MOLDED ARTICLE HAVING ENHANCED AESTHETIC EFFECT AND METHOD AND SYSTEM FOR MAKING THE MOLDED ARTICLE

• US 20140170397A1
• Filed: 09/11/2013
• Published: 06/19/2014
• Est. Priority Date: 08/23/2011
• Status: Active Grant

• Current Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Original Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Inventors: Shen, Qingya, Kong, Xin, Cao, Shipu, An, Narong, Choi, Jong-Min, Pan, Shengping
• Granted Patent: US 9,975,312 B2
• Time in Patent Office: Days
• US Class Current: 428/212
• CPC Class Codes: B29C 45/0001 characterised by the choice of material
• CPC Class Codes: B29C 45/14434 Coating brittle material, e.g. glass B29C45/14377, B29C45/14418 take precedence
• CPC Class Codes: B29C 45/14778 the article consisting of a material with particular properties, e.g. porous, brittle
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: C08K 7/14 Glass
• CPC Class Codes: C08L 67/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds C08L67/06 takes precedence
• CPC Class Codes: C08L 69/00 Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/31507 Of polycarbonate

Abstract

According to an embodiment, a molded article, comprises: an insert comprising metal, glass, and combinations comprising at least one of the foregoing; a composition injection molded in a first shot on at least a portion of the insert forming a part; and a thermoplastic material injection molded on at least a portion of the part in a second shot of a double shot process, wherein the thermoplastic material of the second shot adheres to at least a portion of the composition of the first shot; and the molded article is configured to be attached to an electronic device. The composition comprises: a) an aromatic polycarbonate (PC) and poly(1,4-cyclohexane dimethylene 1,4-cyclohexanedicarboxcylate) (PCCD), the weight ratio of PC to PCCD being in the range of 30 to 90 PC to 70 to 10 PCCD, b) glass fiber greater than or equal to 0.75 mm in length and the quantity of glass fiber from 1 to 50 wt. % of the composition, and c) the refractive index of the polycarbonate and PCCD closely matching the refractive index of the glass fiber and being in the range of from 1.540 to 1.570.

Claims

1. A molded article, comprising:

an insert comprising metal, glass, and combinations comprising at least one of the foregoing;

a composition injection molded in a first shot on at least a portion of the insert forming a part, the composition comprising;

a) an aromatic polycarbonate (PC) and poly(1,4-cyclohexane dimethylene 1,4-cyclohexanedicarboxcylate) (PCCD), the weight ratio of PC to PCCD being in the range of 30 to 90 PC to 70 to 10 PCCD,

b) glass fiber greater than or equal to 0.75 mm in length and the quantity of glass fiber from 1 to 50 wt. % of the composition, and

c) the refractive index of the polycarbonate and PCCD closely matching the refractive index of the glass fiber and being in the range of from 1.540 to 1.570; and

a thermoplastic material injection molded on at least a portion of the part in a second shot of a double shot process, wherein the thermoplastic material of the second shot adheres to at least a portion of the composition of the first shot; and

the molded article is configured to be attached to an electronic device.

2. The molded article of claim 1, wherein the insert has a first coefficient of thermal expansion and the composition of the first shot has a second coefficient of thermal expansion, the first coefficient of thermal expansion and the second coefficient of thermal expansion is being within a range of 5 ppm/°

C. to 80 ppm/°

C. of each other.

3. The molded article of claim 2, comprising a mobile phone frame.

4. A system that facilitates securing one material to another material without cracking, comprising:

an insert comprising glass, metal, and combinations comprising at least one of the foregoing, and having a first coefficient of thermal expansion;

a thermoplastic part comprising a clear high modulus ductility thermoplastic material having a second coefficient of thermal expansion, wherein the thermoplastic part is injection molded to at least a portion of the insert by a first shot of a double shot injection molding process, and the coefficient of thermal expansion of the insert and the thermoplastic part is within a range of 5 ppm/°

C. to 80 ppm/°

C. of each other; and

a structure comprising a thermoplastic material injection molded and adhered to at least a portion of the thermoplastic part by a second shot of the double shot injection molding process.

5. The system of claim 4, wherein the clear high modulus ductility thermoplastic material comprises:

a) an aromatic polycarbonate (PC) and poly(1,4-cyclohexane dimethylene 1,4-cyclohexanedicarboxcylate) (PCCD), the weight ratio of PC to PCCD being in the range of 30 to 90 PC to 70 to 10 PCCD,

b) the glass fiber greater than or equal to 0.75 mm in length and the quantity of glass fiber from 1 to 50 wt. % of the composition,

c) the refractive index of the polycarbonate and PCCD closely matching the refractive index of the glass fiber and being in the range of from 1.540 to 1.570.

6. The system of claim 4, wherein at least a portion of the structure is a different color than the thermoplastic part.

7. A method for making a molded article, comprising:

locating an insert comprising metal, glass, and combinations comprising at least one of the foregoing, in a tooling of a double shot injection molding apparatus;

injection molding, in a first shot on at least a portion of the insert to form a part, a composition comprising;

a) 55 to 95 mass % of an aromatic polycarbonate resin;

b) 45 to 5 mass % of a glass filler having a refractive index, wherein the difference between the refractive index of the aromatic polycarbonate resin and the refractive index of the glass filler is less than or equal to 0.002;

c) 0.05 to 2.0 parts by mass of a silicon compound having a reactive functional group; and

d) 0.03 to 0.4 parts by mass of an organic alkali metal salt compound, an organic alkaline earth metal salt compound, or a combination thereof, with respect to 100 parts by mass total;

by injection molding a thermoplastic material on at least a portion of the part in a second shot, wherein the thermoplastic material of the second shot adheres to at least a portion of the composition of the first shot.

8. A method for making a molded article, comprising:

locating an insert comprising metal, glass, and combinations comprising at least one of the foregoing, in a tooling of a double shot injection molding apparatus;

injection molding, in a first shot on at least a portion of the insert to form a part, a composition comprising at least one of a polycarbonate and a polyester; and

injection molding a thermoplastic material on at least a portion of the part in a second shot, wherein the thermoplastic material of the second shot adheres to at least a portion of the composition of the first shot,

wherein the insert has a first coefficient of thermal expansion and the composition of the first shot has a second coefficient of thermal expansion, the first coefficient of thermal expansion and the second coefficient of thermal expansion being within a range of 5 ppm/°

C. to 80 ppm/°

C. of each other.