2-SHOT MOLDED ARTICLE WITH MULTIPLE ELECTRICAL CURRENT PATHWAYS

Abstract

A molded article includes a first plateable region spaced apart from a second plateable region the first plateable region by a barrier of electrically insulating material. Each of the plateable regions include an associated plateable layer of electrically conductive material for being electroplated with a different plateable finish. Several different geometries and configurations of the barrier and/or the plateable regions are provided to prevent migration of plating material from one of the plateable regions acting as bipolar electrode while another one of the plateable regions is being electroplated. A non-plateable insert may be disposed between the plateable regions to prevent migration of plating material from one of the plateable regions onto the other one of the plateable regions. A conducive robber in electrical communication with one of the one of the plateable regions, and which may be removable, may also be used to prevent migration of plating material.

Claims

1. An automotive trim component having multiple surface finishes, comprising: a first portion formed of a thermoplastic resin that is electrically conductive, the first portion formed in an injection molding process and having a first outer surface; a second portion formed of a thermoplastic resin that is electrically conductive, the second portion formed in the injection molding process and having a second outer surface; the first outer surface and the second outer surface together form an exterior surface of the automotive trim component; a barrier formed of a thermoplastic resin disposed between the first portion and the second portion, the barrier formed of an electrically insulating material and configured to electrically isolate the first portion of the trim component from the second portion of the trim component; a first metal layer disposed on the first outer surface, the first metal formed of a electroplated metal to provide a first appearance; a second metal layer disposed on the second outer surface, the second metal formed of a second electroplated metal to provide a second appearance; whereby the barrier prevents any of the first electroplated material or the second electroplated material from migrating from one of the portions when the other one of the portions is being electroplated such that the first appearance and the second appearance are different; and wherein the barrier has a cross-sectional shape as one of a rectangle, a triangle, a trapezoid, a U-shape, a T-shape, or a parallelogram and at least partially extends over the first and second outer surfaces of each of the first and second portions.

2. The molded article of claim 1, wherein the barrier is generally trapezoidal in a cross-section taken through the barrier and each of the first and second portions.

3. The molded article of claim 1, wherein the barrier is U-shaped in a cross-section taken through the barrier and each of the first and second portions.

4. The molded article of claim 1, wherein the barrier is triangular in a cross-section taken through the barrier and each of the first and second portions.

5. The molded article of claim 1, wherein the barrier is rectangular in a cross-section taken through the barrier and each of the first and second portions.

6. The molded article of claim 1, wherein the first and second outer surfaces of each of the plateable portions are parallel and staggered from one another.

7. The molded article of claim 1, wherein the barrier extends outwardly beyond one of the first and second outer surfaces of the plateable portions in a direction transverse to the outer surface of the one of the plateable portions.

8. The molded article of claim 1, further comprising a non-plateable insert disposed between the first and second portions and configured to be removed after the first and second portions are electroplated.

9. The molded article of claim 1, wherein the barrier includes an outer barrier surface that is coplanar with the first and second outer surfaces of each of the first and second portions.

10. An injection molded trim component for a vehicle, comprising: a first plateable portion formed of electrically conductive material, the first plateable portion having a first outer surface; a second plateable portion formed of electrically conductive material, the second plateable portion having a second outer surface; a first metal finish electroplated on the first outer surface; a second metal finish electroplated on the second outer surface; a barrier of electrically insulating material disposed between the first plateable portion and the second plateable portion and configured to prevent any of the first metal finish or the second metal finish from migrating from one of the plateable portions when the other one of the plateable portions is being electroplated; and wherein one of the plateable portions includes an irregular portion adjacent the barrier to prevent the plating material from migrating from one of the plateable portions when the other one of the plateable portions is being electroplated; wherein the first outer surface and the second outer surface form an exterior surface exposed surface of the molded trim components and wherein the first metal finish and the second metal finish provide different appearance to provide the exterior surface with different metal finish appearances.

11. The molded article of claim 10, wherein the barrier defines a cross-sectional shape taken through the barrier and each of the plateable portions, and wherein the cross-sectional shape of the barrier is rectangular, trapezoidal, triangular, parallelogram, U-shaped, or T-shaped.

12. The molded article of claim 10, wherein each of the plateable portions includes an irregular portion adjacent the barrier.

13. The molded article of claim 10, wherein the irregular portion adjacent the barrier includes a notch recessed below the outer surface.

14. The molded article of claim 10, wherein the irregular portion adjacent the barrier includes a ramp portion sloping away from the outer surface and toward the barrier.

15. The molded article of claim 10, wherein the barrier extends outwardly beyond the outer surface of one of the plateable portions in a direction transverse to the outer surface of the one of the plateable portions.

16. The molded article of claim 15, wherein the barrier extends outwardly beyond the outer surfaces of each of the plateable portions in a direction transverse to the outer surface of one of the plateable portions.

17. An injection molded automotive trim component having an exterior surface with a decorative finish, comprising: a first plateable portion of electrically conductive material, the first plateable portion having a first outer surface; a second plateable portion of electrically conductive material, the second plateable portion having a second outer surface; a first metal finish plated on the first outer surface in an electroplating process; a second metal finish plated on the second outer surface in the electroplating process, wherein the second metal finish is different than the first metal finish; a barrier of electrically insulating material disposed between the first plateable portion and the second plateable portion and configured to prevent any metal which makes up the first metal finish or the second metal finish from migrating from one of the plateable portions when the other one of the plateable portions is being electroplated; and a current robber of electrically conductive material in electrical communication with one of the plateable portions and disposed between the plateable portions.

18. The molded article of claim 17, wherein the current robber extends through the barrier.

19. The molded article of claim 17, wherein the current robber is configured to be removed after the plateable portions are electroplated.

20. The molded article of claim 17, wherein the barrier defines a cross-sectional shape taken through the barrier and each of the plateable portions, and wherein the cross-sectional shape of the barrier is rectangular, trapezoidal, triangular, parallelogram, U-shaped, or T-shaped.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Other aspects of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0014] FIG. 1 is a cross-sectional view of a part with two separate plateable regions according to an aspect of the present disclosure;

[0015] FIG. 2 is a schematic side view of a part with two separate plateable regions within an electroplating bath according to an aspect of the present disclosure;

[0016] FIG. 3 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to an aspect of the present disclosure;

[0017] FIG. 4 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to another aspect of the present disclosure;

[0018] FIG. 5 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to still another aspect of the present disclosure;

[0019] FIG. 6 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to a further aspect of the present disclosure;

[0020] FIG. 7 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to yet another aspect of the present disclosure;

[0021] FIG. 8 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to still yet another aspect of the present disclosure;

[0022] FIG. 9 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to yet a further aspect of the present disclosure;

[0023] FIG. 10 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to still yet a further aspect of the present disclosure;

[0024] FIG. 11 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to another aspect of the present disclosure;

[0025] FIG. 12 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to still another aspect of the present disclosure;

[0026] FIG. 13 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to yet another aspect of the present disclosure;

[0027] FIG. 14 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to still yet another aspect of the present disclosure;

[0028] FIG. 15 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to yet a further aspect of the present disclosure;

[0029] FIG. 16 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to still yet a further aspect of the present disclosure; and

[0030] FIG. 17 is a cross-sectional side view of a part with an exemplary insulating barrier between two separate plateable regions according to still yet another aspect of the present disclosure.

DESCRIPTION OF THE DISCLOSURE

[0031] Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a molded article 10 with two separate plateable regions 20, 22 is provided. As shown in FIG. 1, the molded article 10 includes a first plateable region 20 and a second plateable region 22 spaced apart from the first plateable region by a barrier 24 of electrically insulating material. According to an aspect, the first plateable region 20 can include a first plateable layer 26 of electrically conductive material capable of receiving an electroplated metal finish, such as bright chrome, low gloss satin chrome, black chrome, trivalent chrome, or another plateable finish. The second plateable region 22 can include a second plateable layer 28 of electrically conductive material capable of receiving an electroplated metal finish, such as bright chrome, low gloss satin chrome, black chrome, trivalent chrome, or another plateable finish. According to an aspect, the barrier 24 may be formed of a non-conductive resin and functions to electrically isolate the different plateable regions 20, 22, allowing them to be separately plated with different finishes. It will be appreciated that the barrier can take on various forms and can be formed in a variety of different ways. It will also be appreciated that a variety of different metal finishes may be employed.

[0032] With reference to FIGS. 1 and 2 which schematically illustrate the first plateable region 20 of the molded article 10 with two separate plateable regions 20, 22 being electroplated in an electroplating bath 30 in which the molded article 10 is submerged in a plating solution 32. As shown, a cathode connection 34 is electrically connected to the first plateable region 20 to cause positive ions to be deposited thereon to form the first plateable layer 26 from the plating solution 32. An anode 36 is submerged in the plating solution 32 and is energized with a positive voltage relative to the cathode connection 34 for inducing an electrical current therebetween and to provide the positive ions in the plating solution 32. In other words, the first plateable region 20 functions as a cathode and receives the positive ions that are oxidized from the anode 36 by action of the electrical current.

[0033] As also illustrated in the figures, the second plateable region 22 is electrically isolated from each of the cathode connection 34 and the anode 36. However, despite this isolation, the second plateable region 22 may experience a charge separation between a collector end 38 and a discharge end 40 that is adjacent to the first plateable layer 26 such that the second platable region may still have a second plateable layer 28 deposited thereon. Although the second plateable region 22 has no electrical connection to either the first plateable layer 26 or the anode 36, it becomes polarized in solution due to the current taking the path of least resistance. The second plateable region 22 may therefore act as a bipolar electrode. Since the bipolar portion (second plateable layer 28) conducts electricity more readily than the solution, current will prefer to pass through the metal bipolar part rather than the solution. As shown in FIG. 2, the second plateable region 22 can become cathodic near the anode 36 and anodic near the first plateable layer 26, causing it to function as the cathode. Therefore, material may be oxidized from the discharge end 40 of the second plateable layer 28 and migrate to the first plateable region 22, where the material is deposited.

[0034] In other words, when a first plateable layer 26 of a first plateable region 20 of a molded article 10 with two separate and electrically isolated plateable regions 20, 22 is subjected to current, the non-electrified second plateable region 22 will become polarized. The degree of the polarization depends on the spacing between the plateable regions 20, 22 and the shape of the interface therebetween. In practice, when one of the plateable regions 20, 22 becomes a bipolar electrode, it will deplate by losing material into the plating solution 32 and act as an auxiliary electrode. In this scenario, extra plate will deposit in the high current areas nearest the bipolar electrode.

[0035] The issue of deplating one of the plateable regions 20, 22 is a problem since it can create a visible defect. In other words, this effect is detrimental for the first plateable layer 26, in that it may be electroplated with an undesirable type of material from the second plateable layer 28, which may cause an uneven or discolored finish. This is also detrimental for the second plateable layer 28 which may also be unevenly coated as a result of material being oxidized from areas proximate to the first plateable layer 26. The deplating effect can be mitigated by decreasing the voltage, but this has the disadvantage of increasing the plating time. The deplating effect can also be mitigated by increasing the size of the non-conductive barrier 24 which separates the plateable regions 20, 22. However, it may not be aesthetically pleasing to have wide gaps between the different plateable regions 20, 22. According to an aspect, it is possible to structure the plateable/non-plateable resin interface to reduce the current density of the bipolar zone. This has the desired effect of enabling designs where the electrically isolated plateable regions 20, 22 may be closer together which will create a visual look that is more pleasing to the consumer.

[0036] As shown in the exemplary aspects of FIGS. 3-17, the barrier 24 and/or the plateable layers 26, 28 may be provided in various different arrangements configured to reduce high current density (HCD) edges of either of the plateable regions 20, 22 and to prevent migration of plating material from one of the plateable regions 20, 22 while a plateable layer 26, 28 on another one of the plateable regions 20, 22 is being electroplated. The provided arrangements are also intended to minimize the visible size of the barrier 24, allowing the plateable regions 20, 22 to appear in close proximity to one another. It will be appreciated that the sequence in which the various plateable surfaces may be plated may vary. For example, according to one aspect, the first plateable region may be plated before the second plateable region. According to another aspect, the second plateable region may be plated before the first plateable region. More specifically, for parts that are non-symmetrical, the sequence in which the surfaces is plated is not critical.

[0037] According to an aspect, the geometry of the barrier 24 may be configured to prevent the plating material from migrating from one of the plateable portions 26, 28 when the other one of the plateable portions 26, 28 is being electroplated. For example, the barrier 24 may be generally trapezoidal in cross-section taken through the barrier 24 and each of the plateable portions 26, 28 as shown in FIG. 3. As another example, the barrier 24 may be U-shaped in a cross-section taken through the barrier 24 and each of the plateable portions 26, 28 as shown in FIGS. 4 and 5. According to this aspect, the U-shaped barrier 24 can define a central groove 25, which may help with mold shutoff. The barrier 24 may have a rectangular cross-section as shown in FIG. 6. The barrier 24 may be triangular in a cross-section taken through the barrier 24 and each of the plateable portions 26, 28 as shown in FIG. 10. The barrier 24 may be T-shaped in cross-section, as shown in the example of FIG. 14. More specifically, the barrier 24 may be configured such that arms of the barrier extend over each of the plateable portions 26, 28. It will be appreciated that other configurations and geometries of the barrier 24 may be employed and are within the scope of the present disclosure, and the above are just a few illustrative examples. For example, the barrier may take on the shape of a parallelogram or the outer surface of the barrier may have a variety of different geometries, including curved or arced.

[0038] According to an aspect, one or both of the plateable portions 26, 28 includes an outer surface 42 that functions as a class-A surface, which may be directly visible to and/or touched by a user. It may be critical to provide the class-A surfaces, such as the outer surfaces 42 of either or both of the plateable portions 26, 28, with even plated finishes. On the other hand, other surfaces, such as rear surfaces opposite the outer surfaces 42 of either or both of the plateable portions 26, 28, which may be hidden from view in a finished product, may be less critical to be evenly and cleanly plated. Thus, in some aspects, the barrier 24 and/or the outer surfaces 42 of either or both of the plateable portions 26, 28 may be configured to optimize the finishes on the class-A surfaces.

[0039] According to an aspect, the barrier 24 may include an outer barrier surface 48 that is non-coplanar with the outer surface 42 of one or both of the plateable portions 26, 28 at a location immediately adjacent to the barrier 24. According to other aspects, the outer barrier surface 48 may be recessed below the outer surface 42 of one or both of the plateable portions 26, 28. In some embodiments, the outer barrier surface 48 may extend outwardly above the outer surface 42 of one or both of the plateable portions 26, 28. For example, one or more of the plateable portions 26, 28 may include an irregular portion 44, 46 adjacent the barrier 24 and which is different than other parts of the associated one of the plateable portions 26, 28. The irregular portion 44, 46 may include, for example, a notch 44, a ramp portion 46, or a different finish or texture adjacent the barrier 24 to prevent the plating material from migrating from one of the plateable portions 26, 28 when the other one of the plateable portions 26, 28 is being electroplated.

[0040] For example, as shown in FIG. 12, the first plateable portion 26 may include an outer surface 42, which defines a notch 44 having a generally rectangular profile adjacent the barrier 24 and recessed below the outer surface 42. The notch 44 may have other profile shapes, such as a trapezoidal or triangular shape. According to some aspects, and as shown in FIG. 6, each of the plateable portions 26, 28 can include an outer surface 42 defining a notch 44 having a generally rectangular profile adjacent the barrier 24 and recessed below the outer surface 42. Additionally, and as shown in FIGS. 6 and 12, the outer barrier surface 48 may be coplanar with the outer surface 42 of one or both of the plateable portions 26, 28, except for a location immediately adjacent to the barrier 24, where an irregular portion 44, 46 of one or both of the plateable portions 26, 28 is non-coplanar with the outer barrier surface 48.

[0041] According to another aspect, the outer surfaces 42 of each of the plateable portions 26, 28 may be coplanar. Examples of such configurations are shown in FIGS. 3-6, and 9-17. Alternatively, the outer surfaces 42 of each of the plateable portions 26, 28 may be parallel and staggered from one another to define a step. Examples of such configurations are shown in FIGS. 7 and 8. Such a stepped configuration between the outer surfaces 42 of each of the plateable portions 26, 28 can space the outer surfaces 42 to protect the associated plateable portions 26, 28 from the high current density (HCD) edge area.

[0042] According to another aspect of the disclosure, one or more of the plateable portions 26, 28 may include a ramp portion 46 adjacent the barrier 24 and sloping away from the outer surface 42 toward the barrier 24 to prevent the plating material from migrating from one of the plateable portions 26, 28 when the other one of the plateable portions 26, 28 is being electroplated. For example, as shown in FIG. 15, each of the plateable portions 26, 28 can include such a ramp portion 46. The ramp portions 46 may, therefore, act as shields to reduce high current density (HCD) edges of the plateable regions 20, 22. In the example shown in FIG. 15, the barrier 24 defines an outer barrier surface 48 which is coplanar with the outer surfaces 42 of the plateable portions 26, 28.

[0043] According to another aspect, the barrier 24 may be generally flush with the outer surfaces 42 of each of the plateable portions 26, 28 and not protrude outwardly beyond the outer surfaces 42. Examples of such configurations are shown in FIGS. 4, 6, and 12. Alternatively, the barrier 24 may extend outwardly beyond the outer surface 42 of at least one of the plateable portions 26, 28 in a direction transverse to the outer surface 42. Examples of such configurations are shown in FIGS. 3, 5, 7-11, and 13-14. The barrier 24 may extend, for example, about 0.25 to 0.5 mm beyond the outer surfaces 42, and may define a separation of about 1.2 mm between the plateable portions 26, 28. In the example shown in FIG. 9, the barrier 24 may extend proud of the outer surface 42 of one of the plateable portions 26, 28 by a first distance and raised above the outer surface 42 of the other one of the plateable portions 26, 28 by a second, larger distance. For example, the barrier 24 may extend 0.25 mm proud of the outer surface 42 of the first plateable portion 26 and 0.5 mm proud of the outer surface 42 of the second plateable portion 28.

[0044] In the example shown in FIG. 13, the barrier 24 defines a trapezoidal cross-section. More specifically, the barrier 24 shown in FIG. 13 includes an outer barrier surface 48 having a convex shape that meets the outer surfaces 42 of the plateable portions 26, 28, but which bulges outwardly in a direction transverse to the outer surfaces 42.

[0045] As illustrated in the example diagram on FIG. 16, a non-plateable insert 50 may be disposed between the plateable portions 26, 28 and configured to be removed after the plateable portions 26, 28 are electroplated. This may allow the barrier 24 to be entirely recessed below the outer surfaces 42 of the plateable portions 26, 28. The non-plateable insert 50 prevents high current density edges that would otherwise be formed as a result of the recessed barrier 24 and the non-electrified one of the plateable portions 26, 28 becoming bipolar during the plating of the other one of the plateable portions 26, 28. This arrangement may be advantageous since the non-plateable barrier 24 will be less prone to scratch and mar failures, and may allow for a design that is more aesthetically pleasing. The molded article 10 may be formed as a 3-shot part as shown in FIG. 16 where the non-plateable insert 50 is a third resin designed to have poor adhesion to the other resins. In this case, the molded article 10 may be plated with 2 or more finishes. The non-plateable insert 50 may be removed after plating revealing a resistive layer that is lower than the outer surfaces 42 of the plateable portions 26, 28.

[0046] As illustrated in the example diagram on FIG. 17, a current robber 52 of electrically conductive material may be connected in electrical communication with one of the plateable portions 26, 28 and disposed between the plateable portions 26, 28. The current robber 52 would function to rob current from the area between the electrically isolated plateable portions 26, 28 thereby minimizing the bipolar effect on the main body of the one of the plateable portions 26, 28 to which it is electrically connected. The current robber 52 may include a head 54 and include a conductive wire or strip 56 which makes electrical contact with one of the plateable portions 26, 28. The conductive wire or strip 56 may pass through or extend around the barrier 24 and away from the outer surfaces 42 of the plateable portions 26, 28 as shown in the example of FIG. 17. The head 54 of the current robber 52 may be configured to be removed after the plateable portions 26, 28 are electroplated such as for example, by cutting or trimming the conductive wire or strip 56, which may be performed in a subsequent step after plating. In some embodiments, the conductive wire or strip 56 may include weakened location 58, which may be, for example, pre-stressed or thinned in order to control how much of the conductive wire or strip 56 remains after cutting or trimming. The weakened location 58 may be at, near, or recessed within a surface of the barrier 24.

[0047] In the example cross-section shown on FIG. 17, the first plateable portion 26 may act as a bipolar electrode during the plating of the second plateable portion 28. The plating on the current robber 52 above the barrier 24 would preferentially become anodic. Since the head 54 of the current robber 52 would be designed to be easily removed at the base of the first plateable portion 26, cosmetic defects of the current robber 52 due to anodic removal of metal would not be detrimental to the molded article 10 since the current robber 52 would be removed. According to an aspect, the current robber 52 may be an integral portion of the part and molded together with the remainder of the part. According to another aspect, the current robber 52 may be a separate part that is associated with the remainder of the part.

[0048] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements, assemblies/subassemblies, or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.