U.S. patent application number 13/268173 was filed with the patent office on 2012-09-27 for coated article and method for manufacturing same.
This patent application is currently assigned to HON HAI PRECISION INDUSTRY CO., LTD.. Invention is credited to HSIN-PEI CHANG, CHENG-SHI CHEN, WEN-RONG CHEN, HUANN-WU CHIANG, CHAO-YONG ZHANG.
Application Number | 20120241324 13/268173 |
Document ID | / |
Family ID | 46856811 |
Filed Date | 2012-09-27 |
United States Patent
Application |
20120241324 |
Kind Code |
A1 |
CHANG; HSIN-PEI ; et
al. |
September 27, 2012 |
COATED ARTICLE AND METHOD FOR MANUFACTURING SAME
Abstract
A coated article includes a substrate including a porous surface
and an anodic oxidation film. The porous surface defines a
plurality of nanopores. The anodic oxidation film is formed on the
substrate covering the porous surface by anodic oxidation process.
The anodic oxidation film has a plurality of bonding protrusions,
and each bonding protrusion is retained in one of the nanopores to
improve a binding force between the substrate and the anodic
oxidation film.
Inventors: |
CHANG; HSIN-PEI; (Tu-Cheng,
TW) ; CHEN; WEN-RONG; (Tu-Cheng, TW) ; CHIANG;
HUANN-WU; (Tu-Cheng, TW) ; CHEN; CHENG-SHI;
(Tu-Cheng, TW) ; ZHANG; CHAO-YONG; (Shenzhen City,
CN) |
Assignee: |
HON HAI PRECISION INDUSTRY CO.,
LTD.
Tu-Cheng
TW
Hong Fu Jin Precision Industry (ShenZhen) Co., Ltd
Shenzhen City
TW
|
Family ID: |
46856811 |
Appl. No.: |
13/268173 |
Filed: |
October 7, 2011 |
Current U.S.
Class: |
205/50 ; 205/199;
205/210; 205/219; 205/324; 205/328; 205/333 |
Current CPC
Class: |
C25D 11/04 20130101;
C23C 28/044 20130101; C25D 11/16 20130101; C25D 11/18 20130101;
C25D 11/243 20130101; C23C 28/042 20130101; C25F 3/04 20130101 |
Class at
Publication: |
205/50 ; 205/333;
205/324; 205/210; 205/219; 205/328; 205/199 |
International
Class: |
C25D 11/02 20060101
C25D011/02; C25D 11/14 20060101 C25D011/14; C25D 11/16 20060101
C25D011/16; C25D 11/08 20060101 C25D011/08; C25D 7/00 20060101
C25D007/00; C25D 11/04 20060101 C25D011/04 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 24, 2011 |
CN |
201110072038.6 |
Claims
1. A coated article, comprising: a substrate including a porous
surface, the porous surface defining a plurality of nanopores; and
an anodic oxidation film formed on the substrate covering the
porous surface by anodic oxidation process; wherein the anodic
oxidation film has a plurality of bonding protrusions, and each
bonding protrusion is retained in a nanopore to improve a binding
force between the substrate and the anodic oxidation film.
2. The coated article as claimed in claim 1, wherein the substrate
is made of aluminum or aluminum alloy.
3. The coated article as claimed in claim 1, wherein the nanopores
are formed by electrochemical etching.
4. The coated article as claimed in claim 1, wherein each nanopore
has a pore opening size between 8 nm and 20 nm in
circumference.
5. The coated article as claimed in claim 1, wherein each nanopore
has a pore opening size between 10 nm and 15 nm in
circumference.
6. The coated article as claimed in claim 1, wherein the anodic
oxidation film has a thickness between about 5 micrometers and
about 20 micrometers.
7. The coated article as claimed in claim 1, further comprising a
color layer formed on the anodic oxidation film opposite to the
substrate.
8. The coated article as claimed in claim 7, wherein the color
layer has a thickness between about 0.5 micrometers and about 2
micrometers.
9. The coated article as claimed in claim 7, wherein the color
layer is one selecting from a group consisting of a titanium
nitride layer, a titanium nitric-oxide layer, a titanium
carbon-nitride layer, a chromium nitride layer and a chromium
carbon-nitride layer.
10. A method for manufacturing a coated article, the method
comprising: providing a substrate, the substrate including a porous
surface, the porous surface defining a plurality of nanopores;
forming an anodic oxidation film on the substrate covering the
porous surface by anodic oxidation process; during forming the
anodic oxidation film, portions of the anodic oxidation film enter
into the nanopores to form a plurality of bonding protrusions, and
each bonding protrusion is retained in one of the nanopores to
improve a binding force between the substrate and the anodic
oxidation film.
11. The method of claim 10, wherein the substrate is made of
aluminum or aluminum alloy.
12. The method of claim 10, wherein before the anodic oxidation
film is deposited on the substrate, the substrate is treated by
alkali treatment.
13. The method of claim 12, wherein during the substrate is treated
by alkali treatment, the substrate is dipped in a solution
including 30-50 g/L of NaOH and 1-2 g/L of sodium gluconate at a
temperature of 40-60.degree. C. for a time of 1-5 minutes.
14. The method of claim 10, wherein the nanopores are defined by
electrochemical etching.
15. The method of claim 14, wherein during electrochemical etching,
the substrate acts as an anode, a platinum plate acts as cathode,
using 20-30 g/L of hydrochloric acid or 250-350 g/L of sulphuric
acid as electrolyte, a constant power applied between the anode and
the cathode have a current density between about 6 A/d m.sup.2 and
about 10 A/d m.sup.2 for about 5 minutes to about 10 minutes to
define the nanopores.
16. The method of claim 10, wherein during anodic oxidation, using
180-220 g/L of sulphuric acid as electrolyte, the electrolyte has a
temperature between 19.degree. C. and 21.degree. C., a constant
power applied to the electrolyte has a current density between
about 1 A/m.sup.2 and about 1.5 A/m.sup.2 for about 20 minutes to
about 40 minutes to form the anodic oxidation film.
17. The method of claim 10, wherein after depositing the anodic
oxidation film, the substrate is dipped in a 5-10 g/L of nickel
acetate solution at a temperature between 90.degree. C. and
100.degree. C. for a time of 10 minutes to 15 minutes, to improve
corrosion resistance of the anodic oxidation film.
18. The method of claim 10, further comprising a step of depositing
a color layer on the anodic oxidation film by vacuum deposition.
Description
BACKGROUND
[0001] 1. Technical Field
[0002] The disclosure generally relates to coated articles and
method for manufacturing the coated articles.
[0003] 2. Description of Related Art
[0004] For improving corrosion resistance of metal, such as
aluminum or aluminum alloy, physical vapor deposition (PVD) can be
used to deposit a coating on a surface of the metal. However,
coatings deposited by PVD typically contain micropores that can
allow penetration of contaminants, such as air and moisture, which
can corrode the metal.
[0005] Therefore, there is room for improvement within the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Many aspects of the embodiments can be better understood
with reference to the following drawings. The components in the
drawings are not necessarily drawn to scale, the emphasis instead
being placed upon clearly illustrating the principles of the
exemplary coated article and method for manufacturing the coated
article. Moreover, in the drawings like reference numerals
designate corresponding parts throughout the several views.
Wherever possible, the same reference numbers are used throughout
the drawings to refer to the same or like elements of an
embodiment.
[0007] FIG. 1 illustrates a cross-sectional view of a substrate of
an embodiment of a coated article, in which a plurality of
nanopores are defined in the substrate.
[0008] FIG. 2 illustrates a cross-sectional view of an embodiment
of a coated article.
DETAILED DESCRIPTION
[0009] Referring to FIGS. 1 and 2, a coated article 100 includes a
substrate 10, an anodic oxidation film 20 deposited on the
substrate 10 and a color layer 30 deposited on the anodic oxidation
film 20. The coated article 100 may be a housing of an electronic
device.
[0010] The substrate 10 may be made of aluminum or aluminum alloy.
The substrate 10 includes a porous surface 12 that defines a
plurality of nanopores 122 made by electrochemical etching. Each
nanopore 122 has a pore opening size between 8 nanometers (nm) and
20 nm in circumference. In this exemplary embodiment, each nanopore
122 has a pore opening size between 10 nm and 15 nm.
[0011] The anodic oxidation film 20 is formed on the substrate 10
covering the porous surface 12 by anodic oxidation process. The
anodic oxidation film 20 has a plurality of bonding protrusions 22,
and each bonding protrusion 22 enters into one of the nanopores 122
so the anodic oxidation film 20 is firmly attached to the substrate
10 by the combination of the bonding protrusions 22 and the
nanopores 122. The anodic oxidation film 20 has a thickness between
about 5 micrometers and about 20 micrometers.
[0012] The color layer 30 is formed on the anodic oxidation film 20
opposite to the substrate 10 by vacuum deposition. The color layer
30 has a thickness between about 0.5 micrometers and about 2
micrometers. The color layer 30 may be a titanium nitride (TiN)
layer, a titanium nitric-oxide (TiNO) layer, a titanium
carbon-nitride (TiCN) layer, a chromium nitride (CrN) layer or a
chromium carbon-nitride (CrCN) layer.
[0013] A method for manufacturing the coated article 100 may
include at least the following steps.
[0014] Providing a substrate 10. The substrate 10 may be made of
aluminum or aluminum alloy.
[0015] Pre-treating the substrate 10 by washing the substrate with
a solution (e.g., deionized water or acetone) in an ultrasonic
cleaner, to remove impurities, such as grease or dirt. The
substrate 10 is dried. The substrate 10 is then treated by alkali
treatment in the following way: dipping the substrate 10 in a
solution including about 30-50 g/L of NaOH and about 1-2 g/L of
sodium gluconate at a temperature of about 40 Celsius degree
(.degree. C.)-60.degree. C. for a time of about 1 minute-5
minutes.
[0016] The substrate 10 is electrochemically etched to form a
porous surface 12 with a plurality of nanopores 122. During
electrochemical etching, the substrate 10 acts as an anode, a
platinum plate acts as cathode, using about 20 g/L-30 g/L of
hydrochloric acid or about 250 g/L-350 g/L of sulphuric acid as
electrolyte. A constant power having a current density between
about 6 A/d m.sup.2 and about 10 A/d m.sup.2 is applied between the
anode and the cathode for about 5 minutes to about 10 minutes to
form the porous surface 12.
[0017] The substrate 10 is treated by anodic oxidation process, to
form an anodic oxidation film 20 on the porous surface 12.
Sulphuric acid having about 180 g/L-220 g/L is used as electrolyte.
The electrolyte has a temperature between about 19.degree. C. and
21.degree. C. A constant power having a current density between
about 1 A/m.sup.2 and about 1.5 A/m.sup.2 is applied to the
electrolyte for about 20 minutes to about 40 minutes to form the
anodic oxidation film 20. During depositing the anodic oxidation
film 20, portions of the anodic oxidation film 20 enter into the
nanopores 122 to form a plurality of bonding protrusions 22.
Additionally, each bonding protrusion 22 is retained in one of the
nanopores 122 to improve a binding force between the substrate 10
and the anodic oxidation film 20.
[0018] The substrate 10 is dipped in an about 5 g/L-10 g/L of
nickel acetate solution at a temperature between 90.degree. C. and
100.degree. C. for a time of 10 minutes to 15 minutes, to seal the
anodic oxidation film 20. Therefore, corrosion resistance of the
anodic oxidation film 20 is improved.
[0019] A color layer 30 is deposited on the anodic oxidation film
20 by vacuum deposition, such as vacuum sputtering or vacuum
evaporation.
[0020] In above exemplary, the substrate 10 defines a plurality of
the nanopores 122, the anodic oxidation film 20 includes a
plurality of the bonding protrusions 22. Each bonding protrusion 22
is retained in one of the nanopores 122 so a binding force between
the substrate 10 and the anodic oxidation film 20 can be improved.
Additionally, the anodic oxidation film 20 can prevent the coated
article from electrochemically etching.
[0021] It is to be understood, however, that even through numerous
characteristics and advantages of the exemplary disclosure have
been set forth in the foregoing description, together with details
of the system and function of the disclosure, the disclosure is
illustrative only, and changes may be made in detail, especially in
matters of shape, size, and arrangement of parts within the
principles of the disclosure to the full extent indicated by the
broad general meaning of the terms in which the appended claims are
expressed.
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