Method for bonding plastic to metal

Abstract

A method for bonding plastic to a metallic member is described which comprises the steps of forming a preselected pattern of etched cavities in the metallic surface to be bonded, which cavities at least in part increase in width with depth of etching, and subsequently applying a plastic layer to the metallic surface so that a portion of the applied plastic layer fills the cavities and form an interlock with the metallic surface.

I claim: 
     
       1. A method for bonding plastic to metal comprising the steps of: (a) providing a metallic member for bonding plastic thereto;   (b) overlaying a mask onto a selected surface of said metallic member, said mask having a preselected pattern therein defining preselected masked and unmasked protions of said selected surface;   (c) chemically etching said unmasked portions of said selected surface to preselected depth into said selected surface whereby cavities in said selected surface are formed which at least in part increase in width with depth of etching; and   (d) applying a layer of plastic to said selected surface of said metallic member whereby a portion of said layer of plastic fills said cavities and forms an interlock with said selected surface.   
     
     
       2. The method of claim 1 wherein the step of applying a layer of plastic is characterized by overlaying a sheet of said plastic onto said selected surface of said metallic member and applying at least one of heat and pressure to cause a portion of said plastic to fill said cavities to form said interlock. 
     
     
       3. The method of claim 1 wherein said metallic member comprises a metal selected from the group consisting of iron, aluminum, magnesium, copper, tin, zinc, titanium, zirconium, uranium, lead nickel, antimony, beryllium, cadmium, cerium, chromium, cobalt, gold, silver, hafnium, indium, iridium, molybdenum, palladium, platinum, rhenium, rhodium, tantalum, tungsten, and vanadium. 
     
     
       4. The method of claim 1 wherein said metallic member comprises an alloy of a metal selected form the group consisting of iron, aluminum, magnesium, copper, tin, zinc, titanium, zirconium, uranium, lead, nickel, antimony, beryllium, cadmium, cerium, chromium, cobalt, gold, silver, hafnium, indium, iridium, molybdenum, palladium, platinum, rhenium, rhodium, tantalum, tungsten, and vanadium. 
     
     
       5. The method of claim 1 wherein said plastic material is selected from the group consisting of polyolefins, styrene polymers, styrene copolymers, vinyl polymers, vinyl copolymers, polyesters, polyethers, polyamines, polyamides, polyimides, polyurethanes, elastomers, vinylidene polymers, phthalate polymers, ionomers, epoxies, cellulosics and silicones. 
     
     
       6. A method for bonding plastic to metal comprising the steps of: (a) providing a metallic member for bonding plastic thereto;   (b) depositing onto a selected surface of said metallic member a layer of photoresist material;   (c) overlaying onto said layer a photographic mask having a preselected pattern therein defining preselected masked and unmasked portions of said layer;   (d) exposing said unmasked portions of said layer to light to harden said unmasked portions of said layer;   (e) chemically removing said unmasked portions of said layer to expose a portion of said selected surface configured in said preselected pattern;   (f) chemically etching said portion of said selected surface to preselected depth into said selected surface whereby cavities in said selected surface are formed which at least in part increase in width with depth of etching; and   (g) applying a layer of plastic to said selected surface of said metallic member whereby a portion of said layer of plastic fills said cavities and forms an interlock with said selected surface.   
     
     
       7. The method of claim 6 wherein the step of applying a layer of plastic is characterized by overlaying a sheet of said plastic onto said selected surface of said metallic member and applying at least one of heat and pressure to cause a portion of said plastic to fill said cavities to form said interlock. 
     
     
       8. The method of claim 6 wherein said metallic member comprises a metal selected from the group consisting of iron, aluminum, magnesium, copper, tin, zinc, titanium, zirconium, uranium, lead, nickel, antimony, beryllium, cadmium, cerium, chromium, cobalt, gold, silver, hafnium, indium, iridium, molybdenum, palladium, platinum, rhenium, rhodium, tantalum, tungsten, and vanadium. 
     
     
       9. The method of claim 6 wherein said metallic member comprises an alloy of a metal selected form the group consisting of iron, aluminum, magnesium, copper, tin, zinc, titanium, zirconium, uranium, lead, nickel, antimony, beryllium, cadmium, cerium, chromium, cobalt, gold, silver, hafnium, indium, iridium, molybdenum, palladium, platinum, rhenium, rhodium, tantalum, tungsten, and vanadium. 
     
     
       10. The method of claim 6 wherein said plastic material is selected from the group consisting of polyolefins, styrene polymers, styrene copolymers, vinyl polymers, vinyl copolymers, polyesters, polyethers, polyamines, polyamides, polyimides, polyurethanes, elastomers, vinylidene polymers, phthalate polymers, ionomers, epoxies, cellulosics and silicones.