WO2020016788A1

WO2020016788A1 - Metal-plastic hybrid structures and methods of making the same

Info

Publication number: WO2020016788A1
Application number: PCT/IB2019/056086
Authority: WO
Inventors: Lingshan WANG; Chao Liu; Lijuan Wang
Original assignee: Sabic Global Technologies B.V.
Priority date: 2018-07-16
Filing date: 2019-07-16
Publication date: 2020-01-23

Abstract

Various embodiments disclosed relate to metal-plastic hybrid structures and methods of making the same. The metal-plastic hybrid structure includes a central region including a perimeter, a front side, and a back side opposite the front side. The central region includes a metal plate, metal foil, or a combination thereof. The metal-plastic hybrid structure also includes an edge region fused to the perimeter of the central region. The edge region includes plastic. The edge region and the central region are flush at a junction between the central region and the edge region on the back side of the central region.

Description

METAL-PLASTIC HYBRID STRUCTURES AND METHODS OF MAKING THE

SAME

BACKGROUND

[0001] In portable electronic devices, such as laptops, tablets, and phones, most development trends target thinner and lighter devices such as for easier transportation and energy savings. Correspondingly, thinner and lighter covers or housings are required to protect the miniaturized internal components, and must also provide higher strength and rigidity, electromagnetic interference shielding, and good heat conduction. Plastics suffer from lack of electromagnetic interference shielding and low rigidity, while metals suffer from high cost and tedious manufacturing.

[0002] United States Patent No. 3,932,250 discloses a method for manufacturing a metal foil- or plastic film-overlaid laminate which comprises completely covering a cleaned press plate with a cleaned metal foil, a cleaned plastic film or both of them in such a manner that the pressing surface of the press plate comes in intimate contact with the face side of said metal foil or plastic film, partially or completely sealing the resulting covering along at least two edges of the press plate, two of the edges being opposite to each other, applying the covered press plate to one or both sides of a laminating base, subjecting the resulting assembly to a laminating apparatus with heating under pressure, taking the assembly out of the laminating apparatus, and thereafter opening the covering to remove the press plate.

[0003] International Application PCT/IB2016/057692, which published as WO

2017/103861, discloses various embodiments that relate to plastic-metal junctions and methods of making the same via laser-assisted joining. The publication discloses provides a method of forming a junction between a metal form and a solid plastic. The publication discloses that the method can include laser treating a surface of a metal form to generate a feature (e.g., a plurality of at least one of pores and grooves) in the surface of the metal, wherein the laser has an angle of incidence with the surface of the metal of other than O degrees. The publication discloses that the method can include contacting the metal surface including the feature with a flowable resin composition. The publication discloses that the method can include curing the flowable resin composition to form the solid plastic, to provide the junction between the metal form and the solid plastic.

SUMMARY OF THE INVENTION [0004] In various embodiments, the present invention provides a metal-plastic hybrid structure including a central region. The central region includes a perimeter, a front side, and a back side opposite the front side. The central region includes a metal plate, metal foil, or a combination thereof. The central region also includes an edge region fused to the perimeter of the central region. The edge region includes plastic. The edge region and the central region are flush at a junction between the central region and the edge region on the back side of the central region.

[0005] In various embodiments, the present invention provides an electronic device including the metal-plastic hybrid structure, such as a laptop, tablet computer, phone, or a combination thereof.

[0006] In various embodiments, the present invention provides a metal-plastic hybrid structure including a substantially rectangular central region including a perimeter, a front side, and a back side opposite the front side. The central region includes a metal plate and a fiber-filled plastic layer as the outermost layer on the back side of the central region. The central region is free of layers other than the metal plate and the fiber-filled plastic layer. The metal plate has a perimeter that substantially overlaps and is the same as a perimeter of the fiber-filled plastic layer. The fiber includes glass fibers, carbon fibers, or a combination thereof. The metal-plastic hybrid structure also includes a substantially rectangular edge region fused to the perimeter of the central region. The edge region includes plastic. The edge region includes a substantially flat region and a curved region. At least part of the flat region of the edge region is fused to the central region and the curved region of the edge region is free of fusion with the central region. At the perimeter of the central region the edge region has a greater thickness than the central region and the edge region overlaps at least part of the front side of the central region such that the edge region directly contacts the front side of the metal plate or contacts the metal plate via adhesive. The edge region and the fiber-filled plastic layer at the back side of the central region are flush at a junction between the central region and the edge region on the back side of the central region.

[0007] In various embodiments, the present invention provides a metal-plastic hybrid structure including a substantially rectangular central region including a perimeter, a front side, and a back side opposite the front side. The central region includes a metal plate and a fiber-filled plastic layer as the outermost layer on the back side of the central region. The central region is free of layers other than the metal plate and the fiber-filled plastic layer. The fiber-filled plastic layer has a perimeter that is larger than and that encompasses a perimeter of the metal plate. The fiber includes glass fibers, carbon fibers, or a combination thereof. The metal-plastic hybrid structure also includes a substantially rectangular edge region fused to the perimeter of the central region. The edge region includes plastic. The edge region includes a substantially flat region and a curved region. At least part of the flat region of the edge region is fused to the central region and the curved region of the edge region is free of fusion with the central region. At the perimeter of the central region the edge region has a greater thickness than the central region and the edge region overlaps at least part of the front side of the central region such that the edge region directly contacts the front side of the fiber- filled plastic layer or contacts the fiber-filled plastic layer via adhesive. In areas of the central region not including the metal plate and that overlap with the edge region, the front side of the metal plate directly contacts the edge region or the front side of the metal plate contacts the edge region via an adhesive. The edge region and the fiber-filled plastic layer at the back side of the central region are flush at a junction between the central region and the edge region on the back side of the central region.

[0008] In various embodiments, the present invention provides a method of making the metal-plastic hybrid structure. The method includes overmolding the edge region of the central region, to provide the metal-plastic hybrid structure.

[0009] In various embodiments, the present invention provides advantages over other structures (e.g., as compared to other structures having similar applications, such as structures suitable as laptop or tablet covers) and methods of making the same, at least some of which are unexpected. For example, in some embodiments, the metal-plastic hybrid structure can be thinner than other structures. In various embodiments, the metal-plastic hybrid structure of the present invention can be lighter weight than other structures. In various embodiments, the metal-plastic hybrid structure of the present invention can be stronger (e.g., higher tensile strength) than other structures. In various embodiments, the metal-plastic hybrid structure of the present invention can be stiffer (e.g., higher elastic modulus) than other structures. In various embodiments, the metal-plastic hybrid structure of the present invention can have better thermal conductivity than other structures. In various embodiments, the metal-plastic hybrid structure of the present invention can be cheaper than other structures. In various embodiments, the metal-plastic -hybrid structure of the present invention can provide better shielding from electromagnetic interference than other structures. In various embodiments, the metal-plastic hybrid structure of the present invention can be easier to make than other structures.

BRIEF DESCRIPTION OF THE FIGURES

[0010] The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0011] FIGS. 1A-B illustrate back (1A) and front (1B) views of a metal-plastic hybrid structure, in accordance with various embodiments.

[0012] FIG. 2 illustrates a central region that includes a metal plate, in accordance with various embodiments.

[0013] FIG. 3 illustrates a central region that includes a metal plate and a fiber-filled plastic layer, in accordance with various embodiments.

[0014] FIG. 4 illustrates a central region including two plastic layers and metal plate, in accordance with various embodiments.

[0015] FIGS. 5A-B illustrate side cut-away views of a metal-plastic hybrid structure, in accordance with various embodiments.

[0016] FIGS. 6A-B illustrate side cut-away views of a metal-plastic hybrid structure, in accordance with various embodiments.

[0017] FIG. 7 illustrates bonding strength between edge regions and central regions of various metal-plastic hybrid composites, according to various embodiments.

DETAILED DESCRIPTION OF THE INVENTION

[0018] Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of“about 0.1% to about 5%” or“about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g.,

1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement“about X to Y” has the same meaning as“about X to about Y,” unless indicated otherwise. Likewise, the statement“about X, Y, or about Z” has the same meaning as“about X, about Y, or about Z,” unless indicated otherwise.

[0019] In this document, the terms“a,”“an,” or“the” are used to include one or more than one unless the context clearly dictates otherwise. The term“or” is used to refer to a nonexclusive“or” unless otherwise indicated. The statement“at least one of A and B” has the same meaning as“A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

[0020] The term“about” as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range, and includes the exact stated value or range. The term“substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.

[0021] The term“cure” as used herein refers to exposing to radiation in any form, heating, or allowing to undergo a physical or chemical reaction that results in hardening or an increase in viscosity. A flowable thermoplastic material can be cured by cooling it such that the material hardens. A flowable thermoset material can be cured by heating or otherwise exposing to irradiation such that the material hardens.

[0022] As used herein, the term“polymer” refers to a molecule having at least one repeating unit and can include copolymers.

[0023] As used herein, the term“injection molding” refers to a process for producing a molded part or form by injecting a composition including one or more polymers that are thermoplastic, thermosetting, or a combination thereof, into a mold cavity, where the composition cools and hardens to the configuration of the cavity. Injection molding can include the use of heating via sources such as steam, induction, cartridge heater, or laser treatment to heat the mold prior to injection, and the use of cooling sources such as water to cool the mold after injection, allowing faster mold cycling and higher quality molded parts or forms. Metal-plastic hybrid structure.

[0024] The present invention provides a metal-plastic hybrid structure. The metal- plastic hybrid structure includes a central region. The central region includes a perimeter, a front side, and a back side opposite the front side. The central region includes a metal plate, metal foil, or a combination thereof. The metal-plastic hybrid structure also includes an edge region fused to the perimeter of the central region. The edge region includes plastic. The edge region and the central region are flush at a junction between the central region and the edge region on the back side of the central region. For example, at the junction between the central region and the edge region on the back side of the central region, the distance between a plane corresponding to the back side of the central region and a plane corresponding to the back side of the edge region can be about 0 mm, or about 0 mm to about 0.1 mm, about 0 mm to about 0.01 mm, or about 0 mm to about 0.001 mm.

[0025] The edge region can be fused along any suitable proportion of the perimeter of the central region, such as at about 100% of the perimeter of the central region. At the junction between the central region and the edge region on the back side of the central region, the central region and the edge region are adjacent and contact one another directly or via an adhesive as described further herein. The central region and the edge region can be substantially rectangular, wherein substantially rectangular as used herein can designate a rectangular shape with curved corners. The central region can be substantially flat. The edge region can include a substantially flat region and an uneven region. The substantially flat region of the edge region and the central region are substantially flat exclusive of any structural features on these regions, as described further herein. FIGS. 1A-B illustrate an embodiment of the metal-plastic hybrid structure 100, with FIG. 1A showing a view from the back side of the structure (e.g., from the back side of the central region) and with FIG. 1B showing a view from the front side of the structure (e.g., from the front side of the central region). Metal-plastic hybrid structure 100 includes substantially rectangular central region 110 and substantially rectangular edge region 120, wherein the edge region 120 includes substantially flat region 130 and uneven (curved) region 140. The metal-plastic hybrid structure 100 includes structural features 150, which are bosses for screw assembly with other components of a device. Rectangle 160 illustrates the edge of central region 110, which is overlapped on the front side by the substantially flat region 130 of the edge region 120. [0026] At least part of the flat region of the edge region can be fused to the central region. The uneven region of the edge region can be free of fusion with the central region. The substantially flat region of the edge region can be the innermost region of the edge region that is furthest from the outer perimeter of the edge region and can be the portion of the edge region that is closest to the central region. The uneven region of the edge region can be the outermost region of the edge region that is closest to or forms the outer perimeter of the edge region.

[0027] The uneven region of the edge region can include one or more angled surfaces, a curve, one or more corners, or a combination thereof. The uneven region can include a curve, such as a curve along the outer perimeter of the edge region, such as along 100% of the outer perimeter (e.g., outer edge) of the edge region. The uneven region of the edge region can include a sloping (e.g., linear or curved) of the uneven region from a plane parallel to the flat region toward a direction of an outward-pointing normal vector of the front side of the central region.

[0028] At the perimeter of the central region, the edge region can have a greater thickness than the central region and the edge region can overlap at least part of the front side of the central region. At areas of the central region including the metal plate or metal foil and overlapped by the edge region the edge region can directly contact the front side of the metal plate or metal foil, or can contact the front side of the metal plate or metal foil via an adhesive (e.g., in the form of glue or tape). The edge region can have a substantially uniform thickness (e.g., exclusive of any structural features) outside the perimeter of the central region. Inside the perimeter of the central region, the edge region can overlap the central region and can have a substantially uniform thickness (e.g., exclusive of any structural features) that is less than the thickness of the edge region outside the perimeter of the central region.

[0029] In various embodiments, only a portion of the front side of the central region

(e.g., near the perimeter) can be overlapped by the edge region, while another portion of the central region (e.g., the middle area) can be free of the edge region. In other embodiments, a majority of or the entire front side of the central region can be overlapped by the edge region. Any suitable proportion of the surface area of the front side of the central region can be free of the edge region, such as about 50% to about 99.999%, or about 80% to about 99%, or about 50% or less, or less than, equal to, or greater than about 55%, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.9, 99.99, or about 99.999% or more of surface area of the front side of the central region is free of the edge region. Any suitable proportion of the surface area of the front side of the central region can be free of the edge region, such as about 0.001% to about 50%, about 1% to about 20%, or about 0.001% or less, or about 0.01%, 0.1, 1, 2, 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, or about 20% or more. The edge region fused to the perimeter of the central region can directly contact the central region (e.g., the sides of the central region and the front side thereof), such as formed via heat compression lamination, plastic melt injection, or a combination thereof. The edge region fused to the perimeter of the central region can be fused to the central region via an adhesive (e.g., glue or tape).

[0030] Outside the perimeter of the central region the edge region can have a thickness of about 0.1 mm to about 5 mm, about 0.5 mm to about 2 mm, about 0.5 mm to about 1 mm, or about 0.1 mm or less, or less than, equal to, or greater than about 0.2 mm, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, 4, 4.5, or about 5 mm or more. Inside the perimeter of the central region the edge region can have a thickness of about 0.01 mm to about 2 mm, about 0.1 mm to about 1 mm, or less than, equal to, or greater than about 0.01 mm, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or about 2 mm or more.

[0031] The central region can have a substantially uniform thickness exclusive of any structural features on the central region. The areas of the central region fused to the edge region can have a substantially uniform thickness. The areas of the central region not fused to the edge region have a substantially uniform thickness. The areas of the central region fused to the edge region can have about the same (e.g., in the case of a one-step junction, as explained further herein) or greater thickness (e.g., in the case of a two-step or multi-step junction, as explained further herein) as the areas of the central region not fused to the edge region. The areas of the central region fused to the edge region, or not fused to the edge region, can have a thickness of about 0.1 mm to about 5 mm, or about 0.5 mm to about 2 mm, or about 0.1 mm or less, or less than, equal to, or greater than about 0.2 mm, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.8, 3,

3.2, 3.4, 3.6, 3.8, 4, 4.5, or about 5 mm or more.

[0032] The central region, the edge region, or a combination thereof, can include at least one structural feature. The structural feature can be a feature that contributes to the strength or rigidity of the metal-plastic hybrid structure, or that contributes to the assembly of a device such as a laptop, tablet, or phone that includes the metal-plastic hybrid structure (e.g., mounting brackets to attach circuit boards, other covers, or other equipment to the structure). The structural feature can be on a surface of the metal-plastic hybrid structure that corresponds to the inside (e.g., the front side of the central region) or the outside (e.g., the back side of the central region) of a device that includes the structure. The structural feature can be disposed on the front side of the central region, on a side of the edge region

corresponding to the front side of the central region, or a combination thereof. For example, the structural feature can be a boss, a snap, a support rib, a gusset, a hook, a mounting bracket, or a combination thereof.

[0033] The plastic of the edge region can include one or more polymers. The plastic can be a thermoplastic or thermoset material that is injection moldable such that it can be overmolded onto the central region via an injection molding process. The plastic can form any suitable amount of the edge region, such as about 50 wt% to about 100 wt%, or about 90 wt% to about 100 wt%, or about 50 wt% or less, or less than, equal to, or greater than about 55 wt%, 60, 65, 70, 75, 80, 85, 90, or about 95 wt% or more. The plastic can include an acrylonitrile butadiene styrene (ABS) polymer, an acrylic polymer, a celluloid polymer, a cellulose acetate polymer, a cycloolefin copolymer (COC), an ethylene-vinyl acetate (EVA) polymer, an ethylene vinyl alcohol (EVOH) polymer, a fluoroplastic, an ionomer, an acrylic/PVC alloy, a liquid crystal polymer (LCP), a polyacetal polymer (POM or acetal), a polyacrylate polymer, a polymethylmethacrylate polymer (PMMA), a polyacrylonitrile polymer (PAN or acrylonitrile), a polyamide polymer (PA, such as nylon), a polyamide- imide polymer (PAI), a polyaryletherketone polymer (PAEK), a polybutadiene polymer (PBD), a polybutylene polymer (PB), a polybutylene terephthalate polymer (PBT), a polycaprolactone polymer (PCL), a polychlorotrifluoroethylene polymer (PCTFE), a polytetrafluoroethylene polymer (PTFE), a polyethylene terephthalate polymer (PET), a polycyclohexylene dimethylene terephthalate polymer (PCT), a

poly(cyclohexylenedimethylene terephthalate-co-ethylene glycol) (PCTG), a Tritan™ copolyester, a polycarbonate polymer (PC), poly(l,4-cyclohexylidene cyclohexane- 1,4- dicarboxylate) (PCCD), a polyhydroxyalkanoate polymer (PHA), a polyketone polymer (PK), a polyester polymer, a thermoplastic polyester elastomer polymer (TPEE), a polyethylene polymer (PE), a polyetheretherketone polymer (PEEK), a polyetherketoneketone polymer (PEKK), a polyetherketone polymer (PEK), a polyetherimide polymer (PEI), a polyethersulfone polymer (PES), a polyethylenechlorinate polymer (PEC), a polyimide polymer (PI), a polylactic acid polymer (PLA), a polymethylpentene polymer (PMP), a polyphenylene oxide polymer (PPO), a polyphenyl ether polymer (PPE), a polyphenylene sulfide polymer (PPS), a polyphthalamide polymer (PPA), a polypropylene polymer (PP), a polystyrene polymer (PS), a polysulfone polymer (PSET), a polytrimethylene terephthalate polymer (PTT), a polyurethane polymer (PU, e.g., thermoplastic polyurethane), a polyvinyl acetate polymer (PVA), a polyvinyl chloride polymer (PVC), a polyvinylidene chloride polymer (PVDC), a polyamideimide polymer (PAI), a polyarylate polymer, a

polyoxymethylene polymer (POM), a styrene-acrylonitrile polymer (SAN), a copolymer thereof, or a combination thereof. The plastic can include a polycarbonate.

[0034] The plastic can include any one or more optional components, such as a surfactant, an emulsifier, a dispersant, a polymeric stabilizer, a crosslinking agent, a polymer, a combination of polymers, a catalyst, a rheology modifier, a density modifier, an aziridine stabilizer, a cure modifier, a free radical initiator, a diluent, an acid acceptor, an antioxidant, a heat stabilizer, a flame retardant, a scavenging agent, a foam stabilizer, a solvent, a plasticizer, filler, an inorganic particle, a pigment, a dye, a dessicant, an adhesion promoter, a heat stabilizer, a UV stabilizer, a UV absorber, an antioxidant, a pigment, a polyolefin, a flow control additive, scrim, antistatic additives, antiblock additives, or a combination thereof.

Any one of more materials in this paragraph can independently form any suitable proportion of the plastic, such as 0 wt%, such as about 0.001 wt% to about 50 wt%, or about 0.001 wt% or less, or less than, equal to, or greater than about 0.01 wt%, 0.1, 1, 2, 3, 4, 5, 6, 8, 10, 12,

14, 16, 18, 20, 25, 30, 35, 40, 45, or about 50 wt% or more.

[0035] A filler can be fibrous or particulate. Fillers can be glass fibers, aluminum silicate (mullite), synthetic calcium silicate, zirconium silicate, fused silica, crystalline silica graphite, natural silica sand, or the like; boron powders such as boron-nitride powder, boron- silicate powders, or the like; oxides such as Ti0₂, aluminum oxide, magnesium oxide, zinc oxide, or the like; calcium sulfate (as its anhydride, dehydrate or trihydrate); calcium carbonates such as chalk, limestone, marble, synthetic precipitated calcium carbonates, or the like; talc, including fibrous, modular, needle shaped, lamellar talc, or the like; wollastonite; surface-treated wollastonite; glass spheres such as hollow and solid glass spheres, silicate spheres, cenospheres, aluminosilicate (armospheres), or the like; kaolin, including hard kaolin, soft kaolin, calcined kaolin, kaolin including various coatings known in the art to facilitate compatibility with the polymeric matrix resin, or the like; single crystal fibers or “whiskers” such as silicon carbide, alumina, boron carbide, iron, nickel, copper, or the like; fibers (including continuous and chopped fibers) such as asbestos, carbon fibers; sulfides such as molybdenum sulfide, zinc sulfide, or the like; barium compounds such as barium titanate, barium ferrite, barium sulfate, heavy spar, or the like; metals (e.g., metal mesh, metal plate) and metal oxides such as particulate or fibrous aluminum, bronze, zinc, copper and nickel, or the like; flaked fillers such as glass flakes, flaked silicon carbide, aluminum diboride, aluminum flakes, steel flakes or the like; fibrous fillers, for example short inorganic fibers such as those derived from blends including at least one of aluminum silicates, aluminum oxides, magnesium oxides, and calcium sulfate hemihydrate or the like; natural fillers and reinforcements, such as wood flour obtained by pulverizing wood, fibrous products such as kenaf, cellulose, cotton, sisal, jute, flax, starch, com flour, lignin, ramie, rattan, agave, bamboo, hemp, ground nut shells, com, coconut (coir), rice grain husks or the like; organic fillers such as polytetrafluoroethylene, reinforcing organic fibrous fillers formed from organic polymers capable of forming fibers such as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylene sulfide), polyesters, polyethylene, aromatic polyamides, aromatic polyimides, polyetherimides, polytetrafluoroethylene, acrylic resins, poly(vinyl alcohol) or the like; as well as fillers such as mica, clay, feldspar, flue dust, fillite, quartz, quartzite, perlite, Tripoli, diatomaceous earth, carbon black, or the like, or combinations including at least one of the foregoing fillers. The filler can be coated with a layer of metallic material to facilitate conductivity, or surface treated with silanes, siloxanes, or a combination of silanes and siloxanes to improved adhesion and dispersion with the resin. The filler can be carbon fibers, glass beads, glass flakes, glass fibers, or a combination thereof.

[0036] The edge region fused to the perimeter of the central region can be fused via one or more adhesives. The adhesives can be the only intervening layer between the edge region and the central region, or another stabilizing layer for the adhesives can also be present between the regions (e.g., tape). The adhesive can be in the form of a glue or a tape, and can be applied in any suitable manner (e.g., brushing, spraying, and the like). The adhesive can be any suitable adhesive, such as an acrylic (e.g., acrylic acid, methacrylic acid, esters thereof, polymers and copolymers thereof), alpha-olefins, a silicone, chloroprene/acrylonitrile copolymers, a polyvinyl ether, a synthetic rubber (e.g., po!yisohutylene, polyisoprene, butyl rubber, and the like), a vinyl resin, a polyester, a polyurethane, a polymer or copolymer thereof, or a combination thereof. [0037] The central region can include one metal plate or metal foil, or multiple metal plates or metal foils. The metal plate or metal foil of the central region can include any suitable metal or metal alloy. For example, the metal plate or metal foil can include aluminum, magnesium, zinc, copper, steel, stainless steel, titanium, an alloy thereof, or a combination thereof. The metal plate or metal foil can include aluminum, an alloy thereof, or a combination thereof. The metal plate or metal foil can be substantially flat. The metal plate or metal foil can have a thickness of about 0.0001 mm to about 5 mm, about 0.01 mm to about 2 mm, or about 0.0001 mm or less, or about 0.0005 mm, 0.001, 0.005, 0.01, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, 4, 4.5, or about 5 mm or more. In various

embodiments, the metal plate or metal foil can provide electromagnetic interference shielding, such as when the metal-plastic hybrid structure is used as a cover for a laptop, tablet, or phone.

[0038] In some embodiments, the central region can include the one or more metal foils and can be free of the metal plate. In some embodiments, the central region can include the one or more metal plates and be free of the metal foil. FIG. 2 illustrates a side view of a rectangular central region 200 including metal plate 210, wherein the central region is free of other layers. The central region can include the metal plate, and the central region can be free of other layers, wherein the metal plate and the edge region are flush at the junction between the central region and the edge region on the back side of the central region.

[0039] The central region can include one or more fiber-filled plastic layers, such as short or long fiber- filled plastic layers or continuous fiber-filled plastic layers (e.g., continuous fiber-reinforced plastic). In an example, the central region is one fiber-filled plastic layer on one metal plate. In one example, the central region includes two fiber-filled plastic layers sandwiching the metal plate or metal foil. In another example, the central region includes two metal plates sandwiching the fiber-filled plastic layer. The fibers can provide additional strength, rigidity, decreased thermal expansion, or a combination thereof. The plastic layer can include any suitable plastic, such as any plastic described herein as suitable for the plastic of the edge region. The fiber-filled plastic layer can include any suitable component in addition to the plastic and the fiber, such as any suitable optional component described herein as suitable for inclusion in the plastic of the edge region. [0040] The fibers in the fiber- filled plastic layer can be any suitable fibers. The fibers can be glass fibers (e.g., soda-lime glass, fused silica glass, borosilicate glass, lead-oxide glass, aluminosilicate glass, oxide glass, glass with high zirconia content, or a combination thereof), carbon fibers, or a combination thereof (e.g., both glass and carbon fibers, or glass/carbon hybrid fibers). The fibers can be substantially homogeneously distributed in the fiber-filled plastic layer. The fibers can form any suitable proportion of the fiber-filled plastic layer, such as about 0.001 wt% to about 95 wt% of the fiber- filled plastic layer, about 40 wt% to about 90 wt%, about 60 wt% to about 70 wt%, or about 0.001 wt% or less, or less than, equal to, or greater than about 0.01 wt%, 0.1, 1, 2, 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 20,

25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or about 95 wt% or more. The fibers can have a length of about 0.1 mm to about 5,000 m, 0.1 mm to about 500 mm, about 0.1 mm to about 100 mm, about 0.5 mm to about 50 mm, about 1 mm to about 5 mm, or about 0.1 mm or less, or less than, equal to, or greater than about 0.2 mm, 0.4, 0.6, 0.8, 1, 2, 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 125, 150, 175, 200, 225, 250, 500 mm, 1 m, 2, 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 125, 150, 175, 200, 225, 250, 500, 1,000, 2,500, or about 5,000 m or more. The fibers can have a diameter of about 0.1 microns to about 10 mm in diameter, about 0.001 mm to about 1 mm in diameter, or about 0.1 microns or less, or less than, equal to, or greater than about 1 micron, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 24, 26, 28, 30, 35, 40, 45, 50, 60, 70, 80, 90 microns, 0.1 mm, 0.2, 0.4, 0.6, 0.8, 1, 2, 3, 4, 5, 6, 7, 8, 9 mm, or about 10 mm or more.

[0041] In various embodiments, the central region can be free of layers other than the metal plate or metal foil and the one or more fiber-filled plastic layers. FIG. 3 illustrates a side view of a rectangular central region 300 including a metal plate or metal foil 310 and a fiber-filled plastic layer 320, wherein the central region is free of other layers. The fiber- filled plastic layer can be an outermost layer on the back side of the central region. The fiber- filled plastic layer and the edge region can be flush at the junction between the central region and the edge region on the back side of the central region.

[0042] In some embodiments, the junction between the central region and the edge region can be a one-step junction, wherein the metal plate or metal foil has a perimeter that substantially overlaps and is the same as a perimeter of the fiber-filled plastic layer, such as shown in FIG. 3. Such a junction includes a single step of the edge region overlapping the central region, wherein the step is the change in thickness of the edge region as it changes from not overlapping the central region to overlapping the central region. A one-step junction can also occur with a central region that is a metal plate and that is free of other layers, or with any central region whose layers all have the same perimeter and substantially overlap.

[0043] In some embodiments, the fiber-filled plastic layer can have a perimeter that is larger than and that encompasses a perimeter of the metal plate or metal foil. In areas of the central region that do not include the metal plate or metal foil and that overlap with the edge region, the front side of the fiber-filled plastic layer directly contacts the edge region or contacts the edge region via an adhesive. In some embodiments, the junction between the central region and the edge region can be a multi-step junction, such as a two-step junction, wherein the fiber- filled plastic layer has a perimeter that is larger than and that encompasses a perimeter of the metal plate or metal foil, wherein the overlapping edge region overlaps the area of the central region not including the metal foil or metal plate in a first step, and overlaps the area of the central region including the metal foil or metal plate in a second step (e.g., wherein the overlapping edge region directly contacts or contacts via adhesive the front of the fiber-filled plastic layer in the first step, and directly contacts or contacts via adhesive the front of the metal plate or metal foil of the central region in the second step).

[0044] In some embodiments, the central region can include at least one plastic layer.

The central region can include one of the plastic layers, wherein the plastic layer is the only plastic layer in the central region. The central region can be free of layers other than the metal plate or metal foil and the one or more plastic layers. In one embodiment, the central region includes two plastic layers sandwiching the metal plate or metal foil. In another embodiment, the central region includes two metal plates or metal foils sandwiching the plastic layer. The plastic layer can include any suitable plastic, such as any plastic described herein as suitable for the plastic of the edge region. The plastic layer can include any suitable component in addition to the plastic, such as any suitable optional component described herein as suitable for inclusion in the plastic of the edge region. In some embodiments, the plastic layer can include a filler (e.g., fibers or other fillers); in some embodiments, the plastic layer can be substantially free of filler, such as substantially free of fiber filler. The plastic layer can have a substantially uniform thickness (e.g., exclusive of any structural features). The plastic layer can have a thickness of about 0.0001 mm to about 4 mm, about 0.1 mm to about 2 mm, or about 0.0001 mm or less, or less than, equal to, or greater than about 0.0005, 0.001, 0.005, 0.01, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.2, 2.4, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, or about 4 mm or more.

[0045] The plastic layer can be on the front side or the back side of the central region.

In some embodiments, the plastic layer can be an outermost layer on the back side of the central region, wherein the plastic layer and the edge region are flush at the junction between the central region and the edge region on the back side of the central region. In some embodiments, the plastic layer can be an outermost layer on the front side of the central region.

[0046] In some embodiments, the plastic layer can have a perimeter that substantially overlaps and is the same as a perimeter of the metal plate or metal foil. In such an

embodiment which is free of layers other than the plastic layer and the metal plate or metal foil or with one or more other layers that also have the same perimeter that overlaps the perimeter of the metal plate or metal foil, the junction between the central region and the edge region can be a one-step junction, wherein the step is the change in thickness of the edge region as it changes from not overlapping the central region to overlapping the central region.

[0047] In some embodiments, the metal plate or metal foil of a central region including a plastic layer can have a perimeter that is larger than and that encompasses a perimeter of the plastic layer.

[0048] In some embodiments, the metal plate or metal foil has a perimeter that is smaller than and that is encompassed by a perimeter of the plastic layer. In such an embodiment which is free of layers other than the plastic layer and the metal plate or metal foil or with one or more other layers that have the same perimeter as an overlap with the perimeter of the metal plate, metal foil, or plastic layer, the junction between the central region and the edge region can be a multi-step junction, such as a two-step junction, wherein one step is the change in thickness of the edge region as it changes from not overlapping the central region to overlapping the areas of the central region not including the metal plate or foil, and the second step is the change in thickness of the edge region as it changes from overlapping the areas of the central region not including the metal plate or metal foil to overlapping the areas of the central region that do include the metal plate or metal foil. In areas of the central region not including the metal plate or metal foil and that overlap with the edge region, the front side of the plastic layer can directly contact the edge region or the front side of the plastic layer can contact the edge region via an adhesive. In areas of the central region that do include the metal plate or metal foil and that overlap with the edge region, the front side of the metal plate can directly contact the edge region or the front side of the metal plate can contact the edge region via an adhesive.

[0049] The central region can include one of the plastic layers, wherein the plastic layer is the only plastic layer in the central region. The central region can be free of layers other than the metal plate or metal foil and the one or more plastic layers. The central region can include two of the plastic layers on opposite sides of the metal plate or the metal foil.

The central region can be free of layers other than the two plastic layers and the metal plate or metal foil. FIG. 4 illustrates a central region 400, including plastic layers 410 and 420 that are outermost layers on opposite sides of the metal plate 430, wherein the central region 400 is free of layers other than the two plastic layers 410 and 420 and the metal plate 430. The two plastic layers 410 and 420 on opposite sides of the metal plate 430 have a perimeter that substantially overlaps and is the same as a perimeter of the metal plate 430.

[0050] The two plastic layers on opposite sides of the metal plate can be are outermost layers on the front side and back side of the central region, as in the embodiment shown in FIG. 4. In such an embodiment, the plastic layer that is the outermost layer on the back side of the central region and the edge region can be flush at the junction between the central region and the edge region on the back side of the central region. The two plastic layers on opposite sides of the metal plate can have a perimeter that substantially overlaps and is the same as a perimeter of the metal plate or metal foil, such as in the embodiment shown in FIG. 4.

[0051] In some embodiments, at least one of the two plastic layers on opposite sides of the metal plate or metal foil has a perimeter that is larger than and that encompasses a perimeter of the metal plate or metal foil. The plastic layer on the back side of the metal plate or metal foil can have a perimeter that is larger than and that encompasses a perimeter of the metal plate or metal foil. In areas of the central region not including the metal plate or metal foil and that overlap with the edge region, the front side of the plastic layer on the back side of the central region can directly contact the edge region or the front side of the plastic layer on the back side of the central region contacts the edge region via an adhesive. In areas the central region is fused to the edge region and that include the metal plate or metal foil, the metal plate or metal foil can directly contact the edge region, or the metal plate or metal foil contacts the edge region via an adhesive. [0052] The bonding strength between the central region and the edge region can be any suitable bonding strength. For example, the bonding strength can be about 5 MPa to about 30 MPa, about 10 MPa to about 15 MPa, or about 5 MPa or less, or less than, equal to, or greater than about 6 MPa, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 24, 26, 28, or about 30 MPa or more.

[0053] The metal-plastic hybrid structure can have any suitable elastic modulus. For example, the elastic modulus of the metal-plastic hybrid structure (e.g., the edge region, the central region, or a combination thereof) can be about 20 GPa to about 100 GPa, about 30 GPa to about 80 GPa, or about 20 GPa or less, or less than, equal to, or greater than about 25 MPa, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 82, 84, 86, 88, 90, 95, or about 100 GPa or more.

[0054] FIGS. 5A-B illustrate a metal-plastic hybrid structure 500, with cut-away view

5A and zoomed-in cutaway view 5B (showing region 5B-5B). The metal-plastic hybrid structure 500 includes a substantially rectangular central region 505 including a perimeter 510, a front side 515, and a back side 520 opposite the front side 515, the central region including a metal plate 525 and a fiber-filled plastic layer 528 as the outermost layer on the back side 520 of the central region 505. The central region 505 is free of layers other than the metal plate 525 and the fiber-filled plastic layer 528. The metal plate 525 has a perimeter 506 that substantially overlaps and is the same as a perimeter 507 of the fiber-filled plastic layer 528. The fiber (not shown) includes glass fibers, carbon fibers, or a combination thereof.

The metal-plastic hybrid structure 500 includes a substantially rectangular edge region 530 fused to the perimeter 510 of the central region 505, the edge region 530 including plastic, the edge region including a substantially flat region 535 and a curved region 540. At least part of the flat region 535 of the edge region 530 is fused to the central region 505 and the curved region 540 of the edge region 530 is free of fusion with the central region 505. At the perimeter 510 of the central region 505 the edge region 530 has a greater thickness than the central region 505 and the edge region 530 overlaps at least part of the front side 515 of the central region 505 such that the edge region 530 directly contacts the front side 515 of the metal plate 525 or contacts the metal plate 525 via adhesive (not shown). The edge region 530 and the fiber-filled plastic layer 528 at the back side 520 of the central region 505 are flush at a junction 510 between the central region 505 and the edge region 530 on the back side 520 of the central region 505. FIGS. 5 A and 5B illustrate optional structural feature 545. Metal-plastic hybrid structure 500 has a one-step junction between the edge region 530 and the central region 505.

[0055] FIGS. 6A-B illustrate a metal-plastic hybrid structure 600, with cut-away view

6A and zoomed-in cutaway view 6B (showing region 6B-6B). Metal-plastic hybrid structure 600 includes a substantially rectangular central region 605 including a perimeter 610, a front side 615, and a back side 620 opposite the front side 615, the central region 605 including a metal plate 625 and a fiber-filled plastic layer 630 as the outermost layer on the back side 620 of the central region 605. The central region 605 is free of layers other than the metal plate 625 and the fiber-filled plastic layer 630. The fiber-filled plastic layer 630 has a perimeter 635 that is larger than and that encompasses a perimeter 640 of the metal plate 625. The fiber (not shown) includes glass fibers, carbon fibers, or a combination thereof. The metal-plastic hybrid structure 600 includes a substantially rectangular edge region 645 fused to the perimeter 610 of the central region 605, the edge region 645 including plastic, the edge region 645 including a substantially flat region 650 and a curved region 655. At least part of the flat region 650 of the edge region 645 is fused to the central region 605 and the curved region 655 of the edge region 645 is free of fusion with the central region 605. At the perimeter 610 of the central region 605 the edge region 645 has a greater thickness than the central region 605 and the edge region 645 overlaps at least part of the front side 615 of the central region 605 such that the edge region 645 directly contacts the front side 646 of the fiber-filled plastic layer 630 or contacts the fiber-filled plastic layer 630 via adhesive. In areas of the central region 605 including the metal plate 625 and that overlap with the edge region 645, the front side 660 of the metal plate 625 directly contacts the edge region 645 or the front side 660 of the metal plate 625 contacts the edge region 645 via an adhesive. The edge region 645 and the fiber-filled plastic layer 630 at the back side 620 of the central region 605 are flush at a junction 610 between the central region 605 and the edge region 645 on the back side 620 of the central region 605. FIG. 6A illustrates optional structural feature 665. Metal-plastic hybrid structure 600 has a two-step junction between the edge region 645 and the central region 605.

Electronic device.

[0056] In various embodiments, the present invention provides an electronic device that includes the metal-plastic hybrid structure, such as any embodiment of the metal-plastic hybrid structure described herein. For example, various embodiments include an electronic device that includes a metal-plastic hybrid structure including a central region that includes a metal plate, metal foil, or a combination thereof. The metal-plastic hybrid structure also includes an edge region fused to the perimeter of the central region, the edge region including plastic. The edge region and the central region are flush at a junction between the central region and the edge region on the back side of the central region. The electronic device can be any suitable electronic device, such as a laptop, tablet computer, phone, or a combination thereof.

Method of making the metal-plastic hybrid structure.

[0057] In various embodiments, the present invention provides a method of making the metal-plastic hybrid structure, such as any embodiment of the metal-plastic hybrid structure described herein. The method includes overmolding the edge region on the central region, to provide the metal-plastic hybrid structure, such as a metal-plastic hybrid structure including a central region that includes a metal plate, metal foil, or a combination thereof.

The metal-plastic hybrid structure also includes an edge region fused to the perimeter of the central region, the edge region including plastic. The edge region and the central region are flush at a junction between the central region and the edge region on the back side of the central region.

[0058] The overmolding can include placing the central region in mold. The overmolding can include injecting molten plastic including any other components of the edge region into the mold. The overmolding can include allowing the molten plastic to solidify to form the edge region fused to the central region. The overmolding can include removing the hardened composite from the mold to provide the metal-plastic hybrid structure. In various embodiments, the method can include pre-heating the mold, the central region, or a combination thereof, prior to injecting the molten plastic into the mold. In various embodiments, the method can include cooling the mold after injecting the molten plastic into the mold.

[0059] For embodiments of the metal-plastic hybrid structure including adhesive between the edge region and the central region, the method can include applying adhesive (e.g., brushing or spraying, or via application of tape such as double-sided tape) onto the central region in areas that are to be fused to the edge region prior to placement of the central region in the mold or prior to injection of the molten plastic into the mold. [0060] The method can include cleaning the metal of the central region prior to overmolding the edge region there. Cleaning the metal, such as to remove dust, oil, grease, fingerprints, chemicals, and the like, can enhance the bonding strength of the central region with the edge region. In some embodiments, the metal is already cleaned prior to onset of the method, or the metal is not cleaned.

[0061] In some embodiments, the central region can be formed prior to the onset of the method. In other embodiments, the method includes forming the central region.

[0062] The method can include forming structural features on the edge region, the central region, or a combination thereof. In some embodiments, the structural features are formed after completion of the overmolding (e.g., after cooling and solidification of the overmolded edge region). In other embodiments, the structural features are formed during the overmolding, as features of the mold itself.

Examples

[0063] Various embodiments of the present invention can be better understood by reference to the following Examples which are offered by way of illustration. The present invention is not limited to the Examples given herein.

Example 1. Preparation of Samples 1-4.

[0064] General procedure. A flat aluminum plate having a thickness of 1.5 mm was cut to a desired size of 45 mm x 18 mm. The metal plate was cleaned to remove dust, oil, grease, and fingerprints. Adhesive (an in-mold bonding adhesive, LORD IMB 1010) was sprayed onto one side of the metal plate around the perimeter on sections to be fused to the edge region. The metal plate was placed into a mold cavity. Plastic (LEXAN™ resin EXL 1414, a polycarbonate siloxane copolymer) was overmolded onto the metal plate using a pressure of 800 bar. The composite was allowed to cool, to provide the Sample. The edge region had a thickness of 3 mm.

[0065] For Sample 1, the adhesive was allowed to dry in air.

[0066] For Sample 2, the adhesive was dried in an oven at 60 °C for 5 minutes.

[0067] For Sample 3, an injection molding pressure of 1400 bar was used.

[0068] For Sample 4, the formed Sample was annealed at 100 °C for 2 hours. Example 2. Characterization of Samples 1-4.

[0069] Bonding strength between the central region and the edge region was measured following test method standard ISO 19095-3. Results are shown in FIG. 7. The bonding strength was as high as 14 MPa.

[0070] The terms and expressions that have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the embodiments of the present invention. Thus, it should be understood that although the present invention has been specifically disclosed by specific embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those of ordinary skill in the art, and that such modifications and variations are considered to be within the scope of embodiments of the present invention.

Additional Aspects.

[0071] The following exemplary aspects are provided, the numbering of which is not to be construed as designating levels of importance:

[0072] Aspect 1 provides a metal-plastic hybrid structure comprising: a central region comprising a perimeter, a front side, and a back side opposite the front side, the central region comprising a metal plate, metal foil, or a combination thereof; and an edge region fused to the perimeter of the central region, the edge region comprising plastic; wherein the edge region and the central region are flush at a junction between the central region and the edge region on the back side of the central region.

[0073] Aspect 2 provides the metal-plastic hybrid structure of Aspect 1, wherein the edge region is fused along 100% of the perimeter of the central region. [0074] Aspect 3 provides the metal-plastic hybrid structure of any one of Aspects 1-2, wherein the central region and the edge region are substantially rectangular.

[0075] Aspect 4 provides the metal-plastic hybrid structure of any one of Aspects 1-3, wherein the edge region comprises a substantially flat region and an uneven region.

[0076] Aspect 5 provides the metal-hybrid structure of Aspect 4, wherein the uneven region comprises one or more angled surfaces, a curve, one or more comers, or a combination thereof.

[0077] Aspect 6 provides the metal-hybrid structure of any one of Aspects 4-5, wherein the uneven region comprises a curve.

[0078] Aspect 7 provides the metal-plastic hybrid structure of any one of Aspects 4-6, wherein at least part of the flat region of the edge region is fused to the central region and the uneven region of the edge region is free of fusion with the central region.

[0079] Aspect 8 provides the metal-plastic hybrid structure of any one of Aspects 4-7, wherein the uneven region of the edge region comprises a sloping of the uneven region from a plane parallel to the flat region toward a direction of an outward-pointing normal vector of the front side of the central region.

[0080] Aspect 9 provides the metal-plastic hybrid structure of Aspect 8, wherein the sloping of the curved region occurs along 100% of an outer edge of the edge region.

[0081] Aspect 10 provides the metal-plastic hybrid structure of any one of Aspects 1-

9, wherein at the perimeter of the central region the edge region has a greater thickness than the central region and the edge region overlaps at least part of the front side of the central region.

[0082] Aspect 11 provides the metal-plastic hybrid structure of Aspect 10, wherein at areas of the central region including the metal plate or metal foil and overlapped by the edge region the edge region directly contacts the front side of the metal plate or metal foil, or contacts the front side of the metal plate or metal foil via an adhesive.

[0083] Aspect 12 provides the metal-plastic hybrid structure of any one of Aspects 1-

11, wherein outside the perimeter of the central region the edge region has a uniform thickness. [0084] Aspect 13 provides the metal-plastic hybrid structure of any one of Aspects 1-

12, wherein outside the perimeter of the central region the edge region has a thickness of about 0.1 mm to about 5 mm.

[0085] Aspect 14 provides the metal-plastic hybrid structure of any one of Aspects 1-

13, wherein outside the perimeter of the central region the edge region has a thickness of about 0.5 mm to about 2 mm.

[0086] Aspect 15 provides the metal-plastic hybrid structure of any one of Aspects 1-

14, wherein the central region, the edge region, or a combination thereof, comprises at least one structural feature.

[0087] Aspect 16 provides the metal-plastic hybrid structure of Aspect 15, wherein the structural feature is disposed on the front side of the central region, on a side of the edge region corresponding to the front side of the central region, or a combination thereof.

[0088] Aspect 17 provides the metal-plastic hybrid structure of any one of Aspects

15-16, wherein the at least one structural feature comprises a boss, a snap, a support rib, a gusset, a hook, a mounting bracket, or a combination thereof.

[0089] Aspect 18 provides the metal-plastic hybrid structure of any one of Aspects 1-

17, wherein the plastic is about 50 wt% to about 100 wt% of the edge region.

[0090] Aspect 19 provides the metal-plastic hybrid structure of any one of Aspects 1-

18, wherein the plastic is about 90 wt% to about 100 wt% of the edge region.

[0091] Aspect 20 provides the metal-plastic hybrid structure of any one of Aspects 1-

19, wherein the plastic comprises an acrylonitrile butadiene styrene (ABS) polymer, an acrylic polymer, a celluloid polymer, a cellulose acetate polymer, a cycloolefin copolymer (COC), an ethylene-vinyl acetate (EVA) polymer, an ethylene vinyl alcohol (EVOH) polymer, a fluoroplastic, an ionomer, an acrylic/PVC alloy, a liquid crystal polymer (LCP), a poly acetal polymer (POM or acetal), a poly acrylate polymer, a polymethylmethacrylate polymer (PMMA), a polyacrylonitrile polymer (PAN or acrylonitrile), a polyamide polymer (PA, such as nylon), a polyamide-imide polymer (PAI), a polyaryletherketone polymer (PAEK), a polybutadiene polymer (PBD), a polybutylene polymer (PB), a polybutylene terephthalate polymer (PBT), a polycaprolactone polymer (PCL), a

polychlorotrifluoroethylene polymer (PCTFE), a polytetrafluoroethylene polymer (PTFE), a polyethylene terephthalate polymer (PET), a polycyclohexylene dimethylene terephthalate polymer (PCT), a poly(cyclohexylenedimethylene terephthalate-co-ethylene glycol) (PCTG), a Tritan™ copolyester, a polycarbonate polymer (PC), poly(l,4-cyclohexylidene

cyclohexane- l,4-dicarboxylate) (PCCD), a polyhydroxyalkanoate polymer (PHA), a polyketone polymer (PK), a polyester polymer, a thermoplastic polyester elastomer polymer (TPEE), a polyethylene polymer (PE), a polyetheretherketone polymer (PEEK), a

polyetherketoneketone polymer (PEKK), a polyetherketone polymer (PEK), a polyetherimide polymer (PEI), a polyethersulfone polymer (PES), a polyethylenechlorinate polymer (PEC), a polyimide polymer (PI), a polylactic acid polymer (PLA), a polymethylpentene polymer (PMP), a polyphenylene oxide polymer (PPO), a polyphenyl ether polymer (PPE), a polyphenylene sulfide polymer (PPS), a polyphthalamide polymer (PPA), a polypropylene polymer (PP), a polystyrene polymer (PS), a polysulfone polymer (PSET), a polytrimethylene terephthalate polymer (PTT), a polyurethane polymer (PET), a polyvinyl acetate polymer (PVA), a polyvinyl chloride polymer (PVC), a polyvinylidene chloride polymer (PVDC), a polyamideimide polymer (PAI), a polyarylate polymer, a polyoxymethylene polymer (POM), a styrene-acrylonitrile polymer (SAN), a copolymer thereof, or a combination thereof.

[0092] Aspect 21 provides the metal-plastic hybrid structure of any one of Aspects 1-

20, wherein the plastic comprises a polycarbonate.

[0093] Aspect 22 provides the metal-plastic hybrid structure of any one of Aspects 1-

21, wherein the plastic is injection-molded onto the central region.

[0094] Aspect 23 provides the metal-plastic hybrid structure of any one of Aspects 1-

22, wherein a middle area of the central region is free of the edge region.

[0095] Aspect 24 provides the metal-plastic hybrid structure of any one of Aspects 1-

23, wherein about 50% to about 99.999% of surface area of the front side of the central region is free of the edge region.

[0096] Aspect 25 provides the metal-plastic hybrid structure of any one of Aspects 1-

24, wherein about 80% to about 99% of surface area of the front side of the central region is free of the edge region

[0097] Aspect 26 provides the metal-plastic hybrid structure of any one of Aspects 1-

25, wherein about 0.001% to about 50% of surface area of the front side of the central region is fused to the edge region. [0098] Aspect 27 provides the metal-plastic hybrid structure of any one of Aspects 1-

26, wherein about 1% to about 20% of surface area of the front side of the central region is fused to the edge region.

[0099] Aspect 28 provides the metal-plastic hybrid structure of any one of Aspects 1-

27, wherein the edge region fused to the perimeter of the central region directly contacts the central region.

[00100] Aspect 29 provides the metal-plastic hybrid structure of any one of Aspects 1-

28, wherein the edge region fused to the perimeter of the central region is fused via heat compression lamination, plastic melt injection, or a combination thereof.

[00101] Aspect 30 provides the metal-plastic hybrid structure of any one of Aspects 1-

29, wherein the edge region fused to the perimeter of the central region is fused via one or more adhesives.

[00102] Aspect 31 provides the metal-plastic hybrid structure of Aspect 30, wherein the adhesive comprises a glue, a tape, or a combination thereof.

[00103] Aspect 32 provides the metal-plastic hybrid structure of any one of Aspects 30-31, wherein the adhesive comprises an acrylic, alpha-olefins, a silicone,

chloroprene/acrylonitrile copolymers, a polyvinyl ether, a synthetic rubber, a vinyl resin, a polyester, a polyurethane, a polymer or copolymer thereof, or a combination thereof.

[00104] Aspect 33 provides the metal-plastic hybrid structure of any one of Aspects 1-

32, wherein the central region is substantially flat.

[00105] Aspect 34 provides the metal-plastic hybrid structure of any one of Aspects 1-

33, wherein the metal plate or metal foil comprises aluminum, magnesium, zinc, copper, steel, stainless steel, titanium, an alloy thereof, or a combination thereof.

[00106] Aspect 35 provides the metal-plastic hybrid structure of any one of Aspects 1-

34, wherein the metal plate or metal foil comprises aluminum, an alloy thereof, or a combination thereof.

[00107] Aspect 36 provides the metal-plastic hybrid structure of any one of Aspects 1-

35, wherein the metal plate or metal foil is substantially flat. [00108] Aspect 37 provides the metal-plastic hybrid structure of any one of Aspects 1- 36, wherein the metal plate or metal foil has a thickness of about 0.0001 mm to about 5 mm.

[00109] Aspect 38 provides the metal-plastic hybrid structure of any one of Aspects 1-

37, wherein the metal plate or metal foil has a thickness of about 0.01 mm to about 2 mm.

[00110] Aspect 39 provides the metal-plastic hybrid structure of any one of Aspects 1-

38, wherein the metal plate or metal foil provides electromagnetic interference shielding.

[00111] Aspect 40 provides the metal-plastic hybrid structure of any one of Aspects 1-

39, wherein the central region has a substantially uniform thickness.

[00112] Aspect 41 provides the metal-plastic hybrid structure of any one of Aspects 1- 40, wherein areas of the central region fused to the edge region have a substantially uniform thickness.

[00113] Aspect 42 provides the metal-plastic hybrid structure of any one of Aspects 1- 41, wherein areas of the central region not fused to the edge region have a substantially uniform thickness.

[00114] Aspect 43 provides the metal-plastic hybrid structure of any one of Aspects 1-

42, wherein areas of the central region not fused to the edge region have a thickness of about 0.1 mm to about 5 mm.

[00115] Aspect 44 provides the metal-plastic hybrid structure of any one of Aspects 1-

43, wherein areas of the central region not fused to the edge region have a thickness of about 0.5 mm to about 2 mm.

[00116] Aspect 45 provides the metal-plastic hybrid structure of any one of Aspects 1-

44, wherein the central region comprises the metal foil and is free of the metal plate.

[00117] Aspect 46 provides the metal-plastic hybrid structure of any one of Aspects 1-

45, wherein the central region comprises the metal plate and is free of the metal foil.

[00118] Aspect 47 provides the metal-plastic hybrid structure of any one of Aspects 1-

46, wherein the central region comprises the metal plate, wherein the central region is free of other layers, wherein the metal plate and the edge region are flush at the junction between the central region and the edge region on the back side of the central region. [00119] Aspect 48 provides the metal-plastic hybrid structure of any one of Aspects 1- 47, wherein the central region comprises a fiber-filled plastic layer.

[00120] Aspect 49 provides the metal-plastic hybrid structure of Aspect 48, wherein the fiber comprises glass fibers, carbon fibers, or a combination thereof.

[00121] Aspect 50 provides the metal-plastic hybrid structure of any one of Aspects 48-49, wherein the fibers are about 0.001 wt% to about 95 wt% of the fiber- filled plastic layer.

[00122] Aspect 51 provides the metal-plastic hybrid structure of any one of Aspects 48-50, wherein the fibers are about 60 wt% to about 70 wt% of the fiber-filled plastic layer.

[00123] Aspect 52 provides the metal-plastic hybrid structure of any one of Aspects 48-51, wherein the central region is free of layers other than the metal plate or metal foil and the fiber-filled plastic layer.

[00124] Aspect 53 provides the metal-plastic hybrid structure of any one of Aspects 48-52, wherein the fiber-filled plastic layer is an outermost layer on the back side of the central region, wherein the fiber-filled plastic layer and the edge region are flush at the junction between the central region and the edge region on the back side of the central region.

[00125] Aspect 54 provides the metal-plastic hybrid structure of any one of Aspects 48-53, wherein the metal plate or metal foil has a perimeter that substantially overlaps and is the same as a perimeter of the fiber-filled plastic layer.

[00126] Aspect 55 provides the metal-plastic hybrid structure of any one of Aspects 48-54, wherein the fiber-filled plastic layer has a perimeter that is larger than and that encompasses a perimeter of the metal plate or metal foil.

[00127] Aspect 56 provides the metal-plastic hybrid structure of Aspect 55, wherein in areas of the central region that do not include the metal plate or metal foil and that overlap with the edge region, the front side of the fiber-filled plastic layer directly contacts the edge region or contacts the edge region via an adhesive.

[00128] Aspect 57 provides the metal-plastic hybrid structure of any one of Aspects 1- 56, wherein the central region comprises at least one plastic layer. [00129] Aspect 58 provides the metal-plastic hybrid structure of Aspect 57, wherein the plastic layer has a substantially uniform thickness.

[00130] Aspect 59 provides the metal-plastic hybrid structure of any one of Aspects 57-58, wherein the plastic layer has a thickness of about 0.0001 mm to about 4 mm.

[00131] Aspect 60 provides the metal-plastic hybrid structure of any one of Aspects 57-59, wherein the plastic layer has a thickness of about 0.1 mm to about 2 mm.

[00132] Aspect 61 provides the metal-plastic hybrid structure of any one of Aspects 57-60, wherein the plastic layer in the central region is substantially free of fiber filler.

[00133] Aspect 62 provides the metal-plastic hybrid structure of any one of Aspects 57-61, wherein the plastic layer is an outermost layer on the back side of the central region, wherein the plastic layer and the edge region are flush at the junction between the central region and the edge region on the back side of the central region.

[00134] Aspect 63 provides the metal-plastic hybrid structure of any one of Aspects 57-62, wherein the plastic layer is an outermost layer on the front side of the central region.

[00135] Aspect 64 provides the metal-plastic hybrid structure of any one of Aspects 57-63, wherein the plastic layer has a perimeter that substantially overlaps and is the same as a perimeter of the metal plate or metal foil.

[00136] Aspect 65 provides the metal-plastic hybrid structure of any one of Aspects 57-64, wherein the metal plate or metal foil has a perimeter that is larger than and that encompasses a perimeter of the plastic layer.

[00137] Aspect 66 provides the metal-plastic hybrid structure of Aspect 65, wherein in areas of the central region not including the metal plate or metal foil and that overlap with the edge region, the front side of the plastic layer directly contacts the edge region or the front side of the plastic layer contacts the edge region via an adhesive.

[00138] Aspect 67 provides the metal-plastic hybrid structure of any one of Aspects 57-66, wherein the metal plate or metal foil has a perimeter that is smaller than and that is encompassed by a perimeter of the plastic layer. [00139] Aspect 68 provides the metal-plastic hybrid structure of any one of Aspects 57-67, wherein the central region comprises one of the plastic layers, wherein the plastic layer is the only plastic layer in the central region.

[00140] Aspect 69 provides the metal-plastic hybrid structure of any one of Aspects 57-68, wherein the central region is free of layers other than the metal plate or metal foil and the plastic layer.

[00141] Aspect 70 provides the metal-plastic hybrid structure of any one of Aspects 57-69, wherein in areas the central region is fused to the edge region and that include the metal plate or metal foil, the metal plate or metal foil directly contacts the edge region, or the metal plate or metal foil contacts the edge region via an adhesive.

[00142] Aspect 71 provides the metal-plastic hybrid structure of any one of Aspects 57-70, wherein the central region comprises two of the plastic layers on opposite sides of the metal plate or the metal foil.

[00143] Aspect 72 provides the metal-plastic hybrid structure of Aspect 71, wherein the central region is free of layers other than the two plastic layers and the metal plate or metal foil.

[00144] Aspect 73 provides the metal-plastic hybrid structure of any one of Aspects 71-72, wherein the two plastic layers on opposite sides of the metal plate are outermost layers on the front side and back side of the central region, wherein the plastic layer that is the outermost layer on the back side of the central region and the edge region are flush at the junction between the central region and the edge region on the back side of the central region.

[00145] Aspect 74 provides the metal-plastic hybrid structure of any one of Aspects 71-73, wherein the two plastic layers on opposite sides of the metal plate have a perimeter that substantially overlaps and is the same as a perimeter of the metal plate or metal foil.

[00146] Aspect 75 provides the metal-plastic hybrid structure of any one of Aspects 71-74, wherein at least one of the two plastic layers on opposite sides of the metal plate or metal foil has a perimeter that is larger than and that encompasses a perimeter of the metal plate or metal foil. [00147] Aspect 76 provides the metal-plastic hybrid structure of any one of Aspects 71-75, wherein the plastic layer on the back side of the metal plate or metal foil has a perimeter that is larger than and that encompasses a perimeter of the metal plate or metal foil.

[00148] Aspect 77 provides the metal-plastic hybrid structure of Aspect 76, wherein in areas of the central region not including the metal plate or metal foil and that overlap with the edge region, the front side of the plastic layer on the back side of the central region directly contacts the edge region or the front side of the plastic layer on the back side of the central region contacts the edge region via an adhesive.

[00149] Aspect 78 provides the metal-plastic hybrid structure of any one of Aspects 71-77, wherein in areas the central region is fused to the edge region and that include the metal plate or metal foil, the metal plate or metal foil directly contacts the edge region, or the metal plate or metal foil contacts the edge region via an adhesive.

[00150] Aspect 79 provides the metal-plastic hybrid structure of any one of Aspects 1-

78, wherein a bonding strength between the central region and the edge region is about 5 MPa to about 30 MPa.

[00151] Aspect 80 provides the metal-plastic hybrid structure of any one of Aspects 1-

79, wherein a bonding strength between the central region and the edge region is about 10 MPa to about 15 MPa.

[00152] Aspect 81 provides the metal-plastic hybrid structure of any one of Aspects 1-

80, wherein the metal-plastic hybrid structure has an elastic modulus of about 20 GPa to about 100 GPa.

[00153] Aspect 82 provides the metal-plastic hybrid structure of any one of Aspects 1-

81, wherein the metal-plastic hybrid structure has an elastic modulus of about 30 GPa to about 80 GPa.

[00154] Aspect 83 provides an electronic device comprising the metal-plastic hybrid structure of any one of Aspects 1-82.

[00155] Aspect 84 provides the electronic device of Aspect 83, wherein the electronic device is a laptop, tablet computer, phone, or a combination thereof. [00156] Aspect 85 provides a method of making the metal-plastic hybrid structure of any one of Aspects 1-82, the method comprising: overmolding the edge region on the central region, to provide the metal-plastic hybrid structure of any one of Aspects 1-82.

[00157] Aspect 86 provides the method of Aspect 85, wherein the overmolding comprises injection molding the edge region onto the central region.

[00158] Aspect 87 provides the method of any one of Aspects 85-86, further comprising applying adhesive on the central region prior to overmolding the edge region thereon.

[00159] Aspect 88 provides the method of any one of Aspects 85-87, further comprising cleaning the metal of the central region prior to overmolding the edge region thereon.

[00160] Aspect 89 provides the method of any one of Aspects 85-88, further comprising forming the central region prior to overmolding the edge region thereon.

[00161] Aspect 90 provides the method of any one of Aspects 85-89, wherein the overmolding the edge region on the central region comprises forming structural features on the edge region, the central region, or a combination thereof.

[00162] Aspect 91 provides the method of any one of Aspects 85-90, further comprising, forming structural features on the edge region, the central region, or a combination thereof, after overmolding the edge region on the central region.

[00163] Aspect 92 provides a metal-plastic hybrid structure comprising: a substantially rectangular central region comprising a perimeter, a front side, and a back side opposite the front side, the central region comprising a metal plate and a fiber-filled plastic layer as the outermost layer on the back side of the central region, wherein the central region is free of layers other than the metal plate and the fiber- filled plastic layer, the metal plate has a perimeter that substantially overlaps and is the same as a perimeter of the fiber-filled plastic layer, and the fiber comprises glass fibers, carbon fibers, or a combination thereof; and a substantially rectangular edge region fused to the perimeter of the central region, the edge region comprising plastic, the edge region comprising a substantially flat region and a curved region, wherein at least part of the flat region of the edge region is fused to the central region and the curved region of the edge region is free of fusion with the central region, and at the perimeter of the central region the edge region has a greater thickness than the central region and the edge region overlaps at least part of the front side of the central region such that the edge region directly contacts the front side of the metal plate or contacts the metal plate via adhesive; wherein the edge region and the fiber-filled plastic layer at the back side of the central region are flush at a junction between the central region and the edge region on the back side of the central region.

[00164] Aspect 93 provides a metal-plastic hybrid structure comprising: a substantially rectangular central region comprising a perimeter, a front side, and a back side opposite the front side, the central region comprising a metal plate and a fiber-filled plastic layer as the outermost layer on the back side of the central region, wherein the central region is free of layers other than the metal plate and the fiber- filled plastic layer, the fiber- filled plastic layer has a perimeter that is larger than and that encompasses a perimeter of the metal plate, and the fiber comprises glass fibers, carbon fibers, or a combination thereof; and a substantially rectangular edge region fused to the perimeter of the central region, the edge region comprising plastic, the edge region comprising a substantially flat region and a curved region, wherein at least part of the flat region of the edge region is fused to the central region and the curved region of the edge region is free of fusion with the central region, at the perimeter of the central region the edge region has a greater thickness than the central region and the edge region overlaps at least part of the front side of the central region such that the edge region directly contacts the front side of the fiber-filled plastic layer or contacts the fiber-filled plastic layer via adhesive, and in areas of the central region including the metal plate and that overlap with the edge region, the front side of the metal plate directly contacts the edge region or the front side of the metal plate contacts the edge region via an adhesive; wherein the edge region and the fiber-filled plastic layer at the back side of the central region are flush at a junction between the central region and the edge region on the back side of the central region.

[00165] Aspect 94 provides the metal-plastic hybrid structure of any one or any combination of Aspects 1-93, wherein: the central region is substantially rectangular, the central region comprises the metal plate and a fiber-filled plastic layer as the outermost layer on the back side of the central region, wherein the central region is free of layers other than the metal plate and the fiber-filled plastic layer, the metal plate has a perimeter that substantially overlaps and is the same as a perimeter of the fiber-filled plastic layer, and the fiber comprises glass fibers, carbon fibers, or a combination thereof; and the edge region is substantially rectangular.

[00166] Aspect 95 provides the metal-plastic hybrid structure of any one or any combination of Aspects 1-94, wherein: the central region is substantially rectangular, the central region comprises the metal plate and a fiber-filled plastic layer as the outermost layer on the back side of the central region, wherein the central region is free of layers other than the metal plate and the fiber-filled plastic layer, the fiber- filled plastic layer has a perimeter that is larger than and that encompasses a perimeter of the metal plate, and the fiber comprises glass fibers, carbon fibers, or a combination thereof; and the edge region is substantially rectangular and fused to the perimeter of the central region, the edge region comprising plastic.

[00167] Aspect 96 provides the metal-plastic hybrid structure of any one or any combination of Aspects 1-95, wherein the edge region includes one or more bosses configured for receiving a respective one or more screws.

[00168] Aspect 97 provides the metal-plastic hybrid structure of any one or any combination of Aspects 1-96, wherein the one or more bosses are in the curved region of the edge region.

[00169] Aspect 98 provides the metal-plastic hybrid structure of any one or any combination of Aspects 1-97, wherein the curved region is defined by sloping of the curved region from a plane parallel to the flat region toward a direction of an outward-pointing normal vector of the front side of the central region.

[00170] Aspect 99 provides the metal-plastic hybrid structure of any one or any combination of Aspects 1-98, wherein the edge region is fused to the central region by one or more adhesives.

[00171] Aspect 100 provides the metal-plastic hybrid structure of any one or any combination of Aspects 1-99, wherein the edge region is fused to the central region by tape.

[00172] Aspect 101 provides the metal-plastic hybrid structure of any one or any combination of Aspects 1-100, wherein the edge region is fused to the central region by glue.

[00173] Aspect 102 provides the metal-plastic hybrid structure of any one or any combination of Aspects 1-101, wherein the junction is a one- step junction. [00174] Aspect 103 provides the metal-plastic hybrid structure of any one or any combination of Aspects 1-102, wherein the junction is a multi-step junction.

[00175] Aspect 104 provides the metal-plastic hybrid structure, the electronic device, or method of any one or any combination of Aspects 1-103 optionally configured such that all elements or options recited are available to use or select from.

Claims

CLAIMS We claim:

1. A metal-plastic hybrid structure comprising: a central region comprising a perimeter, a front side, and a back side opposite the front side, the central region comprising a metal plate, metal foil, or a combination thereof; and an edge region fused to the perimeter of the central region, the edge region comprising plastic; wherein the edge region and the central region are flush at a junction between the central region and the edge region on the back side of the central region; wherein the edge region comprises a substantially flat region and a curved region; wherein at least part of the flat region of the edge region is fused to the central region and the curved region of the edge region is free of fusion with the central region; and wherein at the perimeter of the central region the edge region has a greater thickness than the central region and the edge region overlaps at least part of the front side of the central region.

2. The metal-plastic hybrid structure of claim 1, wherein at areas of the central region including the metal plate or metal foil and overlapped by the edge region, the edge region directly contacts the front side of the metal plate or metal foil, or contacts the front side of the metal plate or metal foil via an adhesive.

3. The metal-plastic hybrid structure of either of claims 1 or 2, wherein outside the perimeter of the central region the edge region has a uniform thickness.

4. The metal-plastic hybrid structure of any one of claims 1 to 3, wherein outside the perimeter of the central region the edge region has a thickness of about 0.1 mm to about 5 mm.

5. The metal-plastic hybrid structure of any one of claims 1 to 4, wherein the central region is substantially flat.

6. The metal-plastic hybrid structure of any one of claims 1 to 5, wherein the metal plate or metal foil comprises aluminum, magnesium, zinc, copper, steel, stainless steel, titanium, an alloy thereof, or a combination thereof.

7. The metal-plastic hybrid structure of any one of claims 1 to 6, wherein a bonding strength between the central region and the edge region is about 5 MPa to about 30 MPa.

8. The metal-plastic hybrid structure of any one of claims 1 to 7, wherein the metal- plastic hybrid structure has an elastic modulus of about 20 GPa to about 100 GPa.

9. An electronic device comprising the metal-plastic hybrid structure of any one of claims 1 to 8.

10. A method of making the metal-plastic hybrid structure of any one of claims 1 to 9, the method comprising: overmolding the edge region on the central region, to provide the metal-plastic hybrid structure of any one of claims 1 to 9.

11. The metal-plastic hybrid structure of any one of claims 1 to 10, wherein: the central region is substantially rectangular, the central region comprises the metal plate and a fiber- filled plastic layer as the outermost layer on the back side of the central region, wherein the central region is free of layers other than the metal plate and the fiber- filled plastic layer, the metal plate has a perimeter that substantially overlaps and is the same as a perimeter of the fiber-filled plastic layer, and the fiber comprises glass fibers, carbon fibers, or a combination thereof; and the edge region is substantially rectangular.

12. The metal-plastic hybrid structure of any one of claims 1 to 11, wherein: the central region is substantially rectangular, the central region comprises the metal plate and a fiber- filled plastic layer as the outermost layer on the back side of the central region, wherein the central region is free of layers other than the metal plate and the fiber- filled plastic layer, the fiber- filled plastic layer has a perimeter that is larger than and that encompasses a perimeter of the metal plate, and the fiber comprises glass fibers, carbon fibers, or a combination thereof; and the edge region is substantially rectangular and fused to the perimeter of the central region, the edge region comprising plastic.

13. The metal-plastic hybrid structure of any one of claims 1 to 12, wherein the edge region includes one or more bosses configured for receiving a respective one or more screws.

14. The metal-plastic hybrid structure of any one of claims 1 to 13, wherein the one or more bosses are in the curved region of the edge region.

15. The metal-plastic hybrid structure of any one of claims 1 to 14, wherein the curved region is defined by sloping of the curved region from a plane parallel to the flat region toward a direction of an outward-pointing normal vector of the front side of the central region.

16. The metal-plastic hybrid structure of any one of claims to 15, wherein the edge region is fused to the central region by one or more adhesives.

17. The metal-plastic hybrid structure of any one of claims to 16, wherein the edge region is fused to the central region by tape.

18. The metal-plastic hybrid structure of any one of claims 1 to 17, wherein the edge region is fused to the central region by glue.

19. The metal-plastic hybrid structure of any one of claims 1 to 18, wherein the junction is a one-step junction.

20. The metal-plastic hybrid structure of any one of claims 1 to 19, wherein the junction is a multi-step junction.