Article containing conductive fibers

Patent metadata

Field	Value
Publication number	US-2020346401-A1
Application number	US-201916401250-A
Country	US
Kind code	A1
Filing date	May 2, 2019
Priority date	May 2, 2019
Publication date	Nov 5, 2020
Grant date	—

Abstract

An article includes a body, which includes a thermoplastic or thermoset material and a plurality of metallic fibers distributed throughout the thermoplastic or thermoset material and has a first subset of the plurality of metallic fibers extending onto a first surface of the body. The manufactured article includes a metallic coating metallically bonded to the first subset of the plurality of metallic fibers. The metal fibers extending onto the first surface are configured to bond with the metallic coating.

First claim

1 . An article comprising:
a body comprising:
a thermoplastic or thermoset material; and
a plurality of metallic fibers distributed throughout the thermoplastic or thermoset material, wherein a first subset of the plurality of metallic fibers extends onto a first surface of the body; and
a metallic coating metallically bonded to the first subset of the plurality of metallic fibers, wherein the first subset of the plurality of metallic fibers is configured to bond with the metallic coating.

2 . The article of claim 1 , wherein the first subset of the plurality of metallic fibers is configured to allow the metallic coating to be applied directly on the first surface of the body.

3 . The article of claim 2 , wherein the metallic coating is applied directly on the first surface of the body using an electroplating, ion vapor deposition, or a dynamic cold spray process.

4 . The article of claim 1 , wherein the thermoplastic or thermoset is selected from the group consisting of polyphenylene sulfide, polyether imide, polyarylether ketones, or combinations thereof.

5 . The article of claim 1 , wherein the metallic coating is formed of a metal or alloy selected from the group consisting of chromium, nickel, aluminum, titanium, cobalt, iron, copper, gold, silver, stainless steel, Inconel, Waspaloy, Hastelloy, or combinations thereof.

6 . The article of claim 1 , wherein the plurality of metallic fibers is formed entirely of a metal or alloy capable of forming a metallic bond with the metallic coating.

7 . The article of claim 1 , wherein the plurality of metallic fibers is metallic coated particles and the particles are selected from the group consisting of graphite, graphene, carbon fibers, carbon nanotubes, or combinations thereof.

8 . The body of claim 1 and further comprising:
an interior feature formed within the body, wherein the interior feature is a cooling void; and
a second surface, lining the cooling void, wherein a second subset of the plurality of metallic fibers extends onto the second surface of the body and is configured to metallically bond with the metallic coating.

9 . The body of claim 1 and further comprising:
an interior feature formed within the body, wherein the interior feature is formed of a different material than the body.

10 . A method of manufacturing a coated article, the method comprising:
co-extruding a thermoplastic or thermoset material with a plurality of metallic fibers distributed throughout the thermoplastic or thermoset material; forming a body from the co-extruded material, wherein a first subset of the plurality of metallic fibers extends onto a first surface of the thermoplastic or thermoset material and is configured to bond with a metallic coating; and applying the metallic coating to the body, wherein the metallic coat is metallically bonded to the first subset of the plurality of metallic fibers.

11 . The method of claim 10 , wherein the plurality of metallic fibers is configured to allow the metallic coating to be applied directly on the first surface of the body.

12 . The method of claim 11 , wherein the metallic coating is applied directly on the first surface of the body using an electroplating, ion vapor deposition, or a dynamic cold spray process.

13 . The method of claim 10 , wherein the thermoplastic or thermoset is selected from the group consisting of polyphenylene sulfide, polyether imide, polyarylether ketones, or combinations thereof.

14 . The method of claim 10 , wherein the metallic coating is formed of a metal or alloy selected from the group consisting of chromium, nickel, aluminum, titanium, cobalt, iron, copper, gold, silver, stainless steel, Inconel, Waspaloy, Hastelloy, or combinations thereof.

15 . The method of claim 10 , wherein the plurality of metallic fibers is formed entirely of a metal or alloy capable of forming a metallic bond with the metallic coating.

16 . The method of claim 10 , wherein the plurality of metallic fibers is metallic coated particles and the particles are selected from the group consisting of graphite, graphene, carbon fibers, carbon nanotubes, or combinations thereof.

17 . The method of claim 10 and further comprising:
forming an interior feature within the body, wherein the interior feature is a cooling void; and
forming a second surface, lining the cooling void, wherein a second subset of the plurality of metallic fibers extends onto the second surface of the thermoplastic or thermoset material and is configured to metallically bond with the metallic coating.

18 . The method of claim 10 and further comprising:
forming an interior feature within the body, wherein the interior feature is formed of a different material than the body.

19 . The method of claim 10 , wherein forming the body is carried out using a fused filament fabrication printing process.

20 . An article comprising:
a body formed from a thermoplastic or thermoset material; a plurality of metallic fibers distributed throughout the thermoplastic or thermoset material; and a metallic coating covering the first surface of the body, wherein the plurality of metallic fibers is configured to allow the metallic coating to be applied directly on a first surface of the body and wherein the metallic coating is applied directly on the first surface of the body using an electroplating, ion vapor deposition, or a dynamic cold spray process.

Assignees

• Hamilton Sundstrand Corp

Inventors

• Brown Ricardo O
• Smith Blair A

Classifications

• B22F2303/40

  Layer in a composite stack of layers, workpiece or article · CPC title

• C23C24/00

  Coating starting from inorganic powder (spraying of the coating material in molten state C23C4/00; solid state diffusion C23C8/00 - C23C12/00) · CPC title

• C23C18/00

  Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating · CPC title

• C23C14/00

  Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title