Composite sheet, method for manufacturing the same and composite structure

Abstract

To provide a composite sheet, a method for manufacturing the same and a composite structure.SOLUTION: A composite sheet includes a first resin layer, a metal layer and a second resin layer. The first resin layer includes a first surface, a second surface opposite to the first surface, and a plurality of first resin projections projecting from the second surface. The metal layer can reflect visible light, and includes a third surface, a fourth surface opposite to the third surface, and a plurality of metal projections projecting from the fourth surface. The metal layer is fixed to the second surface through the third surface. The plurality of metal projections correspond to a plurality of first resin projections. The second resin layer includes a fifth surface, a sixth surface opposite to the fifth surface, and a plurality of second resin projections projecting from the sixth surface. The plurality of second resin projections correspond to the plurality of metal projections.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a composite sheet, a method for producing the same, and a composite structure, and more particularly to a composite sheet having a metal layer, a method for producing the same, and a composite structure having the composite sheet. [Background technology]

[0002] Metallic materials have bright luster and are widely used in the production of logos and decorative patterns on products to enhance the recognition and beauty of the products. However, when the logo or decorative pattern is produced by a lamination method, the glossiness of the metallic material is often reduced by the process. As a result, the visual effect provided by the finished product does not meet expectations. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Taiwan Registered Utility Model No. M462275U1 Specification [Patent Document 2] Taiwan Patent No. I679132B Specification Summary of the Invention [Means for solving the problem]

[0004] In one embodiment of the present disclosure, the composite sheet includes a first resin layer, a metal layer, and a second resin layer. The first resin layer includes a first surface, a second surface opposite to the first surface, and a plurality of first resin protrusions protruding from the second surface. The metal layer can reflect visible light. The metal layer includes a third surface, a fourth surface opposite to the third surface, and a plurality of metal protrusions protruding from the fourth surface. The metal layer is fixed to the second surface via the third surface. The plurality of metal protrusions correspond to the plurality of first resin protrusions. The second resin layer includes a fifth surface, a sixth surface opposite to the fifth surface, and a plurality of second resin protrusions protruding from the sixth surface. The second resin layer is removably disposed on the fourth surface via the fifth surface. The plurality of second resin protrusions correspond to the plurality of metal protrusions.

[0005] In another embodiment of the present disclosure, a method for manufacturing a composite sheet includes the steps of: providing a film layer laminate, the film layer laminate including 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 hot-pressing step, the film layer laminate being heated and pressurized to fix the metal layer to the first resin layer and maintain the second resin layer so as to be removably disposed on the metal layer; laminating a release member onto the film layer laminate, the surface of the release member being formed with a plurality of recesses toward a surface of the metal layer away from the first resin layer; performing a second hot-pressing step, the release member and the film layer laminate being heated and pressurized to form a plurality of metal protrusions in the metal layer corresponding to the plurality of recesses, and a plurality of first resin protrusions in the first resin layer corresponding to the plurality of recesses; and removing the release member.

[0006] In yet another embodiment of the present disclosure, a method for manufacturing a composite sheet includes a step of providing a film layer laminate, the film layer laminate including 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, the second resin layer being removably disposed on the metal layer, and a surface of the first resin layer facing the metal layer having a plurality of first resin protrusions; and a step of performing a hot pressing step, the film layer laminate being heated and pressurized to fix the metal layer to the first resin layer and maintain the second resin layer so as to be removably disposed on the metal layer, forming a plurality of metal protrusions in the metal layer corresponding to a plurality of the first resin protrusions, and forming a plurality of second resin protrusions in the second resin layer corresponding to a plurality of the first resin protrusions.

[0007] In yet another embodiment of the present disclosure, a composite structure includes the composite sheet described above and a substrate member secured to the first surface.

[0008] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is a schematic top view of a composite sheet according to one embodiment of the present disclosure. [Diagram 2] 2 is a partial cross-sectional view of the composite sheet taken along line AA' shown in FIG. [Diagram 3] 3 is an enlarged view of a portion T1 of the metal projection shown in FIG. 2. [Figure 4] 3 is an enlarged view of a portion T2 of the metal flat portion shown in FIG. 2. [Diagram 5] 1 is a flowchart illustrating a method for manufacturing a composite sheet according to an embodiment of the present disclosure. [Figure 6] 1 is a schematic diagram illustrating steps in a method for making a composite sheet according to one embodiment of the present disclosure. [Figure 7]3A-3C are schematic diagrams illustrating steps in a method for making a composite sheet according to another embodiment of the present disclosure. [Figure 8] 5 is a flow chart illustrating a method for manufacturing a composite sheet according to another embodiment of the present disclosure. [Figure 9] 3A-3C are schematic diagrams illustrating steps in a method for making a composite sheet according to another embodiment of the present disclosure. [Figure 10] FIG. 13 is a schematic top view of a composite structure according to yet another embodiment of the present disclosure. [Figure 11] 11 is a partial cross-sectional view of the composite structure taken along line BB' shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] In order to allow those skilled in the art to better understand the present disclosure, the following provides preferred embodiments with reference to the drawings to describe the present disclosure and the effects achieved. The drawings are simplified schematic diagrams. Therefore, in order to more clearly describe the basic framework or implementation method of the present disclosure, only elements related to the present disclosure and their combination relationships are shown. The actual elements and configurations may be more complicated. Also, for convenience, the number of elements in the drawings may not match the actual number of elements, and the shapes and sizes of the elements may not be drawn in proportion to the actual shapes and sizes, and the ratios may be adjusted according to design requirements. All drawings in the present disclosure are illustrated based on an XYZ Cartesian coordinate system for ease of explanation.

[0011] In the following embodiments, directional terms such as up, down, left, right, front, rear, etc. are used with reference to the orientation of the figures being described, and therefore, the directional terms are for illustrative purposes only and are in no way limiting.

[0012] In this specification, terms such as first, second, third, etc. are used to describe various elements, but it should be understood that these elements are not to be limited by these terms, and these terms are only used to distinguish one element from another within the specification.

[0013] In this disclosure, a statement that "an element is disposed on another element" or "an element is connected to another element" may mean that "the element is in direct contact with the other element" or that "there is an additional element between the element and the other element", thereby indicating that the element is not in direct contact with the other element.

[0014] <Composite sheet> Please refer to FIG. 1 and FIG. 2. FIG. 1 is a schematic top view of a composite sheet 10 according to an embodiment of the present disclosure. FIG. 2 is a partial cross-sectional view of the composite sheet 10 along the line A-A' shown in FIG. 1. 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 faces the first surface 111 (opposite each other), 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 via the third surface 121. The fourth surface 122 faces the third surface 121. The multiple metal protrusions 123 protrude from the fourth surface 122. The multiple metal protrusions 123 correspond to the multiple first resin protrusions 113. The second resin layer 130 includes a fifth surface 131, a sixth surface 132, and multiple 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 faces the fifth surface 131. The multiple second resin protrusions 133 protrude from the sixth surface 132 and correspond to the multiple metal protrusions 123.

[0015] In this embodiment, the second resin layer 130 is formed of a transparent material, and the metal layer 120 is formed of an opaque material. Thus, although the fourth surface 122 and the metal protrusions 123 (shown by dotted lines) of the metal layer 120 are visible from the viewing angle of FIG. 1, the present disclosure is not limited thereto. In other embodiments, the second resin layer 130 may be formed of an opaque material. The second resin layer 130 is configured to protect the metal layer 120. For example, when performing the hot pressing step, the second resin layer 130 can prevent the metal layer 120 from directly contacting the peeling member (e.g., the peeling member 50 shown in FIG. 6) or the hot pressing device (e.g., see the hot pressing device 40 shown in FIG. 9), thereby preventing the smoothness of the fourth surface 122 of the metal layer 120 from being destroyed by the relatively rough surfaces of the peeling member and the hot pressing device, which affect the glossiness of the metal layer 120. 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 may be removed according to actual needs. Furthermore, another protective layer (such as the third resin layer 140a shown in FIG. 7) may be disposed on the metal layer 120 according to actual needs.

[0016] In this embodiment, the first resin layer 110 bulges along a direction from the first surface 111 to the second surface 112 (for example, the Z direction) to form a first resin protrusion 113, and a first recessed space 114 is formed in the first surface 111 corresponding to the first resin protrusion 113. The non-bulging portion of the first resin layer 110 is the first resin flat portion 115. The metal layer 120 bulges along a direction from the third surface 121 to the fourth surface 122 to form a metal protrusion 123, and a second recessed space 124 is formed in the third surface 121 corresponding to the first resin protrusion 113. The non-bulging portion of the metal layer 120 is the metal flat portion 125. The second resin layer 130 bulges along a direction from the fifth surface 131 to the sixth surface 132 to form a second resin protrusion 133, and a third recessed space 134 is formed in the fifth surface 131 corresponding to the second resin protrusion 113. The non-bulging portion of the second resin layer 130 is the second resin flat portion 135. In this embodiment, the first resin protrusion 113 is disposed in correspondence with the second recess space 124, and the metal protrusion 123 is disposed in correspondence with the third recess space 134.

[0017] The ratio of the thickness t2 of the metal layer 120 to the thickness t1 of the first resin layer 110 may be in the range of 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 in the range of 0.01 to 0.1. For example, the thickness t1 of the first resin layer 110 may be in the range of 0.5 mm to 1.5 mm, the thickness t2 of the metal layer 120 may be in the range of 10 μm to 30 μm, and the thickness t3 of the second resin layer 130 may be in the range of 15 μm to 50 μm. The breaking elongation of the first resin layer 110 may be in the range of 300% to 600%, and the melting point of the first resin layer 110 may be in the range of 90°C to 180°C. The breaking elongation of the second resin layer 130 may be in the range of 5% to 200%, and the melting point of the second resin layer 130 may be in the range of 130°C to 260°C. The breaking elongation data may be measured based on the specifications of ASTM D412. For example, the material of the first resin layer 110 may include thermoplastic polyurethane (TPU). The thermoplastic polyurethane may be a transparent thermoplastic polyurethane that is not recycled, having a breaking elongation of about 500%, a melting point of about 170°C, and a thickness t1 of 0.5 mm, 0.7 mm, or 1 mm. Alternatively, the thermoplastic polyurethane may be a black thermoplastic polyurethane that is recycled, having a breaking elongation of about 450%, a melting point of about 120°C, and a thickness t1 of 0.5 mm, 0.7 mm, or 1 mm. The material of the second resin layer 130 may include polyethylene terephthalate (PET) having a breaking elongation of about 6%, a melting point of about 240° C., and a thickness t3 of 20 μm. Alternatively, the second resin layer 130 may include biaxially oriented polypropylene (OPP) having a breaking elongation of about 160%, a melting point of about 140° C., and a thickness t3 of 23 μm.

[0018] The material of the metal layer 120 may include aluminum, silver, gold, chrome, or a combination thereof. Thus, the metal layer 120 may have a delicate glossiness. In addition, the material of the metal layer 120 may selectively include a polymer material to improve its ductility and malleability. As shown in FIG. 1, the separation distance D1 between two adjacent metal protrusions of the metal protrusions 123 may be in the range of 0.1 mm to 10 mm. As shown in FIG. 2, the height H1 protruding from the fourth surface 122 of each of the metal protrusions 123 may be in the range of 0.1 mm to 1 mm. That is, the metal protrusions 123 are three-dimensional structures observable by the naked eye, and can provide special visual effects and decorative styles. The aforementioned separation distance D1 may be the shortest distance between two adjacent metal protrusions 123. The normal direction may be defined in the composite sheet 10 and parallel to the Z direction. 2, the height H1 may be the normal distance between the upper surface (not indicated) of the metal flat portion 125 and the apex P1 of the metal protrusion 123. In other embodiments, the metal protrusions of the composite sheet are not limited to the rivet pattern of the present embodiment, but may be designed to present a more complex pattern or design, such as a lattice pattern, a zigzag pattern, a steel plate pattern, a water ripple pattern, a grain pattern, a litchi pattern, etc.

[0019] The glossiness of each metal protrusion 123 may be greater than 80 GU (gloss units). The aforementioned glossiness data may be measured based on the specifications of ASTM D523. The measurement system is based on the refractive index of light having a wavelength of 589.3 nm on a polished glass surface, and the measurement is performed by a solar simulator and a detector simulating human visual response. The solar simulator can emit incident light, which hits the surface of the measurement object at a predetermined angle (in this embodiment, the measurement object is, for example, either the metal protrusion 123 or the metal flat portion 125). The detector simulating human visual response detects the reflected light of the incident light, and the glossiness of the measurement object at a predetermined angle can be calculated based on the brightness of the incident light and the reflected light. The method of calculating the glossiness based on the brightness of the incident light and the reflected light is well known to those skilled in the art and will not be described herein.

[0020] Please refer to FIG. 3, which is an enlarged view of a portion T1 of the metal protrusion 123 shown in FIG. 2. A normal direction N1 can be defined at the apex P1 of the metal protrusion 123. An incident light having an incident angle of a predetermined angle A1 is R11, and a reflected light thereof is R12. An incident light having an incident angle of a predetermined angle A2 is R21, and a reflected light thereof is R22. An incident light having an incident angle of a predetermined angle A3 is R31, and a reflected light thereof is R32. In this specification, the predetermined angle A1 is 20 degrees with respect to the normal direction N1, the predetermined angle A2 is 60 degrees with respect to the normal direction N1, and the predetermined angle A3 is 85 degrees with respect to the normal direction N1, but these are merely exemplary. As mentioned above, the glossiness of the apex 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, R21, R31 and the reflected light R12, R22, and R32, respectively. Please refer to FIG. 4, which is an enlarged view of the T2 portion of the metal plane portion 125 shown in FIG. 2. The normal direction N2 can be defined at the point P2 of the metal plane portion 125. Similarly, for the predetermined angles A1, A2, and A3, the incident light R11, R21, and R31, and the reflected light R12, R22, and R32, you may refer to the related description of FIG. 3. As mentioned above, the glossiness of the point P2 of the metal plane portion 125 at 20 degrees, 60 degrees, and 85 degrees can be calculated based on the brightness of the incident light R11, R21, and R31 and the reflected light R12, R22, and R32, respectively. 3 and 4, when the apex P1 of the metal protrusion 123 shown in FIG. 2 is enlarged, the curved surface on which the apex P1 is located tends to be a plane due to the angles of the incident light R11, R21, and R31, and the apex P1 may be considered as a point on the plane (because the measurement area is actually smaller than the area of ​​a circle with a diameter of 2 mm). Therefore, the glossiness of the apex P1 tends to be similar to the glossiness of the point P2. In one embodiment of the present disclosure, the glossiness of the apex P1 and the point P2 at an (incident angle) of 20 degrees is greater than 300 GU, the glossiness of the apex P1 and the point P2 at an (incident angle) of 60 degrees is greater than 200 GU, and the glossiness of the apex P1 and the point P2 at an (incident angle) of 85 degrees is greater than 80 GU.

[0021] <Method of manufacturing the composite sheet> Please refer to FIG. 5, which is a flow chart showing a method 200 for manufacturing a composite sheet according to an embodiment of the present disclosure. The method 200 for manufacturing a composite sheet includes steps 210, 220, and 250 to 270, and may selectively include steps 230 and 240. In step 210, a film layer laminate is provided, the film layer laminate includes a first resin layer, a metal layer, and a second resin layer laminated in order, the metal layer is removably disposed on the first resin layer, and the second resin layer is removably disposed on the metal layer. In step 220, a first hot pressing step is performed, and the film layer laminate is heated and pressurized to fix the metal layer to the first resin layer and maintain the second resin layer to be removably disposed on the metal layer. In step 250, a release member is laminated on the film layer laminate, and a surface of the release member is formed with a plurality of recesses toward the surface away from the first resin layer of the metal layer. In step 260, a second hot pressing step is performed to heat and pressurize the release member and the film layer laminate, thereby forming a plurality of metal protrusions in the metal layer corresponding to the plurality of recesses, and forming a plurality of first resin protrusions in the first resin layer corresponding to the plurality of recesses. In step 270, the release member is removed.

[0022] Please refer to FIG. 6 at the same time. FIG. 6 is a schematic diagram showing steps of a method 200 for manufacturing a composite sheet according to an embodiment of the present disclosure. First, a film layer laminate 20 is provided. The film layer laminate 20 includes a first resin layer 110a, a metal layer 120a, and a second resin layer 130a, which are laminated in order. 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. In this specification, the second resin layer 130a and the metal layer 120a form a composite 21, and the first resin layer 110a is an independent film layer, but these are exemplary. The second resin layer 130a may be a release film, and the metal layer 120a may be removably attached to the second resin layer 130a to form the composite 21. More specifically, the metal layer 120a may be a metal film, and the second resin layer 130a may be a protective layer attached to the metal film and may be separated from the metal film by tearing or peeling. The film layer laminate 20 is provided by laminating the composite 21 to the first resin layer 110a, and the metal layer 120a of the composite 21 faces the first resin layer 110a, and the metal layer 120a and the first resin layer 110a are not fixed by adhesion or bonding.

[0023] Next, the film layer laminate 20 is placed in a hot press device 40 to perform a first hot press step, in which the film layer laminate 20 is heated and pressurized to fix the metal layer 120a to the first resin layer 110a and maintain the second resin layer 130a so as to be removably disposed on the metal layer 120a. Specifically, in the first hot press step, the first resin layer 110a is softened by hot pressing. After the first resin layer 110a is cooled, the metal layer 120a may be fixed to 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 by the first hot press step, and the second resin layer 130a is not adhered to the metal layer 120a and can maintain a state in which it is removably disposed from the metal layer 120a. The hot press device 40 includes a hot press module 41 and a vacuum module 42. The hot press module 41 includes a plurality of heating units 41a. The hot press module 41 is configured to heat the film layer laminate 20. The vacuum module 42 includes a plurality of gas flow paths 42a. The vacuum module 42 is configured to exhaust (vacuum) gas from the film layer laminate 20. By the vacuum module 42 exhausting gas from the film layer laminate 20, the hot press device 40 can simultaneously apply negative pressure to the film layer laminate 20. This may reduce the melting point of the first resin layer 110a, thereby reducing the energy consumption required for the process. The first hot press step may be performed under the conditions that the heating temperature is 80°C to 170°C, the heating time is 30 seconds to 120 seconds, and the pressure applied to the film layer laminate 20 by the hot press device 40 is 0.8 bar to 1.2 bar.

[0024] Next, the film layer laminate 20 is removed from the hot press device 40, and the peeling member 50 is laminated on the film layer laminate 20, and a surface 51 of the peeling member 50 has a plurality of recesses 52 formed thereon and faces the surface 122a of the metal layer 120a that is away from the first resin layer 110a. In this specification, the surface 51 of the peeling member 50 is disposed on the surface 132a of the second resin layer 130a. That is, the peeling member 50 is indirectly disposed on the metal layer 120a via the second resin layer 130a. Next, the peeling member 50 and the film layer laminate 20 are placed in a hot press device 40 to perform a second hot press step, in which the peeling member 50 and the film layer laminate 20 are heated and pressurized to form a plurality of second resin protrusions 133 corresponding to the plurality of recesses 52 in the second resin layer 130a, a plurality of metal protrusions 123 corresponding to the plurality of recesses 52 in the metal layer 120a, and a plurality of first resin protrusions 113 corresponding to the plurality of recesses 52 in the first resin layer 110a. In this embodiment, while the film layer laminate 20 and the peeling member 50 are heated and pressurized by the hot press device 40, the gas between the film layer laminate 20 and the peeling member 50 can be discharged, so that the film layer laminate 20 may fall together with the peeling member 50 under negative pressure (i.e., the fit between the film layer laminate 20 and the peeling member 50 may be achieved under negative pressure). After the second hot pressing step, the second resin layer 130a becomes the second resin layer 130 having the second resin protrusions 133, the metal layer 120a becomes the metal layer 120 having the metal protrusions 123, and the first resin layer 110a becomes the first resin layer 110 having the first resin protrusions 113. That is, the film layer laminate 20 becomes the composite sheet 10. The second hot pressing step may be performed under the conditions that the heating temperature is 90°C to 180°C, the heating time is 50 seconds to 300 seconds, and the pressure applied to the film layer laminate 20 by the hot pressing device 40 is 0.8 bar to 1.2 bar. In the second hot pressing step, the first resin layer 110a and the second resin layer 130a are heated and softened, and the three-dimensional pattern of the peeling member 50 (i.e., the layout shown by the recesses 52) is reproduced on the film layer laminate 20 to form the composite sheet 10.Finally, the release member 50 and the composite sheet 10 are taken out of the hot press device 40, and the release member 50 is removed, thereby completing the manufacture of the composite sheet 10. For details of the composite sheet 10, reference may be made to the above description, and the description will not be repeated here.

[0025] According to the above description, a composite sheet 10 having a bright and shiny three-dimensional pattern (e.g., a layout indicated by metal protrusions 123) is manufactured by a process similar to a thermal transfer press, which is a dry process. Compared with a wet coating process, the dry process does not require an organic solvent and / or dispersant, so that intermediate products (such as toxic gases) can be effectively reduced, which is beneficial to environmental protection. Furthermore, by utilizing a dry process, the manufacturing of the composite sheet can be simplified, and the cost of raw materials and environmental safety may be reduced. Meanwhile, compared with an electroplating, deposition, or sputtering process, the present disclosure does not require the use of highly polluting electrolytic baths and expensive deposition equipment, which is beneficial to reducing industrial wastewater and manufacturing costs.

[0026] Please refer back to FIG. 5. The manufacturing method 200 of the composite sheet may selectively include step 230 and step 240. After step 220 (i.e., the first hot pressing step) is performed, step 230 and step 240 may be performed as necessary. In step 230, the second resin layer is removed. In step 240, a third resin layer (replacing the second resin layer) is removably disposed on the metal layer. In this case, the next step 260 (i.e., the second hot pressing step) further includes a step of forming a plurality of third resin protrusions in the third resin layer, which correspond to the plurality of recesses.

[0027] Further, please refer to FIG. 7, which is a schematic diagram showing the steps of a manufacturing method 200 of a composite sheet according to another embodiment of the present disclosure. The difference between FIG. 7 and FIG. 6 is described as follows. After performing 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 layer laminate 20'. Then, the peeling member 50 is also laminated on the film layer laminate 20', and the surface 51 of the peeling member 50 is disposed on the surface 142a of the third resin layer 140a. That is, the peeling member 50 is indirectly disposed on the metal layer 120a via the third resin layer 140a.

[0028] Next, the peeling member 50 and the film layer laminate 20' are placed in the hot press device 40. A second hot press step is performed, in which the peeling member 50 and the film layer laminate 20' are heated and pressurized, so that a plurality of third resin protrusions 143 corresponding to the plurality of recesses 52 are formed in the third resin layer 140a, a plurality of metal protrusions 123 corresponding to the plurality of recesses 52 are formed in the metal layer 120a, and a plurality of first resin protrusions 113 corresponding to the plurality of recesses 52 are formed in the first resin layer 110a. In the second hot press step, the first resin layer 110a and the third resin layer 140a are heated and softened, and the three-dimensional pattern of the peeling member 50 (i.e., the layout shown by the recesses 52) can be reproduced in the film layer laminate 20' to form the composite sheet 10'. After the second hot pressing step, the third resin layer 140a becomes the third resin layer 140 having the third resin protrusions 143, the metal layer 120a becomes the metal layer 120 having the metal protrusions 123, and the first resin layer 110a becomes the first resin layer 110 having the first resin protrusions 113. That is, the film layer laminate 20' becomes the composite sheet 10'. The second hot pressing step may be performed under the conditions that the heating temperature is 90°C to 180°C, the heating time is 50 seconds to 300 seconds, and the pressure applied to the film layer laminate 20' by the hot pressing device 40 is 0.8 bar to 1.2 bar. Finally, the peeling member 50 and the composite sheet 10' are taken out of the hot pressing device 40, and the peeling member 50 is removed, thereby completing the manufacturing process of the composite sheet 10'.

[0029] According to the above description, the difference between the composite sheet 10' and the composite sheet 10 is that in the composite sheet 10', the second resin layer 130 of the composite sheet 10 is replaced 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. 2) via the seventh surface 141. The eighth surface 142 faces the seventh surface 141, and the plurality of third resin protrusions 143 protrude from the eighth surface 142 and correspond to the plurality of metal protrusions 123. Other details of the composite sheet 10' may be the same as those of the composite sheet 10, and will not be repeated here.

[0030] It should be noted 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 breaking elongation (or ductility and malleability) of the third resin layer 140a may be superior to the breaking elongation (or ductility and malleability) of the second resin layer 130a. This is beneficial to improve the result of reproducing the three-dimensional pattern (layout shown by the recesses 52) of the peeling member 50 in the film layer laminate 20' and maintain the glossiness of the peripheral area of ​​the metal layer 120a when performing the second hot pressing step. Specifically, when the third resin layer 140a having a lower melting point (or softening point) or better breaking elongation (ductility and malleability) is used to cover the metal layer 120a and the second hot pressing step is performed in the peripheral region of the film layer laminate 20', the third resin layer 140a is sufficiently softened and / or sufficiently stretched, so that it can completely cover the metal layer 120a, thereby avoiding undesirable interlayer positional deviation caused by the difference in film hardness when the heating temperature is rapidly increased. That is, when the second resin layer 130a is misaligned with other layers, it is not preferable that the three-dimensional pattern (formed by the recess 52) of the peeling member 50 is reproduced in the metal layer 120a and the first resin layer 110a through the second resin layer 130a, and it is also not preferable for the protection of the three-dimensional pattern of the metal layer 120a. Therefore, in order to maintain quality consistency throughout the composite sheet 10', it is beneficial to replace the second resin layer 130a with a third resin layer 140a before performing the second hot pressing step, thereby improving the reproduction results of the three-dimensional pattern, especially in the peripheral region of the composite sheet 10', and maintaining the glossiness of the metal layer 120a in the peripheral region.

[0031] Please refer to FIG. 8, which is a flow chart showing a method 300 for manufacturing a composite sheet according to another embodiment of the present disclosure. The method 300 for manufacturing a composite sheet includes steps 310 and 320. In step 310, a film layer laminate is provided, the film layer laminate including a first resin layer, a metal layer, and a second resin layer laminated in order, 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 the surface of the first resin layer facing the metal layer. In step 320, a hot pressing step is performed to heat and press the film layer laminate to fix the metal layer to the first resin layer and maintain the second resin layer to be removably disposed on the metal layer. In addition, a plurality of metal protrusions corresponding to the plurality of first resin protrusions are formed on the metal layer, and a plurality of second resin protrusions corresponding to the plurality of first resin protrusions are formed on the second resin layer.

[0032] Please also refer to FIG. 9, which is a schematic diagram showing steps of a manufacturing method 300 of a composite sheet according to another embodiment of the present disclosure. First, a film layer laminate 30 is provided, which includes a first resin layer 110b, a metal layer 120a, and a second resin layer 130a, which are laminated in order, the metal layer 120a is removably disposed on the first resin layer 110b, 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 second surface 112 of the first resin layer 110b facing the metal layer 120a (opposed to the first surface on which no label is attached). In this specification, the second resin layer 130a and the metal layer 120a form a composite 21, and the first resin layer 110b is an independent film layer, which are merely exemplary. For details of the composite 21, please refer to the above description. The film layer laminate 30 is provided by laminating the composite 21 onto the first resin layer 110b, with the metal layer 120a of the composite 21 facing the first resin layer 110b, and the metal layer 120a and the first resin layer 110b not fixed by adhesion or bonding.

[0033] Next, the film layer laminate 30 is placed in a hot press apparatus 40 to perform a hot press step, in which the film layer laminate 30 is heated and pressurized to fix the metal layer 120a to the first resin layer 110b and maintain the second resin layer 130a removably disposed on the metal layer 120a. The hot press apparatus 40 includes a hot press module 41 and a vacuum module 42. The hot press module 41 includes a plurality of heating units 41a. The hot press module 41 is configured to heat the film layer laminate 30. The vacuum module 42 includes a plurality of gas flow paths 42a. The vacuum module 42 is configured to exhaust gas (vacuum) from the film layer laminate 30. In this embodiment, the gas between the composite 21 and the first resin layer 110b can be discharged while the film layer laminate 30 is heated and pressurized by the hot press device 40, so that the composite 21 may fall together with the first resin layer 110b under negative pressure (i.e., the fitting between the composite 21 and the first resin layer 110b may be achieved under negative pressure). The hot press step may be performed under the conditions that the heating temperature is 80°C to 180°C, the heating time is 30 seconds to 300 seconds, and the pressure applied to the film layer laminate 30 by the hot press device 40 is 0.8 bar to 1.2 bar. In the hot press step, the first resin layer 110b is heated and softened. After the first resin layer 110b is cooled, the metal layer 120a can be fixed to the first resin layer 110b by adhesion, and a plurality of metal protrusions 123 corresponding to the plurality of first resin protrusions 113 are formed on the metal layer 120a. At the same time, the second resin layer 130a is heated and softened, and a plurality of second resin protrusions 133 corresponding to the plurality of first resin protrusions 113 are formed in the second resin layer 130a. 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 layer laminate 30 becomes the composite sheet 10b. For details of the composite sheet 10b, the above description may be referred to, and will not be repeated here.

[0034] <composite structure> Please refer to Fig. 10 and Fig. 11. Fig. 10 is a top schematic view of a composite structure 1 according to yet another embodiment of the present disclosure. Fig. 11 is a partial cross-sectional view of the composite structure 1 along the line B-B' shown in Fig. 10. The composite structure 1 includes a composite sheet 2 and a substrate member 3. For example, the composite sheet 10 shown in Fig. 1 or the composite sheet 10' shown in Fig. 7 may be cut into a desired contour shape such as a product logo or a decorative pattern (in this specification, the shape shown in Fig. 10 is exemplarily cut into a hexagon) to form the composite sheet 2. In this specification, the composite sheet 2 is exemplarily cut from the composite sheet 10 shown in Fig. 1. In other words, in this embodiment, the main difference between the composite sheet 2 and the composite sheet 10 is their contour shapes. For other details of the composite sheet 2, reference may be made to the related description of the composite sheet 10. The substrate 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 may be fixed to the first surface 111 by hot melt adhesive or glue, or may be fixed to the first surface 111 by sewing. Furthermore, the base member 3 may completely cover the first surface 111 depending on a specific application. This allows the base member 3 to completely support the composite sheet 2, which is advantageous for the composite sheet 2 to be combined with or become a part of another object via the base member 3. Materials for the base member 3 include, but are not limited to, spacer mesh fabric, fiber cloth, woven fabric, nonwoven fabric, leather, etc.

[0035] As shown in FIG. 11, compared with the composite sheet 10 (see FIG. 2), 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. This allows the composite structure 1 to have a bright metallic luster even at the edge of the composite sheet 2 in the peripheral region. As shown in FIG. 10, the contour shape and size of the substrate member 3 are different from those of the composite sheet 2, but the present disclosure is not limited thereto. In other embodiments, the contour shape and size of the substrate member 3 may be substantially the same as those of the composite sheet 2. For example, the substrate member 3 may be cut so that the outer edge (not shown) of the substrate member 3 is aligned with the outer edge (without label) of the composite sheet 2, which is advantageous for combining the composite structure 1 with other objects. EXAMPLES

[0036] <Glossiness of Examples and Comparative Examples> Please refer to Table 1. Table 1 shows the measurement results of the glossiness of some examples according to the present disclosure, together with the measured glossiness of some comparative examples. In Example 1, the film layer laminate includes a first resin layer, a metal layer and a second resin layer. The material of the first resin layer is TPU, the metal layer is aluminum film, and the material of the second resin layer is transparent PET. After performing the first hot pressing step and disposing the second resin layer still on the metal layer, the glossiness of the whole film layer laminate at 20 degrees, 60 degrees and 85 degrees is measured from the surface of the second resin layer according to the specifications of ASTM D523. In other words, Example 1 is a semi-finished product formed by steps 210 and 220 (see FIG. 5) of the manufacturing method 200 of the composite sheet. For details of the specifications of ASTM D523, the above description may be referred to. The difference between Example 2 and Example 1 is described as follows: In Example 2, after the first hot pressing step is performed to remove the second resin layer, the glossiness of the entire film layer laminate (including only the metal layer and the first resin layer) is measured from the surface of the metal layer according to the specifications of ASTM D523 at 20 degrees, 60 degrees, and 85 degrees. More specifically, the difference between the film layer laminate of Example 2 and the film layer laminate of Example 1 subjected to the glossiness measurement is that the film layer laminate of Example 2 lacks the second resin layer compared with the film layer laminate of Example 1. The main difference between Example 3 and Example 1 is described as follows: The material of the second resin layer of the film layer laminate is changed from transparent PET to transparent OPP, the first hot pressing step is performed, and the second resin layer is still placed on the metal layer, and the glossiness of the entire film layer laminate is measured from the surface of the second resin layer (OPP) according to the specifications of ASTM D523. The difference between Example 4 and Example 3 is described as follows. In Example 4, after performing the first hot pressing step to remove the second resin layer, the glossiness of the entire film layer laminate (including only the metal layer and the first resin layer) is measured from the surface of the metal layer at 20 degrees, 60 degrees, and 85 degrees. More specifically, the difference between the film layer laminate of Example 4 and the film layer laminate of Example 3 subjected to the glossiness measurement is that the film layer laminate of Example 4 lacks the second resin layer compared to the film layer laminate of Example 3.The difference between Comparative Example 1 and Example 2 is described as follows: In Comparative Example 1, the second resin layer (PET) is removed before the first hot press step. Therefore, after the first hot press step is performed, the glossiness of the entire film layer laminate (including only the metal layer and the first resin layer) at 20 degrees, 60 degrees, and 85 degrees is measured from the surface of the metal layer based on the specifications of ASTM D523. More specifically, the difference between Comparative Example 1 and Example 2 is that the first hot press step is performed on the film layer laminate of Comparative Example 1 without the second resin layer. The difference between Comparative Example 2 and Example 4 is described as follows: In Comparative Example 2, the second resin layer (OPP) is removed before the first hot press step. Therefore, after the first hot press step is performed, the glossiness of the entire film layer laminate (including only the metal layer and the first resin layer) at 20 degrees, 60 degrees, and 85 degrees is measured from the surface of the metal layer based on the specifications of ASTM D523. More specifically, the difference between Comparative Example 2 and Example 4 is that the first hot pressing step is performed on the film layer laminate of Comparative Example 2 without the second resin layer.

[0037] [Table 1]

[0038] Comparing the measurement results of Example 1 and Example 2, or comparing the measurement results of Example 3 and Example 4, when the metal layer is disposed with the transparent second resin layer, respectively, the glossiness of the entire film layer laminate is not significantly affected by the transparent second resin layer. As demonstrated in Example 2 and Comparative Example 1, when the second resin layer (PET) is disposed on the metal layer to protect the metal layer during the first hot pressing step, the glossiness of the metal layer is not significantly decreased by heating and pressing. Similarly, as demonstrated in Example 4 and Comparative Example 2, when the second resin layer (OPP) is disposed on the metal layer to protect the metal layer during the first hot pressing step, the glossiness of the metal layer is not significantly decreased by heating and pressing. In other words, while performing the hot pressing step during the manufacturing process of the composite sheet, the second resin layer can reduce the effect of heating and pressing on the metal layer by protecting the metal layer from thermal energy and pressure, which is beneficial to maintaining the glossiness of the metal layer.

[0039] Compared with the prior art, in the manufacturing method of the composite sheet according to the present disclosure, the second resin layer is removably disposed on the metal layer, so that the second resin layer can protect the metal layer during the hot pressing step, which is beneficial to maintain the glossiness of the metal layer, so that the composite sheet having the metal layer and the composite structure having the composite sheet can provide a brighter visual effect when the decoration style is diversified.

[0040] Those skilled in the art will readily recognize that numerous modifications and variations of the apparatus and method may be made while retaining the teachings of this invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. [Explanation of symbols]

[0041] 1 Composite structure 2 Composite Sheet 3. Substrate Materials 10 Composite Sheet 10' Composite Sheet 10b Composite sheet 110 1st resin layer 110a 1st resin layer 110b 1st resin layer 111 1st surface 112 Second surface 113 1st resin protrusion 114 First recessed space 115 First resin plane part 116 Side 120 metal layer 120a metal layer 121 Third surface 122 4th surface 122a: Surface away from the first resin layer 110a 123 Metal protrusion 124 Second recessed space 125 Metal flat part 130 Second resin layer 131 Fifth surface 132 6th surface 133 2nd resin protrusion 134 Third recessed space 135 Second resin plane part 130a 2nd resin layer 132a: Surface of the second resin layer 130a 140 3rd resin layer 140a 3rd resin layer 141 7th surface 142 8th surface 143 Third resin protrusion 20 Film layer laminate 20' Different Film Layer Laminate 21 Complex 30 Film layer laminate 40 Hot press equipment 41 Hot Press Module 41a Heating unit 42 Vacuum Module 42a Gas flow path 50 Peeling member 51 Surface of peeling member 50 52 Recess A1 Prescribed angle A2 Prescribed angle A3 Prescribed angle D1 The distance between two adjacent metal protrusions H1 Height protruding from the fourth surface 122 N1: Normal direction at apex P1 of metal protrusion 123 N2 Normal direction at point P2 of metal plane portion 125 P1 Apex of metal protrusion 123 P2 Metal plane part 125 points R11 is the incident light with a given angle A1 R12 Incident light R11 reflected light R21: Incident light with a given angle of incidence A2 R22 Incident light R21 reflected light R31 is the incident light with a given angle A3 R32 Incident light R31 reflected light t1: thickness of the first resin layer 110 t2 thickness of metal layer 120 t3: Thickness of the second resin layer 130

Claims

1. A first resin layer, a metal layer, and a second resin layer, A first surface; and a second surface opposite the first surface; and a plurality of first resin protrusions protruding from the second surface; wherein the metal layer is capable of reflecting visible light; a third surface, the metal layer being secured to the second surface via the third surface; and a fourth surface opposite the third surface; and a plurality of metal protrusions protruding from the fourth surface corresponding to the plurality of first resin protrusions; The second resin layer comprises a fifth surface, the second resin layer being removably disposed on the fourth surface via the fifth surface; and a sixth surface opposite the fifth surface; and a plurality of second resin protrusions protruding from the sixth surface corresponding to the plurality of metal protrusions; A composite sheet comprising:

2. 10. The composite sheet of claim 1, wherein the gloss of each of said metal projections is greater than 80 GU.

3. The composite sheet of claim 1 , wherein the material of the metal layer comprises aluminum, silver, gold, chromium, or a combination thereof.

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

5. The composite sheet of claim 1 , wherein a material of the first resin layer includes a thermoplastic polyurethane and a material of the second resin layer includes a polyethylene terephthalate.

6. The composite sheet of claim 1 , wherein the material of the first resin layer comprises thermoplastic polyurethane and the material of the second resin layer comprises biaxially oriented polypropylene.

7. 2. The composite sheet according to claim 1, wherein a distance between two adjacent metal protrusions among the metal protrusions is in the range of 0.1 mm to 10 mm, and a protruding height of each of the metal protrusions from the fourth surface is in the range of 0.1 mm to 1 mm.

8. providing a film layer laminate, the film layer laminate including a first resin layer, a metal layer, and a second resin layer, which are laminated 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 hot pressing step, heating and pressing the film layer laminate to fix the metal layer to the first resin layer and maintain the second resin layer in removably disposed relation to the metal layer; laminating a release member to the film layer laminate, the release member having a surface formed with a plurality of recesses and directed toward a surface of the metal layer away from the first resin layer; a step of performing a second hot pressing step, in which the peeling member and the film layer laminate are heated and pressurized to form a plurality of metal protrusions in the metal layer corresponding to the plurality of recesses, and a plurality of first resin protrusions in the first resin layer corresponding to the plurality of recesses; removing the peeling member; A method for producing a composite sheet, comprising:

9. The method for producing a composite sheet according to claim 8 , wherein the step of performing the second hot pressing further comprises the step of forming a plurality of second resin protrusions in the second resin layer corresponding to the plurality of recesses.

10. The method for manufacturing a composite sheet as described in claim 8, further comprising a step of removing the second resin layer and removably disposing a third resin layer on the metal layer, and the step of performing the second hot pressing step further comprises a step of forming a plurality of third resin protrusions in the third resin layer corresponding to the plurality of recesses.

11. providing a film layer laminate, the film layer laminate including a first resin layer, a metal layer, and a second resin layer laminated in order, the metal layer being removably disposed on the first resin layer, the second resin layer being removably disposed on the metal layer, and a plurality of first resin protrusions being formed on a surface of the first resin layer facing the metal layer; performing a hot pressing step, heating and pressing the film layer laminate to fix the metal layer to the first resin layer, maintain the second resin layer in a removably disposed position on the metal layer, form a plurality of metal protrusions on the metal layer corresponding to the plurality of first resin protrusions, and form a plurality of second resin protrusions on the second resin layer corresponding to the plurality of first resin protrusions; A method for producing a composite sheet, comprising:

12. The composite sheet according to claim 1 ; a substrate member secured to the first surface; A complex structure that contains

13. The composite structure of claim 12 , wherein the first resin layer further includes a side surface connected between the first surface and the second surface, and the metal layer completely shields the side surface.

14. The composite structure of claim 12 , wherein the substrate member material comprises a spacer mesh fabric.

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