阅读说明：本技术 复合层结构、加饰成型品及其制造方法 (Composite layer structure, decorated molded article, and method for manufacturing same ) 是由 应国良 于 2018-11-02 设计创作，主要内容包括：本发明提供一种复合层结构,包括：第一层与第二层。第二层配置在第一层上。第二层的材料与第一层的材料不同。复合层结构是由共押成型薄膜工艺所形成,且复合层结构的厚度介于0.01毫米至1毫米之间。另外,本发明也提供一种加饰成型品及其制造方法。(The present invention provides a composite layer structure comprising: a first layer and a second layer. The second layer is disposed on the first layer. The material of the second layer is different from the material of the first layer. The composite layer structure is formed by co-extrusion molding film process, and the thickness of the composite layer structure is between 0.01 mm and 1 mm. The invention also provides a decorated molded article and a method for producing the same.)

1. A composite layer structure comprising:

a first layer; and

a second layer disposed on the first layer, wherein the second layer is made of a material different from the first layer, the composite layer structure is formed by co-extrusion molding thin film process, and the thickness of the composite layer structure is between 0.01 mm and 1 mm.

2. The composite layer structure of claim 1, wherein the material of the first layer comprises acrylonitrile-butadiene-styrene copolymer, polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber co-polymer, acrylonitrile-styrene copolymer, methyl methacrylate-acrylonitrile-butadiene-styrene copolymer, polystyrene, methyl methacrylate-styrene, or a combination thereof.

3. The composite layer structure of claim 1, wherein the material of the second layer comprises polymethylmethacrylate, polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber co-polymer, acrylonitrile-styrene copolymer, methyl methacrylate-acrylonitrile-butadiene-styrene copolymer, polystyrene, methyl methacrylate-styrene, or a combination thereof.

4. The composite layer structure of claim 1, wherein the first layer and the second layer have a blended region therebetween, the blended region comprising a material of the first layer and a material of the second layer.

5. The composite layer structure of claim 1, wherein the first layer further comprises color concentrates, pigments, pearl powder, or combinations thereof, such that the composite layer structure has a color, pearlescent, shiny, specular, or other visual effect.

6. The composite layer structure of claim 1, wherein the composite layer structure is a transparent composite layer structure.

7. A decorated molded article comprising:

a workpiece; and

the composite layer structure of any of claims 1-6 affixed to an outer surface of the workpiece by an adhesive layer.

8. The decorated article according to claim 7, further comprising a decorative layer disposed between the decorated article and the adhesive layer.

9. The decorated article according to claim 7, wherein the material of the outer surface of the workpiece comprises plastic, resin, metal, carbon fiber, glass, or a combination thereof.

10. The decorated article according to claim 7, wherein the workpiece comprises an electronic device housing or component, a vehicle housing or component, or a combination thereof, and the vehicle housing or component comprises an automobile interior, an automobile exterior, an automobile logo, an automobile dashboard, a smart key, an engine start button, or a combination thereof.

11. A method for manufacturing a decorated molded article, comprising:

providing a first material to a first screw of a co-extrusion film blowing machine;

providing a second material to a second screw of the co-extrusion film blowing machine; and

and carrying out a co-extrusion film forming process to enable the first material and the second material to be extruded to form a composite layer structure, wherein the first material is different from the second material.

12. The method of manufacturing a decorated molded article according to claim 11, wherein the first material includes acrylonitrile-butadiene-styrene copolymer, polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber copolymer, acrylonitrile-styrene copolymer, methyl methacrylate-acrylonitrile-butadiene-styrene copolymer, polystyrene, methyl methacrylate-styrene, or a combination thereof.

13. The method of manufacturing a decorated molded article according to claim 11, wherein the second material comprises polymethylmethacrylate, polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber copolymer, acrylonitrile-styrene copolymer, methyl methacrylate-acrylonitrile-butadiene-styrene copolymer, polystyrene, methyl methacrylate-styrene, and combinations thereof.

14. The method of claim 11, further comprising a third screw for supplying a third material to the coextrusion blow molding machine before the coextrusion film process, wherein the third material comprises color masterbatch, pigment, pearl powder or a combination thereof.

15. The method of claim 11, further comprising a fourth screw for supplying a fourth material to the coextrusion blow molding machine before the coextrusion film process, wherein the fourth material comprises an additive.

16. The method of claim 11, further comprising forming a decorative layer on the composite layer structure after the co-extrusion film forming process, wherein the decorative layer is formed by a printing method, a spraying method, an electroplating method, an evaporation method, a sputtering method or a combination thereof.

17. The method of claim 11, wherein after the co-extrusion molding process, further comprising performing an in-mold decoration technique or an out-mold decoration technique on the composite layer structure, so that the composite layer structure is attached to the outer surface of the workpiece through an adhesive layer to form the decorated article.

18. The method of manufacturing a decorated molded article according to claim 17, wherein the step of subjecting the composite layer structure to the in-mold decoration technique includes:

disposing the composite layer structure in an in-mold decorative mold having a mold cavity, wherein the composite layer structure covers at least a portion of a surface of the mold cavity;

pouring 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 shaped material; and

and taking the decorated molding product out of the in-mold decoration mold.

19. The method of manufacturing a decorated molded article according to claim 17, wherein the step of subjecting the composite layer structure to the in-mold decoration technique includes:

providing a workpiece;

placing a workpiece and the composite layer structure in a jig; and

and carrying out a high-pressure decoration forming process so that the composite layer structure is attached to the outer surface of the workpiece through the adhesive layer.

20. The method of manufacturing a decorated molded article according to claim 19, wherein the high-pressure decoration molding process includes:

heating and softening the composite layer structure;

contacting the composite layer structure with the workpiece and performing a pressing step; and

and carrying out a high-pressure vacuum forming step on the composite layer structure and the workpiece, so that the composite layer structure is attached to the outer surface of the workpiece.

Technical Field

The invention relates to a composite layer structure, a decorated molded article and a manufacturing method thereof.

Background

Generally, decorations such as patterns or letters formed on the surface of the housing of the object are mainly formed through a spraying (spraying) or printing (printing) process so as to present a specific visual effect, thereby adding variability in the appearance of the object. The conventional method of forming the case is to apply a hardened layer on the surface of the case by spraying after the case of the related product is completed, which is complicated in process, poor in yield, and causes pollution of organic solvent gas, thereby causing many pollution problems. On the other hand, the spray coating process is not suitable for mass production because it has disadvantages of time consumption, complicated process, low thickness uniformity, etc.

In order to solve the above problems, various specific Decoration processes using a Decoration film have been proposed, such as In-Mold Decoration (IMD) or Out-of-film Decoration (OMD) have been another option for forming surface patterns of objects.

The materials of the polymer substrate commonly used in the in-mold decoration technology at present include Polycarbonate (PC), polymethyl methacrylate (also called poly (acrylic), PMMA), Polyethylene Terephthalate (PET), and Acrylonitrile-Butadiene-Styrene (ABS). However, since the hardness of the substrate composed of PC and ABS is low and the surface of the substrate is easily damaged, the hardness and scratch resistance of the surface of the substrate are often increased by coating a protective layer. On the other hand, the base material made of PMMA has high hardness, but is easily cracked at the time of molding, and thus is not easily subjected to the hot press process.

Disclosure of Invention

The invention provides a composite layer structure which has the characteristics of high hardness and high tensile property, has the effects of high bright surface, dull matte surface and various geometric grain effects and is suitable for the subsequent in-mold decoration technology or the film outer decoration technology.

The invention provides a manufacturing method of a decorated molding, which can carry out dyeing treatment when a composite layer structure is formed, so that the composite layer structure can achieve the decoration effect without an additional printing process, thereby achieving the effects of reducing the cost and improving the yield.

The present invention provides a composite layer structure comprising: a first layer and a second layer. The second layer is disposed on the first layer. The material of the second layer is different from the material of the first layer. The composite layer structure is formed by co-extrusion molding film process, and the thickness of the composite layer structure is between 0.01 mm and 1 mm.

In an embodiment of the present invention, a material of the first layer includes Acrylonitrile-Butadiene-Styrene Copolymer (ABS), Polycarbonate (PC), Polypropylene (PP), Polyurethane (PU), Styrene-Acrylonitrile-acryl rubber Copolymer (ASA), Acrylonitrile-Styrene Copolymer (acrylnitrile-Styrene, SAN), methyl methacrylate-Acrylonitrile-Butadiene-Styrene Copolymer (MABS), polystyrene (polystyrene, PS), methyl methacrylate-Styrene (MMA Styrene Copolymer, MS), or a combination thereof.

In an embodiment of the present invention, the material of the second layer includes polymethyl methacrylate (PMMA), polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber copolymer (ASA), acrylonitrile-styrene copolymer (SAN), methyl methacrylate-acrylonitrile-butadiene-styrene copolymer (MABS), Polystyrene (PS), methyl methacrylate-styrene (MS), or a combination thereof.

In an embodiment of the invention, there is a blending region between the first layer and the second layer, the blending region comprising the material of the first layer and the material of the second layer.

In an embodiment of the present invention, the first layer, the second layer or both of the first layer and the second layer further comprise color masterbatch, pigment, pearl powder or a combination thereof, so that the composite layer structure has color, pearlescence, bright surface, mirror surface or other visual effects.

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

The invention provides a decorative molded article, comprising: the workpiece and the composite layer structure. The composite layer structure is attached to the outer surface of the workpiece through the adhesive layer.

In an embodiment of the invention, the decorative layer is disposed between the decorative molding and the adhesive layer.

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

In one embodiment of the present invention, the workpiece comprises an electronic device housing or component, a vehicle housing or component, or a combination thereof, and the vehicle housing or component comprises an automobile interior, an automobile exterior, an automobile logo (logo), an automobile dashboard, an intelligent key (I-key), an engine start button, or a combination thereof.

The invention provides a method for manufacturing a decorated molding, comprising the following steps. A first material is provided to a first screw of a co-extrusion film blowing machine. A second material is provided to a second screw of the co-extrusion film blowing machine. And carrying out a co-extrusion film forming process to extrude the first material and the second material to form a composite layer structure. The first material is different from the second material.

In an embodiment of the present invention, the first material includes acrylonitrile-butadiene-styrene copolymer, polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber copolymer (ASA), acrylonitrile-styrene copolymer (SAN), methyl methacrylate-acrylonitrile-butadiene-styrene copolymer (MABS), Polystyrene (PS), methyl methacrylate-styrene (MS), or a combination thereof.

In an embodiment of the present invention, the second material includes polymethylmethacrylate, polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber copolymer (ASA), acrylonitrile-styrene copolymer (SAN), methyl methacrylate-acrylonitrile-butadiene-styrene copolymer (MABS), Polystyrene (PS), methyl methacrylate-styrene (MS), or a combination thereof.

In an embodiment of the present invention, before the co-extrusion molding process, the manufacturing method further includes providing a third material to a third screw of the co-extrusion film blowing machine, wherein the third material includes color masterbatch, pigment, pearl powder or a combination thereof.

In an embodiment of the present invention, before the co-extrusion film forming process, the manufacturing method further includes providing a fourth material to a fourth screw of the co-extrusion film blowing machine, wherein the fourth material includes an additive.

In an embodiment of the present invention, before the co-extrusion molding process, the first material, the color master, the pigment, the pearl powder and the related additives may be mixed, and then the mixture may be co-extruded with the second material to form the composite layer structure.

In an embodiment of the invention, after the co-extrusion film forming process is performed, the manufacturing method further includes forming a decoration layer on the composite layer structure, wherein the method for forming the decoration layer includes a printing method, a spraying method, an electroplating method, an evaporation method, a sputtering method, or a combination thereof.

In an embodiment of the invention, after the co-extrusion molding of the film process is performed, the manufacturing method further includes performing an in-mold decoration technique or an out-mold decoration technique on the composite layer structure, so that the composite layer structure is attached to the outer surface of the workpiece through the adhesive layer to form the decorated molded article.

In one embodiment of the present invention, the step of performing the in-mold decoration technique on the composite layer structure is as follows. The composite layer structure is arranged in an in-mold decoration mold with a mold cavity, heating preforming is carried out, excess film materials are cut off, and the composite layer structure at least covers one part of the surface of the mold cavity. And pouring the molding material into the in-mold decoration mold, so that the molding material and the composite layer structure are combined with each other. And cooling the molding material. And taking out the decorated molding product from the in-mold decoration mold.

In an embodiment of the present invention, the step of performing the mold exterior decoration technique on the composite layer structure is as follows. A workpiece is provided. And placing the workpiece and the composite layer structure in a jig. And carrying out a high-pressure decoration forming process to enable the composite layer structure to be attached to the outer surface of the workpiece through the adhesive layer.

In an embodiment of the present invention, the steps of the high pressure trim molding process are as follows. And heating and softening the composite layer structure and cutting to remove redundant membrane materials. And contacting the composite layer structure with a workpiece, and performing a pressurizing step. And carrying out high-pressure vacuum forming on the composite layer structure and the workpiece so that the composite layer structure is attached to the outer surface of the workpiece.

Based on the above, the present invention combines the first layer and the second layer made of different materials to form a composite layer structure, which enables the composite layer structure to have high hardness and high tensile properties, and can perform various texture effects (such as bright surface, extinction and geometric texture) on the pressing wheel at the rear stage of extrusion, so as to be suitable for the subsequent in-mold decoration technology or the film-out decoration technology. In addition, the invention provides a manufacturing method of a decorated molding, which can carry out dyeing treatment when forming a composite layer structure, so that the composite layer structure can achieve the decoration effect without an additional printing process, thereby achieving the effects of reducing the cost and improving the yield.

In order to make the aforementioned and other features and advantages of the invention more comprehensible, embodiments accompanied with figures are described in detail below.

Drawings

FIG. 1 is a schematic cross-sectional view of a composite layer structure according to an embodiment of the invention.

Fig. 2 is a schematic flow chart of a method for manufacturing a composite layer structure according to a first embodiment of the present invention.

Fig. 3 is a side schematic view of the first screw of fig. 2.

Fig. 4 is a flowchart illustrating a method for manufacturing a composite layer structure according to a second embodiment of the present invention.

Fig. 5 is a schematic cross-sectional view of a decorative molded article according to an embodiment of the present invention.

Fig. 6 is a flowchart of the steps of a method for manufacturing a decorated article according to a third embodiment of the present invention.

Fig. 7 is a flowchart illustrating steps of a method for manufacturing a decorated article according to a fourth embodiment of the present invention.

Detailed Description

The present invention is described more fully hereinafter with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Directional phrases used in the following embodiments, such as "upper", "lower", etc., refer only to the direction of the attached drawings and are, therefore, used in the detailed description and should not be construed as limiting the present invention. In addition, the thickness of layers and regions in the drawings may be exaggerated for clarity. The same or similar element numbers refer to the same or similar elements, and the description thereof will not be repeated in the following paragraphs.

FIG. 1 is a schematic cross-sectional view of a composite layer structure according to an embodiment of the invention.

Referring to fig. 1, an embodiment of the invention provides a composite layer structure 100 including: a first layer 102 and a second layer 104. The second layer 104 is disposed on the first layer 102. In an embodiment, the material of the first layer 102 includes acrylonitrile-butadiene-styrene copolymer, polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber copolymer (ASA), acrylonitrile-styrene copolymer (SAN), methyl methacrylate-acrylonitrile-butadiene-styrene copolymer (MABS), Polystyrene (PS), methyl methacrylate-styrene (MS), or a combination thereof. The material of the second layer 104 includes polymethylmethacrylate, polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber copolymer (ASA), acrylonitrile-styrene copolymer (SAN), methyl methacrylate-acrylonitrile-butadiene-styrene copolymer (MABS), Polystyrene (PS), methyl methacrylate-styrene (MS), or a combination thereof. In this embodiment, the material of the first layer 102 is different from the material of the second layer 104. For example, the material of the first layer 102 may be Acrylonitrile Butadiene Styrene (ABS), while the material of the second layer 104 may be methyl methacrylate (PMMA).

In one embodiment, the composite layer structure 100 is formed by a co-extrusion film process. Thus, there is a blended region 106 between the first layer 102 and the second layer 104. The blend region 106 includes a portion of the first layer 102 and a portion of the second layer 104. That is, the blended region 106 includes the material of the first layer 102 and the material of the second layer 104. For example, the mixing region 106 includes acrylonitrile-butadiene-styrene copolymer and methyl methacrylate. In some embodiments, the acrylonitrile-butadiene-styrene copolymer and the methyl methacrylate in the mixing region 106 may be mixed together. In an alternative embodiment, the methyl methacrylate in the mixing region 106 may also be disposed on an acrylonitrile-butadiene-styrene copolymer. The following paragraphs will describe the method of manufacturing the composite layer structure 100 in detail, and will not be described in detail here.

In one embodiment, the first layer 102 of the composite layer structure 100 further comprises color concentrate, pigment, pearl powder, or a combination thereof, such that the composite layer structure 100 has a color, pearlescence, bright surface, mirror surface, or other visual effect. For example, the composite layer structure 100 may have a decorative effect of piano black or silver plating. However, the invention is not limited thereto, and in other embodiments, the second layer 104 of the composite layer structure 100 may also include color masterbatch, pigment, pearl powder, or a combination thereof. In alternative embodiments, both the first layer 102 and the second layer 104 of the composite layer structure 100 may include color concentrates, pigments, pearl powder, or combinations thereof. In another embodiment, the composite layer structure 100 may also be a transparent composite layer structure.

In one embodiment, the thickness of the composite layer structure 100 is between 0.01 mm and 1 mm. In alternative embodiments, the apparent surface gloss (i.e., measured at a 60 degree angle using a surface gloss meter) of the composite layer structure 100 is about 80% or greater. In other embodiments, the density of the composite layer structure 100 is about 1.06g/ml or greater. However, the present invention is not limited thereto, and in other embodiments, the thickness, the brightness uniformity, the density, and other characteristics of the composite layer structure 100 may be adjusted according to different materials.

Fig. 2 is a flow chart illustrating a method for manufacturing a composite layer structure according to an embodiment of the invention. Fig. 3 is a side schematic view of the first screw of fig. 2. The composite layer structure 100 of the present embodiment can be formed by a co-extrusion film blowing machine with two or more layers, but the invention is not limited thereto.

Referring to fig. 2, a first material is provided to a first screw 10 of a co-extrusion film blowing machine, and a second material is provided to a second screw 20 of the co-extrusion film blowing machine. In one embodiment, the first material is used to form the first layer 102 of fig. 1 and includes acrylonitrile-butadiene-styrene copolymer, polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber copolymer (ASA), acrylonitrile-styrene copolymer (SAN), methyl methacrylate-acrylonitrile-butadiene-styrene copolymer (MABS), Polystyrene (PS), methyl methacrylate-styrene (MS), or a combination thereof. The second material is used to form the second layer 104 of fig. 1 and includes polymethylmethacrylate, polycarbonate, polypropylene, polyurethane, styrene-acrylonitrile-acryl rubber copolymer (ASA), acrylonitrile-styrene copolymer (SAN), methyl methacrylate-acrylonitrile-butadiene-styrene copolymer (MABS), Polystyrene (PS), methyl methacrylate-styrene (MS), or a combination thereof. In this embodiment, the first material is different from the second material. For example, the first material may be Acrylonitrile Butadiene Styrene (ABS) and the second material may be methyl methacrylate (PMMA). In some embodiments, the first material is present in an amount of 70 wt% to 90 wt%, and the second material is present in an amount of 20 wt% to 30 wt%, but the present invention is not limited thereto.

In one embodiment, the screw is a unit for providing molten glue in the extrusion process, and is also an important ring depending on the quality of the molten glue. That is, the primary functions of the screw are to melt the solid plastic, transport the melt, homogenize the plastic, and provide the pressure required to extrude the melt out of the die. Specifically, as shown in FIG. 3, the first screw 10 may be functionally broadly divided into a feed zone (Feeding section)12, a Compression zone (Compression section)14, and a Metering section (Metering section) 16. The other screws 20, 30, 40 (as shown in fig. 4) have the same function, and thus are not described in detail.

In one embodiment, the purpose of the feeding zone 12 (also called solids conveying zone) is to compress and smoothly push the solid plastic particles forward. The transport in this section is guided by the drag of the screw, in other words the solid plastic (here the first material) is pushed forward by the difference between the friction of the plastic against the inside of the sleeve and the friction of the plastic against the surface of the screw. The greater the difference between the friction of the plastic against the sleeve and the friction of the plastic against the screw surface, the greater the conveying capacity. To increase the friction between the plastic and the sleeve, the surface of the sleeve may be grooved with longitudinal grooves parallel to the screw to increase the friction and to allow the first material to advance axially along the screw rather than rotate along the screw, thereby increasing the capacity of the solids conveying zone.

In one embodiment, a compression zone (also referred to as a melt zone) 14 is located at the end of the feed zone 12 where the depth of the longitudinal grooves tapers in the direction of the screw. As the first material is transported from the feed zone 12 to the compression zone 14, the frictional heat of the solid particles of the first material and the external heat cause the plastic to begin to melt, and the volume of the plastic begins to decrease after the plastic melts, requiring a reduction in the depth of the grooves to accommodate the decrease in volume of the plastic. In addition, the flow is pressed due to the reduction of the depth of the groove, the pressure in the area is gradually increased, and the first material is pressurized.

In one embodiment, the metering zone (also known as the melt conveying zone) 16 is the last zone in the first screw 10 where flow is controlled. The melt is sufficiently mixed and pressurized after entering this zone to resist the back pressure of the die drag at the front end of the first screw 10.

Referring back to fig. 2, after providing the first material to the first screw 10 and the second material to the second screw 20, a co-extrusion film forming process 45 is performed to merge and form a composite material at a merge region 50. The composite material may then be extended longitudinally and/or transversely through the extension zone 60 to form a composite layer structure 100 a. The configuration and materials of the composite layer structure 100a are similar to those of the composite layer structure 100 of fig. 1, and thus are not described in detail herein. In one embodiment, the step of cooling and forming is further included between the confluence region 50 and the extension region 60.

In this case, the composite layer structure 100a of the first embodiment may be a transparent composite layer structure. However, the invention is not limited thereto, and in other embodiments, the first material, the color concentrate, the pigment, the pearl powder and the related additives may be mixed to form a mixture before the co-extrusion molding process 45. Then, the mixture and the second material are co-extruded to form a film process 45 to form another composite layer structure, so that the composite layer structure has visual effects of color, pearlescence, bright surface, mirror surface, extinction fog surface and the like.

In addition, after the co-extrusion film forming process 45, various texture effects (such as bright surface, extinction and geometric texture) can be performed on the extrusion rear-stage pressing wheel.

Fig. 4 is a flowchart illustrating a method for manufacturing a composite layer structure according to a second embodiment of the present invention. The composite layer structure 100b of the second embodiment may have a dyeing effect, and a detailed manufacturing method is as follows.

Referring to fig. 4, a first material is provided to a first screw 10 of a co-extrusion film blowing machine, and a second material is provided to a second screw 20 of the co-extrusion film blowing machine. The types and contents of the first material and the second material have been described in detail in the above paragraphs, and are not described in detail herein. In addition, the manufacturing method of the second embodiment also provides a third material to the third screw 30 of the co-extrusion film blowing machine, and provides a fourth material to the fourth screw 40 of the co-extrusion film blowing machine. In one embodiment, the third material comprises color concentrate, pigment, pearl powder, or a combination thereof to provide color, pearlescence, a shiny surface, a mirror surface, or other visual effects. The fourth material may include additives of lubricants, dispersants, ultraviolet light absorbers, oxidation inhibitors, or combinations thereof.

As shown in fig. 4, the first, second, third, and fourth materials are subjected to a co-extrusion film forming process 45 to merge and form a composite material at a merge region 50. Then, after extending in the longitudinal and/or transverse directions of the extension region 60, a composite layer structure 100b may be formed. The configuration and materials of the composite layer structure 100b are similar to those of the composite layer structure 100 of fig. 1, and thus are not described in detail herein. It is noted that the first layer (first material) of the composite layer structure 100b of the second embodiment may be dyed in the co-extrusion molding film process 45, so that the composite layer structure 100b has color, pearlescence, bright surface, mirror surface or other visual effects. Therefore, the composite layer structure 100b of the present embodiment can achieve the decoration effect without an additional printing process, so as to achieve the effects of reducing the cost and improving the yield.

Although the embodiments of fig. 2 and 4 only illustrate the method for manufacturing the dual-layer composite layer structure, the invention is not limited thereto. In other embodiments, a co-extrusion film blowing machine with two or more layers may be used to form a composite layer structure with two or more layers.

Fig. 5 is a schematic cross-sectional view of a decorative molded article according to an embodiment of the present invention.

Referring to fig. 5, the present embodiment provides a decorative molding product 1 including a composite layer structure 100, a decoration layer 110, an adhesion layer 120 and a workpiece 200. The configuration and materials of the composite layer structure 100 are described in detail in the above paragraphs, and thus are not described in detail herein.

As shown in fig. 5, decorative layer 110 may be disposed on surface 102a of first layer 102 of composite layer structure 100 to form composite layer structure 100' with decorative layer 110. In one embodiment, when the composite layer structure 100 is a transparent composite layer structure, different visual effects can be achieved through the decorative layer 110. However, the invention is not limited thereto, and in other embodiments, the decorative layer 110 may be omitted when the composite layer structure 100 has been colored, pearlescent, shiny, mirror-like or other visual effects through dyeing effects.

In one embodiment, the decoration layer 110 can be formed by printing, spraying, electroplating, evaporation, sputtering or a combination thereof. For example, the decoration layer 110 may be composed of a printing ink or a printing material, such as a single layer ink layer, a multi-layer ink layer or a patterned ink layer, so as to present a single color, multiple colors or a desired pattern, respectively. The decorative layer 110 can increase the variety of patterns and colors of the composite layer structure 100 to enrich the visual effect of the user or viewer. In alternative embodiments, the decoration layer 110 may be formed by a suitable printing method such as a gravure printing method, a screen printing method, a offset printing method, a reverse printing method, or an inkjet printing method. In other embodiments, the material of the decoration layer 110 may be, for example, Polyurethane (PU), Polyacrylate (Polyacrylate), Polyethylene terephthalate (PET), polymer of ethylene, propylene, higher olefin (polyofin, PO), polymethyl methacrylate (PMMA), Styrene-Acrylonitrile-acryl rubber Copolymer (ASA), Acrylonitrile-Styrene Copolymer (acrylnitrile-Styrene Copolymer, SAN), methyl methacrylate-Acrylonitrile-Butadiene-Styrene Copolymer (methyl acrylate Copolymer, MABS), polystyrene (polystyrene, PS), MMA methyl methacrylate-Styrene (MS), and other suitable materials.

As shown in fig. 5, the composite layer structure 100' is attached to the outer surface 200a of the workpiece 200 by the adhesive layer 120 to form the decorative molding article 1. In one embodiment, the adhesive layer 120 may be, for example, a hot melt adhesive, a UV curable adhesive, a photo curable adhesive, an electronic curable adhesive, or a combination thereof. For example, the material of the adhesion layer 120 may include polyacrylate (polyacrylate), polymethacrylate (polymethacrylate), polycarbonate (polycarbonate), polyurethane (polyurethane), polyester (polyester), polyamide (polyamide), epoxy resin (epoxyresin), ethylene vinyl acetate Copolymer (EVA), Styrene-Acrylonitrile-acryl rubber Copolymer (ASA), Acrylonitrile-Styrene Copolymer (acrylnitrile-Styrene, SAN), Methyl methacrylate-Acrylonitrile-Butadiene-Styrene Copolymer (MABS), polystyrene (polystyrene, PS), Methyl methacrylate-Styrene (MMA Styrene polymer, MS), or thermoplastic elastomer (thermoplastic elastomer) or a Copolymer, mixture, or composite of the above materials.

Fig. 6 is a flowchart of the steps of a method for manufacturing a decorated article according to a third embodiment of the present invention.

Fig. 7 is a flowchart illustrating steps of a method for manufacturing a decorated article according to a fourth embodiment of the present invention.

Fig. 5 shows that the composite layer structure 100 is attached to the outer surface 200a of the workpiece 200 by the adhesive layer 120 to form the decorated molding 1. The decorated article 1 can be manufactured by the manufacturing method of fig. 6 (for example, in-mold decoration technique) or the manufacturing method of fig. 7 (for example, out-mold decoration technique).

Specifically, referring to fig. 6, the flow of steps S100 of the method for manufacturing a decorated molded article according to the first embodiment is as follows. First, step S102 is performed to provide a composite layer structure. The composite layer structure may be, for example, the composite layer structure 100 shown in fig. 5 or a composite layer structure 100' having a decorative layer 110 (hereinafter, referred to as the composite layer structure 100). The composition of the composite layer structure 100 is described in the above paragraphs, and thus, the description thereof is omitted.

Next, step S104 is performed to place the composite layer structure 100 in an in-mold decoration mold. In detail, the in-mold decoration mold includes a hollow mold cavity. The mold cavity has a surface. Thereafter, the composite layer structure 100 is attached to the surface of the mold cavity such that the composite layer structure 100 covers at least a portion of the surface of the mold cavity. In an alternative embodiment, before performing step S106, a thermal pre-forming process may be optionally performed and the excess composite layer structure may be removed by using a knife cutting process, a laser cutting process, or a water cutting process.

Then, step S106 is performed to fill the molding material into the mold cavity of the in-mold decoration mold, so that the molding material and the composite layer structure 100 are combined with each other. In one embodiment, the molding material may be, for example, a plastic material, a resin material, a metal material, a carbon fiber material, glass, or other suitable molding material.

Thereafter, step S108 is performed to cool the molding material to form the workpiece 200. The workpiece 200 is an application of the decorated article according to the present invention, and may be an electronic device housing or component, a vehicle housing or component, or a combination thereof. For example, the workpiece 200 may be a housing or a component used in a mobile phone, a digital camera, a Personal Digital Assistant (PDA), a notebook computer, a desktop computer, a touch panel, a television, a satellite positioning system (GPS) device, a car monitor, a navigation device, a display, a digital photo frame, a DVD player, a car interior trim panel (e.g., a handle, a trim panel, a touch front, etc.), a car exterior trim panel (e.g., an exterior handle, a back door trim panel, etc.), a car dashboard, a car logo, an intelligent key (I-key), an engine start button, a clock, a radio, a toy, a watch, or other electronic products requiring electric power. However, the present invention is not limited to the shape and structure of the workpiece 200, and any shape and structure of the workpiece 200 that can be finished by the in-mold decoration technique is within the scope of the present invention.

Next, step S110 is performed to take out the decorated molded article 1 from the in-mold decoration mold. The obtained decorated molded article 1 has been described in detail in fig. 5, and is not described again here.

On the other hand, the decorated article 1 may be produced by an outside mold decoration technique. Referring to fig. 7, a process flow S200 of the manufacturing method of the decorated molded article of the second embodiment is as follows. First, step S202 is performed to provide a workpiece 200. In one embodiment, the workpiece 200 is an application of a decorated article according to the present invention, which may be an electronic device housing or component, a vehicle housing or component, or a combination thereof. In alternative embodiments, the material of the outer surface 200a of the workpiece 200 may be plastic, resin, metal, carbon fiber, glass, or other various formed housing materials, and may be subjected to appropriate pre-processing to produce a workpiece with desired characteristics, for example. For example, when the workpiece is made of plastic, the plastic workpiece (such as a plastic housing) can be obtained by an injection molding process using an injection molding mold; alternatively, when the workpiece is made of metal, the metal may be first surface-treated to obtain a metal workpiece (e.g., a metal housing).

Next, step S204 is performed to provide a composite layer structure. The composite layer structure may be, for example, the composite layer structure 100 shown in fig. 5 or a composite layer structure 100' having a decorative layer 110 (hereinafter, referred to as the composite layer structure 100). The composition of the composite layer structure 100 is described in the above paragraphs, and thus, the description thereof is omitted.

Then, step S206 is performed to place the workpiece 200 and the composite layer structure 100 in a jig. It is noted that before performing step S206, a jig may be optionally designed according to the requirement of the final product and the jig is prepared.

Then, step S208 is performed to perform a high pressure decoration molding process, so that the composite layer structure 100 is attached to the outer surface 200a of the workpiece 200 through the adhesive layer 120. Therefore, the adhesion layer 120 is disposed between the decoration layer 110 and the workpiece 200. In detail, the high-pressure decoration forming process is, for example, to perform a heating softening step on the composite layer structure 100. In one embodiment, the temperature of the heat softening step may be between 80 ℃ and 150 ℃; the time for the heat softening step may be between 30 seconds and 180 seconds. Next, the composite layer structure 100 is brought into contact with the workpiece 200, and a pressing step is performed. Then, a high-pressure vacuum forming step is performed on the composite layer structure 100, so that the composite layer structure 100 is attached to the workpiece 200. Finally, the remaining composite layer structure can be selectively removed by die cutting, laser cutting or water jet cutting. In short, the present embodiment can closely adhere the composite layer structure 100 to a portion of the outer surface 200a of the workpiece 200 by using the mold decoration technique.

In summary, the present invention combines the first layer and the second layer with different materials to form a composite layer structure, which enables the composite layer structure to have high hardness and high tensile properties at the same time, so as to be suitable for the subsequent in-mold decoration technology or the film-out decoration technology. In addition, the invention provides a manufacturing method of a decorated molding, which can carry out dyeing treatment when forming a composite layer structure, so that the composite layer structure can achieve the decoration effect without an additional printing process, thereby achieving the effects of reducing the cost and improving the yield.

Although the present invention has been described with reference to the above embodiments, it should be understood that various changes and modifications can be made therein by those skilled in the art without departing from the spirit and scope of the invention.