Blackened composite electroless nickel coatings

Abstract

In particular, the present invention is directed processes and product related to blackened coatings, blackened electroless nickel coatings, blackened electroless nickel coatings including particulate matter, coatings with cover coats, coatings with voids, and the methods of application and products with such coatings. Examples of parts which it may be beneficial to plate using the present invention include, but are not limited to textile parts electronics components and firearm parts

Description

[0001]This patent application claims priority to U.S. Provisional Patent Application No. 61 / 852,939, filed on Mar. 22, 2013 and incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]Electroless composite technology is a more recent development as compared to electrolytic composite technology. The fundamentals of composite electroless plating are documented in a text entitled “Electroless Plating Fundamentals and Applications,” edited by G. Mallory and J. B. Hajdu, Chapter 11, published by American Electroplaters and Surface Finishers Society (1990).[0003]The plating of articles with a composite coating bearing finely dispersed divided particulate matter is well documented. This technology has been widely practiced in the field of electroplating as well as electroless plating. The acceptance of such composite coating stems from the recognition that the inclusion of finely divided particulate matter within metallic matrices can significantly alter the properties of the coa...

AI Technical Summary

Benefits of technology

This patent text describes a technology called electroless composite plating, which involves the deposition of a coating on a substrate with finely dispersed particulate matter. This technology has been developed over the past several decades and has been widely practiced in various fields such as electronics, machinery, and surface finishes. The patent text also describes various methods and techniques for preparing and utilizing composite electroless plating, including the use of stabilizers, surfactants, and cationic and non-ionic fluorocarbon surfactants. The patent text also mentions the use of composite coatings in improving the properties of machinery parts, such as thermal transfer and wear resistance. The technical effects of this technology include improved properties such as wear resistance, lubricity, friction, and appearance, as well as improved thermal transfer and corrosion resistance.

Problems solved by technology

The inclusion of insoluble particulate matter in composite electroless baths introduces additional instability.

But this incorporation of heavy metals into the plating baths presents multiple challenges.

The heavy metals must be added in a sufficient amount to prevent the decomposition of the plating bath, but an increased concentration beyond the necessary level required to prevent the decomposition results in cessation or reduction of the plating rate.

Another example is in components used in consumer and industrial products such as automotives, electronics, and others which may ultimately be disposed and the disposition may lead to exposure or transfer of the PFOA or PFOS into the environment.

The EPA has been investigating PFOA because PFOA is very persistent in the environment, is found at very low levels both in the environment and in the blood of the general U.S. population, remains in people for a very long time, and causes developmental and other adverse effects in laboratory animals.

However, consumer products made with fluoropolymers and fluorinated telomers, including Teflon® and other products, are not PFOA.

That draft was preliminary and did not provide conclusions regarding potential levels of concern.

PFOS is persistent, bioaccumulative and toxic to mammalian species.

Repeated exposure results in hepatotoxicity and mortality; the dose-response curve is very steep for mortality.

It appears to be of low to moderate toxicity to aquatic organisms but there is evidence of high acute toxicity to honey bees.

No information is available on effects on soil- and sediment-dwelling organisms and the equilibrium partitioning method may not be suitable for predicting PNECs [Predicted No Effect Concentrations] for these compartments.

However, the article to be coated may require preliminary preparation prior to this contact.

While it is well documented that the use of composite coatings bearing wear resistance particles extends the lifetime of machinery parts, their use creates certain potential problems as to the degradation of the physical properties of the yarn when contacted with the wear resistant coated machinery part.

As is well known in the field of textile manufacturing and as can be seen on the surface of the traditional composite electroless nickel coatings used in this field, these traditional coatings, even those with an overcoat free of particles, may be too rough for an acceptable break-in period and / or effective use in processing certain types of fibers.

The problem with such roughness on the surface of textile machine parts is that this roughness can destroy small fibers not fully attached to the shaft of the yarn.

This creates dust in the processing of the fibers that can accumulate in the groove of a rotor cup used in rotor spinning applications and other areas of the spinning apparatus.

The accumulation of dust in this groove can lower yarn quality and cause yarn breaks, thereby adding time and expense to the textile preparation process.

Further, this text concurs that the traditional composite electroless nickel-diamond coating is too rough for the sensitive polyester fibers.

Moreover, these other methods suffer from various drawbacks, including high cost of manufacture and incompatibility with the substrate.

The added wear life provided by electroless nickel alone is less than commercially desirable for production and economic concerns.

More frequent replacement of worn components means additional cost for the replacement parts, and is a cost of time, labor, and lost productivity to accomplish the replacing of worn with new parts.

Moreover, the quality of the textile product produced by the spinning parts will then not be consistent throughout the operating lifetime of the spinning parts.

Once the part is sufficiently worn, the quality of the product again degrades.

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