(a) Field of the Invention
The present invention relates to in mold films and in mold labels, and more particularly to both the in mold film and in mold label with a 2D or 3D pattern, which has a 2D or 3D pattern layer and a protective layer printed on the 2D or 3D pattern layer for adhesion to a molding product during injection or pressure casting molding of the product.
(b) Description of the Prior Art
In mold film (IMF) and in mold labeling (IML) techniques have been intensively used in the fabrication of shells for notebook computers, palm-top computers, wireless communication products, consumer electronic products, telecommunication systems, vehicle parts, electric home appliances, etc. In mold film and labeling techniques have also been intensively used in the fabrication of cell phones, keyboards, and food containers to provide a fine shape and colorful design for generating a unique sense of beauty. In mold film and labeling techniques enable the outer or external part of the product to have an integrated 2D or 3D pattern attractive to consumers.
Further, the material of a grating plate itself or the ink to be used for printing a pattern on a grating plate will be deformed when heated to a certain temperature level. Therefore, a printed grating plate cannot stand the high temperature environment during an in mold film or in mold labeling process. Therefore, decorating a product shell with a 2D or 3D pattern is generally achieved by printing a grating plate with 2D or 3D pattern and then adhering the pattern-printed grating plate to the surface of the product shell or inserting the pattern-printed grating plate into the inside of the product shell. By this method high quantity products cannot be obtained because the grating plate is not integrally formed with the product shell.
The present invention has been accomplished under the circumstances in view. According to one aspect of the present invention, both the in mold film and in mold label comprise a base layer, an adhesion layer, a pattern layer disposed between the base layer and the adhesion layer, and a protective layer disposed between the pattern layer and the adhesion layer. The base layer is prepared from a polymer material, having an inner surface, and a 2D visual surface or a 3D grating surface opposite to said inner surface. The pattern layer is prepared from a polymer material and printed on the inner surface of the base layer to show a 2D or 3D pattern. The protective layer is prepared from a polymer material having high temperature resistance, acid resistance and alkali resistance characteristics, and printed on one side of the pattern layer opposite to the base layer. The adhesion layer is covered on one side of the protective layer opposite to the pattern layer. The in mold film and in mold label with a 2D or 3D pattern thus obtained can be directly molded on one product member during injection molding or pressure-casting molding of the product member so that the product member has an integrated 2D or 3D pattern.
According to another aspect of the present invention, the protective layer is prepared from polyethylene terephthalate (PET), polyimide (PI), polypropylene (PP), polyurethane (PU), polymethylmethacrylate (PMMA), polycarbonate (PC), polybutylene terephthalate (PBT), nylon, silicone, or a mixture thereof, which has high temperature resistance acid resistance, and alkali resistance characteristics. The protective layer enhances the mechanical properties and physical strength of the material, and provides excellent adhesion. The protective layer also enhances the photo effects of the 2D or 3D pattern layer.
According to still another aspect of the present invention, the in mold film and in mold label further comprise an anti-EMI layer prepared from an electromagnetic interference (EMI) protective material and sandwiched between the protective layer and the adhesion layer for protection against electromagnetic interference.
Referring to
The base layer 1 is prepared from a polymer compound material such as polyethylene terephthalate (PET), polyimide (PI), polypropylene (PP), polystyrene (PS), polyurethane (PU), polymethylmethacrylate (PMMA), polycarbonate (PC), polybutylene terephthalate (PBT), acrylonitrile butadiene styrene (ABS), nylon, or a mixture thereof. The base layer 1 can be made to have a visual surface (see
The pattern layer 2 is prepared from a polymer material such as PET, PI, PP, PU, PMMA, PC, PBT, nylon, silicone, or a mixture thereof. The pattern layer 2 can be a 2D or 3D pattern printed on the inner surface of the base layer 1 by means of any of a variety of printing techniques, such as gravure printing, flexographic printing, lithographic printing, screen printing, or transfer printing. The printing is a mirror image printing. Therefore, the positive image is seen from the outer side of the base layer 1.
The protective layer 3 is prepared from a polymer material such as PET, PI, PP, PU, PMMA, PC, PBT, nylon, silicone, or a mixture thereof, and is directly printed on one side of the pattern layer 2 opposite to the base layer 1. The protective layer 3 has high temperature resistance, acid resistance, and alkali resistance characteristics. It enhances the mechanical properties and physical strength of the material, and provides excellent adhesion. It also enhances the photo effects of the 2D or 3D pattern layer 2.
The adhesion layer 4 is prepared from a polymer compound material such as PET, PI, PP, PS, PU, PMMA, PC, PBT, ABS, or nylon, and is covered on the surface of the protective layer 3.
By means of in mold decoration technology, the in mold films and in mold labels thus obtained are directly adhesive to an injection-molding/pressure casting molding product 5 during injection (pressure casting) molding of the molding product 5 (see
As stated above, the base layer 1 can be made to have a visual surface suitable for the printing of a 2D mirror image pattern, or a grating surface suitable for the printing of a 3D mirror image pattern. Direct printing of graphics on the grating surface will show a motion effect or other 3D motion picture effects.
The pattern layer 2 can be made by means of single-layer printing or multi-layer printing.
Further, the ratio of the base layer 1 both in mold film and in mold label are about 50%˜80%; the ratio of the pattern layer 2 both in mold film and in mold label are about 3%˜10%; the ratio of the protective layer 3 both in mold film and in mold label are about 5%˜10%; the ratio of the adhesion layer 4 both in mold film and in mold label are about 3%˜10%; the ratio of the anti-EMI layer 6 both in mold film and in mold label are about 9%˜20%.
Although a particular embodiment of the invention has been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.