth positioning hole is used for positioning the composite film 100 in a subsequent processing process, so as to ensure that the processing effect of the composite film 100 is ideal. In this embodiment, the molding member 200 has the functional hole 50 penetrating through the substrate layer 40 and the entire composite membrane 100, and in the process of combining the composite membrane 100 with the substrate layer 40, a hole aligned with the sixth positioning hole is formed in the substrate layer 40 by an insert pin, so that the functional hole 50 penetrating through the entire molding member 200 is formed in the molding member 200.
In one specific embodiment, the wall thickness of the molding member 50 is thin, and the functional hole 50 penetrates through the molding member 50; in this embodiment, the composite film 100 and the substrate layer 40 are combined to form a molding member 200 without the functional hole 50, and then the molding member 50 is punched to form the functional hole 50 on the molding member.
The present invention is not limited to the above preferred embodiments, and any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (15)
1. A composite membrane for bonding with a substrate layer to form a shaped article, characterized in that: the composite membrane comprises a plastic film layer and a decorative layer attached to the film layer, the decorative layer is a flexible sheet, and the film layer is formed after being at least cut after the decorative layer is attached to the composite membrane.
2. The composite film of claim 1 wherein the decorative layer is a sheet made of a non-plastic material or a sheet made of a PU material.
3. The composite film of claim 1 wherein the decorative layer is attached to the film layer after hot pressing and/or wherein the decorative layer is attached to the film layer by an adhesive.
4. The composite film of claim 1, further comprising a pattern layer disposed on the film layer, wherein the decorative layer defines a viewing aperture for viewing the pattern layer.
5. The composite film according to claim 4, wherein the film layer protrudes into the window hole at a position corresponding to the window hole to form a protrusion, and an outer side surface of the protrusion and a side of the decorative layer away from the film layer are in smooth transition or are in a stepped arrangement.
6. The composite film of claim 4, wherein a light-transmitting layer attached to the thin film layer is disposed at a position of the thin film layer corresponding to the viewing window, and one side of the light-transmitting layer away from the thin film layer and one side of the decorative layer away from the thin film layer are in smooth transition or are in a stepped arrangement.
7. A shaped article characterized by: the composite film of any one of claims 1-6 comprising a substrate layer and a decorative layer overlying the substrate layer, the decorative layer of the composite film being on a side away from the substrate layer.
8. The molded part according to claim 7, wherein the substrate layer and the composite membrane are injection molded or/and the substrate layer and the composite membrane are hot press molded.
9. The formed part according to claim 7, wherein the substrate layer is of a light-transmitting structure, and/or the substrate layer is of a hollow structure at a position corresponding to the viewing window of the composite membrane.
10. A formed part according to claim 7 wherein the substrate layer is of a light-transmitting construction and/or the substrate layer is of a thin-walled construction in a position corresponding to the viewing aperture of the composite membrane.
11. The formed part according to claim 7, wherein the formed part is provided with a functional hole, and the functional hole at least penetrates through the thin film layer and the substrate layer of the composite membrane.
12. An IML forming process is characterized by comprising the following steps:
s1: attaching the thin film layer to the decorative layer to prepare a composite film with the decorative layer;
s2: cutting the composite membrane into a composite membrane for combining with a base material layer;
s3: and placing the composite membrane in a mold so that the composite membrane is combined with the base material layer to form a formed part.
13. The molding process according to claim 12, wherein the step S1 specifically includes:
s1: coating glue and/or carrying out hot melting treatment on one side surface of the film layer to form an adhesive surface with an adhesive effect on one side of the film layer, flatly attaching the decorative layer to the adhesive surface, and flattening to form the composite film; and carrying out hot pressing on the composite film to ensure that at least part of the outline of the composite film is matched with the outline of the substrate layer to be combined.
14. The molding process according to claim 12, further comprising, before said step S1, the steps of:
the decorative layer is provided with a first positioning hole, the thin film layer is provided with a second positioning hole opposite to the first positioning hole, the thin film layer is provided with a pattern layer, the decorative layer is provided with a window hole corresponding to the pattern layer, and the relative position of the window hole and the first positioning hole is determined according to the relative position of the pattern layer and the second positioning hole.
15. The molding process of claim 13, further comprising the steps of:
before the step S1, forming a third positioning hole in the thin film layer, and providing a first insert pin adapted to the third positioning hole on a device for hot-pressing the composite film; a second insert pin matched with the third positioning hole is arranged on a device for dividing the composite film; arranging a third insert pin matched with the third positioning hole on the die for combining the composite membrane with the substrate layer;
in the step S1, the third positioning hole is engaged with the first insert pin to position the composite film, and then hot-pressing is performed;
in the step S2, the third positioning hole is engaged with the second insert pin to position the composite film, and then the composite film is cut;
in step S3, the composite film is placed in the mold, so that the third positioning hole is engaged with the third insert pin, and the third positioning hole is blocked by the third insert pin, and the composite film is positioned at the same time, and then the substrate layer is formed by injection molding in the mold, and the substrate layer is drawn out by the third insert pin after the composite film is combined with the substrate layer to obtain the molded article, and the functional hole penetrating through the substrate layer and the film layer is formed on the molded article.
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| CN202110175215.7A CN114905828A (en) | 2021-02-09 | 2021-02-09 | Composite membrane, formed part and IML forming process |
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| CN202110175215.7A CN114905828A (en) | 2021-02-09 | 2021-02-09 | Composite membrane, formed part and IML forming process |
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