Method for manufacturing a multi-component component, multi-component component and composite component

Abstract

A method for producing a multi-component component, in which an electrically conductive insert element is inserted into a first injection mold, in which a first portion of the insert element is overmolded with a first, electroplating-resistant plastic, the insert element is either overmolded in the first contact region with only a thin layer of the first plastic or not at all, the insert element, which is overmolded in the first portion with the first plastic, is fixed in a second injection mold, in which a second portion of the insert element, which is complementary to the first portion, is overmolded with a second, electroplatable plastic, the overmolding with the second plastic is such that the insert element is closed with the second plastic flush on the outside in the second contact region, the insert element is removed from the second injection mold, the insert element is contacted in the first contact region by means of a contact pin through the thin layer or directly, and a metal layer is applied to the second plastic on the outside and to the second contact region by electroplating in this state. The invention also relates to a composite component and a multi-component component.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a multi-component component, the multi-component component having its surface coated with metal by electroplating.

[0002] The present invention also relates to such a multi-component component.

[0003] The present invention also relates to a composite component comprising a matrix and a multi-component component wherein the multi-component component is mounted in the matrix. Background Technology

[0004] Electroplated components are commonly known. Typically, electroplatable plastics are used for these components. "Electroplated" means that multiple metal layers are applied to the outer surface of the corresponding plastic during the electroplating process. Such plastics (often also called electroplating-compatible plastics) are widely used in industrial applications. In professional circles, some of these plastics are known by the abbreviations ABS, PC / ABS, and PA.

[0005] For electroplating, a portion of the outer side of a multi-component component (i.e., the contact area) is electrically contacted by means of contact elements. Subsequently, metal deposits are electrochemically deposited uniformly on the outer side of the component. These deposits form an electroplated layer. However, because the contact elements (i.e., electrodes, typically needles) are in contact with the surface of the component and generate voltage peaks in that area, the surface area in contact with the contact elements is not coated or is unevenly coated.

[0006] While this practice is satisfactory in many cases, it is unacceptable for components where the contact area is within the visible zone (i.e., an area that remains visible when the component is used later). More precisely, some damage to the visible surface occurs after the electrode is removed. In these areas, the plastic beneath the metal layer can be seen.

[0007] In existing technology, for example, to manufacture a chromium-coated decorative ring (a brass ring that has already been plated with chromium), it is inserted into an injection mold and then encapsulated in plastic.

[0008] The dimensional fluctuations during the manufacturing process of brass rings are relatively large. This causes various manufacturing problems during further processing.

[0009] For example, over-molding of the thermoplastic component and suboptimal fixation of the brass ring in the injection mold may occur. Furthermore, high demolding forces may result, leading to noticeable marks on the decorative surface (surface A). This results in a relatively large, and often incalculable, number of defective products. The semi-finished products (brass rings) are very expensive to manufacture. Due to the occurrence of defective products, a large amount of difficult-to-recycle "valuable waste" may subsequently be generated in downstream processes. Summary of the Invention

[0010] The purpose of this invention is to provide a possibility for eliminating the problems of the prior art.

[0011] This objective is achieved through a manufacturing method, wherein:

[0012] A conductive insert element is inserted into a first injection mold, and a first portion of the injection molded insert element is covered with a first plastic that is resistant to electroplating, such that the insert element in the first contact area is either covered by only a thin layer of the first plastic or is not covered at all.

[0013] The insert element, which is injection molded with a first plastic coating in the first part, is fixed in a second injection mold, and the second part of the insert element, which is complementary to the first part of the insert element, is injection molded with a second plastic that can be electroplated.

[0014] Furthermore, it is injection molded with a second plastic coating, so that the insertion element is flush-sealed with the outer side of the second plastic in the second contact area, and

[0015] The insertion element, which is encapsulated in first and second plastics and injection molded, is removed from the second injection mold. It then contacts or directly contacts the insertion element in the first contact area by means of a contact needle piercing through the thin layer. In this state, a metal layer is applied to the outside of the second plastic and the second contact area by electroplating.

[0016] The term "electroplatable" has been explained. Electroplating resistance specifically refers to the fact that, during electroplating, a metal layer cannot be applied to the outer surface of the plastic due to its chemical properties. Therefore, the surface will not be corroded, and no visual defects will occur.

[0017] According to the present invention, in the case of a component that is 100% in the visible area, the required contact is always visible, or the component must be re-injected with an injection mold.

[0018] In the case of a thin layer, the layer in the first contact area has a maximum layer thickness of 0.5 mm. The layer thickness is typically between 0.1 mm and 0.4 mm. When the insert element is not completely encapsulated in the first contact area, the first contact area is preferably open to contact.

[0019] According to the present invention, the insert element is completely covered by a metal layer applied by electroplating in the second contact area (so-called "epitaxial growth"). This provides a visually appealing, completely undamaged surface.

[0020] According to the present invention, a non-electroplated component is directly contacted by means of a contact needle, or, for example, by means of an electrode directly piercing the thin skin of the non-electroplated component.

[0021] According to the invention, the required current is thus conducted internally through the component. This contact is ensured by means of contact pins in both the electroplatable plastic and the conductive insertion element. The invention provides a minimal current outflow surface, which can be sealed off by process-related layer deposition.

[0022] In particular, this invention provides reliable and reproducible multi-component components with high-quality decorative surfaces. This invention also ensures process reliability and reduces manufacturing costs.

[0023] The first part can be removed from the first injection mold and then inserted into the second injection mold and fixed there. This transfer can be performed by means of, for example, a turntable, carriage, cube, stacking technique, or other transfer technique. In this case, the inserted element can remain in the base between the injection molding with the first plastic overlay and the injection molding with the second plastic overlay (Coreback Technik).

[0024] Preferably, the insertion element is made of metal, brass, or a material with high conductivity.

[0025] This allows for particularly high current conductivity.

[0026] The insert element may also be left undyed. Alternatively, it may be dyed the same color as the first plastic. Dyeing is particularly advantageous when the insert element is not completely covered by injection molding in the first contact area and thus the base material remains visible. The color can be, in particular, black. On the other hand, when a thin layer is present in the first contact area, dyeing is generally not necessary. In this case, the insert element can therefore have its natural color.

[0027] The first plastic is typically a thermoplastic, thermosetting plastic, or elastomer, such as polycarbonate. The second plastic is also typically a thermoplastic, but usually of a different type. For example, the second plastic could be electroplatable ABS, polycarbonate ABS, or polyamide.

[0028] This objective is further achieved by a multi-component component having a conductive insert element having a first portion and a second portion complementary to the first portion, and wherein:

[0029] The first portion of the injection-molded insert element is covered with a first plastic that is resistant to electroplating, such that the insert element in the first contact area is either covered by only a thin layer of the first plastic or is not covered at all.

[0030] The second part of the injection-molded insert element is covered with a second plastic that can be electroplated, such that the insert element is flush with the outside of the second plastic, and a metal layer is applied to the outside of the second plastic and the second contact area.

[0031] The advantages achieved through this manufacturing method can also be transferred to multi-component components. The advantageous designs of multi-element components and the advantages achieved through these designs are the same as those achieved through the manufacturing method.

[0032] This objective is also achieved by a composite component having a substrate and a multi-component component as described above, wherein the multi-component component is mounted in the substrate such that the first contact area is visually covered by the substrate.

[0033] The advantages achieved through multi-component components and manufacturing methods can also be transferred to the components.

[0034] The substrate itself can be a single piece. However, the substrate can also be composed of multiple components. The only determining factor is that the substrate visually covers the first contact area. Attached Figure Description

[0035] Other features, characteristics, and advantages of the invention will become apparent from the following description with reference to the accompanying drawings. These drawings schematically illustrate:

[0036] Figure 1 : Show the flowchart,

[0037] Figure 2 : Shows a partially encapsulated injection-molded insert element,

[0038] Figure 3 : Show Figure 2 Details of the inserted elements,

[0039] Figure 4 : Show Figure 2 Alternative design solutions,

[0040] Figure 5 : Shows a fully encapsulated injection-molded insert element,

[0041] Figure 6 : Show Figure 5 Details of the inserted elements,

[0042] Figure 7 : Shows the electroplated insert element, and

[0043] Figure 8 : This shows a composite component. Detailed Implementation

[0044] To manufacture multi-component components, firstly according to... Figure 1In step S1, the conductive insertion element 1 (see...) Figure 2 It is inserted into the first injection mold 2. The insert element 1 may be made of metal, especially brass, or a conductive material.

[0045] When the insert element 1 is located in the cavity of the first injection mold 2, particularly the injection mold cavity, in step S2, the first portion 1a of the insert element 1 is encapsulated and injection molded with a first plastic 3. The first plastic 3 is electroplating resistant. For example, the plastic can be electrically insulating. Such plastics are generally known. The first plastic 3 is preferably a thermoplastic or thermosetting plastic or an elastomer, such as polycarbonate.

[0046] The insert element 1 has a first contact area 4. The first contact area 4 is a component of the first part 1a of the insert element 1. The insert element 1 is either completely unencapsulated in the first contact area 4 (see [link to insert element 1]). Figure 3 ), or simply cover the injection molding with a thin layer of the first plastic 3 (see Figure 4 In the latter case, there is a layer thickness d within a maximum range of 0.5 mm.

[0047] The insert element 1 may be undyed or dyed the same color as the first plastic 3. When the insert element 1 is injection molded with a thin layer of the first plastic 3 in the first contact area 4, the insert element may be undyed, and when the insert element is not injection molded with a thin layer of the first plastic 3, it may be dyed the color of the first plastic 3.

[0048] Preferably, the insertion element 1 gradually tapers in the first contact area 4 (corresponding to...). Figures 2 to 4 (The illustration in the image). This thinning can correspond to... Figures 2 to 4 The diagram in the image is linear. However, thinning that is more intense or more gradual than linear thinning is also possible.

[0049] If necessary, the insertion element 1, which is encased in the first plastic 3 in its first part 1a and injection-molded, is removed from the first injection mold 2, particularly the cavity of the injection mold 2, in step S3 and inserted into the second injection mold 5, particularly the cavity of the second injection mold. However, in any case, the insertion element 1 is fixed in the second injection mold 5 in step S4.

[0050] When the insert element 1 is located in the second injection mold 5, in step S5, the second part 1b of the insert element 1 is encapsulated and injection molded with the second plastic 6. Figure 5 The corresponding state of inserted element 1 is shown.

[0051] The second portion 1b of the insert element 1 is complementary to the first portion 1a of the insert element 1. The first portion 1a and the second portion 1b thus complement each other to form the entire insert element 1. The second plastic 6 is electroplatable. Suitable plastics are generally known. The second plastic 6 is preferably a thermoplastic, such as ABS, polycarbonate ABS, or polyamide.

[0052] The insertion element 1 is injection molded and encapsulated with a second plastic 6, such that the insertion element 1 is flush-closed with the outer side of the second plastic 6 in the second contact area 7. This is in Figure 6 As shown in the image.

[0053] Preferably, the insertion element 1 gradually tapers in the second contact area 7 (corresponding to...). Figure 5 and Figure 6 (The illustration in the image). This thinning can correspond to... Figure 5 and Figure 6 The diagram in the image is linear. However, thinning that is more intense or more gradual than linear thinning is also possible.

[0054] After the second plastic 6 is also used for encapsulation injection molding, the insert element 1 is removed from the second injection mold 5 in step S6. In the subsequent step S7, the insert element 1 is contacted in the first contact area 4 by means of a contact pin 8. If the insert element 1 is not encapsulated in the first contact area 4, direct contact is made. If a thin layer is present, the thin layer is pierced within the contact area.

[0055] Figure 7 The diagram shows the state after the insertion element 1 contacts the contact pin 8. In this state, in step S8, a metal layer 9 is applied to the outer side of the second plastic 6 and the second contact area 7. The final metal layer 9 is applied by electroplating.

[0056] After electroplating, the multi-component components manufactured in this way (corresponding to...) can be... Figure 8 (As shown in the diagram) it is installed into the base 10 of the composite component as part of the composite component.

[0057] like Figure 8 As shown, installation can be carried out in such a way that the first contact area 4 is visually covered by the substrate 10.

[0058] This invention offers numerous advantages. In particular, the first contact area 4 can be covered within the frame of the composite component, making it invisible when the multi-component component is assembled. No additional overmolding is required after electroplating. Contact via the contact pins 8 is a well-established technology and reliably ensures contact. Furthermore, the second contact area 7 is very small and is coated during electroplating. Therefore, this contact area is invisible to the naked eye.

[0059] This invention is widely applicable. The corresponding multi-component components can be used, for example, in the interior and exterior areas of motor vehicles, household appliances, entertainment electronic devices, etc.

[0060] List of reference numerals

[0061] 1. Inserting elements

[0062] 1a The first part of the inserted element

[0063] 1b The second part of the inserted element

[0064] 2 First Injection Mold

[0065] 3 First Plastic

[0066] 4 First contact area

[0067] 5. Second Injection Mold

[0068] 6 Second Plastic

[0069] 7 Second contact area

[0070] 8 Contact needles

[0071] 9 Metal Layers

[0072] 10 Matrix

[0073] d layer thickness

[0074] Steps S1 to S8

Claims

1. A method for the production of a multi-component component, characterized in that an electrically conductive insert element (1) is inserted into a first injection mold (2) and is overmolded there with a first, electroplating-resistant plastic (3) in a first portion (la) of the insert element (1) in such a way that the insert element (1) is either overmolded only with a thin layer of the first plastic (3) or not at all in a first contact area (4), wherein the insert element (1) overmolded with the first plastic (3) in the first portion (la) is fixed in a second injection mold (5) and is overmolded there with a second, electroplatable plastic (6) in a second portion (lb) of the insert element (1) complementary to the first portion (la) of the insert element (1), wherein the overmolding with the second plastic (6) is such that the insert element (1) is closed flush with the outside of the second plastic (6) in a second contact area (7), wherein the insert element (1) overmolded with the first plastic (3) and the second plastic (6) is removed from the second injection mold (5), the insert element (1) is contacted in the first contact area (4) either by piercing the thin layer with the aid of a contact pin (8) or directly, and a metal layer (9) is applied to the outside of the second plastic (6) and the second contact area (7) by electroplating in this state.

2. The method for the production according to claim 1, characterized in that the insert element (1) consists of metal.

3. The method for the production according to claim 1 or 2, characterized in that the insert element (1) is not dyed or is dyed in the same color as the first plastic (3).

4. The method for the production according to claim 1 or 2, characterized in that the first plastic (3) is a thermoplastic or a thermoset.

5. The method for the production according to claim 4, characterized in that the second plastic (6) is a thermoplastic, wherein the first plastic (3) and the second plastic (6) are different.

6. A multi-component member characterized by, The multi-component component has an electrically conductive insert element (1) which has a first portion (la) and a second portion (lb) complementary to the first portion (la), and the first portion (la) of the insert element (1) is overmolded with a first, electroplating-resistant plastic (3) in such a way that the insert element (1) is either overmolded only with a thin layer of the first plastic (3) or not at all in a first contact area (4), the second portion (lb) of the insert element (1) is overmolded with a second, electroplatable plastic (6) in such a way that the insert element (1) is closed flush with the outside of the second plastic (6) in a second contact area (7), wherein a metal layer (9) is applied to the outside of the second plastic (6) and the second contact area (7).

7. The multi-component component according to claim 6, characterized in that the insert element (1) consists of metal.

8. The multi-component component according to claim 6 or 7, characterized in that The insert element (1) is either not dyed or dyed in the same color as the first plastic (3).

9. Multicomponent member according to claim 6 or 7, characterized in that The first plastic (3) is a thermoplastic or a thermoset.

10. Multicomponent member according to claim 9, characterized in that The second plastic (6) is a thermoplastic, wherein the first plastic (3) and the second plastic (6) are different.

11. A composite member, characterized in that The composite member has a base body (10) and a multicomponent member according to one of claims 6 to 10, wherein the multicomponent member is mounted into the base body (10) such that the first contact area (4) is visually covered by the base body (10).

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