A method for preparing an injection molded part with a transparent three-dimensional texture

Abstract

A method for preparing an injection molded part with a transparent three-dimensional texture includes: (1) providing a decorative surface with a transparent three-dimensional texture, and then molding the decorative surface; (2) placing the molded decorative surface in a mold cavity, wherein one side of the decorative surface arranged opposite to each other along its thickness direction is in contact with the inner wall of the mold cavity, and an adhesive layer is provided on the other side for bonding with the injection molding material; the decorative surface contains an organic material layer, and a coloring layer is provided on each of the two sides arranged opposite to each other along the thickness direction of the organic material layer, and the organic material layer is a transparent layer; (3) closing the mold, and then injecting the injection molding material into the mold cavity, wherein the injection molding material fills the gap formed between the decorative surface and the mold cavity, and after the injection molding material cools and solidifies, the mold is opened to obtain the injection molded part; the method has the advantages of a strong injection molding bond between the three-dimensional textured decorative surface and the injection molded part, and also improves the transparency of the three-dimensional texture display.

Description

Technical Field

[0001] This application relates to the technical field of product exterior finishes, specifically to a method for preparing an injection molded part with a transparent three-dimensional texture. Background Technology

[0002] Three-dimensional textures are currently widely used in the surface finishes of furniture, home appliances, and other products. These textures give products a three-dimensional display effect, making the overall exterior surface more realistic and three-dimensional, thereby increasing the product's added value and providing consumers with more choices in product surface finishes. Currently, three-dimensional textures are mostly combined with products using a lamination method. For example, the textured surface is first created, and then adhered to the product's outer surface using adhesive. This method requires cutting the textured surface, and this bonding method may cause peeling or lifting from the product's outer surface during product use due to aging or loose adhesion. Furthermore, due to the limitations of the carrier layer material, to achieve a higher degree of conformity with the product's outer surface contour, the textured surface needs to be bent or folded. This process may cause localized deformation of the textured surface, affecting the display of the three-dimensional texture. Moreover, bending during the bonding process makes it difficult for the surface to maintain its bent shape, leading to easy reversion and a loose adhesion to the product surface.

[0003] Furthermore, existing three-dimensional texture finishes simply attach the three-dimensional texture layer and the coloring layer to the carrier layer. Generally, the coloring layer is placed on the same side of the carrier layer in the thickness direction. Thus, no matter how many layers of coloring are stacked, the coloring layer simply serves to give the three-dimensional texture a base color. However, as consumers have higher demands for the display effect of the finish, how to effectively give the three-dimensional texture a base color while improving the transparency of the three-dimensional texture display has become a new demand in the industry. Summary of the Invention

[0004] In view of the above-mentioned shortcomings of the prior art, this application provides a method for preparing an injection molded part with transparent three-dimensional texture by directly combining the three-dimensional textured surface with the injection molded part, thereby improving the bonding strength, reducing the likelihood of peeling or lifting, and also improving the transparency of the three-dimensional texture display.

[0005] To solve the above-mentioned technical problems, the technical solution adopted in this application is: a method for preparing an injection molded part with a transparent three-dimensional texture, the steps of which include:

[0006] (1) Provide a finish with a transparent three-dimensional texture, and then shape the finish so that the shape of the finish matches the inner wall contour of the mold cavity to be placed.

[0007] (2) The molded decorative surface is placed in the mold cavity, and one side of the decorative surface is arranged opposite to the inner wall of the mold cavity along its thickness direction, and an adhesive layer is provided on the other side for bonding with the injection molding material; the decorative surface contains an organic material layer, and a coloring layer is provided on each side arranged opposite to the organic material layer along its thickness direction, and the organic material layer is a transparent layer.

[0008] (3) Close the mold, and then inject the injection material into the mold cavity. The injection material fills the gap formed between the decorative surface and the mold cavity. After the injection material cools and solidifies, open the mold to obtain the injection molded part of this application.

[0009] Furthermore, the thickness of the organic material layer described in this application is 0.05-5 mm.

[0010] Furthermore, the molding process described in this application is hot pressing, and the hot pressing temperature is 130-280℃.

[0011] Furthermore, the injection pressure of the injection molding material described in this application is 80-150 MPa.

[0012] Furthermore, the temperature of the mold cavity described in this application is 100-140°C, and the molding temperature of the injection molding material is 220-280°C.

[0013] Furthermore, the two outer surfaces of the material layer arranged opposite each other along the thickness direction are the upper surface on one side and the lower surface on the other side. The coloring layer located on the upper surface is the upper coloring layer, and the coloring layer located on the lower surface is the lower coloring layer. The thickness of the upper coloring layer is less than the thickness of the lower coloring layer.

[0014] Furthermore, the upper coloring layer is a transparent or semi-transparent coloring layer.

[0015] Furthermore, a UV three-dimensional texture layer is provided between the upper coloring layer and the upper surface.

[0016] Furthermore, a UV layer is provided on the outer surface of the upper coloring layer and the adjacent UV three-dimensional texture layer, which are opposite to each other. The UV layer is a transparent or semi-transparent UV layer with a glossy or AG surface.

[0017] Furthermore, the organic material layer is one of PMMC, PET, PC, PVC, ABS, PS, APET, or PETG, that is, any organic material that can be thermoformed is suitable for this application.

[0018] Furthermore, the coloring layer is a metallic pigment layer or a pearlescent powder layer.

[0019] Furthermore, the UV three-dimensional texture layer is formed on the organic material layer through photolithography and curing processes.

[0020] Furthermore, a protective layer is also attached to the outer surface of the lower coloring layer and the adjacent lower surface side.

[0021] Furthermore, the mold cavity is provided with a double layer near the injection material side, specifically including a first injection cavity and a second injection cavity. The first injection cavity forms a space for accommodating the injection material, and the second injection cavity is arranged adjacent to the first injection cavity. A cooling medium is introduced into the second injection cavity. With the above structure, effective cooling of the injection molded part can be achieved during the injection molding process. Attached Figure Description

[0022] Figure 1 This application features a flowchart illustrating the structure of a transparent three-dimensional textured finish.

[0023] Figure 2 This application presents a structural schematic diagram of a transparent three-dimensional textured finish.

[0024] Figure 3 This application presents a schematic diagram of the structure after hot pressing of a transparent three-dimensional textured finish.

[0025] Figure 4 This application provides a schematic diagram of the mold structure used for an example injection molded part.

[0026] Figure 5 This is a schematic diagram of the structure after the hot-pressed finish is placed in the mold cavity.

[0027] Figure 6 A schematic diagram of the mold structure used in another example of an injection molded part in this application.

[0028] Figure 7 This is a schematic diagram of the structure after the hot-pressed finish is placed in the mold cavity.

[0029] Figure 8 This application includes images of a transparent, three-dimensional textured finish prior to hot pressing.

[0030] As shown in the attached diagram: 1. Organic material layer, 101. Upper surface, 102. Lower surface, 2. UV three-dimensional texture layer, 3. Upper coloring layer, 4. UV layer, 5. Lower coloring layer, 6. Protective layer, 7. Mold cavity, 701. First injection cavity, 702. Second injection cavity. Detailed Implementation

[0031] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are merely preferred embodiments, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0032] Furthermore, it should be noted that when a component is referred to as being "fixed to" (or similarly contained in "fixed to") another component, it can be directly attached to the other component or may be fixed via another intermediate component. When a component is referred to as being "connected to" (or similarly contained in "connected") another component, it can be directly connected to the other component or may be simultaneously attached to another intermediate component. When a component is referred to as being "set on" (or similarly contained in "set on") another component, it can be directly set on the other component or may be simultaneously attached to another intermediate component. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0033] The transparency of this application refers to the fact that a coloring layer is set on each side opposite to the thickness of the transparent organic material layer, and the color and texture of the lower coloring layer can be superimposed on the transparent organic material layer and the upper coloring layer to form a transparent display effect (i.e., a texture display effect similar to the transparent appearance of jade). This method of superimposing two coloring layers through the middle transparent layer and then setting a transparent UV layer on the top can improve the overall transparency of the finish, such as creating the effect of a transparent material that imitates jade or porcelain.

[0034] Because the upper coloring layer is transparent or semi-transparent, and the organic material layer is transparent, light passes through both and enters the lower coloring layer, producing various reflections and refractions, resulting in a transparent and three-dimensional texture effect that resembles jade, natural marble, or semi-transparent ceramics.

[0035] Moreover, the solution proposed in this application uses organic materials, which can greatly reduce the weight of the finish. After being combined with the injection-molded body, it will not cause any burden on the finish, and the fit is more secure, resulting in a more durable display effect.

[0036] Example

[0037] A method for preparing an injection molded part with a transparent three-dimensional texture, the method comprising the following steps:

[0038] (1) Provide a finish with a transparent three-dimensional texture, and then shape the finish so that the shape of the finish matches the inner wall contour of the mold cavity to be placed.

[0039] Specifically, first, a 3D texture to be displayed is determined, and a mold for this texture is prepared. Then, a UV adhesive is coated onto the mold, followed by an organic material layer. The UV coating (UV adhesive) is then imprinted with the texture. The imprinted UV coating is then photocured using a UV light source. After curing, the master mold is removed, revealing an organic material layer with the master pattern. This layer forms the cured UV 3D texture layer on one surface along the thickness direction of the organic material layer (the photocuring process ensures a strong bond between the UV 3D texture layer and the organic material layer). Excess UV adhesive on the organic material layer is removed. Finally, a coloring layer is applied to the outer surface of the UV 3D texture layer. This coloring layer can be a metallic pigment layer, and can be transparent or semi-transparent. The upper coloring layer consists of a metallic pigment layer or pearlescent powder layer formed from nano- or micron-sized metallic pigment powder, which is screen-printed onto a UV three-dimensional texture layer (transparent three-dimensional texture layer). The particle size of the pigment or pearlescent powder in this upper coloring layer must pass through a 300-mesh sieve. A lower coloring layer, also a metallic pigment layer or pearlescent powder layer, is disposed on the opposite side of the organic material layer along its thickness direction. The particle size of this lower coloring layer must pass through a 200-mesh sieve. Both the upper and lower coloring layers are screen-printed from the same material on the two outer surfaces of the same organic material layer along its thickness direction, and the aforementioned particle size limitation ensures that the thickness of the upper coloring layer is less than that of the lower coloring layer. This design achieves a semi-transparent or fully transparent effect after the upper coloring layer adheres, allowing for color superposition with the lower coloring layer. Furthermore, the color of the lower coloring layer can be transmitted through the organic material layer to overlap with the upper coloring layer, improving the overall transparency of the finish and creating a realistic jade-like effect. In addition, the upper coloring layer is made thinner, allowing it to penetrate into the texture gaps of the UV three-dimensional texture layer without covering the texture, resulting in a more three-dimensional and pronounced texture effect. Then, a UV layer is applied to the outer surface of the upper coloring layer. This UV layer is smooth and without any texture; it is achieved by coating the outer surface of the upper coloring layer with UV adhesive and then curing it to achieve a two-dimensional effect. The two are firmly connected; or an AG surface UV layer can be set. The AG surface can be made through a three-dimensional texture mold. The process is similar to that of the above-mentioned UV three-dimensional texture layer. The difference is that the UV layer formed is an AG surface UV layer, and the UV layer is a transparent material. In this application, the UV layer, the upper coloring layer, the UV three-dimensional texture layer and the organic material layer are all transparent material layers. The upper coloring layer is placed between multiple transparent layers, while the lower coloring layer is placed below the UV layer, the upper coloring layer, the UV three-dimensional texture layer and the organic material layer. The colors of the upper coloring layer and the lower coloring layer overlap each other, and the transparent layers between them also overlap each other, so as to give the overall surface a transparent three-dimensional texture display effect, and can realize the surface display effect of imitation jade and other stones.

[0040] In addition, to effectively protect the superimposed texture and improve the high-temperature resistance of the finish during subsequent injection molding, preventing deformation of the texture under high-temperature injection molding conditions, a protective layer is set on the lower surface of the lower coloring layer. The color of this protective layer will not be exposed on the front of the finish, but will be covered by the color of the lower coloring layer to avoid affecting the overall finish display effect. For example, this protective layer can be a protective gray (achieved by ink screen printing), formed by spraying or screen printing processes, which is a common method of setting protective layers in the finish field, and will not be described in detail here.

[0041] The above-mentioned surface structure with transparent three-dimensional texture is formed before injection molding. Then, the surface is molded and formed into a shape structure that can match the mold cavity by hot pressing process. Hot pressing is completed by hot pressing machine.

[0042] The mold for forming the UV three-dimensional texture layer described in this application can be obtained by referring to the contents of "Preparation method of multi-channel 3D nano-texture and three-dimensional LOGO mold" or "Preparation method of multi-channel 3D nano-texture mold";

[0043] (2) The molded decorative surface is placed in the mold cavity, and one side of the decorative surface along its thickness direction is in contact with the inner wall of the mold cavity, and an adhesive layer is provided on the other side for bonding with the injection molding material; the decorative surface contains an organic material layer, and a coloring layer is provided on each side along the thickness direction of the organic material layer, and the organic material layer is a transparent layer; the material of the adhesive layer achieves bonding performance under the temperature influence of the high-temperature material after the heated and molten injection molding material enters the cavity, thereby achieving a stable bond between the injection molding material and the decorative surface;

[0044] (3) Close the mold and then inject injection material into the mold cavity. The injection material fills the gap between the decorative surface and the mold cavity. After the injection material cools and solidifies, open the mold to obtain the injection molded part of this application. The mold cavity of this application can be formed by combining the upper and lower mold modules.

[0045] As an example, the thickness of the organic material layer described in this application is between 1 and 1.2 mm.

[0046] As an example, the molding process described in this application is hot pressing, and the hot pressing temperature is 170-175°C.

[0047] As an example, the injection pressure of the injection molding material described in this application is 120 MPa.

[0048] As an example, the temperature of the mold cavity described in this application (i.e., the mold is preheated before injection molding so that the temperature difference between the injection molding material and the mold is small, which facilitates bonding and molding) is 120-122°C, and the molding temperature of the injection molding material is 220-225°C.

[0049] The organic material layer described in this application is one of PMMC, PET, PC, PVC, ABS, PS, APET, or PETG, that is, any organic material that can be thermoformed is suitable for this application.

[0050] For details, see attached. Figure 1-2 As shown, taking the preparation of a finish with a transparent three-dimensional texture using the method of this application as an example, firstly as shown in the attached... Figure 1 As shown, this is a finish with a transparent three-dimensional texture. The structure of this finish includes: an organic material layer 1, which has at least two surfaces along its thickness direction, namely an upper surface 101 and a lower surface 102 (the upper surface is the texture display surface of the final injection molded part, and the lower surface is the main surface that adheres to the injection molding material of the injection molded part); a UV three-dimensional texture layer 2 is provided on the upper surface 101; an upper coloring layer 3 is provided on the outer surface (upper surface) of the UV three-dimensional texture layer 2; a UV layer 4 is provided on the outer surface of the upper coloring layer 3; a lower coloring layer 5 is provided on the lower surface 102; and a protective layer 6 is provided on the lower surface of the lower coloring layer 5, which can be a protective gray (i.e., gray ink screen-printed on the lower surface of the lower coloring layer); thus, the above-mentioned finish structure is finally formed; then, the finish structure is placed in a thermoforming machine for thermoforming, as shown in the attached figure. Figure 3 As shown, a molded surface structure with a specific contour is formed, and the contour structure of this molded surface can be adapted to the mold cavity; specifically, as shown in the attached figure. Figure 4-5 The diagram shows a mold structure in which the finished surface of this application is placed. The side of the protective layer described herein is used for bonding with the injection molding material. Before injection molding, an adhesive layer 7 needs to be provided on the side of the protective layer 6. See attached diagram for details. Figure 5 All adhesives capable of achieving injection molding bonding in this field are applicable to this application;

[0051] As attached Figure 6-7 As shown, another mold of this application is provided. The mold cavity 7 of this mold is provided with a double layer near the injection material side, specifically including a first injection cavity 701 and a second injection cavity 702. The first injection cavity 701 forms a space for accommodating the injection material. The second injection cavity 702 is arranged adjacent to the first injection cavity 701. A cooling medium (such as water, etc., and is flowing water with an inlet on one side and an outlet on the other side) is introduced into the second injection cavity to facilitate real-time water flow and improve the cooling effect. With the above structure, effective cooling of the injection molded part can be achieved during the injection molding process.

[0052] As attached Figure 8 The transparent textured surface structure of this application (purple surface in the image) is the surface structure before hot pressing, exhibiting a planar extension. The attached figure clearly shows that the prepared surface has good transparency and can present a texture effect similar to jade. Injection molded parts prepared using this method not only have a transparent, three-dimensional textured surface display effect, but also reduce the overall weight of the injection molded parts, eliminating the need for natural jade pieces to be bonded to the injection molded parts. Furthermore, it can undergo molding processing and adapt to the production of injection molded products with different structural shapes, unlike natural jade which is only flat and brittle, prone to cracking and breakage. Injection molded parts with this transparent surface of the present application have strong adhesion, stable texture, and can be mass-produced, reducing production costs and improving production efficiency.

Claims

1. A method for preparing an injection molded part with a transparent three-dimensional texture, characterized in that: The steps of this method include: (1) Provide a finish with a transparent three-dimensional texture, and then shape the finish so that the shape of the finish matches the inner wall contour of the mold cavity to be placed. (2) The molded decorative surface is placed in the mold cavity, and one side of the decorative surface is arranged opposite to the inner wall of the mold cavity along its thickness direction, and an adhesive layer is provided on the other side for bonding with the injection molding material; the decorative surface contains an organic material layer, and a coloring layer is provided on each side arranged opposite to the organic material layer along its thickness direction, and the organic material layer is a transparent layer. (3) Close the mold and then inject injection material into the mold cavity. The injection material fills the gap formed between the decorative surface and the mold cavity. After the injection material cools and solidifies, open the mold to obtain the injection molded part. The two outer surfaces of the material layer are arranged opposite each other along the thickness direction. One side is the upper surface and the other side is the lower surface. The coloring layer on the upper surface side is the upper coloring layer, and the coloring layer on the lower surface side is the lower coloring layer. The thickness of the upper coloring layer is less than the thickness of the lower coloring layer. The upper coloring layer is a transparent or semi-transparent coloring layer; a UV three-dimensional texture layer is provided between the upper coloring layer and the upper surface; a UV layer is provided on the outer surface of the upper coloring layer and the adjacent UV three-dimensional texture layer, and the UV layer is a transparent or semi-transparent UV layer with a glossy or AG surface.

2. The method for preparing an injection molded part with a transparent three-dimensional texture according to claim 1, characterized in that: The thickness of the organic material layer is 0.05-5 mm.

3. The method for preparing an injection molded part with a transparent three-dimensional texture according to claim 1, characterized in that: The molding process is hot pressing, and the hot pressing temperature is 130-280℃; the injection pressure of the injection molding material is 80-150MPa; the temperature of the mold cavity is 100-140℃, and the molding temperature of the injection molding material is 220-280℃.

4. The method for preparing an injection molded part with a transparent three-dimensional texture according to claim 1, characterized in that: The organic material layer is one of PMMC, PET, PC, PVC, ABS, PS, APET, or PETG.

5. The method for preparing an injection molded part with a transparent three-dimensional texture according to claim 1, characterized in that: The coloring layer is a metallic pigment layer or a pearlescent powder layer.

6. The method for preparing an injection molded part with a transparent three-dimensional texture according to claim 5, characterized in that: The UV three-dimensional texture layer is formed on the organic material layer by photolithography and curing processes; a protective layer is also attached to the outer surface of the lower coloring layer and the adjacent lower surface side.

7. The method for preparing an injection molded part with a transparent three-dimensional texture according to claim 6, characterized in that: The mold cavity is provided with two layers near the injection material side, specifically including a first injection cavity and a second injection cavity. The first injection cavity forms a space for accommodating the injection material, and the second injection cavity is arranged adjacent to the first injection cavity, and a cooling medium is introduced into the second injection cavity.

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