Optical thin film with high hardness made by insert mold technology and manufacturing processes thereof

Abstract

An optical thin film with high hardness made by insert mold technology and manufacturing processes thereof are disclosed. The optical thin film is applied on surface of a plastic housing for increasing hardness of the plastic housing so as to prevent scratches. During manufacturing processes of insert mold for producing a hard coating film, the step of hardening treatment is moved to the last step so as to avoid cracks on the optical thin film generated during the procedures. Thus the yield rate is increased and the manufacturing cost is reduced.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings, wherein

FIG. 1 is a flow chart of conventional technology for coating film on plastic housings;

FIG. 2 is a flow chart showing manufacturing processes of conventional insert mold decoration technology;

FIG. 2A is a schematic drawing showing structure of an optical thin film made by conventional insert mold decoration technology;

FIG. 3 is a flow chart of showing manufacturing processes of another embodiment according to the present invention with high hardness made by insert mold decoration technology;

FIG. 3A is a schematic drawing showing the hardened layer formed above the optical thin film;

FIG. 3B is a schematic drawing showing a protective film formed above the hardened layer;

FIG. 3C is a schematic drawing showing a figure formed under the optical thin film;

FIG. 3D is a schematic drawing showing the protective film being taken off;

FIG. 3E is a schematic drawing showing the shaping of the optical thin film through heat treatment; and

FIG. 3F is a schematic drawing showing the plastic material injected under a figure by injection molding.

Claims

1. A manufacturing processes for an optical thin film with high hardness made by insert mold technology comprising the steps of: providing an optical thin film not being hardened yet;forming a hardened layer above the optical thin film;preforming the optical thin film through heat treatment;forming a plastic material under the optical thin film by injection molding; andhardening the hardened layer by ultraviolet(UV) light.

2. The manufacturing processes for the optical thin film as claimed in claim 1, wherein after the step of forming a hardened layer above the optical thin film, the processes further comprising a step of: forming a figure under the optical thin film.

3. The manufacturing processes for the optical thin film as claimed in claim 2, wherein on the step of forming a figure under the optical thin film, the figure can be a color layer.

4. The manufacturing processes for the optical thin film as claimed in claim 2, wherein a way to forming a figure is direct printing or transfer printing.

5. The manufacturing processes for the optical thin film as claimed in claim 2, wherein before the step of forming a figure under the optical thin film, the processes further comprising a step of: providing a protective film attached above the hardened layer.

6. The manufacturing processes for the optical thin film as claimed in claim 5, wherein after the step of forming a figure under the optical thin film, the processes further comprising a step of: taking off the protective film.

7. The manufacturing processes for the optical thin film as claimed in claim 1, wherein after the step of forming a hardened layer above the optical thin film, the processes further comprising a step of: heating the hardened layer to unstuck status.

8. The manufacturing processes for the optical thin film as claimed in claim 7, wherein temperature of heating ranges from 70 Celsius degrees to 200 Celsius degrees.

9. The manufacturing processes for the optical thin film as claimed in claim 7, wherein temperature of heating is preferably from 100 Celsius degrees to 280 Celsius degrees.

10. The manufacturing processes for the optical thin film as claimed in claim 7, wherein time of heating ranges from 3 minutes to 120 minutes.

11. The manufacturing processes for the optical thin film as claimed in claim 9, wherein time of heating is preferably from 5 minutes to 90 minutes.

12. The manufacturing processes for the optical thin film as claimed in claim 1, wherein the way of forming the hardened layer is slot coating, roll coating or curtain coating.

13. The manufacturing processes for the optical thin film as claimed in claim 1, wherein the UV energy output ranges from 300 mJ/cm2 to 3000 mJ/cm2.

14. The manufacturing processes for the optical thin film as claimed in claim 1, wherein way of heat treatment includes hot stamping or thermal vacuum.

15. An optical thin film with high hardness made by insert mold technology comprising: an optical thin film;a hardened layer disposed above the optical thin film; anda plastic material disposed under the optical thin filmwherein the hardened layer and the plastic material are respectively disposed above and under the optical thin film by insert mold technology.

16. The optical thin film as claimed in claim 15, wherein a figured layer is disposed under the optical thin film.

17. The optical thin film as claimed in claim 15, wherein a colored layer is disposed under the optical thin film.

18. The optical thin film as claimed in claim 15, wherein the optical thin film is made from polyethylene terephthalate (PET), polycarbonate (PC), Triacetyl Cellulose (TAC), polymeric methyl methacrylate (PMMA), methyl methacrylate styrene copolymer (MS), or cyclic olefins copolymer

19. The optical thin film as claimed in claim 15, wherein the plastic material is selected from one of polycarbonate (PC), polypropylene (PP), polymeric methyl methacrylate (PMMA), methyl methacrylate styrene copolymer (MS), acrylonitrile butadine styrene (ABS), polystyene (PS), polyethylene terephthalate (PET), polyacetal, polyoxy Methylene (POM) and Nylon.

20. The optical thin film as claimed in claim 15, wherein a thickness of the optical thin film ranges from 3 μm to 300 μm.

21. The optical thin film as claimed in claim 15, wherein a thickness of the hardened layer ranges from 3 μm to 50 μm.

22. The optical thin film as claimed in claim 15, wherein material of the hardened layer includes UV curing resin.

23. The optical thin film as claimed in claim 22, wherein the UV curing resin is selected from high molecular weight acrylate oligomer with a plurality of functional groups, polyurethane acrylate oligomer, monomer or combinations of them.