초록 ▼

Metal-coated polymer articles containing structural substantially porosity-free, fine-grained and/or amorphous metallic coatings/layers optionally containing solid particulates dispersed therein on polymer substrates, are disclosed. The substantially porosity-free metallic coatings/layers/patches ar

Metal-coated polymer articles containing structural substantially porosity-free, fine-grained and/or amorphous metallic coatings/layers optionally containing solid particulates dispersed therein on polymer substrates, are disclosed. The substantially porosity-free metallic coatings/layers/patches are applied to polymer or polymer composite substrates to provide, enhance or restore vacuum/pressure integrity and fluid sealing functions. Due to the excellent adhesion between the metallic coating and the polymer article satisfactory thermal cycling performance is achieved. The fine-grained and/or amorphous metallic coatings are particularly suited for strong and lightweight articles, precision molds, sporting goods, aerospace and automotive parts and other components exposed to thermal cycling and stress created by erosion and impact damage.

대표청구항 ▼

1. A metal-coated polymer article comprising: (i) a polymeric material;(ii) a metallic material having a microstructure which is fine-grained with an average grain size between 2 and 5,000 nm and/or amorphous, wherein the metallic material is in the form of a metallic layer having a thickness betwee

1. A metal-coated polymer article comprising: (i) a polymeric material;(ii) a metallic material having a microstructure which is fine-grained with an average grain size between 2 and 5,000 nm and/or amorphous, wherein the metallic material is in the form of a metallic layer having a thickness between 10 micron and 2.5 cm and a maximum porosity of 1.5%;(iii) with or without at least one intermediate layer between the polymeric material and the metallic material;wherein said metal-coated polymer article having a leak rate in air of between 0 and 6.6 mm Hg pressure per hour and per cm2 measuring area after applying a vacuum of 29″ of Hg and measuring the loss of vacuum over the duration of 60 minutes. 2. The article of claim 1, wherein the metal-coated polymer article has a leak rate in air of between 0 and 6.6 mm Hg pressure per hour and per cm2 measuring area after applying a vacuum of 29″ of Hg and measuring the loss of vacuum over the duration of 60 minutes after said metal-coated polymer article is subjected to at least one of the conditions selected from the group consisting of: (i) at least one temperature cycle according to ASTM B553-71 service condition 1, 2, 3 or 4;(ii) the drop test as specified in ASTM D7136; and(iii) the gravelometer test as specified in ASTM D3170-03 or SAE J4001 projecting one pint of gravel at said metal-coated polymer article at 70 psi over 10 seconds. 3. The article according to claim 1, wherein said metallic material is selected from the group consisting of: (i) one or more metals selected from the group consisting of Ag, Al, Au, Co, Cr, Cu, Fe, Ni, Mo, Pd, Pt, Rh, Ru, Sn, Ti W, Zn and Zr,(ii) metals or alloys containing at least two of metals of (i), further containing at least one element selected from the group of B, C, H, O, P and S; and(iii) any of (i), or (ii) where said metallic layer also contains particulate additions in the volume fraction between 0 and 95% by volume. 4. The article according to claim 3, wherein the metallic material contains at least one particulate addition, wherein said particulate addition is at least one of a material selected from the group consisting of a metal selected from the group consisting of Ag, Al, Cu, In, Mg, Si, Sn, Pt, Ti, V, W, and Zn; a metal oxide selected from the group consisting of Ag2O, Al2O3, SiO2, SnO2, TiO2, and ZnO; a carbide of B, Cr, Bi, Si, and/or W; a carbon material selected from the group consisting of carbon nanotubes, diamond, graphite, and graphite fibers; a material selected from the group consisting of a ceramic and glass; and a polymer material selected from the group consisting of PTFE, PVC, PE, PP, ABS, and epoxy resin. 5. The article according to claim 1, wherein the polymeric material comprises at least one polymer selected from the group consisting of epoxy resins, phenolic resins, urea resins, melamine resins, thermoplastic polymers, polyolefins, polyethylenes, polypropylenes, polyamides, poly-ether-ether-ketones, mineral filled polyamide resin composites, polyphthalamide, polyphthalates, polystyrene, polysulfone, polyimides, neoprenes, polyisoprenes, polybutadienes, polyisoprenes, polyurethanes, butadiene-styrene copolymers, chlorinated polymers, polyvinyl chloride, fluorinated polymers, polytetrafluoroethylene, polycarbonates, polyesters, liquid crystal polymers, partially crystalline aromatic polyesters based on p-hydroxybenzoic acid, and acrylonitrile-butadiene-styrene. 6. The article according to claim 1, wherein the metallic material is between 5 and 95% of the total weight of the article. 7. The article according to claim 1, comprising said at least one intermediate layer between said metallic material and said polymeric material. 8. The article according to claim 7, wherein the at least one intermediate layer comprises at least one metal selected from the group consisting of Ag, Ni, and Cu. 9. The article according to claim 7, wherein the at least one intermediate layer comprises an adhesive layer. 10. The article according to claim 9, wherein the at least one intermediate layer comprises a partially or fully cured bonding layer. 11. The article according to claim 1, wherein said article has a tubular structure and said metallic material extends over at least part of the inner or outer surface of said tubular structure. 12. The article according to claim 1, wherein said polymeric material contains between 2.5% and 75% per weight or volume of one or more fillers selected from the group consisting of carbon, carbon nanotubes, graphite, carbon fibers, graphite fibers, fiberglass, glass fibers, metals, metal alloys, metalized fibers, and metal coated glass fibers. 13. The article according to claim 1, wherein said polymeric material contains between 2.5% and 95% per weight or volume of an electrically conductive filler. 14. The metal-coated polymer article according to claim 1, wherein the metal-coated polymer article is configured to exhibit a pull-off strength between the polymeric material and the metallic material and between any intermediate layer(s) and the metallic material and between any intermediate layer(s) and the polymeric material is at least 200 psi as determined by ASTM D4541-02 Method A-E. 15. The metal-coated polymer article according to claim 1, wherein said metallic material comprises nickel and wherein the polymer article has at least one intermediate layer between the polymeric material and the metallic material, said at least one intermediate layer comprising nickel. 16. The metal-coated polymer article according to claim 1, wherein said metallic material comprises cobalt and wherein the polymer article has at least one intermediate layer between the polymeric material and the metallic material, said at least one intermediate layer comprising cobalt. 17. The article according to claim 1, wherein said metallic material comprises at least two metallic layers of the same or different chemical composition and/or microstructure. 18. The article according to claim 1, wherein said metallic material comprises laminated layers. 19. The article according to claim 1, wherein said metallic material is graded.