Metallized sheeting, composites, and methods for their formation

Abstract

A metallized composite includes a thermoplastic sheet and at least one discontinuous layer of metal within the thermoplastic sheet. The discontinuous metal layer can be disposed between two thermoplastic layers that are bound together, such as by melting the layers together, pressing, or by use of an adhesive. The metallized composites of the invention can be employed as reflective surfaces, such as are used as mirrors or substitutes for chrome trim on automobiles. A particularly preferred metal as a component of the discontinuous layer of the composite is indium.

What is claimed is:  
     
         1 . A method for forming an metallized composite, comprising the steps of: 
 a) depositing a metal on a first thermoplastic layer to from a discontinuous layer of said metal; and    b) laminating a second thermoplastic layer onto said discontinuous layer to form said metallized composite, thereby forming the metallized composite.    
     
     
         2 . The method of  claim 1 , further including the step of injection molding a thermoplastic polymer at a surface of the metallized composite.  
     
     
         3 . The method of  claim 1 , further including the step of blow molding a thermoplastic polymer at a surface of the metallized composite.  
     
     
         4 . The method of  claim 1 , further including the step of thermoforming a thermoplastic polymer at a surface of the metallized composite.  
     
     
         5 . The method of  claim 1 , further including the step of vacuum-forming a thermoplastic polymer at a surface of the metallized composite.  
     
     
         6 . The method of  claim 1 , further including the step of adhering the metallized composite to a substrate.  
     
     
         7 . The method of  claim 1 , wherein said metal is deposited on the first thermoplastic layer by electron beam evaporation.  
     
     
         8 . The method of  claim 7 , wherein indium is deposited on the first thermoplastic layer.  
     
     
         9 . The method of  claim 1 , wherein said metal is deposited on the first thermoplastic layer by sputtering.  
     
     
         10 . The method of  claim 1 , wherein said metal is deposited in the first thermoplastic layer by ion plating.  
     
     
         11 . The method of  claim 1 , wherein said metal is deposited in the first thermoplastic layer by induction heating.  
     
     
         12 . The method of  claim 1 , wherein said metal is deposited in the first thermoplastic layer by thermal evaporation.  
     
     
         13 . The method of  claim 1 , further including the step of bonding said first thermoplastic layer to said second thermoplastic layer.  
     
     
         14 . The method of  claim 13 , wherein said first thermoplastic layer is bonded to said second thermoplastic layer by heating said first and second thermoplastic layers.  
     
     
         15 . The method of  claim 14 , wherein said first and second thermoplastic layers bond by at least partially melting said layers, whereby said layers become a continuous thermoplastic sheet.  
     
     
         16 . The method of  claim 15 , wherein said first thermoplastic layer is bonded to said second thermoplastic layer by pressing said first and second layers together.  
     
     
         17 . The method of  claim 15 , wherein said first thermoplastic layer is bonded to said second thermoplastic layer by depositing an adhesive on said discontinuous layer of metal and said first thermoplastic layer prior to laminating said second thermoplastic layer onto the discontinuous layer.  
     
     
         18 . The method of  claim 17 , further including the step of curing said adhesive by exposure to ultraviolet light.  
     
     
         19 . The method of  claim 15 , wherein said first thermoplastic layer is bonded to said second thermoplastic layer by depositing an adhesive on said second thermoplastic layer prior to laminating the second layer onto the discontinuous layer, whereby said adhesive is trapped between said first and second thermoplastic layers of the metallized sheeting.  
     
     
         20 . The method of  claim 19 , further including the step of curing the adhesive by exposing to ultraviolet light.  
     
     
         21 . The method of  claim 1 , wherein said metal is deposited on said first thermoplastic layer by transferring said metal from a substrate applied to said first layer.  
     
     
         22 . The method of  claim 1 , further including the step of embossing said metallized composite.  
     
     
         23 . The method of  claim 1 , further including the step of folding said metallized composite.  
     
     
         24 . The method of  claim 1 , further including the step of applying said metallized composite to a support.  
     
     
         25 . The method of  claim 24 , further including the step of bonding said metallized composite to said support.  
     
     
         26 . The method of  claim 1 , further including the steps of: 
 a) depositing a metal onto the metallized composite to form a second discontinuous layer of metal; and    b) laminating a third thermoplastic layer onto said second discontinuous layer.