Shell preparation method, shell prepared by method and electronic equipment

Abstract

The invention relates to the technical field of electronic equipment, and particularly discloses a preparation method of a shell, the shell prepared by the method and electronic equipment. According to the shell disclosed by the invention, an adhesive layer is arranged between a thermosetting structural layer (prepreg) and a decorative layer group, and meanwhile, a membrane material carrier and a hardened layer are sequentially arranged on one side, far away from the adhesive layer, of the decorative layer group. By arranging the adhesive layer, a large-height and high-inclination crater model can be smoothly attached and formed, and meanwhile the thermosetting structural layer and the decorative layer set are assisted to be stably bonded. According to the shell, the membrane material carrier and the hardened layer are added, and the hardened layer is arranged on the outer side of the membrane material carrier, so that the hardness and the wear resistance of the shell subjected to hot press molding are greatly improved, and the shell with the large-fall crater can be molded and has relatively high hardness at the same time.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electronic equipment, in particular to a shell manufacturing method, a shell manufactured by the method and an electronic device. BACKGROUND

[0002] With the development of 5G communication technology, in order to meet the requirements of barrier-free transmission of high-frequency signals, the backboard material of intelligent terminals is evolving towards non-metalization. Among them, fiber (glass fiber, alumina fiber, etc.) composite materials have become a new type of mobile phone backboard solution favored due to their lightweight, high strength, excellent drop resistance and no signal shielding.

[0003] At present, a typical manufacturing process of this type of fiber backboard is to combine the decorative layer with the semi-cured sheet (Prepreg) as the base in advance, and then perform one-piece hot pressing molding. The fundamental defect of this scheme is that during the hot pressing process, the resin in the semi-cured sheet will undergo a melting flow stage, and this flow will directly impact and damage the decorative layer on it, resulting in pattern blurring and texture failure, thereby causing low appearance yield of the finished product.

[0004] To solve the above problems, the industry adds a layer of fiber (glass fiber, alumina fiber, etc.) thermoplastic material as a separation layer between the decorative layer and the semi-cured sheet. This separation layer can effectively block the flow of molten resin during hot pressing, thereby protecting the decorative layer. However, this scheme introduces new technical challenges: the fiber (glass fiber, alumina fiber, etc.) thermoplastic material used as a separation layer generally has poor ductility. Therefore, when it is necessary to form a backboard containing a three-dimensional complex structure with large depth and large slope (such as the "crater" shape of the camera module area), this scheme cannot be used due to insufficient material tensile deformation capability.

[0005] In order to overcome the problem of insufficient ductility, the industry has turned to another scheme for the molding of complex structures: using an epoxy resin with better ductility as an adhesive layer instead of a thermoplastic layer, and using a PET, PPS, etc. release film as a temporary carrier for hot pressing. In this process, the PET, PPS, etc. release film is only used as a disposable auxiliary mold and is peeled off after molding and does not synchronize with the final backboard structure. Although this method meets the molding requirements of complex structures, the overall hardness of the shell after molding is low and cannot meet the use requirements of some products for high hardness.

[0006] The existing technology is in a technical dilemma when manufacturing glass fiber composite backboards with complex three-dimensional structures and exquisite appearances: the thermoplastic separation layer scheme aimed at protecting the decorative layer sacrifices the molding capability of complex structures, and the epoxy resin scheme capable of molding complex structures sacrifices the structural hardness of the final product.

[0007] Therefore, the prior art remains to be improved and developed. SUMMARY

[0008] The application discloses a shell manufacturing method, a shell manufactured by the method, and an electronic device. In view of the defects in the prior art, the technical scheme is provided to introduce a film material carrier into the shell and set a hardening layer on the outer side of the film material carrier, so as to be especially suitable for the production process of a mobile phone backboard with high fall / steep crater and hardness requirement.

[0009] To achieve the above-mentioned purpose, the application adopts the following technical scheme: A shell comprises the following layers which are sequentially laminated and integrally formed by hot pressing from the outside to the inside: a hardening layer; a film material carrier, the hardening layer being arranged on the outer surface of the film material carrier; a decorative layer group arranged on the inner surface of the film material carrier; an adhesive layer arranged on the inner surface of the decorative layer group; and a thermosetting structural layer arranged on the inner surface of the adhesive layer.

[0010] Preferably, the decorative layer group comprises: a functional coating layer arranged on the inner surface of the film material carrier; and a color layer arranged on the inner surface of the functional coating layer.

[0011] Preferably, the decorative layer group further comprises a light-shielding layer arranged between the color layer and the adhesive layer.

[0012] Preferably, the decorative layer group further comprises a plating layer arranged between the functional coating layer and the color layer.

[0013] Preferably, the hardening layer is a UV-cured coating layer with a hardness ranging from 2H to 6H.

[0014] Preferably, the material of the hardening layer is polyurethane acrylate, and the thickness thereof ranges from 3µm to 30µm.

[0015] Preferably, the material of the film material carrier is one of polyethylene terephthalate (PET), polycarbonate (PC), polyolefin (PO), polyurethane (PUR), polyphenylene sulfide (PPS), etc., and the thickness thereof ranges from 0.05mm to 0.8mm.

[0016] Preferably, the material of the adhesive layer is epoxy resin or polyurethane acrylate, and the thickness thereof ranges from 5µm to 15µm.

[0017] Preferably, the thermosetting structural layer is composed of at least one glass fiber prepreg.

[0018] Preferably, the coating layer is a metal or non-metal film layer formed by physical vapor deposition or vacuum coating process, and the material is at least one selected from the group consisting of In / Sn, TiO2, NbO, NbO2, Nb2O3, Nb2O5, SiO2, ZrO2.

[0019] The application further discloses a preparation method of the shell, comprising the following steps: providing a film material carrier, and sequentially forming a decorative layer group and an adhesive layer on the inner surface of the film material carrier; forming a hardening layer on the outer surface of the film material carrier; stacking a thermosetting structural layer on the inner surface of the adhesive layer to form a laminated body; and performing hot-pressing treatment on the laminated body, so that the thermosetting structural layer, the adhesive layer and the decorative layer group are cured and integrated with the film material carrier and the hardening layer to form the shell.

[0020] Preferably, the step of forming the decorative layer group comprises sequentially forming a functional coating layer and a color layer on the inner surface of the film material carrier.

[0021] The application further discloses an electronic device, characterized in that comprising: a shell, wherein the shell is the shell as described above or the shell prepared by the method as described above; and at least one electronic component arranged in the space defined by the shell.

[0022] Compared with the prior art, the application has the following advantages: The shell disclosed by the application is provided with an adhesive layer between the thermosetting structural layer (prepreg) and the decorative layer group, and is sequentially provided with a film material carrier and a hardening layer on the side of the decorative layer group away from the adhesive layer. By arranging the adhesive layer, the shell with large height and large slope can be successfully hot-pressed and formed, and the bonding between the thermosetting structural layer and the decorative layer group is stable. By arranging the film material carrier and the hardening layer, and arranging the hardening layer on the outer side of the film material carrier, the hardness and wear resistance of the shell after hot-pressing are greatly increased, so that the shell with large drop-off craters can be formed and has high hardness.

[0023] This invention also discloses a method for preparing a shell, which includes sequentially forming a decorative layer, an adhesive layer, and a thermosetting structural layer on the inner surface of a membrane carrier, and forming a hardening layer on the outer surface of the membrane carrier. While ensuring that the high-height, high-angle crater shape can be successfully hot-pressed, the cooperation between the membrane carrier and the hardening layer greatly increases the hardness and wear resistance of the hot-pressed shell, thus enabling the shell with a large-diameter crater to possess high hardness while being able to be formed.

[0024] Furthermore, the present invention also discloses an electronic device that includes the aforementioned housing and possesses all the advantages of the aforementioned housing. Attached Figure Description

[0025] Figure 1 A schematic diagram of the multi-layer structure of the housing provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of a multi-layer structure of another housing provided in one embodiment of the present invention; Figure 3 A schematic diagram of a multi-layer structure of another housing provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the multi-layer structure of the shell during production according to an embodiment of the present invention; Figure 5 This is a schematic flowchart of a method for preparing a shell according to an embodiment of the present invention; Figure 6 This is a schematic flowchart of another shell preparation method provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of an electronic device provided in an embodiment of the present invention.

[0026] Explanation of key component symbols: 10-Housing; 100-Hardened layer; 200-Membrane carrier; 300-Decorative layer assembly; 310-Functional coating; 320-Color layer; 330-Light-shielding layer; 340-Coating layer; 400-Adhesive layer; 500-Thermosetting structural layer; 600-Hot-press protective film; 700-Hot-press release film; 20-Electronic component. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] In this invention, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing the invention and its embodiments, and are not intended to limit the indicated devices, elements, or components to having a specific orientation, or to be constructed and operated in a specific orientation.

[0029] Furthermore, in addition to indicating direction or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in certain situations to indicate a dependency or connection. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0030] Furthermore, the terms "installation," "setup," "equipped with," "connection," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0031] Furthermore, the terms "first," "second," etc., are primarily used to distinguish different devices, elements, or components (which may be the same or different in specific type and construction), and are not intended to indicate or imply the relative importance or quantity of the indicated devices, elements, or components. Unless otherwise stated, "a plurality of" means two or more.

[0032] The technical solution of the present invention will be further described below with reference to the embodiments and accompanying drawings.

[0033] Example This invention discloses a housing, its manufacturing method, and an electronic device. The housing incorporates an adhesive layer that softens but does not flow during the hot-pressing and curing process of a thermosetting material. Simultaneously, a film carrier and a hardening layer are introduced on the outer surface of the decorative layer assembly. The adhesive layer effectively isolates and protects the complex and process-sensitive decorative layer assembly, while allowing the material to perfectly adhere to the mold, enabling the formation of a large-drop crater. Furthermore, the introduced film carrier and hardening layer allow the hot-pressed housing to possess both higher hardness and wear resistance, making it suitable for use in mobile phone back panels requiring high hardness and wear resistance.

[0034] In one embodiment of the present invention, reference is made to... Figure 1The specific structure of the shell 10 may include a membrane carrier 200, a hardened layer 100 disposed on the outer surface of the membrane carrier 200, a decorative layer group 300 disposed sequentially on the inner surface of the membrane carrier 200, an adhesive layer 400, and a thermosetting structural layer 500. By providing the membrane carrier 200 and the hardened layer 100, the shell 10 possesses higher hardness and wear resistance after hot pressing. Simultaneously, the adhesive layer 400 softens to a rubbery state during hot pressing and adheres tightly to the large-drop crater of the mold, thus enabling the shell 10 with the large-drop crater to be successfully formed. Therefore, the shell 10 combines the large-drop crater with higher hardness, making it suitable for more demanding applications.

[0035] Furthermore, the adhesive layer 400 not only makes the bond between the decorative layer assembly 300 and the thermosetting structural layer 500 more stable, but also separates the decorative layer assembly 300 and the thermosetting structural layer 500 during the hot pressing process, thereby protecting the decorative layer assembly 300 during the hot pressing process and preventing the decorative layer assembly 300 from pasting.

[0036] In one specific embodiment, the thermosetting structural layer 500 is the main load-bearing component of the housing 10, providing the necessary mechanical strength, rigidity, and impact resistance for the entire housing 10. This thermosetting structural layer 500 can be composed of at least one layer of fiber (glass fiber or alumina fiber, etc.) prepreg (also known as a prepreg). The fiber (glass fiber or alumina fiber, etc.) prepreg is a composite material sheet pre-bonded with a thermosetting resin (e.g., epoxy resin) before curing. By selecting prepregs of different thicknesses and numbers of layers for lamination, the final thickness and strength of the housing 10 can be flexibly adjusted to meet the structural performance requirements of different electronic devices.

[0037] Preferably, in one embodiment of the present invention, multiple layers of glass fiber thermosetting prepregs of different specifications, such as 0.065mm, 0.11mm, or 0.13mm, can be laminated to achieve a predetermined thickness of the final molded shell 10 within the range of 0.30mm to 1.0mm. In the subsequent hot pressing process, the thermosetting resin in the prepreg undergoes a cross-linking and curing reaction, forming a robust and stable three-dimensional network structure, giving the shell 10 excellent physical properties.

[0038] Specifically, in one application of the present invention, the adhesive layer 400 is an epoxy resin material. By controlling the Tg of the epoxy resin material, that is, by controlling the glass transition temperature of the epoxy resin, the epoxy resin adhesive layer 400 softens to a rubber state during hot pressing. At this time, the epoxy resin of the adhesive layer 400 is soft and retains its shape.

[0039] In this state, the rubber-like epoxy resin adhesive layer 400 will deform during hot pressing and perfectly adhere to the bending edge of the high-height, high-angle crater, thus allowing the decorative layer assembly 300 and the thermosetting structural layer 500 to be smoothly bonded together with excellent molding results. Simultaneously, the epoxy resin adhesive layer 400 not only ensures a strong bond between the decorative layer assembly 300 and the thermosetting structural layer 500, but also prevents the decorative layer assembly 300 from becoming pasty due to the molten thermosetting structural layer 500 during hot pressing.

[0040] Specifically, the epoxy resin adhesive layer 400 can remain in a rubber state during the hot-pressing curing process of the thermosetting structural layer 500 (e.g., at a temperature of 130-200°C and a pressure of 10-100 Bar), without melting or degradation, thus providing effective isolation and protection.

[0041] The decorative layer assembly 300 of the housing 10 has a rich aesthetic effect and is disposed on the side of the adhesive layer 400 away from the thermosetting structural layer 500. Referring to Figure 2, the decorative layer assembly 300 itself is also a multi-layer structure and may include a functional coating 310 and a color layer 320.

[0042] In one embodiment of the present invention, a functional coating 310 is disposed on the inner surface of the membrane carrier 200. This coating is typically a UV-cured coating, primarily used to provide the housing 10 with hardness, texture, and abrasion resistance. Its material can be polyurethane acrylate, formed via a UV transfer process.

[0043] In another embodiment of the invention, after coating with liquid UV adhesive (polyurethane acrylate), the mixture can be pressed using a mold with fine texture, and then cured by irradiation with a high-energy LED lamp or mercury lamp. After curing, the UV adhesive replicates the texture of the mold, forming a textured layer with effects such as grating, brushed finish, matte finish, or holographic effect.

[0044] Preferably, in one embodiment of the present invention, the thickness of the functional coating 310 is typically in the range of 3µm to 30µm to obtain excellent texture effects. This allows the functional coating 310 to possess both superior texture and lower brittleness with higher hardness, resulting in better performance.

[0045] In one embodiment of the present invention, the color layer 320 is disposed on the inner surface of the functional coating 310 and is the main source of the appearance color of the housing 10. The color layer 320 can be formed by printing a first color ink, and its material may include polyurethane, polyester resin, etc.

[0046] Furthermore, in one embodiment of the present invention, a second or more colors of ink can be printed again on the first color ink layer to form a complex pattern effect with multiple colors and overlapping colors.

[0047] Furthermore, in one embodiment of the present invention, to ensure that the color layer 320 presents a pure and uniform color and to shield the electronic components inside the housing 10, the decorative layer assembly 300 may further include a light-shielding layer 330. This light-shielding layer 330 is disposed between the adhesive layer 400 and the color layer 320, and its light transmittance is no more than 1%, effectively preventing light penetration and avoiding interference from the internal structure on the appearance. The material of the light-shielding layer 330 may include at least one of black ink, white ink, and pearlescent ink. For example, black or white ink can be uniformly coated on the surface of the color layer 320 by screen printing or other methods, and then cured by baking.

[0048] In one embodiment of the present invention, multiple printing and baking processes can be performed to achieve the desired light-shielding effect. The thickness of the light-shielding layer 330 is typically controlled between 6µm and 30µm.

[0049] Furthermore, in one embodiment of the present invention, referring to Figure 3 To enhance the decorative effect of the decorative layer assembly 300, it may further include a coating layer 340. This coating layer 340 is disposed between the functional coating layer 310 and the color layer 320. The microstructure of the coating layer 340, combined with the microtexture of the functional coating layer 310, produces a dazzling metallic luster or gradient color effect through light interference, diffraction, and reflection. This coating layer 340 can be formed using processes such as physical vapor deposition (PVD) or vacuum deposition (e.g., vacuum non-conductive coating process NVCM).

[0050] In one embodiment of the present invention, the material of the coating layer 340 can be a metallic or non-metallic film layer, such as at least one or more combinations of In / Sn (indium tin alloy, exhibiting a silver effect), TiO2, NbO, NbO2, Nb2O3, Nb2O5, SiO2, and ZrO2. By precisely controlling the thickness and stacking order of different material films, various color effects such as blue, purple, and gold can be achieved.

[0051] Furthermore, in one embodiment of the present invention, the thickness of the coating layer 340 is very thin, typically ranging from 5 nm to 350 nm.

[0052] In some embodiments where surface hardness and scratch resistance are required to be higher, the housing 10 may further include a hardened layer 100 disposed outside the functional coating 310, and a membrane carrier 200 disposed between the functional coating 310 and the hardened layer 100.

[0053] In one embodiment of the present invention, the function of the membrane carrier 200 is to provide a molding carrier for the decorative layer group 300 and the adhesive layer 400, based on the requirement that the thermosetting structural layer 500 needs to be stacked layer by layer. That is, the decorative layer, adhesive layer 400 and hardening layer 100 are formed on the membrane carrier 200 in a predetermined order. The membrane carrier 200 can be made of materials such as polyethylene terephthalate (PET), polycarbonate (PC), polyolefin (PO), polyurethane (PUR), and polyphenylene sulfide (PPS), and the thickness of the membrane carrier 200 can be from 0.05 mm to 0.8 mm.

[0054] The hardened layer 100 is a protective layer for the housing 10, with a hardness typically ranging from 2H to 6H, effectively resisting scratches and wear during daily use. This coating can also be formed using a UV transfer process, and its material is typically a polyurethane acrylate that combines hardness and toughness.

[0055] In one embodiment of the present invention, the thickness of the hardened layer 100 can range from 3µm to 30µm, providing sufficient protection while also allowing the creation of an outer texture effect on this layer.

[0056] This embodiment provides a method for preparing the shell 10 described above, referring to... Figures 5-6 This method involves sequentially forming a decorative layer assembly 300 on the inner surface of a membrane carrier 200, then forming an adhesive layer 400 on the inner surface of the decorative layer assembly 300, followed by forming a hardening layer 100 on the outer surface of the membrane carrier 200. Finally, a thermosetting structural layer 500 is layered onto the inner surface of the adhesive layer 400 and hot-pressed to obtain a shell 10. In this invention, by introducing the membrane carrier 200 and the hardening layer 100 into the shell 10, the shell 10 achieves higher hardness after molding. By separating the decorative layer assembly 300 and the thermosetting structural layer 500 with the adhesive layer 400, the yield rate of product manufacturing is significantly improved while achieving a large-drop volcano effect. This preparation method includes the following steps: First, a membrane carrier 200 is provided. This membrane carrier 200 serves as the base for all subsequent decorative layer assemblies 300. As mentioned earlier, the membrane carrier 200 can be made of materials such as polyethylene terephthalate (PET), polycarbonate (PC), polyolefin (PO), polyurethane (PUR), and polyphenylene sulfide (PPS), and the thickness of the membrane carrier 200 can be from 0.05 mm to 0.8 mm.

[0057] Next, a decorative layer assembly 300 is formed on the inner surface of the membrane carrier 200, and an adhesive layer 400 is formed on the inner surface of the decorative layer assembly 300. Then, a hardening layer 100 is formed on the outer surface of the membrane carrier 200. A thermosetting structural layer 500 is then laminated to the side of the adhesive layer 400 away from the decorative layer assembly 300 to form a laminated structure. After obtaining the laminated structure, it is subjected to hot pressing to cure the thermosetting structural layer 500, thereby obtaining the shell 10.

[0058] In one embodiment of the present invention, the process of forming the decorative layer group 300 is multi-step, and may specifically include: Forming functional coating 310: On the inner surface of the film carrier 200, a UV adhesive with polyurethane acrylate as the transfer component is transferred, and the desired UV texture is obtained by means of mold replication, etc., and then UV cured by LED lamp or mercury lamp to form functional coating 310.

[0059] Specifically, in one embodiment of the present invention, the thickness of the functional coating 310 is 3µm to 30µm. This allows the functional coating 310 to achieve better performance by having both good UV texture effects and low brittleness and high hardness.

[0060] In one embodiment of the present invention, the UV curing energy needs to be precisely controlled so that the functional coating 310 is partially cured and has strong adhesion, while the functional coating 310 remains flexible, clear and does not yellow, and has low internal stress.

[0061] Preferably, in one embodiment of the present invention, the UV curing energy is typically controlled at 300 mJ / cm². 2 Up to 3000mj / cm 2 between.

[0062] Specifically, in one embodiment of the present invention, the UV curing energy can be 1000 mJ / cm. 2 It can reach 1500mj / cm 2 It can reach 2000mj / cm 2 It can reach 2300mj / cm 2 The specific UV curing capability needs to be selected based on the thickness of the functional coating 310.

[0063] Forming the coating layer 340: The film carrier 200 with the functional coating 310 transferred is placed in a PVD or vacuum coating equipment, and one or more metal or non-metal films are deposited on the side of the functional coating 310 away from the film carrier 200 to form a coating layer 340 with a thickness of 5nm to 350nm.

[0064] In one embodiment of the present invention, the material of the coating layer 340 can be a metal or non-metal film layer, such as at least one or a combination of In / Sn (indium tin alloy, which presents a silver effect), TiO2, NbO, NbO2, Nb2O3, Nb2O5, SiO2, and ZrO2.

[0065] Preferably, in one embodiment of the present invention, the coating layer 340 may include a plurality of stacked coating sublayers, that is, multiple of the aforementioned materials may be coated on one side of the film carrier 200 to form a plurality of stacked coating sublayers, thereby forming the coating layer 340.

[0066] Specifically, in one embodiment of the present invention, by precisely controlling the thickness and stacking order of different material films, various color effects such as blue, purple, and gold can be achieved.

[0067] Forming color layer 320: A first color ink of polyurethane or polyester resin is applied to the inner surface of the coating layer 340 by means of screen printing or offset printing, and then baked and cured.

[0068] In one embodiment of the present invention, the position of the first color ink can be controlled by using a film or other means in a screen printing or offset printing device, forming a color layer 320 on part or all of the surface of the functional coating 310. When the color layer 320 is only disposed on part of the surface of the functional coating 310, the formed color layer 320 has a hollowed-out area, thereby forming a specific pattern or reserving a position for a logo.

[0069] Furthermore, in one embodiment of the present invention, a second color ink can be printed on the inner surface of the functional coating 310, and the printed first color ink can be covered to form other color layers 320 on a portion of the surface of the color layer 320.

[0070] Specifically, the first color ink can be printed on the side of the functional coating 310 away from the film carrier 200, and then cured by baking. After the first color ink is cured, the second color ink is printed again to form a color layer 320 on part of the surface of the functional coating 310, thereby creating a richer visual effect.

[0071] Of course, in one embodiment of the present invention, the shape of the hollowed-out area in the formed color layer 320 is not particularly limited, and can be numbers, letters, patterns, etc.

[0072] Furthermore, in one embodiment of the present invention, for some complex color patterns, the color layer 320 may have more layers.

[0073] Furthermore, in one embodiment of the present invention, in the method for forming the color layer 320 described above, when printing to form the color layer 320, the mesh count of the screen can be 200-420 mesh, the baking temperature after printing can be 60-80℃, and the baking time can be 20-60min. The baking temperature and time are determined by the thickness of the color layer 320.

[0074] Specifically, in one embodiment of the present invention, the thickness of the formed color layer 320 can be 5-15 μm.

[0075] Furthermore, in order to achieve a better decorative effect for the housing 10, in one embodiment of the present invention, the step of forming the decorative layer group 300 may further include: Forming a light-shielding layer 330: Black, white, or pearlescent inks are applied to the inner surface of the color layer 320 by screen printing, and then baked and cured to form a light-shielding layer 330 with a thickness of 6µm to 30µm, and the light transmittance of the light-shielding layer 330 is not greater than 1%.

[0076] Specifically, in one embodiment of the present invention, the printing and coating of the light-shielding layer 330 can be repeated multiple times to further prevent light leakage from the cover layer.

[0077] After the decorative layer assembly 300 is formed on the membrane carrier 200, an adhesive layer 400 is formed on the inner surface of the decorative layer assembly 300 (i.e., the inner surface of the light-shielding layer 330): an adhesive layer is printed on the inner surface of the light-shielding layer 330 and baked to form an adhesive layer 400 with a thickness of 6µm to 15µm, so that the large drop crater can be formed smoothly, and at the same time, the decorative layer assembly 300 is protected during the hot pressing process.

[0078] Specifically, the UV adhesive of the adhesive layer 400 may include one of the following materials: epoxy resin and polyurethane acrylate.

[0079] Specifically, the thickness of the adhesive layer 400 can be between 5µm and 15µm.

[0080] Specifically, in one embodiment of the present invention, when printing to form the adhesive layer 400, the mesh count of the screen can be 200-420 mesh, the baking temperature after printing can be 60-80℃, and the baking time can be 20-60 min, wherein the baking temperature and time are determined by the thickness of the adhesive layer 400.

[0081] Forming the hardened layer 100: UV adhesive is transferred onto the outer surface of the membrane carrier 200 to obtain the desired UV texture, and then UV cured by LED lamp or mercury lamp to form the hardened layer 100.

[0082] Specifically, in one embodiment of the present invention, the hardened layer 100 may include materials such as polyurethane acrylate.

[0083] Specifically, in one embodiment of the present invention, the hardened layer 100 has a thickness of 3µm to 30µm and a hardness of 2H to 6H. This allows the hardened layer 100 to have better UV texture effects while also having lower brittleness, higher hardness, and better performance (wear resistance).

[0084] In one embodiment of the present invention, the UV curing energy needs to be precisely controlled so that the hardened layer 100 is partially cured and has strong bonding, while the hardened layer 100 maintains the film's flexibility, clarity, and non-yellowing, and has low internal stress.

[0085] Preferably, in one embodiment of the present invention, the UV curing energy is typically controlled at 300 mJ / cm². 2 Up to 3000mj / cm 2 between.

[0086] Specifically, in one embodiment of the present invention, the UV curing energy can be 1000 mJ / cm. 2 It can reach 1500mj / cm 2 It can reach 2000mj / cm 2 It can reach 2300mj / cm 2 The specific UV curing capability needs to be selected based on the thickness of the hardened layer 100.

[0087] More specifically, in one embodiment of the present invention, the functional coating 310 is an inner UV transfer layer, and the hardening layer 100 is an outer UV transfer layer. The inner UV transfer layer may or may not have a textured pattern. The UV texture of the outer UV transfer layer and the UV texture of the inner UV transfer layer may be the same or different.

[0088] This allows the formed logo and other patterns to have a dazzling metallic luster effect that differs from other parts of the casing 10. Specifically, the desired texture patterns for the outer and inner UV transfer layers can be formed by adjusting the texture patterns during the transfer process.

[0089] After a hardening layer 100 is formed on the membrane carrier 200, one or more thermosetting structural layers 500 (such as prepreg) are stacked on the inner surface of the adhesive layer 400 to form a laminated structure.

[0090] Specifically, in one embodiment of the present invention, prepreg sheets of different thicknesses, such as 0.065mm, 0.11mm, and 0.13mm, can be stacked to achieve the required finished product thickness of 0.30mm to 1.0mm. Reference Figure 4In one embodiment of the present invention, a hot-press release film 700 may be placed on the outermost side of the thermosetting structural layer 500 to prevent it from sticking to the mold during the hot pressing process.

[0091] Reference Figure 4 In one embodiment of the present invention, a hot-pressing protective film 600 can be covered on the side of the film carrier 200 away from the decorative layer group 300 to protect the decorative layer group 300 during the hot-pressing process.

[0092] In one embodiment of the present invention, the film carrier 200 can also be used directly as the hot-pressing protective film 600 to protect the decorative layer group 300 during the hot-pressing process.

[0093] Finally, the stacked structure is heated and pressurized using a hot-pressing process. The stacked materials are placed in a hot-press mold with a pre-set specific curvature and hot-pressed for 0.3 to 10 minutes at a temperature of 130-200℃ and a pressure of 10-100 Bar. During this process, the resin in the thermosetting structural layer 500 undergoes a curing reaction, firmly bonding with the decorative layer assembly 300, while the entire shell 10 is molded into the pre-set curved shape. During the hot-pressing process, the adhesive layer 400 is in a rubbery state. The soft, rubbery adhesive layer 400 can perfectly and tightly conform to the large drop crater position of the mold, resulting in excellent molding of the shell 10. The adhesive layer 400 also ensures a strong bond between the decorative layer assembly 300 and the thermosetting structural layer 500; at the same time, the rubbery adhesive layer 400 plays a crucial protective role. With its excellent thermal stability, it effectively prevents damage to the decorative layer assembly 300 from high temperature and high pressure, protecting the integrity and appearance of the decorative layer assembly 300. After hot pressing, the hardened layer 100, together with the membrane carrier 200, forms a sturdy shell, enabling the shell 10 with a large drop crater to have higher hardness and be applicable to more scenarios.

[0094] In one embodiment of the present invention, multiple steps of the decorative layer group 300 disclosed in the present invention can be appropriately reduced according to actual needs to form shells 10 with different costs and requirements.

[0095] For example, for some simpler housings 10, the decorative layer group 300 can be formed by only including a color layer 320 and a functional coating 310. That is, the housing 10 has a basic color and a relatively hard outer shell, meeting the most basic needs. In the process, the functional coating 310 and the color layer 320 are sequentially formed onto the film carrier 200, and then an adhesive layer 400 is formed on the color layer 320. After stacking the thermosetting structural layer 500, it can be hot-pressed into shape.

[0096] For example, for some more complex housings 10, the decorative layer group 300 can be formed after the color layer 320, functional coating 310, and coating layer 340 are formed, and then the color layer 320, functional coating 310, and coating layer 340 are repeated once. That is, the housing 10 has more colors and a more rigid outer shell to meet higher requirements. In other words, during the process, multiple layers of functional coating 310, coating layer 340, and color layer 320 are sequentially formed onto the film carrier 200, and then an adhesive layer 400 is formed at the light-shielding layer 330. After stacking the thermosetting structural layer 500, it can be hot-pressed into shape.

[0097] After hot pressing, the shell 10 undergoes further processing, such as punching or CNC (computer numerical control) machining, to remove excess scrap and refine it to the precise size and shape required for the final product, thereby obtaining the final shell 10 finished product.

[0098] Specifically, in one embodiment of the present invention, the Tg of the epoxy resin in the adhesive layer 400 is greater than the Tg of the epoxy resin in the portion of the thermosetting structural layer 500. Consequently, at the hot-pressing temperature, the epoxy resin adhesive layer 400 can be in a rubbery state, while the thermosetting structural layer 500 melts and is completely cured at that temperature.

[0099] Furthermore, in one embodiment of the present invention, the epoxy resin adhesive layer 400 baked for 20-60 minutes is only partially cured. Therefore, during the subsequent hot pressing process, the hot pressing temperature reaches the glass transition temperature of the epoxy resin, and the partially cured epoxy resin adhesive layer 400 is in a rubbery state, thus protecting the decorative layer during the hot pressing process. At the same time, the rubbery adhesive layer 400 is soft and can fit well into the mold with a high drop at the crater under hot pressing, thereby enabling the crater shell 10 product with a large drop to be successfully formed.

[0100] In one embodiment of the present invention, an electronic device is also provided, with reference to... Figure 7 The electronic device can be a smartphone, tablet, laptop, wearable device, etc. The electronic device includes a housing 10 and at least one electronic component 20 disposed within a space defined by the housing 10.

[0101] The housing 10 can be any of the housings 10 described in Embodiment 1, or the housing 10 prepared by the method described in Embodiment 2. This housing 10 not only possesses high strength and durability due to the thermosetting structural layer 500, but also an exquisite appearance due to the complex decorative layer group 300.

[0102] The electronic components 20 may include a motherboard, processor, memory, battery, screen, etc. These electronic components 20 are installed and secured within the receiving space defined by the housing 10. The housing 10 provides reliable physical protection for these internal components, preventing damage from external impacts, pressure, etc. At the same time, the excellent appearance design of the housing 10 greatly enhances the overall quality and market competitiveness of the electronic product.

[0103] It is understood that those skilled in the art can make equivalent substitutions or changes to the technical solution and inventive concept of the present invention, and all such changes or substitutions should fall within the protection scope of the present invention.

Claims

1. A housing, characterized in that, It includes the following layers, which are stacked and integrally hot-pressed in order from the outside in: Hardened layer; A membrane carrier, wherein the hardening layer is disposed on the outer surface of the membrane carrier; Decorative layer assembly, disposed on the inner surface of the membrane carrier; An adhesive layer is disposed on the inner surface of the decorative layer assembly; as well as A thermosetting structural layer is disposed on the inner surface of the adhesive layer.

2. The housing according to claim 1, characterized in that, The decorative layer assembly includes: A functional coating is disposed on the inner surface of the membrane carrier; and A color layer is disposed on the inner surface of the functional coating.

3. The housing according to claim 2, characterized in that, The decorative layer assembly also includes a light-shielding layer disposed between the color layer and the adhesive layer.

4. The housing according to claim 2, characterized in that, The decorative layer group further includes a coating layer disposed between the functional coating layer and the color layer.

5. The housing according to claim 1, characterized in that, The hardened layer is a UV-curable coating with a hardness range of 2H to 6H.

6. The housing according to claim 5, characterized in that, The hardened layer is made of polyurethane acrylate and has a thickness ranging from 3µm to 30µm.

7. The housing according to claim 1, characterized in that, The material of the membrane carrier is one of polyethylene terephthalate (PET), polycarbonate (PC), polyolefin (PO), polyurethane (PUR), and polyphenylene sulfide (PPS), and its thickness ranges from 0.05 mm to 0.8 mm.

8. The housing according to claim 1, characterized in that, The adhesive layer is made of epoxy resin or polyurethane acrylate, and its thickness ranges from 5µm to 15µm.

9. The housing according to claim 1, characterized in that, The thermosetting structural layer consists of at least one layer of glass fiber and / or alumina fiber prepreg.

10. The housing according to claim 4, characterized in that, The coating layer is a metal or non-metal film layer formed by physical vapor deposition or vacuum coating process, and its material is selected from at least one of the group consisting of In / Sn, TiO2, NbO, NbO2, Nb2O3, Nb2O5, SiO2, and ZrO2.

11. A method for preparing a shell, characterized in that, Includes the following steps: Provide a membrane carrier; A decorative layer group is formed on the inner surface of the membrane carrier; An adhesive layer is formed on the inner surface of the decorative layer assembly; A hardened layer is formed on the outer surface of the membrane carrier; A thermosetting structural layer is laminated to the inner surface of the adhesive layer to form a laminate. as well as The laminate is subjected to hot pressing treatment, thereby curing the thermosetting structural layer, adhesive layer and decorative layer group, and integrally bonding them with the film carrier and hardened layer to form the shell.

12. The method according to claim 11, characterized in that, The steps of forming the decorative layer group include: sequentially forming a functional coating and a color layer on the inner surface of the membrane carrier.

13. An electronic device, characterized in that, include: A housing, wherein the housing is the housing according to any one of claims 1 to 10 or the housing prepared by the method according to any one of claims 11-12; and At least one electronic component is disposed within the space defined by the housing.

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