WO2013053362A1 - Hybrid unit composed of metal and pdv coated plastic material, and method producing it - Google Patents
Hybrid unit composed of metal and pdv coated plastic material, and method producing it Download PDFInfo
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- WO2013053362A1 WO2013053362A1 PCT/DK2012/050383 DK2012050383W WO2013053362A1 WO 2013053362 A1 WO2013053362 A1 WO 2013053362A1 DK 2012050383 W DK2012050383 W DK 2012050383W WO 2013053362 A1 WO2013053362 A1 WO 2013053362A1
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- hybrid unit
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- plastic
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- hybrid
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/124—Tongue and groove joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/305—Decorative or coloured joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
- B29C66/545—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles one hollow-preform being placed inside the other
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
- B29C66/7336—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light
- B29C66/73361—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being opaque to visible light
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
- B29C65/485—Multi-component adhesives, i.e. chemically curing as a result of the mixing of said multi-components
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
- B29C66/7422—Aluminium or alloys of aluminium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2019/00—Buttons or semi-finished parts of buttons for haberdashery
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/46—Knobs or handles, push-buttons, grips
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/723—Articles for displaying or advertising
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/737—Articles provided with holes, e.g. grids, sieves
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H2219/00—Legends
- H01H2219/054—Optical elements
- H01H2219/062—Light conductor
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H2229/00—Manufacturing
- H01H2229/012—Vacuum deposition
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H2229/00—Manufacturing
- H01H2229/014—Electro deposition
Definitions
- the present invention relates to a hybrid unit comprising a metal part combined with a plastics part, the surface of which is coated using for instance a PVD process (Physical Vapour Deposition).
- the hybrid unit according to the invention makes it possible to manufacture and apply objects of a very fine decorative quality, which objects possess special characteristics that are achieved by the combination with integrated plastic parts, upon which a coating of aluminium or aluminium alloys has been applied by an evaporation technique.
- the complete hybrid unit has an anodisable surface having op- timal decorative and corrosion protecting characteristics.
- This control button comprises a metallic base body, in the inner portion of which is formed (by use of a stamp) an inner cavity, which comprises outwardly extending leg portions that extend from the inner cavity in a direction towards the front face of the metallic base body. These leg portions however do not extend all the way to the front face of the metallic base body but only to a certain distance from the front surface.
- the inner cavity including the leg portions are filled with a liquid plastic material that undergoes a hardening process.
- the front face of the metallic base body is milled to such a degree that the end portions of the leg portions that face away from the inner cavity are exposed at the front face, after which processing (milling) the resulting front face comprises metal portions and a suitable pattern of plastic portions, through which plastic portions light from a light source placed behind the metallic base body can pass.
- the end faces of the exposed plastic leg portions remain uncovered.
- the applicant has developed a system including aluminium surfaces that are permeable for ordinary light. The system is described in the applicant's patent US 7,663,612. The system fulfils the above requirements completely, but it is desired to obtain an alternative that is more simple, and hence cheaper, to produce.
- An alternative to light-permeable metal objects is metal coated plastic objects.
- the present invention combines different technologies into a new and effective manufacturing process, which is practically applicable.
- Standard processes that can be used for manufacturing metal coated plastic objects are for instance:
- PVD Physical vapour deposition
- Ion vapour deposition which is a physical process, wherein pure aluminium are vapour deposited on different substrates. The process takes place in vacuum to avoid oxidation of the surface of the substrate.
- metal parts and plastic parts that have been surface treated are combined to a complete hybrid unit.
- Surface treatment can in this context be a material coating that is (a) painted on the object, or (b) PVD or IVD treated, or a combination of these means.
- a hybrid unit that consists of a metal part combined with a plastic part is characterised by: • A first part made of metal is processed to enable it to accommodate another (second) part;
- the second part which is made of plastic, is processed to enable it to be accommodated within the first part;
- the second part is completely or partially surface treated by a material applying process
- the first and the second parts are assembled to provide a homogenous unit, such that the treated surface on the second part totally or partially appears as an integrated portion of the surface of the first part;
- the plastic part and/or the metal part can optionally be coated with a protective layer that reduces abrasion of the surface.
- the second part consists of a plastic material that is transparent for light.
- plastic materials can be used, such as PMMA that can be milled or injection moulded. Examples of suitable materials are PMMA, PC, PVC or PE.
- the second part may be coated by a layer of the same basis material as the first part, for instance aluminium.
- a hybrid unit may comprise a second part with the treated surface on the second part being completely or partially transparent for light.
- a layer of aluminium is applied of a thickness of approximately 10 nano meters. This thickness ensures that the layer is of sufficient strength and also transparent for light.
- a protective layer of AI2O 3 of a thickness of a few nano meters is achieved by rotation of the respective parts in a vacuum chamber a number of times.
- the surface can be coated with a hardcoat based on UV hardened acrylic.
- a combination of aluminium and another metal can be evaporated onto the surface. The purpose of this is to provide a desired colour effect of the coating.
- the PVD process operates in this case at a temperature of typically 70 degrees Centigrade.
- a second aspect of the invention relates to implementing optic fibres (light conducting portions, such as one or more channels) and possibly diffusers into the compound unit. Processing of the first part is carried out in order to be able to include the second part herein, which results in subdividing the first part in two or more other parts
- the first part and the second part and two or more other parts are assembled to a single hybrid unit.
- the first and the second parts are assembled such that there is created one or more light-transparent channels or regions from the rear face to the front face of the hybrid unit.
- the plastic and the aluminium objects can for instance be glued together using Loctite ® 3295 two-component acrylic glue.
- a third aspect of the invention relates to the provision of light sources behind the compound unit.
- a light source When a light source is placed on the rear face of the hybrid unit, one or more points, symbols or regions are illuminated that appears on the front face of the hybrid unit.
- One or more points, symbols or regions that appear on the front face of the hybrid unit are created by:
- the first part of metal has through holes corresponding to those symbols (e.g. points, text, numbers and letters, 7-segment graphics) that shall be illuminated. ⁇ If the first part is subdivided in two or more other parts, these can have the same types of holes as described above. • The second part, that shall function as an light transmission path or optical fibre is formed such that it fits into - and fills the above mentioned holes in the first part plus holes in two or more other parts, if such parts are present.
- symbols e.g. points, text, numbers and letters, 7-segment graphics
- a unit that uses the present invention may find application in many fields. Specifically, where the unit is an operational button and/or a source of information in consumer electronics, cars, boats, aeroplanes and control systems.
- the basic part 1 is a metal object that has been processed into a given shape.
- the shown embodiment is a round operational button made of aluminium.
- This can be moulded, processed, drilled, roulet, etc. depending on the specific functional requirements or use requirements.
- a cavity 4 has been provided allowing a plastic part 5 to be inserted into the cavity 4 and secured herein for instance by gluing of the plastic part 5 to the basic part 1.
- the surface of the basic part 1 may be processed to provide it with symbols, points, text, etc. as functional or decorative elements on the front face of the operational button, according to the requirements of the specific application. Processing of the basic part 1 can take place from the front face and may be confined to the surface, i.e. not extending through the unit. Processing may also comprise through holes 2 depending on the specific need.
- a circular cavity 2 has been milled in the part.
- the milling is extending through the part such that a separate circular object 3 with a specified distance between the basic part 1 and the circular object 3 is created.
- the shown plastic part 5 is according to one embodiment of the invention made of transparent plastic material.
- This object can hence be used as an optical fibre or light conducting portion in addition to function as a stabilizing object for the basic part 1 and the circular object 3, when these are glued together.
- the shown plastic part 5 is according to one embodiment of the invention provided with a layer of aluminium in a PVD/IVD vaporization process.
- the thickness of the aluminium layer is typically 10 nano meters, which makes the layer transparent for normal light, but still appears as an object in homogeneous aluminium, when light is not passing through it.
- the entire part 5 can be provided with a metal layer, such as aluminium or alloys com- prising aluminium, but normally only those portions 6 that pass through the cavities or holes 2 that extend through the entire wall portion of the basic part 1 will be coated with aluminium or an aluminium alloy.
- the plastic part 5 can thus function as a light conducting path or fibre optic, when light is passed through if from the rear portion of the hybrid unit, and still make the hybrid unit appear as a homogeneous body of for instance aluminium when light is not passed through the cavities or holes 2.
- the complete hybrid unit includes the basic part 1, the plastic part 5 and the separate circular object 3.
- the surface of the hybrid unit appears homogeneous, which makes the unit appear as a complete aluminium construction.
- the cavities appear as lighting symbols via the transparent aluminium-coated regions.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
Abstract
The present invention relates to a hybrid unit comprising a metal part (l)combined with a plastic part (5), which is surface treated, for instance using a PVD process (Physical vapour deposition). The hybrid unit makes it possible to produce and apply units having a high decorative quality and comprising special characteristics that are achieved by combination with integrated plastic parts, upon which there is applied a layer of aluminium by vapour deposition. The complete hybrid unit has an anodisable surface, having optimal decorative and corrosion protecting characteristics.
Description
HYBRID UNIT COMPOSED OF METAL AND PDV COATED
PLASTIC MATERIAL, AND METHOD OF PRODUCING IT
Field of the Invention
The present invention relates to a hybrid unit comprising a metal part combined with a plastics part, the surface of which is coated using for instance a PVD process (Physical Vapour Deposition). The hybrid unit according to the invention makes it possible to manufacture and apply objects of a very fine decorative quality, which objects possess special characteristics that are achieved by the combination with integrated plastic parts, upon which a coating of aluminium or aluminium alloys has been applied by an evaporation technique. The complete hybrid unit has an anodisable surface having op- timal decorative and corrosion protecting characteristics.
Background of the Invention
It is of interest to be able to apply user interfaces with a high content of information in dialogue with the user of a given apparatus. This means that for instance control but- tons and displays can aid the user with interactive display means. An extended use of metal for surfaces and operational handles that enhances the aesthetic appearance of an apparatus raises the need for new means for communication with the user. In summary, the need can be expressed as how is it possible to communicate information via a metal surface? How can a control button indicate a status or an information?
DE 100 18 933 CI describes a control button that can indicate a status or an information. This control button comprises a metallic base body, in the inner portion of which is formed (by use of a stamp) an inner cavity, which comprises outwardly extending leg portions that extend from the inner cavity in a direction towards the front face of the metallic base body. These leg portions however do not extend all the way to the front face of the metallic base body but only to a certain distance from the front surface. The inner cavity including the leg portions are filled with a liquid plastic material that undergoes a hardening process. When this is completed, the front face of the metallic base body is milled to such a degree that the end portions of the leg portions that face away from the inner cavity are exposed at the front face, after which processing (milling) the
resulting front face comprises metal portions and a suitable pattern of plastic portions, through which plastic portions light from a light source placed behind the metallic base body can pass. The end faces of the exposed plastic leg portions remain uncovered. The applicant has developed a system including aluminium surfaces that are permeable for ordinary light. The system is described in the applicant's patent US 7,663,612. The system fulfils the above requirements completely, but it is desired to obtain an alternative that is more simple, and hence cheaper, to produce. An alternative to light-permeable metal objects is metal coated plastic objects.
The present invention combines different technologies into a new and effective manufacturing process, which is practically applicable. Standard processes that can be used for manufacturing metal coated plastic objects are for instance:
• Physical vapour deposition (PVD), which is a general method, in which a thin film of material is applied in the form of vapour. The coating method involves physical processes, such as high temperatures or plasma sputter bombardment.
• Ion vapour deposition (IVD), which is a physical process, wherein pure aluminium are vapour deposited on different substrates. The process takes place in vacuum to avoid oxidation of the surface of the substrate.
Description of the Invention
According to a first aspect of the invention, metal parts and plastic parts that have been surface treated are combined to a complete hybrid unit. Surface treatment can in this context be a material coating that is (a) painted on the object, or (b) PVD or IVD treated, or a combination of these means.
A hybrid unit that consists of a metal part combined with a plastic part is characterised by:
• A first part made of metal is processed to enable it to accommodate another (second) part;
• The second part, which is made of plastic, is processed to enable it to be accommodated within the first part;
· The second part is completely or partially surface treated by a material applying process;
• The first and the second parts are assembled to provide a homogenous unit, such that the treated surface on the second part totally or partially appears as an integrated portion of the surface of the first part;
· The plastic part and/or the metal part can optionally be coated with a protective layer that reduces abrasion of the surface.
The second part consists of a plastic material that is transparent for light. Different plastic materials can be used, such as PMMA that can be milled or injection moulded. Examples of suitable materials are PMMA, PC, PVC or PE.
The second part may be coated by a layer of the same basis material as the first part, for instance aluminium.
A hybrid unit may comprise a second part with the treated surface on the second part being completely or partially transparent for light.
According to a preferred embodiment of the invention a layer of aluminium is applied of a thickness of approximately 10 nano meters. This thickness ensures that the layer is of sufficient strength and also transparent for light.
As an option it is possible to apply a protective layer of AI2O3 of a thickness of a few nano meters. The mentioned thickness of approximately 10 nano meters is achieved by rotation of the respective parts in a vacuum chamber a number of times. Alternatively, the surface can be coated with a hardcoat based on UV hardened acrylic.
As an option to pure aluminium a combination of aluminium and another metal can be evaporated onto the surface. The purpose of this is to provide a desired colour effect of the coating. The PVD process operates in this case at a temperature of typically 70 degrees Centigrade.
A second aspect of the invention relates to implementing optic fibres (light conducting portions, such as one or more channels) and possibly diffusers into the compound unit. Processing of the first part is carried out in order to be able to include the second part herein, which results in subdividing the first part in two or more other parts
The first part and the second part and two or more other parts are assembled to a single hybrid unit. The first and the second parts are assembled such that there is created one or more light-transparent channels or regions from the rear face to the front face of the hybrid unit.
The plastic and the aluminium objects can for instance be glued together using Loctite® 3295 two-component acrylic glue.
A third aspect of the invention relates to the provision of light sources behind the compound unit. When a light source is placed on the rear face of the hybrid unit, one or more points, symbols or regions are illuminated that appears on the front face of the hybrid unit. One or more points, symbols or regions that appear on the front face of the hybrid unit are created by:
• The first part of metal has through holes corresponding to those symbols (e.g. points, text, numbers and letters, 7-segment graphics) that shall be illuminated. · If the first part is subdivided in two or more other parts, these can have the same types of holes as described above.
• The second part, that shall function as an light transmission path or optical fibre is formed such that it fits into - and fills the above mentioned holes in the first part plus holes in two or more other parts, if such parts are present.
• Those portions of the second part that shall function as a light-conducting ob- ject are vaporized onto the transparent aluminium layer.
A unit that uses the present invention may find application in many fields. Specifically, where the unit is an operational button and/or a source of information in consumer electronics, cars, boats, aeroplanes and control systems.
Description of the Drawing
The present invention will be better understood with reference to the cross-sectional view presented in figure 1 in conjunction with the following detailed description of an embodiment of the invention.
Detailed Description of the Invention
With reference to figure 1 there is shown cross-sectional views of the two parts that are used to implement an embodiment of the hybrid unit according to the invention. The basic part 1 is a metal object that has been processed into a given shape. The shown embodiment is a round operational button made of aluminium.
This can be moulded, processed, drilled, roulet, etc. depending on the specific functional requirements or use requirements.
In the basic part a cavity 4 has been provided allowing a plastic part 5 to be inserted into the cavity 4 and secured herein for instance by gluing of the plastic part 5 to the basic part 1.
The surface of the basic part 1 may be processed to provide it with symbols, points, text, etc. as functional or decorative elements on the front face of the operational button, according to the requirements of the specific application. Processing of the basic part 1 can take place from the front face and may be confined to the surface, i.e. not
extending through the unit. Processing may also comprise through holes 2 depending on the specific need.
In the shown embodiment of a basic part 1 a circular cavity 2 has been milled in the part. The milling is extending through the part such that a separate circular object 3 with a specified distance between the basic part 1 and the circular object 3 is created.
The shown plastic part 5 is according to one embodiment of the invention made of transparent plastic material. This object can hence be used as an optical fibre or light conducting portion in addition to function as a stabilizing object for the basic part 1 and the circular object 3, when these are glued together.
The shown plastic part 5 is according to one embodiment of the invention provided with a layer of aluminium in a PVD/IVD vaporization process. The thickness of the aluminium layer is typically 10 nano meters, which makes the layer transparent for normal light, but still appears as an object in homogeneous aluminium, when light is not passing through it.
The entire part 5 can be provided with a metal layer, such as aluminium or alloys com- prising aluminium, but normally only those portions 6 that pass through the cavities or holes 2 that extend through the entire wall portion of the basic part 1 will be coated with aluminium or an aluminium alloy. The plastic part 5 can thus function as a light conducting path or fibre optic, when light is passed through if from the rear portion of the hybrid unit, and still make the hybrid unit appear as a homogeneous body of for instance aluminium when light is not passed through the cavities or holes 2.
In the preferred embodiment the complete hybrid unit includes the basic part 1, the plastic part 5 and the separate circular object 3. The surface of the hybrid unit appears homogeneous, which makes the unit appear as a complete aluminium construction. When lighted from the rear face, the cavities appear as lighting symbols via the transparent aluminium-coated regions.
Units made after the teachings of the present invention can find wide application in products with particularly severe requirements for optimal decorative and/or corrosion protecting characteristics, such as: · Consumer electronic devices, such as audio/video systems, PC's, portable units like mobile phones, GPS's, media players, etc.
• Consumer implements for home use, such as white goods and sanitary implements.
• Consumer implements for use outside the home, such as in cars, boats, aero- planes and caravans.
Claims
1. A hybrid unit comprising a metal part (1) combined with a plastic part (5), where the hybrid unit is characterised by:
(a) a first part (1) made of metal is processed such that is can include a second part (5);
(b) a second part (5) made of plastics is processed such that it can be included in said first part (1);
(c) said second part (5) is totally or partly surface treated by means of a material application process;
(d) said first part (1) and said second part (5) form a complete, homogeneous unit, such that the processed surface of the second part (5) totally or partly appears as an integrated part of the surface of the first part (1).
2. A hybrid unit according to claim 1, wherein said second part (5) is made of plastic material that is transparent for light.
3. A hybrid unit according to claim 2, wherein said second part (5) is provided with a layer of the same basic material as the material of the first part (1).
4. A hybrid unit according to claim 3, wherein the treated surface of the second part (5) totally or partly is transparent for light.
5. A hybrid unit according to claim 4, wherein the processing of said first part (1), in order to be able to include said second part (5), involve subdivision of the first part (1) in two or more other objects (3).
6. A hybrid unit according to claim 5, wherein said first part (1) and said second part (5) and two or more other objects (3) are assembled to an complete hybrid unit.
7. A hybrid unit according to claim 6, wherein said first part (1) and said second part (5) are assembled such that one or more light transparent channels are created from the rear face of the assembled hybrid unit to the front face of the hybrid unit.
8. A hybrid unit according to claim 7, wherein a light source provided on the rear face of the hybrid unit lights up one or more points, symbols or regions, which appear on the front face of the hybrid unit.
9. A unit comprising a hybrid unit according to any of the preceding claims, where the unit is an operational button and/or an information provider for use in consumer electronics, cars, boats, aeroplanes and control systems.
10. A method for making a hybrid unit according to any of the preceding claims 1 to 8, the method comprising the steps of:
(i) providing a metal part and a plastic part (5), where the plastic part (5) is transparent for light;
(ii) processing said metal part to provide a processed metal part (1) that can include said plastic part (5) in a suitably shaped inner cavity (4);
(iii) providing the processed metal part (1) with at least one channel, hole or cavity (2) that penetrate the wall of the metal part (1) from said inner cavity (4) to the outer surface of the metal part (1);
(iii) processing said plastic part (5), such that it can be included in said processed metal part (1) and such that portions of the plastic part (5) are formed for extension through said at least one channel, hole or cavity (2) from the inner cavity (4) to the outer surface of the metal part (1);
(iv) providing at least one or more portions (6) of said plastic part (5) with a metallic surface layer by means of a material application process, such that at least those surface portions of the plastic part (5) that extends through said channels, holes or cavities (2) and that are visible from the outer surface of the metal part (1) are provided with said metallic surface layer.
11. A method according to claim 10, wherein said material application process is a PVD or IVD vaporization process.
12. A method according to claim 10 or 11, wherein said material is aluminium or an aluminium alloy.
13. A method according to any of the preceding claims 10, 11 and 12, wherein the thickness of said layer of aluminium or aluminium alloy is approximately 10 nano meters.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DKPA201100782 | 2011-10-10 | ||
DKPA201100782 | 2011-10-10 |
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WO2013053362A1 true WO2013053362A1 (en) | 2013-04-18 |
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PCT/DK2012/050383 WO2013053362A1 (en) | 2011-10-10 | 2012-10-09 | Hybrid unit composed of metal and pdv coated plastic material, and method producing it |
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WO2008034611A1 (en) * | 2006-09-22 | 2008-03-27 | Preh Gmbh | Cap for a display or control element, comprising a light-permeable metal coating, and method for the production thereof |
WO2008034610A1 (en) * | 2006-09-22 | 2008-03-27 | Preh Gmbh | Display and/or control element in a motor vehicle |
WO2008061786A1 (en) * | 2006-11-24 | 2008-05-29 | Preh Gmbh | Control element comprising a metallic coating for a motor vehicle |
US7663612B2 (en) | 2003-02-27 | 2010-02-16 | Bang & Olufsen A/S | Metal display panel having one or more translucent regions |
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DE19915510C1 (en) * | 1999-04-07 | 2000-07-27 | Preh Elektro Feinmechanik | Making metal casings, manual controls and transparent plastic indicator scales for vehicular use is achieved by stamping, machining, anodizing and coloring |
DE10018933C1 (en) | 2000-04-17 | 2001-11-15 | Harman Becker Automotive Sys | Push-button element for electrical video or audio device e.g. car radio, has base body provided with symbol island surrounded by gap filled with transparent plastics filling material block |
US7663612B2 (en) | 2003-02-27 | 2010-02-16 | Bang & Olufsen A/S | Metal display panel having one or more translucent regions |
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WO2008034611A1 (en) * | 2006-09-22 | 2008-03-27 | Preh Gmbh | Cap for a display or control element, comprising a light-permeable metal coating, and method for the production thereof |
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