U.S. patent application number 13/855650 was filed with the patent office on 2013-08-22 for housing for electroni device.
This patent application is currently assigned to FOXCONN TECHNOLOGY CO., LTD.. The applicant listed for this patent is FOXCONN TECHNOLOGY CO., LTD., FU ZHUN PRECISION INDUSTRY (SHEN ZHEN) CO., LTD.. Invention is credited to HAI-LIN CHEN, YING-HAO FENG, JEN-HONG HSU, YONG YANG, JIAN-WEI ZHANG, YU-GUO ZHANG.
Application Number | 20130216852 13/855650 |
Document ID | / |
Family ID | 43030574 |
Filed Date | 2013-08-22 |
United States Patent
Application |
20130216852 |
Kind Code |
A1 |
HSU; JEN-HONG ; et
al. |
August 22, 2013 |
HOUSING FOR ELECTRONI DEVICE
Abstract
A housing for a portable electronic device includes a metallic
base, a chemical plating layer, a primer layer, a color coating
layer, a metallic luster layer, and a transparent protection layer.
The chemical plating layer, the primer layer, the color coating
layer, the metallic luster layer, and the transparent protection
layer are coated on the metallic base in that order. The metallic
luster layer defines a pattern extending through the metallic
luster layer.
Inventors: |
HSU; JEN-HONG; (New Taipei,
TW) ; CHEN; HAI-LIN; (Shenzhen, CN) ; ZHANG;
JIAN-WEI; (Shenzhen, CN) ; YANG; YONG;
(Shenzhen, CN) ; FENG; YING-HAO; (Shenzhen,
CN) ; ZHANG; YU-GUO; (Shenzhen, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
(SHEN ZHEN) CO., LTD.; FU ZHUN PRECISION INDUSTRY
FOXCONN TECHNOLOGY CO., LTD.; |
|
|
US
US |
|
|
Assignee: |
FOXCONN TECHNOLOGY CO.,
LTD.
New Taipei
TW
FU ZHUN PRECISION INDUSTRY (SHEN ZHEN) CO., LTD.
Shenzhen
CN
|
Family ID: |
43030574 |
Appl. No.: |
13/855650 |
Filed: |
April 2, 2013 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12534251 |
Aug 3, 2009 |
8435607 |
|
|
13855650 |
|
|
|
|
Current U.S.
Class: |
428/596 |
Current CPC
Class: |
C09D 163/00 20130101;
H05K 5/04 20130101; Y10T 428/13 20150115; Y10T 428/12361 20150115;
B05D 5/06 20130101; C08L 63/00 20130101; B44C 1/228 20130101; B05D
5/068 20130101; Y10T 428/1352 20150115 |
Class at
Publication: |
428/596 |
International
Class: |
H05K 5/04 20060101
H05K005/04 |
Foreign Application Data
Date |
Code |
Application Number |
May 4, 2009 |
CN |
200910302094.7 |
Claims
1. A housing for a portable electronic device, comprising: a
metallic base; a chemical plating layer, a primer layer, a color
coating layer, a metallic luster layer, and a transparent
protection layer coated on the metallic base in that order; wherein
the metallic luster layer defines a pattern extending through the
metallic luster layer for exposing the color coating layer, the
color coating layer comprises acrylic resin, polyester resin, epoxy
resin, amino resin, acrylate copolymer, propylene glycol methyl
ether acetate, butyl ester, and pigments dispersed therein, the
metallic luster layer comprises acrylic resin, polyester resin,
epoxy resin, amino resin, acrylate copolymer, propylene glycol
methyl ether acetate, butyl ester, pigments and aluminum oxide
powder dispersed therein, the transparent protection layer is
formed on the metallic luster layer for protecting the metallic
luster layer from abrasion.
2. The housing of claim 1, wherein the primer layer comprises a
first connecting layer and a second connecting layer coated
thereon.
3. The housing of claim 2, wherein the first connecting layer
comprises a material selected from the group consisting of
polyester resin, epoxy resin, and combination thereof; and the
first connecting layer also comprises pigments dispersed
therein.
4. The housing of claim 2, wherein the second connecting layer
comprises a material selected from the group consisting of acrylic
resin, polyester resin, epoxy resin, amino resin, acrylate
copolymer, propylene glycol methyl ether acetate, butyl ester, and
any suitable combination thereof; the second connecting layer also
comprises pigments dispersed therein.
5. The housing of claim 1, wherein the pigments and the aluminum
oxide powder are in a nanometer scale.
6. The housing of claim 1, wherein the transparent protection layer
comprises a material selected from the group consisting of acrylic
resin, polyester resin, epoxy resin, amino resin, acrylate
copolymer, propylene glycol methyl ether acetate, butyl ester, and
any suitable combination thereof; the transparent protection layer
also comprises silicon dioxide dispersed therein.
7. The housing of claim 1, wherein the pattern is defined in the
metallic luster layer via laser engraving.
8. The housing of claim 2, wherein the thickness of the first
connecting layer is about 25 .mu.m to about 50 .mu.m, the thickness
of the second connecting layer is about 15 .mu.m to about 20 .mu.m,
the thickness of the color coating layer is about 15 .mu.m to about
80 .mu.m, the thickness of the metallic luster layer is about 2
.mu.m to about 7 .mu.m, and the thickness of the transparent
protection layer is about 20 .mu.m to about 80 .mu.m.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a divisional application of U.S.
patent application Ser. No. 12/534251, filed on Aug. 3, 2009.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure generally relates to housings and,
particularly, to a housing for a portable electronic device and a
method of manufacturing the housing.
[0004] 2. Description of Related Art
[0005] Electronic devices such as notebook computers, MP3 players,
personal digital assistants, and mobile phones are in common use. A
pleasing appearance and finish, such as a metallic finish, are
often important to users.
[0006] Accordingly, textured patterns or stripes are often formed
on the exterior housing of such devices. Hair lines are commonly
formed on metallic housings of materials such as magnesium alloy,
aluminum, and stainless steel. However, such metallic housings are
difficult to manufacture and at a high cost. Plastic housings are
easily manufactured by injection molding and have a low cost, but
lack the appeal of the metallic appearance and texturing which can
be difficult to directly form on the plastic housing.
[0007] Therefore, what is needed, is a housing that overcomes the
limitations described.
BRIEF DESCRIPTION OF THE DRAWING
[0008] The components in the drawing is not necessarily drawn to
scale, the emphasis instead being placed upon clearly illustrating
the principles of the present disclosure.
[0009] FIG. 1 is a cross-section of a portion of an embodiment of a
housing.
[0010] FIG. 2 is a flowchart of an embodiment of a method for
manufacturing the housing in FIG. 1.
DETAILED DESCRIPTION
[0011] Referring to FIG. 1, an embodiment of a housing 10 includes
a metallic base 11, a chemical plating layer 12, a primer layer 13,
a color coating layer 14, a metallic luster layer 15, and a
transparent protection layer 16. The chemical plating layer 12, the
primer layer 13, the color coating layer 14, the metallic luster
layer 15, and the transparent protection layer 16 are coated on the
metallic base 11 in that order. The metallic luster layer 15
defines a pattern 17 extending through the metallic luster layer
15.
[0012] The metallic base 11 may be magnesium alloy, aluminum alloy,
or any other metal.
[0013] The chemical plating layer 12 protects the metallic base 11
from oxidation, and improves coating performance of the metallic
base 11. The chemical plating layer 12 may be mainly phosphate.
[0014] The primer layer 13 further protects the metallic base 11
from oxidation and corrosion. In the illustrated embodiment, the
primer layer 13 includes a first connecting layer 132 adjacent to
the chemical plating layer 12, and a second connecting layer 134
coated on the first connecting layer 132.
[0015] The first connecting layer 132 masks surface defects of the
metallic base 11, and enhances bonding between the chemical plating
layer 12 and the second connecting layer 134. The first connecting
layer 132 includes a material selected from the group consisting of
polyester resin, epoxy resin, and combination thereof, and includes
pigments dispersed therein. (Dear Clifford, I think the amendments
are no new matter, because the first connecting layer, the second
connecting layer and the transparent protection layer are Markush
group described in claims 3, 4, and 8 of original document filed on
Aug. 3, 2009, I have added the features to the specification) The
pigments may be carbon black, exhibiting favorable absorption of
laser energy. The thickness of the first connecting layer 132 may
be about 25 micrometers (.mu.m) to about 50 .mu.m.
[0016] The second connecting layer 134 further masks surface
defects of the metallic base 11. The second connecting layer 134
include a material selected from the group consisting of acrylic
resin, polyester resin, epoxy resin, amino resin, acrylate
copolymer, propylene glycol methyl ether acetate (PMA), butyl
ester, and any suitable combination thereof, and pigments dispersed
therein. The pigments may be carbon black, exhibiting favorable
absorption of laser energy. The thickness of the second connecting
layer 134 may be about 15 .mu.m to about 20 .mu.m.
[0017] The color coating layer 14 normalizes the surface of the
metallic base 11 and provides a background color to the pattern 17.
The color coating layer 14 include acrylic resin, polyester resin,
epoxy resin, amino resin, acrylate copolymer, PMA, butyl ester, and
pigments dispersed therein. The pigments may be any desired color.
The thickness of the color coating layer 14 may be about 15 .mu.m
to about 80 .mu.m.
[0018] The metallic luster layer 15 includes acrylic resin,
polyester resin, epoxy resin, amino resin, acrylate copolymer, PMA,
butyl ester, pigments and aluminum oxide powder dispersed therein.
The pigments and the aluminum oxide powder may be in a nanometer
scale. The aluminum oxide powder provides metallic luster to the
housing 10, and generates a light reflection effect to provide the
pattern 17 with a stereoscopic appearance. The thickness of the
metallic luster layer 15 may be about 2 .mu.m to about 7 .mu.m.
[0019] The pattern 17 is defined in the metallic luster layer 15
via laser engraving. In the illustrated embodiment, the pattern 17
extends through the metallic luster layer 15 to the color coating
layer 14. Thus, the pattern 17 shows the color of the color coating
layer 14. Alternatively, the pattern 17 may extend through the
metallic luster layer 15 and the color coating layer 14 to the
primer layer 13. Thus, the pattern 17 may show the color of the
connecting layer 132 or the color of the second connecting layer
134.
[0020] The transparent protection layer 16 protects the metallic
luster layer 15 and the pattern 17 from abrasion, and improves
glossiness of the housing 10. The transparent protection layer 16
includes a material selected from the group consisting of acrylic
resin, polyester resin, epoxy resin, amino resin, silicon dioxide,
acrylate copolymer, PMA, and butyl ester, and any suitable
combination thereof. Thickness of the transparent protection layer
16 may be about 20 .mu.m to about 80 .mu.m.
[0021] Because the pattern 17 extends through the metallic luster
layer 15 and shows the color of the color coating layer 14, when
viewed from the front, the pattern 17 shows a color different from
the metallic luster layer 15, thus the pattern 17 is conspicuously
defined in the metallic luster layer 15. At the same time, the
metallic luster layer 15 provides metallic luster to the housing
10, and generates a light reflection effect to enable the pattern
17 to exhibit a stereoscopic appearance. When viewed from the side,
the pattern 17 may show changed color, due to the light reflection
of the metallic luster layer 15 and the light refraction of the
transparent protection layer 16.
[0022] In alternative embodiments, if the metallic base 11 has
minimal surface defects, the connecting layer 132 or the second
connecting layer 134 may be omitted.
[0023] Referring to FIG. 2, an embodiment of a method of
manufacturing the housing 10 is also provided.
[0024] The metallic base 11 may be manufactured by casting,
forging, or extrusion molding.
[0025] The metallic base 11 is submerged in a chemical solution,
such as a phosphate solution, forming the chemical plating layer 12
on a surface thereof.
[0026] The primer layer 13 is coated on the chemical plating layer
12. The primer layer 13 includes the first connecting layer 132 and
the second connecting layer 134. A first connecting coating is
coated on the chemical plating layer 12 and dried, thereby forming
the first connecting layer 132. A second connecting coating is then
coated on the first connecting layer 132 and dried, thereby forming
the second connecting layer 134. The first connecting coating
includes a material selected from the group consisting of polyester
resin, epoxy resin, and combination thereof, and includes pigments
dispersed therein. The first connecting coating may be coated on
the chemical plating layer 12 by spray coating. A drying
temperature of the first connecting coating is about 150 degrees
Celsius (.degree. C.) to about 200.degree. C. A drying time of the
first connecting coating is about 10 minutes to about 30 minutes.
The second connecting coating includes a material selected from the
group consisting of acrylic resin, polyester resin, epoxy resin,
amino resin, acrylate copolymer, PMA, butyl ester, and any suitable
combination thereof, and pigments dispersed therein. The second
connecting coating may be coated on the first connecting layer 132
by spray coating. A drying temperature of the second connecting
coating is about 130.degree. C. to about 180.degree. C. A drying
time of the second connecting coating is about 10 minutes to about
30 minutes.
[0027] A color coating is coated on the second connecting layer 134
and dried, thereby forming the color coating layer 14. The color
coating include acrylic resin, polyester resin, epoxy resin, amino
resin, acrylate copolymer, PMA, butyl ester, and pigments dispersed
therein. The color coating may be coated on the second connecting
layer 134 by spray coating. A drying temperature of the color
coating is about 50.degree. C. to about 180.degree. C. A drying
time of the color coating is about 10 minutes to about 30
minutes.
[0028] A metallic luster coating is coated on the color coating
layer 14 and dried, thereby forming the metallic luster layer 15.
The metallic luster coating include acrylic resin, polyester resin,
epoxy resin, amino resin, acrylate copolymer, PMA, butyl ester,
pigments and aluminum oxide powder dispersed therein. The metallic
luster coating may be coated on the color coating layer 14 by spray
coating. A drying temperature of the metallic luster coating is
about 50.degree. C. to about 180.degree. C. A drying time of the
metallic luster coating is about 10 minutes to about 30
minutes.
[0029] The metallic base 11 is received in a laser engraver, and
predetermined regions of the metallic luster layer 15 are engraved.
The materials of the metallic luster layer 15 at the predetermined
regions disintegrate due to the energy of the laser, thus defining
the pattern 17 in the metallic luster layer 15. The power of the
laser is adjusted to enable the pattern 17 to extend through the
metallic luster layer 15.
[0030] A transparent coating is coated on the metallic luster layer
15 and dried, thereby forming the transparent protection layer 16.
The transparent coating include acrylic resin, polyester resin,
epoxy resin, amino resin, silicon dioxide, acrylate copolymer, PMA,
and butyl ester. The transparent coating may be coated on the
metallic luster layer 15 by spray coating. A drying temperature of
the transparent coating is about 50.degree. C. to about 180.degree.
C. A drying time of the transparent coating is about 10 minutes to
about 30 minutes.
[0031] Alternatively, the first connecting layer 132 may be
omitted, and the second connecting layer 134 directly coated on the
chemical plating layer 12, or second connecting layer 134 may be
omitted, and the color coating layer 14 directly coated on the
first connecting layer 132.
[0032] In one embodiment of the method of manufacturing a housing
10, a metallic base 11 is cast of magnesium alloy, and then
submerged in a phosphate solution to form a chemical plating layer
12. A first connecting coating is coated on the chemical plating
layer 12 and dried for about 30 minutes, at about 150.degree. C.,
thus forming a first connecting layer 132 about 50 .mu.m thick. A
color coating is coated on the connecting layer 132 and dried for
about 15 minutes, at about 100.degree. C., thus forming a color
coating layer 14 about 15 .mu.m thick. A metallic luster coating is
coated on the color coating layer 14 and dried for about 30
minutes, at about 50.degree. C., thus forming the metallic luster
layer 15 about 5 .mu.m thick. A laser is irradiated on the
predetermined regions of the metallic luster layer 15, thus
defining a pattern 17 extending through the metallic luster layer
15. Finally, a transparent coating is coated on the metallic luster
layer 15 and dried for about 10 minutes, at about 180.degree. C.,
thus forming a transparent protection layer 16 about 50 .mu.m
thick.
[0033] In another embodiment of the method of manufacturing a
housing 10, a metallic base 11 is forged of aluminum alloy. The
metallic base 11 is then submerged in a phosphate solution to form
a chemical plating layer 12. A second connecting coating is coated
on the chemical plating layer 12 and dried for about 10 minutes, at
about 180.degree. C., thus forming a second connecting layer 134
about 15 .mu.m thick. A color coating is coated on the second
connecting layer 134 and dried for about 30 minutes, at about
50.degree. C., thus forming a color coating layer 14 about 80 .mu.m
thick. A metallic luster coating is coated on the color coating
layer 14 and dried for about 10 minutes, at about 100.degree. C.,
thus forming a metallic luster layer 15 about 7 .mu.m thick. A
laser is irradiated on the predetermined regions of the metallic
luster layer 15, thus defining a pattern 17 extending through the
metallic luster layer 15. Finally, a transparent coating is coated
on the metallic luster layer 15 and dried for about 30 minutes, at
about 50.degree. C., thus forming a transparent protection layer 16
about 80 .mu.m thick.
[0034] In yet another embodiment of the method of manufacturing a
housing 10, a metallic base 11 is cast of magnesium alloy and then
submerged in a phosphate solution to form a chemical plating layer
12. A first connecting coating is coated on the chemical plating
layer 12 and dried for about 10 minutes, at about 200.degree. C.,
thus forming a first connecting layer 132 about 25 .mu.m thick. A
second connecting coating is coated on the first connecting layer
132 and dried for about 30 minutes, at about 130.degree. C., thus
forming a second connecting layer 134 about 20 .mu.m thick. A color
coating is coated on the second connecting layer 134 and dried for
about 10 minutes, at about 180.degree. C., thus forming a color
coating layer 14 about 30 .mu.m thick. A metallic luster coating is
coated on the color coating layer 14 and dried for about 15
minutes, at about 180.degree. C., thus forming a metallic luster
layer 15 about 2 .mu.m thick. A laser is irradiated on the
predetermined regions of the metallic luster layer 15, thus
defining a pattern 17 extending through the metallic luster layer
15. Finally, a transparent coating is coated on the metallic luster
layer 15 and dried for about 15 minutes, at about 100.degree. C.,
thus forming a transparent protection layer 16 about 20 .mu.m
thick.
[0035] It is believed that the present embodiments and their
advantages will be understood from the foregoing description, and
it will be apparent that various changes may be made thereto
without departing from the spirit and scope of the disclosure or
sacrificing all of its material advantages.
* * * * *