Selective Metalizing via Two-Shot Molding Resins
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Solution Overview
Problem
Current methods for metalizing parts with complex geometries, such as those in the automotive industry, face challenges with premature coating failure, high costs, and geometric limitations, particularly in areas with low current density, leading to defects and increased production costs due to the need for auxiliary anodes and design modifications.
Innovation Solution
A method that selectively metalizes parts by using a plateable resin in high current density areas and a non-plateable resin in low current density areas, without the use of auxiliary anodes, allowing for increased plate thickness and contrasting finishes while preserving the original design intent, and eliminating the need for subsequent finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If auxiliary anodes are used to provide plate thickness to low current density areas, then manufacturing precision is improved, but device complexity and cost increase dramatically
Solution Approach 1:
The part is segmented into plateable and non-plateable regions through two-shot molding, where the first resin material is selectively plated and the second resin material remains non-plateable. This eliminates the need for auxiliary anodes while achieving uniform plate thickness in the plateable areas.
Solution Approach 2:
Different regions of the part are assigned different properties: the first area is made plateable with a plateable resin while the second area is made non-plateable with a non-plateable resin. This local differentiation allows selective plating without requiring auxiliary anodes to address low current density issues throughout the entire part.
2Manufacturing precision
If longer plating times are used to allow current into recesses, then manufacturing precision is improved, but productivity decreases and cost increases
Solution Approach 1:
The part geometry is segmented into plateable and non-plateable regions during molding. By placing non-plateable resin in areas that would require extended plating times (such as recesses and complex geometries), the plating process can be completed quickly on the plateable areas without sacrificing coverage or thickness.
Solution Approach 2:
The non-plateable resin is pre-positioned in the mold in areas where plating would be difficult or time-consuming. This preliminary action prevents the need for long plating times by design, as these areas are intentionally excluded from the plating process while still achieving the desired final appearance and function.
3Manufacturing precision
If auxiliary anodes are deployed to reach low current density areas, then manufacturing precision is improved, but cost increases due to tooling construction and maintenance
Solution Approach 1:
The part is divided into plateable and non-plateable sections through selective resin placement. This segmentation eliminates the need for expensive auxiliary anodes with mixed metal oxide coatings, as the non-plateable resin areas are simply not subjected to the plating process.
Solution Approach 2:
Instead of investing in expensive, maintenance-intensive auxiliary anodes with limited lifetimes, the patent uses a cost-effective two-shot molding approach where the non-plateable resin serves as a permanent, maintenance-free solution for areas that would otherwise require auxiliary anodes.
4Ease of manufacture
If geometry is modified to accommodate plating (shallowing recesses, widening openings), then ease of manufacture is improved, but the original design intent and aesthetics are compromised
Solution Approach 1:
The patent applies different properties to different regions: the first resin material allows for the original complex geometry to be maintained, while the second resin material is placed in specific areas to prevent plating. This preserves the original design intent and aesthetics without requiring geometric modifications for plating ease.
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 results in cost-effective, high-quality metalized parts with increased plate thickness, reduced defects, and improved aesthetics, as well as the ability to maintain complex geometries without the need for auxiliary anodes or design modifications, thereby enhancing the durability and appearance of parts like wheel covers and grilles.
Implementation Method 1
a first area comprising a plateable resin configured to be plated using the plating process without the auxiliary anode and having a first current density during the plating process
Implementation Method 2
a second area comprising a non-plateable resin configured to not be plated using the plating process without the auxiliary anode
Data Source
AI summary
A method of making a work piece without the use of an auxiliary anode and a work piece created using the method are provided. The work piece includes a main face being generally planar. The work piece also includes a first area comprising a plateable resin configured to be plated using the plating process without the auxiliary anode and having a first current density during the plating process. Additionally, the work piece includes a second area comprising a non-plateable resin configured to not be plated using the plating process without the auxiliary anode. The first area and the second area are determined by a process referencing a predetermined minimum current density value with the first current density being greater than the predetermined minimum current density value.