1295226 - 九、發明說明： . 【發明所屬之技術領域】 本發明係關於一種模内裝飾用薄膜及其製造方法，以及 .一種模内裝飾製程。 【先前技術】 模内裝飾係指産品於模具***出成型時，其産品表面同 時形成具有裝飾圖案之工藝技術，其一般係預先形成一具有 裝飾圖案之薄膜，然後對該形成有裝飾圖案之薄膜進行熱壓 ®成型以形成預定之形狀，將該薄膜進行裁切後再置於射出成 型模具之模穴内，最後將熔融材料注入模穴内，薄膜與熔融 材料相結合並形成具有裝飾圖案之産品。採用模内裝飾所製 得之産品，其外觀較射出成型後再採用塗裝而形成圖案之産 品具有更強之實體感，並且，圖案不存在褪色、脫落等不良 現象發生，其已廣泛用於製造各類産品之外殼。 請參閱圖1，其爲習知模内裝飾用薄膜10,其包括一透 •明基片11及一圖案層12，該透明基片11包括兩相對表面 111和112。該圖案層12形成於一表面111上。該薄膜10 之製造方法爲：首先提供一透明基片11，該透明基片11包 括兩相對表面111和112，然後，於該透明基片11之其中一 ^ 表面111之預定位置形成一圖案層12。 „ 請參閱圖2,其爲採用習知模内裝飾用薄膜所製得之産 品20,該産品20包括一基體21、一薄膜22及一保護層23。 該薄膜22包括一透明基片221及一圖案層222,該透明基片 221包括兩相對表面2211和2212，該圖案層222形成於其 1295226 - 中一表面2211上。該保護層23形成於另一表面2212上。 - 該産品20之整個製造過程爲：首先提供一透明基片221，該 透明基片221包括兩相對表面2211和2212，其次，於該透 . 明基片221之其中一表面2211之預定位置形成一圖案層 、222，再對該形成有圖案層222之透明基片221進行熱壓成 型，以使得該透明基片221形成與後續産品表面形狀一致之 形狀，然後對其進行裁切，最後將經過上述方法步驟之透明 基片221置於一模穴（圖未示）内，注入熔融材料，熔融材 *料冷卻凝固形成基體21，薄膜22與熔融材料相結合並形成 具有裝飾圖案之産品毛坯（圖未示），最後於産品毛坯之表 面塗裝一具有較高表面硬度之透明保護層23,即形成所需産 品20，該透明保護層23之主要作用在於用以防止薄膜22 遭受外物刮傷或磨損。 該産品20藉由於産品毛坯之表面塗裝一具有保護功能 之透明保護層23，而增加該産品20之表面硬度，以增加産 @品之耐磨性及抗刮傷性能。惟射出成型産品之形狀一般較爲 複雜，産品一般具複數表面，且存在一些凹陷或棱角，其不 易進行塗裝或不能塗裝到，即射出成型後塗裝保護層23之 過程中存在塗裝死角，且塗裝後之保護層23厚度均勻性能 ， 不易控制，造成産品良率較低，相對成本提高。另，射出成 .型後再對産品塗裝，爲保證産品表面均能覆蓋上塗層，需進 行較大範圍塗裝，塗料利用率低，而且，複雜之産品外形表 面造成塗料利用率低下，造成産品20成本增加。 【發明内容】 1295226 .*鑒於上述狀況，有必要提供一種表面硬度高且成本低之 •模内裝飾用薄膜及其製造方法，以及採用該薄膜之模内裝飾 製程。 一種模内裝飾用薄膜，其包括一透明基片，該透明基片 '包括兩表面，該透明基片之一表面形成一圖案層，該透明基 片之另一表面形成一硬膜層。 一種所述之模内裝飾用薄膜之製作方法，其包括以下步 修驟· k供一透明基片，該透明基片包括兩表面；於該透明基 片之一表面形成一圖案層；於該透明基片之另一表面形成一 硬膜層。 以及一種模内裝飾製程，其包括以下步驟：提供一透明 基片及一射出成型用模具，該透明基片包括兩表面，該模具 具有一模穴，於該透明基片之一表面形成一圖案層；於該透 明基片之另一表面形成一硬膜層；粉該形成有圖案層及硬膜 層之透明基片進行熱壓成型，以形成預定之形狀，並將多餘 _部分予以裁切；將經過熱壓成型及裁切之透明基片置入模穴 内，射出成型。 相較于習知技術，所述薄膜於透明基片表面塗裝了一具 有較高表面硬度之硬膜層，使採用該薄膜得到之産品具有較 ，高之表面硬度，無需射出成型後再對產品之複雜表面進行塗 -裝’避免了複雜産品表面塗裝過程中存在之塗裝死角、塗層 不均等缺陷影響，同時，該方式避免了射出成型後再塗裝因 爲塗裝不良而導致之整個產品報廢，從而克服了射出成型後 再塗裝而導致之産品良率較低。而且，透明基片表面之塗裝 1295226 - 係於一簡單之平面上進行大面積塗裝，相較於單個産品之複 ， 數複雜之小面積塗裝，簡單平面之大面積塗裝不存在不易處 理之凹陷或棱角等塗裝死角，相對縮小了塗裝範圍，提高了 塗料塗裝利用率，減少了塗料浪費，有效地控制了最終産品 • 之成本。 【實施方式】 下面將以實施例說明一種模内裝飾用薄膜及其製造方 法0 胃請參閱圖3，本發明較佳實施例提供之一種模内裝飾用 薄膜30,其包括一透明基片31、一圖案層32及一硬膜層33, 該透明基片31包括兩相對表面311和322，該圖案層32形 成於其中一表面311上，該硬膜層33形成於另一表面312 上。本發明提供之薄膜可用於電子裝置外殼及日常用品等。 該透明基片31爲一平面狀透明薄膜，其厚度介於0.127 毫米至0.381毫米之間，其材質可選用聚碳酸脂類高分子聚 鲁合物。該圖案層32可爲一具有預定圖案之油墨層，其厚度 介於0.02毫米至0.03毫米之間。該硬膜層33係由一透明塗 料經過塗裝與烘烤而製得。本實施例優選之塗料係由重量百 分比爲60%至70%之丙烯酸樹脂、5%至20%之矽丙烯酸及 ▼ 20%至25%之稀釋劑組成，且該稀釋劑爲市場上塗料常用之 . 稀釋劑。該硬膜層33之厚度介於0.01毫米至0.015毫米之 間，其表面硬度可達2H以上。 請參閱圖4A至4C，本發明另提供一種所述之模内裝 飾用薄膜之製作方法，其包括以下步驟： 1295226 . 首先，提供一透明基片41，該透明基片41具有兩相對 表面411與412,其厚度介於0.127毫米至0.381毫米之間。 其次，於該透明基片41之其中一表面411之預定位置 形成一圖案層42，該圖案層42係採用塗裝或印刷等技術形 • 成，其厚度介於0.02毫米至0.03毫米之間。 最後，於該透明基片41之另一表面412形成一硬膜層 43，即得到所需要之薄膜。該硬膜層43係採用透明塗料並 藉由塗裝與烘烤之技術方法形成，烘烤溫度爲60至80攝氏 *度，時間控制於10至30分鐘。本實施例優選之塗料包括重 量百分比爲60%至70%之丙烯酸樹脂、5%至20%之矽丙烯 酸及20%至25%之稀釋劑。該硬膜層43具有較好之延展性 能。 本發明還提供一種模内裝飾製程，其包括以下步驟： 首先，提供一透明基片及一射出成型用模具，該透明基 片具有兩相對表面，其厚度介於0.127毫米至0.381毫米之 φ間，該模具具有一模穴。 其次，於該透明基片之其中一表面之預定位置形成一圖 案層，該圖案層係採用塗裝或印刷等技術形成，其厚度介於 0.02毫米至0.03毫米之間。 ， 再次，於該透明基片之另一表面形成一硬膜層，即得到 . 所需要之薄膜。該硬膜層係採用透明塗料並藉由塗裝與烘烤 之技術方法形成，烘烤溫度爲60至80攝氏度，時間控制於 10至30分鐘。 然後，對該形成有圖案層及硬膜層之透明基片進行熱壓 1295226 - 成型，以形成預定之形狀，並將多餘部分予以裁切。 _ 最後，將經過熱壓成型及裁切之透明基片置入模穴内， 向其中注入熔融材料，保溫、冷卻，即經過射出成型得到需 要之產品。 • 所述模内裝飾製程先於透明基片上形成一圖案層及一 硬膜層，再依據後續射出成型産品之外觀形狀要求，將該形 成有硬膜層與圖案層之透明基片進行熱壓成型，以使得透明 基片成爲預定之形狀，然後將多餘部分予以裁切後並置於模 * 穴内，再將熔融材料注入模穴中，該熔融材料與該薄膜相結 合並成爲産品之一部分，而且該薄膜之硬膜層成爲産品之外 表面。採用該薄膜射出成型所製得之産品，具有較高之表面 硬度，無需射出成型後再對産品之複雜表面進行塗裝，避免 了複雜産品表面塗裝過程中存在之塗裝死角、塗層不均等缺 陷影響，同時，該方式避免了射出成型後再塗裝時因爲塗裝 不良而導致之整個産品報廢，從而克服了射出成型後再塗裝 • 而導致之産品良率較低。而且，透明基片表面之塗裝係於一 簡單之平面上進行大面積塗裝，相較於單個産品之複數複雜 之小面積塗裝，簡單平面之大面積塗裝不存在不易處理之凹 陷或棱角等塗裝死角，相對縮小了塗裝範圍，提高了塗料塗 - 裝利用率，減少了塗料浪費，有效地控制了最終産品之成本。 _ 綜上所述，本發明符合發明專利要件，爰依法提出專利 申請。惟，以上所述者僅為本發明之較佳實施例，舉凡熟悉 本案技藝之人士，在爰依本發明精神所作之等效修飾或變 化，皆應涵蓋於以下之申請專利範圍内。 11 1295226 【圖式簡單說明】 圖1係習知模内裝飾用薄膜示意圖； 圖2係一般習知模内裝飾用薄膜所得產品不意圖， 圖3係本發明模内裝飾用薄膜示意圖； 圖4A至4C係本發明模内裝飾用薄膜之製造流程之具 體實施方式之示意圖。 【主要元件符號說明】 (本發明）1295226 - IX. Description of the Invention: [Technical Field] The present invention relates to a film for in-mold decoration and a method for producing the same, and an in-mold decoration process. [Prior Art] In-mold decoration refers to a process in which a product has a decorative pattern formed on the surface of a product when it is injection molded in a mold. Generally, a film having a decorative pattern is formed in advance, and then the film having the decorative pattern is formed. The hot press is formed to form a predetermined shape, the film is cut, placed in a cavity of the injection molding die, and finally the molten material is injected into the cavity, and the film is combined with the molten material to form a product having a decorative pattern. The product obtained by the in-mold decoration has a stronger physical feeling than the product which is formed by patterning after being formed by injection molding, and the pattern has no undesirable phenomenon such as fading or falling off, and has been widely used. Manufacture of outer casings for all types of products. Referring to Figure 1, there is shown a conventional in-mold decorative film 10 comprising a transparent substrate 11 and a patterned layer 12 comprising two opposing surfaces 111 and 112. The pattern layer 12 is formed on a surface 111. The film 10 is manufactured by first providing a transparent substrate 11 including two opposite surfaces 111 and 112, and then forming a pattern layer at a predetermined position of one of the surfaces 111 of the transparent substrate 11. 12. „Please refer to FIG. 2, which is a product 20 obtained by using a conventional in-mold decorative film. The product 20 includes a substrate 21, a film 22 and a protective layer 23. The film 22 includes a transparent substrate 221 and a pattern. Layer 222, the transparent substrate 221 includes two opposing surfaces 2211 and 2212 formed on a surface 2211 of the 1295226 - the protective layer 23 is formed on the other surface 2212. - The entire manufacturing of the product 20 The process is as follows: firstly, a transparent substrate 221 is provided. The transparent substrate 221 includes two opposite surfaces 2211 and 2212. Secondly, a pattern layer 222 is formed on a predetermined position of one surface 2211 of the transparent substrate 221, and then The transparent substrate 221 on which the patterned layer 222 is formed is subjected to hot press forming so that the transparent substrate 221 is formed into a shape conforming to the surface shape of the subsequent product, and then cut, and finally the transparent substrate subjected to the above method steps. 221 is placed in a cavity (not shown), molten material is injected, and the molten material is cooled and solidified to form a substrate 21, and the film 22 is combined with the molten material to form a product blank having a decorative pattern (not shown). Finally, a transparent protective layer 23 having a high surface hardness is applied to the surface of the product blank to form a desired product 20, and the main function of the transparent protective layer 23 is to prevent the film 22 from being scratched or worn by foreign objects. The product 20 increases the surface hardness of the product 20 by coating a surface of the product blank with a transparent protective layer 23 having a protective function to increase the wear resistance and scratch resistance of the product. However, the shape of the molded product is injected. Generally, the product is generally complicated, and the product generally has a plurality of surfaces, and there are some depressions or corners, which are difficult to apply or cannot be applied, that is, there is a coating dead angle in the process of coating the protective layer 23 after injection molding, and after painting The protective layer 23 has uniform thickness and is difficult to control, resulting in lower product yield and higher relative cost. In addition, the product is coated and then coated on the product to ensure that the surface of the product can cover the upper coating. Range coating, low utilization rate of paint, and complex product appearance surface causes low utilization of paint, resulting in an increase in product cost. [Summary] 1295226 .* In view of the above circumstances, it is necessary to provide a film for in-mold decoration having a high surface hardness and a low cost, a method for producing the same, and an in-mold decoration process using the film. An in-mold decorative film comprising a transparent substrate, The transparent substrate 'comprises two surfaces, one surface of which forms a patterned layer, and the other surface of the transparent substrate forms a hard coat layer. A method for manufacturing the in-mold decorative film includes the following The step of repairing k is for a transparent substrate, the transparent substrate comprises two surfaces; a pattern layer is formed on one surface of the transparent substrate; a hard film layer is formed on the other surface of the transparent substrate; and a mold The inner decorative process comprises the steps of: providing a transparent substrate and an injection molding die, the transparent substrate comprising two surfaces, the mold having a cavity, forming a pattern layer on one surface of the transparent substrate; The other surface of the transparent substrate forms a hard coat layer; the transparent substrate on which the patterned layer and the hard coat layer are formed is subjected to hot press forming to form a predetermined shape, and the excess portion is given Cut; thermoforming and cutting through the transparent substrate into the mold cavity, injection molding. Compared with the prior art, the film is coated with a hard film layer having a high surface hardness on the surface of the transparent substrate, so that the product obtained by using the film has a relatively high surface hardness, and does not need to be formed after injection molding. The complex surface of the product is coated-packed' to avoid the defects of coating dead angle and uneven coating during the surface coating process of complex products. At the same time, this method avoids the coating after injection molding and is caused by poor coating. The entire product is scrapped, thereby overcoming the low yield of the product caused by injection molding and repainting. Moreover, the coating of the surface of the transparent substrate 1295226 - is applied on a simple plane for large-area coating, compared with a single product, a small number of complex small-area coating, a large flat surface coating is not easy The treatment of the recessed corners or corners and other painted corners, the coating range is relatively reduced, the paint coating utilization rate is improved, the paint waste is reduced, and the cost of the final product is effectively controlled. [Embodiment] Hereinafter, an in-mold decorative film and a manufacturing method thereof will be described with reference to an embodiment. Referring to FIG. 3, an in-mold decorative film 30 according to a preferred embodiment of the present invention includes a transparent substrate 31. A pattern layer 32 and a hard film layer 33 including two opposite surfaces 311 and 322 formed on one of the surfaces 311, the hard film layer 33 being formed on the other surface 312. The film provided by the present invention can be used for an electronic device casing, daily articles, and the like. The transparent substrate 31 is a planar transparent film having a thickness of between 0.127 mm and 0.381 mm, and is made of a polycarbonate polymer polymer. The pattern layer 32 may be an ink layer having a predetermined pattern having a thickness of between 0.02 mm and 0.03 mm. The hard coat layer 33 is obtained by coating and baking a transparent coating. The preferred coating of this embodiment is composed of 60% to 70% by weight of acrylic resin, 5% to 20% of hydrazine acrylic acid and ▼20% to 25% of diluent, and the diluent is commonly used in the market coating. Thinner. The hard coat layer 33 has a thickness of between 0.01 mm and 0.015 mm and a surface hardness of 2 H or more. 4A to 4C, the present invention further provides a method for fabricating the in-mold decorative film, comprising the following steps: 1295226. First, a transparent substrate 41 having two opposite surfaces 411 is provided. And 412, the thickness of which is between 0.127 mm and 0.381 mm. Next, a pattern layer 42 is formed at a predetermined position on one surface 411 of the transparent substrate 41, and the pattern layer 42 is formed by a technique such as painting or printing, and has a thickness of between 0.02 mm and 0.03 mm. Finally, a hard film layer 43 is formed on the other surface 412 of the transparent substrate 41 to obtain a desired film. The hard coat layer 43 is formed by a clear coating and is formed by a coating and baking technique at a baking temperature of 60 to 80 ° C and a time of 10 to 30 minutes. Preferred coatings in this embodiment include from 60% to 70% by weight of acrylic resin, from 5% to 20% of decacrylic acid and from 20% to 25% of diluent. The hard coat layer 43 has good ductility. The invention also provides an in-mold decoration process comprising the steps of: firstly, providing a transparent substrate and an injection molding die, the transparent substrate having two opposite surfaces, the thickness of which is between 0.127 mm and 0.381 mm. The mold has a cavity. Next, a pattern layer is formed at a predetermined position on one of the surfaces of the transparent substrate, and the pattern layer is formed by a technique such as painting or printing, and has a thickness of between 0.02 mm and 0.03 mm. Further, a hard coat layer is formed on the other surface of the transparent substrate to obtain a desired film. The hard coat layer is formed by a clear coating and is formed by a coating and baking technique at a baking temperature of 60 to 80 ° C and a time of 10 to 30 minutes. Then, the transparent substrate on which the patterned layer and the hard coat layer are formed is subjected to hot pressing 1295226 - molding to form a predetermined shape, and the excess portion is cut. _ Finally, the hot-formed and cut transparent substrate is placed in a cavity, and molten material is injected therein to be kept warm and cooled, that is, after injection molding, the desired product is obtained. • The in-mold decoration process forms a pattern layer and a hard film layer on the transparent substrate, and then heat-presses the transparent substrate formed with the hard film layer and the pattern layer according to the appearance and shape requirements of the subsequent injection molded product. Forming such that the transparent substrate has a predetermined shape, then cutting the excess portion and placing it in the cavity, and then injecting the molten material into the cavity, the molten material being combined with the film and becoming part of the product, and The hard coat layer of the film becomes the outer surface of the product. The product obtained by the film injection molding has high surface hardness, and the complicated surface of the product is not required to be formed after injection molding, thereby avoiding the coating dead angle and coating not existing in the surface coating process of the complex product. The effect of equal defects, at the same time, avoids the scrapping of the entire product due to poor coating when re-painting after injection molding, thereby overcoming the re-coating after injection molding. Moreover, the coating on the surface of the transparent substrate is applied on a simple plane for large-area coating. Compared with the complex small-area coating of a single product, the large-area coating of a simple plane does not have a recess that is difficult to handle or The corners and the like are coated with dead angles, which narrows the coating range, improves the coating-coating utilization rate, reduces paint waste, and effectively controls the cost of the final product. _ In summary, the present invention complies with the requirements of the invention patent and submits a patent application according to law. However, the above description is only the preferred embodiment of the present invention, and equivalent modifications or variations made by those skilled in the art of the present invention should be included in the following claims. 11 1295226 BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of a conventional film for in-mold decoration; FIG. 2 is a schematic view of a conventional film for in-mold decoration, and FIG. 3 is a schematic view of a film for in-mold decoration of the present invention; FIGS. 4A to 4C are drawings. A schematic view of a specific embodiment of a manufacturing process for inventing a film for in-mold decoration. [Main component symbol description] (Invention)
薄膜 30 透明基片 31、41 表面 311 、 312 、411、412圖案層 32 ^ 42 硬膜層 33 ^ 43 知） 薄膜 10、22 產品 20 透明基片 11 、 221 基體 21 表面 111、112、 2211、2212圖案層 12 、 222 保護層 23 12Film 30 transparent substrate 31, 41 surface 311, 312, 411, 412 pattern layer 32 ^ 42 hard film layer 33 ^ 43 know) film 10, 22 product 20 transparent substrate 11, 221 substrate 21 surface 111, 112, 2211, 2212 pattern layer 12, 222 protective layer 23 12