Patent Application
20080081159
Many aspects of the cover with a soft surface can be better understood with reference to the following drawing. The components in the drawing are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the cover with a soft surface. Moreover, in the drawing like reference numerals designate corresponding parts throughout the several views.
Referring to
The substrate 10 is preferably made of a plastic material. The plastic material can be chosen from the group including acrylonitrile butadiene styrene polymer, polyethylmethacrylate, polycarbonate, polymethyl methacrylate, polystyrene, and any desired combination thereof. It is, of course, to be understood that the substrate 10 could be made of metal such as steel, titanium, or aluminum. Such factors as the substrate material and thickness will help determine the flexibility displayed by the substrate 10.
The intermediate layer 20 advantageously is made of a flexible paint, which includes a flexible resin as major constituent (e.g., about 10% by weight). The flexible resin is a polyurethane resin and preferably should be a polyether-urethane resin. The intermediate layer 20 may, usefully, be formed via spray painting the flexible paint onto the surface of the substrate 10. The flexible paint may contain, e.g., polyurethane prepolymer, flexible resin powder, and silicone oil. The polyurethane prepolymer may be obtained by the reaction of isocynate and polyether polyol and, preferably, should be obtained by the reaction of diisocynate and polyether diol. The flexible resin powder is, beneficially, composed of polymerized urethane resin particles, which is used in an approximate portion of 8 to 12 wt % and should preferably be about 10 wt % of the flexible paint. The flexible resin powder is added to the flexible paint for improving flexibility of the intermediate layer 20. The silicone oil is, opportunely, polyorganosiloxane or a modified polyorganosiloxane, which is added as a surfactant in an approximate portion of 3 to 5 wt %. The silicone oil should preferably be 4 wt % of the flexible paint.
A process for forming the ink coating 30 onto the surface of the intermediate layer 20 may, for example, be carried out via screen printing or stencil printing, so as to form designs, such as pictures or patterns. The ink used in the process may include a resin component to improve its ability to bond with the other layers. The resin can, e.g., be polyurethane and should preferably be polyether-urethane. During the process of forming the ink coating 30, the polyurethane component contained in the ink is, advantageously, partially cross-linked with the polyurethane component contained in the intermediate layer 20, so as to improve adhesion of the ink coating 30 to the intermediate layer 20.
The top layer 40 is beneficially made of transparent adhesive, which may, for example, be a one-component polyurethane adhesive, to permit optimal viewing of the ink coating 30. Such a polyurethane adhesive is cured (e.g., using heat and/or UV) so as to form the top layer 40. The adhesive contains polyurethane prepolymer as a major component, which is obtained by the reaction of isocynate and polyether polyol and, more preferably, by the reaction of diisocynate and polyether diol. The adhesive includes toluene, xylene, methyl ethyl ketone, methoxy propyl acetate, or mixture thereof as a solvent. It is, of course, to be understood that the adhesive could be two-component polyurethane adhesive, which has an epoxy component added for improving the durability of the top layer 40.
A process for forming the top layer 40 may be carried out, e.g., via spray painting, dipping, or brushing. During the process of forming the top layer 40, the polyurethane component contained in the adhesive is partially cross-linked with the polyurethane component contained in the ink coating 30 and/or partially cross-linked with the polyurethane component contained in and the intermediate layer 20 not covered by the ink coating 30. Such partial cross-linking improves adhesion of the top layer 40 to the ink coating 30 and/or the intermediate layer 20 and thereby promotes the durability of the cover 100. The adhesive coating also functions as a protective layer for preventing the ink coating 30 from being worn/abraded away. Further, the presence of polyurethane in the layers 20, 30, 40 contributes positively to the overall softness and flexibility of the cover 100.
It should be understood, of course, that the substrate 10 could also be coated with a color resin before forming the intermediate layer 20 thereon, so as to improve the decorative appearance of the cover 100.
The intermediate layer 20 can also instead be made of a transparent adhesive, and, accordingly, the top layer 40 instead be made of the flexible paint.
It should be also understood, however, that even though numerous characteristics and advantages of the present embodiments have been set forth in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
| Number | Date | Country | Kind |
|---|---|---|---|
| 200610062908.0 | Sep 2006 | CN | national |
