Molding composite part with metal layer

Abstract

A method of molding a metalized composite part. The method comprises: introducing particles comprising at least one metal into a gas stream; directing the gas stream toward a surface of a thermoplastic composite part, thereby depositing a metal layer on the composite part to form a metallized composite part; and molding the metallized composite part to introduce a bend without delamination of the metal layer from the metallized composite part.

What is claimed is: 
     
         1 . A method of molding a metalized composite part, the method comprising:
 introducing particles comprising at least one metal into a gas stream;   directing the gas stream toward a surface of a thermoplastic composite part, thereby depositing a metal layer on the composite part to form a metallized composite part; and   molding the metallized composite part to introduce a bend without delamination of the metal layer from the metallized composite part.   
     
     
         2 . The method of  claim 1 , wherein the at least one metal is chosen from aluminum, copper, gold, and silver. 
     
     
         3 . The method of  claim 1 , wherein the thermoplastic composite part comprises a thermoplastic and one or more filler materials. 
     
     
         4 . The method of  claim 3 , wherein the one or more filler materials are chosen from carbon nanotubes, inorganic fibers, carbon fibers, graphite fibers, woven glass fibers, unwoven glass fibers, ceramic fibers, alumina fibers, boron fibers, metal fibers, metalized fibers, metal coated glass fibers, metal coated alumina fibers, metal coated boron fibers, carbon particles, graphite particles, metal particles, glass particles, organic fibers and combinations thereof. 
     
     
         5 . The method of  claim 1 , wherein the metal layer imparts electrical EMI resistance or lightning protection, erosion protection, electromagnetic interference shielding, electromagnetic emission shielding, or lightning strike protection to the metalized composite part. 
     
     
         6 . The method of  claim 1 , further comprising heating the metal layer at an anneal temperature ranging from about 315° C. to about 400° C. 
     
     
         7 . The method of  claim 6 , wherein the heating occurs prior to the molding of the metal layer. 
     
     
         8 . The method of  claim 6 , wherein the anneal temperature is maintained for a period of time ranging from about 30 seconds to about 30 minutes. 
     
     
         9 . The method of  claim 1 , further comprising heating the particles prior to the depositing of the metal layer at an anneal temperature ranging from about 315° C. to about 400° C. to increase ductility of the metal layer. 
     
     
         10 . The method of  claim 1 , wherein the metal layer has a thickness ranging from about 0.01 mil to about 20 mils. 
     
     
         11 . The method of  claim 1 , further comprising cold spray coating or thermal spray coating onto the metal layer at least one additional metal layer different from the metal layer. 
     
     
         12 . The method of  claim 11 , wherein the at least one additional metal layer comprises at least one metal chosen from Ag, Al, Au, Co, Cr, Cu, Fe, Ni, Mo, Pd, Pt, Rh, Ru, Sn, Ti, W, Zn, and Zr. 
     
     
         13 . The method of  claim 1 , wherein an electrochemical insulating layer is disposed between the thermoplastic composite part and the metal layer. 
     
     
         14 . A cold sprayed metal coated article comprising:
 a thermoplastic composite part having at least one surface; and   a cold sprayed metal layer present on the thermoplastic composite part, the cold sprayed metal layer having a deformation produced by molding the thermoplastic composite part together with the cold sprayed metal layer;   optionally an electrochemical insulating layer disposed between the thermoplastic composite part and the cold sprayed metal layer; and   optionally at least one additional metal layer, the at least one additional metal layer sandwiching at least a portion of the metal layer between the at least one additional metal layer and the thermoplastic composite part; and   the cold sprayed metal coated article having an increase in one or more properties chosen from EMI resistance, erosion protection, lightning protection, electromagnetic interference shielding, electromagnetic emission shielding and lightning strike protection compared to the same thermoplastic composite part without the cold sprayed metal layer.   
     
     
         15 . The article of  claim 14 , wherein the metal layer comprises at least one metal chosen from aluminum, copper, gold and silver. 
     
     
         16 . The article of  claim 14 , wherein the at least one additional metal layer comprises at least one metal chosen from Ag, Al, Au, Co, Cr, Cu, Fe, Ni, Mo, Pd, Pt, Rh, Ru, Sn, Ti, W, Zn, and Zr. 
     
     
         17 . The article of  claim 14 , wherein the thermoplastic composite part comprises a thermoplastic and one or more filler materials. 
     
     
         18 . The article of  claim 17 , wherein the thermoplastic comprises at least one polymer chosen from epoxies, phenolics, polyesters, ureas, melamines, polyamides, polyimides, poly-ether-ether-ketones (PEEK), poly-ether-ketone-ketones (PEKK), polyetherimides, polyphthalamides, polyphthalates, polysulfones, polyurethanes, chlorinated polymers, fluorinated polymers, polytetrafluoroethylene, polycarbonates, liquid crystal polymers, and partially crystalline aromatic polyesters. 
     
     
         19 . The article of  claim 17 , wherein the one or more filler materials are chosen from carbon nanotubes, graphite particles, carbon fibers, graphite fibers, woven glass fibers, unwoven glass fibers, ceramic fibers, alumina fibers, boron fibers, metal fibers, metalized fibers, metal coated glass fibers, metal coated alumina fibers, metal coated boron fibers, carbon particles, graphite particles, metal particles, glass particles, organic fibers, and combinations thereof. 
     
     
         20 . The article of  claim 14 , wherein the thermoplastic composite part is a component or part of an aerospace vehicle.