In mold manufacture of an object with embedded display panel

Abstract

This invention relates to an object having a display panel embedded in its top surface and processes for its manufacture. The process comprises the steps of: forming an in-mold display transfer film or foil which comprises a temporary carrier layer, a release layer, a display panel, an adhesive layer and optionally a durable layer; feeding said in-mold display transfer film or foil into a mold with the temporary carrier film in contact with the inner surface of the mold; forming an object in the mold and transferring the in-mold display transfer film or foil onto the object; removing the object formed from the mold; and simultaneously removing both temporary carrier layer and release layer.

1 . A process for manufacturing an object having a display panel embedded in its top surface, comprising:
 a) forming an in-mold display transfer film or foil which comprises a temporary carrier layer, a release layer, a display panel, an adhesive layer and optionally a durable layer;   b) feeding said in-mold display transfer film or foil into a mold with the temporary carrier film in contact with the inner surface of the mold;   c) forming an object in the mold and transferring the in-mold display transfer film or foil onto the object;   d) removing the object formed from the mold; and   e) simultaneously removing both temporary carrier layer and release layer.   
   
   
       2 . The process of  claim 1 , wherein the object is formed by injecting a melted plastic material into the mold. 
   
   
       3 . The process of  claim 1 , wherein the object is formed by thermoforming or blow molding a plastic material in the mold. 
   
   
       4 . The process of  claim 1 , wherein the object is formed by compression forming a plastic material in the mold. 
   
   
       5 . The process of  claim 1 , wherein said display panel is an electrophoretic display. 
   
   
       6 . The process of  claim 1 , wherein said display panel is a liquid crystal display. 
   
   
       7 . The process of  claim 1 , wherein said temporary carrier layer is a thin film of PET, PEN or PC. 
   
   
       8 . The process of  claim 1 , wherein said release layer is formed from a material or a blend thereof selected from the group consisting of wax, paraffin, silicone, and a coating prepared from a radiation curable multifunctional acrylate, silicone acrylate, epoxide, vinyl ester, vinyl ether, allyl unsaturated polyester, or vinyl unsaturated polyester. 
   
   
       9 . The process of  claim 1 , wherein said release layer comprises a condensation polymer, copolymer, blend or composite selected from the group consisting of epoxy resin, polyurethane, polyimide, polyamide, melamine formaldehyde, urea formaldehyde and phenol formaldehyde. 
   
   
       10 . The process of  claim 1 , wherein said optional durable layer is formed from a radiation curable multifunctional acrylate, epoxide, vinyl ester, diallyl phthalate, vinyl ether, or a blend thereof. 
   
   
       11 . The process of  claim 10 , wherein said radiation curable multifunctional acrylate is epoxy acrylate, polyurethane acrylate, polyester acrylate, silicone acrylate, or glycidyl acrylate. 
   
   
       12 . The process of  claim 1 , wherein said optional durable layer comprises a condensation polymer or copolymer. 
   
   
       13 . The process of  claim 12 , wherein said condensation polymer or copolymer is selected from the group consisting of epoxy resin, polyurethane, polyamide, polyimide, melamine formaldehyde, urea formaldehyde and phenol formaldehyde. 
   
   
       14 . The process of  claim 1 , wherein said optional durable layer comprises a sol-gel silicate or titanium ester. 
   
   
       15 . The process of  claim 1 , wherein said adhesive layer is formed from polyacrylate, polymethacrylate, polystyrene, polycarbonate, polyurethane, polyester, polyamide, epoxy resin, a ethylene vinylacetate copolymer, a thermoplastic elastomer, or a copolymer, blend or composite thereof. 
   
   
       16 . The process of  claim 1 , wherein said adhesive layer is a hot melt or heat activated adhesive. 
   
   
       17 . The process of  claim 1 , wherein said adhesive layer is polyurethane, polyamide or a copolymer, blend or composite thereof. 
   
   
       18 . The process of  claim 1 , wherein said adhesive layer is polycarbonate, polyacrylate, polymethacrylate or a copolymer, blend or composite thereof. 
   
   
       19 . A process for manufacturing an object having a display panel embedded in its top surface, comprising:
 a) forming an in-mold display insertion film or foil which comprises a carrier layer, a display panel and an adhesive layer;   b) inserting said in-mold display insertion film or foil into a mold with said carrier layer in contact with the inner surface of the mold;   c) forming an object in the mold and transferring the in-mold display insertion film or foil onto the object; and   d) removing the formed object from the mold.   
   
   
       20 . The process of  claim 19 , wherein said display panel is formed directly on the carrier layer. 
   
   
       21 . The process of  claim 19 , wherein the object is formed by injecting a melted plastic material into the mold. 
   
   
       22 . The process of  claim 19 , wherein the object is formed by thermoforming or blow molding a plastic material in the mold. 
   
   
       23 . The process of  claim 19 , wherein the object is formed by compression forming a plastic material in the mold. 
   
   
       24 . The process of  claim 19 , wherein said display panel is an electrophoretic display. 
   
   
       25 . The process of  claim 19 , wherein said display panel is a liquid crystal display.