Printed Conductive Layer Plating for Embossed Surface Finish
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Solution Overview
Problem
Conventional plating methods either result in printed layers being easily damaged or oxidized, leading to high defect rates and premature detachment during the plating process, and fail to provide aesthetically appealing designs.
Innovation Solution
A plating method that forms a semi-bright nickel protective layer over a printed layer of electrical conductive material, including mixtures with metal particles, to prevent detachment and create a unique embossed or matte effect, such as a diamond-like surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a printed layer is formed on plated surfaces through ink printing after plating, then aesthetic designs can be achieved, but the printed layer protrudes from the plated layer and is easily damaged or scratched off
Solution Approach 1:
The printed layer is formed on the metal work piece surface before the plating process. This preliminary action ensures that the printed layer becomes embedded within the plated layer structure, preventing protrusion and improving durability. The plating process then coats over the printed layer, securing it firmly to the substrate.
Solution Approach 2:
The printed layer is nested within the plated layer structure. The plating process deposits metal layers that encapsulate the printed design, creating a nested configuration where the printed layer is protected inside the plated layer, eliminating the protrusion issue and enhancing resistance to damage and scratching.
2Reliability
If a printed layer is formed on metal work piece surfaces through ink printing before plating, then the printed layer can be protected by plating, but the metal work piece oxidizes in the printing step before plating
Solution Approach 1:
The printing process is conducted in an inert atmosphere or controlled environment that prevents oxidation of the metal work piece surface. This inert environment protects the metal substrate from oxidizing during the printing step, while still allowing the printed layer to be formed and subsequently plated for enhanced protection.
Solution Approach 2:
The printing process is performed as a preliminary step before plating, but with the addition of oxidation prevention measures. The printed layer is applied to the metal surface in advance, and the entire process is designed to prevent oxidation during this preliminary stage, ensuring both protection and absence of harmful oxidation effects.
3Ease of manufacture
If conventional ink printing is used to form printed layers, then printing can be performed, but the printed layer easily falls off during the plating process
Solution Approach 1:
The printed layer incorporates electrical conductive material combined with adhesive components, creating a composite material structure. This composite printed layer has improved bonding characteristics that prevent falling off during the plating process, while maintaining the printing capability and aesthetic design features.
Solution Approach 2:
An adhesive intermediary layer or component is introduced between the printed layer and the metal work piece surface. This intermediary substance enhances the attachment of the printed layer, preventing it from falling off during plating, while allowing the printing process to proceed as intended.
4Ease of manufacture
If plated surfaces are printed with ink after plating, then designs can be added, but the printed layer lacks integration with the plated layer
Solution Approach 1:
The printing process is performed as a preliminary step before plating, allowing the printed layer to be integrated into the plated layer structure. This preliminary action ensures that the printed design becomes part of the overall plated surface, achieving both design flexibility and surface integration.
Solution Approach 2:
The printing and plating processes are merged into a single integrated manufacturing sequence. The printed layer is applied and then immediately plated over, combining the design application and protective coating steps. This merging ensures that the printed layer and plated layer become integrated, eliminating the separation issue while maintaining design flexibility.
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 method effectively protects printed layers from damage and oxidation, ensuring a smooth surface finish and a decorative effect resembling embedded diamond pieces, while securely attaching the plated layer to the work piece.
Implementation Method 1
forming a plated layer through plating the printed layer and the surface of the work piece
Data Source
AI summary
A plating method includes: providing a work piece which is metal or non-metal; forming a printed layer on a predetermined region of a surface of the work piece through printing electrical conductive material on the predetermined region; forming a plated layer through plating the printed layer and the surface of the work piece.