In-mold metallized polymer components and method of manufacturing same
AssigneeCool Options, Inc.
InventorKevin McCullough
Life of this patent
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Abstract
A method is provided for forming a net shape molded component that includes an integral metallized coating or layer on the exterior surface thereof. The method includes injecting a carefully matched mixture of a molten polymer resin and a molten metallic alloy into a mold cavity under pressure. Due to the differential in material viscosities, the metal tends to migrate to the outer surface of the molded part when placed under pressure, ultimately creating a net shape molded part having a polymer core with a metallic layer at the exterior surfaces thereof. Further, the present invention provides for the compounding of a feedstock suitable for use in conjunction with the method described above.
Claims26
A method of forming a net shape molded component having a metallic layer about an exterior surface thereof, the method comprising the steps of:
- providing a polymer resin, said polymer resin having a usable molten state that exists between a first temperature and a second temperature higher than said first temperature;
- providing a granular metal having a melting temperature that is greater than said first temperature and less than said second temperature;
- heating said polymer resin to a temperature that is greater than said first temperature and less than said melting temperature of said granular metal, thereby causing said polymer resin to become molten;
- uniformly dispersing said granular metal throughout said molten polymer resin to form a composition;
- further heating said composition to a temperature that is greater than said melting temperature of said granular metal;
- injecting said composition under pressure into a mold cavity, having cavity walls;
- separating the metal from said polymer, said metal migrating toward said cavity walls and said polymer migrating toward the interior of said cavity;
- and
- cooling said composition to form a component having a metallic layer surrounding a polymer core.
A net shape molded component, comprising:
- a polymer core having an exterior surface, said polymer core having a usable molten state that exists between a first temperature and a second temperature higher than said first temperature;
- and
- a metal layer disposed about said exterior surface of said polymer core, said metal layer having a melting temperature that is greater than said first temperature and less than said second temperature.
A method of forming a polymer composite feedstock for use in net shape molding a component having a metallic layer about an exterior surface thereof, the method comprising the steps of:
- providing a polymer resin, said polymer resin having a usable molten state that exists between a first temperature and a second temperature higher than said first temperature;
- providing a granular metal having a melting temperature that is greater than said first temperature and less than said second temperature;
- heating said polymer resin to a temperature that is greater than said first temperature and less than said melting temperature of said granular metal, thereby causing said polymer resin to become molten;
- uniformly dispersing said granular metal throughout said molten polymer resin to form a composition;
- and
- extruding said composition to form injection molding feedstock.
A polymer composite feedstock for use in net shape molding a component having a metallic layer about an exterior surface thereof, comprising:
- a polymer resin, said polymer resin having a usable molten state that exists between a first temperature and a second temperature higher than said first temperature;
- and
- a granular metal having a melting temperature that is greater than said first temperature and less than said second temperature, said granular metal being dispersed uniformly throughout said polymer resin.
A method of forming a polymer core having a metal layer dispose about an exterior surface thereof, the method comprising the steps of:
- providing a polymer resin, said polymer resin having a usable molten state that exists between a first temperature and a second temperature higher than said first temperature;
- providing a granular metal having a melting temperature that is greater than said first temperature and less than said second temperature;
- heating said polymer resin to a temperature that is greater than said first temperature and less than said melting temperature of said granular metal, thereby causing said polymer resin to become molten;
- uniformly dispersing said granular metal throughout said molten polymer resin to form a composition;
- further heating said composition to a temperature that is greater than said melting temperature of said granular metal;
- and
- molding said composition under pressure, said pressure causing said polymer resin to consolidate at the core of said composition and said metal to migrate to an exterior surface of said polymer core.
Dependencies are inferred from the claim text.