# US 2020/0399763 A1 · Molding composite part with metal layer > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2020/0399763 A1 - Document ID: US20200399763A1 - Status: Published application - Kind: A1 - Application number: 16/445,102 - Filed: 2019-06-18 - Published: 2020-12-24 - Earliest claimed: 2019-06-18 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Eric A. Bruton; Christopher H. Childers; Stephen P. Gaydos - Web page: https://patentgrep.com/patent/US20200399763A1 ## CPC - C23C 24/04: Impact or kinetic deposition of particles - B29C 53/04: of plates or sheets {(B29C63/04 takes precedence; bending or folding paper B31F1/0003; folding films B65H45/00)} - B64D 45/02: Lightning protectors; Static dischargers - C23C 28/023: {only coatings of metal elements only} - H05K 9/0081: {Electromagnetic shielding materials, e.g. EMI, RFI shielding (H05K9/0003 takes precedence)} - H05K 9/0088: {comprising a plurality of shielding layers; combining different shielding material structure} - B29C 53/005: {characterised by the choice of material (B29C53/36 and B29C53/56 take precedence)} - B29K 2105/251: {Particles, powder or granules (expandable particles B29K2105/046)} - B29K 2995/0011: Electromagnetic wave shielding material - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B64D: EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT - H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract A method of molding a metalized composite part. The method comprises: introducing particles comprising at least one metal into a gas stream; directing the gas stream toward a surface of a thermoplastic composite part, thereby depositing a metal layer on the composite part to form a metallized composite part; and molding the metallized composite part to introduce a bend without delamination of the metal layer from the metallized composite part. ## Claims ### Claim 1 A method of molding a metalized composite part, the method comprising: introducing particles comprising at least one metal into a gas stream; directing the gas stream toward a surface of a thermoplastic composite part, thereby depositing a metal layer on the composite part to form a metallized composite part; and molding the metallized composite part to introduce a bend without delamination of the metal layer from the metallized composite part. ### Claim 2 (depends on 1) The method of claim 1, wherein the at least one metal is chosen from aluminum, copper, gold, and silver. ### Claim 3 (depends on 1) The method of claim 1, wherein the thermoplastic composite part comprises a thermoplastic and one or more filler materials ### Claim 4 (depends on 3) The method of claim 3, wherein the one or more filler materials are chosen from carbon nanotubes, inorganic fibers, carbon fibers, graphite fibers, woven glass fibers, unwoven glass fibers, ceramic fibers, alumina fibers, boron fibers, metal fibers, metalized fibers, metal coated glass fibers, metal coated alumina fibers, metal coated boron fibers, carbon particles, graphite particles, metal particles, glass particles, organic fibers and combinations thereof. ### Claim 5 (depends on 1) The method of claim 1, wherein the metal layer imparts electrical EMI resistance or lightning protection, erosion protection, electromagnetic interference shielding, electromagnetic emission shielding, or lightning strike protection to the metalized composite part. ### Claim 6 (depends on 1) The method of claim 1, further comprising heating the metal layer at an anneal temperature ranging from about 315° C. to about 400° C. ### Claim 7 (depends on 6) The method of claim 6, wherein the heating occurs prior to the molding of the metal layer. ### Claim 8 (depends on 6) The method of claim 6, wherein the anneal temperature is maintained for a period of time ranging from about 30 seconds to about 30 minutes. ### Claim 9 (depends on 1) The method of claim 1, further comprising heating the particles prior to the depositing of the metal layer at an anneal temperature ranging from about 315° C. to about 400° C. to increase ductility of the metal layer. ### Claim 10 (depends on 1) The method of claim 1, wherein the metal layer has a thickness ranging from about 0.01 mil to about 20 mils. ### Claim 11 (depends on 1) The method of claim 1, wherein the metal layer allows the composite to be paintable. ### Claim 12 (depends on 1) The method of claim 1, wherein the metal layer provides UV protection to the thermoplastic composite part. ### Claim 13 (depends on 1) The method of claim 1, further comprising cold spray coating or thermal spray coating onto the metal layer at least one additional metal layer different from the metal layer. ### Claim 14 (depends on 13) The method of claim 13, wherein the at least one additional metal layer comprises at least one metal chosen from Ag, Al, Au, Co, Cr, Cu, Fe, Ni, Mo, Pd, Pt, Rh, Ru, Sn, Ti, W, Zn, and Zr. ### Claim 15 (depends on 1) The method of claim 1, wherein an electrochemical insulating layer is disposed between the thermoplastic composite part and the metal layer. ### Claim 16 (depends on 15) The method of claim 15, wherein the gas stream has a temperature and pressure adjusted to prevent significant thermal softening or significant ablation of the surface of the electrochemical insulating layer. ### Claim 17 A method of imparting electrical EMI resistance or lightning protection to a thermoplastic composite part, the method comprising: introducing particles comprising at least one metal into a gas stream; directing the gas stream toward a surface of a thermoplastic composite part, thereby depositing a metal layer on the composite part to form a metallized composite part; and molding the metallized composite part to introduce a bend without delamination of the metal layer from the metallized composite part, wherein the metal layer imparts electrical EMI resistance or lightning protection to the thermoplastic composite part. ### Claim 18 (depends on 17) The method of claim 17, wherein the metal layer comprises at least one metal chosen from aluminum, copper, gold, and silver. ### Claim 19 (depends on 17) The method of claim 17, further comprising heating the metal layer at an anneal temperature ranging from about 315° C. to about 400° C., such as about 345° C. to about 400° C., to increase ductility during the molding. ### Claim 20 (depends on 19) The method of claim 19, wherein the heating occurs prior to the molding of the metal layer. ### Claim 21 (depends on 19) The method of claim 19, wherein the anneal temperature is maintained for a period of time ranging from about 30 seconds to about 30 minutes. ### Claim 22 (depends on 17) The method of claim 17, further comprising heating the particles prior to the depositing of the metal layer at an anneal temperature ranging from about 315° C. to about 400° C., such as about 345° C. to about 400° C., to increase ductility of the metal layer. ### Claim 23 A cold sprayed metal coated article comprising: a thermoplastic composite part having at least one surface; and a cold sprayed metal layer present on the thermoplastic composite part, the cold sprayed metal layer having a deformation produced by molding the thermoplastic composite part together with the cold sprayed metal layer; optionally an electrochemical insulating layer disposed between the thermoplastic composite part and the cold sprayed metal layer; and optionally at least one additional metal layer, the at least one additional metal layer sandwiching at least a portion of the metal layer between the at least one additional metal layer and the thermoplastic composite part; the cold sprayed metal coated article having an increase in one or more properties chosen from EMI resistance, erosion protection, lightning protection, electromagnetic interference shielding, electromagnetic emission shielding and lightning strike protection compared to the same thermoplastic composite part without the cold sprayed metal layer. ### Claim 24 (depends on 23) The article of claim 23, wherein the metal layer comprises at least one metal chosen from aluminum, copper, gold and silver. ### Claim 25 (depends on 23) The article of claim 23, wherein the at least one additional metal layer comprises at least one metal chosen from Ag, Al, Au, Co, Cr, Cu, Fe, Ni, Mo, Pd, Pt, Rh, Ru, Sn, Ti, W, Zn, and Zr. ### Claim 26 (depends on 23) The article of claim 23, wherein the thermoplastic composite part comprises a thermoplastic and one or more filler materials. ### Claim 27 (depends on 26) The article of claim 26, wherein the thermoplastic comprises at least one polymer chosen from epoxies, phenolics, polyesters, ureas, melamines, polyamides, polyimides, poly-ether-ether-ketones (PEEK), poly-ether-ketone-ketones (PEKK), polyetherimides, polyphthalamides, polyphthalates, polysulfones, polyurethanes, chlorinated polymers, fluorinated polymers, polytetrafluoroethylene, polycarbonates, liquid crystal polymers, and partially crystalline aromatic polyesters. ### Claim 28 (depends on 26) The article of claim 26, wherein the one or more filler materials are chosen from carbon nanotubes, graphite particles, carbon fibers, graphite fibers, woven glass fibers, unwoven glass fibers, ceramic fibers, alumina fibers, boron fibers, metal fibers, metalized fibers, metal coated glass fibers, metal coated alumina fibers, metal coated boron fibers, carbon particles, graphite particles, metal particles, glass particles, organic fibers, and combinations thereof. ### Claim 29 (depends on 23) The article of claim 23, wherein the thermoplastic composite part is a component or part of an aerospace vehicle. ### Claim 30 (depends on 29) The article of claim 29, wherein the component or part of an aerospace vehicle is an external surface thereof.