Multi-layer film, injection molded article decorated therewith and process for the production of the decorated injection molded article

• US 7,976,931 B2
• Filed: 02/03/2006
• Issued: 07/12/2011
• Est. Priority Date: 02/10/2005
• Status: Active Grant

• Current Assignee: Leonhard Kurz GmbH & Co. KG
• Original Assignee: Leonhard KURZ Stiftung & Company KG
• Inventors: Hirschfelder, Andreas, Heinrich, Matthias, Schilling, Andreas
• Primary Examiner(s): Sample; David R
• Assistant Examiner(s): SIMONE, CATHERINE A
• Application Number:
  US11/884,058
• Publication Number:
  US 20080213541A1
• Time in Patent Office: 1,985 Days
• Field of Search: 428/156, 428/195.1, 428/209, 428/40.1, 428/41.8, 428/42.1, 428/913.3, 428/161, 428/164, 428/202, 428/203, 428/201, 264/293
• US Class Current: 428/156
• CPC Class Codes: B29C 45/14778 the article consisting of a material with particular properties, e.g. porous, brittle
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/7224 Holograms
• CPC Class Codes: B44C 1/00 Processes, not specifically provided for elsewhere, for producing decorative surface effects decorating textiles D06Q
• CPC Class Codes: B44C 1/16 for applying transfer pictures or the like
• CPC Class Codes: B44C 1/1712 Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive
• CPC Class Codes: G03H 1/0252 Laminate comprising a hologram layer
• CPC Class Codes: Y10T 428/24479 including variation in thickness
• CPC Class Codes: Y10T 428/24521 with component conforming to contour of nonplanar surface
• CPC Class Codes: Y10T 428/24545 Containing metal or metal compound
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24851 Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/24868 Translucent outer layer

Abstract

The invention concerns multi-layer films for back-molding with a liquid plastic material in an inmold process for the production of a decorated injection molded article of high optical quality and utilitarian suitability, in particular having curved surfaces, wherein the multi-layer film has at least one replication lacquer layer which at least on one of its surfaces has a spatial structure producing a visually perceptible and/or technical effect, wherein a contrast layer which is preferably in the form of a reflection layer is arranged in adjoining relationship with at least one surface with a spatial structure at least in region-wise manner. The invention further concerns an injection molded article which is decorated with a multi-layer film and a process for the production of the article.

Claims

1. A multi-layer film for back-molding with a liquid plastic material in an inmold process for the production of a decorated injection molded article having curved surfaces, wherein the multi-layer film has at least one replication lacquer layer which at least on one of its surfaces has a spatial structure producing a visually perceptible and/or technical effect, wherein a contrast layer is arranged in adjoining relationship with at least one surface with a spatial structure at least in region-wise manner,

wherein the at least one replication lacquer layer is in the form of a radiation-hardened replication lacquer layer, and

wherein the multi-layer film has a receiving layer which is provided over the full surface area as viewed perpendicularly to the plane of the multi-layer film and on which the radiation-hardened replication lacquer layer is arranged only region-wise, and

wherein the radiation-hardened replication lacquer layer is arranged only in regions of the multi-layer film, which on the injection molded article decorated with the multi-layer film have a radius of curvature of greater than 0.7 mm and a stretch of less than 10%.

2. A multi-layer film as set forth in claim 1, wherein the radiation-hardened replication lacquer layer softens at temperatures above the injection temperature of the plastic material used for the back-molding operation.

3. A multi-layer film as set forth in claim 1, wherein the at least one radiation-hardened replication lacquer layer is hardened by means of UV radiation.

4. A multi-layer film as set forth in claim 1, wherein the multi-layer film forms the transfer layer means of a transfer film, wherein the transfer film has a carrier film which is releasable from the multi-layer film and wherein the multi-layer film is arranged at least region-wise on one side of the carrier film.

5. A multi-layer film as set forth in claim 4, wherein the multi-layer film on its side remote from the carrier film has an adhesive layer.

6. A multi-layer film as set forth in claim 4, wherein a transparent radiation-hardened replication lacquer layer adjoins the carrier film, wherein the spatial structure is embossed on the side of the radiation-hardened replication lacquer layer, that is remote from the carrier film.

7. A multi-layer film as set forth in claim 4, wherein a transparent receiving layer is arranged between the carrier film and the radiation-hardened replication lacquer layer.

8. A multi-layer film as set forth in claim 1, wherein the contrast layer is in the form of a reflection layer formed from metallic and/or non-metallically inorganic reflective materials.

9. A multi-layer film as set forth in claim 1, wherein the contrast layer has first regions and viewed in the plane of the multi-layer film arranged therebeside or in partially overlapping relationship with the first regions at least second regions, wherein the contrast layer is different in respect of transparency and color impression, in the first regions and in at least the second regions.

10. A multi-layer film as set forth in claim 1, wherein the spatial structure is at least region-wise in the form of a macroscopic structure, wherein the macroscopic structure has a length in the plane of the radiation-hardened replication lacquer layer of at least 0.03 mm and a length perpendicularly to the plane of the radiation-hardened replication lacquer layer in a range of between 0.01 and 0.1 mm.

11. A multi-layer film as set forth in claim 1, wherein the spatial structure is formed at least region-wise as a diffractive structure.

12. A multi-layer film as set forth in claim 11, wherein the spatial structure is formed at least region-wise as an asymmetrical matt structure.

13. A multi-layer film as set forth in claim 1, wherein the multi-layer film has a marking applied by means of laser, the marking being in the form of alphanumeric characters, geometrical patterns or graphic representations.

14. A multi-layer film as set forth in claim 1, wherein the multi-layer film has at least one colored decorative print.

15. A multi-layer film as set forth in claim 1, wherein the multi-layer film has at least one decorative print which is the same in color as the radiation-hardened replication lacquer layer, wherein the decorative print is arranged on the radiation-hardened replication lacquer layer and optically extinguishes region-wise the spatial structure in the radiation-hardened replication lacquer layer.

16. A multi-layer film as set forth in claim 1, wherein the multi-layer film as the spatial structure has lens elements or free form surfaces.

17. A multi-layer film as set forth in claim 1, wherein the multi-layer film has a dirt-repellent layer and/or a scratch-resistant layer which forms the surface of the decorated injection molded article.

18. A multi-layer film for back-molding with a liquid plastic material in an inmold process for the production of a decorated injection molded article having curved surfaces, wherein the multi-layer film has at least one replication lacquer layer which at least on one of its surfaces has a spatial structure producing a visually perceptible and/or technical effect, wherein a contrast layer is arranged in adjoining relationship with at least one surface with a spatial structure at least in region-wise manner,

wherein the at least one replication lacquer layer is in the form of a radiation-hardened replication lacquer layer, and

wherein the spatial structure is formed at least region-wise as a diffractive structure, and

wherein the diffractive structure forms an optically variable element, and is arranged only in regions of the multi-layer film which have a stretch of less than 10% on the article which is decorated with the multi-layer film.

19. A multi-layer film as set forth in claim 18, wherein the multi-layer film has a receiving layer which is provided over the full surface area as viewed perpendicularly to the plane of the multi-layer film and on which the radiation-hardened replication lacquer layer is arranged only region-wise.

20. A multi-layer film for back-molding with a liquid plastic material in an inmold process for the production of decorated injection molded articles, wherein the multi layer film has at least one replication lacquer layer which at least on one of its surfaces has a spatial structure producing a visually perceptible and/or technical effect, wherein a contrast layer is arranged only region-wise in adjoining relationship with at least one surface with a spatial structure, and

wherein the multi-layer film in regions without a contrast layer has at least in region-wise manner at least one function layer which can correspond to the replication lacquer layer, wherein the at least one function layer has reflecting and/or transmitting structures which are in the form of light-diffracting, light-refracting, light-diffusing, light-polarising or light-absorbing microstructures or nanostructures, and

wherein the function layer includes:

a. at least one diffuser element for producing a uniform or adapted light distribution over the surface of the injection molded article decorated with the multi-layer film, and/or

b. at least one magnification lens having diffractive or refractive lens optical means, and/or

c. at least one dereflection layer or a motheye structure for reducing reflections or for improving transmission, and/or

d. at least one polarisation filter layer, and/or

e. at least one filter layer for filtering given wavelengths of visible light.

21. A multi-layer film as set forth in claim 20, wherein the microstructures or nanostructures are selected from the group consisting of matt structures, Fresnel lenses, microprisms, free form surfaces, diffractive structures and grating structures.

22. A decorated injection molded article having an injection molded plastic body whose surface is at least region-wise covered with and connected to a multi-layer film as set forth in claim 20, in an inmold process.

23. A decorated injection molded article as set forth in claim 22, wherein the decorated injection molded article forms an opaque or at least partially transparent housing component of a telephone or a cell phone.

24. A decorated injection molded article as set forth in claim 23, wherein at least one function layer is arranged in the region of the at least partially transparent housing component.

25. A decorated injection molded article as set forth in claim 22, wherein the decorated article is a cladding component for the interior or exterior region of an automobile.

26. A process for the production of a decorated injection molded article as set forth in claim 22, wherein the multi-layer film for forming a mechanically reinforced multi-layer film is embossed on to a flat, thermoplastic plate, the mechanically reinforced multi-layer film is thermoformed to afford a shell portion and the shell portion is back-molded with a plastic material in an inmold process.

27. A process as set forth in claim 26, wherein the mechanically reinforced multi-layer film is only deformed in partial regions in the thermoforming operation.