METHOD OF FABRICATING INJECTION-MOLDED PRODUCT

• US 20110250400A1
• Filed: 04/06/2011
• Published: 10/13/2011
• Est. Priority Date: 04/07/2010
• Status: Abandoned Application

• Current Assignee: Samsung Electronics Co. Ltd.
• Original Assignee: Samsung Electronics Co. Ltd.
• Inventors: PARK, Jong-Bae, SEOL, Gi-Won, LEE, Pil-Woo, KIM, Jong-Hwa, KIM, Hak-Ju
• Application Number:
  US13/080,752
• Publication Number:
  US 20110250400A1
• Time in Patent Office: Days
• US Class Current: 428/161
• CPC Class Codes: B29C 2045/0058 removing material
• CPC Class Codes: B29C 2045/0079 applying a coating or covering
• CPC Class Codes: B29C 2791/009 Using laser
• CPC Class Codes: B29C 45/0053 combined with a final operation, e.g. shaping injection-compression moulding B29C45/561
• CPC Class Codes: B29C 59/16 by wave energy or particle radiation , e.g. infrared heating B29C59/007 takes precedence
• CPC Class Codes: Y10T 428/24479 including variation in thickness
• CPC Class Codes: Y10T 428/24521 with component conforming to contour of nonplanar surface
• CPC Class Codes: Y10T 428/24868 Translucent outer layer
• CPC Class Codes: Y10T 428/24917 including metal layer

Abstract

A method of fabricating an injection-molded product includes: manufacturing an injection-molded material using a mold; forming a metal layer on an inner or outer surface of the injection-molded material; and removing a portion of the metal layer using a laser, and forming a pattern. Since the injection-molded product fabricated through the method has pattern with a metallic feeling, it can provide a metallic feeling of a high brightness that cannot be realized by a method such as printing and can provide a cubic feeling due to removal of a metal layer. The method provides portable products such as cases for cosmetic products and portable terminals with various visually appealing feelings, allowing users to express various individual styles or preferences using the portable products.

Claims

1. A method of fabricating an injection-molded product, the method comprising:

manufacturing an injection-molded material using a mold;

forming a metal layer on one of an inner or outer surface of the injection-molded material; and

removing a portion of the metal layer using a laser, and forming a pattern thereon.

2. The method as claimed in claim 1, wherein the pattern formed on the injection molded material is a one of regular or irregular pattern, character shape or logo.

3. The method as claimed in claim 1, wherein the metal layer is formed through a deposition or painting process.

4. The method as claimed in claim 1, wherein the injection-molded product comprises a transparent or semi-transparent material, and the metal layer is formed on the inner surface of the injection-molded material.

5. The method as claimed in claim 4, further comprising:

painting an inner surface of the injection-molded material after removing a portion of the metal layer and forming the pattern on the inner surface of the injection-molded material, and forming a painted layer.

6. The method as claimed in claim 5, wherein a paint used to paint the inner surface of the injection-molded material provides its own opaque color after drying.

7. The method as claimed in claim 4, further comprising:

forming a clear coating layer on the outer surface of the injection-molded material.

8. The method as claimed in claim 7, further comprising:

forming a base coating layer on the outer surface of the injection-molded material prior to forming the clear coating layer.

9. The method as claimed in claim 1, further comprising:

forming a clear coating layer on the outer surface of the injection-molded material, after forming the metal layer on the outer surface of the injection-molded material, removing a portion of the metal layer, and forming the pattern on the outer surface of the injection-molded material.

10. The method as claimed in claim 9, further comprising:

forming a base coating layer on the outer surface of the injection-molded material prior to forming the clear coating layer.

11. The method as claimed in claim 1, wherein the metal layer is formed by depositing tin or aluminum.

12. A product by the process of claim 4.

13. A product by the process of claim 9.

14. A method of fabricating an injection-molded product, the method comprising:

manufacturing an injection-molded material using a mold; and

machining an interior or exterior surface of the injection-molded material using a laser, and forming a pattern on one of the interior or exterior surfaces that is visible from an exterior of the material.

15. The method as claimed in claim 14, further comprising:

machining the outer surface of the injection-molded material using a laser, and forming a clear coating layer on the outer surface of the injection-molded material machined using a laser.

16. The method as claimed in claim 15, further comprising:

forming a base coating layer on the outer surface of the injection-molded material prior to forming the clear coating layer.

17. The method as claimed in claim 14, wherein the injection-molded material comprises a transparent or semi-transparent material and the pattern is formed on the interior surface of the injection-molded material by machining with a laser, and wherein the pattern is visible from an exterior of the material and said pattern comprises at least one of a regular pattern, irregular pattern, character shape or logo.

18. The method as claimed in claim 17, further comprising:

painting the interior surface of the injection-molded material machined using a laser.

19. The method as claimed in claim 17, further comprising:

forming a clear coating layer on the exterior surface of the injection-molded material.

20. The method as claimed in claim 19, further comprising:

forming a base coating layer on the exterior surface of the injection-molded material prior to forming the clear coating layer.

21. A product by the process of claim 17.

22. A product by the process of claim 18.