Composite sheet, manufacturing method thereof and composite structure

Abstract

The invention discloses a composite sheet, a manufacturing method thereof and a composite structure. The composite sheet comprises a first resin layer, a metal layer and a second resin layer. The first resin layer comprises a first surface, a second surface and a plurality of first resin convex parts which are opposite to each other; the plurality of first resin convex parts are convex from the second surface; the metal layer comprises a third surface, a fourth surface and a plurality of metal convex parts which are opposite. The metal layer is fixed on the second surface through the third surface, and the plurality of metal convex parts protrude from the fourth surface and correspond to the plurality of first resin convex parts. The second resin layer comprises a fifth surface, a sixth surface and a plurality of second resin convex parts which are opposite to each other. The second resin layer is removably disposed on the fourth surface through the fifth surface. The plurality of second resin protrusions protrude from the sixth surface and correspond to the plurality of metal protrusions. In the hot pressing step, the second resin layer can protect the metal layer, so that the surface glossiness of the metal layer can be maintained, and the manufactured and molded composite sheet and composite structure have a brighter visual effect.

Description

Technical Field

[0001] The present invention relates to the technical field of composite sheet manufacturing, and in particular to a composite sheet with a metal layer, a manufacturing method thereof, and a composite structure. Background Art

[0002] Metal materials are often used to make product logos and decorative patterns due to their bright luster to enhance the recognition and beauty of products. However, in today's logos or decorative patterns made by lamination, the production process often causes the glossiness of the metal material to decrease, making the visual effect of the finished product less than expected. Summary of the invention

[0003] The object of the present invention is to provide a composite sheet material and a manufacturing method thereof as well as a composite structure to solve the above-mentioned problems, so that the composite sheet material and composite structure after manufacturing and forming can provide brighter visual and modeling effects.

[0004] According to one embodiment of the present invention, a composite sheet is provided, which includes a first resin layer, a metal layer and a second resin layer. The first resin layer includes a first surface, a second surface and a plurality of first resin protrusions. The second surface is opposite to the first surface, and a plurality of first resin protrusions protrude from the second surface. The metal layer can reflect visible light. The metal layer includes a third surface, a fourth surface and a plurality of metal protrusions. The metal layer is fixed to the second surface through the third surface, the fourth surface is opposite to the third surface, and a plurality of metal protrusions protrude from the fourth surface, wherein the plurality of metal protrusions correspond to the plurality of first resin protrusions. The second resin layer includes a fifth surface, a sixth surface and a plurality of second resin protrusions. The second resin layer is removably disposed on the fourth surface through the fifth surface, the sixth surface is opposite to the fifth surface, and a plurality of second resin protrusions protrude from the sixth surface, wherein the plurality of second resin protrusions correspond to the plurality of metal protrusions.

[0005] In a preferred embodiment of the present invention, the surface glossiness of each of the metal protrusions is greater than 80GU.

[0006] In a preferred embodiment of the present invention, the material of the metal layer includes aluminum, silver, gold, chromium or a combination thereof.

[0007] In a preferred embodiment of the present invention, the elongation at break of the first resin layer is 300% to 600%, the melting point of the first resin layer is 90°C to 180°C, the elongation at break of the second resin layer is 5% to 200%, and the melting point of the second resin layer is 130°C to 260°C.

[0008] In a preferred embodiment of the present invention, the material of the first resin layer includes thermoplastic polyurethane, and the material of the second resin layer includes polyethylene terephthalate.

[0009] In a preferred embodiment of the present invention, the material of the first resin layer includes thermoplastic polyurethane, and the material of the second resin layer includes oriented stretched polypropylene.

[0010] In a preferred embodiment of the present invention, the distance between two adjacent metal protrusions is 0.1 mm to 10 mm, and the height of each metal protrusion protruding from the fourth surface is 0.1 mm to 1 mm.

[0011] According to another embodiment of the present invention, a method for making a composite sheet is provided, which includes the following steps: providing a film layer stack, wherein the film layer stack includes a first resin layer, a metal layer and a second resin layer stacked in sequence, the metal layer is removably disposed on the first resin layer, and the second resin layer is removably disposed on the metal layer. Performing a first hot pressing step, heating and pressurizing the film layer stack, fixing the metal layer to the first resin layer, and maintaining the second resin layer removably disposed on the metal layer. Stacking a release member on the film layer stack, wherein a surface of the release member is formed with a plurality of recesses, and the surface of the release member faces a surface of the metal layer away from the first resin layer. Performing a second hot pressing step, heating and pressurizing the release member and the film layer stack, so that the metal layer forms a plurality of metal protrusions corresponding to the plurality of recesses, and the first resin layer forms a plurality of first resin protrusions corresponding to the plurality of recesses. Remove the release member.

[0012] In a preferred embodiment of the present invention, performing the second heat pressing step further comprises forming a plurality of second resin protrusions on the second resin layer corresponding to the plurality of concave portions.

[0013] In a preferred embodiment of the present invention, the method for making a composite sheet also includes removing the second resin layer after performing the first hot pressing step, and removably disposing a third resin layer on the metal layer, and performing the second hot pressing step also includes making the third resin layer form a plurality of third resin protrusions corresponding to the plurality of concave portions.

[0014] According to another embodiment of the present invention, a method for making a composite sheet is provided, which includes the following steps: providing a film layer stack, wherein the film layer stack includes a first resin layer, a metal layer, and a second resin layer stacked in sequence, the metal layer is removably disposed on the first resin layer, the second resin layer is removably disposed on the metal layer, and a plurality of first resin protrusions are formed on a surface of the first resin layer facing the metal layer. Performing a hot pressing step, heating and pressurizing the film layer stack, fixing the metal layer to the first resin layer, and maintaining the second resin layer removably disposed on the metal layer, and forming a plurality of metal protrusions on the metal layer corresponding to the plurality of first resin protrusions, and forming a plurality of second resin protrusions on the second resin layer corresponding to the plurality of first resin protrusions.

[0015] According to another embodiment of the present invention, a composite structure is provided, which includes the composite sheet material and a base member, wherein the base member is fixed to the first surface of the first resin layer.

[0016] In a preferred embodiment of the present invention, the first resin layer further includes a side surface connected between the first surface and the second surface, and the metal layer completely covers the side surface.

[0017] In a preferred embodiment of the present invention, the material of the base member includes sandwich mesh cloth.

[0018] Compared to the prior art, the composite sheet manufacturing method of the present invention is characterized by a second resin layer being removably disposed on the metal layer. During the hot pressing step, the second resin layer can protect the metal layer, thereby facilitating the maintenance of the surface gloss of the metal layer, so that the composite sheet and composite structure after manufacturing can provide a brighter visual and styling effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a schematic top view of a composite sheet according to one embodiment of the present invention;

[0020] Figure 2 yes Figure 1 A partial cross-sectional schematic diagram of the composite sheet along the section line A-A';

[0021] Figure 3 yes Figure 2 A magnified view of the T1 portion of the metal protrusion;

[0022] Figure 4 yes Figure 2 An enlarged view of the T2 portion of the metal flat portion;

[0023] Figure 5 is a flowchart of steps of a method for making a composite sheet according to one embodiment of the present invention;

[0024] Figure 6 is a schematic diagram of the steps of a method for making a composite sheet according to one embodiment of the present invention;

[0025] Figure 7 is a schematic diagram of steps of a method for making a composite sheet according to another embodiment of the present invention;

[0026] Figure 8 is a flowchart of steps of a method for making a composite sheet according to another embodiment of the present invention;

[0027] Fig. 9 is a schematic diagram of steps of a method for making a composite sheet according to another embodiment of the present invention;

[0028] Fig.10 is a schematic top view of a composite structure according to another embodiment of the present invention;

[0029] Fig.11 yes Fig.10 A schematic partial cross-sectional view of the composite structure along the section line BB'.

[0030] Description of reference numerals:

[0031] 1. composite structure; 2. composite sheet; 10. composite sheet; 10', composite sheet; 3. base member;

[0032] 20. Membrane stacking; 20'. Membrane stacking; 30. Membrane stacking; 21. Composite unit;

[0033] 40. hot pressing equipment; 41. hot pressing module; 41a. heating unit; 42. vacuum module; 42a. gas flow channel;

[0034] 50. Release parts; 51. Surface; 52. Recessed parts;

[0035] 110, first resin layer; 10a, first resin layer; 111, first surface; 112, second surface; 113, first resin protrusion; 114, first concave space; 115, first resin flat portion; 116, side surface;

[0036] 120, metal layer; 120a, metal layer; 121, third surface; 122, fourth surface; 122a, surface; 123, metal protrusion; 124, second concave space; 125, metal flat portion;

[0037] 130, second resin layer; 130a, second resin layer; 131, fifth surface; 132, sixth surface; 132a, surface; 133, second resin protrusion; 134, third concave space; 135, second resin flat portion;

[0038] 140, third resin layer; 140a, third resin layer; 141, seventh surface; 142, eighth surface; 142a, surface; 143, third resin protrusion;

[0039] 200. Method for making a composite sheet; 300. Method for making a composite sheet;

[0040] 210, step; 220, step; 230, step; 240, step; 250, step; 260, step; 270, step; 310, step; 320, step;

[0041] A1, preset angle; A2, preset angle; A3, preset angle;

[0042] D1, spacing; H1, height;

[0043] N1, normal direction; N2, normal direction;

[0044] P1, vertex; P2, point;

[0045] R11, incident light; R21, incident light; R31, incident light;

[0046] R12, reflected light; R22, reflected light; R32, reflected light;

[0047] T1, part; T2, part;

[0048] t1, thickness; t2, thickness; t3, thickness;

[0049] X, direction; Y, direction; Z, direction. DETAILED DESCRIPTION

[0050] In order to enable those skilled in the art to further understand the present invention, the preferred embodiments of the present invention are listed below, and the components of the present invention and the effects to be achieved are described in detail with the accompanying drawings. It should be noted that the accompanying drawings are simplified schematic diagrams, and therefore, only the components and combination relationships related to the present invention are shown to provide a clearer description of the basic structure or implementation method of the present invention, and the actual components and layout may be more complicated. In addition, for the convenience of explanation, the components or components shown in the various drawings of the present invention are not drawn in proportion to the actual number, shape, and size, and the detailed proportions can be adjusted according to the design requirements. For the convenience of explanation, the following drawings are all described in conjunction with the XYZ rectangular coordinate system.

[0051] The directional terms mentioned in the following embodiments, such as up, down, left, right, front or back, etc., are only used to refer to the directions of the drawings. Therefore, the directional terms used are used to illustrate and not to limit the present invention.

[0052] It should be noted that, although the terms first, second, third, etc. can be used to describe a variety of components, the components are not limited to these terms. These terms are only used to distinguish a single component from other components in the specification.

[0053] In the present invention, the statements such as "a component is arranged on another component" and "a component is connected to another component" may mean "the component is in direct contact with the other component" or "there are other components between the component and the other component", so that the component is not in direct contact with the other component.

[0054] <Composite Sheet>

[0055] Please refer to Figure 1 and Figure 2 , Figure 1 is a schematic top view of a composite sheet 10 according to one embodiment of the present invention, Figure 2 yes Figure 1 A partial cross-sectional schematic diagram of the composite sheet 10 along the section line A-A'. The composite sheet 10 includes a first resin layer 110, a metal layer 120 and a second resin layer 130. The first resin layer 110 includes a first surface 111, a second surface 112 and a plurality of first resin protrusions 113. The second surface 112 is opposite to the first surface 111, and the plurality of first resin protrusions 113 protrude from the second surface 112. The metal layer 120 can reflect visible light. The metal layer 120 includes a third surface 121, a fourth surface 122 and a plurality of metal protrusions 123. The metal layer 120 is fixed to the second surface 112 through the third surface 121, the fourth surface 122 is opposite to the third surface 121, and the plurality of metal protrusions 123 protrude from the fourth surface 122, wherein the plurality of metal protrusions 123 correspond to the plurality of first resin protrusions 113. The second resin layer 130 includes a fifth surface 131, a sixth surface 132 and a plurality of second resin protrusions 133. The second resin layer 130 is removably disposed on the fourth surface 122 via the fifth surface 131 . The sixth surface 132 is opposite to the fifth surface 131 . A plurality of second resin protrusions 133 protrude from the sixth surface 132 , wherein the plurality of second resin protrusions 133 correspond to the plurality of metal protrusions 123 .

[0056] In this embodiment, the second resin layer 130 is made of a transparent material, and the metal layer 120 is made of an opaque material. Figure 1 The fourth surface 122 and the metal protrusion 123 (shown by dotted lines) of the metal layer 120 can be seen from the perspective of FIG. 1 , but the present invention is not limited thereto. In other embodiments, the second resin layer 130 can be made of an opaque material. The second resin layer 130 is used to protect the metal layer 120. For example, during the hot pressing step, the second resin layer 130 can protect the metal layer 120 from contacting with the release member (such as Figure 6 Release piece 50) or hot pressing equipment (refer to Fig. 9 The second resin layer 130 is configured to be removably disposed on the fourth surface 122 of the metal layer 120. In subsequent applications, the second resin layer 130 can be removed according to actual needs, and other protective layers (such as protective films) can be disposed on the metal layer 120 according to actual needs. Figure 7 The third resin layer 140a in.

[0057] In this embodiment, the first resin layer 110 is raised from the first surface 111 to the direction of the second surface 112 (for example, direction Z) to form a first resin protrusion 113, the first surface 111 is correspondingly formed with a first concave space 114, and the unraised portion of the first resin layer 110 is a first resin flat portion 115. The metal layer 120 is raised from the third surface 121 to the fourth surface 122 to form a metal protrusion 123, the third surface 121 is correspondingly formed with a second concave space 124, and the unraised portion of the metal layer 120 is a metal flat portion 125. The second resin layer 130 is raised from the fifth surface 131 to the sixth surface 132 to form a second resin protrusion 133, the fifth surface 131 is correspondingly formed with a third concave space 134, and the unraised portion of the second resin layer 130 is a second resin flat portion 135. The first resin protrusion 113 is correspondingly disposed in the second concave space 124, and the metal protrusion 123 is correspondingly disposed in the third concave space 134.

[0058] The ratio of the thickness t2 of the metal layer 120 to the thickness t1 of the first resin layer 110 may be 0.006 to 0.06, and the ratio of the thickness t3 of the second resin layer 130 to the thickness t1 of the first resin layer 110 may be 0.01 to 0.1. For example, the thickness t1 of the first resin layer 110 may be 0.5 mm to 1.5 mm, the thickness t2 of the metal layer 120 may be 10 μm to 30 μm, and the thickness t3 of the second resin layer 130 may be 15 μm to 50 μm. The breaking elongation of the first resin layer 110 may be 300% to 600%, and the melting point of the first resin layer 110 may be 90° C. to 180° C. The breaking elongation of the second resin layer 130 may be 5% to 200%, and the melting point of the second resin layer 130 may be 130° C. to 260° C. The measurement data of the elongation at break mentioned above can be measured according to the specification of ASTM D412. For example, the material of the first resin layer 110 may include thermoplastic polyurethane (TPU), wherein the thermoplastic polyurethane may be a non-recycled, transparent thermoplastic polyurethane, whose elongation at break is about 500%, whose melting point is about 170°C, and whose thickness t1 is 0.5mm, 0.7mm or 1mm; or, the thermoplastic polyurethane may be a recycled, black thermoplastic polyurethane, whose elongation at break is about 450%, whose melting point is about 120°C, and whose thickness t1 is 0.5mm, 0.7mm or 1mm. The material of the second resin layer 130 may include polyethylene terephthalate (PET), which has an elongation at break of approximately 6%, a melting point of approximately 240°C, and a thickness t3 of 20μm; or, the second resin layer 130 may include oriented polypropylene (OPP), which has an elongation at break of approximately 160%, a melting point of approximately 140°C, and a thickness t3 of 23μm.

[0059] The material of the metal layer 120 may include aluminum, silver, gold, chromium or a combination thereof, so that the metal layer 120 has excellent surface gloss. In addition, the material of the metal layer 120 may selectively include a polymer material to improve its ductility. Figure 1 As shown, the distance D1 between two adjacent metal protrusions 123 may be 0.1 mm to 10 mm. Figure 2As shown, the height H1 of each metal protrusion 123 protruding from the fourth surface 122 may be 0.1 mm to 1 mm. That is, the metal protrusion 123 is a three-dimensional structure observable by the naked eye, which can provide special visual and modeling effects. The aforementioned spacing D1 may be the shortest distance between two adjacent metal protrusions 123. The composite sheet 10 may define a normal direction, which may be parallel to the direction Z. The aforementioned height H1 may be the distance between the top surface (not separately labeled) of the metal flat portion 125 and the vertex P1 of the metal protrusion 123 in the normal direction, such as Figure 2 In other embodiments, the metal protrusions of the composite sheet can be designed to present complex patterns, such as grid patterns, sawtooth patterns, iron plate patterns, water ripples, wood grains, lychee grains, etc., and are not limited to the rivet patterns exemplified in this embodiment.

[0060] The surface gloss (gloss) of each metal protrusion 123 can be greater than 80GU (Gloss Unit). The aforementioned surface gloss measurement data is measured according to the specification of ASTM D523, wherein the measurement system is based on the refractive index of light with a wavelength of 589.3nm on the polished glass surface, and uses a daylight light source simulator and a human eye visual response simulation detector for measurement. The daylight light source simulator can emit incident light and hit the surface of the object to be measured at a predetermined angle (in this embodiment, the object to be measured is, for example, a metal protrusion 123 or a metal flat portion 125), and the human eye visual response simulation detector detects the reflected light of the incident light, and calculates the surface gloss of the object to be measured at the predetermined angle based on the brightness of the incident light and the reflected light. How to calculate the surface gloss based on the brightness of the incident light and the reflected light is a technique well known to technicians in this measurement field and will not be elaborated on here.

[0061] Please refer to Figure 3 , which is Figure 2 An enlarged view of the T1 portion of the metal protrusion 123. A normal direction N1 can be defined at the vertex P1 of the metal protrusion 123. The incident light at a predetermined angle A1 is R11, and the reflected light is R12. The incident light at a predetermined angle A2 is R21, and the reflected light is R22. The incident light at a predetermined angle A3 is R31, and the reflected light is R32. Here, the predetermined angle A1 is 20 degrees, the predetermined angle A2 is 60 degrees, and the predetermined angle A3 is 85 degrees. As mentioned above, the surface glossiness of the vertex P1 of the metal protrusion 123 at 20 degrees, 60 degrees, and 85 degrees can be calculated based on the brightness of the incident light R11, incident light R21, incident light R31 and the reflected light R12, reflected light R22, and reflected light R32, respectively. Please refer to Figure 4 , which is Figure 2The point P2 of the metal flat portion 125 can define a normal direction N2. For the predetermined angles A1, A2, A3, the incident light R11, R21, R31 and the reflected light R12, R22, R32, please refer to Figure 3 As mentioned above, the surface glossiness of the point P2 of the metal flat portion 125 at 20 degrees, 60 degrees and 85 degrees can be calculated based on the brightness of the incident light R11, incident light R21, incident light R31 and the reflected light R12, reflected light R22, reflected light R32. Figure 3 and Figure 4 It is known that when Figure 2 When the vertex P1 of the metal protrusion 123 is magnified, for the incident light R11, the incident light R21, and the incident light R31, the curved surface where the vertex P1 is set is close to the plane, and the vertex P1 can be regarded as a point set on the plane (in practice, when the measurement area is smaller than a circle with a diameter of 2 mm), therefore, the surface glossiness of the vertex P1 is similar to the surface glossiness of the point P2. According to one embodiment of the present invention, the surface glossiness of the vertex P1 and the point P2 at 20 degrees is greater than 300GU, the surface glossiness of the vertex P1 and the point P2 at 60 degrees is greater than 200GU, and the surface glossiness of the vertex P1 and the point P2 at 85 degrees is greater than 80GU.

[0062] <Method for producing composite sheet>

[0063] Please refer to Figure 5, which is a step flow chart of a method 200 for making a composite sheet according to an embodiment of the present invention. The method 200 for making a composite sheet includes steps 210, 220, and 250 to 270, and optionally includes steps 230 and 240. Step 210 is to provide a film stack 20, wherein the film stack 20 includes a first resin layer 110a, a metal layer 120a, and a second resin layer 130a stacked in sequence, the metal layer 120a is removably disposed on the first resin layer 110a, and the second resin layer 130a is removably disposed on the metal layer 120a. Step 220 is to perform a first hot pressing step to heat and pressurize the film stack 20 so that the metal layer 120a is fixed to the first resin layer 110a, and the second resin layer 130a is maintained to be removably disposed on the metal layer 120a. Step 250 is to stack the release member 50 on the film stack 20, wherein a surface 51 of the release member 50 is formed with a plurality of recesses 52, and the surface 51 of the release member 50 faces the metal layer and is away from a surface 122a of the first resin layer 110a. Step 260 is to perform a second hot pressing step, which is to heat and pressurize the release member 50 and the film stack 20, so that the metal layer 120a forms a plurality of metal protrusions 123 corresponding to the plurality of recesses 52, and the first resin layer 110a forms a plurality of first resin protrusions 113 corresponding to the plurality of recesses 52. Step 270 is to remove the release member 50.

[0064] Please also refer to Figure 6 , which is a schematic diagram of the steps of a method 200 for making a composite sheet according to an embodiment of the present invention. First, a film layer stack 20 is provided, and the film layer stack 20 includes a first resin layer 110a, a metal layer 120a, and a second resin layer 130a stacked in sequence, the metal layer 120a is removably disposed on the first resin layer 110a, and the second resin layer 130a is removably disposed on the metal layer 120a. Here, the second resin layer 130a and the metal layer 120a are taken as a composite unit 21, and the first resin layer 110a is taken as an independent film layer as an example, wherein the second resin layer 130a may be a release film, and the metal layer 120a may be releasably attached to the second resin layer 130a to form the composite unit 21. For a more specific example, the metal layer 120a may be a metal diaphragm, and the second resin layer 130a may be a protective layer attached to the metal diaphragm, and the second resin layer 130a may be separated from the metal diaphragm by tearing or peeling. The provided film layer stack 20 is a composite unit 21 stacked on the first resin layer 110a, wherein the composite unit 21 is stacked with the metal layer 120a facing the first resin layer 110a, and at this time, the metal layer 120a and the first resin layer 110a have no fixed relationship such as bonding or attachment.

[0065] Next, the film stack 20 is placed in the hot pressing device 40 for the first hot pressing step, the film stack 20 is heated and pressurized, the metal layer 120a is fixed on the first resin layer 110a, and the second resin layer 130a is maintained to be removably disposed on the metal layer 120a. Specifically, in the first hot pressing step, the first resin layer 110a is softened by the hot pressing, and after the first resin layer 110a is cooled, the metal layer 120a can be fixed on the first resin layer 110a by adhesion. Since the melting point of the second resin layer 130a is higher than the melting point of the first resin layer 110a, the second resin layer 130a is basically not affected in the first hot pressing step, and will not adhere to the metal layer 120a, and can be maintained to be removably disposed on the metal layer 120a. The hot pressing device 40 includes a hot pressing module 41 and a vacuum module 42. The hot pressing module 41 includes a plurality of heating units 41a, and the hot pressing module 41 is used to heat the film stack 20; the vacuum module 42 includes a plurality of gas flow channels 42a, and the vacuum module 42 is used to evacuate the film stack 20. By evacuating the film stack 20 by the vacuum module 42, the hot pressing device 40 can simultaneously apply negative pressure to the film stack 20, and can reduce the melting point of the first resin layer 110a, thereby reducing the energy consumption required during the manufacturing process. The first hot pressing step can be performed under the following conditions: the heating temperature ranges from 80°C to 170°C, the heating time ranges from 30 seconds to 120 seconds, and the pressure range applied by the hot pressing device 40 to the film stack 20 is from 0.8 bar to 1.2 bar.

[0066] Next, the film layer stack 20 is taken out from the hot pressing device 40, and a release piece 50 is stacked on the film layer stack 20, wherein a surface 51 of the release piece 50 is formed with a plurality of recesses 52, and the surface 51 of the release piece 50 is facing the metal layer 120a away from the surface 122a of the first resin layer 110a. Here, the surface 51 of the release piece 50 is arranged on the surface 132a of the second resin layer 130a, that is, the release piece 50 is indirectly arranged on the metal layer 120a through the second resin layer 130a. Next, the release member 50 and the film stack 20 are placed together in the hot pressing device 40 for a second hot pressing step, and the release member 50 and the film stack 20 are heated and pressurized so that the second resin layer 130a forms a plurality of second resin protrusions 133 corresponding to the plurality of recesses 52, the metal layer 120a forms a plurality of metal protrusions 123 corresponding to the plurality of recesses 52, and the first resin layer 110a forms a plurality of first resin protrusions 113 corresponding to the plurality of recesses 52. When the hot pressing device 40 heats and evacuates the film stack 20 and the release member 50, the air between the film stack 20 and the release member 50 can be removed, so that the film stack 20 is compliant with the release member 50 under negative pressure. After the second hot pressing step, the second resin layer 130a becomes the second resin layer 130 having the second resin protrusion 133, the metal layer 120a becomes the metal layer 120 having the metal protrusion 123, and the first resin layer 110a becomes the first resin layer 110 having the first resin protrusion 113, that is, the film stack 20 finally becomes the composite sheet 10. The second hot pressing step can be performed under the following conditions: the heating temperature ranges from 90°C to 180°C, the heating time ranges from 50 seconds to 300 seconds, and the pressure range applied by the hot pressing device 40 to the film stack 20 is from 0.8 bar to 1.2 bar. Through the second hot pressing step, the first resin layer 110a and the second resin layer 130a are softened by heat, so that the three-dimensional pattern of the release member 50 (i.e., the collection presented by the concave portions 52) can be transferred to the film stack 20 to complete the composite sheet 10. Finally, the release member 50 and the composite sheet 10 are taken out of the hot pressing device 40, and the release member 50 is removed to complete the manufacturing process of the composite sheet 10. For details about the composite sheet 10, please refer to the above, which will not be repeated here.

[0067] From the above content, it can be seen that the method of the present invention to form a three-dimensional pattern with a bright luster (i.e., the metal protrusion 123) on the composite sheet 10 is to use heat transfer pressing, which is a dry process: compared with the wet coating process, the dry process does not require the use of organic solvents and / or dispersants, can effectively reduce intermediate products (such as toxic gases) and is beneficial to environmental protection, and can streamline the production process and reduce raw material and environmental safety costs; compared with electroplating, evaporation, and sputtering processes, the present invention does not require the use of highly polluting electrolytic cells and expensive vapor deposition equipment, which is beneficial to reducing industrial waste liquid and reducing production costs.

[0068] Please refer to Figure 5The method 200 for making the composite sheet may optionally include step 230 and step 240. After step 220 (i.e., performing the first hot pressing step), step 230 and step 240 may be performed as required. Step 230 is to remove the second resin layer 130a, and step 240 is to removably set the third resin layer 140a on the metal layer 120a (to replace the second resin layer 130a). At this time, the subsequent step 260 (i.e., performing the second hot pressing step) will also include forming a plurality of third resin protrusions 143 on the third resin layer 140a corresponding to the plurality of concave portions 52.

[0069] Please also refer to Figure 7 , which is a schematic diagram of the steps of a method 200 for making a composite sheet according to another embodiment of the present invention, Figure 7 and Figure 6 The difference is that after the first hot pressing step, the second resin layer 130a is removed, and the third resin layer 140a is removably disposed on the metal layer 120a to form another film stack 20'. Then, a release member 50 is also stacked on the film stack 20', wherein the surface 51 of the release member 50 is disposed on the surface 142a of the third resin layer 140a, that is, the release member 50 is indirectly disposed on the metal layer 120a through the third resin layer 140a.

[0070] Next, the release member 50 and the film stack 20' are placed together in the hot pressing device 40 to perform a second hot pressing step, in which the release member 50 and the film stack 20' are heated and pressurized so that the third resin layer 140a forms a plurality of third resin protrusions 143 corresponding to the plurality of concave portions 52, the metal layer 120a forms a plurality of metal protrusions 123 corresponding to the plurality of concave portions 52, and the first resin layer 110a forms a plurality of first resin protrusions 113 corresponding to the plurality of concave portions 52. In the second hot pressing step, the first resin layer 110a and the third resin layer 140a are softened by heat, so that the three-dimensional pattern of the release member 50 (i.e., the collection of concave portions 52) can be transferred to the film stack 20' to complete the composite sheet 10'. After the second hot pressing step, the third resin layer 140a becomes a third resin layer 140 having a third resin protrusion 143, the metal layer 120a becomes a metal layer 120 having a metal protrusion 123, and the first resin layer 110a becomes a first resin layer 110 having a first resin protrusion 113, that is, the film layer stack 20' finally becomes a composite sheet 10'. The second hot pressing step can also be performed under the following conditions: the heating temperature ranges from 90°C to 180°C, the heating time ranges from 50 seconds to 300 seconds, and the pressure range applied by the hot pressing equipment 40 to the film layer stack 20' is from 0.8 bar to 1.2 bar. Finally, the release member 50 and the composite sheet 10' are taken out of the hot pressing equipment 40, and the release member 50 is removed to complete the production process of the composite sheet 10'.

[0071] As can be seen from the above, the difference between the composite sheet 10' and the composite sheet 10 is that the composite sheet 10' replaces the second resin layer 130 in the composite sheet 10 with the third resin layer 140. The third resin layer 140 includes a seventh surface 141, an eighth surface 142, and a plurality of third resin protrusions 143. The third resin layer 140 is removably disposed on the fourth surface 122 (see FIG. 1 ) through the seventh surface 141. Figure 2 ), the eighth surface 142 is opposite to the seventh surface 141, and a plurality of third resin protrusions 143 protrude from the eighth surface 142, wherein the plurality of third resin protrusions 143 correspond to the plurality of metal protrusions 123. Other details about the composite sheet 10' may be the same as those of the composite sheet 10, and will not be further described herein.

[0072] It is worth mentioning that in this embodiment, the melting point (or softening point) of the third resin layer 140a may be lower than the melting point (or softening point) of the second resin layer 130a and / or the elongation at break (or ductility) of the third resin layer 140a may be better than the elongation at break (ductility) of the second resin layer 130a. Therefore, when performing the second hot pressing step, it is helpful to improve the effect of transferring the three-dimensional pattern (the collection of recesses 52) of the release member 50 to the film layer stack 20', and it is helpful to maintain the surface glossiness of the peripheral area of ​​the metal layer 120a. Specifically, when the third resin layer 140a with a lower melting point (or softening point) or better elongation at break (ductility) is used to cover the metal layer 120a and the second hot pressing step is performed, the third resin layer 140a can completely cover the metal layer 120a in the peripheral area of ​​the film layer stack 20' because it is fully softened and / or fully extended, and can avoid the interlayer misalignment caused by the instantaneous hardness difference under high temperature. In other words, if the second resin layer 130a is misaligned, it will be disadvantageous for the three-dimensional pattern (the collection of recesses 52) of the release member 50 to be transferred to the metal layer 120a and the first resin layer 110a through the second resin layer 130a, and it will be disadvantageous for protecting the metal layer 120a. Therefore, by replacing the second resin layer 130a with the third resin layer 140a before performing the second hot pressing step, it is beneficial to enable the composite sheet 10' to maintain a good three-dimensional pattern transfer effect in the peripheral area, and it is beneficial to maintain the surface gloss of the metal layer 120a in the peripheral area, and maintain the overall consistency of the composite sheet 10'.

[0073] Please refer to Figure 8, which is a flow chart of the steps of a method 300 for making a composite sheet according to another embodiment of the present invention. The method 300 for making a composite sheet includes steps 310 and 320. Step 310 is to provide a film layer stack 30, wherein the film layer stack 30 includes a first resin layer 110, a metal layer 120a, and a second resin layer 130a stacked in sequence, wherein the metal layer 120a is removably disposed on the first resin layer 110, the second resin layer 130a is removably disposed on the metal layer 120a, and a plurality of first resin protrusions 113 are formed on a surface 112 of the first resin layer 110 facing the metal layer 120a. Step 320 is to perform a hot pressing step to heat and pressurize the film layer stack 30, so that the metal layer 120a is fixed to the first resin layer 110, and the second resin layer 130a is maintained to be removably disposed on the metal layer 120a, and the metal layer 120a forms a plurality of metal protrusions 123 corresponding to the plurality of first resin protrusions 113, and the second resin layer 130a forms a plurality of second resin protrusions 133 corresponding to the plurality of first resin protrusions 113.

[0074] Please also refer to Fig. 9 , which is a schematic diagram of the steps of a method 300 for making a composite sheet according to another embodiment of the present invention. First, a film layer stack 30 is provided, wherein the film layer stack 30 includes a first resin layer 110, a metal layer 120a, and a second resin layer 130a stacked in sequence, wherein the metal layer 120a is removably disposed on the first resin layer 110, the second resin layer 130a is removably disposed on the metal layer 120a, and the first resin layer 110 is formed with a plurality of first resin protrusions 113 on a second surface 112 facing the metal layer 120a. Here, the second resin layer 130a and the metal layer 120a are taken as a composite unit 21, and the first resin layer 110 is taken as an independent film layer for example. For the composite unit 21, please refer to the above. The film stack 30 is provided by stacking the composite unit 21 on the first resin layer 110 , wherein the composite unit 21 is stacked with the metal layer 120 a facing the first resin layer 110 , and the metal layer 120 a and the first resin layer 110 are not fixedly bonded or attached to each other.

[0075] Next, the film stack 30 is placed in a hot pressing device 40 for a hot pressing step, where the film stack 30 is heated and pressurized, so that the metal layer 120a is fixed to the first resin layer 110, and the second resin layer 130a is maintained to be removably disposed on the metal layer 120a. The hot pressing device 40 includes a hot pressing module 41 and a vacuum module 42. The hot pressing module 41 includes a plurality of heating units 41a, and the hot pressing module 41 is used to heat the film stack 30; the vacuum module 42 includes a plurality of gas flow channels 42a, and the vacuum module 42 is used to evacuate the film stack 30. When the hot pressing device 40 heats and evacuates the film stack 30, the air between the composite unit 21 and the first resin layer 110 can be removed, so that the composite unit 21 is compliant with the first resin layer 110 under negative pressure. The hot pressing step can be performed under the following conditions: the heating temperature ranges from 80°C to 180°C, the heating time ranges from 30 seconds to 300 seconds, and the pressure applied by the hot pressing device 40 to the film stack 30 ranges from 0.8 bar to 1.2 bar. Through the hot pressing step, the first resin layer 110 is softened by heat, and after the first resin layer 110 is cooled, the metal layer 120a can be fixed on the first resin layer 110 by adhesion, and the metal layer 120a forms a plurality of metal protrusions 123 corresponding to the plurality of first resin protrusions 113. At the same time, the second resin layer 130a is softened by heat, and the second resin layer 130a forms a plurality of second resin protrusions 133 corresponding to the plurality of first resin protrusions 113. After the hot pressing step, the second resin layer 130a becomes the second resin layer 130 having the second resin protrusions 133, and the metal layer 120a becomes the metal layer 120 having the metal protrusions 123, that is, the film stack 30 finally becomes the composite sheet 10. Please refer to the above for details about the composite sheet 10, which will not be repeated here.

[0076] <Compound Structure>

[0077] Please refer to Fig.10 and Fig.11 , Fig.10 is a schematic top view of a composite structure 1 according to another embodiment of the present invention, Fig.11 yes Fig.10 The composite structure 1 is a partial cross-sectional schematic diagram along the section line BB'. The composite structure 1 includes a composite sheet 2 and a base member 3. For example, Figure 1 The composite sheet 10 shown in Figure 7The composite sheet 10' shown in is cut into a desired shape, such as a product logo or a decorative pattern (here illustrated as a hexagon), to form a composite sheet 2. Here, the composite sheet 2 is illustrated as being cut from the composite sheet 10. In other words, the main difference between the composite sheet 2 and the composite sheet 10 is only the shape of the sheet. For other details about the composite sheet 2, please refer to the relevant description of the composite sheet 10. The base member 3 is fixed to the first surface 111 of the first resin layer 110 of the composite sheet 2. For example, the base member 3 can be fixed to the first surface 111 by hot melt adhesive or adhesive, or the base member 3 can also be fixed to the first surface 111 by sewing. In addition, the base member 3 can completely cover the first surface 111, so that the base member 3 can completely carry the composite sheet 2, which is conducive to combining the composite sheet 2 with other items through the base member 3 or becoming a part of the item. The material of the base member 3 may include but is not limited to sandwich mesh, and may also be fiber cloth, woven fabric, non-woven fabric, leather, etc.

[0078] like Fig.11 As shown, the first resin layer 110 of the composite sheet 2 further includes a side surface 116 connected between the first surface 111 and the second surface 112, and the metal layer 120 completely covers the side surface 116. Thus, the composite structure 1 can also provide a bright metallic luster in the peripheral area. Fig.10 In the embodiment, the shape and size of the base member 3 are different from those of the composite sheet 2, but the present invention is not limited thereto. In other embodiments, the shape and size of the base member 3 may be substantially the same as those of the composite sheet 2. For example, the base member 3 may be cut so that the outer periphery (not shown) of the base member 3 is aligned with the outer periphery (not separately numbered) of the composite sheet 2 to facilitate combination with other items.

[0079] <Surface glossiness of examples and comparative examples>

[0080] Please refer to Table 1, which is the measurement results of the surface gloss of multiple embodiments and comparative examples of the present invention. In Example 1, the film stack includes a first resin layer 110, a metal layer 120 and a second resin layer 130, the material of the first resin layer 110 is TPU, the metal layer 120 is an aluminum film, and the material of the second resin layer 130 is transparent PET; after the film stack 20 undergoes the first hot pressing step, the second resin layer 130 is still disposed on the metal layer, and the surface gloss of the film stack 20 as a whole is measured from the surface of the second resin layer 130 at 20 degrees, 60 degrees and 85 degrees according to the specification of ASTM D523. In other words, Example 1 is equivalent to a semi-finished product after the steps 210 and 220 in the method 200 for making a composite sheet. Please refer to the above for the specification of ASTMD523. The difference between Example 2 and Example 1 is that: in Example 2, after the film stack undergoes the first heat pressing step, the second resin layer 130 is removed, and then the surface glossiness of the film stack as a whole (at this time, only the metal layer 120 and the first resin layer 110 are left) at 20 degrees, 60 degrees, and 85 degrees is measured from the surface of the metal layer 120. The difference between Example 3 and Example 1 is that: the material of the second resin layer 130 in the film stack is changed from transparent PET to transparent OPP; after the film stack undergoes the first heat pressing step, the surface glossiness of the film stack as a whole at 20 degrees, 60 degrees, and 85 degrees is measured from the surface of the second resin layer 130 in accordance with the specification of ASTM D523, while the second resin layer 130 is still disposed on the metal layer 120. The difference between Example 4 and Example 3 is that in Example 4, the second resin layer 130 is removed after the first hot pressing step of the aforementioned film stack, and then the surface gloss of the entire film stack (at this time, only the metal layer 120 and the first resin layer 110 are left) at 20 degrees, 60 degrees and 85 degrees is measured from the surface of the metal layer 120. The difference between Comparative Example 1 and Example 2 is that in Comparative Example 1, the second resin layer 130 is removed before the first hot pressing step is performed. The difference between Comparative Example 2 and Example 4 is that in Comparative Example 2, the second resin layer 130 is removed before the first hot pressing step is performed.

[0081]

[0082] By comparing the measurement results of Example 1 and Example 2, or comparing the measurement results of Example 3 and Example 4, it can be seen that the transparent second resin layer 130 is provided on the metal layer 120, which has little effect on the surface gloss of the entire film layer stack. It can be seen from Example 2 and Comparative Example 1 that if the second resin layer 130 is used to protect the metal layer during the first hot pressing step, the surface gloss will not be drastically attenuated due to pressure and heating. Similarly, it can be seen from Example 4 and Comparative Example 2 that if the second resin layer 130 is also used to protect the metal layer during the first hot pressing step, the surface gloss will not be drastically attenuated due to pressure and heating. In other words, when the hot pressing step is performed, the second resin layer 130 can protect the metal layer 120, reduce the impact of pressure and heating, and help maintain the gloss effect of the metal layer 120.

[0083] Compared to the prior art, the manufacturing method of the composite sheet of the present invention is that the second resin layer 130 is removably disposed on the metal layer 130. During the hot pressing step, the second resin layer 130 can protect the metal layer 120, which is beneficial to maintaining the surface gloss of the metal layer 120, so that the composite sheet and the composite structure can provide brighter visual and styling effects.

[0084] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made within the scope defined by the claims of the present invention should fall within the protection scope of the present invention.

Claims

1. A composite sheet, characterized in that: include: a first resin layer, comprising: a first surface; a second surface, opposite to the first surface; and a plurality of first resin protrusions protruding from the second surface; A metal layer capable of reflecting visible light, the metal layer comprising: a third surface, the metal layer being fixed to the second surface via the third surface; a fourth surface, opposite to the third surface; and a plurality of metal protrusions protruding from the fourth surface, the plurality of metal protrusions corresponding to the plurality of first resin protrusions; and a second resin layer, comprising: a fifth surface, wherein the second resin layer is removably disposed on the fourth surface through the fifth surface; a sixth surface, opposite to the fifth surface; and A plurality of second resin protrusions protrude from the sixth surface, and the plurality of second resin protrusions correspond to the plurality of metal protrusions.

2. The composite sheet according to claim 1, characterized in that: The surface glossiness of each of the metal protrusions is greater than 80GU.

3. The composite sheet according to claim 1, characterized in that: The material of the metal layer includes aluminum, silver, gold, chromium or a combination thereof.

4. The composite sheet according to claim 1, characterized in that: The elongation at break of the first resin layer is 300% to 600%, the melting point of the first resin layer is 90°C to 180°C, the elongation at break of the second resin layer is 5% to 200%, and the melting point of the second resin layer is 130°C to 260°C.

5. The composite sheet according to claim 1, characterized in that: The material of the first resin layer includes thermoplastic polyurethane, and the material of the second resin layer includes polyethylene terephthalate.

6. The composite sheet according to claim 1, characterized in that: The material of the first resin layer includes thermoplastic polyurethane, and the material of the second resin layer includes oriented stretched polypropylene.

7. The composite sheet according to claim 1, characterized in that: The distance between two adjacent metal protrusions is 0.1 mm to 10 mm, and the height of each metal protrusion protruding from the fourth surface is 0.1 mm to 1 mm.

8. A method for making a composite sheet, characterized in that: include: Providing a film layer stack, the film layer stack comprising a first resin layer, a metal layer and a second resin layer stacked in sequence, the metal layer being removably disposed on the first resin layer, and the second resin layer being removably disposed on the metal layer; Performing a first heat-pressing step to heat and pressurize the film layer stack so that the metal layer is fixed to the first resin layer and the second resin layer is kept removably disposed on the metal layer; A release member is stacked on the film layer stack, a surface of the release member is formed with a plurality of recesses, and the surface of the release member faces a surface of the metal layer away from the first resin layer; Performing a second hot pressing step to heat and pressurize the release member and the film layer stack, so that the metal layer forms a plurality of metal protrusions corresponding to the plurality of concave portions, and the first resin layer forms a plurality of first resin protrusions corresponding to the plurality of concave portions; as well as The release piece is removed.

9. The method for making a composite sheet according to claim 8, characterized in that: The second heat pressing step further includes forming a plurality of second resin protrusions on the second resin layer corresponding to the plurality of concave portions.

10. The method for making a composite sheet according to claim 8, characterized in that: Also includes: After performing the first hot pressing step, the second resin layer is removed, and a third resin layer is removably disposed on the metal layer. The second hot pressing step also includes forming a plurality of third resin protrusions on the third resin layer corresponding to the plurality of concave portions.

11. A method for making a composite sheet, characterized in that: include: A film layer stack is provided, the film layer stack comprising a first resin layer, a metal layer and a second resin layer stacked in sequence, the metal layer is removably disposed on the first resin layer, the second resin layer is removably disposed on the metal layer, and a plurality of first resin protrusions are formed on a surface of the first resin layer facing the metal layer; as well as A heat pressing step is performed to heat and pressurize the film layer stack, so that the metal layer is fixed to the first resin layer, and the second resin layer is maintained removably disposed on the metal layer, and the metal layer forms a plurality of metal protrusions corresponding to the plurality of first resin protrusions, and the second resin layer forms a plurality of second resin protrusions corresponding to the plurality of first resin protrusions.

12. A composite structure, characterized in that: It comprises the composite sheet material as claimed in any one of claims 1 to 7; and a base member fixed to the first surface.

13. The composite structure according to claim 12, characterized in that The first resin layer also includes a side surface connected between the first surface and the second surface, and the metal layer completely covers the side surface.

14. The composite structure according to claim 12, characterized in that The material of the base member includes sandwich mesh.

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