CN115305447A - 一种塑料基材上镀光亮铬的方法 - Google Patents
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Abstract
本发明公开一种塑料基材上镀光亮铬的方法,包括:1)采用急冷急热注塑成型工艺,获得表面光亮的高光塑料毛坯;2)将获得的高光塑料毛坯置于PVD镀膜设备中,抽真空后通入不活泼气体和氧气,腔体内维持负压,进行等离子辉光清洗;3)将中频溅射电源连接金属Cr靶或含Cr合金靶,开启中频溅射电源,调节中频溅射电源输出电流为20‑40A,分多步进行中频溅射Cr或含Cr合金;4)将电弧靶电源连接金属Cr靶,调节电弧靶电源输出电流为80‑120A,分多步进行电弧镀Cr,完成镀膜。本发明不涉重金属及Voc排放,表面最后一层为光亮的金属Cr层,具有与传统的塑料电镀光亮铬镀层(CP镀种)一致的外观效果,膜层与塑料基材结合力良好,具备良好的耐磨性和耐蚀性。
Description
技术领域
本发明涉及镀膜技术领域,具体涉及一种塑料基材上镀光亮铬的方法。
背景技术
在厨卫、汽配和家电等行业中,为了在塑胶基材上获得较为高级的外观和质感,通常采用电镀的方式来提升产品的金属质感和装饰效果,其基本流程为:塑胶基材注塑成型→表面抛光(如去除合模线等)→电镀铜镍铬。
近年来,由于环保政策的日益收紧,替代传统电镀工艺的表面处理工艺成为技术研究的一大热点。当前,行业内一种常规塑胶基材的替代电镀工艺路线为:塑胶基材→底漆喷涂→真空镀膜→面漆喷涂。即在塑胶基材上先进行底漆喷涂,以覆盖塑胶毛坯的表面缺陷并获得一种高光效果,随后再进行物理气相沉积(PVD)一层金属层以获得一种金属外观效果,由于PVD的金属层较薄,且与底漆的结合力不佳,因此还需要再喷涂一层面漆进行保护,以提升膜层的耐摩性和耐久性。以上工艺路线取代了电镀工艺,无废水排放,但存在以下几点缺陷:
1.虽替代了电镀,但两道喷涂工艺带来了VOC(挥发性有机化合物)排放问题;
2.表面最后一层为有机涂料,无金属质感,不能满足市场需求;
3.工序较多且复杂,需要多次周转,生产成本高。
发明内容
本发明以改善以上技术问题为目的,提供一种塑料基材上镀光亮铬的方法,与传统电镀工艺及替代工艺相比,能够改善以上问题。为此,本发明采取了以下技术路线。
一种塑料基材上镀光亮铬的方法,包括以下步骤:
1)采用急冷急热注塑成型工艺,获得表面光亮的高光塑料毛坯;
2)将获得的高光塑料毛坯装载于镀膜挂具上,进行表面清洁后置于PVD镀膜设备中,抽真空后通入不活泼气体和氧气,并且腔体内维持负压,进行等离子辉光清洗;
3)通入不活泼气体,并且腔体内维持负压,将中频溅射电源连接金属Cr靶或含Cr合金靶,开启中频溅射电源,调节中频溅射电源输出电流为20-40A,分多步进行中频溅射Cr或含Cr合金,每步1~10min,每次间隔1-5min;
4)通入不活泼气体,并且腔体内维持负压,将电弧靶电源连接金属Cr靶,调节电弧靶电源输出电流为80-120A,分多步进行电弧镀Cr,每步0.5~2min,每次间隔0.5-5min,完成镀膜。
作为本发明的塑料基材上镀光亮铬的方法的一种改进,所述含Cr合金靶为铜镍铬合金靶。
作为本发明的塑料基材上镀光亮铬的方法的一种改进,所述塑料为丙烯腈-丁二烯-苯乙烯、聚丙烯、聚碳酸酯或聚酰胺。
作为本发明的塑料基材上镀光亮铬的方法的一种改进,所述不活泼气体为氩气。
作为本发明的塑料基材上镀光亮铬的方法的一种改进,步骤2)中,在对塑料进行等离子辉光清洗时,对腔体内的不活泼气体和氧气所施加的偏压为300-1800V。
作为本发明的塑料基材上镀光亮铬的方法的一种改进,步骤2)中,维持腔体内真空度为2.5Pa;步骤3)中,维持腔体内真空度为3*10-1Pa;步骤4)中,维持腔体内真空度为2.5*10-1Pa。
作为本发明的塑料基材上镀光亮铬的方法的一种改进,步骤3)中,调节中频溅射电源输出电流为25-30A,分3-4步进行中频溅射Cr或含Cr合金,每步溅射5min,每次间隔3min。
作为本发明的塑料基材上镀光亮铬的方法的一种改进,步骤4)中,分4-5步进行电弧镀 Cr,每步1min,每次间隔3min。
本发明中的工艺过程中不涉重金属及Voc排放,表面最后一层为光亮的金属Cr层,具有与传统的塑料电镀光亮铬镀层(CP镀种)一致的外观效果,膜层与塑料基材结合力良好,具备良好的耐磨性和耐蚀性。此外本发明采用的工艺工序简单,成本低于传统电镀工艺及替代工艺,且适用于ABS、PP、PC、尼龙等多种塑料基材,具有广阔的应用前景。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚,下面对本发明实施例的技术方案进行清楚、完整地描述。实施例中未注明具体条件者,按照常规条件或制造商建议的条件进行。所用试剂或仪器未注明生产厂商者,均为可以通过市售购买获得的常规产品。
一种塑料基材上镀光亮铬的方法,其工艺流程如下:
1)采用急冷急热注塑成型工艺,获得表面光亮的高光塑料毛坯;
2)将获得的高光塑料毛坯装载于不锈钢挂具,进行表面清洁后置于PVD镀膜设备,抽真空后通入氩气和氧气,使腔体内真空度维持在1.0-3.0Pa,调节偏压电源输出电压300-1800V,进行等离子辉光清洗,时间3-8min;
3)通入氩气使腔体内真空度维持在2.0*10-1-5.0*10-1Pa,将中频溅射电源连接金属Cr靶或含Cr合金靶,开启中频溅射电源,调节中频溅射电源输出电流为20-40A,中频溅射Cr靶或含Cr合金靶共10-20min,分多步进行,每步5min,每次镀膜间隔3-5min;其中,中频是指,频段由300KHz到3000KHz的频率;
4)通入氩气300sccm,使腔体内真空度维持在2.0*10-1-5.0*10-1Pa,将电弧靶电源连接金属Cr靶,开启2列共9个电弧靶电源,调节电弧靶电源输出电流为80-120A,电弧镀Cr靶 3-5min,每步1min,每次镀膜间隔3-5min。
本方法采用急冷急热注塑成型工艺,可获得具有镜面外观效果、达到卫浴行业电镀CP 镀种A级外观标准高光塑料毛坯。采用中频溅射Cr靶或含Cr合金靶的方式进行打底,可以获得良好的结合力。采用电弧镀Cr的方式做外观层,以获得与传统电镀六价铬工艺相同的金属质感和颜色外观。本方法可处理包含ABS、PP、PC、尼龙在内的多种塑料基材,而传统电镀工艺只能选用ABS及PC等几种特定材料。
其中,急冷急热成型技术又称之为高光无痕注塑,是通过急冷急热设备在注塑前加热模具,令模温快速升高至塑料的玻璃化温度以上,注塑结束后再快速降低模温至顶出温度,是成型过程中模温可变的成型工艺。该成型方式利用了热塑性塑料在高弹态下的固有特性,可有效消除塑料制品的表面缺陷,如熔合线、橘皮、气纹等。由于成型温度较高,成型后塑件表面粗糙度较常规成型好。
以下对本发明的塑料基材上镀光亮铬的方法的一些实施例进行阐述。
实施例1
1)选用ABS材料,采用急冷急热注塑成型工艺,获得表面光亮的高光塑料毛坯;
2)将获得的高光塑料毛坯装载于不锈钢挂具,进行表面清洁后置于PVD镀膜设备,PVD 镀膜设备的真空腔尺寸为φ1400mm×H1600mm,抽真空后通入氩气800sccm,氧气600sccm,使腔体内真空度维持在2.5Pa,调节偏压电源输出电压600V,进行等离子辉光清洗,时间5min;
3)通入氩气300sccm,使腔体内真空度维持在3.0*10-1Pa,将中频溅射电源连接金属Cr 靶,开启中频溅射电源,调节中频溅射电源输出电流为30A,中频溅射Cr共15min,分3步进行,每步5min,每次镀膜间隔3min(不计入镀膜时长);
4)通入氩气300sccm,使腔体内真空度维持在2.5*10-1Pa,将电弧靶电源连接金属Cr靶,开启2列共9个电弧靶电源,调节电弧靶电源输出电流为90A,电弧镀Cr共4min,每步1min,每次镀膜间隔3min(不计入镀膜时长),完成镀膜。采用分光光度计在样品表面随机取三个点测试其Lab数值,数据如下:
实施例2
1)选用PP材料,采用急冷急热注塑成型工艺,获得表面光亮的高光塑料毛坯;
2)将获得的高光塑料毛坯装载于不锈钢挂具,进行表面清洁后置于PVD镀膜设备,PVD 镀膜设备的真空腔尺寸为φ1400mm×H1600mm,抽真空后通入氩气800sccm,氧气600sccm,使腔体内真空度维持在2.5Pa,调节偏压电源输出电压650V,进行等离子辉光清洗,时间5min;
3)通入氩气300sccm,使腔体内真空度维持在3.0*10-1Pa,将中频溅射电源连接金属Cr 靶,开启中频溅射电源,调节中频溅射电源输出电流为25A,中频溅射Cr共15min,分3步进行,每步5min,每次镀膜间隔3min(不计入镀膜时长);
4)通入氩气300sccm,使腔体内真空度维持在2.5*10-1Pa,将电弧靶电源连接金属Cr靶,开启2列共9个电弧靶电源,调节电弧靶电源输出电流为90A,电弧镀Cr共5min,每步1min,每次镀膜间隔3min(不计入镀膜时长),完成镀膜。采用分光光度计在样品表面随机取三个点测试其Lab数值,数据如下:
L | a | b | |
点1 | 84.37 | -0.57 | -1.48 |
点2 | 84.83 | -0.62 | -1.54 |
点3 | 84.72 | -0.61 | -1.55 |
备注:Lab模式是根据Commission International Eclairage(CIE)在1931年所制定的一种测定颜色的国际标准建立的。于1976年被改进,并且命名的一种色彩模式。Lab颜色模型由三个要素组成,一个要素是亮度(L),a和b是两个颜色通道。a包括的颜色是从深绿色(低亮度值)到灰色(中亮度值)再到亮粉红色(高亮度值);b是从亮灰色(低亮度值)到灰色(中亮度值)再到黄色(高亮度值)。
对比例1
采用实施例1中相同的ABS毛坯,经传统电镀铜镍铬后,目视颜色和光泽度和实施例1 得到的产品类似,采用分光光度计在样品表面随机取三个点测试其Lab数值,数据如下:
以上数据表明,采用实施例1的表面处理方法对ABS等塑料进行处理,获得的金属镀层外观颜色与传统电镀光亮铬(CP镀种)基本一致。
本发明的塑料基材上镀光亮铬的方法,过程中不涉重金属及Voc排放,可获得与塑料电镀光亮铬镀层(CP镀种)相同的外观效果,膜层与塑料基材结合力良好,具备良好的耐磨性和耐蚀性,该工艺适用于ABS、PP、PC、尼龙等多种塑料基材,在厨卫家电及汽车装饰表面处理领域具备广阔的市场前景。
以上实施例仅用以说明本发明的技术方案,而非对本发明要求保护的范围进行限制,基于本发明的实施例,本领域的普通技术人员对本发明的技术方案进行修改或者等同替换,而不脱离本发明的精神和范围,均属于本发明要求保护的范围。
Claims (8)
1.一种塑料基材上镀光亮铬的方法,其特征在于,包括以下步骤:
1)采用急冷急热注塑成型工艺,获得表面光亮的高光塑料毛坯;
2)将获得的高光塑料毛坯装载于镀膜挂具上,进行表面清洁后置于PVD镀膜设备中,抽真空后通入不活泼气体和氧气,并且腔体内维持负压,进行等离子辉光清洗;
3)通入不活泼气体,并且腔体内维持负压,将中频溅射电源连接金属Cr靶或含Cr合金靶,开启中频溅射电源,调节中频溅射电源输出电流为20-40A,分多步进行中频溅射Cr或含Cr合金,每步1~10min,每次间隔1-5min;
4)通入不活泼气体,并且腔体内维持负压,将电弧靶电源连接金属Cr靶,调节电弧靶电源输出电流为80-120A,分多步进行电弧镀Cr,每步0.5~2min,每次间隔0.5-5min,完成镀膜。
2.根据权利要求1所述的一种塑料基材上镀光亮铬的方法,其特征在于,所述含Cr合金靶为铜镍铬合金靶。
3.根据权利要求1所述的一种塑料基材上镀光亮铬的方法,其特征在于,所述塑料为丙烯腈-丁二烯-苯乙烯、聚丙烯、聚碳酸酯或聚酰胺。
4.根据权利要求1所述的一种塑料基材上镀光亮铬的方法,其特征在于,所述不活泼气体为氩气。
5.根据权利要求1所述的一种塑料基材上镀光亮铬的方法,其特征在于,步骤2)中,在对塑料进行等离子辉光清洗时,对腔体内的不活泼气体和氧气所施加的偏压为300-1800V。
6.根据权利要求1所述的一种塑料基材上镀光亮铬的方法,其特征在于,步骤2)中,维持腔体内真空度为2.5Pa;步骤3)中,维持腔体内真空度为3*10-1Pa;步骤4)中,维持腔体内真空度为2.5*10-1Pa。
7.根据权利要求1所述的一种塑料基材上镀光亮铬的方法,其特征在于,步骤3)中,调节中频溅射电源输出电流为25-30A,分3-4步进行中频溅射Cr或含Cr合金,每步溅射5min,每次间隔3min。
8.根据权利要求1或7所述的一种塑料基材上镀光亮铬的方法,其特征在于,步骤4)中,分4-5步进行电弧镀Cr,每步1min,每次间隔3min。
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