WO2013083967A2 - Improvements in or relating to injection moulded components - Google Patents

Improvements in or relating to injection moulded components Download PDF

Info

Publication number
WO2013083967A2
WO2013083967A2 PCT/GB2012/053002 GB2012053002W WO2013083967A2 WO 2013083967 A2 WO2013083967 A2 WO 2013083967A2 GB 2012053002 W GB2012053002 W GB 2012053002W WO 2013083967 A2 WO2013083967 A2 WO 2013083967A2
Authority
WO
WIPO (PCT)
Prior art keywords
sheet
injection moulding
adhesive
moulding process
insert
Prior art date
Application number
PCT/GB2012/053002
Other languages
French (fr)
Other versions
WO2013083967A3 (en
Inventor
Linda Susan MCCABE
Guy Winston HOOD
Original Assignee
Worldmark International Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Worldmark International Limited filed Critical Worldmark International Limited
Publication of WO2013083967A2 publication Critical patent/WO2013083967A2/en
Publication of WO2013083967A3 publication Critical patent/WO2013083967A3/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/002—Coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0025—Opaque
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0026—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0029—Translucent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0087—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B29L2009/005—Layered products coated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B29L2009/005—Layered products coated
    • B29L2009/006—Layered products coated painted
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B29L2009/005—Layered products coated
    • B29L2009/008—Layered products coated metalized, galvanized
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/34—Inserts
    • B32B2305/347—Security elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/41—Opaque
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/412—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/414—Translucent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
    • B32B2310/0831—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B32B37/025—Transfer laminating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • B32B37/1292—Application of adhesive selectively, e.g. in stripes, in patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/12—Deep-drawing

Definitions

  • the present invention relates to an insert sheet for use in an injection moulding process, a process for forming an insert sheet for use in an injection moulding process and a moulded component incorporating said insert sheet.
  • insert sheets In injection moulding processes it is known to use insert sheets to provide, for example, an outward facing surface of an injection moulded component with a particular physical property.
  • the insert sheet may be formed from a hard coated material, which protects the component from being scratched.
  • the material of the insert sheet may be chosen to provide the component with a desired reflectivity or absorption level.
  • a process for forming an insert sheet for use in an injection moulding process comprising the steps of:
  • one or more protective coatings to at least a portion of the rear surface of the plastic sheet, wherein the one or more protective coatings are configured to prevent damage occurring to the plastic sheet during an injection moulding process.
  • the plastic sheet may comprise a thermoplastic.
  • the plastic sheet may be a thermoplastic polymer sheet.
  • the plastic sheet may comprise a thermosetting plastic.
  • the plastic sheet may be a polycarbonate sheet.
  • the plastic sheet may be at least partially transparent.
  • the plastic sheet may be transparent.
  • the plastic sheet may be at least partially translucent.
  • the plastic sheet may be translucent.
  • the plastic sheet may be at least partially opaque.
  • the plastic sheet may include one or more transparent and translucent portions.
  • the plastic sheet may include one or more transparent and opaque portions.
  • the plastic sheet may include one or more transparent and/or translucent and/or opaque portions.
  • the plastic sheet may include one or more colour pigments.
  • the process may comprise the further step of applying one or more inks to at least a portion of a surface of the plastic sheet to create an at least partially inked surface.
  • the one or more inks may be applied to a plurality of locations on the plastic sheet.
  • the one or more inks may be applied to the at least a portion of the plastic sheet in one or more predetermined graphic patterns.
  • the predetermined graphic pattern may include one or more informative graphic patterns, or informational graphic patterns, such as a barcode, or the like.
  • the predetermined graphic pattern may include one or more decorative patterns.
  • the predetermined graphic pattern may include one or more alphanumeric characters, or sets or groups of alphanumeric characters.
  • the one or more inks may be transparent.
  • the at least partial inking of the plastic sheet results in the plastic sheet having "inked” and "non-inked” portions.
  • the one or more inks may be applied to the entire surface of the plastic sheet.
  • the one or more inks may be applied to the at least a portion of the plastic sheet by printing.
  • the one or more inks may be applied to the at least a portion of the plastic sheet by screen printing.
  • the one or more inks may be applied to the at least a portion of the plastic sheet by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
  • the one or more inks may be solvent-based inks.
  • the one or more inks may have a high resistance to heat.
  • the one or more inks may have a high adhesion, high printability and high formability.
  • the one or more inks may be capable of withstanding high shear forces.
  • the one or more inks are suitable for injection moulding.
  • the one or more inks may have a high resistance to "wash out".
  • the term “wash out” refers to undesirable removal of the ink during the injection moulding process.
  • the plastic sheet may have a front surface and a rear surface (sub surface).
  • the one or more inks may be applied to at least a portion of the rear surface of the plastic sheet. This may be termed the "second surface”. Printing on the second surface (rear surface) may be termed "reverse printing”. Alternatively, or additionally, the one or more inks may be applied to at least a portion of the front surface of the plastic sheet. A plurality of inks may be applied to the at least a portion of the surface of the plastic sheet.
  • the adhesive may be applied to a plurality of locations on the rear surface of the plastic sheet.
  • the adhesive may be applied to at least a portion of an inked portion of the plastic sheet and/or at least a portion of a non-inked portion of the plastic sheet.
  • the adhesive may be applied to the entire inked portion of the plastic sheet and/or the entire portion of the non-inked portion of the plastic sheet. In the arrangement where the adhesive is applied to the entire inked portion of the plastic sheet, the adhesive substantially covers the entire inked portion of the plastic sheet.
  • the adhesive may be applied to inked and/or non-inked portions of the plastic sheet.
  • the adhesive may be applied to the at least a portion of the rear surface of the plastic sheet by printing.
  • the adhesive may be applied to the at least a portion of the rear surface of the plastic sheet by screen printing.
  • the adhesive may be applied to the at least a portion of the plastic sheet by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
  • the adhesive may be an ultraviolet (UV) reactive adhesive.
  • the adhesive may be a clear ultraviolet (UV) reactive adhesive.
  • the adhesive may be a solvent-based adhesive.
  • the adhesive may be a water-based adhesive.
  • the adhesive may include one or more colour pigments.
  • the transferable layer of the transfer sheet may contain metal.
  • the transferable layer of the transfer sheet may contain metal particles.
  • the transferable layer of the transfer sheet may contain metal flakes.
  • the transferable layer of the transfer sheet may contain metal and non-metal particles.
  • the transferable layer of the transfer sheet may contain one or more holographic portions.
  • the transferable layer of the transfer sheet may be a foil.
  • the transferable layer of the transfer sheet may be a metal foil.
  • the metal foil may include one or more holographic portions.
  • the metal foil may be a holographic foil.
  • the transferable layer of the transfer sheet may contain one or more security features and/or security markings.
  • the security features/markings may be overt and/or covert.
  • the security features/markings may include one or more of group consisting of micro text, nano text, Infrared Radiation (IR) tags and colour shifting tags.
  • IR Infrared Radiation
  • the transferable layer of the transfer sheet is a foil
  • the security features and/or security markings are formed as part of the foil. That is, the security features and/or security markings are formed with the foil.
  • the transferable layer of the transfer sheet may contain one or more features.
  • the one or more features may be a security feature and/or an authenticating feature.
  • the label may contain one or more holographic portions.
  • the feature may contain one or more smart codes and/or bar codes.
  • the transferable layer of the transfer sheet may contain one or more labels.
  • the one or more labels may be a security label and/or an authenticating label.
  • the label may contain one or more holographic portions.
  • the label may contain one or more smart codes and/or bar codes.
  • the transferable layer of the transfer sheet may contain one or more decorative patterns.
  • the transferable layer of the transfer sheet may contain one or more alphanumeric characters.
  • the support layer of the transfer sheet may include polyester.
  • the support layer of the transfer sheet may be polyester.
  • the transfer sheet may be a cold foil.
  • the transfer sheet may be applied to a plurality of locations on the rear surface of the plastic sheet.
  • the step of applying the at least one transfer sheet to the rear surface of the plastic sheet may be carried out by applying pressure and/or heat to the transfer sheet and plastic sheet.
  • the at least one transfer sheet may be rolled onto the plastic sheet.
  • nip rollers may be used to apply the at least one transfer sheet to the rear surface of the plastic sheet.
  • the step of transferring the transferable layer of the at least one transfer sheet to the adhesive may be carried out by curing the adhesive, such that the transferable layer of the at least one transfer sheet adheres to the adhesive.
  • the adhesive used would be a so-called "wet adhesive", which cures with the transfer layer applied to the adhesive.
  • the step of curing the adhesive may be carried out using ultraviolet (UV) radiation.
  • UV radiation ultraviolet
  • a UV lamp, drier, or the like may be used to cure the adhesive.
  • the adhesive is a solvent-based adhesive or water-based adhesive
  • the adhesive may be cured by applying a source of air and/or a source of heat to the adhesive.
  • the process may include an alterative step of curing the adhesive before the at least one transfer sheet is applied to the adhesive.
  • the adhesive used would be a so-called "dry adhesive", which is cured before application of the transfer layer.
  • the transferable layer of the at least one transfer sheet is transferred to the adhesive by the step of applying a pressure to the transfer sheet.
  • the protective coatings may include solvent inks.
  • the protective coatings may include polyurethane.
  • the protective coating may include a water-based polyurethane.
  • the protective coatings may include hardener. The hardener promotes adhesion of the plastic sheet to the plastic resin during the injection moulding process. The hardener also provides protection to the one or more inks and transferable layer of the transfer sheet.
  • the protective coatings may include an aliphatic polyisocyanate.
  • the process may comprise the further step of laminating the at least one transfer sheet to the plastic sheet before curing the adhesive.
  • the step of laminating the at least one transfer sheet to the plastic sheet may include applying heat and/or pressure.
  • the process may include the further step of heating the insert sheet and manipulating the sheet into a three-dimensional shape.
  • This process may be termed "thermo-forming" and may be carried out before the insert sheet is fitted into the mould for the injection moulding process.
  • the process may further comprise removing the bonded component and insert sheet from the mould.
  • the moulded component may be part of a casing for an electronic device.
  • the electronic device may be a mobile phone, desktop computer, portable computer, handheld computer, or the like.
  • the plastics material may be a plastic resin.
  • the plastics material may be polycarbonate, acrylonitrile butadiene styrene (ABS), polycarbonate/ABS blends, or the like.
  • the electronic device may include a mobile phone, desktop computer, portable computer, handheld computer, or the like.
  • an insert sheet for use in an injection moulding process comprising:
  • plastic sheet comprising one or more plastic materials
  • the plastic sheet may comprise a thermoplastic.
  • the plastic sheet may be a thermoplastic polymer sheet.
  • the plastic sheet may comprise a thermosetting plastic.
  • the plastic sheet may be a polycarbonate sheet.
  • the plastic sheet may be at least partially transparent.
  • the plastic sheet may be transparent.
  • the plastic sheet may be at least partially translucent.
  • the plastic sheet may be translucent.
  • the plastic sheet may be at least partially opaque.
  • the plastic sheet may include one or more transparent and translucent portions.
  • the plastic sheet may include one or more transparent and opaque portions.
  • the plastic sheet may include one or more transparent and/or translucent and/or opaque portions.
  • the plastic sheet may include one or more colour pigments.
  • the plastic sheet may include one or more ink layers on at least a portion of a surface of the plastic sheet.
  • the one or more inks may be applied to a plurality of locations on the plastic sheet.
  • the one or more inks may be applied to the at least a portion of the plastic sheet in one or more predetermined graphic patterns.
  • the predetermined graphic pattern may include one or more informative graphic patterns, or informational graphic patterns, such as a barcode, or the like.
  • the predetermined graphic pattern may include one or more decorative patterns.
  • the predetermined graphic pattern may include one or more alphanumeric characters, or sets or groups of alphanumeric characters.
  • the one or more inks may be transparent.
  • the at least partial inking of the plastic sheet results in the plastic sheet having "inked” and “non-inked” portions.
  • the one or more inks may be applied to the entire surface of the plastic sheet.
  • the one or more inks may be applied to the at least a portion of the plastic sheet by printing.
  • the one or more inks may be applied to the at least a portion of the plastic sheet by screen printing.
  • the one or more inks may be applied to the at least a portion of the plastic sheet by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
  • the one or more inks may be solvent-based inks.
  • the one or more inks may have a high resistance to heat.
  • the one or more inks may have a high adhesion, high printability and high formability.
  • the one or more inks may be capable of withstanding high shear forces.
  • the one or more inks are suitable for injection moulding.
  • the one or more inks may have a high resistance to "wash out".
  • the term “wash out” refers to undesirable removal of the ink during the injection moulding process.
  • the plastic sheet may have a front surface and a rear surface (sub surface).
  • the one or more inks may be applied to at least a portion of the rear surface of the plastic sheet. This may be termed the "second surface”. Printing on the second surface (rear surface) may be termed "reverse printing”. Alternatively, or additionally, the one or more inks may be applied to at least a portion of the front surface of the plastic sheet.
  • a plurality of inks may be applied to the at least a portion of the surface of the plastic sheet.
  • the layer of transfer material may be located to a plurality of locations on the rear surface of the plastic sheet.
  • the layer of transfer material may be applied to at least a portion of an inked portion of the plastic sheet and/or at least a portion of a non-inked portion of the plastic sheet.
  • the layer of transfer material may be applied to the entire inked portion of the plastic sheet and/or the entire portion of the non-inked portion of the plastic sheet. In the arrangement where the layer of transfer material is applied to the entire inked portion of the plastic sheet, the layer of transfer material substantially covers the entire inked portion of the plastic sheet.
  • the layer of transfer material may be applied to inked and/or non-inked portions of the plastic sheet.
  • the layer of transfer material may be applied to the at least a portion of the rear surface of the plastic sheet by a printed adhesive.
  • the adhesive may be applied to the at least a portion of the rear surface of the plastic sheet by screen printing.
  • the adhesive may be applied to the at least a portion of the rear surface of the plastic by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
  • the adhesive may be an ultraviolet (UV) reactive adhesive.
  • the adhesive may be a clear ultraviolet (UV) reactive adhesive.
  • the adhesive may be a solvent-based adhesive.
  • the adhesive may be a water-based adhesive.
  • the adhesive may include one or more colour pigments.
  • the layer of transfer material may contain metal.
  • the layer of transfer material may contain metal particles.
  • the layer of transfer material may contain metal flakes.
  • the layer of transfer material may contain metal and non-metal particles.
  • the layer of transfer material may contain one or more holographic portions.
  • the layer of transfer material may be a foil.
  • the layer of transfer material may be a metal foil.
  • the metal foil may include one or more holographic portions.
  • the metal foil may be a holographic foil.
  • the transferable layer of the transfer sheet may contain one or more security features and/or security markings.
  • the security features/markings may be overt and/or covert.
  • the security features/markings may include one or more of group consisting of micro text, nano text, Infrared Radiation (IR) tags and colour shifting tags.
  • IR Infrared Radiation
  • the transferable layer of the transfer sheet is a foil
  • the security features and/or security markings are formed as part of the foil. That is, the security features and/or security markings are formed with the foil.
  • the layer of transfer material may contain one or more labels.
  • the one or more labels may be a security label and/or an authenticating label.
  • the label may contain one or more holographic portions.
  • the label may contain one or more smart codes and/or bar codes.
  • the layer of transfer material may contain one or more decorative patterns.
  • the layer of transfer material may contain one or more alphanumeric characters.
  • the layer of transfer material may be applied to a plurality of locations on the rear surface of the plastic sheet.
  • the protective coatings may include solvent inks.
  • the protective coatings may include polyurethane.
  • the protective coating may include a water-based polyurethane.
  • the protective coatings may include hardener. The hardener promotes adhesion of the plastic sheet to the plastic resin during the injection moulding process. The hardener also provides protection to the one or more inks and transferable layer of the transfer sheet.
  • the protective coatings may include an aliphatic polyisocyanate.
  • a moulded component comprising the insert sheet according to the fourth aspect of the invention, wherein the insert sheet has been bonded to a plastics material during injection moulding of the component.
  • the moulded component may be part of a casing for an electronic device.
  • the electronic device may be a mobile phone, desktop computer, portable computer, handheld computer, or the like.
  • the plastics material may be a plastic resin.
  • the plastics material may be polycarbonate, acrylonitrile butadiene styrene (ABS), polycarbonate/ABS blends, or the like.
  • the electronic device may include a mobile phone, desktop computer, portable computer, handheld computer, or the like.
  • Figure 1 is an exploded view of the insert sheet formed by the process of the present invention
  • Figure 2 a is an illustration of the insert sheet after the removal of the transfer sheet
  • Figure 2b is an illustration of the transfer sheet after removal from the insert sheet
  • Figure 3 is a front view of the insert sheet formed by the process of the present invention.
  • Figure 4 is a flow chart detailing the process steps according to the process of the present invention.
  • FIGS 1 to 4 illustrate the process steps and components involved in forming an insert sheet 10 for use in an injection moulding process.
  • the insert sheet 10 is formed by firstly providing a plastic sheet 12.
  • the plastic sheet 12 is a transparent polycarbonate sheet.
  • any suitable thermoplastic sheet, or thermosetting plastic sheet may be used.
  • a layer of ink 14 is then printed onto the polycarbonate sheet 12.
  • the layer of ink 14 is printed to the rear surface 12a of the polycarbonate sheet 12.
  • the layer of ink 14 is applied to the polycarbonate sheet 12 by screen printing. Printing on the rear surface of the polycarbonate sheet 12 allows for a more durable component, as the ink layer 14 is not exposed on the surface of the component to the environment, chemicals and general wear and tear.
  • the inks used are standard solvent-based or UV-based in mould decoration (IMD) inks. Such inks have a high resistance to heat and also provide high adhesion, printability and formability. They are also capable of withstanding high shear forces.
  • the layer of ink 14 has a predetermined graphic pattern 16, which in this case is the applicant's logo.
  • the predetermined graphic pattern 16 is void of ink. That is, the area surrounding the predetermined pattern 16 includes ink, but the predetermined pattern 16 itself does not contain any ink.
  • the layer of ink 14 therefore includes "inked" portions 14a and "non-inked” portions 14b.
  • the application of the layer of ink 14 to the polycarbonate sheet 12 therefore results in the polycarbonate sheet 12 having "inked” and "non-inked” portions.
  • the ink is therefore considered as being applied to at least a portion of the rear surface 12a of the polycarbonate sheet 12 to create an at least partially inked surface.
  • the predetermined graph pattern 16 has been illustrated in figure 1 as being a decorative pattern, it should be appreciated that the predetermined graphic pattern 16 could be informational, such as a barcode, smartcode, or the like.
  • the predetermined graphic pattern 16 may also be a security pattern, or security marking.
  • the predetermined graphic pattern 16 may also contain one or more alphanumeric characters, or sets or groups of alphanumeric characters.
  • the adhesive 18 is provided on a print sheet 18a and is formed to be the same shape as the predetermined graphic pattern 16, i.e. the applicant's logo.
  • the adhesive 18 is applied to the polycarbonate sheet 12 by printing. After printing, the print sheet 18a is removed from the polycarbonate sheet 1. In this arrangement it is evident that the adhesive 18 is being applied substantially to the rear surface of the polycarbonate sheet 12 through the "non-inked" portions of the ink layer 14. However, it should be appreciated that the adhesive 18 may be applied to any desired portion of the ink layer 14 and/or polycarbonate sheet 12, depending on the requirements and the configuration of the predetermined graphic pattern 16.
  • the adhesive 18 is a clear (transparent) ultraviolet (UV) reactive cold foil adhesive. However, it should be appreciated that other suitable types of adhesives may be used.
  • a transfer sheet 20 is applied to the polycarbonate sheet 12.
  • the transfer sheet 20 is a cold foil.
  • the cold foil consists of a polyester carrier layer 20a (an example of a support layer) and a metal-containing layer 20b (an example of a transferable layer).
  • Suitable cold foils are directly available from a great variety of providers. For example, companies such as Leonard Kurz, Garnet Close, Greycaine Industrial Estate, Watford, Herts, WD 24 7JW, www.kurz.co.uk.
  • the metal-containing layer 20b is a holographic layer.
  • the holographic layer 20b includes one or more security features (not shown).
  • the security features of the holographic layer may be overt and/or covert and may include micro text, nano text, Infrared Radiation (IR) tags or colour shifting tags, or any combination of these.
  • IR Infrared Radiation
  • the transfer sheet 20 is applied to the rear surface 12a of the polycarbonate sheet 12 such that the transfer sheet 20 substantially covers the adhesive 18 and the holographic layer 20b is sandwiched between the adhesive 18 and the polyester carrier layer 20a.
  • the transfer sheet 20 may be applied to the polycarbonate sheet 12 through the use of pressure and/or heat.
  • the transfer sheet 20 may thus be considered as being laminated to the polycarbonate sheet 12.
  • the holographic layer 20b is transferred to the adhesive 18.
  • the holographic layer is transferred to the adhesive 18 by curing the adhesive 18 through use of a UV lamp, drier, or the like, such that the holographic layer 20b adheres to the adhesive 18.
  • the polyester carrier layer 20a of the transfer sheet 20 is removed from the polycarbonate sheet 12.
  • the polyester carrier layer 20a may be removed from the polycarbonate sheet 12 by peeling.
  • the removed polyester carrier layer 20a is illustrated in figure 2b.
  • Figure 2a illustrates the rear surface 12a of the polycarbonate sheet 12 after the polyester carrier layer 20a of the transfer sheet has been removed therefrom. It can be seen that the holographic layer 20b is adhered to the adhesive 18 in the form of the predetermined graphic pattern 16.
  • the holographic layer 20b may be visualised from the front surface 12b of the polycarbonate sheet 12, as illustrated in figure 3.
  • one or more protective coatings 22 are applied to the rear surface of the polycarbonate sheet 12.
  • the protective coatings 22 provide protection to the ink layer 14 and the holographic layer 20b during the injection moulding process and also to promote bonding of the insert sheet 10 to the moulding resin.
  • the protective coatings 22 may include one or more layers of protective inks, such as standard IMD inks.
  • the inks may be mild solvent inks which do not damage or crack the holographic layer 20b, ink layer 14 or adhesive 18.
  • the protective coatings 22 may also include one or more layers of a water-based polyurethane adhesive with an aliphatic polyisocyanate hardener.
  • the water-based polyurethane adhesive with an aliphatic polyisocyanate hardener promotes adhesion to the insert sheet 10 during the injection moulding process and also to provide additional protection to the ink layer 14 and the holographic layer 20b.
  • the protective coatings 22 are typically at least 12 microns thick. Although it should be appreciated that other thicknesses may be used, depending on the requirements of the insert sheet 10.
  • Figure 3 is a front view of the formed insert sheet 10 ready for use in an injection moulding process.
  • the first step 110 is to provide a plastic sheet comprising one or more plastic materials.
  • the second step 120 is to apply an adhesive to at least a portion of a rear surface of the plastic sheet.
  • the third step 130 is to provide at least one transfer sheet comprising a support layer and a transferable layer.
  • the fourth step 140 is to apply the at least one transfer sheet to the rear surface of the plastic sheet at the location of the adhesive, such that the at least one transfer sheet substantially covers the adhesive and the transferable layer of the at least one transfer sheet is sandwiched between the adhesive and the support layer of the at least one transfer sheet.
  • the fifth step 150 is to transfer the transferable layer of the at least one transfer sheet to the adhesive.
  • the sixth step 160 is to remove the support layer of the at least one transfer sheet from the plastic sheet.
  • the seventh step 170 is to apply one or more protective coatings to at least a portion of the rear surface of the plastic sheet, wherein the one or more protective coatings are configured to prevent damage occurring to the plastic sheet during an injection moulding process.
  • the insert sheet 10 of the present invention is a "single layer" construction, i.e. it is not formed from a number of laminated layers. This prevents delamination of the insert sheet 10 or moulded component. This also avoids the need for pressure sensitive adhesives, which can migrate during the moulding process and leave an adhesive build up around the edges of the moulded component. This may adversely affect the moulding tool. Furthermore, pressure sensitive adhesives are more likely to bubble during the moulding process, which affects the physical properties of the insert sheet and moulded component.
  • the process of the present invention allows an insert sheet 10 to be created having an outward facing surface 12b with a desired physical property.
  • the present invention allows the outward facing surface 12b of the insert sheet 10 to have a particular physical property, such as a desired reflectivity or absorption level. Additionally, or alternatively, the present invention allows an insert sheet 10 to be created with one or more holographic security features formed within the insert sheet 10. The process of the present invention thus provides the ability to modify or alter the physical property (or properties) of the outward facing surface of the insert sheet. When the insert sheet 10 is used in an injection moulding process to produce a moulded component, the moulded component, therefore, also has the same enhanced, modified or altered physical properties described above.
  • the polycarbonate sheet 12 has been illustrated and described above as being transparent, it should be appreciated that the polycarbonate sheet 12 could be at least partially transparent.
  • the polycarbonate sheet 12 may be entirely translucent, or at least partially translucent.
  • the polycarbonate sheet 12 may be at least partially opaque.
  • the polycarbonate sheet 12 may include one or more transparent and translucent portions.
  • the polycarbonate sheet 12 may include one or more transparent and opaque portions.
  • the polycarbonate sheet 12 may include one or more transparent and/or translucent and/or opaque portions.
  • the polycarbonate sheet 12 may include one or more colour pigments.
  • the ink layer 14 has been illustrated and described above as having inked and non-inked portions 14a, 14b, it should be appreciated that the ink layer 14 may consist of only inked portions 14a. That is, the ink layer may be applied to the entire surface of the polycarbonate sheet 12.
  • the ink layer 14 may be applied to the polycarbonate sheet 12 by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
  • the ink layer 14 has been illustrated and described above as being applied to the rear surface 12a of the polycarbonate sheet 12, it should be appreciated that the ink layer 14 may be applied to the outward facing surface 12b, or front surface, of the polycarbonate sheet 12. In this case the adhesive 18 would be applied straight to the rear surface 12a of the polycarbonate sheet 12. Note that the application of the ink layer 14 to the front surface 12b of the polycarbonate sheet 12 could be an additional step. That is, the insert sheet 10 could have inks applied to both surfaces 12a, 12b.
  • ink layer 14 has been illustrated and described above being applied to the polycarbonate sheet 12, it should be appreciated that a plurality of ink layers 14 could be applied to the polycarbonate sheet 12. Each ink layer 14 could, for example, be a different colour or type of ink.
  • the adhesive 18 may be applied to a plurality of locations on the rear surface 12a of the polycarbonate sheet 12.
  • the adhesive 18 has been described as being applied to the polycarbonate sheet 12 in the "gaps" of the non-inked portions of the ink layer 14, it should be appreciated that the adhesive 18 may be to at least a portion of an inked portion 14a of the polycarbonate sheet 12 and/or at least a portion of a non-inked portion 14b of the polycarbonate sheet 12.
  • the adhesive 18 may be applied to the entire inked portion 14a of the polycarbonate sheet 12 and/or the entire portion of the non-inked portion 14b of the polycarbonate sheet 12. In the arrangement where the adhesive 18 is applied to the entire inked portion of the polycarbonate sheet 12, the adhesive 18 substantially covers the entire inked portion 14a of the polycarbonate sheet 12.
  • the adhesive 18 may be applied to the polycarbonate sheet 12 by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
  • the adhesive 18 has been illustrated and described above as being clear, it should be appreciated that the adhesive may include on or more colour pigments.
  • the transfer sheet 20 has been illustrated and described above as being a cold foil, it should be appreciated that any suitable transfer sheet 20 that has a support layer and a transferable layer could be used.
  • the transferable layer of the transfer sheet 20 may contain metal.
  • the transferable layer of the transfer sheet 20 may contain metal particles.
  • the transferable layer of the transfer sheet 20 may contain metal flakes.
  • the transferable layer of the transfer sheet 20 may contain metal and non-metal particles.
  • the transferable layer of the transfer sheet 20 may be a foil.
  • the transferable layer of the transfer sheet 20 may be a metal foil.
  • the metal foil may include one or more holographic portions.
  • the metal foil may be a holographic foil.
  • the transferable layer of the transfer sheet 20 may contain one or more security features and/or security markings.
  • the security features/markings may be overt and/or covert.
  • the security features/markings may include one or more of group consisting of micro text, nano text, Infrared Radiation (IR) tags and colour shifting tags.
  • IR Infrared Radiation
  • the transferable layer of the transfer sheet 20 is a foil
  • the security features and/or security markings are formed as part of the foil. That is, the security features and/or security markings are formed with the foil.
  • the transferable layer of the transfer sheet 20 may contain one or more labels.
  • the one or more labels may be a security label and/or an authenticating label.
  • the label may contain one or more holographic portions.
  • the label may contain one or more smart codes and/or bar codes.
  • the transferable layer of the transfer sheet 20 may contain one or more decorative patterns.
  • the transferable layer of the transfer sheet 20 may contain one or more alphanumeric characters.
  • the support layer of the transfer sheet 20 may include polyester.
  • the support layer of the transfer sheet may
  • transfer sheet 20 has been illustrated and described above as being applied to the entire rear surface 12a of the polycarbonate sheet 12, it should be appreciated that one or more transfer sheets 20 could be applied to the rear surface 12a of the polycarbonate sheet 12. That is, any number of transfer sheets 20 could be applied to any number of locations on the rear surface 12a of the polycarbonate sheet 12.
  • the step of transferring the transferable layer (holographic layer 20) to the adhesive 18 has been described above as being done by curing the adhesive 18 with the transferable layer against the adhesive 18 with UV radiation, it should be appreciated that the adhesive 18 may be cured before the transfer sheet 20 is applied to the adhesive 18. In this case the transferable layer of the at least one transfer sheet 20 is transferred to the adhesive 18 by the additional step of applying a pressure to the transfer sheet 20.

Abstract

A process for forming an insert sheet for use in an injection moulding process. The process comprising the steps of providing a plastic sheet comprising one or more plastic materials; applying an adhesive to at least a portion of a rear surface of the plastic sheet; providing at least one transfer sheet comprising a support layer and a transferable layer; applying the at least one transfer sheet to the rear surface of the plastic sheet at the location of the adhesive, such that the at least one transfer sheet substantially covers the adhesive and the transferable layer of the at least one transfer sheet is sandwiched between the adhesive and the support layer of the at least one transfer sheet; transferring the transferable layer of the at least one transfer sheet to the adhesive; removing the support layer of the at least one transfer sheet from the plastic sheet; and applying one or more protective coatings to at least a portion of the rear surface of the plastic sheet, wherein the one or more protective coatings are configured to prevent damage occurring to the plastic sheet during an injection moulding process.

Description

Improvements in or relating to injection moulded components
The present invention relates to an insert sheet for use in an injection moulding process, a process for forming an insert sheet for use in an injection moulding process and a moulded component incorporating said insert sheet.
In injection moulding processes it is known to use insert sheets to provide, for example, an outward facing surface of an injection moulded component with a particular physical property. For example, the insert sheet may be formed from a hard coated material, which protects the component from being scratched. Additionally or alternatively, the material of the insert sheet may be chosen to provide the component with a desired reflectivity or absorption level. The present inventors have appreciated the shortcomings in known insert sheets.
According to a first aspect of the invention there is provided a process for forming an insert sheet for use in an injection moulding process, the process comprising the steps of:
providing a plastic sheet comprising one or more plastic materials;
applying an adhesive to at least a portion of a rear surface of the plastic sheet;
providing at least one transfer sheet comprising a support layer and a transferable layer;
applying the at least one transfer sheet to the rear surface of the plastic sheet at the location of the adhesive, such that the at least one transfer sheet substantially covers the adhesive and the transferable layer of the at least one transfer sheet is sandwiched between the adhesive and the support layer of the at least one transfer sheet;
transferring the transferable layer of the at least one transfer sheet to the adhesive; removing the support layer of the at least one transfer sheet from the plastic sheet; and
applying one or more protective coatings to at least a portion of the rear surface of the plastic sheet, wherein the one or more protective coatings are configured to prevent damage occurring to the plastic sheet during an injection moulding process.
The plastic sheet may comprise a thermoplastic. The plastic sheet may be a thermoplastic polymer sheet. The plastic sheet may comprise a thermosetting plastic. The plastic sheet may be a polycarbonate sheet.
The plastic sheet may be at least partially transparent. The plastic sheet may be transparent. The plastic sheet may be at least partially translucent. The plastic sheet may be translucent. The plastic sheet may be at least partially opaque. The plastic sheet may include one or more transparent and translucent portions. The plastic sheet may include one or more transparent and opaque portions. The plastic sheet may include one or more transparent and/or translucent and/or opaque portions. The plastic sheet may include one or more colour pigments.
The process may comprise the further step of applying one or more inks to at least a portion of a surface of the plastic sheet to create an at least partially inked surface. The one or more inks may be applied to a plurality of locations on the plastic sheet.
The one or more inks may be applied to the at least a portion of the plastic sheet in one or more predetermined graphic patterns. The predetermined graphic pattern may include one or more informative graphic patterns, or informational graphic patterns, such as a barcode, or the like. The predetermined graphic pattern may include one or more decorative patterns. The predetermined graphic pattern may include one or more alphanumeric characters, or sets or groups of alphanumeric characters.
The one or more inks may be transparent.
The at least partial inking of the plastic sheet results in the plastic sheet having "inked" and "non-inked" portions.
The one or more inks may be applied to the entire surface of the plastic sheet.
The one or more inks may be applied to the at least a portion of the plastic sheet by printing. The one or more inks may be applied to the at least a portion of the plastic sheet by screen printing. The one or more inks may be applied to the at least a portion of the plastic sheet by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
The one or more inks may be solvent-based inks. The one or more inks may have a high resistance to heat. The one or more inks may have a high adhesion, high printability and high formability. The one or more inks may be capable of withstanding high shear forces.
The one or more inks are suitable for injection moulding. The one or more inks may have a high resistance to "wash out". The term "wash out" refers to undesirable removal of the ink during the injection moulding process.
The plastic sheet may have a front surface and a rear surface (sub surface). The one or more inks may be applied to at least a portion of the rear surface of the plastic sheet. This may be termed the "second surface". Printing on the second surface (rear surface) may be termed "reverse printing". Alternatively, or additionally, the one or more inks may be applied to at least a portion of the front surface of the plastic sheet. A plurality of inks may be applied to the at least a portion of the surface of the plastic sheet.
The adhesive may be applied to a plurality of locations on the rear surface of the plastic sheet.
The adhesive may be applied to at least a portion of an inked portion of the plastic sheet and/or at least a portion of a non-inked portion of the plastic sheet. The adhesive may be applied to the entire inked portion of the plastic sheet and/or the entire portion of the non-inked portion of the plastic sheet. In the arrangement where the adhesive is applied to the entire inked portion of the plastic sheet, the adhesive substantially covers the entire inked portion of the plastic sheet.
In the arrangement where the one or more inks are applied to the at least a portion of the plastic sheet in one or more predetermined graphic patterns, the adhesive may be applied to inked and/or non-inked portions of the plastic sheet.
The adhesive may be applied to the at least a portion of the rear surface of the plastic sheet by printing. The adhesive may be applied to the at least a portion of the rear surface of the plastic sheet by screen printing. The adhesive may be applied to the at least a portion of the plastic sheet by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
The adhesive may be an ultraviolet (UV) reactive adhesive. The adhesive may be a clear ultraviolet (UV) reactive adhesive. The adhesive may be a solvent-based adhesive. The adhesive may be a water-based adhesive.
The adhesive may include one or more colour pigments. The transferable layer of the transfer sheet may contain metal. The transferable layer of the transfer sheet may contain metal particles. The transferable layer of the transfer sheet may contain metal flakes. The transferable layer of the transfer sheet may contain metal and non-metal particles.
The transferable layer of the transfer sheet may contain one or more holographic portions.
The transferable layer of the transfer sheet may be a foil. The transferable layer of the transfer sheet may be a metal foil. The metal foil may include one or more holographic portions. The metal foil may be a holographic foil.
The transferable layer of the transfer sheet may contain one or more security features and/or security markings. The security features/markings may be overt and/or covert. The security features/markings may include one or more of group consisting of micro text, nano text, Infrared Radiation (IR) tags and colour shifting tags. In the case where the transferable layer of the transfer sheet is a foil, the security features and/or security markings are formed as part of the foil. That is, the security features and/or security markings are formed with the foil.
The transferable layer of the transfer sheet may contain one or more features. The one or more features may be a security feature and/or an authenticating feature. The label may contain one or more holographic portions. The feature may contain one or more smart codes and/or bar codes.
The transferable layer of the transfer sheet may contain one or more labels. The one or more labels may be a security label and/or an authenticating label. The label may contain one or more holographic portions. The label may contain one or more smart codes and/or bar codes.
The transferable layer of the transfer sheet may contain one or more decorative patterns. The transferable layer of the transfer sheet may contain one or more alphanumeric characters. The support layer of the transfer sheet may include polyester. The support layer of the transfer sheet may be polyester.
The transfer sheet may be a cold foil.
The transfer sheet may be applied to a plurality of locations on the rear surface of the plastic sheet.
The step of applying the at least one transfer sheet to the rear surface of the plastic sheet may be carried out by applying pressure and/or heat to the transfer sheet and plastic sheet. The at least one transfer sheet may be rolled onto the plastic sheet. In this arrangement, nip rollers may be used to apply the at least one transfer sheet to the rear surface of the plastic sheet. The step of transferring the transferable layer of the at least one transfer sheet to the adhesive may be carried out by curing the adhesive, such that the transferable layer of the at least one transfer sheet adheres to the adhesive. In this case the adhesive used would be a so-called "wet adhesive", which cures with the transfer layer applied to the adhesive.
The step of curing the adhesive may be carried out using ultraviolet (UV) radiation. Where the adhesive is an ultraviolet (UV) reactive adhesive, a UV lamp, drier, or the like, may be used to cure the adhesive. Where the adhesive is a solvent-based adhesive or water-based adhesive, the adhesive may be cured by applying a source of air and/or a source of heat to the adhesive.
The process may include an alterative step of curing the adhesive before the at least one transfer sheet is applied to the adhesive. In this case the adhesive used would be a so-called "dry adhesive", which is cured before application of the transfer layer. In this case the transferable layer of the at least one transfer sheet is transferred to the adhesive by the step of applying a pressure to the transfer sheet.
The protective coatings may include solvent inks. The protective coatings may include polyurethane. The protective coating may include a water-based polyurethane. The protective coatings may include hardener. The hardener promotes adhesion of the plastic sheet to the plastic resin during the injection moulding process. The hardener also provides protection to the one or more inks and transferable layer of the transfer sheet. The protective coatings may include an aliphatic polyisocyanate.
The process may comprise the further step of laminating the at least one transfer sheet to the plastic sheet before curing the adhesive. The step of laminating the at least one transfer sheet to the plastic sheet may include applying heat and/or pressure.
The process may include the further step of heating the insert sheet and manipulating the sheet into a three-dimensional shape. This process may be termed "thermo-forming" and may be carried out before the insert sheet is fitted into the mould for the injection moulding process.
According to a second aspect of the invention there is provided a process for forming a moulded component comprising the steps of:
providing a mould for the component;
inserting one or more insert sheets according to the first aspect of the invention into the mould, wherein the insert sheet is inserted into the mould with the one or more protective coatings facing outwards from the mould; and
injecting a plastics material into the mould and onto the insert sheet to bond the insert sheet with the plastics material and form the component.
The process may further comprise removing the bonded component and insert sheet from the mould. The moulded component may be part of a casing for an electronic device. The electronic device may be a mobile phone, desktop computer, portable computer, handheld computer, or the like.
The plastics material may be a plastic resin. The plastics material may be polycarbonate, acrylonitrile butadiene styrene (ABS), polycarbonate/ABS blends, or the like. According to a third aspect of the invention there is provided an electronic device including a moulded component according to the second aspect of the invention.
The electronic device may include a mobile phone, desktop computer, portable computer, handheld computer, or the like.
According to a fourth aspect of the invention there is provided an insert sheet for use in an injection moulding process, the insert sheet comprising:
a plastic sheet comprising one or more plastic materials;
a layer of transfer material, wherein the transfer material is adhered to at least a portion of a rear surface of the plastic sheet; and
one or more protective coatings on at least a portion of the rear surface of the plastic sheet, wherein the one or more protective coatings are configured to prevent damage occurring to the plastic sheet during an injection moulding process. The plastic sheet may comprise a thermoplastic. The plastic sheet may be a thermoplastic polymer sheet. The plastic sheet may comprise a thermosetting plastic. The plastic sheet may be a polycarbonate sheet.
The plastic sheet may be at least partially transparent. The plastic sheet may be transparent. The plastic sheet may be at least partially translucent. The plastic sheet may be translucent. The plastic sheet may be at least partially opaque. The plastic sheet may include one or more transparent and translucent portions. The plastic sheet may include one or more transparent and opaque portions. The plastic sheet may include one or more transparent and/or translucent and/or opaque portions. The plastic sheet may include one or more colour pigments.
The plastic sheet may include one or more ink layers on at least a portion of a surface of the plastic sheet. The one or more inks may be applied to a plurality of locations on the plastic sheet.
The one or more inks may be applied to the at least a portion of the plastic sheet in one or more predetermined graphic patterns. The predetermined graphic pattern may include one or more informative graphic patterns, or informational graphic patterns, such as a barcode, or the like. The predetermined graphic pattern may include one or more decorative patterns. The predetermined graphic pattern may include one or more alphanumeric characters, or sets or groups of alphanumeric characters. The one or more inks may be transparent.
The at least partial inking of the plastic sheet results in the plastic sheet having "inked" and "non-inked" portions. The one or more inks may be applied to the entire surface of the plastic sheet.
The one or more inks may be applied to the at least a portion of the plastic sheet by printing. The one or more inks may be applied to the at least a portion of the plastic sheet by screen printing. The one or more inks may be applied to the at least a portion of the plastic sheet by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing. The one or more inks may be solvent-based inks. The one or more inks may have a high resistance to heat. The one or more inks may have a high adhesion, high printability and high formability. The one or more inks may be capable of withstanding high shear forces.
The one or more inks are suitable for injection moulding. The one or more inks may have a high resistance to "wash out". The term "wash out" refers to undesirable removal of the ink during the injection moulding process. The plastic sheet may have a front surface and a rear surface (sub surface). The one or more inks may be applied to at least a portion of the rear surface of the plastic sheet. This may be termed the "second surface". Printing on the second surface (rear surface) may be termed "reverse printing". Alternatively, or additionally, the one or more inks may be applied to at least a portion of the front surface of the plastic sheet.
A plurality of inks may be applied to the at least a portion of the surface of the plastic sheet. The layer of transfer material may be located to a plurality of locations on the rear surface of the plastic sheet.
The layer of transfer material may be applied to at least a portion of an inked portion of the plastic sheet and/or at least a portion of a non-inked portion of the plastic sheet. The layer of transfer material may be applied to the entire inked portion of the plastic sheet and/or the entire portion of the non-inked portion of the plastic sheet. In the arrangement where the layer of transfer material is applied to the entire inked portion of the plastic sheet, the layer of transfer material substantially covers the entire inked portion of the plastic sheet.
In the arrangement where the one or more inks are applied to the at least a portion of the plastic sheet in one or more predetermined graphic patterns, the layer of transfer material may be applied to inked and/or non-inked portions of the plastic sheet.
The layer of transfer material may be applied to the at least a portion of the rear surface of the plastic sheet by a printed adhesive. The adhesive may be applied to the at least a portion of the rear surface of the plastic sheet by screen printing. The adhesive may be applied to the at least a portion of the rear surface of the plastic by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
The adhesive may be an ultraviolet (UV) reactive adhesive. The adhesive may be a clear ultraviolet (UV) reactive adhesive. The adhesive may be a solvent-based adhesive. The adhesive may be a water-based adhesive. The adhesive may include one or more colour pigments.
The layer of transfer material may contain metal. The layer of transfer material may contain metal particles. The layer of transfer material may contain metal flakes. The layer of transfer material may contain metal and non-metal particles.
The layer of transfer material may contain one or more holographic portions.
The layer of transfer material may be a foil. The layer of transfer material may be a metal foil. The metal foil may include one or more holographic portions. The metal foil may be a holographic foil.
The transferable layer of the transfer sheet may contain one or more security features and/or security markings. The security features/markings may be overt and/or covert. The security features/markings may include one or more of group consisting of micro text, nano text, Infrared Radiation (IR) tags and colour shifting tags. In the case where the transferable layer of the transfer sheet is a foil, the security features and/or security markings are formed as part of the foil. That is, the security features and/or security markings are formed with the foil.
The layer of transfer material may contain one or more labels. The one or more labels may be a security label and/or an authenticating label. The label may contain one or more holographic portions. The label may contain one or more smart codes and/or bar codes.
The layer of transfer material may contain one or more decorative patterns. The layer of transfer material may contain one or more alphanumeric characters.
The layer of transfer material may be applied to a plurality of locations on the rear surface of the plastic sheet. The protective coatings may include solvent inks. The protective coatings may include polyurethane. The protective coating may include a water-based polyurethane. The protective coatings may include hardener. The hardener promotes adhesion of the plastic sheet to the plastic resin during the injection moulding process. The hardener also provides protection to the one or more inks and transferable layer of the transfer sheet. The protective coatings may include an aliphatic polyisocyanate.
According to a fifth aspect of the invention there is provided a moulded component comprising the insert sheet according to the fourth aspect of the invention, wherein the insert sheet has been bonded to a plastics material during injection moulding of the component.
The moulded component may be part of a casing for an electronic device. The electronic device may be a mobile phone, desktop computer, portable computer, handheld computer, or the like. The plastics material may be a plastic resin. The plastics material may be polycarbonate, acrylonitrile butadiene styrene (ABS), polycarbonate/ABS blends, or the like. According to a sixth aspect of the invention there is provided an electronic device including a moulded component according to the fifth aspect of the invention.
The electronic device may include a mobile phone, desktop computer, portable computer, handheld computer, or the like.
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: -
Figure 1 is an exploded view of the insert sheet formed by the process of the present invention;
Figure 2 a is an illustration of the insert sheet after the removal of the transfer sheet; Figure 2b is an illustration of the transfer sheet after removal from the insert sheet;
Figure 3 is a front view of the insert sheet formed by the process of the present invention; and
Figure 4 is a flow chart detailing the process steps according to the process of the present invention.
Figures 1 to 4 illustrate the process steps and components involved in forming an insert sheet 10 for use in an injection moulding process. With reference to figures 1, 2a and 2b, the insert sheet 10 is formed by firstly providing a plastic sheet 12. In the embodiment illustrated and described here the plastic sheet 12 is a transparent polycarbonate sheet. However, it is appreciated that any suitable thermoplastic sheet, or thermosetting plastic sheet may be used.
A layer of ink 14 is then printed onto the polycarbonate sheet 12. In the embodiment illustrated and described here the layer of ink 14 is printed to the rear surface 12a of the polycarbonate sheet 12. The layer of ink 14 is applied to the polycarbonate sheet 12 by screen printing. Printing on the rear surface of the polycarbonate sheet 12 allows for a more durable component, as the ink layer 14 is not exposed on the surface of the component to the environment, chemicals and general wear and tear. The inks used are standard solvent-based or UV-based in mould decoration (IMD) inks. Such inks have a high resistance to heat and also provide high adhesion, printability and formability. They are also capable of withstanding high shear forces. As illustrated in figure 1, the layer of ink 14 has a predetermined graphic pattern 16, which in this case is the applicant's logo. The predetermined graphic pattern 16 is void of ink. That is, the area surrounding the predetermined pattern 16 includes ink, but the predetermined pattern 16 itself does not contain any ink. The layer of ink 14 therefore includes "inked" portions 14a and "non-inked" portions 14b.
The application of the layer of ink 14 to the polycarbonate sheet 12 therefore results in the polycarbonate sheet 12 having "inked" and "non-inked" portions. The ink is therefore considered as being applied to at least a portion of the rear surface 12a of the polycarbonate sheet 12 to create an at least partially inked surface.
Although the predetermined graph pattern 16 has been illustrated in figure 1 as being a decorative pattern, it should be appreciated that the predetermined graphic pattern 16 could be informational, such as a barcode, smartcode, or the like. The predetermined graphic pattern 16 may also be a security pattern, or security marking. The predetermined graphic pattern 16 may also contain one or more alphanumeric characters, or sets or groups of alphanumeric characters. After the ink layer 14 has been applied to the polycarbonate sheet 12, an adhesive 18 is applied to the rear surface of the polycarbonate sheet 12.
In the embodiment illustrated and described here the adhesive 18 is provided on a print sheet 18a and is formed to be the same shape as the predetermined graphic pattern 16, i.e. the applicant's logo. The adhesive 18 is applied to the polycarbonate sheet 12 by printing. After printing, the print sheet 18a is removed from the polycarbonate sheet 1. In this arrangement it is evident that the adhesive 18 is being applied substantially to the rear surface of the polycarbonate sheet 12 through the "non-inked" portions of the ink layer 14. However, it should be appreciated that the adhesive 18 may be applied to any desired portion of the ink layer 14 and/or polycarbonate sheet 12, depending on the requirements and the configuration of the predetermined graphic pattern 16. The adhesive 18 is a clear (transparent) ultraviolet (UV) reactive cold foil adhesive. However, it should be appreciated that other suitable types of adhesives may be used.
After application of the adhesive 18, a transfer sheet 20 is applied to the polycarbonate sheet 12.
In the embodiment illustrated and described here, the transfer sheet 20 is a cold foil. The cold foil consists of a polyester carrier layer 20a (an example of a support layer) and a metal-containing layer 20b (an example of a transferable layer). Suitable cold foils are directly available from a great variety of providers. For example, companies such as Leonard Kurz, Garnet Close, Greycaine Industrial Estate, Watford, Herts, WD 24 7JW, www.kurz.co.uk.
As illustrated in figures 1 to 3, the metal-containing layer 20b is a holographic layer. The holographic layer 20b includes one or more security features (not shown). The security features of the holographic layer may be overt and/or covert and may include micro text, nano text, Infrared Radiation (IR) tags or colour shifting tags, or any combination of these.
As illustrated in figure 1, the transfer sheet 20 is applied to the rear surface 12a of the polycarbonate sheet 12 such that the transfer sheet 20 substantially covers the adhesive 18 and the holographic layer 20b is sandwiched between the adhesive 18 and the polyester carrier layer 20a.
The transfer sheet 20 may be applied to the polycarbonate sheet 12 through the use of pressure and/or heat. The transfer sheet 20 may thus be considered as being laminated to the polycarbonate sheet 12.
Once the transfer sheet 20 has been applied to the polycarbonate sheet 12, the holographic layer 20b is transferred to the adhesive 18.
In the embodiment illustrated and described here, the holographic layer is transferred to the adhesive 18 by curing the adhesive 18 through use of a UV lamp, drier, or the like, such that the holographic layer 20b adheres to the adhesive 18. After the holographic layer 20b has adhered to the adhesive 18, the polyester carrier layer 20a of the transfer sheet 20 is removed from the polycarbonate sheet 12. The polyester carrier layer 20a may be removed from the polycarbonate sheet 12 by peeling. The removed polyester carrier layer 20a is illustrated in figure 2b. Figure 2a illustrates the rear surface 12a of the polycarbonate sheet 12 after the polyester carrier layer 20a of the transfer sheet has been removed therefrom. It can be seen that the holographic layer 20b is adhered to the adhesive 18 in the form of the predetermined graphic pattern 16. Since the adhesive 18 is clear, the holographic layer 20b may be visualised from the front surface 12b of the polycarbonate sheet 12, as illustrated in figure 3. Once the polyester carrier layer 20a has been removed from the polycarbonate sheet 12, one or more protective coatings 22 are applied to the rear surface of the polycarbonate sheet 12. The protective coatings 22 provide protection to the ink layer 14 and the holographic layer 20b during the injection moulding process and also to promote bonding of the insert sheet 10 to the moulding resin. The protective coatings 22 may include one or more layers of protective inks, such as standard IMD inks. The inks may be mild solvent inks which do not damage or crack the holographic layer 20b, ink layer 14 or adhesive 18. The protective coatings 22 may also include one or more layers of a water-based polyurethane adhesive with an aliphatic polyisocyanate hardener. The water-based polyurethane adhesive with an aliphatic polyisocyanate hardener promotes adhesion to the insert sheet 10 during the injection moulding process and also to provide additional protection to the ink layer 14 and the holographic layer 20b. The protective coatings 22 are typically at least 12 microns thick. Although it should be appreciated that other thicknesses may be used, depending on the requirements of the insert sheet 10.
Figure 3 is a front view of the formed insert sheet 10 ready for use in an injection moulding process.
Figure 4 summarises the process steps involved in forming the insert sheet 10. The first step 110 is to provide a plastic sheet comprising one or more plastic materials. The second step 120 is to apply an adhesive to at least a portion of a rear surface of the plastic sheet. The third step 130 is to provide at least one transfer sheet comprising a support layer and a transferable layer. The fourth step 140 is to apply the at least one transfer sheet to the rear surface of the plastic sheet at the location of the adhesive, such that the at least one transfer sheet substantially covers the adhesive and the transferable layer of the at least one transfer sheet is sandwiched between the adhesive and the support layer of the at least one transfer sheet. The fifth step 150 is to transfer the transferable layer of the at least one transfer sheet to the adhesive. The sixth step 160 is to remove the support layer of the at least one transfer sheet from the plastic sheet. The seventh step 170 is to apply one or more protective coatings to at least a portion of the rear surface of the plastic sheet, wherein the one or more protective coatings are configured to prevent damage occurring to the plastic sheet during an injection moulding process.
The insert sheet 10 of the present invention is a "single layer" construction, i.e. it is not formed from a number of laminated layers. This prevents delamination of the insert sheet 10 or moulded component. This also avoids the need for pressure sensitive adhesives, which can migrate during the moulding process and leave an adhesive build up around the edges of the moulded component. This may adversely affect the moulding tool. Furthermore, pressure sensitive adhesives are more likely to bubble during the moulding process, which affects the physical properties of the insert sheet and moulded component. The process of the present invention allows an insert sheet 10 to be created having an outward facing surface 12b with a desired physical property. That is, the present invention allows the outward facing surface 12b of the insert sheet 10 to have a particular physical property, such as a desired reflectivity or absorption level. Additionally, or alternatively, the present invention allows an insert sheet 10 to be created with one or more holographic security features formed within the insert sheet 10. The process of the present invention thus provides the ability to modify or alter the physical property (or properties) of the outward facing surface of the insert sheet. When the insert sheet 10 is used in an injection moulding process to produce a moulded component, the moulded component, therefore, also has the same enhanced, modified or altered physical properties described above.
Modifications and improvements may be made to the above without departing from the scope of the invention. For example, although the polycarbonate sheet 12 has been illustrated and described above as being transparent, it should be appreciated that the polycarbonate sheet 12 could be at least partially transparent. The polycarbonate sheet 12 may be entirely translucent, or at least partially translucent. The polycarbonate sheet 12 may be at least partially opaque. The polycarbonate sheet 12 may include one or more transparent and translucent portions. The polycarbonate sheet 12 may include one or more transparent and opaque portions. The polycarbonate sheet 12 may include one or more transparent and/or translucent and/or opaque portions. The polycarbonate sheet 12 may include one or more colour pigments.
Furthermore, although the process illustrated and described above describes the application of one or more inks (ink layer 14) to at least a portion of a surface of the polycarbonate sheet 12 to create an at least partially inked surface, it should be appreciated that it is not essential to carry out this step. That is, this step could be omitted and the adhesive 18 would be applied straight to the rear surface of the polycarbonate sheet 12. The result would be the formation of an insert sheet 10 without any inked portions, just the adhesive 18, transferable layer (holographic layer 20b) and protective coatings 22.
Also, although the ink layer 14 has been illustrated and described above as having inked and non-inked portions 14a, 14b, it should be appreciated that the ink layer 14 may consist of only inked portions 14a. That is, the ink layer may be applied to the entire surface of the polycarbonate sheet 12.
Furthermore, it should be appreciated that the ink layer 14 may be applied to the polycarbonate sheet 12 by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
Also, although the ink layer 14 has been illustrated and described above as being applied to the rear surface 12a of the polycarbonate sheet 12, it should be appreciated that the ink layer 14 may be applied to the outward facing surface 12b, or front surface, of the polycarbonate sheet 12. In this case the adhesive 18 would be applied straight to the rear surface 12a of the polycarbonate sheet 12. Note that the application of the ink layer 14 to the front surface 12b of the polycarbonate sheet 12 could be an additional step. That is, the insert sheet 10 could have inks applied to both surfaces 12a, 12b.
Furthermore, although only one ink layer 14 has been illustrated and described above being applied to the polycarbonate sheet 12, it should be appreciated that a plurality of ink layers 14 could be applied to the polycarbonate sheet 12. Each ink layer 14 could, for example, be a different colour or type of ink.
Also, the adhesive 18 may be applied to a plurality of locations on the rear surface 12a of the polycarbonate sheet 12.
Furthermore, although in the embodiment illustrated and described above the adhesive 18 has been described as being applied to the polycarbonate sheet 12 in the "gaps" of the non-inked portions of the ink layer 14, it should be appreciated that the adhesive 18 may be to at least a portion of an inked portion 14a of the polycarbonate sheet 12 and/or at least a portion of a non-inked portion 14b of the polycarbonate sheet 12. The adhesive 18 may be applied to the entire inked portion 14a of the polycarbonate sheet 12 and/or the entire portion of the non-inked portion 14b of the polycarbonate sheet 12. In the arrangement where the adhesive 18 is applied to the entire inked portion of the polycarbonate sheet 12, the adhesive 18 substantially covers the entire inked portion 14a of the polycarbonate sheet 12.
Also, it should be appreciated that the adhesive 18 may be applied to the polycarbonate sheet 12 by digital printing, flexographic printing, rotary screen printing, litho printing or gravure printing.
Furthermore, although the adhesive 18 has been illustrated and described above as being clear, it should be appreciated that the adhesive may include on or more colour pigments.
Also, although the transfer sheet 20 has been illustrated and described above as being a cold foil, it should be appreciated that any suitable transfer sheet 20 that has a support layer and a transferable layer could be used. The transferable layer of the transfer sheet 20 may contain metal. The transferable layer of the transfer sheet 20 may contain metal particles. The transferable layer of the transfer sheet 20 may contain metal flakes. The transferable layer of the transfer sheet 20 may contain metal and non-metal particles. The transferable layer of the transfer sheet 20 may be a foil. The transferable layer of the transfer sheet 20 may be a metal foil. The metal foil may include one or more holographic portions. The metal foil may be a holographic foil. The transferable layer of the transfer sheet 20 may contain one or more security features and/or security markings. The security features/markings may be overt and/or covert. The security features/markings may include one or more of group consisting of micro text, nano text, Infrared Radiation (IR) tags and colour shifting tags. In the case where the transferable layer of the transfer sheet 20 is a foil, the security features and/or security markings are formed as part of the foil. That is, the security features and/or security markings are formed with the foil. The transferable layer of the transfer sheet 20 may contain one or more labels. The one or more labels may be a security label and/or an authenticating label. The label may contain one or more holographic portions. The label may contain one or more smart codes and/or bar codes. The transferable layer of the transfer sheet 20 may contain one or more decorative patterns. The transferable layer of the transfer sheet 20 may contain one or more alphanumeric characters. The support layer of the transfer sheet 20 may include polyester. The support layer of the transfer sheet may be polyester.
Furthermore, although a single transfer sheet 20 has been illustrated and described above as being applied to the entire rear surface 12a of the polycarbonate sheet 12, it should be appreciated that one or more transfer sheets 20 could be applied to the rear surface 12a of the polycarbonate sheet 12. That is, any number of transfer sheets 20 could be applied to any number of locations on the rear surface 12a of the polycarbonate sheet 12.
Also, although the step of transferring the transferable layer (holographic layer 20) to the adhesive 18 has been described above as being done by curing the adhesive 18 with the transferable layer against the adhesive 18 with UV radiation, it should be appreciated that the adhesive 18 may be cured before the transfer sheet 20 is applied to the adhesive 18. In this case the transferable layer of the at least one transfer sheet 20 is transferred to the adhesive 18 by the additional step of applying a pressure to the transfer sheet 20.

Claims

Claims
1. A process for forming an insert sheet for use in an injection moulding process, the process comprising the steps of:
providing a plastic sheet comprising one or more plastic materials;
applying an adhesive to at least a portion of a rear surface of the plastic sheet;
providing at least one transfer sheet comprising a support layer and a transferable layer;
applying the at least one transfer sheet to the rear surface of the plastic sheet at the location of the adhesive, such that the at least one transfer sheet substantially covers the adhesive and the transferable layer of the at least one transfer sheet is sandwiched between the adhesive and the support layer of the at least one transfer sheet;
transferring the transferable layer of the at least one transfer sheet to the adhesive;
removing the support layer of the at least one transfer sheet from the plastic sheet; and
applying one or more protective coatings to at least a portion of the rear surface of the plastic sheet, wherein the one or more protective coatings are configured to prevent damage occurring to the plastic sheet during an injection moulding process.
2. The process for forming an insert sheet for use in an injection moulding process as claimed in claim 1, wherein the process comprises the further step of applying one or more inks to at least a portion of a surface of the plastic sheet to create an at least partially inked surface.
3. The process for forming an insert sheet for use in an injection moulding process as claimed in claim 2, wherein the one or more inks are applied to the at least a portion of the plastic sheet in one or more predetermined graphic patterns.
4. The process for forming an insert sheet for use in an injection moulding process as claimed in claim 2 or claim 3, wherein the one or more inks are transparent.
5. The process for forming an insert sheet for use in an injection moulding process as claimed in any of claims 2 to 4, wherein the one or more inks have a high resistance to heat, have a high adhesion, high printability, high formability and are capable of withstanding high shear forces.
6. The process for forming an insert sheet for use in an injection moulding process as claimed in any of claims 2 to 5, wherein the one or more inks are applied to at least a portion of the front or rear surface of the plastic sheet.
7. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the adhesive is applied to a plurality of locations on the rear surface of the plastic sheet.
8. The process for forming an insert sheet for use in an injection moulding process as claimed in any of claims 2 to 7, wherein the adhesive is applied to at least a portion of an inked portion of the plastic sheet and/or at least a portion of a non- inked portion of the plastic sheet.
9. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the adhesive is an ultraviolet (UV) reactive adhesive.
10. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the adhesive includes one or more colour pigments.
11. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the transferable layer of the transfer sheet contains metal, metal particles, metal flakes, or a mixture of metal and non-metal particles.
12. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the transferable layer of the transfer sheet contains one or more holographic portions.
13. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the transfer sheet is a foil, or a metal foil.
14. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the transfer sheet contains one or more security features and/or security markings.
15. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the transfer sheet contains one or more labels.
16. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the step of applying the at lest one transfer sheet to the rear surface of the plastic sheet is carried out by applying pressure and/or heat to the transfer sheet and plastic sheet.
17. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the step of transferring the transferable layer of the at least one transfer sheet to the adhesive is carried out by curing the adhesive, such that the transferable layer of the at least one transfer sheet adheres to the adhesive.
18. The process for forming an insert sheet for use in an injection moulding process as claimed in claim 17, wherein the step of curing the adhesive is carried out using ultraviolet (UV) radiation.
19. The process for forming an insert sheet for use in an injection moulding process as claimed in any of claims 1 to 16, wherein the of transferring the transferable layer of the at least one transfer sheet to the adhesive is carried out by applying a pressure to the transfer sheet.
20. The process for forming an insert sheet for use in an injection moulding process as claimed in claim 19, wherein the adhesive is pre-cured before the application of the transferable layer and transfer sheet.
21. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the process comprises the further step of laminating the at least one transfer sheet to the plastic sheet before curing the adhesive.
22. The process for forming an insert sheet for use in an injection moulding process as claimed in any preceding claim, wherein the process comprises the further step of the insert sheet and manipulating the sheet into a three-dimensional shape.
23. A process for forming a moulded component comprising the steps of:
providing a mould for the component;
inserting one or more insert sheets according to any of claims 1 to 22 into the mould, wherein the insert sheet is inserted into the mould with the one or more protective coatings facing outwards from the mould; and
injecting a plastics material into the mould and onto the insert sheet to bond the insert sheet with the plastics material and form the component.
24. The process for forming a moulded component as claimed in claim 23, wherein moulded component is part of a casing for an electronic device.
25. An electronic device including a moulded component according to claim 23 or claim 24.
26. An insert sheet for use in an injection moulding process, the insert sheet comprising:
a plastic sheet comprising one or more plastic materials;
a layer of transfer material, wherein the transfer material is adhered to at least a portion of a rear surface of the plastic sheet; and
one or more protective coatings on at least a portion of the rear surface of the plastic sheet, wherein the one or more protective coatings are configured to prevent damage occurring to the plastic sheet during an injection moulding process.
27. The insert sheet for use in an injection moulding process according to claim 26, wherein the plastic sheet includes one or more inks.
28. The insert sheet for use in an injection moulding process according to claim 27, wherein the one or more inks are applied to the at least a portion of the plastic sheet in one or more predetermined graphic patterns.
29. The insert sheet for use in an injection moulding process according to claim 27 or claim 28, wherein the one or more inks are transparent.
30. The insert sheet for use in an injection moulding process according to any of claims 27 to 29, wherein the one or more inks have a high resistance to heat, have a high adhesion, high printability, high formability and are capable of withstanding high shear forces.
31. The insert sheet for use in an injection moulding process according to any of claims 27 to 30, wherein the one or more inks are applied to at least a portion of the front or rear surface of the plastic sheet.
32. The insert sheet for use in an injection moulding process according to any of claims 26 to 31, wherein the layer of transfer material is located on a plurality of locations on the front or rear surface of the plastic sheet.
33. The insert sheet for use in an injection moulding process according to any of claims 26 to 32, wherein the adhesive is applied to a plurality of locations on the rear surface of the plastic sheet.
34. The insert sheet for use in an injection moulding process according to any of claims 26 to 33, wherein the adhesive is applied to at least a portion of an inked portion of the plastic sheet and/or at least a portion of a non-inked portion of the plastic sheet.
35. The insert sheet for use in an injection moulding process according to any of claims 26 to 34, wherein the adhesive is an ultraviolet (UV) reactive adhesive.
36. The insert sheet for use in an injection moulding process according to any of claims 26 to 35, wherein the adhesive includes one or more colour pigments.
37. The insert sheet for use in an injection moulding process according to any of claims 26 to 36, wherein the transferable layer of the transfer sheet contains metal, metal particles, metal flakes, or a mixture of metal and non-metal particles.
38. The insert sheet for use in an injection moulding process according to any of claims 26 to 37, wherein the transferable layer of the transfer sheet contains one or more holographic portions.
39. The insert sheet for use in an injection moulding process according to any of claims 26 to 38, wherein the transfer sheet is a foil, or a metal foil.
40. The insert sheet for use in an injection moulding process according to any of claims 26 to 39, wherein the transfer sheet contains one or more security features and/or security markings.
41. The insert sheet for use in an injection moulding process according to any of claims 26 to 40, wherein the transfer sheet contains one or more labels.
42. A moulded component comprising the insert sheet according to any of claims 26 to 41, wherein the insert sheet has been bonded to a plastics material during injection moulding of the component.
43. An electronic device including a moulded component according to claim 42.
44. An insert sheet for use in an injection moulding process as hereinbefore described with reference to the accompanying drawings.
PCT/GB2012/053002 2011-12-05 2012-12-04 Improvements in or relating to injection moulded components WO2013083967A2 (en)

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KR20200030020A (en) * 2018-09-11 2020-03-19 (주)한교홀로그램 Back cover for portable terminal
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