Metallization of low temperature fibers and porous substrates

Abstract

Devices and methods for metalizing temperature sensitive materials including fabrics are provided. Contemplated method begins with a step of applying a catalyst solution on the temperature-sensitive material to form an at least partially catalyst-coated substrate. Then the catalyst-coated substrate is incubated at a relatively low temperature. Optionally, in some embodiments, the low temperature incubated substrate is incubated at a relatively high temperature. Then, a layer of an electroless metal is deposited on the at least partially catalyst-coated substrate using an electroless metal deposition technique.

What is claimed is: 
     
         1 . A method of metalizing a temperature-sensitive material, comprising steps of:
 applying a catalyst solution on the temperature-sensitive material to form an at least partially catalyst-coated substrate;   incubating the at least partially catalyst-coated substrate at a temperature less than 100 degree Celsius; and   depositing a layer of a metal on the at least partially catalyst-coated substrate using an electroless metal deposition technique.   
     
     
         2 . The method of  claim 1 , wherein the metal comprises at least one of the following: copper and nickel. 
     
     
         3 . The method of  claim 1 , wherein the temperature-sensitive material comprises at least one of the following: paper, polyethylene, clear olefininc polymers, acrylonitrile butadiene styrene, nylon, cotton based material, plant leaves, protein, and keratin-based material. 
     
     
         4 . The method of  claim 1 , wherein the catalyst comprises at least one of the following: palladium, silver, gold, tin, and platinum. 
     
     
         5 . The method of  claim 4 , wherein the catalyst is water insoluble. 
     
     
         6 . The method of  claim 1 , further comprising a step of treating the temperature-sensitive material with a first acidic solution at a temperature less than 100 degree Celsius before applying the catalyst solution. 
     
     
         7 . The method of  claim 6 , wherein the acidic solution comprises potassium permanganate and sulfuric acid. 
     
     
         8 . The method of  claim 6 , further comprising a step of treating the temperature-sensitive material with a second acidic solution after treating with the first acidic solution. 
     
     
         9 . The method of  claim 8 , wherein the second acidic solution comprises oxalic acid. 
     
     
         10 . The method of  claim 1 , further comprising a step of treating the at least partially catalyst-coated substrate with an acidic solution at a temperature less than 100 degree Celsius. 
     
     
         11 . The method of  claim 10 , wherein the acidic solution comprises formic acid. 
     
     
         12 . The method of  claim 10 , further comprising a step of washing the at least partially catalyst-coated substrate with at least one of water and methanol after treating with the acidic solution. 
     
     
         13 . The method of  claim 1 , further comprising a step of treating the at least partially catalyst-coated substrate with a solution of a reducing agent in an aqueous or mixed aqueous solvent or solvents. 
     
     
         14 . The method of  claim 13 , wherein the reducing agent is hydrazineN 2 H 4 . 
     
     
         15 . A method of metalizing a fabric comprising:
 applying a catalyst solution on the fabric to form a catalyst-coated fabric;   incubating the catalyst-coated substrate at a temperature less than 100 degree Celsius;   heating the catalyst-coated substrate at a temperature at least 250 degree Celsius; and   placing an electroless metal layer on the catalyst-coated fabric.   
     
     
         16 . The method of  claim 15 , wherein the electroless metal comprises at least one of the following: copper and nickel. 
     
     
         17 . The method of  claim 15 , wherein the fabric comprises a carbon fiber cloth, a Kevlar cloth, a cloth containing a natural fiber, a cloth containing a synthetic fiber. 
     
     
         18 . The method of  claim 15 , wherein the catalyst comprises at least one of the following: palladium, silver, gold, tin and platinum 
     
     
         19 . A method of metallizing a substrate comprising:
 applying to the substrate a catalyst precursor that has limited solubility in aqueous or mixed aqueous media to form a catalyst precursor layer;   drying the catalyst precursor layer;   treating the substrate with an aqueous or mixed aqueous solution of a reducing agent to converts the catalyst precursor to its active form; and   placing an electroless layer of metal on the substrate.   
     
     
         20 . The method of  claim 19 , wherein the limited solubility is less than 100 mg/L.