Composite layer structure, decorated molding article and method for fabricating the same

Abstract

Provided is a composite layer structure comprising a first layer and a second layer. The second layer is disposed on the first layer. A material of the second layer is different from a material of the first layer. The composite layer structure is formed by a co-extrusion molding film process, and the composite layer structure has a thickness of between 0.01 mm and 1 mm. Further, the present invention also provides a decorated molding article and a method for fabricating the same.

What is claimed is: 
     
         1 . A composite layer structure comprising:
 a first layer; and   a second layer disposed on the first layer, wherein a material of the second layer is different from a material of the first layer, the composite layer structure is formed by a co-extrusion molding film process, and the composite layer structure has a thickness of between 0.01 mm and 1 mm.   
     
     
         2 . The composite layer structure of  claim 1 , wherein the material of the first layer comprises acrylonitrile butadiene styrene copolymer, polycarbonate, polypropylene, polyurethane, acrylonitrile styrene acrylate rubber copolymer, acrylonitrile-styrene copolymer, methyl methacrylate acrylonitrile butadiene styrene copolymer, polystyrene, methyl methacrylate styrene copolymer, or a combination thereof. 
     
     
         3 . The composite layer structure of  claim 1 , wherein the material of the second layer comprises poly(methyl methacrylate), polycarbonate, polypropylene, polyurethane, acrylonitrile styrene acrylate rubber copolymer, acrylonitrile-styrene copolymer, methyl methacrylate acrylonitrile butadiene styrene copolymer, polystyrene, methyl methacrylate styrene copolymer, or a combination thereof. 
     
     
         4 . The composite layer structure of  claim 1 , wherein a mixed region is included between the first layer and the second layer, the mixed region comprises both of the material of the first layer and the material of the second layer. 
     
     
         5 . The composite layer structure of  claim 1 , wherein the first layer further comprises a color concentrate, a pigment, a pearl powder or a combination thereof, so that the composite layer structure has colorful, pearlescent, glossy, mirror-like or other visual effects. 
     
     
         6 . The composite layer structure of  claim 1 , wherein the composite layer structure is a transparent composite layer structure. 
     
     
         7 . A decorated molding article comprising:
 a workpiece; and   the composite layer structure according to  claim 1  attached onto an outer surface of the workpiece via an adhesive layer.   
     
     
         8 . The decorated molding article of  claim 7 , further comprising a decorative layer disposed between the decorated molding article and the adhesive layer. 
     
     
         9 . The decorated molding article of  claim 7 , wherein a material of the outer surface of the workpiece comprises plastics, resin, metal, carbon fiber, glass, or a combination thereof. 
     
     
         10 . The decorated molding article of  claim 7 , wherein the workpiece comprises a housing or component of an electronic device, a housing or component of a vehicle, or a combination thereof; and the housing or component of the vehicle comprises an automotive interior decoration, an automotive exterior decoration, an automotive logo, an automotive dashboard, an intelligent key, an engine start button or a combination thereof. 
     
     
         11 . A method for fabricating a decorated molding article comprising:
 providing a first material to a first screw of a co-extrusion blow molding machine;   providing a second material to a second screw of the co-extrusion blow molding machine; and   performing a co-extrusion molding film process, so that the first material and the second material are extruded to form a composite layer structure, wherein the first material is different from the second material.   
     
     
         12 . The method for fabricating the decorated molding article of  claim 11 , wherein the first material comprises acrylonitrile butadiene styrene copolymer, polycarbonate, polypropylene, polyurethane, acrylonitrile styrene acrylate rubber copolymer, acrylonitrile-styrene copolymer, methyl methacrylate acrylonitrile butadiene styrene copolymer, polystyrene, methyl methacrylate styrene copolymer, or a combination thereof. 
     
     
         13 . The method for fabricating the decorated molding article of  claim 11 , wherein the second material comprises poly(methyl methacrylate), polycarbonate, polypropylene, polyurethane, acrylonitrile styrene acrylate rubber copolymer, acrylonitrile-styrene copolymer, methyl methacrylate acrylonitrile butadiene styrene copolymer, polystyrene, methyl methacrylate styrene copolymer, or a combination thereof. 
     
     
         14 . The method for fabricating a decorated molding article of  claim 11 , further comprising, prior to performing the co-extrusion molding film process, providing a third material to a third screw of the co-extrusion blow molding machine, wherein the third material comprises a color concentrate, a pigment, a pearl powder, or a combination thereof. 
     
     
         15 . The method for fabricating a decorated molding article of  claim 11 , further comprising, prior to performing the co-extrusion molding film process, providing a fourth material to a fourth screw of the co-extrusion blow molding machine, wherein the fourth material comprises an additive. 
     
     
         16 . The method for fabricating a decorated molding article of  claim 11 , further comprising, after performing the co-extrusion molding film process, forming a decorative layer on the composite layer structure, wherein a method for forming the decorative layer comprises printing, spraying, electroplating, evaporation deposition, sputtering, or a combination thereof. 
     
     
         17 . The method for fabricating a decorated molding article of  claim 11 , further comprising, after performing the co-extrusion molding film process, performing an in-mold decoration or an out mold decoration on the composite layer structure, so that the composite layer structure is attached onto an outer surface of a workpiece via an adhesive layer to form the decorated molding article. 
     
     
         18 . The method for fabricating a decorated molding article of  claim 17 , wherein the performing the in-mold decoration on the composite layer structure comprises:
 disposing the composite layer structure in an in-mold decoration mold having a mold cavity, wherein the composite layer structure covers at least a portion of a surface of the mold cavity;   injecting a molding material into the in-mold decoration mold, so that the molding material and the composite layer structure are combined with each other;   cooling the molding material; and   taking the decorated molding article out from the in-mold decoration mold.   
     
     
         19 . The method for fabricating a decorated molding article of  claim 17 , wherein the performing the out mold decoration on the composite layer structure comprises:
 providing a workpiece;   placing the workpiece and the composite layer structure in a fixture; and   performing a high pressure decorative molding process, so that the composite layer structure is attached onto the outer surface of the workpiece via the adhesive layer.   
     
     
         20 . The method for fabricating a decorated molding article of  claim 19 , wherein the high pressure decorative molding process comprises:
 performing a heating and softening step on the composite layer structure;   contacting the composite layer structure with the workpiece, and performing a pressurizing step; and   performing a high pressure vacuum molding step on the composite layer structure and the workpiece, so that the composite layer structure is attached onto the outer surface of the workpiece.