Laser Structured Chrome Layer on Plastic
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Solution Overview
Problem
Existing methods for creating brushed or structured surfaces on galvanized plastic components fail to replicate the visual and haptic qualities of metallic surfaces, as the thin metal layers are prone to abrasion and do not maintain the corrosion mechanism of chrome components, and mechanical brushing damages the nickel layers, potentially causing allergies.
Innovation Solution
A method involving laser processing to simulate a brushed surface after galvanic deposition, where a 3D data set of a reference surface is created and used to precisely ablate the chromium layer, preventing penetration into nickel layers and maintaining the corrosion mechanism, allowing for detailed and precise replication of brushed metal surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a thin metal layer is deposited using the PVD process to replicate brushed structures, then the molded structures and brushed structures are reproduced in great detail, but the metal layer does not have sufficient resistance to abrasion without an additional protective layer
Solution Approach 1:
The patent uses a silicone rubber mold that has been mechanically brushed to create a negative impression of the desired brushed structure. This mold is then used in injection molding to replicate the brushed pattern on the plastic component surface, achieving detailed structure reproduction without requiring thin metal layers that would need additional protective coating
Solution Approach 2:
The patent replaces the PVD (physical vapor deposition) process with a mechanical injection molding process using a brushed silicone mold. This substitution allows the brushed structure to be directly formed during molding, eliminating the need for subsequent thin metal layer deposition and protective coating operations
2Reliability
If a protective layer is applied after the PVD layer to improve abrasion resistance, then the abrasion resistance is sufficient, but the additional operation increases the costs
Solution Approach 1:
The patent combines the brushed structure formation and the plastic material deposition into a single injection molding operation. The silicone rubber mold with brushed structure is used directly during injection molding, allowing both the structural pattern and the plastic material to be formed simultaneously in one process step, eliminating multiple separate coating and treatment operations
3Ease of manufacture
If the warm haptic sensation of PVD components is perceived as not appealing in terms of quality, then the manufacturing process is simpler, but the haptic quality does not meet requirements
Solution Approach 1:
The patent creates local variations in surface properties by using a mechanically brushed silicone rubber mold. The brushing process on the mold creates specific local surface patterns that are transferred to the plastic component, providing a cold metallic-like haptic sensation in the brushed areas while maintaining the advantages of plastic material
4Manufacturing precision
If a brushed structure is introduced into the surface molding side of the injection mold and is transferred to the plastic component, then the brushed structure can be optically imitated, but the visual appearance is completely lost due to metal layers deposited during electroplating
Solution Approach 1:
The patent performs the brushing action on the silicone rubber mold before injection molding, creating a permanent negative impression of the brushed structure. This preliminary structuring of the mold ensures that the brushed pattern is built into the molding tool itself, so it is transferred to every component during injection molding, and the structure remains visible even after subsequent electroplating because the metal layers conform to the pre-formed pattern rather than filling it in
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 method enables the creation of electroplated plastic components with a structured surface that closely resembles brushed metal, maintaining the corrosion mechanism and avoiding nickel layer exposure, while allowing for precise control over surface features and combinations of brushed and glossy areas.
Implementation Method 1
the structure or brushing is introduced into the visible surface by means of a burning and displacing laser beam
Implementation Method 2
a burning and displacing laser beam is used to simulate the brushed surface
Implementation Method 3
the standard structure of a chrome decoration deposited galvanically on plastic begins after chemical roughening and the autocatalytic deposition of very thin auxiliary conductive layers
Implementation Method 4
chrome decoration deposited galvanically on plastic
Data Source
Figure 1
AI summary
The invention relates to a galvanically decorated component (1) made of plastic (5) having a galvanically applied chrome layer (3), wherein the chrome layer is processed with a laser in such a way that a mechanically applied brush structure or structure (4a, 4b) is reproduced on the surface. The component decorated in this way satisfies all requirements in accordance with the respective test specifications of the planned area of application. The invention also relates to a method for producing a plastic component (1) having a structured surface. Components of this type made of plastic for the automotive industry are substantially decorative and operative elements.