Cosmetic anodic oxide coatings
11131036 · 2021-09-28
Assignee
Inventors
- Masashige Tatebe (Kakogawa, JP)
- Jody R. Akana (San Francisco, CA, US)
- Takahiro Oshima (Tokyo, JP)
- Peter N. Russell-Clarke (San Francisco, CA, US)
- Ayumi Hongou (Kyoto, JP)
- Kenji Hara (Nara, JP)
Cpc classification
C25D11/12
CHEMISTRY; METALLURGY
International classification
C25D11/12
CHEMISTRY; METALLURGY
Abstract
The embodiments described herein relate to anodizing and anodized films. The methods described can be used to form opaque and white anodized films on a substrate. In some embodiments, the methods involve forming anodized films having branched pore structures. The branched pore structure provides a light scattering medium for incident visible light, imparting an opaque and white appearance to the anodized film. In some embodiments, the methods involve infusing metal complex ions within pores of an anodized. Once within the pores, the metal complex ions undergo a chemical change forming metal oxide particles. The metal oxide particles provide a light scattering medium for incident visible light, imparting an opaque and white appearance to the anodized film. In some embodiments, aspects of the methods for creating irregular or branched pores and methods for infusing metal complex ions within pores are combined.
Claims
1. A metal part, comprising: an anodic layer defining an external surface and a pore having a pore opening at the external surface, the pore opening having an opening size of between 10 nanometers and 20 nanometers; and titanium oxide particles having a particle size greater than the opening size so that the titanium oxide particles are entrapped within the pore, the titanium oxide particles substantially filling an entire volume of the pore.
2. The metal part of claim 1, wherein the pore is one of multiple pores defined by the anodic layer.
3. The metal part of claim 1, wherein the pore opening is sealed.
4. The metal part of claim 1, further comprising: a metal substrate overlaid by the anodic layer, wherein the metal substrate comprises an aluminum alloy.
5. The metal part of claim 1, wherein the anodic layer has a thickness between 5 micrometers and 30 micrometers.
6. The metal part of claim 1, wherein the metal part comprises an enclosure for an electronic device.
7. The metal part of claim 1, wherein the anodic layer comprises: a barrier layer defining the external surface; and branches in communication with the pore.
8. The metal part of claim 7, wherein the barrier layer has a thickness of less than about 1 micrometer.
9. The metal part of claim 7, wherein the titanium oxide particles are entrapped within the branches.
10. The metal part of claim 7, wherein the metal part has an opaque white appearance.
11. An enclosure for an electronic device, comprising: a metal substrate; an anodic layer overlaying the metal substrate and defining an external surface, the anodic layer defining a pore having an opening at the external surface; and titanium oxide particles entrapped within the pore and filling substantially an entire volume of the pore, the opening size of the pore being less than 20 nanometers and smaller than a size of the titanium oxide particles.
12. The enclosure of claim 11, wherein the metal substrate comprises an aluminum alloy.
13. The enclosure of claim 11, wherein the opening is sealed.
14. The enclosure of claim 11, wherein the anodic layer has a thickness of between 5 micrometers and 30 micrometers.
15. The enclosure of claim 11, wherein the anodic layer comprises: a barrier layer defining the external surface; and a porous layer disposed below the barrier layer.
16. The enclosure of claim 15, wherein the barrier layer has a thickness of less than about 1 micrometer.
17. The enclosure of claim 16, wherein: the barrier layer defines branches in communication with the pore; and the titanium oxide particles are entrapped within the branches.
18. The enclosure of claim 11, wherein the external surface has an opaque white appearance.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The described embodiments may be better understood by reference to the following description and the accompanying drawings. Additionally, advantages of the described embodiments may be better understood by reference to the following description and accompanying drawings.
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DETAILED DESCRIPTION OF SELECTED EMBODIMENTS
(9) The following disclosure describes various embodiments of anodic films and methods for forming anodic films. Certain details are set forth in the following description and Figures to provide a thorough understanding of various embodiments of the present technology. Moreover, various features, structures, and/or characteristics of the present technology can be combined in other suitable structures and environments. In other instances, well-known structures, materials, operations, and/or systems are not shown or described in detail in the following disclosure to avoid unnecessarily obscuring the description of the various embodiments of the technology. Those of ordinary skill in the art will recognize, however, that the present technology can be practiced without one or more of the details set forth herein, or with other structures, methods, components, and so forth.
(10) This application discusses anodic films that are white in appearance and methods for forming such anodic films. In general, white is the color of objects that diffusely reflect nearly all visible wavelengths of light. Methods described herein provide internal surfaces within the anodic film that can diffusely reflect substantially all wavelengths of visible light passing through an external surface of the anodic film, thereby imparting a white appearance to the anodic film. The anodic film can act as a protective layer in that it can provide corrosion resistance and surface hardness for the underlying substrate. The white anodic film is well suited for providing a protective and attractive surface to visible portions of a consumer product. For example, methods described herein can be used for providing protective and cosmetically appealing exterior portions of metal enclosures and casings for electronic devices.
(11) One technique for forming white anodic films involves an optical approach where the porous microstructures of the films are modified to provide a light scattering medium. This technique involves forming branched or irregularly arranged pores within an anodic film. The system of branched pores can scatter or diffuse incident visible light coming from a top surface of the substrate, giving the anodic film white appearance as viewed from the top surface of the substrate.
(12) Another technique involves a chemical approach where metal complexes are infused within the pores of an anodic film. The metal complexes, which are ionic forms of metal oxides, are provided in an electrolytic solution. When a voltage is applied to the electrolytic solution, the metal complexes can be drawn into pores of the anodic film. Once in the pores, the metal complexes can undergo chemical reactions to form metal oxides. In some embodiments, the metal oxides are white in color, thereby imparting a white appearance to the anodic film, which is observable from a top surface of the substrate.
(13) As used herein, the terms anodic film, anodized film, anodic layer, anodized layer, oxide film, and oxide layer are used interchangeably and refer to any appropriate oxide film. The anodic films are formed on metal surfaces of a metal substrate. The metal substrate can include any of a number of suitable metals. In some embodiments, the metal substrate includes pure aluminum or aluminum alloy. In some embodiments, suitable aluminum alloys include 1000, 2000, 5000, 6000, and 7000 series aluminum alloys.
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(15) Forming Branched Pore Structures
(16) One method for providing a white anodic film on a substrate involves forming a branched pore structure within the anodic film.
(17) At
(18) TABLE-US-00001 TABLE 1 Parameter Value range Bath temperature 16 C.-24 C. Voltage (DC) 5 V-30 V Current Density 0.2-3.0 A/dm.sup.2 Duration ≤60 minutes
(19) Since barrier layer 206 is generally non-conductive and dense, the electrolytic process forming branched structures 210 within barrier layer 206 is generally slow compared to forming pores using a typical anodizing process. The current density value during this process is generally low since the electrolytic process is slow. Instead of long parallel pores, such as pores 106 of
(20) When branched structures 210 have completed formation through the thickness of barrier layer 206, the current density reaches what can be referred to as a recovery current value. At that point, the current density rises and the electrolytic process continues to convert metal substrate 202 to a porous anodic oxide.
(21) Pores 214 actually continue or branch out from branched structures 210. That is, the acidic electrolytic solution can travel through to the bottoms of branched structures 210 where pores 214 begin to form. As shown, pores 214 are formed in substantially parallel orientation with respect to each other and are substantially perpendicular with respect to top surface 204, much like standard anodizing processes. Pores 214 have top ends that continue from branched structures 210 and bottom ends adjacent to the surface of underlying metal substrate 202. After porous anodic layer 212 is formed, substrate 202 has protective layer 216 that includes a system of branched structures 210, imparting an opaque and white quality to part 200, and supporting porous anodic layer 212.
(22) In some embodiments, an opaque and white quality can also be imparted to porous anodic layer 212.
(23) TABLE-US-00002 TABLE 2 Parameter Value range Bath temperature 12 C.-30 C. Voltage (DC) 2 V-25 V Duration 0.5 min-16 min
(24) As shown, the shapes of bottom portions 218 of pores 214 have been modified to have bulbous shapes. The average width of bulbous-shaped bottom portions 218 is wider than the average width of remaining portions 220 of pores 214. Bulbous-shaped bottom portions 218 have rounded sidewalls that extend outward with respect to remaining portions 220 of pores 214. Light ray 244 can enter from top surface 204 and reflect off a portion of bulbous-shaped bottom portions 218 at a first angle. Light ray 246 can enter top surface 204 and reflect off a different portion of bulbous-shaped bottom portions 218 at a second angle different from the first angle. In this way, the assembly of bulbous-shaped bottom portions 218 within porous anodic layer 212 can act as a light scattering medium for diffusing incident visible light entering from top surface 204, adding an opaque and white appearance to porous anodic layer 212 and part 200. The amount of opacity of porous anodic layer 212 can depend upon the amount of light that is reflecting off of bulbous-shaped bottom portions 218 rather than penetrating through porous anodic layer 212.
(25) In some embodiments, additional treatments can be applied to porous anodic layer 212.
(26) TABLE-US-00003 TABLE 3 Parameter Value range Bath temperature 30 C.-100 C. pH 1-3 Duration 2 sec-2 min
(27) Portions of irregularly shaped pore walls 232 extend outward with respect to remaining portions 220 of pores 214, creating a surface that incoming light can scatter off of Light ray 248 can enter from top surface 204 and reflect off irregularly shaped pore walls 232 at a first angle. Light ray 250 can enter top surface 204 and reflect off a different portion of irregularly shaped pore walls 232 at a second angle different from the first angle. In this way, the assembly of irregularly shaped pore walls 232 within porous anodic layer 212 can act as a light scattering medium for diffusing incident visible light entering from top surface 204, thereby adding to the opaque and white appearance of porous anodic layer 212 and part 200.
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(29) At 308, the shapes of the bottoms of the pores are optionally modified to have a bulbous shape. The bulbous shape of the pore bottoms within the porous anodic layer can act as a second light scattering medium for adding an opaque and white quality to the substrate. At 310, the pores are optionally widened and the pore walls are optionally roughened. The roughened irregularly shaped walls can increases the amount of light scattered from the porous anodic layer and add to the white color and opacity of the substrate.
(30) Infusing Metal Complexes
(31) Another method for providing a white anodic film on a substrate involves infusing metal complexes within the pores of an anodic film. Standard dyes that are white in color are generally not able to fit within the pores of an anodic film. For example, some white dyes contain titanium dioxide (TiO.sub.2) particles. Titanium dioxide generally forms in particles that have a diameter on the scale of 2 to 3 microns. However, the pores of typical aluminum oxide films typically have diameters on the scale of 10 to 20 nanometers. Methods described herein involve infusing metal complexes into the pores of anodic films, where they undergo chemical reactions to form metal oxide particles once lodged within the pores. In this way, metal oxide particles can be formed within anodic pores that would not otherwise be able to fit within the anodic pores.
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(33) At
(34) At
(35) TABLE-US-00004 TABLE 4 Parameter Value range Bath temperature 10 C.-80 C. pH 1-7 Duration 30 sec-60 min Voltage ≥2 V
(36) At
[TiO(C.sub.2O.sub.4).sub.2].sup.2-+2OH.sup.−.fwdarw.TiO.sub.2.Math.H.sub.2O+2C.sub.2O.sub.4.sup.2-
(37) Thus, once inside pores 414, the titanium oxide (IV) complex can be converted to a titanium oxide compound. Once inside pores 414, particles 434 of the metal oxide compound generally have a size larger than metal complexes 424 and are thereby entrapped within pores 414. In some embodiments, metal oxide particles 434 conform to a shape and size in accordance with pores 414. In embodiments described herein, metal oxide particles 434 are generally white in color in that they substantially diffusely reflect all visible wavelengths of light. For example, light ray 444 can enter from top surface 404 and reflect off a portion of metal oxide particles 434 at a first angle. Light ray 446 can enter top surface 404 and reflect off a different portion of metal oxide particles 434 at a second angle different from the first angle. In this way, the metal oxide particles 434 within porous anodic layer 412 can act as a light scattering medium for diffusing incident visible light entering from top surface 404, giving porous anodic layer 412 and part 400 an opaque and white appearance. The whiteness of porous anodic layer 412 can be controlled by adjusting the amount of metal complexes 424 that are infused within pores 414 and converted to metal oxide particles 434. In general, the more metal oxide particles 434 within pores 414, the more saturated white porous anodic layer 412 and part 400 will appear.
(38) At
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(40) In some embodiments, the aspects of the methods of forming branched pores structures and the methods of infusing metal complexes described above can be combined.
(41) Flowchart 700 indicates an anodizing process for forming an anodized film with branched pores and infused metal complexes, such as shown in
(42) Note that after any of the processes of flowcharts 300, 500, and 700 are complete, the substrates can be further treated with one or more suitable post-anodizing processes. In some embodiments, the porous anodic film is further colored using a dye or electrochemical coloring process. In some embodiments, the surface of the porous anodic film is polished using mechanical methods such as buffing or lapping.
(43) In some embodiments, portions of a part can be masked prior to one or more of the whitening processes described above such that the masked portions of the part are not exposed to the whitening processes. For example, portions of the part can be masked off using a photoresist material. In this way, portions of the part can have a white anodic film and other portions can have a standard translucent anodic film.
(44) The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.