Composite sheet, its manufacturing method 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 manufacturing the same, and a composite structure, and more particularly to a composite sheet having a metal layer, a method for manufacturing the same, and a composite structure having the composite sheet. [Background technology]

[0002] Metallic materials have a bright luster and are widely used to produce logos and decorative patterns on products to enhance product recognition and beauty. However, when logos or decorative patterns are produced using 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 [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 the first surface, and a plurality of first resin protrusions protruding from the second surface. The metal layer is capable of reflecting visible light. The metal layer includes a third surface, a fourth surface opposite 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 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 laminated in order, 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 pressurizing the film layer laminate 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 having a plurality of recesses formed thereon, the surface of the metal layer facing away from the first resin layer; performing a second hot-pressing step, heating and pressurizing the release member and the film layer laminate to form a plurality of metal protrusions corresponding to the plurality of recesses in the metal layer and a plurality of first resin protrusions corresponding to the plurality of recesses in the first resin layer; 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 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; and a step of performing a hot pressing step, in which the film layer laminate is 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 objects of the present invention will no doubt become obvious to those skilled in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic top view of a composite sheet according to an embodiment of the present disclosure. [Figure 2] FIG. 2 is a partial cross-sectional view of the composite sheet taken along line AA' shown in FIG. [Figure 3] FIG. 3 is an enlarged view of a portion T1 of the metal projection shown in FIG. [Figure 4] FIG. 3 is an enlarged view of a portion T2 of the metal flat portion shown in FIG. [Figure 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 manufacturing a composite sheet according to another embodiment of the present disclosure. [Figure 8] 10 is a flowchart 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 manufacturing a composite sheet according to another embodiment of the present disclosure. [Figure 10] FIG. 10 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 INVENTION

[0010] To help those skilled in the art 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, only elements relevant to the present disclosure and their combination relationships are shown to more clearly explain the basic framework or implementation method of the present disclosure. Actual elements and configurations may be more complex. For convenience, the number of elements in the drawings may not correspond to the actual number of elements, and the shapes and sizes of elements may not be drawn proportionally to the actual shapes and sizes, and their proportions may be adjusted according to design requirements. For ease of explanation, all drawings in the present disclosure are drawn based on an XYZ Cartesian coordinate system.

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

[0012] Although the specification uses terms such as first, second, third, etc. to describe various elements, it should be understood that these elements are not to be limited by these terms, but rather are used solely 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 refer to "the element is in direct contact with the other element" or may refer to "there is another element between the element and the other element" and thus the element is not in direct contact with the other element.

[0014] <Composite sheet> Please refer to FIGS. 1 and 2. FIG. 1 is a schematic top view of a composite sheet 10 according to one embodiment of the present disclosure. FIG. 2 is a partial cross-sectional view of the composite sheet 10 taken along line A-A' 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 is capable of reflecting 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. A plurality of metal protrusions 123 protrude from the fourth surface 122. The plurality of metal protrusions 123 correspond to the plurality of first resin protrusions 113. The second resin layer 130 includes a fifth surface 131, a sixth surface 132, and a plurality of second resin protrusions 133. The second resin layer 130 is removably disposed on the fourth surface 122 via the fifth surface 131. The sixth surface 132 faces the fifth surface 131. The plurality of second resin protrusions 133 protrude from the sixth surface 132 and correspond to the plurality of 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. Therefore, 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 in 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, during the hot pressing step, the second resin layer 130 prevents the metal layer 120 from directly contacting a peeling member (e.g., the peeling member 50 shown in FIG. 6 ) or a hot pressing device (e.g., see the hot pressing device 40 shown in FIG. 9 ). This prevents 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 would 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, other protective layers (for example, 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 in a direction from the first surface 111 to the second surface 112 (e.g., the Z direction) to form a first resin protrusion 113, and a corresponding first recessed space 114 is formed in the first surface 111. The non-bulging portion of the first resin layer 110 is a first resin flat portion 115. The metal layer 120 bulges in a direction from the third surface 121 to the fourth surface 122 to form a metal protrusion 123, and a corresponding second recessed space 124 is formed in the third surface 121. The non-bulging portion of the metal layer 120 is a metal flat portion 125. The second resin layer 130 bulges in a direction from the fifth surface 131 to the sixth surface 132 to form a second resin protrusion 133, and a corresponding third recessed space 134 is formed in the fifth surface 131. The non-bulging portion of the second resin layer 130 is a 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 be thermoplastic polyurethane (TPU). The thermoplastic polyurethane may be a non-recycled transparent thermoplastic polyurethane having a breaking elongation of approximately 500%, a melting point of approximately 170°C, and a thickness t1 of 0.5 mm, 0.7 mm, or 1 mm. Alternatively, the thermoplastic polyurethane may be a recycled black thermoplastic polyurethane having a breaking elongation of approximately 450%, a melting point of approximately 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, chromium, or a combination thereof. This allows the metal layer 120 to have a delicate luster. Furthermore, the material of the metal layer 120 may optionally include a polymer material to improve its ductility and malleability. As shown in FIG. 1, the distance D1 between two adjacent metal protrusions 123 may be in the range of 0.1 mm to 10 mm. As shown in FIG. 2, the height H1 of each metal protrusion 123 protruding from the fourth surface 122 may be in the range of 0.1 mm to 1 mm. That is, the metal protrusions 123 have a three-dimensional structure observable with the naked eye, which can provide special visual effects and decorative styles. The distance D1 may be the shortest distance between two adjacent metal protrusions 123. The normal direction may be defined by the composite sheet 10 and may be parallel to the Z direction. 2, the height H1 may be the distance in the normal direction between the upper surface (unnumbered) 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 this embodiment, and may be designed to have more complex patterns 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 ASTM D523 specification. This 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 using a solar simulator and a detector that simulates human visual response. The solar simulator can emit incident light, which strikes 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 that simulates human visual response detects 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. Methods for calculating glossiness based on the brightness of the incident light and the reflected light are well known to those skilled in the art and will not be described herein.

[0020] 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 vertex P1 of the metal protrusion 123. When the incident angle is a predetermined angle A1, the incident light is R11, and the reflected light is R12. When the incident angle is a predetermined angle A2, the incident light is R21, and the reflected light is R22. When the incident angle is a predetermined angle A3, the incident light is R31, and the reflected light 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 examples. As described above, the glossiness of the apex P1 of the metal protrusion 123 at angles of 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. Please refer to FIG. 4, which is an enlarged view of the T2 portion of the metal flat portion 125 shown in FIG. 2. A normal direction N2 can be defined at point P2 of the metal flat 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, please refer to the related description of FIG. 3. As described above, the glossiness of point P2 of the metal flat portion 125 at angles of 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 vertex P1 of the metal protrusion 123 shown in FIG. 2 is enlarged, the curved surface on which the vertex P1 is located tends to be flat due to the angles of the incident light R11, R21, and R31, and the vertex P1 may be considered a point on the plane (because the measured area is actually smaller than the area of ​​a circle with a diameter of 2 mm). Therefore, the glossiness of the vertex P1 tends to be similar to that of the point P2. In one embodiment of the present disclosure, the glossiness of the vertices P1 and P2 at an incident angle of 20 degrees is greater than 300 GU, the glossiness of the vertices P1 and P2 at an incident angle of 60 degrees is greater than 200 GU, and the glossiness of the vertices P1 and P2 at an incident angle of 85 degrees is greater than 80 GU.

[0021] <Manufacturing method of composite sheet> See FIG. 5, a flowchart illustrating a composite sheet manufacturing method 200 according to an embodiment of the present disclosure. The composite sheet manufacturing method 200 includes steps 210, 220, and 250 to 270, and may optionally 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 stacked in order, with the metal layer removably disposed on the first resin layer and the second resin layer removably disposed on the metal layer. In step 220, a first hot-press step is performed, in which the film layer laminate is heated and pressurized to fix the metal layer to the first resin layer and maintain the second resin layer removably disposed on the metal layer. In step 250, a release member is laminated on the film layer laminate, with a surface of the release member having a plurality of recesses formed thereon, facing the surface of the metal layer away from the first resin 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 corresponding to the plurality of recesses in the metal layer and a plurality of first resin protrusions corresponding to the plurality of recesses in the first resin layer. In step 270, the release member is removed.

[0022] Please also refer to FIG. 6. FIG. 6 is a schematic diagram illustrating steps of a method 200 for manufacturing a composite sheet according to one 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 stacked in this 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 merely 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, with the metal layer 120a of the composite 21 facing the first resin layer 110a, and the metal layer 120a and the first resin layer 110a not fixed by adhesion or bonding.

[0023] Next, the film layer laminate 20 is placed in a hot press apparatus 40 to perform a first hot press step. In this step, 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 in a removably disposed state 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. Because the melting point of the second resin layer 130a is higher than that of the first resin layer 110a, the second resin layer 130a is essentially unaffected by the first hot press step. The second resin layer 130a does not adhere to the metal layer 120a and can maintain a removably disposed state 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 20. 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 20. By exhausting gas from the film layer laminate 20 using the vacuum module 42, the hot press apparatus 40 can simultaneously apply negative pressure to the film layer laminate 20. This may lower the melting point of the first resin layer 110a, thereby reducing the amount of energy consumed in the process. The first hot press step may be performed under the following conditions: a heating temperature of 80°C to 170°C, a heating time of 30 to 120 seconds, and a pressure of 0.8 to 1.2 bar applied to the film layer laminate 20 by the hot press apparatus 40.

[0024] Next, the film layer laminate 20 is removed from the hot press device 40, and a release member 50 is laminated on the film layer laminate 20. A surface 51 of the release member 50 has a plurality of recesses 52 formed thereon and faces the surface 122a of the metal layer 120a, away from the first resin layer 110a. In this specification, the surface 51 of the release member 50 is disposed on the surface 132a of the second resin layer 130a. That is, the release member 50 is disposed indirectly on the metal layer 120a via the second resin layer 130a. Next, the release 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 release member 50 and the film layer laminate 20 are heated and pressurized, so that a plurality of second resin protrusions 133 corresponding to the plurality of recesses 52 are formed in the second resin layer 130a, 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 this embodiment, while the film layer laminate 20 and the release member 50 are heated and pressurized by the hot press device 40, gas can be discharged between the film layer laminate 20 and the release member 50, so that the film layer laminate 20 may fall together with the release member 50 under negative pressure (i.e., the snug fit between the film layer laminate 20 and the release 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 of a heating temperature of 90°C to 180°C, a heating time of 50 to 300 seconds, and a pressure of 0.8 bar to 1.2 bar applied to the film layer laminate 20 by the hot-pressing device 40. 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 release member 50 (i.e., the layout represented by the recesses 52) is reproduced in the film layer laminate 20, thereby forming the composite sheet 10.Finally, the release member 50 and the composite sheet 10 are removed from 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, please refer to the above description, and the description will not be repeated here.

[0025] As described above, a composite sheet 10 having a bright and glossy three-dimensional pattern (e.g., a layout indicated by metal protrusions 123) is manufactured using a dry process similar to thermal transfer pressing. Compared to wet coating processes, dry processes do not require organic solvents and / or dispersants, which can effectively reduce intermediate products (such as toxic gases) and benefit environmental protection. Furthermore, using a dry process can simplify the manufacturing of composite sheets and reduce raw material and environmental safety costs. Meanwhile, compared to electroplating, vapor deposition, or sputtering processes, the present disclosure eliminates the need for highly polluting electrolytic baths and expensive vapor deposition equipment, which is beneficial for reducing industrial wastewater and manufacturing costs.

[0026] Please refer back to FIG. 5. The composite sheet manufacturing method 200 may optionally include steps 230 and 240. After step 220 (i.e., the first hot-pressing step) is performed, steps 230 and 240 may be performed as needed. 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, the protrusions corresponding to the plurality of recesses.

[0027] Further, please refer to FIG. 7, which is a schematic diagram illustrating steps of a composite sheet manufacturing method 200 according to another embodiment of the present disclosure. The difference between FIG. 7 and FIG. 6 is as follows: After performing the first hot-pressing step, the second resin layer 130a is removed, and a third resin layer 140a is removably disposed on the metal layer 120a to form another film layer laminate 20′. Next, a release member 50 is also laminated on the film layer laminate 20′, and the surface 51 of the release member 50 is disposed on the surface 142a of the third resin layer 140a. That is, the release member 50 is indirectly disposed on the metal layer 120a via the third resin layer 140a.

[0028] Next, the release member 50 and the film layer laminate 20′ are placed in a hot press apparatus 40. A second hot press step is performed, in which the release 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 release member 50 (i.e., the layout indicated by the recesses 52) is reproduced in the film layer laminate 20′, thereby forming a 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 following conditions: a heating temperature of 90°C to 180°C, a heating time of 50 to 300 seconds, and a pressure of 0.8 bar to 1.2 bar applied to the film layer laminate 20' by the hot-pressing device 40. Finally, the release member 50 and the composite sheet 10' are removed from the hot-pressing device 40, and the manufacturing process of the composite sheet 10' is completed by removing the release member 50.

[0029] According to the above description, the difference between composite sheet 10' and composite sheet 10 is that in composite sheet 10', second resin layer 130 of composite sheet 10 is replaced with third resin layer 140. Third resin layer 140 includes seventh surface 141, eighth surface 142, and a plurality of third resin protrusions 143. Third resin layer 140 is removably disposed on fourth surface 122 (see FIG. 2 ) via seventh surface 141. Eighth surface 142 faces seventh surface 141, and a plurality of third resin protrusions 143 protrude from eighth surface 142 and correspond to a plurality of metal protrusions 123. Other details of composite sheet 10' may be the same as those of 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 that 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 that of the second resin layer 130a, which is beneficial in improving the result of replicating the three-dimensional pattern of the release member 50 (the layout indicated by the recesses 52) in the film layer laminate 20′ and maintaining the glossiness of the peripheral region 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 fracture elongation (ductility and malleability) is used to cover the metal layer 120a and the second hot-pressing step is performed on the peripheral region of the film layer laminate 20′, the third resin layer 140a is sufficiently softened and / or stretched to completely cover the metal layer 120a, thereby avoiding undesirable interlayer misalignment caused by differences in film hardness when the heating temperature is rapidly increased. That is, if the second resin layer 130a is misaligned with the other layers, it is undesirable for the three-dimensional pattern (formed by the recesses 52) of the release member 50 to be reproduced on the metal layer 120a and the first resin layer 110a via the second resin layer 130a, which is undesirable for protecting the three-dimensional pattern of the metal layer 120a. Therefore, in order to maintain consistency in the quality of the entire 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] See FIG. 8 , a flowchart illustrating a composite sheet manufacturing method 300 according to another embodiment of the present disclosure. The composite sheet manufacturing method 300 includes steps 310 and 320. In step 310, a film layer laminate is provided. The film layer laminate includes a first resin layer, a metal layer, and a second resin layer stacked 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. 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 so that it is removably disposed on the metal layer. Furthermore, 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] See also FIG. 9, which is a schematic diagram illustrating steps of a composite sheet manufacturing method 300 according to another embodiment of the present disclosure. First, a film layer laminate 30 is provided. The film layer laminate 30 includes a first resin layer 110b, a metal layer 120a, and a second resin layer 130a, which are stacked in this order. The metal layer 120a is removably disposed on the first resin layer 110b, and the second resin layer 130a is removably disposed on the metal layer 120a. 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 (opposite the first surface without a label). 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. For details about 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 being 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 so that it can be 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 (vacuumize) the film layer laminate 30. In this embodiment, while the film layer laminate 30 is heated and pressurized by the hot press device 40, gas can be discharged between the composite 21 and the first resin layer 110b, so that the composite 21 can fall together with the first resin layer 110b under negative pressure (i.e., the tight fit between the composite 21 and the first resin layer 110b can be achieved under negative pressure). The hot press step can be performed under conditions where 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, please refer to the above description, and the description will not be repeated here.

[0034] <composite structure> Please refer to FIGS. 10 and 11. FIG. 10 is a schematic top 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 taken along line B-B' in FIG. 10. The composite structure 1 includes a composite sheet 2 and a substrate member 3. For example, the composite sheet 2 may be formed by cutting the composite sheet 10 shown in FIG. 1 or the composite sheet 10' shown in FIG. 7 into a desired contour shape, such as a product logo or decorative pattern (exemplary in this specification is cutting the shape shown in FIG. 10 into a hexagon). 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, please refer 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 a hot melt adhesive or an adhesive, 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 the 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 to 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 in the peripheral region, even at the edge of the composite sheet 2. As shown in FIG. 10 , the outline 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 outline 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 (not labeled) of the composite sheet 2, which is advantageous for combining the composite structure 1 with another object. [Example]

[0036] <Glossiness of Examples and Comparative Examples> See Table 1. Table 1 shows the gloss measurement results of several examples according to the present disclosure, along with the gloss measurements of several 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 gloss of the entire film layer laminate at 20 degrees, 60 degrees, and 85 degrees is measured from the surface of the second resin layer according to the ASTM D523 specifications. In other words, Example 1 is a semi-finished product formed by steps 210 and 220 (see FIG. 5) of the composite sheet manufacturing method 200. For details of the ASTM D523 specifications, please refer to the above description. The differences between Example 2 and Example 1 are as follows: In Example 2, after the first hot-press step was performed to remove the second resin layer, the gloss of the entire film layer laminate (including only the metal layer and the first resin layer) was measured from the surface of the metal layer according to the ASTM D523 specifications at 20°, 60°, and 85°. More specifically, the difference between the film layer laminate of Example 2 and the film layer laminate of Example 1, which was subjected to the gloss measurement, is that the film layer laminate of Example 2 lacks the second resin layer compared to the film layer laminate of Example 1. The main difference between Example 3 and Example 1 is as follows: The material of the second resin layer of the film layer laminate was changed from transparent PET to transparent OPP, and after the first hot-press step was performed and the second resin layer was still placed on the metal layer, the gloss of the entire film layer laminate was measured from the surface of the second resin layer (OPP) according to the ASTM D523 specifications at 20°, 60°, and 85°. The difference between Example 4 and Example 3 is as follows: In Example 4, after performing the first hot pressing step to remove the second resin layer, the gloss 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 gloss 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 can be described as follows: In Comparative Example 1, the second resin layer (PET) is removed before the first hot-pressing step. Therefore, after the first hot-pressing step, the gloss 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 according to the ASTM D523 specifications. More specifically, the difference between Comparative Example 1 and Example 2 is that the first hot-pressing 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 can be described as follows: In Comparative Example 2, the second resin layer (OPP) is removed before the first hot-pressing step. Therefore, after the first hot-pressing step, the gloss 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 according to the ASTM D523 specifications. 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 Examples 1 and 2, or Examples 3 and 4, it can be seen that when a metal layer is disposed with a transparent second resin layer, the gloss 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 a second resin layer (PET) is disposed on the metal layer to protect it during the first hot-pressing step, the gloss of the metal layer is not significantly reduced by heating and pressure. Similarly, as demonstrated in Example 4 and Comparative Example 2, when a second resin layer (OPP) is disposed on the metal layer to protect it during the first hot-pressing step, the gloss of the metal layer is not significantly reduced by heating and pressure. In other words, during the hot-pressing step in the composite sheet manufacturing process, the second resin layer protects the metal layer from heat energy and pressure, thereby reducing the impact of heating and pressure on the metal layer, which is beneficial for maintaining the gloss of the metal layer.

[0039] Compared with the prior art, in the method for manufacturing a 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 maintaining the glossiness of the metal layer, and therefore the composite sheet having the metal layer and the composite structure having the composite sheet can provide a brighter visual effect when decorative styles are 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 the present 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' separate 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 specified angle A2 specified angle A3 specified angle D1: The distance between two adjacent metal projections H1 Height of protrusion from the fourth surface 122 N1: Normal direction at the vertex P1 of the metal protrusion 123 N2 Normal direction at point P2 of metal plane portion 125 P1 Top of metal protrusion 123 P2: Point 125 on the metal plane R11 is the incident light with a predetermined angle A1 R12 Reflected light of incident light R11 R21 is the incident light with a predetermined angle A2 R22 is the reflected light of incident light R21 R31 is the incident light with a predetermined 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. 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, and the second resin layer being removably disposed on the metal layer; performing a first hot pressing step, wherein the film layer laminate is heated and pressurized to fix the metal layer to the first resin layer and maintain the second resin layer removably disposed on the metal layer; a step of laminating a release member to the film layer laminate, the release member having a surface formed with a plurality of recesses facing 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:

2. The method for manufacturing a composite sheet according to claim 1 , 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.

3. 2. The method for manufacturing a composite sheet according to claim 1, further comprising the steps of removing the second resin layer and removably positioning a third resin layer on the metal layer, and the step of performing the second hot pressing step further comprises the step of forming a plurality of third resin protrusions in the third resin layer corresponding to the plurality of recesses.

4. 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, in which the film layer laminate is heated and pressurized to fix the metal layer to the first resin layer, maintain the second resin layer so as to be removably disposed 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:

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