Composite diaphragms, molded parts and IML molding process

Abstract

The present invention relates to the technical field of product decoration, and provides a composite film, a molded part, and an IML molding process. The film layer of the composite film has plasticity, and the decorative layer is a flexible non-plastic thin film. After the decorative layer is attached to the film layer, the decorative layer can adapt to the structure of the film layer to fit tightly on the film layer, and when the shape of the film layer changes, the decorative layer can change accordingly with the shape of the film layer. After the decorative layer is attached to the film layer, it is divided to form a composite film. In this way, the decorative layer and the film layer in the composite film obtained are highly consistent, which is convenient for mass production. When the composite film is used on the molded part and subsequently applied to the product, the user can touch the decorative layer when using it, thereby bringing a different use experience and satisfying more user preferences.

Description

Technical Field

[0001] The present invention relates to the technical field of product decoration, and in particular to a composite diaphragm, a molded part and an IML molding process. Background Art

[0002] In-mold label (IML) has a very significant feature: the surface of the product produced by the in-mold label process is a hardened transparent film, the middle is a printed pattern layer, and the back is a plastic layer. Since the transparent film covers the printed pattern layer, the first thing that comes into contact during use is the transparent film. The transparent film can protect the product, increase the wear resistance of the product surface, and prevent the product surface from being scratched. At the same time, since the ink on the printed pattern layer is sandwiched in the middle, the ink can be prevented from being scratched and the ink color can be kept bright for a long time.

[0003] At present, more and more electronic product shells are made of in-mold injection molding technology. With the improvement of people's material consumption level, some consumers' choice of electronic products is no longer limited to their functions. More and more consumers have higher requirements on the appearance of products.

[0004] Traditional IML mainly relies on the pattern layer or ink layer in the film to enhance the appearance of the product. However, with the development of science and technology, the traditional plastic decorative layer can no longer meet customer requirements, especially for some high-end products. Customers not only require the product to be beautiful, but also require the product to have various other usage requirements, such as good touch, etc. This puts forward new requirements for traditional IML production. Summary of the invention

[0005] The purpose of the present invention is to provide a composite diaphragm, aiming to solve the problem of poor user experience caused by process defects of existing IML diaphragms.

[0006] To achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a composite film sheet, used to be combined with a substrate layer to form a molded part, the composite film sheet includes a film layer with plasticity and a decorative layer adhered to the film layer, the decorative layer is a flexible thin sheet, and the film layer and the decorative layer are adhered to each other and then at least divided to form the composite film sheet.

[0007] In one embodiment, the decorative layer is a thin sheet made of non-plastic material, or the decorative layer is a thin sheet made of PU material.

[0008] In one embodiment, the decorative layer and the film layer are bonded together after heat pressing, and / or the decorative layer and the film layer are bonded together by an adhesive.

[0009] In one embodiment, the composite film further comprises a pattern layer disposed on the film layer, and a window hole for observing the pattern layer is opened on the decorative layer.

[0010] 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 smoothly transitions to the side of the decoration layer away from the film layer or is arranged in a stepped manner.

[0011] In one embodiment, the film layer is provided with a light-transmitting layer in contact with the film layer at a position corresponding to the window hole, and a side of the light-transmitting layer away from the film layer and a side of the decorative layer away from the film layer are smoothly transitioned or arranged in steps.

[0012] The present application also proposes a molded part, comprising a substrate layer and the composite film as described above, wherein the composite film covers the substrate layer, and the decorative layer of the composite film is located on a side away from the substrate layer.

[0013] In one embodiment, the substrate layer and the composite film are injection molded, or / and the substrate layer and the composite film are hot-pressed.

[0014] In one embodiment, the substrate layer is a light-transmitting structure, and / or the position of the substrate layer corresponding to the window hole of the composite film is a hollow structure.

[0015] In one embodiment, the substrate layer is a light-transmitting structure, and / or the position of the substrate layer corresponding to the window hole of the composite film is a thin-walled structure.

[0016] In one embodiment, a functional hole is formed on the molded part, and the functional hole at least penetrates the film layer and the substrate layer of the composite membrane.

[0017] This application also proposes an IML molding process, comprising the following steps:

[0018] S1: Laminating the film layer and the decorative layer to obtain a composite film with the decorative layer;

[0019] S2: dividing the composite film into composite film sheets for combining with the substrate layer;

[0020] S3: placing the composite film in a mold so that the composite film is combined with the substrate layer to form a molded part.

[0021] In one embodiment, the step S1 specifically includes:

[0022] S1: Glue and / or hot-melt one side of the film layer to form an adhesive surface with adhesive effect on one side of the film layer, and evenly attach the decorative layer to the adhesive surface and flatten it to form the composite film; hot-press the composite film to make at least a partial outer contour of the composite film match the outer contour of the substrate layer to be combined.

[0023] In one embodiment, before step S1, the following steps are also included:

[0024] A first positioning hole is opened in the decorative layer, a second positioning hole is opened in the film layer at a position directly opposite to the first positioning hole, a pattern layer is provided on the film layer, a window hole is opened in the decorative layer at a position 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.

[0025] In one embodiment, the following steps are also included:

[0026] Before step S1, a third positioning hole is opened on the film layer, a first inserting pin adapted to the third positioning hole is provided on the device for hot pressing the composite film; a second inserting pin adapted to the third positioning hole is provided on the device for dividing the composite film; a third inserting pin adapted to the third positioning hole is provided on the mold for combining the composite film sheet with the substrate layer;

[0027] In the step S1, the third positioning hole cooperates with the first inserting pin to position the composite film and then perform hot pressing;

[0028] In the step S2, the third positioning hole cooperates with the second inserting pin to position the composite film and then perform a splitting operation;

[0029] In step S3, the composite diaphragm is placed in the mold, the third positioning hole is matched with the third insert pin, and the third positioning hole is blocked with the help of the third insert pin, and the composite diaphragm is positioned at the same time, and then the substrate layer is formed by injection molding in the mold. After the substrate layer and the composite diaphragm are combined, the third insert pin is pulled out to obtain the molded part, and a functional hole that penetrates the substrate layer and the film layer is formed on the molded part.

[0030] The beneficial effects of the present invention are as follows: the film layer has plasticity, and the decorative layer is a flexible non-plastic sheet or a PU material sheet. After the decorative layer is bonded to the film layer, the decorative layer can adapt to the structure of the film layer to fit tightly on the film layer, and when the shape of the film layer changes, the decorative layer can change accordingly with the shape of the film layer. After the decorative layer is bonded to the film layer, it is divided to form a composite film. In this way, the decorative layer and the film layer in the obtained composite film have high consistency, which is convenient for mass production, and the bonding position between the decorative layer and the film layer is more neat, and does not require manual cutting like traditional cloth or skin to achieve uniformity. At the same time, it can overcome the problem that the traditional cloth or skin process group requires single bonding and cutting operations, resulting in the inability to achieve mass production, which is not conducive to improving production efficiency and dimensional accuracy, and can better meet the needs of users and industrial production. When the composite film is used on a molded part and is subsequently applied to a product, the user can touch the decorative layer when using it, thereby bringing a different use experience and satisfying more user preferences. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0032] Figure 1 A schematic diagram of the structure of a composite diaphragm provided in an embodiment of the present invention;

[0033] Figure 2 A schematic structural diagram of a composite film with a pattern layer provided in an embodiment of the present invention;

[0034] Figure 3 Schematic diagram of the structure of a composite membrane with a window hole and a pattern layer provided in an embodiment of the present invention Figure 1 ;

[0035] Figure 4 Schematic diagram of the structure of a composite membrane with a window hole and a pattern layer provided in an embodiment of the present invention Figure 2 ;

[0036] Figure 5 Schematic diagram of the structure of a composite membrane with a window hole and a pattern layer provided in an embodiment of the present invention Figure 3 ;

[0037] Figure 6 A schematic structural diagram of a molded part without a window hole provided in an embodiment of the present invention;

[0038] Figure 7 A schematic diagram of a molded part with a window hole provided in an embodiment of the present invention Figure 1 ;

[0039] Figure 8 A schematic diagram of a molded part with a window hole provided in an embodiment of the present invention Figure 2 ;

[0040] Fig. 9 A schematic diagram of a molded part with a window hole provided in an embodiment of the present invention Figure 3 ;

[0041] Fig.10 Schematic diagram of the structure of a molded part with functional holes provided in an embodiment of the present invention Figure 1 ;

[0042] Fig.11 Schematic diagram of the structure of a molded part with functional holes provided in an embodiment of the present invention Figure 2 ;

[0043] Fig.12 Schematic diagram of the structure of a molded part with functional holes provided in an embodiment of the present invention Figure 3 ;

[0044] Fig.13 Schematic diagram of the structure of a molded part with functional holes provided in an embodiment of the present invention Figure 4 ;

[0045] Fig.14 Schematic diagram of the structure of a molded part with functional holes provided in an embodiment of the present invention Figure 5 ;

[0046] Fig.15 Schematic diagram of the structure of a molded part with functional holes provided in an embodiment of the present invention Figure 6 ;

[0047] Fig.16 Schematic diagram of the structure of a molded part with functional holes provided in an embodiment of the present invention Figure 7 .

[0048] Description of main component symbols:

[0049] Composite membrane-100; molded part-200; decorative layer-10; film layer-20; raised portion-21; light-transmitting layer-22; pattern layer-30; substrate layer-40; functional hole-50; window hole-11; hollow structure-41; thin-wall structure-42. DETAILED DESCRIPTION

[0050] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0051] In the description of the present invention, it should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0052] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0053] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0054] See also Figures 1 to 5 , shown is a composite film sheet 100 of the present application, which is used to be combined with a substrate layer 40 to form a molded part 200. The composite film sheet 100 includes a film layer 20 with plasticity and a decorative layer 10 adhered to the film layer 20. The decorative layer 10 is a flexible thin sheet. After the film layer 20 and the decorative layer 10 are adhered, they are at least split to form the composite film sheet 100. In this embodiment, the outer contour of the composite film sheet 100 is adapted to the outer contour of the substrate layer 40; the splitting method is punching, shearing, or other feasible splitting methods, as long as the composite film sheet 100 used to be combined with the substrate layer 40 can be separated from the composite film.

[0055] In this embodiment, the film layer 20 has plasticity, and the decorative layer 10 is a flexible thin sheet. After the decorative layer 10 is bonded to the film layer 20, the decorative layer 10 can adapt to the structure of the film layer 20 to fit tightly on the film layer 20, and when the shape of the film layer 20 changes, the decorative layer 10 can change accordingly with the shape of the film layer 20. After the decorative layer 10 is bonded to the film layer 20, it is cut to form a composite film sheet 100. In this way, the decorative layer 10 and the film layer 20 in the obtained composite film sheet 100 have high consistency, which is convenient for mass production, and the bonding position between the decorative layer 10 and the film layer 20 is more neat, and it does not require manual cutting like traditional covering cloth or skin and cannot be neat and consistent. At the same time, it can overcome the problem that the traditional covering cloth or skin process group requires single bonding and cutting operations, resulting in the inability to achieve mass production, which is not conducive to improving production efficiency and dimensional accuracy, and can better meet the needs of users and industrial production.

[0056] In an optional embodiment, the decorative layer is a thin sheet made of non-plastic material, or the decorative layer is a thin sheet made of PU material.

[0057] Specifically, the decorative layer 10 in this embodiment can be any flexible non-plastic material that can be bonded to the film layer 20, such as at least any one of cloth, leather, plant sheets, synthetic leather, synthetic plant sheets, non-woven fabrics, paper sheets, and metal sheets. The above-mentioned plant sheets include at least wood chips, bamboo chips, bark, leaves, etc. After the decorative layer 10 is bonded to the film layer 20, the decorative layer 10 can modify the film layer 20, and the decorative layer 10 is located on one side of the film layer 20. After being applied to the product later, the user can touch the decorative layer 10 when using it, thereby bringing a different usage experience and satisfying more user preferences. The decorative layer 10 can be a sheet of a single material, or it can be a flexible thin sheet formed by arranging or / weaving sheets of multiple different materials according to a certain pattern.

[0058] Furthermore, the decorative layer 10 in this embodiment can be a thin sheet made of flexible PU material that can be bonded to the film layer 20. The decorative layer 10 made of flexible PU material can be well bonded to the film layer 20, thereby modifying the product and bringing users more different usage experiences.

[0059] In an optional embodiment, the decorative layer 10 and the film layer 20 are bonded after hot pressing, or / and, the decorative layer 10 and the film layer 20 are bonded by an adhesive. In this embodiment, the decorative layer 10 can be tightly bonded to the film layer 20 by hot pressing one side of the film layer 20 to form a sticky bonding surface, and then the decorative layer 10 is covered on the bonding surface. Alternatively / and, the film layer 20 and the decorative layer 10 can also be tightly bonded by applying an adhesive between the film layer 20 and the decorative layer 10. No matter which method is used, the decorative layer 10 and the film layer 20 can be tightly bonded, which is more convenient than the existing skin or cloth covering method, and the bonding between the two layers can be made tighter by pressing during or after the bonding process; or, the two layers can be pressed by a roller with embossing / embossing to make the two layers tightly bonded according to certain patterns, thereby further enhancing the local bonding strength of some decorative layers 10 with patterns and the film layer 20.

[0060] See also Figure 2 As another specific embodiment of the composite film 100 provided in the present application, the composite film 100 further includes a pattern layer 30 disposed on the film layer 20. The conventional IML film is provided with an ink layer. The pattern layer 30 in this embodiment may be a portion with a special shape pattern or / and color in the conventional ink layer, or a hollow portion disposed in the ink layer. The pattern layer 30 may be a double-sided light-transmitting or unidirectional light-transmitting pattern layer 30. In this embodiment, the decorative layer 10 is made of a light-transmitting material, and the user may directly observe the pattern layer 30 through the decorative layer 10.

[0061] See also Figure 3 As another specific embodiment of the composite film 100 provided in the present application, the composite film 100 further includes a pattern layer 30 disposed on the film layer 20, and a window hole 11 for observing the pattern layer 30 is provided on the decorative layer 10. In this embodiment, the decorative layer 10 is made of a material that does not have good light transmittance, and the film layer 20 has good light transmittance. When the pattern layer 30 is disposed on the film layer 20, the pattern can be observed and appreciated through the window hole 11 provided on the decorative layer 10.

[0062] In this embodiment, by providing a pattern layer 30 and opening a window hole 11 on the decorative layer 10, on the one hand, the product is ensured to have a beautiful appearance and a good touch, and on the other hand, the characteristics of the traditional IML film product with a pattern layer 30 that is not easily damaged are retained, thereby enhancing the beauty and interest of the product.

[0063] like Figure 4As a specific embodiment of the composite film 100 provided in the present application, the film layer 20 protrudes into the window hole 11 at a position corresponding to the window hole 11 to form a raised portion 21, and the outer side surface of the raised portion 21 is flush with the side of the decorative layer 10 away from the film layer 20. In this embodiment, the decorative layer 10 is provided with a window hole 11, and the decorative layer 10 has a certain thickness. After the window hole 11 is provided, there is a depression between the decorative layer 10 and the film layer 20, which affects the hand feel when the user uses it. Therefore, after the raised portion 21 is provided, the shape of the raised portion 21 is completely adapted to the window hole 11, and the outer side surface of the raised portion 21 is flush with the side of the decorative layer 10 away from the film layer 20, so that when the user uses it, the user will not touch the depression on the surface of the composite film 100, and the hand feel is better. The film layer 20 in this embodiment is a transparent structure. Therefore, the setting of the raised portion 21 does not affect the user's observation of the pattern layer 30 through the window hole 11; of course, in some embodiments, the raised portion 21 may simply be a smooth transition between the outer edge and the decorative layer 10, or the raised portion may be set in a stepped manner with the outer side surface of the decorative layer 10.

[0064] Furthermore, in this embodiment, a recessed portion is provided on the side of the film layer 20 facing away from the decorative layer 10, and the position of the recessed portion corresponds to the position of the window hole 11. The pattern layer 30 is arranged in the recessed portion, and the completed pattern layer 30 can be observed through the portion of the film layer 20 protruding from the window hole 11.

[0065] like Figure 5 As a specific embodiment of the composite film 100 provided in the present application, a light-transmitting layer 22 is provided at the position of the film layer 20 corresponding to the window hole 11, and the side of the light-transmitting layer 22 away from the film layer 20 is flush with the side of the decorative layer 10 away from the film layer 20. In this embodiment, the shape of the light-transmitting layer 22 is completely compatible with the shape of the window hole 11, and after the light-transmitting layer 22 is attached to the film layer 20, the side of the light-transmitting layer 22 away from the film layer 20 is flush with the side of the decorative layer 10 away from the film layer 20, so that users feel better when using it.

[0066] See also Figure 6-16, shown is a molded part 200 proposed in the present application, comprising 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 comprises a film layer 20 and a decorative layer 10 bonded to the film layer 20, a pattern layer 30 is provided on a side of the film layer 20 facing away from the decorative layer 10, and a side of the film layer 20 on which the pattern layer 30 is provided is bonded to the substrate layer 40. The substrate layer 40 is made of a material that can be bonded to the film layer 20 of the composite membrane 100 or the pattern layer 30, specifically an injection or / and hot pressing material, such as a plastic material, a silicone material or a rubber material, etc. The substrate layer 40 and the composite membrane 100 can be bonded directly during the molding process, or can be bonded with the help of an adhesive during the molding process, or can be bonded with the help of a process that can enhance the bonding surface and / or bonding degree between the substrate layer 40 and the composite membrane 100, which will not be described one by one here.

[0067] As a specific embodiment, in this embodiment, the decorative layer 10 is made of a material with a certain light transmittance, and the substrate layer 40 is light transmittance. When the molded part 200 is applied to an electronic product, the light of the electronic product is irradiated onto the substrate layer 40. Since the substrate layer 40 is light transmittance, the pattern layer 30 located between the substrate layer 40 and the film layer 20 will be illuminated. The decorative layer 10 has a certain light transmittance. Therefore, even if the window hole 11 is not opened on the decorative layer 10 in this embodiment, the user can still observe the pattern of the pattern layer 30.

[0068] In an optional embodiment, the substrate layer 40 and the composite diaphragm 100 are injection molded, and the bonding between the substrate layer 40 and the composite diaphragm 100 is carried out in a mold. Specifically, the substrate layer 40 in this embodiment is made of a flowable injection moldable material. When the substrate layer 40 and the composite diaphragm 100 are bonded, the composite diaphragm 100 is first placed in a mold. The mold has a processing cavity for bonding the substrate layer 40 and the composite diaphragm 100. High-temperature and high-pressure materials for making the substrate layer 40 are injected into the processing cavity. After solidification, the composite diaphragm 100 and the substrate layer 40 are bonded together.

[0069] In an optional embodiment, the substrate layer 40 and the composite film 100 are heat-pressed. The substrate layer 40 in this embodiment is made of a heat-pressable material. After the composite film 100 is placed in the mold, the heat-pressable material in the mold is heated and pressurized to form a substrate layer 40 that is bonded to the composite film 100 on the side away from the decorative layer 10.

[0070] like Figure 6As a specific embodiment of the molded part 200 provided in the present application, the substrate layer 40 is a light-transmitting structure. In this embodiment, light irradiating 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 window hole 11.

[0071] like Figure 7 As a specific embodiment of the molded part 200 provided in the present application, the position corresponding to the window hole 11 of the substrate layer 40 and the composite film 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 pass through the hollow position to illuminate the pattern layer 30, so that the user can clearly see the pattern of the pattern layer 30 through the window hole 11.

[0072] In an optional 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 of a light-transmitting material, and the position of the substrate layer 40 corresponding to the window hole 11 is hollowed out. In this case, light can illuminate the pattern layer 30 through the hollow position, and can also illuminate other parts outside the pattern layer 30 through the substrate layer 40, but the brightness of the pattern layer 30 is the highest, that is, the brightness of the window hole 11 is the highest, and the brightness of other positions is slightly lower. This is mainly because the substrate layer 40 of the light-transmitting material will reflect part of the light, resulting in the actual light transmittance being lower than the light transmittance of the hollow layer, so that the light intensity passing through the substrate layer 40 to other positions outside the pattern layer 30 is lower than the light intensity irradiated to the pattern layer 30. In this embodiment, the user can clearly see the pattern of the pattern layer 30 through the window hole 11, and can see that there is a layer of hazy light around the pattern, which further enhances the visual experience.

[0073] like Figure 8 As a specific embodiment of the molded part 200 provided in the present application, the position corresponding to the window hole 11 of the substrate layer 40 and the composite film 100 is a thin-walled structure 42. In this embodiment, the substrate layer 40 is made of an opaque material, but due to the existence of the thin-walled structure 42, the wall thickness of the thin-walled structure 42 is very thin. When the light irradiates the thin-walled structure 42 from one side, the brightness of the other side of the thin-walled structure 42 increases, forming an effect similar to that of a gel being lit up, so that the light can directly illuminate the thin-walled structure 42, and the bright light on the illuminated thin-walled structure 42 can illuminate the pattern layer 30, so that the user can observe the pattern layer 30 through the window hole 11. The thin-walled structure 42 has a certain light transmittance. When the light source irradiates the thin-walled structure 42, the light source will illuminate the pattern layer 30 through the thin-walled structure 42.

[0074] like Fig. 9As a specific embodiment of the molded part 200 provided in the present application, the substrate layer 40 is a light-transmitting structure, and the position corresponding to the substrate layer 40 and the window hole 11 of the composite film 100 is a thin-walled structure 42. In this embodiment, the light can illuminate the pattern layer 30 and other parts outside the pattern layer 30, but the pattern layer 30 has the highest brightness, that is, the window position has the highest brightness, and the brightness of other positions is slightly lower. This is mainly because the light-transmitting material will reflect part of the light. The thicker the light-transmitting material, the lower the transmittance, resulting in the actual transmittance of other positions of the substrate layer 40 being lower than the transmittance of the thin-walled structure 42 position, so that the light intensity passing through the substrate layer 40 to other positions outside the pattern layer 30 is lower than the light intensity irradiated to the pattern layer 30 position. In this embodiment, the user can clearly see the pattern of the pattern layer 30 through the window hole 11, and can see that there is a layer of hazy light around the pattern, which further enhances the visual experience.

[0075] In an optional embodiment, a functional hole 50 is provided on the molded part 200, and the functional hole 50 at least penetrates the film layer 20 and the substrate layer 40 of the composite diaphragm 100. The functional hole 50 in this embodiment is used to realize various specific functions after the molded part 200 is installed on the product, such as the functional hole 50 can be a sound hole for sound to pass through, a heat dissipation hole for heat dissipation of the product, a light-transmitting hole for light to pass through, a gas-permeable hole for gas to pass through, an atomization hole for atomization, etc. The specific function of the functional hole 50 is determined according to the specific environment of the electronic product to which the molded part 200 is applied.

[0076] like Fig.10 As a specific embodiment of the molded part 200 provided in the present application, the functional hole 50 passes 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, and the decorative layer 10 has a certain light transmittance. When the molded part 200 is applied to an electronic product, the electronic product emits light to irradiate the substrate layer 40, and the user can directly observe the pattern layer 30 from one side of the decorative layer 10. Specifically, the functional hole 50 in this embodiment can be a light-transmitting hole, so that when the electronic product emits light, the light can be irradiated onto the decorative layer 10 through the functional hole 50, and because the decorative layer 10 is a light-transmitting structure, the electronic product can play a lighting role due to the setting of the functional hole 50. The functional hole 50 in this embodiment can also have more functions according to specific application scenarios.

[0077] like Fig.11As a specific embodiment of the molded part 200 provided in the present application, the functional hole 50 passes through the substrate layer 40 and the entire composite diaphragm 100. The substrate layer 40 is made of a light-transmitting material. The decorative layer 10 is provided with a window hole 11. When the molded part 200 is applied to a product, the light source of the product is irradiated onto the substrate layer 40, and the user can observe the pattern layer 30 through the window hole 11. Specifically, the functional hole 50 in this embodiment can be a light-transmitting hole, a heat dissipation hole, a ventilation hole, a sound hole, etc., and even the functional hole 50 can have multiple functions. Through the functional hole 50 that runs through the entire composite diaphragm 100 and the substrate layer 40, the environment inside the molded part 200 in the product can be connected with the environment outside the molded part 200, thereby satisfying various functions required during application.

[0078] like Fig.12 As a specific embodiment of the molded part 200 provided in the present application, the functional hole 50 passes through the substrate layer 40 and the entire composite film 100, the decorative layer 10 is provided with a window hole 11, and the substrate layer 40 is provided with a hollow structure 41 at a position corresponding to the window hole 11. The substrate layer 40 and the decorative layer 10 can both be made of opaque materials. The light source shines from the hollow structure 41 of the substrate layer 40 onto the pattern layer 30, and the user can observe the pattern layer 30 through the window hole 11. Specifically, the functional hole 50 in this embodiment can be a light-transmitting hole. When both the substrate layer 40 and the decorative layer 10 are opaque, light can shine from the inside of the molded part 200 to the outside of the molded part 200 through the functional hole 50, thereby playing a lighting role. According to the specific application environment, the functional hole 50 can also be used to achieve various other functions.

[0079] like Fig.13 As a specific embodiment of the molded part 200 provided in the present application, the functional hole 50 passes through the substrate layer 40 and the entire composite film 100, and the decorative layer 10 is provided with a window hole 11. A thin-walled structure 42 is provided at a position corresponding to the window hole 11 on the substrate layer 40. The thin-walled structure 42 has a certain light transmittance. Therefore, the user can observe the pattern layer 30 through the window hole 11. In this embodiment, through the functional hole 50 that runs through the entire composite film 100 and the substrate layer 40, the environment located inside the molded part 200 in the product can be connected with the environment located outside the molded part 200, thereby meeting various functions required during application. Specifically, the functional hole 50 in this embodiment can be a light-transmitting hole, a heat dissipation hole, a vent hole, a sound hole, etc., and even the functional hole 50 can have multiple functions.

[0080] like Fig.14As a specific embodiment of the molded part 200 provided in the present application, the functional hole 50 passes through the substrate layer 40 and the film layer 20 of the composite diaphragm 100, and the decorative layer 10 is provided with a window hole 11. The decorative layer 10 is made of an opaque material, and the substrate layer 40 is made of a translucent material. The light source can penetrate the substrate layer 40 and irradiate the pattern layer 30, so that the user can observe the pattern of the pattern layer 30 through the window hole 11. Specifically, the functional hole 50 in this embodiment can be a sound hole. The material of the decorative layer 10 has little barrier to sound. After the molded part 200 is applied to the product, the sound emitted by the product can be transmitted through the functional hole 50. The functional hole 50 in this embodiment can also be a heat dissipation hole for dissipating heat from the product.

[0081] like Fig.15 As a specific embodiment of the molded part 200 provided in the present application, the functional hole 50 passes through the substrate layer 40 and the film layer 20 of the composite diaphragm 100, and the decorative layer 10 is provided with a window hole 11. A hollow structure 41 is provided at a position corresponding to the window hole 11 on the substrate layer 40. When light is irradiated from one side of the substrate layer 40 to the composite diaphragm 100, the user can see the pattern layer 30 through the window hole 11. In this embodiment, the substrate layer 40 can be made of a light-transmitting material or an opaque material, and the decorative layer 10 is made of an opaque material. The functional hole 50 in this embodiment can be a heat dissipation hole, a sound hole, a vent hole, etc., which can be specifically set according to the needs of the product. At the same time, according to the different functions of the functional hole 50, when making the composite diaphragm 100, the material of the decorative layer 10 can also be adjusted accordingly. For example, when the functional hole 50 is a vent hole, the decorative layer 10 needs to be made of a material with good air permeability.

[0082] like Fig.16 As a specific embodiment of the molded part 200 provided in the present application, the functional hole 50 passes through the substrate layer 40 and the thin film layer 20 of the composite diaphragm 100, and the decorative layer 10 is provided with a window hole 11. A thin-walled structure 42 is provided at a position corresponding to the window hole 11 on the substrate layer 40. The thin-walled structure 42 has a certain light transmittance, so the user can observe the pattern layer 30 through the window hole 11. In this embodiment, the decorative layer 10 is made of an opaque material, and the functional hole 50 can be a heat dissipation hole, a sound hole, a ventilation hole, etc., which can be specifically set according to the needs of the product. At the same time, according to the different functions of the functional hole 50, when making the composite diaphragm 100, the material of the decorative layer 10 can also 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.

[0083] The present application also proposes an IML molding process, comprising the following steps:

[0084] S1: Laminating the film layer and the decorative layer 10 to obtain a composite film having the decorative layer 10;

[0085] S2: dividing the composite film into composite film sheets 100 for combining with the substrate layer;

[0086] S3: placing the composite film 100 in a mold so that the composite film 100 and the substrate layer 40 are combined to form a molded part 200 .

[0087] In this embodiment, the decorative layer 10 is first attached to the film layer 20 to obtain a composite film having the decorative layer 10, and then the composite film is at least segmented to obtain a composite film sheet 100 that matches the contour of the substrate layer 40. The composite film sheet 100 has the same thickness as the composite mold, but the composite film sheet 100 is smaller than the composite film. Then, the substrate layer 40 and the composite film sheet 100 are combined in the mold to obtain a molded part 200. The molded part 200 finally obtained in this embodiment has a decorative layer 10, which can meet the needs of some high-end products or customers with higher requirements.

[0088] Furthermore, during the process of combining the composite diaphragm 100 and the substrate layer 40 in the mold, the substrate layer 40 and the composite diaphragm 100 are injection molded, and the combination of the substrate layer 40 and the composite diaphragm 100 is carried out in the mold. Specifically, the substrate layer 40 in this embodiment is made of a flowable injection moldable material. When combining the substrate layer 40 and the composite diaphragm 100, the composite diaphragm 100 is first placed in the mold. The mold has a processing cavity for combining the substrate layer 40 and the composite diaphragm 100. The high-temperature and high-pressure material used to make the substrate layer 40 is injected into the processing cavity. After solidification, the composite diaphragm 100 and the substrate layer 40 are combined together.

[0089] In an optional embodiment, the substrate layer 40 is thermoformed with the composite film 100. The substrate layer 40 in this embodiment is made of a thermoformable material, and after the composite film 100 is placed in the mold, the thermoformable material in the mold is heated and pressurized to form a substrate layer 40 that is bonded to the decorative layer 10 on the side of the composite film 100 away from the decorative layer 10.

[0090] In an optional embodiment, after the film layer 20 and the decorative layer 10 are prepared, one side of the film layer is coated with glue and / or hot-melt treated to form an adhesive surface with an adhesive effect on one side of the film layer, and the decorative layer is flatly attached to the adhesive surface; the composite film is hot-pressed so that at least a partial outer contour of the composite film is adapted to the outer contour of the substrate layer 40 to be combined. A composite film can eventually be divided into several composite film sheets 100, and the outer contour of each composite film sheet 100 can be adapted to the outer contour of the substrate layer 40 to be combined, that is, the composite film has several parts whose outer contours are adapted to the outer contour of the substrate layer 40 to be combined.

[0091] In this embodiment, two methods of laminating the decorative layer 10 to the film layer 20 are proposed. One method is to use an adhesive between the decorative layer 10 and the film layer 20 so that the decorative layer 10 is laminating to the film layer 20. The other method is to hot-melt one side of the film layer 20 to form an adhesive surface, and then cover the decorative layer 10 on the adhesive surface so that the decorative layer 10 is laminating to the film layer 20. Regardless of which method is used to laminating the decorative layer 10 to the film layer 20, compared with the traditional cloth or skin covering operation, this method is easier to ensure the flatness and bonding effect of the surface of the decorative layer 10, thereby helping to improve the quality and appearance of the final product, and at the same time, it can also increase the service life of the product.

[0092] Specifically, the film layer 20 in this embodiment is a planar structure before being bonded to the decorative layer 10. Therefore, in the process of attaching the decorative layer 10 to the film layer 20, the decorative layer 10 can be simply and smoothly attached to the film layer 20 without being constrained by the space at the corners of the product, which causes problems such as inconvenient pasting or loose fitting during the covering process. After the decorative layer 10 is bonded to the film layer 20, the film layer 20 is hot pressed to form a contour that matches the substrate layer 40, and then the composite film sheet 100 for combining with the substrate layer 40 is cut out. In this way, during the production process, a number of composite film sheets 100 can be cut out in batches from a group of laminated decorative layers 10 and film layers 20, and because before cutting, the decorative layer 10 and the film layer 20 have been laminated to form a contour adapted to the substrate layer 40 directly or / and after hot pressing, the decorative layer 10 and the film layer 20 in the composite film sheet 100 obtained after cutting must be tightly fitted and have completely consistent edges and corners, and can be adaptively combined with the substrate layer 40.

[0093] In a specific embodiment, before the decorative layer 10 and the film layer 20 are bonded together, it is necessary to open a first positioning hole in the decorative layer 10, and open a second positioning hole on the film layer 20 at a position directly opposite to the first positioning hole. A pattern layer 30 is provided on the film layer 20, and a window hole 11 is opened at a position on the decorative layer 10 corresponding to the pattern layer 30. The relative position of the window hole 11 and the first positioning hole is determined according to the relative position of the pattern layer 30 and the second positioning hole.

[0094] In the present embodiment, the decorative layer 10 is made of an opaque material, and a window hole 11 is required to be opened on the decorative layer 10 to observe the pattern layer 30 on the inner side of the film layer 20. Before the decorative layer 10 and the film layer 20 are bonded together, a first positioning hole and a second positioning hole are respectively opened on the decorative layer 10 and the film layer 20 to determine the relative position of the pattern layer 30 and the second positioning hole. Since the first positioning hole and the second positioning hole are directly opposite to each other, the position of the window hole 11 can be determined on the decorative layer 10 according to the relative position of the pattern layer 30 and the second positioning hole, and then the window hole 11 is opened on the decorative layer 10. This ensures that the window hole 11 opened on the decorative layer 10 can accurately observe the pattern layer 30. At the same time, it is also convenient for positioning the composite film in the subsequent shaping, segmentation and combining with the substrate layer 40 steps, ensuring the relative position of the window hole 11 in each step, and ensuring the accuracy of the window hole 11 on the final product.

[0095] In a specific embodiment, the molded part 200 has a functional hole 50 that penetrates the substrate layer 40 and the film layer 20. Specifically, in this embodiment:

[0096] Before the film layer 20 is attached to the decorative layer 10, a third positioning hole is opened on the film layer 20, and a first insert pin adapted to the third positioning hole is provided on the device for hot pressing the composite film; a second insert pin adapted to the third positioning hole is provided on the device for cutting the composite film; and a third insert pin adapted to the third positioning hole is provided on the mold for combining the composite film sheet 100 with the substrate layer 40;

[0097] During the hot pressing process, the third positioning hole cooperates with the first insert pin to position the composite membrane 100 and then perform hot pressing;

[0098] During the splitting process, the third positioning hole cooperates with the second inserting pin to position the composite membrane 100 and then perform the splitting operation;

[0099] During the process of combining the composite diaphragm 100 and the substrate layer 40, after the composite diaphragm 100 is placed in the mold, the third positioning hole is first matched with the third insert pin, and the third positioning hole is blocked with the help of the third insert pin. At the same time, the composite diaphragm 100 is positioned, and then the substrate layer 40 is formed in the mold by injection molding. After the substrate layer 40 and the composite diaphragm 100 are combined, the third insert pin is pulled out to obtain the molded part 200, and at the same time, a functional hole 50 that penetrates the substrate layer 40 and the film layer 20 is formed on the molded part 200.

[0100] In this embodiment, the decorative layer 10 does not need to have a window hole 11 .

[0101] In a specific embodiment, a visible window needs to be provided on the decoration layer 10 , and a functional hole 50 that penetrates the composite film 100 and the substrate layer 40 needs to be provided on the molded part 200 .

[0102] In this embodiment, before the decorative layer 10 and the film layer 20 are bonded together, a fourth positioning hole and a fifth positioning hole are respectively opened on the decorative layer 10 and the film layer 20, and the fourth positioning hole and the fifth positioning hole are located opposite to each other. During the process of combining the composite membrane 100 and the substrate layer 40, a hole that is located opposite to the fourth positioning hole and the fifth positioning hole is opened on the substrate layer 40 with the help of an inlay needle, thereby forming a functional hole 50 that runs through the entire molded part 200.

[0103] In a specific embodiment, the window hole 11 does not need to be provided on the decorative layer 10. After the decorative layer 10 is bonded to the film layer 20 and divided into the composite film 100, a sixth positioning hole is provided on the composite film 100. The sixth positioning hole is used to position the composite film 100 in the subsequent processing to ensure an ideal processing effect of the composite film 100. In this embodiment, the molded part 200 has a functional hole 50 that penetrates the substrate layer 40 and the entire composite film 100. In the process of combining the composite film 100 with the substrate layer 40, a hole that is directly opposite to the position of the sixth positioning hole is provided on the substrate layer 40 by means of an inlay needle, so that a functional hole 50 that penetrates the entire molded part 200 is formed on the molded part 200.

[0104] In a specific embodiment, the wall thickness of the molded part 200 is relatively thin, and the functional hole 50 passes through the molded part 200; in this embodiment, the composite membrane 100 is first combined with the substrate layer 40 to form a molded part 200 without the functional hole 50, and then the molded part 200 is punched to form the functional hole 50 on the molded part.

[0105] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A composite membrane for combining with a substrate layer to form a molded part, characterized in that: The composite film sheet includes a plastic film layer and a decorative layer attached to the film layer, wherein the decorative layer is a flexible thin sheet, and the film layer and the decorative layer are attached to each other and then at least divided to form the composite film sheet; the composite film sheet also includes a pattern layer arranged on the film layer, wherein the pattern layer is arranged on the side of the film layer away from the decorative layer, and a window hole for observing the pattern layer is opened on the decorative layer; the decorative layer is at least one of cloth, leather, plant sheet, non-woven fabric, paper sheet, and metal sheet.

2. The composite membrane according to claim 1, characterized in that: The decorative layer and the film layer are bonded together after heat pressing, or the decorative layer and the film layer are bonded together by an adhesive.

3. The composite diaphragm according to claim 1, characterized in that: 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 smoothly transitions with the side of the decoration layer away from the film layer or is arranged in a stepped manner.

4. The composite diaphragm according to claim 1, characterized in that: The film layer is provided with a light-transmitting layer in contact with the film layer at a position corresponding to the window hole, and a side of the light-transmitting layer away from the film layer and a side of the decorative layer away from the film layer have a smooth transition or are arranged in steps.

5. A molded part, characterized in that: It comprises a substrate layer and the composite film according to any one of claims 1 to 4, wherein the composite film is covered on the substrate layer, and the decorative layer of the composite film is located on a side away from the substrate layer.

6. The molded part according to claim 5, characterized in that The substrate layer and the composite film are injection molded, or the substrate layer and the composite film are hot pressed.

7. The molded part according to claim 5, characterized in that The substrate layer is a light-transmitting structure, and / or the position of the substrate layer corresponding to the window hole of the composite film is a hollow structure.

8. The molded part according to claim 5, characterized in that The substrate layer is a light-transmitting structure, and / or the position of the substrate layer corresponding to the window hole of the composite film is a thin-walled structure.

9. The molded part according to claim 5, characterized in that The molded part is provided with a functional hole, and the functional hole at least penetrates the film layer and the substrate layer of the composite membrane.

10. An IML molding process, characterized in that: The steps include: S1: Laminating the film layer and the decorative layer to obtain a composite film with the decorative layer; S2: dividing the composite film into composite film sheets for combining with the substrate layer; S3: placing the composite film in a mold so that the composite film is combined with the substrate layer to form a molded part; Before step S1, the method further includes the following steps: A first positioning hole is provided in the decorative layer, a second positioning hole is provided on the film layer at a position directly opposite to the first positioning hole, a pattern layer is provided on the film layer, a window hole is provided on the decorative layer at a position 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; the decorative layer is a flexible thin sheet, the pattern layer is provided on a side of the film layer away from the decorative layer, and the decorative layer is at least one of cloth, leather, plant sheet, non-woven fabric, paper sheet, and metal sheet.

11. The molding process according to claim 10, characterized in that: The step S1 specifically includes: S1: Glue or hot-melt one side of the film layer to form an adhesive surface with adhesive effect on one side of the film layer, and evenly attach the decorative layer to the adhesive surface and flatten it to form the composite film; hot-press the composite film to make at least a partial outer contour of the composite film match the outer contour of the substrate layer to be combined.

12. The molding process according to claim 11, characterized in that: The following steps are also included: Before step S1, a third positioning hole is opened on the film layer, a first inserting pin adapted to the third positioning hole is provided on the device for hot pressing the composite film; a second inserting pin adapted to the third positioning hole is provided on the device for dividing the composite film; a third inserting pin adapted to the third positioning hole is provided on the mold for combining the composite film sheet with the substrate layer; In the step S1, the third positioning hole cooperates with the first inserting pin to position the composite film and then perform hot pressing; In the step S2, the third positioning hole cooperates with the second inserting pin to position the composite film and then perform a splitting operation; In step S3, the composite diaphragm is placed in the mold, the third positioning hole is matched with the third insert pin, and the third positioning hole is blocked with the help of the third insert pin, and the composite diaphragm is positioned at the same time, and then the substrate layer is formed by injection molding in the mold. After the substrate layer and the composite diaphragm are combined, the third insert pin is pulled out to obtain the molded part, and a functional hole that penetrates the substrate layer and the film layer is formed on the molded part.

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