JP2009174014A - Method of forming surface layer on substrate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of forming a surface layer on a substrate. <P>SOLUTION: The method of forming the surface layer on the substrate includes: a step of providing a mold 10 having a hole; a step of forming the surface layer 108 on at least a part of interior of the hole 104 of the mold 10; and a step of molding the substrate. The surface layer 108 includes e.g. a metal material or a ceramic material. The mold 10 includes e.g. an upper mold 102, a lower mold 100 and at least one aperture 106. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for forming a surface layer of a substrate, and more particularly to a method for forming a surface layer of a plastic / fiber reinforced composite material or a metal housing.

  In the advanced information age, electronic products have become widespread. Electronic devices such as notebook computers, mobile phones, PDAs, and MP3 players have become indispensable for people's daily lives due to advances in performance and weight. The housing of many of these electronic devices is increasingly used as a metal housing or a plastic housing having a metal surface in order to improve designability or to prevent electromagnetic interference (EMI).

  Such metal housings may be manufactured using die casting and injection molding. In this case, an aluminum / magnesium alloy is frequently used. However, in the die casting process or the injection molding process, pores may be generated on the surface of the aluminum / magnesium alloy. In addition, anodization or other surface treatment steps may be required so that corrosion does not occur when the metal housing and air contact each other. These problems adversely affect the manufacturing process and cost. Patent Document 1 discloses a method for discharging air from a hole in a die casting process, which solves the problem of the pores described above. Patent Document 2 discloses a novel anodizing process. However, both these two techniques tend to increase manufacturing time and cost in addition to requiring extra steps.

  On the other hand, a plastic housing having a metal surface may be manufactured using a thermal spraying method. Specifically, a plastic housing mold is formed using injection molding, and a metal layer is formed on the surface using thermal spraying. However, when the thermal spraying method is used, since the environmental temperature is high, problems such as deformation and baking may occur in the plastic housing. Patent Document 3 discloses a high-temperature soluble spray material for preventing this problem.

  Alternatively, the metal surface may be manufactured using a sputtering method instead of the thermal spraying method. However, the sputtering process is not only complicated, it is difficult to increase the thickness of the metal surface, and it is also difficult to increase the yield.

  Further, when manufacturing other types of housings made of fiber reinforced composite materials such as glass fibers, charcoal fibers, Kepler fibers, ceramic fibers, and metal fibers, the same problems as in plastic housings arise.

US Pat. No. 6,176,294 US Pat. No. 6,322,689 US Pat. No. 5,718,970

  The present invention has been made to solve the above problems, and an object of the present invention is to provide a method for forming a surface layer of a substrate. This surface layer forming method can be applied to plastic / fiber reinforced composite materials or metals, avoiding problems such as deformation and baking that occur in the housing of plastic / fiber reinforced composite materials, and the problem of pores on the metal surface Can be solved.

  In order to achieve the above object, the present invention according to claim 1 is a method for forming a surface layer of a substrate, wherein (a) a step of preparing a mold having holes, and (b) at least in the holes of the mold. It comprises a step of forming a surface layer in part and (c) a step of molding the substrate.

  According to a second aspect of the present invention, in the first aspect of the present invention, the surface layer includes a metal material or a ceramic material.

  According to a third aspect of the present invention, in the first aspect of the present invention, the step (b) is performed using a thermal spraying method.

  According to a fourth aspect of the present invention, in the first aspect of the present invention, the step (b) is performed using a surface material previously formed in a part of the hole of the mold. .

  According to a fifth aspect of the present invention, in the first aspect of the present invention, the mold includes a plurality of molding parts, and the molding parts include an upper mold, a lower mold, and at least one opening. It is characterized by that.

  According to a sixth aspect of the present invention, in the fifth aspect of the present invention, the plurality of molding parts are at least two molding parts.

  According to a seventh aspect of the present invention, in the present invention according to the fifth aspect, the surface layer is formed on an inner surface of the upper mold or the lower mold in the hole.

  According to an eighth aspect of the present invention, in the present invention according to the fifth aspect, the surface layer is formed on a plurality of inner surfaces in the upper mold or the lower mold in the hole.

  The present invention according to claim 9 further includes the step of using a demolding aid on the inner surface in the hole of the mold before the step (b) in the present invention according to claim 1. It is characterized by becoming.

  The present invention described in claim 10 further comprises a step of attaching an adherent to an inner surface in the hole of the mold after the step (b) in the present invention described in claim 1. It is characterized by that.

  The present invention according to claim 11 is the invention according to claim 10, wherein the deposit is an antenna, a lead pellet, or a bulletproof piece.

  The invention according to claim 12 is the invention according to claim 1, further comprising a step of roughening the surface layer after the step (b).

  The present invention described in claim 13 further comprises a step of roughening the surface layer with the deposit after the step of depositing the deposit in the present invention according to claim 10. It is characterized by.

  The invention described in claim 14 is the invention described in claim 1, further comprising a step of trimming the surface layer after the step (b).

  The present invention according to claim 15 is the invention according to claim 10, further comprising a step of trimming the surface layer with the deposit after the step of depositing the deposit. And

  The present invention described in claim 16 is characterized in that, in the present invention described in claim 1, the step (c) is performed by injection molding.

  According to a seventeenth aspect of the present invention, in the present invention according to the sixteenth aspect, the injection molding is performed using a plastic / fiber reinforced composite material or a metal material.

  The present invention described in claim 18 is characterized in that, in the present invention described in claim 1, the step (c) is performed by casting.

  According to a nineteenth aspect of the present invention, in the present invention according to the eighteenth aspect, the casting is performed using a metal material.

  The present invention described in claim 20 is characterized in that, in the present invention described in claim 1, the step (c) is performed by die casting.

  According to a twenty-first aspect of the present invention, in the present invention according to the twentieth aspect, the die casting is performed using a metal material.

  The present invention described in claim 22 is the present invention described in claim 17, 19 or 21, wherein the metal material is an aluminum-magnesium alloy, titanium alloy, aluminum alloy, magnesium alloy, zirconium alloy, or zinc alloy. It is characterized by including.

  According to the surface layer forming method of the present invention, the surface layer can be flattened by forming the surface layer on a part of the mold in the hole before molding the plastic / fiber reinforced composite material or the metal housing. . When the housing is made of metal, the subsequent processes do not affect the surface layer, so that the pores in the surface layer can be reduced. When a plastic housing is used, the surface layer can be formed before the housing is formed, so that problems such as deformation and baking of the housing can be avoided. Further, the problem of the thickness of the surface layer caused by the sputtering method can be solved.

  Other advantages and features of the present invention will become more apparent from the following description of embodiments of the invention. The following embodiments are intended to more specifically describe the technical means of the present invention. Naturally, the present invention is not limited thereto, and simple design changes by those skilled in the art without departing from the scope of the appended claims. Any additions, modifications, and substitutions are within the scope of the present invention.

  FIG. 1 is a view showing a mold having holes and openings according to the present invention. The mold 10 includes a lower mold 100, an upper mold 102, and at least one opening 106. In this embodiment, only one opening is displayed. By combining the lower mold 100 and the upper mold 102 together, a space in the mold 10 is formed as the hole 104. When the plastic / fiber reinforced composite material or metal material is filled into the hole 104 through the opening 106 of the upper mold 102, the final product having the shape of the hole 104 is completed.

  FIG. 2 is a diagram showing a surface layer located on the surface of the mold in the hole according to the present invention. As shown in FIG. 2, a surface layer 108 is formed on at least a part of the mold 10 in the hole 104. In this embodiment, the surface layer 108 is formed on the entire surface of the lower mold 100 in the hole 104. Prior to combining the lower mold 100 and the upper mold 102 together, the surface layer 108 can be formed on the surface of the lower mold 100 in the hole 104 using a thermal spraying method. The surface layer 108 may be formed using metal or ceramics (for example, bone ash porcelain, aluminum oxide, zirconium oxide, titanium oxide). In particular, by forming the surface layer 108 on a part of the surface of the lower mold 100 in the hole 104, the required pattern can be formed on the plastic / fiber reinforced composite material or the metal housing in the following process. Of course, the surface layer 108 may be formed on a part of the surface of the upper mold 102 in the hole 104. Further, the surface layer 108 may be formed on part or all of the surfaces of the lower mold 100 and the upper mold 102 in the hole 104. Instead of the thermal spraying method, the surface layer 108 may be formed by arranging a previously formed surface material on at least a part of the mold 10 in the hole 104.

  Since the surfaces of the lower mold 100 and the upper mold 102 in which the holes 104 are formed are very smooth, the surface layer 108 is easily peeled off from the mold 10. In addition, in order to ensure that the surface layer 108 completely peels from the mold 10, before forming the surface layer 108, a demolding aid is applied to the surfaces of the lower mold 100 and the upper mold 102 in which the holes 104 are formed. You may use it.

  After forming the surface layer 108 so that the housing to be formed next has other functions (for example, antenna, bulletproof, anti-radiation, anti-EMI, etc.), other deposits (for example, antenna, A bulletproof piece or the like may be attached. Of course, the above adhesion process may be performed before the material of the surface layer 108 is disposed on at least a part of the surfaces of the lower mold 100 and the upper mold 102 in the hole 104.

  Furthermore, the surface of the surface layer 108 or the deposit may be roughened in order to further strengthen the adhesion between the substrate 112 (plastic / fiber reinforced composite material or metal) and the surface layer 108 or the deposit. . The surface roughening process may be performed before placing the material of the surface layer 108 or the deposit on at least a part of the surface of the lower mold 100 and the upper mold 102 in the hole 104.

  In addition, after forming the surface layer 108, the edge of the surface layer 108 or the edge of the deposit may be trimmed to modify the profile. The above trimming process may be performed before the material or deposit of the surface layer 108 is placed on at least a portion of the surface of the lower mold 100 and the upper mold 102 in the hole 104.

  FIG. 3 is a diagram showing a molding process according to the present invention. As shown in FIG. 3, in the molding process such as injection molding or casting, there is a step of filling the molding material 110 into the hole 104 of the mold 10. The molding material 110 used for injection molding is a plastic / fiber reinforced composite material or a metal material. In the case of casting, a metal molding material may be used. In particular, the molding process may be die casting. A metal molding material may be used for die casting. The metal molding material includes an aluminum / magnesium alloy, a titanium alloy, an aluminum alloy, a magnesium alloy, a zirconium alloy, or a zinc alloy.

  After the above process, the mold 10 is removed. FIG. 4 is a view showing the surface layer 108 disposed on the substrate 112 from which the lower mold 100 and the upper mold 102 according to the present invention are removed. Performing the formation process of the substrate 112 after the surface layer 108 is disposed can solve the problem of deformation of the substrate 112 made of plastic or fiber reinforced molding material caused by very high environmental temperature. it can.

  Depending on the specifications of the final product, a mold including a front mold and a rear mold may be used. The number of molds adopted is not necessarily two. In this embodiment, a mold having an opening may be used.

  The present invention can obtain the effect of reducing pores in the surface layer in the next process by forming the surface layer on the inner surface of the mold in the hole before the molding process.

  In addition, in the case of a housing made of plastic or fiber reinforced molding material, the surface layer is formed before the housing is formed, so when using the thermal spraying method, the plastic generated when the environmental temperature is high Problems such as housing deformation and baking can be avoided. Moreover, the problem of the thickness of the surface layer in which the thermal spraying method occurs can be solved.

  The above-described embodiments are intended to more specifically describe the technical means of the present invention. Naturally, the present invention is not limited thereto, and simple design changes by those skilled in the art without departing from the scope of the appended claims. Any additions, modifications, and substitutions are within the scope of the present invention.

It is a figure which shows the mold which has a hole and opening based on this invention. It is a figure which shows the surface layer located in the surface of the mold in a hole based on this invention. It is a figure which shows the process of the molding based on this invention. It is a figure which shows the surface layer located in the base material from which the mold was removed based on this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Mold 100 Lower mold 102 Upper mold 104 Hole 106 Opening 108 Surface layer 110 Molding material 112 Base material

Claims (22)

A method for forming a surface layer of a substrate,
(A) preparing a mold having a hole;
(B) forming a surface layer at least in a part of the hole of the mold;
(C) molding the substrate;
A forming method comprising the steps of:   The method according to claim 1, wherein the surface layer includes a metal material or a ceramic material.   The forming method according to claim 1, wherein the step (b) is performed using a thermal spraying method.   The method according to claim 1, wherein the step (b) is performed using a surface material previously formed in a part of the hole of the mold. The mold has a plurality of molding parts,
The method according to claim 1, wherein the molding part includes an upper mold, a lower mold, and at least one opening.   6. The forming method according to claim 5, wherein the plurality of molding parts are at least two molding parts.   6. The forming method according to claim 5, wherein the surface layer is formed on an inner surface of the upper mold or the lower mold in the hole.   6. The forming method according to claim 5, wherein the surface layer is formed on a plurality of inner surfaces in the upper mold or the lower mold in the hole.   2. The forming method according to claim 1, further comprising the step of using a demolding aid on the inner surface in the hole of the mold before the step (b).   The method according to claim 1, further comprising a step of attaching a deposit to an inner surface in the hole of the mold after the step (b).   The forming method according to claim 10, wherein the deposit is an antenna, a lead pellet, or a bulletproof piece.   The method according to claim 1, further comprising a step of roughening the surface layer after the step (b).   The method according to claim 10, further comprising a step of roughening the surface layer with the deposit after the step of depositing the deposit.   The method according to claim 1, further comprising a step of trimming the surface layer after the step (b).   The method according to claim 10, further comprising a step of trimming the surface layer with the deposit after the step of depositing the deposit.   The method according to claim 1, wherein the step (c) is performed by injection molding.   17. The forming method according to claim 16, wherein the injection molding is performed using a plastic / fiber reinforced composite material or a metal material.   The forming method according to claim 1, wherein the step (c) is performed by casting.   The forming method according to claim 18, wherein the casting is performed using a metal material.   The method according to claim 1, wherein the step (c) is performed by die casting.   21. The forming method according to claim 20, wherein the die casting is performed using a metal material.   The formation method according to claim 17, 19 or 21, wherein the metal material includes an aluminum-magnesium alloy, a titanium alloy, an aluminum alloy, a magnesium alloy, a zirconium alloy, or a zinc alloy.

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