Metal-clad polymer article

摘要

Metal-clad polymer articles containing structural fine-grained and/or amorphous metallic coatings/layers optionally containing solid particulates dispersed therein, are disclosed. The fine-grained and/or amorphous metallic coatings are particularly suited for strong and lightweight articles, precision molds, sporting goods, automotive parts and components exposed to thermal cycling although the coefficient of linear thermal expansion (CLTE) of the metallic layer and the substrate are mismatched. The interface between the metallic layer and the polymer is suitably pretreated to withstand thermal cycling without failure.

主权项

1. A metal-clad polymer article comprising:
(i) a polymeric material which at room temperature has a coefficient of linear thermal expansion in the range between 30×10−6 K−1 and 250×10−6 K−1 in at least one direction; and (ii) a metallic material having a microstructure which is fine-grained with an average grain size between 2 and 5,000 nm and/or an amorphous microstructure, the metallic material being in the form of a metallic layer having a thickness between 10 microns and 2.5 cm and a coefficient of linear thermal expansion at room temperature in all directions in the range between −5.0×10−6 K−1 and 25×10−6 K−1; (iii) with or without at least one intermediate layer between the polymeric material and the metallic material; (iv) an interface between the polymeric material and the metallic material or an interface between the polymeric material and one of any intermediate layer if present and an interface between one of any intermediate layer if present and the metallic material; (v) anchoring structure at said interface(s) comprising recesses and/or protrusions to increase the interface area and provide enhanced physical bond at the interface between the polymeric material and the metallic material or at the interface between the polymeric material and one of any intermediate layer if present and at the interface between one of any intermediate layer if present and the metallic material; (vi) said metal-clad polymer article exhibiting no delamination after said article has been exposed to at least one temperature cycle according to ASTM B553-71 service condition 1, 2, 3 or 4; and (vii) said metal-clad polymer article exhibiting a pull-off strength between the polymeric material and the metallic material or a pull-off strength between one of any intermediate layer if present and the metallic material exceeding 200 psi as determined by ASTM D4541-02 Method A-E; and (viii) said metal-clad polymer article or portions thereof having a yield strength and/or ultimate tensile strength of between 10 and 7,500 MPa and an elastic limit between 0.5 and 30%.