Molded article having enhanced aesthetic effect and method and system for making the molded article

• US 8,557,158 B2
• Filed: 08/23/2011
• Issued: 10/15/2013
• Est. Priority Date: 08/23/2011
• Status: Expired due to Fees

• 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
• Primary Examiner(s): HEITBRINK, JILL LYNNE
• Application Number:
  US13/215,461
• Publication Number:
  US 20130052465A1
• Time in Patent Office: 784 Days
• Field of Search: 264/255
• US Class Current: 264/255
• 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, disclosed is a method for making a molded article. The method comprises: locating an insert comprising metal, glass, or combination comprising at least one of the foregoing, in a tooling of a double shot injection molding apparatus; and injection molding, in a first shot on at least a portion of the insert to form a part, a composition. 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. The method further comprises injection molding a thermoplastic material on at least a portion of the part in a second shot. The thermoplastic material of the second shot adheres to at least a portion of the composition of the first shot.

Claims

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

locating an insert comprising metal, glass, or combination 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) 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

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.

2. The method of claim 1, wherein the weight ratio of polycarbonate to PCCD is 60 to 90 PC to 40 to 10 PCCD.

3. The method of claim 2, wherein glass fibers are present from 5 to 30 weight percent.

4. The method of claim 3, wherein the aromatic polycarbonate comprises bisphenol-A-polycarbonate or a polycarbonate of formula

5. The method of claim 1, wherein the insert comprises a glass panel configured for a portable electronic device.

6. The method of claim 5, wherein the portable electronic device comprises at least one of a handheld computer, a mobile phone, a laptop computer, a tablet computer, a notebook, a media player, and a personal digital assistant.

7. The method of claim 6, wherein the portable electronic device is a mobile phone and the glass panel has edges and comprises a glass mobile phone display or glass mobile phone touch panel.

8. The method of claim 7, wherein the glass panel comprises a bezel around the edges of the panel.

9. The method of claim 7, comprising injecting the composition of the first shot around the edges of the glass panel to form the part, which comprises a frame and injecting the thermoplastic material of the second shot on a portion of the frame to form an attachment structure.

10. The method of claim 1, wherein the thermoplastic material of the second shot comprises a glass fiber reinforced thermoplastic material.

11. The method of claim 1, wherein the thermoplastic material of the second shot comprises the same material as the composition of the first shot.

12. The method of claim 1, wherein the molded article is a multi-colored article.

13. The method 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 being within a range of 5 ppm/°

C. to 80 ppm/°

C. of each other.

14. The method of claim 13, wherein the range is 5 ppm/°

C. to 30 ppm/°

C. of each other.

15. The method of claim 1, wherein the insert is a metal sheet.

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

locating an insert comprising metal, glass, and a 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) a copolyestercarbonate and poly(1,4-cyclohexane dimethyl-1,4-cyclohexanedicarboxcylate (PCCD), the weight ration of copolyestercarbonate to PCCD 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 copolyestercarbonate and PCCD closely matching the refractive index of the glass fiber and being in the range of from 1.508 to 1.585; 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.

17. The method of claim 16, wherein the copolyestercarbonate has ester bonds of the residue selected from the group consisting of terephthalic acid, isophthalic acid and mixtures thereof, with 1,3-resorcinol.

18. The method of claim 17, wherein the ester groups are in block form.

19. The method of claim 16, wherein the range is 5 ppm/°

C. to 30 ppm/°

C. of each other.