Fiber-reinforced plastic decoration member using double-sided thin film lamination method and manufacturing method therefor

Abstract

Disclosed are a fiber-reinforced plastic decoration member using a double-sided thin film lamination method and a manufacturing method therefor, the fiber-reinforced plastic decoration member preventing fiber mesh marks of fiber-reinforced plastic (FRP) from being visible and enabling various colors and three-dimensional patterns to be expressed without adhesion problems and curling problems between the fiber-reinforced plastic and a printing layer. The fiber-reinforced plastic decoration member using the double-sided thin film lamination method and the manufacturing method therefor according to the present invention not only completely eliminate the curling problem that occurs when forming a decoration member on a single side, but also completely eliminate adhesion problems, which are chronic problems of existing methods.

Description

Fiber-reinforced plastic decorative member using a double-sided thin film lamination method and a method for manufacturing the same

[0001] The present invention relates to a fiber-reinforced plastic decorative member using a double-sided thin film lamination method and a method for manufacturing the same. More specifically, it relates to a fiber-reinforced plastic decorative member using a double-sided thin film lamination method and a method for manufacturing the same that can express various colors and 3D three-dimensional patterns without problems of adhesion between the fiber-reinforced plastic and the printing layer, as well as problems of curling, in addition to preventing the fiber mesh marks of the fiber-reinforced plastic (FRP) from being visible.

[0002]

[0003] Currently, the most commonly used materials for smartphone back covers include polycarbonate (PC), composites of polymethyl methacrylate (PMMA), and reinforced glass.

[0004] Reinforced glass is most commonly used as a back cover for high-end smartphones, composites of reinforced glass, PC, and PMMA are commonly used as back covers for mid-range smartphones, and general PC and composites of PC and PMMA are mainly used as back covers for low-end smartphones.

[0005] However, as price competition in the low-end segment has intensified due to the growth of Chinese smartphone manufacturers, significant efforts are being made to develop materials and decorative technologies that maintain durability while remaining affordable, enabling the expression of luxurious designs comparable to high-end models.

[0006] As an alternative to this, there has recently been a growing interest in fiber-reinforced plastic (FRP) materials, which have slightly lower durability than reinforced glass but higher stiffness than PC or composites of PC and PMMA.

[0007] Fiber reinforced plastic (FRP) materials mainly being considered include glass fiber reinforced plastic (GFRP), carbon fiber reinforced plastic (CFRP), and polybenzoxazole (PBO) reinforced plastic (PBOFRP). In this case, glass fiber reinforced plastic (GFRP) is mainly being considered for low-cost smartphones, while PBO reinforced plastic (PBOFRP) is being considered as a substitute for reinforced glass for high-end smartphones.

[0008] However, due to the physical properties of fiber-reinforced plastic (FRP) materials, while they offer excellent elasticity and stiffness relative to their weight, their strong corrosion and chemical resistance make it difficult to decorate surfaces in a luxurious manner.

[0009] Accordingly, Chinese smartphone manufacturers are currently mass-producing some products by decorating fiber-reinforced plastic (FRP) materials with only solid colors, such as silk printing, spray painting, or laminated artificial leather.

[0010] These single colors have limitations in appealing to consumers for differentiation due to their plain design. Therefore, there is a need to develop a technology to manufacture decorative components that can freely express various colors and 3D patterns on fiber-reinforced plastic (FRP) materials, which are difficult to implement decorative effects on due to their strong chemical resistance.

[0011] Currently, various manufacturing methods for decorative components are being considered, but a method that satisfies all the requirements of decorative effect, quality, reliability, and price has not been found. Among these, the biggest difficulty is the problem of not maintaining adhesion between various decorations and materials due to strong chemical resistance, and the problem of curling occurring due to the difference in physical properties between the decorative material and the fiber-reinforced plastic material.

[0012] As attempts are made to resolve these issues, the process becomes more complex, leading to price increases.

[0013]

[0014] Below, we will explain the representative methods for decorating fiber-reinforced plastics currently under review and discuss their advantages and disadvantages, while specifically detailing the difficulties associated with decorating fiber-reinforced plastic materials.

[0015] FIG. 1 is a cross-sectional view showing a fiber-reinforced plastic decorative member according to a first example of the prior art.

[0016] As illustrated in FIG. 1, a fiber-reinforced plastic decorative member (100) according to a conventional first example comprises a primary decorative member film (120), a bonding member (140), and a fiber-reinforced plastic (160).

[0017] Here, the primary decorative film (120) includes a transparent substrate layer (121), a color printing layer (122), an imprinting pattern layer (123), a deposition layer (124), and a printing layer (125) stacked sequentially from the top.

[0018] The transparent substrate layer (121) may be a PET film with one side hard-coated. Additionally, the color printing layer (122) may be tinted, and the imprinting pattern layer (123) may be made of UV paint.

[0019] In this way, the primary decorative member film (120) has a color printing layer (122), an imprinting pattern layer (123), a deposition layer (124), and a printing layer (125) sequentially laminated on the lower surface of a transparent substrate layer (121) (PET film) that has one side hard-coated. Here, the color is expressed in the color printing layer (122) and the deposition layer (124).

[0020] A bonding member (140) and a fiber-reinforced plastic (160) are arranged sequentially on the back surface of the primary decorative member film (120), and the primary decorative member film (120) and the fiber-reinforced plastic (160) are laminated by heat pressing through the bonding member (140). At this time, an optical clearance adhesive (OCA) may be used as the bonding member (140).

[0021] In this way, the fiber-reinforced plastic decorative member (100) according to the first example of the prior art is manufactured by a method in which a bonding member (140) is placed between the fiber-reinforced plastic (160) and the primary decorative member film (120), and the two materials are laminated by applying a constant pressure and, if necessary, a constant heat to complete the fiber-reinforced plastic decorative member (100), then placed in a vacuum chamber (autoclave) to remove air bubbles formed in the laminated layer and improve adhesion to complete the final product.

[0022] However, since this method laminates fiber-reinforced plastic (160) and PET film (121) with different physical properties on one side, there is a problem that curl occurs in the direction of the primary decorative film (120) laminated with the bonding member (140) (OCA).

[0023] In addition, the adhesion between the fiber-reinforced plastic (160) and the bonding member (140) (OCA) is weak and easily peels off, and the problem of adhesion between the materials is serious due to mesh marks on the surface of the fiber-reinforced plastic (160).

[0024] Furthermore, since this method consists of multiple layers and the process is complex, it is not suitable for application as a method for manufacturing fiber-reinforced plastic decorative members due to issues of reduced reliability and quality. That is, the deposition layer (124) is vulnerable to moisture and sweat and has interlayer delamination problems, and the OCA used as the bonding member (140) is weak in adhesion.

[0025]

[0026] FIG. 2 is a cross-sectional view showing a fiber-reinforced plastic decorative member according to a second example of the prior art.

[0027] As illustrated in FIG. 2, a fiber-reinforced plastic decorative member (200) according to the second example of the prior art comprises a fiber-reinforced plastic (220), a primer coating layer (240), and an imprinting pattern layer (260).

[0028] In this way, the fiber-reinforced plastic decorative member (200) according to the second example of the prior art has a primer coating layer (240) formed on one side of the fiber-reinforced plastic (220) to minimize fiber marks and smooth the surface, and to maintain adhesion between the fiber-reinforced plastic (220) and the imprinting pattern layer (260).

[0029] At this time, an imprinting pattern layer (260) is formed on the exposed surface of a primer coating layer (240) located on the fiber-reinforced plastic (220) using UV paint of various colors to produce a fiber-reinforced plastic decorative member (200).

[0030] However, the fiber-reinforced plastic decorative member (200) according to the second example of the prior art is manufactured using a very simple method, but since the decoration is expressed on one side, there is a serious problem of curling occurring toward the decorative surface where the primer coating layer (240) and the imprinting pattern layer (260) are located, and there is a difficulty in developing color UV paints for each color, and the colors that can be expressed are limited.

[0031] In addition, there are limitations in covering fiber mesh marks, resulting in a problem where mesh marks are visible on the surface.

[0032] The fiber-reinforced plastic decorative member (200) according to the second example of the prior art has a primer coating to maintain adhesion between the fiber-reinforced plastic (220) and the imprinting pattern layer (260), so there is no adhesion problem and there is no deposition process, so the reliability quality is relatively stable and the price is competitive.

[0033] However, the fiber-reinforced plastic decorative member (200) according to the conventional second example requires expensive color UV dedicated imprinting equipment, and the most critical problem is that it can only express a single color and cannot be applied to decorations that express multiple colors simultaneously, such as gradation effects or photorealistic printing. This becomes a significant disadvantage that makes it very vulnerable to expressing various designs.

[0034]

[0035] FIG. 3 is a cross-sectional view showing a fiber-reinforced plastic decorative member according to the third example of the prior art.

[0036] As illustrated in FIG. 3, a fiber-reinforced plastic decorative member (300) according to the third example of the prior art comprises a fiber-reinforced plastic (310), a primer coating layer (320), an imprinting pattern layer (330), a deposition layer (340), and a UV coating layer (350).

[0037] In this way, the fiber-reinforced plastic decorative member (300) according to the third example of the prior art is formed by first performing UV imprinting without a pattern on one surface of the fiber-reinforced plastic (310) using a color UV paint or a transparent UV paint to form a primer coating layer (320). Subsequently, a second UV imprinting is performed on the primer coating layer (320) to form an imprinting pattern layer (330), and a deposition layer (340) is formed on the imprinting pattern layer (330). Subsequently, to protect the deposition layer (340), a third imprinting is performed to form a UV coating layer (350) on the deposition layer (340) to produce the fiber-reinforced plastic decorative member (300).

[0038] Although this method has the advantage of having a smooth surface so that no foreign matter gets stuck, there is a serious problem with the adhesion between the fiber-reinforced plastic (310) and the primer coating layer (320) on which the first imprinting is performed.

[0039] In addition, since this method has a decoration on one side, there is a problem of curling occurring in the direction of the decoration surface. Also, due to the deposition layer (340), there are problems with reliability and increased cost.

[0040] In addition, because it requires three imprinting processes, the mass production yield is low, which leads to an increase in cost. Above all, although this method is continuously being reviewed, it is difficult to apply in practice because the aforementioned issues of adhesion, warping, and increased process costs have not yet been resolved.

[0041]

[0042] FIG. 4 is a cross-sectional view showing a fiber-reinforced plastic decorative member according to the fourth example of the prior art.

[0043] As illustrated in FIG. 4, the fiber-reinforced plastic decorative member (400) according to the fourth example of the prior art comprises a fiber-reinforced plastic (420), a primer coating layer (440), an imprinting pattern layer (460), and a back coating layer (480).

[0044] In this way, the fiber-reinforced plastic decorative member (400) according to the fourth example of the prior art has a back coating layer (480) formed on the lower surface of the fiber-reinforced plastic (420) to solve the problems of curl and interlayer adhesion, which are common problems that appear in all three of the aforementioned methods. At this time, the back coating layer (480) can be formed by performing patternless imprinting, laminating a film, or printing.

[0045] However, this method cannot be applied because there are problems with adhesion and increased costs, and all methods of patternless imprinting, printing, and laminating films on the lower surface of the fiber-reinforced plastic (420) have problems with adhesion and increased costs.

[0046]

[0047] In conclusion, various methods are being considered to manufacture fiber-reinforced plastic decorative members, but they have not been able to solve the problems of interlayer adhesion and bending.

[0048] To address this, the continuous addition of new processes is creating new problems, and since the cost also rises with these additions, it is difficult to use fiber-reinforced plastics as a low-cost material.

[0049] In addition, due to the strong chemical resistance, a physical property of fiber-reinforced plastics, there is a problem where the adhesive strength weakens when attaching various adhesives and auxiliary materials during assembly with sets, which is hindering the widespread use of fiber-reinforced plastics.

[0050] A relevant prior art document is Korean Published Patent Application No. 10-2020-0039663 (published April 16, 2020), which describes a laminated sheet, a coated fiber, a coated fiber bundle, and a fiber-reinforced plastic.

[0051]

[0052] The objective of the present invention is to provide a fiber-reinforced plastic decorative member using a double-sided thin film lamination method and a method for manufacturing the same, which can express various colors and 3D three-dimensional patterns without the problem of adhesion between the fiber-reinforced plastic and the printing layer and the problem of curling, in addition to making the fiber mesh marks of the fiber-reinforced plastic (FRP) invisible.

[0053]

[0054] A fiber-reinforced plastic decorative member of a double-sided thin film lamination method according to an embodiment of the present invention for achieving the above objective comprises: a fiber-reinforced plastic structure having a fiber-reinforced plastic and a first bonding member formed on the fiber-reinforced plastic; an upper overlay film structure laminated to the upper portion of the fiber-reinforced plastic structure via the first bonding member, having an upper overlay film and a printing layer formed on the lower surface of the upper overlay film and bonded to the first bonding member; a lower overlay film structure disposed to the lower portion of the fiber-reinforced plastic structure, having a lower overlay film and a second bonding member formed on the upper surface of the lower overlay film and laminated to the fiber-reinforced plastic; and a UV pattern layer formed on the upper surface of the upper overlay film.

[0055] The above fiber-reinforced plastic includes one or more types selected from glass fiber reinforced plastic, carbon fiber reinforced plastic, PBO fiber reinforced plastic, and Kevlar reinforced plastic.

[0056] Each of the above upper and lower overlay films is formed from one or more materials selected from transparent PVC, colored PVC, PET, PI, PMMA, and PC.

[0057] Each of the above upper and lower overlay films has a thickness of 10 to 200 μm.

[0058] For each of the first and second bonding members, a thermosetting adhesive or a hot melt adhesive is used.

[0059] A surface reinforcement surface is formed on the upper surface of the above upper overlay film.

[0060]

[0061] A method for manufacturing a fiber-reinforced plastic decorative member using a double-sided thin film lamination method according to an embodiment of the present invention for achieving the above objective comprises: (a) forming an upper overlay film structure by forming a printing layer on the lower surface of an upper overlay film; (b) forming a fiber-reinforced plastic structure by forming a first bonding member on the upper surface of the fiber-reinforced plastic; (c) forming a lower overlay film structure by forming a second bonding member on the upper surface of a lower overlay film; (d) sequentially loading the lower overlay film structure, the fiber-reinforced plastic structure, and the upper overlay film structure onto a dedicated jig; (e) mounting the dedicated jig so as to be fixed onto a lamination dedicated plate, and then aligning a metal plate and a heat press device on the upper overlay film; (f) laminating the upper overlay film structure, the fiber-reinforced plastic structure, and the lower overlay film structure by heat pressing using the metal plate and the heat press device. and (g) a step of forming a fiber-reinforced plastic decorative member by forming a UV pattern layer on the exposed upper overlay film structure after removing the metal plate from the laminated upper overlay film structure, fiber-reinforced plastic structure and lower overlay film structure; characterized by including

[0062] Each of the above upper and lower overlay films is formed from a material selected from transparent PVC and colored PVC.

[0063] In step (f) above, the laminate is heat-pressed at 150 to 250°C under a pressure of 30 to 60 bar.

[0064] In step (g) above, a surface-reinforced surface formed by increasing surface density and surface roughness is located on the upper surface of the upper overlay film by heat press lamination using the metal plate.

[0065]

[0066] A method for manufacturing a fiber-reinforced plastic decorative member using a double-sided thin film lamination method according to a modified embodiment of the present invention for achieving the above objective comprises: (a) forming a printing layer on the lower surface of an upper overlay film to manufacture an upper overlay film structure, and then forming a UV pattern layer on the upper surface of the upper overlay film; (b) forming a fiber-reinforced plastic structure by forming a first bonding member on the upper surface of the fiber-reinforced plastic; (c) forming a lower overlay film structure by forming a second bonding member on the upper surface of a lower overlay film; (d) sequentially loading the lower overlay film structure, the fiber-reinforced plastic structure, and the upper overlay film structure with the formed UV pattern layer onto a dedicated jig; (e) mounting the dedicated jig so as to be fixed onto a lamination dedicated plate, and then aligning a metal plate and a heat press device on the upper overlay film with the formed UV pattern layer; (f) laminating the upper overlay film structure with the formed UV pattern layer, the fiber-reinforced plastic structure, and the lower overlay film structure by heat pressing using the metal plate and the heat press device. and (g) a step of forming a fiber-reinforced plastic decorative member by removing a metal plate from an upper overlay film structure, a fiber-reinforced plastic structure, and a lower overlay film structure on which the UV pattern layer is formed; characterized by including

[0067] Each of the above upper and lower overlay films is formed from one or more materials selected from PET, PI, PMMA, and PC.

[0068] In step (f) above, the laminate is heat-pressed at 150 to 250°C under a pressure of 30 to 60 bar.

[0069]

[0070] According to the present invention, fiber mesh marks (resin shrinkage phenomenon) of fiber-reinforced plastic are not visible, and various colors and three-dimensional pattern designs can be formed without problems of adhesion between the fiber-reinforced plastic and the printing layer and curling.

[0071] In addition, according to the present invention, the manufacturing method is varied depending on the type of upper overlay film and lower overlay film laminated to both sides of the fiber-reinforced plastic by first and second bonding members.

[0072] In addition, according to the present invention, the problem of curling that occurs while forming a decorative member on the cross-section is completely improved, and there is no problem with adhesion, which is a chronic problem of existing methods.

[0073] In addition, according to the present invention, not only can various color expressions and multi-colors such as gradation be freely expressed, but 3D three-dimensional decoration is also easy.

[0074] In addition, according to the present invention, a hard surface reinforcement surface with a hardness level of 2H or higher is formed on the surface of the upper overlay film, making it resistant to scratches.

[0075] In addition, according to the present invention, since the printing layer is printed on the lower surface of the upper overlay film, it is highly resistant to wear.

[0076] In particular, according to the present invention, a color film can be used as a lower overlay film laminated to the lower surface of a fiber-reinforced plastic, so there is no problem with adhesion to various auxiliary materials used during set assembly without separate printing or imprinting, and there is no problem with internal transparency or light leakage due to excellent opacity (shielding power).

[0077] Furthermore, according to the present invention, while a reflective surface such as a deposition surface is required to obtain the effect of a three-dimensional pattern, the present invention can sufficiently realize the three-dimensional pattern effect even without a deposition surface. This resolves reliability issues that may arise from the deposition process (the oxide used in the deposition process is susceptible to moisture and salt, and there are problems with weak interlayer adhesion), reduces deposition costs, and improves price competitiveness.

[0078] In addition, according to the present invention, since fibers woven from fiber-reinforced plastic are used and the fiber-reinforced plastic is manufactured through a prepreg process, mesh marks (shrinkage) inevitably occur due to the shrinkage action of the resin; however, by using the method of the present invention, upper and lower overlay films of a thin film are laminated on both sides of the fiber-reinforced plastic, so the mesh marks can be perfectly covered.

[0079] As a result, by using the method of the present invention, a smooth surface can be obtained and the three-dimensional pattern effect can be effectively utilized, and above all, the problem of adhesion, which is a chronic issue of fiber-reinforced plastics used as decorative members, can be dramatically improved.

[0080]

[0081] FIG. 1 is a cross-sectional view showing an FRP decorative member according to a conventional first example.

[0082] FIG. 2 is a cross-sectional view showing an FRP decorative member according to a conventional second example.

[0083] FIG. 3 is a cross-sectional view showing an FRP decorative member according to the third example of the prior art.

[0084] FIG. 4 is a cross-sectional view showing an FRP decorative member according to the fourth example of the prior art.

[0085] FIG. 5 is an exploded perspective view showing a fiber-reinforced plastic decorative member with a double-sided thin film lamination method according to an embodiment of the present invention.

[0086] FIG. 6 is an exploded cross-sectional view showing a fiber-reinforced plastic decorative member of a double-sided thin film lamination method according to an embodiment of the present invention.

[0087] FIGS. 7 to 12 are process cross-sectional views illustrating a method for manufacturing a fiber-reinforced plastic decorative member using a double-sided thin film lamination method according to an embodiment of the present invention.

[0088] FIGS. 13 to 18 are process cross-sectional views illustrating a method for manufacturing a fiber-reinforced plastic decorative member using a double-sided thin film lamination method according to a modified example of the present invention.

[0089]

[0090] The advantages and features of the present invention and the methods for achieving them will become clear by referring to the embodiments described below in detail together with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below but may be implemented in various different forms. These embodiments are provided merely to ensure that the disclosure of the present invention is complete and to fully inform those skilled in the art of the scope of the invention, and the present invention is defined only by the scope of the claims. Throughout the specification, the same reference numerals refer to the same components.

[0091] The fiber-reinforced plastic decorative member and the method of manufacturing the same, according to a preferred embodiment of the present invention, will be described in detail below with reference to the attached drawings.

[0092]

[0093] FIG. 5 is an exploded perspective view showing a fiber-reinforced plastic decorative member with a double-sided thin film lamination method according to an embodiment of the present invention, and FIG. 6 is an exploded cross-sectional view showing a fiber-reinforced plastic decorative member with a double-sided thin film lamination method according to an embodiment of the present invention.

[0094] Referring to FIGS. 5 and 6, a fiber-reinforced plastic decorative member (500) of a double-sided thin film lamination method according to an embodiment of the present invention includes a fiber-reinforced plastic structure (540), an upper overlay film structure (520), a lower overlay film structure (560), and a UV pattern layer (580).

[0095]

[0096] The fiber-reinforced plastic structure (540) has a fiber-reinforced plastic (542) and a first bonding member (544) formed on the fiber-reinforced plastic (542).

[0097] Here, any type of fiber-reinforced plastic (542) can be used without limitation. More specifically, it is preferable that the fiber-reinforced plastic (542) include one or more selected from glass fiber reinforced plastic, carbon fiber reinforced plastic, PBO (polybenzoxazole) fiber reinforced plastic, and Kevlar reinforced plastic.

[0098] The first bonding member (544) is formed by applying and drying an adhesive or glue to a uniform thickness using a silk screen printing method. The choice of adhesive or glue can be optimized by considering the interlayer adhesion strength, leveling after lamination, and degree of bending, depending on the type of fiber-reinforced plastic (542) and the choice of upper overlay film (522). To this end, it is preferable to use a thermosetting adhesive or a hot melt adhesive for the first bonding member (544).

[0099]

[0100] The upper overlay film structure (520) is laminated to the upper portion of the fiber-reinforced plastic structure (540) via a first bonding member (544).

[0101] This upper overlay film structure (520) has an upper overlay film (522) and a printed layer (524) formed on the lower surface of the upper overlay film (522) and bonded to a first bonding member (544).

[0102] The upper overlay film (522) preferably has a thickness of 10 to 200 μm, and more preferably has a thickness of 100 to 150 μm. If the thickness of the upper overlay film (522) is less than 10 μm, it is difficult to ensure durability, and there is a risk of bending deformation occurring during heat press lamination. Conversely, if the thickness of the upper overlay film (522) exceeds 200 μm, it increases the overall thickness of the decorative member (500), which results in a condition that runs counter to the trend of thin and light lightweighting, and is therefore undesirable.

[0103] The upper overlay film (522) may use a film of various materials depending on the requirements. The upper overlay film (522) may include one or more selected from transparent PVC (polyvinyl chloride), colored PVC (polyvinyl chloride), PET (polyethylene terephthalate), PI (polyimide), PMMA (polymethyl methacrylate) and PC (polycarbonate).

[0104] The printed layer (524) is formed by printing on the lower surface of the upper overlay film (522) using a color and printing method that matches the customer's specifications. At this time, it is desirable to select an appropriate ink and printing method to ensure that the adhesion between the upper overlay film (522) and the printed layer (524) is well maintained. More specifically, the printed layer (524) can be printed using one or more methods selected from digital printing, offset printing, gravure printing, silkscreen printing, etc., and various other types of printing methods may also be applied. At this time, the printed layer (524) can be single color, multi-color, gradient, realistic, black and white, etc.

[0105]

[0106] The lower overlay film structure (560) is placed on the lower part of the fiber-reinforced plastic structure (540).

[0107] This lower overlay film structure (560) has a lower overlay film (562) and a second bonding member (564) formed on the upper surface of the lower overlay film (562) and laminated to the fiber-reinforced plastic (540).

[0108] The lower overlay film (562), like the upper overlay film (522), preferably has a thickness of 10 to 200 μm, and more preferably has a thickness of 100 to 150 μm. If the thickness of the lower overlay film (562) is less than 10 μm, it is difficult to ensure durability, and there is a risk of bending deformation occurring during heat press lamination. Conversely, if the thickness of the lower overlay film (562) exceeds 200 μm, it increases the overall thickness of the decorative member (500), resulting in a outcome that runs counter to the trend of thin and light lightweighting, which is undesirable.

[0109] The lower overlay film (562) may use a film of various materials depending on the requirements. The lower overlay film (562), like the upper overlay film (522), may include one or more selected from transparent PVC (polyvinyl chloride), colored PVC (polyvinyl chloride), PET (polyethylene terephthalate), PI (polyimide), PMMA (polymethyl methacrylate), and PC (polycarbonate). At this time, it is preferable that the material of the lower overlay film (562) be the same material having the same physical properties as the upper overlay film (522).

[0110]

[0111] A UV pattern layer (580) is formed on the upper surface of the upper overlay film (522).

[0112] Here, the UV pattern layer (580) can be formed by applying UV paint on an upper overlay film (522) to form a UV paint layer, and then imprinting the UV paint layer with a pattern mold.

[0113]

[0114] The fiber-reinforced plastic decorative member (500) according to the embodiment of the present invention described above may apply a method of laminating the upper overlay film (522) and the lower overlay film (562) on both sides of the fiber-reinforced plastic (542) using first and second bonding members (thermosetting adhesive or hot melt adhesive) by applying heat and pressure to laminate the double-sided thin film, and then forming a UV pattern layer (580) by an imprinting process.

[0115] In contrast, the fiber-reinforced plastic decorative member (500) of the double-sided thin film lamination method according to an embodiment of the present invention may apply a double-sided lamination method in which a UV pattern layer (580) is first formed by an imprinting process, and then the double-sided thin film is laminated using heat and pressure.

[0116] In the present invention, if the upper overlay film (522) uses a material with a soft hardness such as a PVC film, the imprinting process is first performed on the PVC film of the soft material, and then double-sided lamination is performed. In this case, the UV pattern layer (580) formed on the surface of the upper overlay film (522) may be crushed or deformed due to the heat and pressure applied during lamination, which may cause a problem in which the three-dimensional pattern effect is reduced.

[0117] For this reason, when using a soft material upper overlay film (522) such as PVC film, it is necessary to perform double-sided lamination and then perform imprinting to manufacture a fiber-reinforced plastic decorative member (500) so that the effect of the three-dimensional pattern can be fully realized.

[0118] In this case, the density and roughness of the surface of the upper overlay film (522) are increased by the heat and high pressure generated during double-sided lamination using a metal plate and a heat press device, thereby forming a hard surface reinforced surface with a hardness of 2H or higher on the upper surface of the upper overlay film (522). In this way, by increasing the density and roughness of the surface of the upper overlay film (522) to form a hard surface reinforced surface, the pattern of the UV pattern layer (580) can be brought to life after imprinting without forming a separate reflective layer such as deposition, thereby maximizing the three-dimensional effect.

[0119] In contrast, in the present invention, the upper overlay film (522) may be made of a film such as PET (polyethylene terephthalate), PI (polyimide), PMMA (polymethyl methacrylate), or PC (polycarbonate) which has relatively high hardness.

[0120] In this way, if a material with relatively high strength, such as PET, PI, PMMA, or PC film, is used as the upper overlay film (522), then even if a UV pattern layer (580) is first formed on the upper overlay film (522) by an imprinting process and then double-sided lamination is performed, the upper overlay film (522) is made of a material with relatively high strength, so the UV pattern layer (580) is not crushed or severely deformed by heat and pressure, and thus the three-dimensional effect of the UV pattern layer (580) can be preserved after imprinting without forming a separate reflective layer such as deposition.

[0121]

[0122] As described above, the fiber-reinforced plastic decorative member with a double-sided thin film lamination method according to an embodiment of the present invention is formed by laminating an upper overlay film and a lower overlay film on both sides of the fiber-reinforced plastic using a heat-curing adhesive or a hot-melt adhesive and applying heat and pressure, and then applying a method of forming a UV pattern layer by an imprinting process, or by forming a UV pattern layer first by an imprinting process and then laminating.

[0123] As a result, the fiber-reinforced plastic decorative member according to the double-sided thin film lamination method of the embodiment of the present invention makes the fiber mesh marks (resin shrinkage phenomenon) of the fiber-reinforced plastic invisible, and enables the formation of various colors and three-dimensional pattern designs without problems of adhesion between the fiber-reinforced plastic and the printing layer or curling.

[0124]

[0125] This will be explained in more detail below through a method for manufacturing a fiber-reinforced plastic decorative member using a double-sided thin film lamination method according to an embodiment of the present invention.

[0126] FIGS. 7 to 12 are process cross-sectional views illustrating a method for manufacturing a fiber-reinforced plastic decorative member using a double-sided thin film lamination method according to an embodiment of the present invention.

[0127] As shown in FIG. 7, an upper overlay film structure (520) is formed by forming a printing layer (524) on the lower surface of the upper overlay film (522).

[0128] In this way, an upper overlay film structure (520) is completed by forming a printing layer (524) on the lower surface of the upper overlay film (522) using a color and printing method that matches the customer's specifications. At this time, it is desirable to select an appropriate ink and printing method to ensure that the adhesion between the upper overlay film (522) and the printing layer (524) is well maintained. More specifically, the printing layer (524) can be printed using one or more methods selected from digital printing, offset printing, gravure printing, silkscreen printing, etc., and various other types of printing methods may also be applied. At this time, the printing layer (524) can be single color, multi-color, gradient, realistic, black and white, etc.

[0129] It is preferable that the upper overlay film (522) has a thickness of 10 to 200 μm, and more preferable that it has a thickness of 100 to 150 μm. If the thickness of the upper overlay film (522) is less than 10 μm, it is difficult to ensure durability, and there is a risk of bending deformation occurring during heat press lamination. Conversely, if the thickness of the upper overlay film (522) exceeds 200 μm, it increases the overall thickness of the decorative member, resulting in a outcome that runs counter to the trend of thin and light lightweighting, so it is not desirable.

[0130] In the manufacturing method according to an embodiment of the present invention, it is preferable to use a PVC film such as transparent PVC (polyvinyl chloride) or colored PVC (polyvinyl chloride), which is a material with relatively soft hardness, for the upper overlay film (522). As such, in the embodiment of the present invention, it is preferable to apply this method only in a limited manner when a PVC film with relatively soft hardness is used as the material for the upper overlay film (522).

[0131] Therefore, when using a film such as PET (polyethylene terephthalate), PI (polyimide), PMMA (polymethyl methacrylate), or PC (polycarbonate) with relatively high hardness as the upper overlay film (522), it is preferable not to apply the manufacturing method according to the embodiment of the present invention. That is, when using a material with relatively high hardness as the upper overlay film (522), it is preferable to apply the manufacturing method according to the modified example of the present invention described later.

[0132]

[0133] Next, as shown in FIG. 8, a first bonding member (544) is formed on the upper surface of the fiber-reinforced plastic (542) to form a fiber-reinforced plastic structure (540).

[0134] In this way, an adhesive or bonding agent is applied to one side, that is, the upper surface, of a fiber-reinforced plastic (542) that meets the customer's specifications, in a uniform thickness and dried to form a first bonding member (544), thereby forming a fiber-reinforced plastic structure (540).

[0135] Here, the first bonding member (544) is formed by applying an adhesive or glue to a uniform thickness using a silk screen printing method and drying it. At this time, the choice of adhesive or glue can be optimized by considering the interlayer adhesion strength, leveling after lamination, and degree of bending, depending on the type of fiber-reinforced plastic (542) and the choice of upper overlay film (522). To this end, it is preferable to use a thermosetting adhesive or a hot melt adhesive for the first bonding member (544).

[0136] Any type of fiber-reinforced plastic (542) can be used without limitation. More specifically, it is preferable that the fiber-reinforced plastic (542) include one or more selected from glass fiber reinforced plastic, carbon fiber reinforced plastic, PBO (polybenzoxazole) fiber reinforced plastic, and Kevlar reinforced plastic.

[0137]

[0138] As shown in FIG. 9, a second bonding member (564) is formed on the upper surface of the lower overlay film (562) to form a lower overlay film structure (560).

[0139] In this way, an adhesive or adhesive is applied to the upper surface of the lower overlay film (562) to a certain thickness and dried to form a second bonding member (564), thereby forming a lower overlay film structure (560).

[0140] Here, the second bonding member (564) is formed by applying an adhesive or glue to a uniform thickness using a silk screen printing method and drying it, just like the first bonding member (544). At this time, the choice of adhesive or glue can be optimized by considering the interlayer adhesion strength, leveling after lamination, and degree of bending, depending on the type of fiber-reinforced plastic (542) and the choice of lower overlay film (562). To this end, it is preferable for the second bonding member (564) to use a thermosetting adhesive or a hot melt adhesive, just like the first bonding member (544).

[0141] The lower overlay film (562), like the upper overlay film (522), preferably has a thickness of 10 to 200 μm, and more preferably has a thickness of 100 to 150 μm. If the thickness of the lower overlay film (562) is less than 10 μm, it is difficult to ensure durability, and there is a risk of bending deformation occurring during heat press lamination. Conversely, if the thickness of the lower overlay film (562) exceeds 200 μm, it increases the overall thickness of the decorative member, resulting in a outcome that runs counter to the trend of thin and light lightweighting, which is undesirable.

[0142] In the manufacturing method according to an embodiment of the present invention, it is preferable to use a PVC film such as transparent PVC (polyvinyl chloride) or colored PVC (polyvinyl chloride), which is a material with relatively soft hardness, for the lower overlay film (562). As such, in the embodiment of the present invention, it is preferable to apply this method only in a limited manner when a PVC film with relatively soft hardness is used as the material for the lower overlay film (562).

[0143] Therefore, when using a film such as PET (polyethylene terephthalate), PI (polyimide), PMMA (polymethyl methacrylate), or PC (polycarbonate) with relatively high hardness as the lower overlay film (562), it is preferable not to apply the manufacturing method according to the embodiment of the present invention. That is, when using a material with relatively high hardness as the lower overlay film (562), it is preferable to apply the manufacturing method according to the modified example of the present invention described later. At this time, it is preferable to use the same material as the upper overlay film (522) having the same physical properties as the material of the lower overlay film (562).

[0144]

[0145] As shown in FIG. 10, a lower overlay film structure (560), a fiber-reinforced plastic structure (540), and an upper overlay film structure (520) are loaded sequentially onto a dedicated jig (620).

[0146] In this way, the lower overlay film structure (560), the fiber-reinforced plastic structure (540), and the upper overlay film structure (520) are sequentially aligned and loaded onto a dedicated jig (620) to complete the preparation for double-sided lamination.

[0147] Accordingly, the first bonding member (544) of the fiber-reinforced plastic structure (540) is positioned to face the printed layer (524) of the upper overlay film structure (520), and the second bonding member (564) of the lower overlay film structure (560) is positioned to face the fiber-reinforced plastic (542) of the fiber-reinforced plastic structure (542). As a result, the first bonding member (544) is positioned on the upper surface of the fiber-reinforced plastic (542), and the second bonding member (564) is positioned on the lower surface of the fiber-reinforced plastic (542).

[0148]

[0149] As shown in FIG. 11, after mounting a dedicated jig (620) so as to be fixed onto a lamination dedicated plate (640), a metal plate (660) and a heat press device (680) are positioned and aligned on an upper overlay film (522).

[0150] Here, it is preferable to align the upper overlay film (522) of the upper overlay film structure (520) so that it comes into contact with the metal plate (660).

[0151] Next, the upper overlay film structure (520), the fiber-reinforced plastic structure (540), and the lower overlay film structure (560) are laminated by heat pressing using a metal plate (660) and a heat press device (680).

[0152] In this way, a dedicated jig (620) in which a lower overlay film structure (560), a fiber-reinforced plastic structure (540), and an upper overlay film structure (520) are sequentially loaded is mounted so as to be fixed on a lamination dedicated plate (640), and then a metal plate (660) is placed on the upper surface of the upper overlay film (522), and double-sided lamination is performed under appropriate heat and pressure conditions to complete a double-sided laminated fiber-reinforced plastic sheet. At this time, the lamination temperature and pressure conditions must be set to optimal conditions by considering the type of fiber-reinforced plastic (542), the types of upper and lower overlay films (522, 562), the type of adhesive or pressure-sensitive adhesive, and the interlayer adhesion strength, leveling, bending, surface roughness, etc.

[0153] Here, the reason for using a metal plate (660) is to increase the density and roughness of the surface of the upper overlay film (522) due to the heat and high pressure generated during lamination, thereby forming a hard surface reinforced surface with a hardness of 2H or higher on the upper surface of the upper overlay film (522). In this way, by increasing the density and roughness of the surface of the upper overlay film (522) to form a hard surface reinforced surface, the three-dimensional effect of the UV pattern layer can be maximized after imprinting without forming a separate reflective layer such as deposition.

[0154] In this step, it is preferable to heat press the lamination at a temperature of 150 to 250°C under a pressure of 30 to 60 bar, and more preferable to heat press the lamination at a temperature of 180 to 220°C under a pressure of 40 to 50 bar. In the lamination step, if the heat press temperature is less than 150°C or the heat press pressure is less than 30 bar, there is a risk that a hard surface reinforcement surface may not be formed on the upper surface of the upper overlay film (522) because the surface density and surface roughness of the upper overlay film (522) are not sufficiently increased. Conversely, if the heat press temperature exceeds 250°C or the heat press pressure exceeds 60 bar, it is not desirable because excessive heat and pressure are applied, which may cause warping defects due to shape deformation of the upper and lower overlay films (522, 562).

[0155]

[0156] As shown in FIG. 12, after removing the metal plate (660 in FIG. 11) from the laminated upper overlay film structure (520), fiber-reinforced plastic structure (540) and lower overlay film structure (560), a UV pattern layer (580) is formed on the exposed upper overlay film structure (520) to form a fiber-reinforced plastic decorative member (500).

[0157] As described above, by applying heat and pressure using a metal plate and a heat press device to laminate the two sides, a hard surface reinforcement surface is formed on the upper surface of the upper overlay film (522).

[0158] This surface reinforcement surface is formed by increasing the surface density and surface roughness of the upper surface of the upper overlay film (522) through heat press lamination using a metal plate.

[0159] In this way, by forming a UV pattern layer (580) on the upper surface of the upper overlay film (522) having a hard surface reinforcement surface, it becomes possible to maximize the three-dimensional effect of the UV pattern layer (580) after imprinting without forming a separate reflective layer such as deposition.

[0160] Here, the UV pattern layer (580) can be formed by applying UV paint on an upper overlay film (522) to form a UV paint layer, and then imprinting the UV paint layer with a pattern mold.

[0161] The key to the method for manufacturing a fiber-reinforced plastic decorative member using a double-sided thin film lamination method according to an embodiment of the present invention is to manufacture the fiber-reinforced plastic decorative member (500) by performing an imprinting process after the double-sided lamination process to form a UV pattern layer (580).

[0162] As in the embodiment of the present invention, when the upper overlay film (522) uses a material with a soft hardness such as a PVC film, if the imprinting process is first performed on the PVC film of the soft material and then double-sided lamination is performed, the UV pattern layer (580) formed on the surface of the upper overlay film (522) is crushed or deformed due to the heat and pressure applied during lamination, and thus the three-dimensional pattern effect is reduced.

[0163] For this reason, when using a soft material such as a PVC film, the upper surface overlay film (522) must be laminated on both sides and then imprinted to manufacture the fiber-reinforced plastic decorative member (500), so that the pattern of the UV pattern layer (580) is brought to life and the three-dimensional pattern effect can be maximized.

[0164] After forming a UV pattern layer (580) by such imprinting, an anti-fingerprint (AF) coating process may be additionally performed on the UV pattern layer (580) as needed to further form an anti-fingerprint coating layer (not shown).

[0165] With this, the method for manufacturing a fiber-reinforced plastic decorative member using a double-sided thin film lamination method according to an embodiment of the present invention may be concluded.

[0166]

[0167] Meanwhile, FIGS. 13 to 18 are process cross-sectional views illustrating a method for manufacturing a fiber-reinforced plastic decorative member using a double-sided thin film lamination method according to a modified example of the present invention. In this modified example of the present invention, components identical to those in the example are indicated by the same drawing numbers.

[0168] As shown in FIG. 13, an upper overlay film structure (520) is manufactured by forming a printing layer (524) on the lower surface of the upper overlay film (522), and then a UV pattern layer (580) is formed on the upper surface of the upper overlay film (522).

[0169] In this way, an upper overlay film structure (520) is completed by forming a printing layer (524) on the lower surface of the upper overlay film (522) using a color and printing method that matches the customer's specifications. At this time, it is desirable to select an appropriate ink and printing method to ensure that the adhesion between the upper overlay film (522) and the printing layer (524) is well maintained. More specifically, the printing layer (524) can be printed using one or more methods selected from digital printing, offset printing, gravure printing, silkscreen printing, etc., and various other types of printing methods may also be applied. At this time, the printing layer (524) can be single color, multi-color, gradient, realistic, black and white, etc.

[0170] In addition, a UV paint layer is formed by applying UV paint to the upper surface of the upper overlay film (522), and then a UV pattern layer (580) is formed by imprinting the UV paint layer with a pattern mold.

[0171] Here, the upper overlay film (522) preferably has a thickness of 10 to 200 μm, and more preferably has a thickness of 100 to 150 μm. If the thickness of the upper overlay film (522) is less than 10 μm, it is difficult to ensure durability, and there is a risk of bending deformation occurring during heat press lamination. Conversely, if the thickness of the upper overlay film (522) exceeds 200 μm, it increases the overall thickness of the decorative member, resulting in a outcome that runs counter to the trend of thin and light lightweighting, so it is not desirable.

[0172] In the manufacturing method according to a modified example of the present invention, it is preferable to use a film such as PET (polyethylene terephthalate), PI (polyimide), PMMA (polymethyl methacrylate), or PC (polycarbonate), which has relatively high hardness, as the upper overlay film (522).

[0173] In this way, in a modified embodiment of the present invention, if a material with relatively high strength, such as PET, PI, PMMA, or PC film, is used as the upper overlay film (522), then even if a UV pattern layer (580) is first formed on the upper overlay film (522) by an imprinting process and then double-sided lamination is performed, the upper overlay film (522) is made of a material with relatively high strength, so the UV pattern layer (580) is not crushed or severely deformed by heat and pressure.

[0174]

[0175] Next, as shown in FIG. 14, a first bonding member (544) is formed on the upper surface of the fiber-reinforced plastic (542) to form a fiber-reinforced plastic structure (540).

[0176] In this way, an adhesive or bonding agent is applied to one side, that is, the upper surface, of a fiber-reinforced plastic (542) that meets the customer's specifications, in a uniform thickness and dried to form a first bonding member (544), thereby forming a fiber-reinforced plastic structure (540).

[0177] Here, the first bonding member (544) is formed by applying an adhesive or glue to a uniform thickness using a silk screen printing method and drying it. At this time, the choice of adhesive or glue can be optimized by considering the interlayer adhesion strength, leveling after lamination, and degree of bending, depending on the type of fiber-reinforced plastic (542) and the choice of upper overlay film (522). To this end, it is preferable to use a thermosetting adhesive or a hot melt adhesive for the first bonding member (544).

[0178] Any type of fiber-reinforced plastic (542) can be used without limitation. More specifically, it is preferable that the fiber-reinforced plastic (542) include one or more selected from glass fiber reinforced plastic, carbon fiber reinforced plastic, PBO (polybenzoxazole) fiber reinforced plastic, and Kevlar reinforced plastic.

[0179]

[0180] As shown in FIG. 15, a second bonding member (564) is formed on the upper surface of the lower overlay film (562) to form a lower overlay film structure (560).

[0181] In this way, an adhesive or adhesive is applied to the upper surface of the lower overlay film (562) to a certain thickness and dried to form a second bonding member (564), thereby forming a lower overlay film structure (560).

[0182] Here, the second bonding member (564) is formed by applying a pressure-sensitive adhesive or adhesive to a uniform thickness using a silk screen printing method and drying it. At this time, the selection of the pressure-sensitive adhesive or adhesive can be optimized by considering the interlayer adhesion strength, leveling after lamination, and degree of bending, depending on the type of fiber-reinforced plastic (542) and the selection of the lower overlay film (562). To this end, it is preferable that the second bonding member (564) use a thermosetting pressure-sensitive adhesive or a hot-melt adhesive, just like the first bonding member (544).

[0183] The lower overlay film (562), like the upper overlay film (522), preferably has a thickness of 10 to 200 μm, and more preferably has a thickness of 100 to 150 μm. If the thickness of the lower overlay film (562) is less than 10 μm, it is difficult to ensure durability, and there is a risk of bending deformation occurring during heat press lamination. Conversely, if the thickness of the lower overlay film (562) exceeds 200 μm, it increases the overall thickness of the decorative member, resulting in a outcome that runs counter to the trend of thin and light lightweighting, which is undesirable.

[0184] In the manufacturing method according to a modified example of the present invention, the lower overlay film (562) preferably uses a film such as PET (polyethylene terephthalate), PI (polyimide), PMMA (polymethyl methacrylate), or PC (polycarbonate), which has relatively high hardness, just like the upper overlay film (522). As such, in the modified example of the present invention, the material of the lower overlay film (562) must be the same material having the same physical properties as the upper overlay film (522), so that the same pressure is applied in the upper and lower directions when laminating the two sides.

[0185]

[0186] As shown in FIG. 16, a lower overlay film structure (560), a fiber-reinforced plastic structure (540), and an upper overlay film structure (520) having a UV pattern layer (580) formed thereon are loaded sequentially onto a dedicated jig (620).

[0187] In this way, the lower overlay film structure (560), the fiber-reinforced plastic structure (540), and the upper overlay film structure (520) having a UV pattern layer (580) formed thereon are sequentially aligned and loaded onto the dedicated jig (620) to complete the preparation for double-sided lamination.

[0188] Accordingly, the first bonding member (544) of the fiber-reinforced plastic structure (540) is positioned to face the printed layer (524) of the upper overlay film structure (520), and the second bonding member (564) of the lower overlay film structure (560) is positioned to face the fiber-reinforced plastic (542) of the fiber-reinforced plastic structure (542). As a result, the first bonding member (544) is positioned on the upper surface of the fiber-reinforced plastic (542), and the second bonding member (564) is positioned on the lower surface of the fiber-reinforced plastic (542).

[0189]

[0190] As shown in FIG. 17, after mounting a dedicated jig (620) so as to be fixed onto a lamination dedicated plate (640), a metal plate (660) and a heat press device (680) are positioned and aligned on an upper overlay film (522) on which a UV pattern layer (580) is formed.

[0191] Here, it is preferable to align the UV pattern layer (580) so that it comes into contact with the metal plate (660).

[0192] Next, the upper overlay film structure (520), fiber-reinforced plastic structure (540), and lower overlay film structure (560), on which a UV pattern layer (580) is formed by heat pressing using a metal plate (660) and a heat press device (680), are laminated.

[0193] In this way, a dedicated jig (620) in which a lower overlay film structure (560), a fiber-reinforced plastic structure (540), and an upper overlay film structure (520) having a UV pattern layer (580) are sequentially stacked is mounted so as to be fixed on a lamination dedicated plate (640), and then a metal plate (660) is placed on the UV pattern layer (580), and then double-sided lamination is performed under appropriate heat and pressure conditions to complete a double-sided laminated fiber-reinforced plastic sheet. At this time, the lamination temperature and pressure conditions must be set to optimal conditions by considering the type of fiber-reinforced plastic (542), the types of upper and lower overlay films (522, 562), the type of adhesive or pressure-sensitive adhesive, and the interlayer adhesion strength, leveling, bending, and surface roughness.

[0194] Here, the reason for using a metal plate (660) is to increase the density and roughness of the surface of the UV pattern layer (580) due to the heat and high pressure generated during lamination, thereby maximizing the three-dimensional effect of the UV pattern layer (580) without forming a separate reflective layer such as deposition. That is, if a material with high specific strength, such as PET, PI, PMMA, or PC film, is used as the upper overlay film (522), the three-dimensional pattern of the UV pattern layer (580) is not severely distorted or squished even under the heat and high pressure applied during the double-sided lamination process using the metal plate (660) and the heat press device (680), so the three-dimensional pattern effect can be well preserved.

[0195] In this step, it is preferable to heat press the lamination at a temperature of 150 to 250°C under a pressure of 30 to 60 bar, and more preferable to heat press the lamination at a temperature of 180 to 220°C under a pressure of 40 to 50 bar. In the lamination step, if the heat press temperature is less than 150°C or the heat press pressure is less than 30 bar, it may be difficult to fully utilize the three-dimensional pattern effect of the UV pattern layer (580) because the density and roughness of the surface of the UV pattern layer (580) are not sufficiently increased. Conversely, if the heat press temperature exceeds 250°C or the heat press pressure exceeds 60 bar, it is not desirable because excessive heat and pressure are applied, which may cause warping defects due to shape deformation of the upper and lower overlay films (522, 562).

[0196]

[0197] As shown in FIG. 18, a metal plate (660 in FIG. 17) is detached from an upper overlay film structure (520) on which a UV pattern layer (580) is formed, a fiber-reinforced plastic structure (540), and a lower overlay film structure (560) to form a fiber-reinforced plastic decorative member (500).

[0198] As described above, in a variation of the present invention, by using a material with relatively high strength such as PET, PI, PMMA, or PC film as the upper overlay film (522), even if a UV pattern layer (580) is first formed on the upper overlay film (522) by an imprinting process and then double-sided lamination is performed, the upper overlay film (522) is made of a material with relatively high strength, so the UV pattern layer (580) is not crushed or severely deformed by heat and pressure.

[0199] Accordingly, the density and roughness of the surface of the UV pattern layer (580) are increased by the heat and high pressure generated during double-sided lamination using a metal plate and a heat press device, thereby enabling the three-dimensional effect of the UV pattern layer (580) to be achieved without forming a separate reflective layer such as deposition.

[0200] After forming a UV pattern layer (580) by such imprinting, an anti-fingerprint (AF) coating process may be additionally performed on the UV pattern layer (580) as needed to further form an anti-fingerprint coating layer (not shown).

[0201] With this, the method for manufacturing a fiber-reinforced plastic decorative member using a double-sided thin film lamination method according to a modified embodiment of the present invention may be concluded.

[0202]

[0203] According to the present invention, a method is applied in which an upper overlay film and a lower overlay film are laminated on both sides of a fiber-reinforced plastic using heat and pressure with a thermosetting adhesive or a hot melt adhesive, and then a UV pattern layer is formed by an imprinting process, or a method is applied in which a UV pattern layer is formed first by an imprinting process and then laminated.

[0204] As a result, according to the present invention, fiber mesh marks (resin shrinkage phenomenon) of fiber-reinforced plastic are not visible, and various colors and three-dimensional pattern designs can be formed without problems of adhesion between the fiber-reinforced plastic and the printing layer and curling.

[0205] In addition, according to the present invention, the manufacturing method is varied depending on the type of upper overlay film and lower overlay film laminated to both sides of the fiber-reinforced plastic by first and second bonding members. That is, the manufacturing method is varied by classifying the upper overlay film and lower overlay film into materials with low strength, such as PVC film, and materials with relatively high strength, such as PET, PI, PMMA, and PC film. In this case, in the present invention, the upper overlay film and lower overlay film must be made of the same material having the same physical properties to obtain the effect of the invention.

[0206] In addition, in the present invention, whether to use a heat-curing adhesive or a hot-melt adhesive is determined depending on the type of upper overlay film and lower overlay film, and since the heat and pressure conditions applied during lamination also differ depending on each method and the materials of the fiber-reinforced plastic and upper and lower overlay films used, it is very important to perform lamination by setting appropriate adhesive strength and conditions that do not cause warping.

[0207]

[0208] As seen so far, according to the present invention, the problem of curling that occurs while forming a decorative member on a cross-section is completely improved.

[0209] Furthermore, according to the present invention, there is absolutely no problem with adhesion, which is a chronic issue of existing methods.

[0210] In addition, according to the present invention, not only can various color expressions and multi-colors such as gradation be freely expressed, but 3D three-dimensional decoration is also easy.

[0211] In addition, according to the present invention, a hard surface reinforcement surface with a hardness level of 2H or higher is formed on the surface of the upper overlay film, making it resistant to scratches.

[0212] In addition, according to the present invention, since the printing layer is printed on the lower surface of the upper overlay film, it is highly resistant to wear.

[0213] In particular, according to the present invention, a color film can be used as a lower overlay film laminated to the lower surface of a fiber-reinforced plastic, so there is no problem with adhesion to various auxiliary materials used during set assembly without separate printing or imprinting, and there is no problem with internal transparency or light leakage due to excellent opacity (shielding power).

[0214] Furthermore, according to the present invention, while a reflective surface such as a deposition surface is required to obtain the effect of a three-dimensional pattern, the present invention can sufficiently realize the three-dimensional pattern effect even without a deposition surface. This resolves reliability issues that may arise from the deposition process (the oxide used in the deposition process is susceptible to moisture and salt, and there are problems with weak interlayer adhesion), reduces deposition costs, and improves price competitiveness.

[0215] In addition, according to the present invention, since fibers woven from fiber-reinforced plastic are used and the fiber-reinforced plastic is manufactured through a prepreg process, mesh marks (shrinkage) inevitably occur due to the shrinkage action of the resin; however, by using the method of the present invention, the mesh marks can be perfectly covered because upper and lower overlay films of thin films are laminated onto both sides of the fiber-reinforced plastic.

[0216] As a result, by using the method of the present invention, a smooth surface can be obtained and the three-dimensional pattern effect can be effectively utilized, and above all, the problem of adhesion, which is a chronic issue of fiber-reinforced plastics used as decorative members, can be dramatically improved.

[0217]

[0218] Although the present invention has been described above with reference to embodiments, various changes and modifications can be made by those skilled in the art to which the present invention pertains. Such changes and modifications are considered to be within the scope of the present invention as long as they do not depart from the technical concept provided by the present invention. Accordingly, the scope of rights of the present invention should be determined by the claims set forth below.

[0219]

[0220] [Explanation of the symbol]

[0221] 500 : Fiber-reinforced plastic decorative member

[0222] 520 : Upper overlay film structure

[0223] 522: Upper overlay film

[0224] 524 : Print layer

[0225] 540 : Fiber-reinforced plastic structure

[0226] 542 : Fiber-reinforced plastic

[0227] 544 : First joining member

[0228] 560 : Lower overlay film structure

[0229] 562 : Bottom overlay film

[0230] 564 : Second joining member

[0231] 580: UV pattern layer

Claims

1. A fiber-reinforced plastic structure having a fiber-reinforced plastic and a first bonding member formed on the fiber-reinforced plastic; An upper overlay film structure having an upper overlay film and a printed layer formed on the lower surface of the upper overlay film and bonded to the first bonding member, which is laminated to the upper surface of the fiber-reinforced plastic structure via a first bonding member; A lower overlay film structure disposed at the lower portion of the fiber-reinforced plastic structure and having a lower overlay film and a second bonding member formed on the upper surface of the lower overlay film and laminated to the fiber-reinforced plastic; and A UV pattern layer formed on the upper surface of the upper overlay film; Characterized by including, Fiber-reinforced plastic decorative member using a double-sided thin film lamination method.

2. In Paragraph 1, The above fiber-reinforced plastic is Characterized by including one or more types selected from glass fiber reinforced plastic, carbon fiber reinforced plastic, PBO fiber reinforced plastic, and Kevlar reinforced plastic, Fiber-reinforced plastic decorative member using a double-sided thin film lamination method.

3. In Paragraph 1, Each of the above upper and lower overlay films is Characterized by being formed of one or more materials selected from transparent PVC, colored PVC, PET, PI, PMMA, and PC, Fiber-reinforced plastic decorative member using a double-sided thin film lamination method.

4. In Paragraph 1, Each of the above upper and lower overlay films is Characterized by having a thickness of 10 to 200㎛, Fiber-reinforced plastic decorative member using a double-sided thin film lamination method.

5. In Paragraph 1, Each of the above first and second joining members is Characterized by the use of a thermosetting adhesive or a hot melt adhesive, Fiber-reinforced plastic decorative member using a double-sided thin film lamination method.

6. In Paragraph 1, Characterized by having a surface reinforcement surface formed on the upper surface of the upper overlay film. Fiber-reinforced plastic decorative member using a double-sided thin film lamination method.

7. (a) A step of forming an upper overlay film structure by forming a printing layer on the lower surface of the upper overlay film; (b) a step of forming a fiber-reinforced plastic structure by forming a first bonding member on the upper surface of the fiber-reinforced plastic; (c) a step of forming a lower overlay film structure by forming a second bonding member on the upper surface of the lower overlay film; (d) a step of sequentially loading the lower overlay film structure, the fiber-reinforced plastic structure, and the upper overlay film structure onto a dedicated jig; (e) a step of mounting the above-described dedicated jig so as to be fixed onto a lamination dedicated plate, and then aligning the metal plate and the heat press device on the upper overlay film; (f) a step of laminating the upper overlay film structure, the fiber-reinforced plastic structure, and the lower overlay film structure by heat pressing using the metal plate and the heat press device; and (g) a step of forming a fiber-reinforced plastic decorative member by forming a UV pattern layer on the exposed upper overlay film structure after removing the metal plate from the laminated upper overlay film structure, fiber-reinforced plastic structure and lower overlay film structure; Characterized by including, Method for manufacturing fiber-reinforced plastic decorative members using a double-sided thin film lamination method.

8. In Paragraph 7, Each of the above upper and lower overlay films is Characterized by using a material formed from either transparent PVC or colored PVC selected from one of the following: Method for manufacturing fiber-reinforced plastic decorative members using a double-sided thin film lamination method.

9. In Paragraph 7, In the above (f) step, The above laminate Characterized by heat press pressing at 150 to 250℃ under pressure conditions of 30 to 60 bar, Method for manufacturing fiber-reinforced plastic decorative members using a double-sided thin film lamination method.

10. In Paragraph 7, In the above (g) step, By heat press lamination using the above metal plate, Characterized by having a surface-reinforced surface formed by increasing surface density and surface roughness located on the upper surface of the upper overlay film. Method for manufacturing fiber-reinforced plastic decorative members using a double-sided thin film lamination method. 11.(a) A step of manufacturing an upper overlay film structure by forming a printing layer on the lower surface of an upper overlay film, and then forming a UV pattern layer on the upper surface of the upper overlay film; (b) a step of forming a fiber-reinforced plastic structure by forming a first bonding member on the upper surface of the fiber-reinforced plastic; (c) a step of forming a lower overlay film structure by forming a second bonding member on the upper surface of the lower overlay film; (d) A step of sequentially loading the lower overlay film structure, the fiber-reinforced plastic structure, and the upper overlay film structure having a UV pattern layer formed thereon onto a dedicated jig; (e) a step of mounting the above-described dedicated jig so as to be fixed onto a lamination dedicated plate, and then aligning the metal plate and the heat press device on the upper overlay film on which the UV pattern layer is formed; (f) a step of laminating the upper overlay film structure, the fiber-reinforced plastic structure, and the lower overlay film structure, wherein the UV pattern layer is formed by heat pressing using the metal plate and the heat press device; and (g) a step of forming a fiber-reinforced plastic decorative member by removing a metal plate from the upper overlay film structure, the fiber-reinforced plastic structure, and the lower overlay film structure on which the above UV pattern layer is formed; Characterized by including, Method for manufacturing fiber-reinforced plastic decorative members using a double-sided thin film lamination method.

12. In Paragraph 11, Each of the above upper and lower overlay films is Characterized by being formed from one or more materials selected from PET, PI, PMMA, and PC, Method for manufacturing fiber-reinforced plastic decorative members using a double-sided thin film lamination method.

13. In Paragraph 11, In the above (f) step, The above laminate Characterized by heat press pressing at 150 to 250℃ under pressure conditions of 30 to 60 bar, Method for manufacturing fiber-reinforced plastic decorative members using a double-sided thin film lamination method.

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