Electroplated metals with silvery-white appearance and method of making

Abstract

Metals having a silvery-white appearance and methods of producing the same. In one embodiment, the composite material of the present invention comprises a metallic core, a first layer, and a second layer. The first layer encases the external surfaces of the metallic core and is produced by electroplating copper or copper alloy from a first bath containing copper ions. The second layer encases the first layer and is produced by electroplating white bronze from a second bath containing copper and tin ions. According to one embodiment of the method of the present invention, the first layer is electroplated on the metallic core and the second layer is electroplated on the first layer. In another embodiment of the composite material and method of the present invention, the material comprises only the metallic core and a first layer of white bronze. The resulting composite has a silvery-white appearance and does not include exposed nickel so that persons allergic to nickel metals are not affected by the composite. The composite material may be configured by standard processing methods to finished products such as coins, tokens, and medallions, keys, and other non-nesting articles.

1 . An article, comprising: 
 a metallic core having external surfaces; and    an electroplated layer of white bronze adhered to and encasing the external surfaces of the metallic core.    
   
   
       2 . The article of  claim 1 , wherein the metallic core comprises one of a group of zinc or zinc alloy.  
   
   
       3 . The article of  claim 1 , wherein the metallic core comprises one of a group of nickel or nickel alloy.  
   
   
       4 . The article of  claim 1 , wherein the metallic core comprises one of a group of iron or iron alloy.  
   
   
       5 . The article of  claim 1 , wherein the metallic core comprises one of a group of copper or copper alloy.  
   
   
       6 . The article of  claim 1 , wherein the metallic core comprises one of a group of aluminum or aluminum alloy.  
   
   
       7 . The article of  claim 1 , wherein the electroplated layer comprises from about 70% by weight of copper and about 30% by weight of tin to about 10% by weight of copper and about 90% by weight of tin.  
   
   
       8 . The article of  claim 1 , wherein the metallic core comprises a plate.  
   
   
       9 . The article of  claim 1 , wherein the metallic core comprises a plate from about 500 μm to about 4,000 μm in thickness.  
   
   
       10 . The article of  claim 1 , wherein the electroplated layer is from about 4 μm to about 25 μm thick.  
   
   
       11 . The article of  claim 1 , wherein the electroplated layer is at least about 25 μm thick.  
   
   
       12 . An article, comprising: 
 a metallic core comprising a plate of from about 500 μm to about 4,000 μm thick, having external surfaces, and comprised of one of a group of zinc, zinc alloy, nickel, nickel alloy, iron, iron alloy, copper, copper alloy, aluminum, or aluminum alloy; and    an electroplated layer adhered to and encasing the external surfaces of the metallic core, the electroplated layer of from at least about 4 μm thick and comprising from about 70% by weight of copper and about 30% by weight of tin to about 10% by weight of copper and about 90% by weight of tin.    
   
   
       13 . An article, comprising: 
 a metallic core having external surfaces;    a first electroplated layer of one of a group of copper or a copper alloy, the first electroplated layer adhered to and encasing the external surfaces of the metallic core; and    a second electroplated layer of white bronze adhered to and encasing the first electroplated layer.    
   
   
       14 . The article of  claim 13 , wherein the metallic core comprises one of a group of zinc or zinc alloy.  
   
   
       15 . The article of  claim 13 , wherein the metallic core comprises one of a group of nickel or nickel alloy.  
   
   
       16 . The article of  claim 13 , wherein the metallic core comprises one of a group of iron or iron alloy.  
   
   
       17 . The article of  claim 13 , wherein the metallic core comprises one of a group of copper or copper alloy.  
   
   
       18 . The article of  claim 13 , wherein the metallic core comprises one of a group of aluminum or aluminum alloy.  
   
   
       19 . The article of  claim 13 , wherein the copper or copper alloy comprises from about 60% by weight of copper to about 100% by weight of copper.  
   
   
       20 . The article of  claim 13 , wherein the white bronze comprises from about 70% by weight of copper and about 30% by weight of tin to about 10% by weight of copper and about 90% by weight of tin.  
   
   
       21 . The article of  claim 13 , wherein the metallic core comprises a plate.  
   
   
       22 . The article of  claim 13 , wherein the metallic core comprises a plate from about 500 μm to about 4,000 μm in thickness.  
   
   
       23 . The article of  claim 13 , wherein the first electroplated layer is from about 4 μm to about 25 μm thick.  
   
   
       24 . The article of  claim 13 , wherein the second electroplated layer is from about 4 μm to about 25 μm thick.  
   
   
       25 . An article, comprising: 
 a metallic core comprising a plate of from about 500 μm to about 4,000 μm thick, having external surfaces, and comprised of one of a group of zinc or a zinc alloy;    a first electroplated layer adhered to and encasing the external surfaces of the metallic core, the first electroplated layer of from about 4 μm to about 25 μm in thickness and comprising from about 60% by weight of copper to about 100% by weight of copper; and    a second electroplated layer adhered to and encasing the first electroplated layer, the second electroplated layer of from about 4 μm to about 25 μm in thickness and comprising from about 70% by weight of copper and about 30% by weight of tin to about 10% by weight of copper and about 90% by weight of tin.    
   
   
       26 . An article, comprising: 
 a metallic core comprising a plate of from about 500 μm to about 4,000 μm thick, having external surfaces, and comprised of one of a group of nickel or a nickel alloy;    a first electroplated layer adhered to and encasing the external surfaces of the metallic core, the first electroplated layer of from about 4 μm to about 25 μm in thickness and comprising from about 60% by weight of copper to about 100% by weight of copper; and    a second electroplated layer adhered to and encasing the first electroplated layer, the second electroplated layer of from about 4 μm to about 25 μm in thickness and comprising from about 70% by weight of copper and about 30% by weight of tin to about 10% by weight of copper and about 90% by weight of tin.    
   
   
       27 . An article, comprising: 
 a metallic core comprising a plate of from about 500 μm to about 4,000 μm thick, having external surfaces, and comprised of one of a group of iron or an iron alloy;    a first electroplated layer adhered to and encasing the external surfaces of the metallic core, the first electroplated layer of from about 4 μm to about 25 μm in thickness and comprising from about 60% by weight of copper to about 100% by weight of copper; and    a second electroplated layer adhered to and encasing the first electroplated layer, the second electroplated layer of from about 4 μm to about 25 μm in thickness and comprising from about 70% by weight of copper and about 30% by weight of tin to about 10% by weight of copper and about 90% by weight of tin.    
   
   
       28 . An article, comprising: 
 a metallic core comprising a plate of from about 500 μm to about 4,000 μm thick, having external surfaces, and comprised of one of a group of copper or a copper alloy;    a first electroplated layer adhered to and encasing the external surfaces of the metallic core, the first electroplated layer of from about 4 μm to about 25 μm in thickness and comprising from about 60% by weight of copper to about 100% by weight of copper; and    a second electroplated layer adhered to and encasing the first electroplated layer, the second electroplated layer of from about 4 μm to about 25 μm in thickness and comprising from about 70% by weight of copper and about 30% by weight of tin to about 10% by weight of copper and about 90% by weight of tin.    
   
   
       29 . An article, comprising: 
 a metallic core comprising a plate of from about 500 μm to about 4,000 μm thick, having external surfaces, and comprised of one of a group of aluminum or an aluminum alloy;    a first electroplated layer adhered to and encasing the external surfaces of the metallic core, the first electroplated layer of from about 4 μm to about 25 μm in thickness and comprising from about 60% by weight of copper to about 100% by weight of copper; and    a second electroplated layer adhered to and encasing the first electroplated layer, the second electroplated layer of from about 4 μm to about 25 μm in thickness and comprising from about 70% by weight of copper and about 30% by weight of tin to about 10% by weight of copper and about 90% by weight of tin.    
   
   
       30 . A method for making an article, the method comprising the steps of: 
 providing a metallic core having external surfaces;    providing a plating bath comprising copper ions and tin ions; and    electroplating a layer onto and encasing the metallic core using the plating bath.    
   
   
       31 . The method of  claim 30 , further including the step of removing contaminants from the metallic core prior to the step of electroplating.  
   
   
       32 . The method of  claim 30 , further comprising the steps of: 
 providing a die; and    placing the metallic core having the first layer thereon in the die.    
   
   
       33 . The method of  claim 32 , further comprising the step of removing contaminants from the layer prior to the step of placing the metallic core into the die.  
   
   
       34 . The method of  claim 30 , wherein the metallic core comprises one of a group of zinc or zinc alloy, such that the step of electroplating places a layer of white bronze on the zinc or zinc alloy metallic core.  
   
   
       35 . The method of  claim 30 , wherein the metallic core comprises one of a group of nickel or nickel alloy, such that the step of electroplating places a layer of white bronze on the nickel or nickel alloy metallic core.  
   
   
       36 . The method of  claim 30 , wherein the metallic core comprises one of a group of iron or iron alloy, such that the step of electroplating places a layer of white bronze on the iron or iron alloy metallic core.  
   
   
       37 . The method of  claim 30 , wherein the metallic core comprises one of a group of copper or copper alloy, such that the step of electroplating places a layer of white bronze on the copper or copper alloy metallic core.  
   
   
       38 . The method of  claim 30 , wherein the metallic core comprises one of a group of aluminum or aluminum alloy, such that the step of electroplating places a layer of white bronze on the aluminum or aluminum alloy metallic core.  
   
   
       39 . The method of  claim 30 , wherein the plating bath comprises copper ions and tin ions sufficient to produce the layer comprising from about 70% by weight of copper and about 30% by weight of tin to about 10% by weight of copper and about 90% by weight of tin from the step of electroplating.  
   
   
       40 . The method of  claim 30 , wherein the metallic core comprises a plate having a thickness from about 500 μm to about 4,000 μm, such that the coin resulting with the electroplated first and second layers has a total thickness of from about 508 μm.  
   
   
       41 . The method of  claim 30 , wherein the step of electroplating a layer results in a layer of at least about 4 μm.  
   
   
       42 . A method for making an article, the method comprising the steps of: 
 providing a metallic core having external surfaces;    providing a first bath comprising copper ions;    providing a second bath comprising copper ions and tin ions;    electroplating a first layer onto and encasing the metallic core using the first bath; and    electroplating a second layer onto and encasing the first layer using the second bath.    
   
   
       43 . The method of  claim 42 , further including the step of removing contaminants from the metallic core prior to the step of electroplating the first layer.  
   
   
       44 . The method of  claim 42 , further including the step of removing contaminants from the first layer prior to the step of electroplating the second layer.  
   
   
       45 . The method of  claim 42 , further comprising the steps of: 
 providing a die; and    placing the metallic core having the first and second layers thereon in the die.    
   
   
       46 . The method of  claim 45 , further comprising the step of removing contaminants from the second layer prior to the step of placing the metallic core into the die.  
   
   
       47 . The method of  claim 42 , wherein the metallic core comprises one of a group of zinc or zinc alloy, such that the step of electroplating a first layer creates a layer of copper or copper alloy on the zinc or zinc alloy.  
   
   
       48 . The method of  claim 42 , wherein the metallic core comprises one of a group of nickel or nickel alloy, such that the step of electroplating a first layer creates a layer of copper or copper alloy on the nickel or nickel alloy.  
   
   
       49 . The method of  claim 42 , wherein the metallic core comprises one of a group of iron or iron alloy, such that the step of electroplating a first layer creates a layer of copper or copper alloy on the iron or iron alloy.  
   
   
       50 . The method of  claim 42 , wherein the metallic core comprises one of a group of copper or copper alloy, such that the step of electroplating a first layer creates a layer of copper or copper alloy on the copper or copper alloy.  
   
   
       51 . The method of  claim 42 , wherein the metallic core comprises one of a group of aluminum or aluminum alloy, such that the step of electroplating a first layer creates a layer of copper or copper alloy on the aluminum or aluminum alloy.  
   
   
       52 . The method of  claim 42 , wherein the first bath comprises copper ions sufficient to produce a first layer comprising from about 60% by weight to about 100% by weight of copper from the step of electroplating a first layer.  
   
   
       53 . The method of  claim 42 , wherein the second bath comprises copper ions and tin ions sufficient to produce a first layer from about 70% by weight of copper and about 30% by weight of tin to about 10% by weight of copper and about 90% by weight of tin from the step of electroplating a second layer.  
   
   
       54 . The method of  claim 42 , wherein the metallic core comprises a plate having a thickness from about 500 μm to about 4,000 μm, such that the coin resulting with the electroplated first and second layers has a total thickness of from about 508 μm to about 4,050 μm.  
   
   
       55 . The method of  claim 42 , wherein the step of electroplating a first layer results in a first layer from about 4 μm to about 25 μm in thickness.  
   
   
       56 . The method of  claim 42 , wherein the step of electroplating a second layer results in a second layer from about 4 μm to about 25 μm in thickness.  
   
   
       57 . A method for making an article, the method comprising the steps of: 
 providing a metallic core in the form of a plate having external surfaces, the metallic core of a thickness from about 500 μm to about 4,000 μm and composed of one of the group of zinc or zinc alloy;    providing a plating bath comprising copper ions and tin ions; and    electroplating a layer onto and encasing the metallic core using the plating bath.    
   
   
       58 . The method of  claim 57 , further comprising the steps of: 
 providing a die; and    placing the metallic coin having the layer thereon in the die.    
   
   
       59 . A method for making an article, the method comprising the steps of: 
 providing a metallic core in the form of a plate having external surfaces, the metallic core of a thickness from about 500 μm to about 4,000 μm and composed of one of the group of nickel or nickel alloy;    providing a plating bath comprising copper ions and tin ions; and    electroplating a layer onto and encasing the metallic core using the plating bath.    
   
   
       60 . A method for making an article, the method comprising the steps of: 
 providing a metallic core in the form of a plate having external surfaces, the metallic core of a thickness from about 500 μm to about 4,000 μm and composed of one of the group of iron or iron alloy;    providing a plating bath comprising copper ions and tin ions; and    electroplating a layer onto and encasing the metallic core using the plating bath.    
   
   
       61 . A method for making an article, the method comprising the steps of: 
 providing a metallic core in the form of a plate having external surfaces, the metallic core of a thickness from about 500 μm to about 4,000 μm and composed of one of the group of copper or copper alloy;    providing a plating bath comprising copper ions and tin ions; and    electroplating a layer onto and encasing the metallic core using the plating bath.    
   
   
       62 . A method for making an article, the method comprising the steps of: 
 providing a metallic core in the form of a plate having external surfaces, the metallic core of a thickness from about 500 μm to about 4,000 μm and composed of one of the group of aluminum or aluminum alloy;    providing a plating bath comprising copper ions and tin ions; and    electroplating a layer onto and encasing the metallic core using the plating bath.    
   
   
       63 . A method for making an article, the method comprising the steps of: 
 providing a metallic core in the form of a plate having external surfaces, the metallic core of a thickness from about 500 μm to about 4,000 μm and composed of one of the group of zinc or zinc alloy;    providing a first bath comprising copper ions;    providing a second bath comprising copper and tin ions;    electroplating a first layer onto and encasing the metallic core using the first bath; and    electroplating a second layer onto and encasing the first layer using the second bath.    
   
   
       64 . The method of  claim 63 , further including the steps of: 
 providing a die; and    placing the metallic core having the first and second layers thereon in the die.    
   
   
       65 . A method for making an article, the method comprising the steps of: 
 providing a metallic core in the form of a plate having external surfaces, the metallic core of a thickness from about 500 μm to about 4,000 μm and composed of one of the group of nickel or nickel alloy;    providing a first bath comprising copper ions;    providing a second bath comprising copper and tin ions;    electroplating a first layer onto and encasing the metallic core using the first bath; and    electroplating a second layer onto and encasing the first layer using the second bath.    
   
   
       66 . A method for making an article, the method comprising the steps of: 
 providing a metallic core in the form of a plate having external surfaces, the metallic core of a thickness from about 500 μm to about 4,000 μm and composed of one of the group of iron or iron alloy;    providing a first bath comprising copper ions;    providing a second bath comprising copper and tin ions;    electroplating a first layer onto and encasing the metallic core using the first bath; and    electroplating a second layer onto and encasing the first layer using the second bath.    
   
   
       67 . A method for making an article, the method comprising the steps of: 
 providing a metallic core in the form of a plate having external surfaces, the metallic core of a thickness from about 500 μm to about 4,000 μm and composed of one of the group of copper or copper alloy;    providing a first bath comprising copper ions;    providing a second bath comprising copper and tin ions;    electroplating a first layer onto and encasing the metallic core using the first bath; and    electroplating a second layer onto and encasing the first layer using the second bath.    
   
   
       68 . A method for making an article, the method comprising the steps of: 
 providing a metallic core in the form of a plate having external surfaces, the metallic core of a thickness from about 500 μm to about 4,000 μm and composed of one of the group of aluminum or aluminum alloy;    providing a first bath comprising copper ions;    providing a second bath comprising copper and tin ions;    electroplating a first layer onto and encasing the metallic core using the first bath; and    electroplating a second layer onto and encasing the first layer using the second bath.