Method of two shot mold metallizing of polymer components

Abstract

A component is provided that is net shape molded using a polymer to form the core structure and which includes an integrally formed metallized coating or layer on at least one of the exterior surfaces thereof. The process of forming the component includes two-shot molding process wherein a thin layer of metal or the base polymer component is molded, the mold is adjusted and then the remainder of the part is molded. Alternately, an insert molding process may be employed such that after the polymer base part is formed, it may be placed into a mold cavity that is slightly larger than the entire part, thereby allowing substantially the entire exterior surface of the part to be over molded with a molten metal.

1 . A method of forming a net shape molded component including a metallic layer about at least one surface thereof, comprising the steps of: 
 providing a mold cavity having a first interior profile;    injecting a molten polymer into said mold cavity;    partially curing said molten polymer;    adjusting said mold cavity to a second interior profile, said second interior profile forming a void adjacent at least one surface of said polymer;    injecting a molten metal into said void; and    cooling said polymer and metal composition to form a polymer component having a metallic layer in communication with at least one surface thereof.    
   
   
       2 . The method of  claim 1 , wherein a melting point of the polymer and a melting point of the metal are approximately equal to one another.  
   
   
       3 . The method of  claim 1 , wherein said metal is a eutectic alloy.  
   
   
       4 . The method of  claim 1 , wherein said metal is an alloy of metals selected from the group consisting of zinc, tin and antimony.  
   
   
       5 . The method of  claim 1 , wherein the polymer is selected from the group consisting of thermoplastic polymer resins and thermoset polymer resins.  
   
   
       6 . The method of  claim 5 , wherein the polymer resin is selected from the group consisting of: polyphenylene sulfide (PPS), polycarbonate, liquid crystal polymers, co-polymers of acrylonitrile, butadiene, styrene (ABS) and mixtures thereof.  
   
   
       7 . The method of  claim 1 , wherein said step of injecting metal causes said at least one surface of said polymer to partially reflow and bond with said metal.  
   
   
       8 . A method of forming a net shape molded component including a metallic layer about at least one surface thereof, comprising the steps of: 
 providing a mold cavity having a first interior profile;    injecting a molten metal into said mold cavity;    cooling said molten metal thereby causing it to solidify;    adjusting said mold cavity to a second interior profile, said second interior profile forming a void adjacent said solidified metal;    injecting a molten polymer into said void; and    cooling said polymer and metal composition to form a polymer component having a metallic layer in communication with at least one surface thereof.    
   
   
       9 . The method of  claim 8 , wherein a melting point of the polymer and a melting point of the metal are approximately equal to one another.  
   
   
       10 . The method of  claim 8 , wherein said metal is and eutectic alloy.  
   
   
       11 . The method of  claim 8 , wherein the polymer is selected from the group consisting of thermoplastic polymer resins and thermoset polymer resins.  
   
   
       12 . A method of forming a net shape molded component including a metallic layer about at least one surface thereof, comprising the steps of: 
 providing a first mold cavity having a first interior profile;    injecting a molten polymer into said mold cavity;    partially curing said molten polymer;    removing said polymer from said first mold cavity;    placing said polymer into a second mold cavity having a second interior profile that is slightly larger than said first interior profile;    injecting a molten metal into said second mold cavity around at least a portion of said polymer; and    cooling said polymer and metal composition to form a polymer component having a metallic layer in communication with at least one surface thereof.    
   
   
       13 . The method of  claim 12 , wherein said metal fully surrounds an exterior surface of said polymer.  
   
   
       14 . The method of  claim 12 , wherein said polymer is positioned within said second mold cavity such that said metal partially surrounds an exterior surface of said polymer.  
   
   
       15 . The method of  claim 12 , wherein a melting point of the polymer and a melting point of the metal are approximately equal to one another.  
   
   
       16 . The method of  claim 12 , wherein said metal is a eutectic alloy.  
   
   
       17 . The method of  claim 12 , wherein the polymer is selected from the group consisting of thermoplastic polymer resins and thermoset polymer resins.  
   
   
       18 . A net shape molded component, comprising: 
 a polymer core having an exterior surface; and    a metal layer molded about at least a portion of said exterior surface of said polymer core, said metal layer having a melting temperature that is approximately equal to a melting temperature of said polymer core.    
   
   
       19 . The net shape molded component of  claim 18 , wherein said metal layer upon molding around said exterior surface of said polymer causes a portion of said exterior surface to temporarily reflow resulting in a bond between said metal and said polymer.  
   
   
       20 . The net shape molded component of  claim 18 , wherein a melting point of the polymer and a melting point of the metal are approximately equal to one another.  
   
   
       21 . The net shape molded component of  claim 18 , wherein said metal is a eutectic alloy.  
   
   
       22 . The net shape molded component of  claim 18 , wherein the polymer is selected from the group consisting of thermoplastic polymer resins and thermoset polymer resins.