Plated polymer composite molding

Patent metadata

Field	Value
Publication number	US-2016168716-A1
Application number	US-201414903942-A
Country	US
Kind code	A1
Filing date	Jul 9, 2014
Priority date	Jul 9, 2013
Publication date	Jun 16, 2016
Grant date	—

Abstract

Plated polymeric articles having a composite layup structure and method of making the same are disclosed. A plated polymeric article comprises a composite layup having first and second polymer layers. The plated polymeric article further comprises a first metal plated onto the polymer. Additionally, methods for fabricating a plated polymeric article are disclosed. A composite layup is provided and compression molded into a desired shape having an outer surface. The outer surface of the article is prepared to receive a catalyst and then is activated with the catalyst. A first metallic layer is then plated onto the outer surface.

First claim

What is claimed is:

1 . A plated polymeric article, comprising:
a composite layup, the composite layup having a first layer and a second layer, the first layer comprising a first polymer, the second layer comprising a second polymer, the composite layup formed into a desired shape having an outer surface; a first metal plated onto the outer surface to form a structure; and a second metal deposited onto the structure.

2 . The plated polymeric article of claim 1 wherein the first polymer is selected from the group consisting of polyetherimide (PEI), polyimide, polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polysulfone, nylon, polyphenylsulfide, and polyester.

3 . The plated polymeric article of claim 1 wherein the second polymer is selected from the group consisting of polyetherimide (PEI), polyimide, polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polysulfone, nylon, polyphenylsulfide, and polyester.

4 . The plated polymeric article of claim 1 wherein the composite layup further comprises reinforcing fiber.

5 . The plated polymeric article of claim 4 wherein the reinforcing fiber is selected from the group consisting of carbon-fiber and glass-fiber.

6 . The plated polymeric article of claim 1 wherein the first metal is selected from the group consisting of nickel, copper, gold, silver, graphite and combinations thereof.

7 . The plated polymeric article of claim 1 wherein the first metal has a thickness ranging from about 0.1 to about 10 microns.

8 . The plated polymeric article of claim 1 wherein the second metal is selected from the group consisting of nickel, copper, gold, silver, graphite and combinations thereof.

9 . The plated polymeric article of claim 1 wherein the second metal has a thickness ranging from about 0.1 to about 10 microns.

10 . A method for fabricating a plated polymeric article, the method comprising:
providing a composite layup; compression molding the composite layup into a desired shape having an outer surface; preparing the outer surface to receive a catalyst; activating the outer surface with the catalyst; and plating a first metal onto the outer surface and the catalyst to form a first layer to form a structure.

11 . The method of claim 10 further including depositing a second metal onto the structure.

12 . The method of claim 11 further including alloying the structure.

13 . The method of claim 12 wherein the alloying is a process selected from the group consisting of transient liquid phase (TLP) bonding, brazing, diffusion bonding, heat treating and combinations thereof.

13 . The method of claim 10 wherein the preparing of the outer surface to receive the catalyst includes a process selected from the group consisting of etching, abrading, reactive ion etching, ionic activation, and deposition of a conductive material.

14 . The method of claim 10 wherein the catalyst is selected from the group consisting of palladium, platinum, gold, and combinations thereof.

15 . The method of claim 10 wherein the catalyst is deposited on the outer surface in an atomic layer thickness.

16 . The method of claim 10 wherein the first metal is selected from the group consisting of nickel, copper, gold, silver, graphite and combinations thereof.

17 . The method of claim 10 wherein the first layer has a thickness ranging from about 0.1 to about 10 microns.

18 . The method of claim 10 wherein the composite layup comprises reinforcing fiber.

19 . The plated polymeric article of claim 18 wherein the reinforcing fiber is selected from the group consisting of carbon-fiber and glass-fiber.

20 . A method for fabricating a plated polymeric article, the method comprising:
providing a composite layup having reinforcing fiber; compression molding the composite layup into a desired shape having an outer surface; activating the outer surface with palladium; electroless plating nickel onto the outer surface and palladium having a thickness ranging from about 2.54 to about 1270 microns to form a first layer; and electrolytically plating copper onto the first layer to form a second layer.

Assignees

• United Technologies Corp

Inventors

• Kling Colin J
• Roach James T
• Bugaj Shari L

Classifications

• B29L2031/082

  Blades, e.g. for helicopters · CPC title

• B29K2105/12

  of short lengths, e.g. chopped filaments, staple fibres or bristles · CPC title

• B32B2250/02

  2 layers · CPC title

• G01N2203/0268

  Dumb-bell specimens · CPC title

• G01D5/12

  using electric or magnetic means (G01D5/06 takes precedence) · CPC title