Color-Matched Polymer Materials for Electronic Enclosures
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Solution Overview
Problem
It is challenging to achieve an exact color match between non-metallic and anodized metallic portions in electronic device enclosures due to the different types of dyes used for each material, leading to a non-uniform appearance under various lighting conditions.
Innovation Solution
The method involves using the same dye used for anodized metal surfaces in polymer materials through a solvent casting process, ensuring the polymer material matches the anodic layer's color, even under different light sources, and applying an optically reflective layer to simulate the appearance of metal, thereby creating a uniform color appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If different types of dyes are used for non-metallic and metallic portions, then each material can be dyed effectively, but the color match between non-metallic and metallic portions becomes inconsistent
Solution Approach 1:
The patent uses the same type of dye (anodizing dye) for both metallic and non-metallic portions to achieve uniform color appearance. The polymer material is dyed with the same dye that is used to dye the anodic oxide layer, ensuring color consistency across different materials in the enclosure.
Solution Approach 2:
The patent changes the chemical composition parameters of the polymer material to enable it to accept and retain the same type of dye as metal anodic layers. This involves selecting polymers with chemical groups that can bond with the dye molecules, allowing the polymer to be dyed with anodizing dyes rather than requiring separate polymer-specific dyes.
2Manufacturing precision
If non-metallic portions are dyed to match metallic surfaces, then color coordination is achieved, but the appearance remains non-uniform under different lighting conditions
Solution Approach 1:
The patent employs dyes with specific spectral properties that provide consistent color appearance under different lighting conditions. The anodizing dyes used have optical characteristics that maintain color fidelity across varying illumination intensities and spectral compositions, reducing metamerism and ensuring uniform appearance.
3Manufacturing precision
If the same dye is used for both non-metallic and metallic portions, then color match consistency is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent makes the polymer material universally compatible with anodizing dyes, allowing the same dyeing process and chemistry to be applied to both metallic and non-metallic portions. This multi-functional approach enables a single dye type to serve both material types, simplifying the overall manufacturing process despite the initial challenge of making polymer compatible with anodizing dyes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures that non-metallic portions match the color of anodized metal surfaces consistently across different lighting conditions, maintaining a uniform and aesthetically pleasing appearance while allowing for proper functionality of components like touch pads and RF antennas.
Implementation Method 1
The polymer material can be any suitable polymer material that is capable of being dyed with the same type of dye used to dye the anodic oxide layer
Implementation Method 2
applying an optically reflective layer to simulate the appearance of metal, thereby creating a uniform color appearance
Data Source
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AI summary
Polymer materials that are color-matched with non-polymer materials are disclosed. Methods involve incorporating the same type of dyes used to colorize the non-polymer materials within the polymer materials. In some embodiments, a solvent casting process is used, which involves dissolving a polymer material and a dye with a solvent or a combination of solvents forming a dye-polymer mixture. In some embodiments, the dye-polymer mixture is dispensed onto a carrier and the solvent is removed forming a dyed polymer layer that can be applied onto a part as a color veneer. In some embodiments, the dye-polymer mixture is dispensed into mold and the solvent is removed forming a dyed polymer structure that can be used as a stand-alone structure or as part of a larger structure.