U.S. patent application number 14/032355 was filed with the patent office on 2014-01-23 for synthetic resin process and article useful for plating applications.
This patent application is currently assigned to SABIC Innovative Plastics IP B.V.. The applicant listed for this patent is Matthew D. Marks, Andrew W. May. Invention is credited to Matthew D. Marks, Andrew W. May.
Application Number | 20140024772 14/032355 |
Document ID | / |
Family ID | 39930726 |
Filed Date | 2014-01-23 |
United States Patent
Application |
20140024772 |
Kind Code |
A1 |
Marks; Matthew D. ; et
al. |
January 23, 2014 |
SYNTHETIC RESIN PROCESS AND ARTICLE USEFUL FOR PLATING
APPLICATIONS
Abstract
A method for processing reinforcing filler-filled synthetic
resins and applications made therefrom wherein the resulting
articles have the ability to be plated to form a structurally
aesthetic product substantially free of visual defects. The process
utilizes an accelerated heat and cool process to form a resin-rich
surface that is substantially free of any reinforcing fillers, such
as fiber strands and/or bundles, on the external surface of the
article. As such, the resulting article is capable of being plated
to form an article that is substantially free of visual defects
caused by these fillers on the surface of the article.
Inventors: |
Marks; Matthew D.;
(Waterford, MI) ; May; Andrew W.; (East Greenbush,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Marks; Matthew D.
May; Andrew W. |
Waterford
East Greenbush |
MI
NY |
US
US |
|
|
Assignee: |
SABIC Innovative Plastics IP
B.V.
Bergen op Zoom
NL
|
Family ID: |
39930726 |
Appl. No.: |
14/032355 |
Filed: |
September 20, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12297512 |
Jan 21, 2009 |
8562894 |
|
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PCT/US2008/075890 |
Sep 10, 2008 |
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14032355 |
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60971080 |
Sep 10, 2007 |
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60971295 |
Sep 11, 2007 |
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Current U.S.
Class: |
524/612 |
Current CPC
Class: |
B29C 45/0005 20130101;
B29C 2045/7393 20130101; B29C 2045/0012 20130101; B29C 2045/7356
20130101; B29C 45/0053 20130101; B29C 45/73 20130101; B29C
2045/0079 20130101; B29C 45/0013 20130101 |
Class at
Publication: |
524/612 |
International
Class: |
B29C 45/00 20060101
B29C045/00 |
Claims
1. A molded article comprising: a thermoplastic resin including a
reinforcement filler; wherein the molded article is capable of
being plated such that at least a portion of surface of the molded
article is substantially free of individual fillers or bundles of
fillers.
2. The molded article of claim 1, wherein the thermoplastic resin
is selected from polyacetals, polyacrylics, polycarbonates,
polystyrenes, polyesters, polyamides, polyamideimides,
polyarylates, polyarylsulfones, polyethersulfones, polyphenylene
sulfides, polyvinyl chlorides, polysulfones, polyimides,
polyetherimides, polytetrafluoroethylenes, polyetherketones,
polyether etherketones, polyether ketone ketones, polybenzoxazoles,
polyoxadiazoles, polybenzothiazinophenothiazines,
polybenzothiazoles, polypyrazinoquinoxalines, polypyromellitimides,
polyquinoxalines, polybenzimidazoles, polyoxindoles,
polyoxoisoindolines, polydioxoisoindolines, polytriazines,
polypyridazines, polypiperazines, polypyridines, polypiperidines,
polytriazoles, polypyrazoles, polypyrrolidines, polycarboranes,
polyoxabicyclononanes, polydibenzofurans, polyphthalides,
polyacetals, polyanhydrides, polyvinyl ethers, polyvinyl
thioethers, polyvinyl alcohols, polyvinyl ketones, polyvinyl
halides, polyvinyl nitriles, polyvinyl esters, polysulfonates,
polysulfides, polythioesters, polysulfones, polysulfonamides,
polyureas, polyphosphazenes, polysilazanes, or a combination
including at least one of the foregoing thermoplastic resins.
3. The molded article of claim 1, wherein the thermoplastic resin
is selected from acrylonitrile-butadiene-styrene (ABS),
polycarbonate, polycarbonate/ABS blend, a
copolycarbonate-polyester, acrylic-styrene-acrylonitrile (ASA),
acrylonitrile-(ethylene-polypropylene diamine modified)-styrene
(AES), phenylene ether resins, glass filled blends of polyphenylene
oxide and polystyrene, blends of polyphenylene ether/polyamide,
blends of polycarbonate/PET/PBT, polybutylene terephthalate and
impact modifier, polyamides, phenylene sulfide resins, polyvinyl
chloride PVC, high impact polystyrene (HIPS), low/high density
polyethylene, polypropylene and thermoplastic olefins (TPO),
polyethylene and fiber composites, polypropylene and fiber
composites, or a combination thereof.
4. The molded article of claim 1, wherein the reinforcing filler is
a fiber and the fiber is selected from glass fiber, ceramic fiber,
carbon fiber, aramid fiber, or a combination including at least one
of the foregoing fibers.
5. The molded article of claim 1, wherein the reinforcing filler is
present in an amount of about 10 wt % to about 30 wt %, based upon
a total weight of the thermoplastic resin with the reinforcing
filler.
6. The molded article of claim 5, wherein the reinforcing filler
comprises glass fiber.
7. The molded article of claim 6, wherein the thermoplastic resin
comprises a polycarbonate/ABS blend.
8. The molded article of claim 1, further comprising chrome
plating.
9. The molded article of claim 1, wherein the thermoplastic resin
comprises a polycarbonate/ABS blend.
10. A molded article comprising: a thermoplastic resin including a
reinforcement filler; wherein the molded article is formed by
injecting a thermoplastic resin having a reinforcing filler into a
mold to contact a mold surface; supplying a heated temperature
control fluid to heat the mold surface to a temperature from 1 to
100.degree. C. above the heat deformation temperature of the
thermoplastic resin at a rate greater than 120.degree. C. per
minute and less than or equal to 500.degree. C. per minute; molding
the thermoplastic resin to form the molded article; and supplying a
cooled temperature control fluid to the mold to cool the molded
article.
11. The molded article of claim 10, wherein the molded article is
capable of being plated such that at least a portion of the surface
of the molded article is substantially free of any reinforcing
fillers.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional of U.S. application
Ser. No. 12/297,512, filed Jan. 21, 2009, which is a 371 filing of
International Application Serial No. PCT/US2008/075890, filed Sep.
10, 2008, which claims priority to U.S. Provisional Application
Ser. No. 60/971,080, filed Sep. 10, 2007, and U.S. Provisional
Application Ser. No. 60/971,295, filed Sep. 11, 2007, all of which
are hereby incorporated by reference in their entirety.
FIELD OF INVENTION
[0002] The present invention relates to synthetic resin processes
and articles made therefrom and, in particular, for synthetic resin
processes and articles made therefrom that have use in plating
applications.
BACKGROUND OF INVENTION
[0003] Many companies are replacing metal parts with alternative
materials that are lighter in weight but that are also capable of
maintaining the structural benefits of metal. Due to the greater
ease in processing plastic material into selected shapes, plastic
materials have increased in popularity in terms of replacing metal
parts. However, in many instances, plastic alone cannot match the
strength properties of metals. As such, reinforced plastics or
plastic composites have been utilized. Specifically, plastic
composites include a reinforcing fiber in a polymer matrix. In many
instances, the reinforcing fiber is glass fiber, although
high-strength fibers such as aramid and carbon have been used in
other applications.
[0004] The use of high glass loadings in thermoplastic materials
tends to increase stiffness (tensile and flexural modulus) and
strength (tensile & flexural strength) of the reinforced
plastic. However, the use of highly glass filled materials has a
negative effect on the surface quality and aesthetics of molded
parts. After molding, the glass fibers on the exterior surface of
the part produce a dull or matted finish and these fibers interfere
with the adhesion of a subsequent painting or plating application
that otherwise would cover the fibers.
[0005] Other types of filled or reinforced plastic materials suffer
from similar problems. Traditional "high modulus" materials contain
glass, or mica, or other fillers that are capable of increasing the
modulus, or stiffness, of the material. Examples include glass
filled PBT, PA, PC/ABS, PP, etc. However, the addition of fillers
also has an adverse effect on the surface quality of the part.
Therefore, these types of materials are molded in low gloss,
textured applications. These parts can also be painted, but a
primer is typically needed to cover the surface imperfections prior
to the top-coat paint layer. As a result, "aesthetic" materials are
typically unfilled, amorphous resins that can be easily
molded-in-color, painted or metal plated. These materials include
unfilled ASA, ABS, PC/ABS, PPO, etc. Again, however, these
materials do not provide the structural strength necessary for many
metal replacement applications.
[0006] Accordingly, it would be beneficial to provide a process for
molding fiber-reinforced thermoplastic resins to produce an article
having a resin-rich surface such that the presence of glass fibers
and/or bundles on the external surface of the article are
substantially eliminated. It would also be beneficial to provide a
process for molding fiber-reinforced thermoplastic resins to
produce an article capable of being plated. It would also be
beneficial to provide an article molded from a fiber-reinforced
thermoplastic resin wherein the resulting article were capable of
being plated with a surface substantially free of visual
defects.
SUMMARY OF THE INVENTION
[0007] The present invention provides a method for processing
reinforcing filler-filled synthetic resins and applications made
therefrom wherein the resulting articles have the ability to be
plated to form a structurally aesthetic product that is
substantially free of visual defects. The process utilizes an
accelerated heat and cool process to form a resin-rich surface that
is substantially free of any reinforcing fillers, such as fiber
strands and/or bundles, on the external surface of the article. As
such, the resulting article is capable of being plated to form an
article that is substantially free of visual defects caused by
these fillers on the surface of the article. The molded article is
beneficially applicable in structural aesthetic applications
wherein the surface quality of the molded article is important.
[0008] Accordingly, in one aspect, the present invention provides a
process for molding an article including the steps of injecting a
thermoplastic resin having a reinforcing filler into a mold to
contact a mold surface, wherein the mold has at least one channel
for receiving a temperature control fluid; supplying a heated
temperature control fluid to rapidly heat the mold surface to a
temperature above the heat deformation temperature of the
thermoplastic resin; molding the thermoplastic resin to form a
molded article; and supplying a cooled temperature control fluid to
the mold to rapidly cool the molded article; wherein the molded
article is capable of being plated such that at least a portion of
surface of the molded article is substantially free of any
reinforcing fillers.
[0009] In another embodiment, a process for molding an article
comprises: injecting a thermoplastic resin having a reinforcing
filler into a mold such that the thermoplastic resin contacts a
mold surface, molding the thermoplastic resin to form a molded
article; and supplying a cooled temperature control fluid to the
mold to cool the molded article. The reinforcing filler is present
in an amount of about 5 wt % to about 70 wt %, based upon a total
weight of the thermoplastic resin with the reinforcing filler. The
mold surface has a temperature greater than a heat deformation
temperature of the thermoplastic, wherein the mold has at least one
channel for receiving a temperature control fluid. The molded
article has a gloss rating of greater than or equal to 40, as
measured with a 60.degree. gloss meter.
[0010] In another aspect, the present invention provides a
thermoplastic resin including a reinforcement filler, wherein the
molded article is capable of being plated such that at least a
portion of surface of the molded article is substantially free of
individual fillers or bundles of fillers.
BRIEF DECRIPTION OF THE DRAWINGS
[0011] The various embodiments of the present invention can be
understood with reference to the following drawings. The components
are not necessarily to scale. Also, in the drawings, like reference
numerals designate corresponding parts throughout the several
views.
[0012] FIG. 1 is a graph showing the temperatures of conventional
molding technologies as compared to the molding temperatures of the
processes of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The present invention is more particularly described in the
following description and examples that are intended to be
illustrative only since numerous modifications and variations
therein will be apparent to those skilled in the art. As used in
the specification and in the claims, the term "comprising" may
include the embodiments "consisting of" and "consisting essentially
of." All ranges disclosed herein are inclusive of the endpoints and
are independently combinable. The endpoints of the ranges and any
values disclosed herein are not limited to the precise range or
value; they are sufficiently imprecise to include values
approximating these ranges and/or values. Reference throughout the
specification to "one embodiment", "another embodiment", "an
embodiment", and so forth, means that a particular element (e.g.,
feature, structure, and/or characteristic) described in connection
with the embodiment is included in at least one embodiment
described herein, and can or can not be present in other
embodiments. In addition, it is to be understood that the described
elements can be combined in any suitable manner in the various
embodiments and are not limited to the specific combination in
which they are discussed.
[0014] As used herein, approximating language may be applied to
modify any quantitative representation that may vary without
resulting in a change in the basic function to which it is related.
Accordingly, a value modified by a term or terms, such as "about"
and "substantially," may not be limited to the precise value
specified, in some cases. In at least some instances, the
approximating language may correspond to the precision of an
instrument for measuring the value.
[0015] It is known that when molding a material for an aesthetic
application, like a metal-plated or high gloss part, that
increasing tool temperature improves the surface quality of the
part. In general, by operating at a slightly higher molding
temperature, a more resin-rich surface (i.e. substantially free of
impurities) helps to reduce molded in stress, provides a resin rich
surface, and allows improved tool surface replication. However,
simply operating at a slightly increased temperature does not
provide a resin-rich surface when the thermoplastic resin includes
a filler, such as a fiber filler.
[0016] Conversely, when a thermoplastic resin is molded by an
injection molding or compression molding, in order to avoid
elongation of time in a molding cycle due to change in temperature
of the mold, molding is carried out at a marginal temperature range
which barely permits the melt to be filled into the mold and the
product taken out from the mold without deformation. As such, the
higher temperatures needed to help provide a resin-rich surface end
up resulting in a longer molding time, thereby increasing the
overall cycle time and reducing the productivity.
[0017] Accordingly, the present invention utilizes a heat and cool
technology whereby the molding process is operated at a higher
molding temperature, and one higher than normally utilized for
filled resins, but that offers reduced cycle times. This is
accomplished by utilizing a heated temperature control fluid to
rapidly (e.g., heat at a rate of 0.1 to 500.degree. C. per minute)
heat the mold followed by the use of a cooled temperature fluid
control fluid to rapidly cool the molded part. As a result, cycle
times are reduced while permitting a resin-rich surface to be
formed that is substantially free of fillers, such as fibers or
fiber bundles, on at least a portion of the exterior surface of the
molded part. Since the presence of impurities on the surface of a
part, such as fibers and fiber bundles, interfere with subsequent
plating processes, the molded articles made by the present
invention are also capable of being plated (e.g., chrome plated).
As used herein, "capable of being plated" refers to a molded part
that is substantially free of any fillers on the portion of the
surface to be plated. A molded part that is capable of being plated
is one that is substantially free of any visual defects on the
plated portion of the molded part. Visual defects include voids and
blisters.
[0018] In addition, when a thermoplastic resin is subjected to
injection molding, if the temperature of the mold is kept at a high
temperature upon filling the melt into the mold, since the fluidity
of the resin is improved, it becomes possible to take an advantage
in forming the product into a thin-walled product as well as in
improving replication property, i.e., how well the shape of the
cavity surface is replicated to the surface of the product. In
addition, a weld line becomes not conspicuous. As such, the
concepts of the present invention can also be utilized to form
thin-walled parts capable of being plated.
[0019] Accordingly, the present invention provides a method for
processing reinforcing filler-filled synthetic resins and
applications made therefrom wherein the resulting articles have the
ability to be plated to form a structurally aesthetic product that
is substantially free of visual defects. The process utilizes an
accelerated heat and cool process to form a resin-rich surface that
is substantially free of any reinforcing fillers, such as fiber
strands and/or bundles, on the portion of the external surface of
the article to be plated. As such, the resulting article is capable
of being plated to form an article that is substantially free of
visual defects, such as voids and blisters, caused by these fillers
on the surface of the article. The molded article is beneficially
applicable in structural aesthetic applications wherein the surface
quality of the molded article is important.
[0020] The present invention utilizes a heat and cool process
technology to help provide a resin-rich surface while also
providing lower cycle times. In this process, the injection mold
(tool) is heated with a heated temperature control fluid, such as
pressurized water, such that the mold temperature is heated to a
temperature well above traditional injection molding temperatures
(and above the HDT of the material). After molding, the tool is
subsequently cooled to provide a resin rich surface on the molded
part.
[0021] Accordingly, in a first aspect, the present invention
provides a method of processing a synthetic resin to form a molded
article capable of being plated. Accordingly, the molded article is
constructed from a thermoplastic resin capable of being injected
molded. In one embodiment, the thermoplastic resin may be selected
from a wide variety of thermoplastic resins, blend of thermoplastic
resins, thermosetting resins, or blends of thermoplastic resins
with thermosetting resins. The thermoplastic resin may also be a
blend of polymers, copolymers, terpolymers, or combinations
including at least one of the foregoing thermoplastic resins.
Examples of the thermoplastic resin include, but are not limited
to, polyacetals, polyacrylics, polycarbonates, polystyrenes,
polyesters, polyamides, polyamideimides, polyarylates,
polyarylsulfones, polyethersulfones, polyphenylene sulfides,
polyvinyl chlorides, polysulfones, polyimides, polyetherimides,
polytetrafluoroethylenes, polyetherketones, polyether etherketones,
polyether ketone ketones, polybenzoxazoles, polyoxadiazoles,
polybenzothiazinophenothiazines, polybenzothiazoles,
polypyrazinoquinoxalines, polypyromellitimides, polyquinoxalines,
polybenzimidazoles, polyoxindoles, polyoxoisoindolines,
polydioxoisoindolines, polytriazines, polypyridazines,
polypiperazines, polypyridines, polypiperidines, polytriazoles,
polypyrazoles, polypyrrolidines, polycarboranes,
polyoxabicyclononanes, polydibenzofurans, polyphthalides,
polyacetals, polyanhydrides, polyvinyl ethers, polyvinyl
thioethers, polyvinyl alcohols, polyvinyl ketones, polyvinyl
halides, polyvinyl nitriles, polyvinyl esters, polysulfonates,
polysulfides, polythioesters, polysulfones, polysulfonamides,
polyureas, polyphosphazenes, polysilazanes, or the like, or a
combination including at least one of the foregoing thermoplastic
resins.
[0022] Specific non-limiting examples of blends of thermoplastic
resins include acrylonitrile-butadiene-styrene/nylon,
polycarbonate/acrylonitrile-butadiene-styrene, polyphenylene
ether/polystyrene, polyphenylene ether/polyamide,
polycarbonate/polyester, polyphenylene ether/polyolefin, and
combinations including at least one of the foregoing blends of
thermoplastic resins.
[0023] Examples of thermosetting resins include polyurethane,
natural rubber, synthetic rubber, epoxy, phenolic, polyesters,
polyamides, silicones, and mixtures including any one of the
foregoing thermosetting resins. Blends of thermoset resins as well
as blends of thermoplastic resins with thermosets can be
utilized.
[0024] Exemplary examples of the thermoplastics resin include
organic polymers that are flexible at temperatures of about
200.degree. C. to about -60.degree. C. Examples of beneficial
thermoplastic resins that may be used in the present invention
include, but are not limited to, acrylonitrile-butadiene-styrene
(ABS), polycarbonate, polycarbonate/ABS blend, a
copolycarbonate-polyester, acrylic-styrene-acrylonitrile (ASA),
acrylonitrile-(ethylene-polypropylene diamine modified)-styrene
(AES), phenylene ether resins, glass filled blends of polyphenylene
oxide and polystyrene, blends of polyphenylene ether/polyamide,
blends of polycarbonate/PET/PBT, polybutylene terephthalate and
impact modifier, polyamides, phenylene sulfide resins, polyvinyl
chloride PVC, high impact polystyrene (HIPS), low/high density
polyethylene, polypropylene and thermoplastic olefins (TPO),
polyethylene and fiber composites, and polypropylene and fiber
composites.
[0025] In addition to the thermoplastic resin, the reinforcing
filler-filled thermoplastic materials used in the present invention
include a plurality of reinforcing fillers, such as fibers fillers.
The concepts of the present invention can be utilized with a
variety of fiber-filled thermoplastic materials, depending on the
selected characteristics of the fiber-filled thermoplastic material
and any article molded from the fiber-filled thermoplastic
material. For example, in one embodiment, the fiber is a glass
fiber used for reinforcement. In an alternative embodiment, the
fiber-filled thermoplastic material includes carbon fibers to
impart improved conductivity to the fiber-filled thermoplastic
materials and any article made therefrom. In another embodiment,
the fiber-filled thermoplastic material may include aramid fibers.
Other fibers that may be used include metal fibers, metal-coated
fibers, organic fibers, ceramic fibers, biocompatible fibers or any
other fiber capable of withstanding the process to impart the
selected characteristic to the molded article. In alternative
embodiments, non-fiber fillers may be used for the reinforcing
fillers, such as glass beads, glass flakes, talc, clay or any other
reinforcement filler. In the various embodiments, the reinforcing
filler can be present in the reinforcing filler-filled
thermoplastic material in an amount of less than or equal to about
70 weight percent (wt %), specifically, about 1 wt % to about 70 wt
%, more specifically, about 5 wt % to about 40 wt %, even more
specifically, about 10 wt % to about 30 wt %, wherein the weight is
based upon a total weight of the reinforcing filler-filled
thermoplastic material.
[0026] In use, the processes of the present invention utilize heat
and cool process technology to heat the tool above the heat
distortion temperature (HDT) of the thermoplastic resin. The
fiber-filled resin is then injected to the mold to form the molded
part. Then, cooling the mold tool cools the molded part. After the
parts have solidified, they are ejected from the tool cavity. The
heating and cooling processes are controlled using a temperature
control fluid. For heating, a heated temperature control fluid is
used. For cooling, a cooled temperature control fluid is utilized.
In one embodiment, the temperature control fluid is pressurized
water, with the temperature of the water being adjusted such that
it helps to rapidly heat or cool the mold. In another embodiment,
the temperature control fluid is unpressurized water, with the
temperature of the water being adjusted such that it helps to
rapidly heat or cool the mold. In other alternative embodiments,
other temperature control fluids may be used including, but not
limited to, steam, oil, or any other non-Freon based temperature
control fluid may be used.
[0027] As may be seen in FIG. 1, the processes of the present
invention operate on a much higher molding temperature as compared
to prior art processes. In the prior art, the molding temperature
is typically less than the HDT of the thermoplastic resin.
Conversely, the methods of the present invention heat the mold
surface to be contacted by the thermoplastic resin to a temperature
above the heat deformation temperature (HDT) of the thermoplastic
resin being molded, e.g., greater than 1.degree. C. above the HDT,
specifically, 1 to 100.degree. C. above the HDT, more specifically,
15 to 100.degree. C. above the HDT, even more specifically, 30 to
100.degree. C. above the HDT, and yet more specifically, 60 to
100.degree. C. above the HDT.
[0028] As a temperature control fluid is used, the mold itself is
designed to be capable of using a temperature control fluid. In one
embodiment, the mold tool includes one or more channels through
which both the heated temperature control fluid and the cooled
temperature control fluid are passed. In an alternative embodiment,
the mold tool includes separate channels, one for the temperature
control fluid and one for the cooled temperature control fluid. The
channels used in the mold tool can be, in one embodiment,
traditional (straight) lines, or they can be, in an alternative
embodiment, conformal (i.e. conforming to the shape of the part),
or they can be flood cooling (where large areas of tool steal are
removed for the water to flow through).
[0029] As mentioned above, in alternative embodiments, several
different types of cooling lines can be used. In one beneficial
embodiment, conformal cooling is utilized since it permits the
rapid heat transfer from the metal used to form the mold tool to
the temperature control fluid lines.
[0030] As discussed, the processes of the present invention help
form molded parts that are capable of being plated. As discussed,
"capable of being plated" refers to a molded part that is
substantially free of any fibers or fiber bundles on the portion of
the surface of the molded part to be plated. As such, the molded
parts of the present invention can be plated such that the
resulting plated part is substantially free of any visual defects,
such as voids and blisters, in the plated portion of the part. The
molded parts capable of being plated may be plated using any known
plating technology capable of applying a metal or metal-containing
coating to a plastic part. Examples of metals that can be plated
include, but are not limited to, cadmium, copper, electrolytic and
electroless nickel, gold, silver, tin, zinc plating, or a
combination including at least one of the foregoing metals.
Examples of plating processes that can be used include, but are not
limited to, electrolytic plating, electroless plating, anodized
plating, physical vapor deposition (PVD) plating, or a combination
including at least one of the foregoing plating processes.
[0031] The concepts of the present invention can be used to form a
variety of structurally aesthetic parts including, but not limited
to, TV bezels, instrument panel center bezels, automotive parts,
such as roof racks, and the like.
[0032] The following examples serve to illustrate the invention but
are not intended to limit the scope of the invention.
EXAMPLES
[0033] In these examples, a polycarbonate/acrylonitrile butadiene
styrene (PC/ABS) resin having 20% glass fiber was molded in an
injection molding high polish tool having a SPI A2 tool surface.
The fiber-filled PC/ABS was molded using a conventional molding
process (the mold temperature was not above the HDT of the PC/ABS)
and was then molded in a process according to the concepts of the
present invention wherein the temperature of the mold was heated to
a temperature above the HDT of the PC/ABS using pressurized heated
water. The mold was cooled also using water as the cooled
temperature control fluid. Gloss measurements were then taken using
a 60.degree. gloss meter, and the results recorded in Table 1
TABLE-US-00001 TABLE 1 60.degree. Gloss readings on PC/ABS resin
molded in a high polish tool (SPI A2 Tool Surface) Conventional
Conventional Heat and Cool Heat and Cool SPI B2 Tool SPI A2 Tool
SPI B2 Tool SPI A2 Tool Sample Surface Surface Surface Surface 1
6.8 21.7 3.8 90.6 2 6.3 20.8 3.4 91.7 3 4.2 11.5 4.0 90.3 4 10.6
16.0 3.5 88.1 5 5.3 17.4 3.3 91.1 Average 6.6 17.5 3.6 90.4
[0034] A2 is a highly polished surface. B2 is a dull, or matte,
finish. Heat and Cool replicates the tool surface very well as can
be seen in the matte finish replication, whereas the parts made
using the polished surface had a much higher gloss rating, thereby
showing the resin-rich surface as well as the substantial reduction
of glass fibers and/or glass bundles on the exterior surface of the
molded parts in either matte or polished parts. The reinforcing
filler-filled articles had a gloss rating of greater than or equal
to 40, specifically, greater than or equal to 60, more
specifically, greater than or equal to 80, and even more
specifically, greater than or equal to 90. As a result, the molded
parts made according to the concepts of the present invention are
capable of being subsequently plated.
[0035] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to make and use the invention. The patentable
scope of the invention is defined by the claims, and may include
other examples that occur to those skilled in the art. Such other
examples are intended to be within the scope of the claims if they
have structural elements that do not differ from the literal
language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages
of the claims All citations referred herein are expressly
incorporated herein by reference.
* * * * *