Overplated thermally conductive part with EMI sheilding

Abstract

A net-shape molded heat transfer component is provided which includes a thermally conductive core and a metallic coating for reflection of electromagnetic interference and radio frequency waves. The heat transfer component is formed by net-shape molding a core body from a thermally conductive composition, such as a polymer composition, and applying a metallic coating. The molded heat transfer part is freely convecting through the part, which makes it more efficient and has an optimal thermal configuration. Additionally, the part is shielded from electromagnetic interference and radio frequency waves, thus preventing the transfer of same into the circuitry housed by the part. In addition, the coating also seals the conductive polymer core against moisture infiltration, making the part well suited for telecommunications applications in potentially harsh environments.

What is claimed is:  
     
         1 . A net-shape molded heat transfer part, comprising: 
 a core of thermally conductive material having an outer surface; and    a metallic coating disposed on said outer surface of said core.    
     
     
         2 . The net-shape molded heat transfer part of  claim 1 , wherein said thermally conductive core is a polymer composite material.  
     
     
         3 . The net-shape molded heat transfer part of  claim 2 , wherein said polymer composite includes a base matrix and a conductive filler loaded therein.  
     
     
         4 . The net-shape molded heat transfer part of  claim 3 , wherein said conductive filler is copper flakes.  
     
     
         5 . The net-shape molded heat transfer part of  claim 3 , wherein said conductive filler is carbon fiber.  
     
     
         6 . The net-shape molded heat transfer part of  claim 1 , wherein said metallic coating is an electromagnetic interference reflective coating.  
     
     
         7 . The net-shape molded heat transfer part of  claim 1 , wherein said metallic coating is a radio frequency wave reflective coating.  
     
     
         8 . The net-shape molded heat transfer part of  claim 1 , wherein said metallic coating is a copper-nickel coating.  
     
     
         9 . A method of forming a thermally conductive part, comprising the steps of: 
 molding a part of a thermally conductive composite material into a net-shape molded configuration; and    applying a metallic coating over said part.    
     
     
         10 . The method of  claim 9 , further comprising the step of: 
 providing an electromagnetic interference reflective layer about said part.    
     
     
         11 . A net-shape moldable heat transfer part, comprising: 
 A core of thermally conductive polymer composite including a base matrix of polymer material loaded with thermally conductive filler; and    A metallic coating on said core; said core being sealed from moisture and sealed from electromagnetic interference and radio frequency waves.    a metallic coating to substantially seal the polymer core against moisture infiltration.