Metallization and Anodization of Plastic Conductive Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The integration of plastic and metal parts in mobile devices leads to aesthetic and functional issues, such as visible seams, differences in tactile feel, and increased wear, due to the use of non-conductive vapor metallization coatings which compromise the uniform appearance and durability.
Innovation Solution
A method of metallizing and anodizing both plastic and conductive parts of a portable electronic device to create a seamless, scratch-resistant, and aesthetically appealing body by combining these parts through co-molding or overmolding, followed by uniform metallization and anodization, eliminating the need for masking and ensuring RF transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic parts are coated separately from metal parts before combination, then the plastic part surface hardness is improved and scratch resistance is enhanced, but color difference and alignment errors occur between plastic and metal parts, detracting from aesthetic appeal
Solution Approach 1:
The patent combines the coating process for both plastic and metal parts into a single simultaneous operation. The coating apparatus applies coating material to both types of parts in one processing step, ensuring they receive identical coating conditions. This eliminates the sequential coating approach that caused alignment errors and color differences, while still providing the scratch resistance benefits of hardened surfaces.
2Manufacturing precision
If NCVM coating is applied to plastic parts to provide metallic appearance, then aesthetic uniformity is improved, but tactile feeling difference remains and surface hardness is reduced leading to increased wear
Solution Approach 1:
The patent employs a multi-layer composite coating structure on plastic parts. The first layer is the NCVM coating that provides metallic appearance and RF transparency. The second layer is a hard clear coat or ceramic-based coating that provides scratch resistance and enhanced surface hardness. This composite structure combines the aesthetic benefits of NCVM with the durability of hard coatings, eliminating the wear problem while maintaining appearance uniformity.
3Reliability
If plastic parts are used in the body to permit RF signal transmission, then RF transparency is improved, but aesthetic issues arise due to visible seams and tactile differences from metal parts
Solution Approach 1:
The patent applies color matching technology where the coating material and color are specifically selected to match the adjacent metal parts. The coating process ensures that plastic parts receiving RF signal transmission requirements are coated with materials that provide both RF transparency and visual matching with metal components. This eliminates visible seams and creates a seamless appearance while maintaining the necessary RF signal transmission properties.
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
The solution results in a body with a consistent metallic appearance, improved tactile feedback, and enhanced durability, while maintaining RF transparency and aesthetic appeal, thereby addressing the issues of seam visibility and tactile differences between plastic and metal parts.
Implementation Method 1
The surfaces of the plastic part and the conductive parts are vapor deposited with a metal, such as aluminum
Implementation Method 2
The metallized surfaces of the plastic part and the conductive parts are anodized
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of fabricating at least a portion of the body (12) of an apparatus, such as a portable electronic device (10), that includes both plastic and conductive parts is provided with the body (12) appearing relatively seamless such that the interface between the plastic and conductive parts is indistinguishable. In this regard, a plastic part (18) may be combined with a conductive part to form at least a portion of the body of the portable electronic device (10). The surfaces of the plastic part (18) and the conductive part may be metallized, such as by being subjected to vapor deposition, to metalize the surfaces of the plastic and conductive parts. The metalized surfaces of the plastic and conductive parts may then be anodized, thereby producing at least a portion of the body (12) of a portable electronic device (10) having plastic and conductive parts with a consistent appearance and a consistent tactile response.