DESCRIPTION

The present invention relates to a method for producing a metal electrical plate, that is to say, an ornamental metal frame which is capable of being fixed to a frame which is engaged with a wall, with the frame which receives electrical or electronic devices, such as electrical outlets, electrical switches, current or signal sockets, and the like. The present invention further relates to the metal electrical plate obtained with the above-mentioned production method.

Electrical plates have a mainly aesthetic function and are used in the domestic area, in domotics, and further in buildings and structures such as, for example, offices, hotels, medical and clinical structures.

The electrical plates are typically engaged with a frame, with which the electrical or electronic devices are further engaged. The frame is fixed to a box which is recessed in the wall and which contains therein the electrical wires which supply the devices.

For many years, the production of the electrical plates has involved the use of metal materials, as indicated, for example, in US1660346.

In particular, an alloy used for producing the metal electrical plates is zamak, as indicated, for example, in KR101638895.

Zamak (also known as zamac) is an alloy of zinc with small percentages of aluminium, magnesium and copper. The most widespread method of processing zamak for producing the metal electrical plates is diecasting. In this process, the molten material is injected under pressure into the die of the plate which is constructed from heat-resistant steel. Upon cooling, the plate is removed and can be processed in order to obtain a surface finish (mechanical processing operations, grinding, metal cleaning and polishing, electroplating processing operations, varnishing and other surface finishes). In addition to the production of the electrical plates, zamak is used in the automotive, building, clothing, accessory sectors and electronic sector in general.

Notwithstanding the extremely widespread use of diecast zamak for producing electrical plates, this solution involves a series of problems.

In particular, the diecasting of the plates from zamak produces a great quantity of waste as a result of the physics of the process which generates inclusions of impurities and gas inside the product with resultant defects which can be detected over the entire production chain downstream. These defects often generate unsatisfactory results in the processes for aesthetic finishing such as, for example, varnishing and/or metal-plating.

Furthermore, the production equipment for diecasting the electrical plates from zamak cannot be used to produce pieces using different materials. Consequently, the diecasting of the zamak substantially limits the production flexibility.

The technical problem addressed by the present invention is to provide a metal electrical plate which is configured to at least partially overcome one or more of the disadvantages set out with reference to the cited prior art.

This problem is solved by the invention by means of a metal electrical plate constructed according to one or more of the appended claims. The metal electrical plate according to the present invention is produced from an alloy based on zinc, with the addition of titanium and copper.

Preferably, the metal electrical plate comprises a covering layer which is produced by means of a rolled product of such a zinc-copper-titanium alloy.

It will be appreciated that, in the context of the present invention, the term "rolled product" is intended to be understood to be a product which is obtained by means of rolling, that is to say, the mechanical process used for reducing the least dimension in a layer, usually the thickness. Typically, the process is carried out by means of opposing cylinders which, by rotating about themselves, press the desired shape into the material. The process may comprise a plurality of passes, in each of which the rollers are positioned closer together.

Preferably, the plate is produced from zinc with a proportion of 99.995 of zinc of quality Z1 according to the European standard EN 1179. The components which constitute the alloy of the metal electrical plate according to the present invention in addition to the zinc improve the characteristics of the rolled zinc product. In particular, titanium confers greater resistance to permanent deformation over time, while copper increases the traction resistance of the material. Furthermore, the combination of titanium with copper reduces the coefficient of expansion of the alloy.

The addition of titanium increases the resistance of the material to deformation, particularly under the effect of alternating thermal stresses. The addition of copper makes the alloy harder and increases the mechanical strength thereof.

Furthermore, the addition of copper confers on the alloy a natural patina as a result of the greyer appearance with respect to zamak.

Preferably, the alloy uses a titanium composition as a percentage between 0.06 and 0.20. Even more preferably, the titanium composition as a percentage is between 0.10 and 0.16.

Furthermore, the alloy preferably uses a copper composition as a percentage between 0.08 and 1.00. Even more preferably, the copper composition as a percentage is 0.09. The alloy which is obtained on the basis of this composition is a zinc- copper-titanium alloy. Possible examples of alloys which can be used in the present invention are those which are commercially known as Zintek® or Rheinzink® or VM Zinc® or Elzinc®. The zinc-copper- titanium alloy is typically used in building works for constructing covers or components of sheet metal.

Preferably, the zinc-copper-titanium alloy complies with the European standard EN 988 "Zinc and zinc alloys. Specification for rolled flat products for building".

As a result of the malleability thereof, the zinc-copper-titanium alloy according to the present invention can be readily processed, allowing the production of reliefs, level differences or particular angles. Furthermore, the zinc-copper-titanium alloy affords great freedom of planning, conforms to complex forms which are difficult to produce with other materials and is bent through small radii of curvature. In addition, the zinc-copper-titanium alloy has a high resistance to corrosion and wear over time.

The natural appearance of the zinc-copper-titanium alloy has a bright grey colour as a result of rolling, is homogeneous and bright. Under the action of the atmospheric agents, the surface is covered with a protective layer which remains stable over time and which confers a natural coating by conferring on the metal electric plate a pleasant aesthetic appearance with a slate grey colour. The protective layer which is formed following contact of the zinc-copper-titanium alloy with oxygen and water comprises a layer of basic zinc carbonate which safeguards the metal. This is the natural protection process of the zinc- copper-titanium alloy which confers on it an extremely long durability over time. In addition to the long service-life thereof, the zinc-copper- titanium alloy does not need particular maintenance. In fact, it continues to develop a protective patina over the entire course of the life thereof and this allows correction of imperfections and scratches.

The material used further allows surface finishing processing which is simpler with a resultant substantial reduction of the defective nature and therefore of the final waste when it is desirable to also confer appearances and colourations which are different from the bright grey colour as a result of rolling. The zinc-copper-titanium alloy can be produced in the form of strips, sheets or bands via a rolling process which reduces the thickness of the strip by using rollers.

According to an advantageous aspect of the present invention, starting from a rolled strip of zinc-copper-titanium there are carried out one or more cutting and/or deep-drawing operations in the cold state, laser cutting, milling, bending or other mechanical processing, in order to directly obtain the metal electrical plate.

Preferably, the mechanical processing process of the rolled strip of zinc- copper-titanium according to the invention comprises forming operations, such as simple bending or multiple bending or punching. Furthermore, the process developed according to the present invention provides for the metal electrical plate obtained in this manner to be able to be subjected to additional processing operations, such as, for example, surface finishing processing operations.

The metal electrical plate obtained in this manner is configured to be used as a cover for a receiving structure for electrical or electronic devices, such as, for example, electrical outlets or electrical switches.

Another advantage which is connected with the use of zinc-copper- titanium alloys involves the fact that the equipment for the mechanical processing of the strip of this alloy can also be used for producing metal electrical plates using metal materials which are different from the zinc- copper-titanium alloy. In fact, unlike the processing of the zamak, it is unnecessary to use equipment which are specifically intended for this material. Advantageously, using a zinc-copper-titanium alloy therefore allows equipment which are also suitable for other types of material to be used, with the possibility of developing typical surface finishes for each material, such as, for example, the typical anodization of aluminium or electroplating and metal-plating processing operations which are characteristic of other alloys.

In one aspect, the technological process developed for the production of the metal electrical plate according to the present invention excludes using dangerous polluting elements, both during the processing step and during the final application thereof. This ensures respect for the environment over time. In fact, zinc is an ecologically compatible metal which benefits from a favourable overall energy balance. 100% of the products made from rolled or processed zinc which have arrived at the end of the lifecycle thereof can be recycled and 95% are effectively recovered for different applications. Furthermore, the production of zinc consumes little energy with respect to other metals used in building.

The characteristics and advantages of the invention will be better appreciated from the detailed description of a preferred embodiment thereof which is illustrated by way of non-limiting example with reference to the appended drawings, in which:

- Figure 1 illustrates the metal electrical plate as an exploded view of a receiving structure for electrical or electronic devices according to a first embodiment of the present invention;

- Figure 2 illustrates the metal electrical plate as an exploded view of a receiving structure for electrical or electronic devices according to a second embodiment of the present invention;

- Figure 3 illustrates the plate of Figure 2 in a receiving structure with the box-shaped body recessed in the wall;

- Figure 4 illustrates the metal electrical plate as an exploded view of a receiving structure for electrical or electronic devices according to a third embodiment of the present invention;

- Figures 5, 6 and 7 are front, side and rear views of the plate of Figure 4, respectively;

- Figures 8 and 9 are front and perspective rear views of the metal electrical plate according to a fourth embodiment of the present invention, respectively. With reference initially to Figure 3, there is generally designated 1 a metal electrical plate and there is generally designated 10 a frame which is configured and intended to be fixed to a box-shaped body 30 which is engaged with a wall M.

The box-shaped body 30 which is recessed in the wall M has therein the electrical wires 40 which supply one or more electrical or electronic devices 100 which are configured and intended to be fixed in a front open portion of the frame 10.

With reference now to Figure 1, the metal electrical plate 1 has a front surface 2a and a rear surface 2b which are opposite each other. Advantageously, the rear surface 2b is configured and intended to be engaged with the front surface 14 of the frame 10. According to another advantageous aspect, the front surface 2a is visible from the exterior even under conditions in which the electrical plate 1 is fixed to the frame 10 and the frame 10 is fixed to the box-shaped body 30 which is recessed in the wall.

In one aspect, the front surface 2a of the plate 1 is substantially planar. Preferably, the rear surface 2b is also substantially planar.

In some embodiments, the plate 1 comprises a covering layer la which defines the front surface 2a.

Therefore, it will be appreciated that the covering layer la confers the aesthetic characteristics on the plate, forming the front surface 2a thereof which is visible during use of the plate 1.

The covering layer la is advantageously constructed by means of a rolled product of a zinc-copper-titanium alloy.

The rolled product is preferably a layer obtained by means of a rolling process.

By way of example, the covering layer la can be constructed from alloys, such as those commercially known under the name of Zintek® or Rheinzink® or VM Zinc® or Elzinc®.

According to preferred embodiments of the invention, a window 31 is formed on the plate 1 in the region of a respective area 3. In some embodiments, the electrical or electronic devices 100 are engaged with the open front portion of the frame 10 by making them pass through the window 31.

When the frame 10 and the devices 100 are mounted on the box- shaped body 30, the devices 100 are accessible from the window 31 of the electrical plate 1. The window 31 of the metal electrical plate 1 is therefore configured and intended to afford access to at least one electrical or electronic device 100 under the condition in which the plate is engaged with the wall.

More generally, as may be observed in the description of the following embodiments of the invention, the area 3 defined in the metal electrical plate 1 may be configured and intended to allow the actuation of and/or access to the electrical or electronic device 100 which is fixed to the frame 10 engaged with the wall M. The actuation may be brought about both by physical contact, as occurs in the present embodiment, and by means of other interaction, for example, by means of a resistive or capacitive variation which is associated with the contact of a finger on the area 3, as in the following embodiments.

In preferred embodiments, the metal electrical plate 1 comprises connection means which are capable of removably fixing the plate 1 to the frame 10.

The connection means can be formed directly on the covering layer la or, as will be seen in greater detail below, they can be formed by means of an adapter 20 which is or can be fixed to the covering layer la.

In order to facilitate the detachment of the metal electrical plate 1 from the frame 10, the metal electrical plate 1 preferably has at least one recess 8 which faces the frame 10 and which is configured and intended to receive the tip of a tool which is capable of separating the plate 1 from the frame 10.

In preferred embodiments, such as, for example, the one illustrated in Figure 1, the connection means of the metal electrical plate 1 with respect to the frame 10 comprise a peripheral wall 5 of the plate 1, the wall being configured and intended to conform to a peripheral edge 11 of the frame 10. By conforming to the peripheral edge 11, the peripheral wall 5 advantageously allows the production of a mechanical interference-fit connection between the plate 1 and the frame 10.

In the preferred embodiment of Figure 1, the connection means of the metal electrical plate 1 with respect to the frame 10 further comprise seats 7 which are capable of receiving tongues 13 of the frame 10. The tongues 13 are preferably resilient tongues and allow the production of a snap-fit type connection with the seats 7.

In an additional preferred embodiment of Figures 2 and 3, the connection means of the metal electrical plate 1 with respect to the frame 10 comprise an adapter 20 which is fixed to the covering layer la of the plate 1. Preferably, the adapter 20 is arranged at a surface opposite the front surface 2a of the plate 1. Preferably, the adapter 20 is of plastics material. Preferably, the front surface 21 of the adapter 20 is adhesively bonded to the surface of the metal electrical plate 1 opposite the front surface 2a. Preferably, the adhesive bonding is brought about by means of an adhesive or adhesive material which is suitable for being used with plastics and metal materials and which is configured to ensure stable fixing between the materials.

According to another advantageous embodiment which is illustrated in Figures 4 to 7, the adapter 20 and the covering layer la of the metal electrical plate 1 are insert-moulded so as to be connected in a stable manner.

Preferably, there extend from the rear surface 2b of the electrical plate 1 or the rear surface 22 of the adapter 20 tongues 6 which are configured and intended to be inserted in corresponding seats 12 in the frame 10. The tongues 6 are preferably resilient tongues and allow the production of a snap-fit type connection with the seats 12.

Preferably, the metal electrical plate 1 has a width L between 50 mm and 200 mm or between 80 mm and 170 mm.

According to another advantageous aspect, the metal electrical plate 1 has a height H between 60 mm and 100 mm or between 70 mm and 90 mm.

In an aspect, the metal electrical plate 1 further has a depth W between 3 mm and 15 mm or between 6 mm and 12 mm.

Preferably, the electrical or electronic devices 100 comprise electrical outlets or electrical switches. In one aspect, the electrical or electronic devices 100 comprise one or more of the following electrical and electronic components: energy distribution sockets, electrical rocker switches, electromechanical controls of the axial type or wireless control devices, touch screen, using radiofrequency or infrared. According to another advantageous aspect, the electrical or electronic devices 100 may comprise one or more of the following devices: devices for video door entry systems, multi-media (for example, sound broadcasting systems or devices for connectivity), lighting, security, managing consumption levels, energy efficiency and remote control.

In the embodiment of Figures 8 and 9, the area 3 of the metal electrical plate 1 provides for a tactile interface 15 which is configured and intended to interact with the electrical or electronic device 100, allowing the actuation thereof. In an aspect, the tactile interface 15 allows tactile control of the electrical or electronic device 100. Preferably, the tactile interface 15 provides for controlling domotic instructions by touch.

In preferred embodiments, the area 3 of the metal electrical plate 1 provides for a screen 16 for communicating information or reading information from the electrical or electronic device 100. Preferably, the screen 16 is touch-sensitive.

According to another advantageous aspect, the tactile interface 15 or the screen 16 provides for back-lighting. In some preferred embodiments, the back-lighting is carried out by the effect of RGB LEDs. The invention thereby solves the problem set out while achieving a number of advantages, including:

• reducing production waste and making the finishing processes easier for the metal electrical plate, such as surface processing operations for aesthetic finishing (for example, varnishing, metal plating, electroplating processing operations), as a result of the replacement of the diecast zamak with the rolled zinc as a novel material and technological process for producing the plate;

• reducing investments because the use of the rolled product of a zinc alloy allows the production of finishes which can currently be attributed to electroplating processes, thereby overcoming the need for constructing diecasting equipment, by using equipment for cutting/deep-drawing used in the processing of other metals, including, for example, brass and aluminium; · reducing the quantity of primary materials used by being able to benefit from thicknesses of the rolled product less than the thicknesses which can normally be obtained with the diecasting process;

• greater freedom of design as a result of it being possible to reduce the volume of the manufactured article;

• the production flexibility, that is to say, the possibility of using the same production equipment for manufacturing electrical plates from different materials and therefore meeting different requirements of the market in a flexible manner.