Corrosion-Resistant Copper Coating via PVD

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Solution Overview

Problem

Existing methods for creating corrosion-resistant metal surfaces, particularly those with high copper content, face challenges due to the expense of electroplating, the use of toxic substances, and inadequate corrosion protection from top layers, which are prone to damage and flaking.

Innovation Solution

A component with a corrosion-resistant copper coating is developed, featuring a plastic carrier part with a copper or copper alloy color layer, a translucent or transparent corrosion protection layer made from specific metals or their alloys, and a top layer, where the corrosion protection layer is applied directly to the color layer using Physical Vapor Deposition (PVD) without intermediate layers, ensuring effective adhesion and protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If electroplating is used to create metallic surfaces, then the component achieves a high-quality metallic appearance, but the process becomes complex and requires toxic substances

Engineering Contradiction:

Improvemetallic appearanceVSAvoidprocess complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent replaces the electroplating process (electrical/chemical system) with a vapor deposition process (physical system). The metallic appearance is achieved by depositing metal particles onto the component surface using vapor phase deposition, eliminating the need for complex electroplating equipment and toxic chemicals while maintaining the desired aesthetic appearance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental parameter of the coating application method from electrochemical deposition to physical vapor deposition. This parameter change allows for simpler processing, elimination of toxic substances, and flexible control of metal layer thickness and composition to achieve the desired metallic appearance.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a protective layer is applied to shield the copper coating from corrosion, then corrosion resistance is improved, but the protective layer is prone to mechanical damage and flaking

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidintegrity of protective layer

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent creates a composite coating structure consisting of multiple layers: a base layer, a copper-containing metal layer, and a protective top layer. This composite structure combines the corrosion resistance of the copper layer with the protective and mechanically robust properties of the top layer, creating a synergistic system that maintains integrity better than single-layer coatings.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements a multi-layer nested structure where the protective top layer is applied over the copper-containing metal layer, which is in turn applied over the base layer. This nested arrangement provides progressive protection: the base layer provides structural support, the copper layer provides corrosion resistance, and the top layer provides additional protection and durability, with each layer protecting the layers beneath.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Strength

If plasma or corona treatment is applied to ensure good adhesion between layers, then adhesion is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveadhesion between layersVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the adhesion promotion function with the vapor deposition process itself. By incorporating adhesion promoters directly into the vapor deposition system, the patent achieves good adhesion between layers without requiring separate plasma or corona treatment steps, thus simplifying the overall manufacturing process while maintaining strong interlayer bonding.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution provides a cost-effective, corrosion-resistant, and aesthetically appealing surface that maintains its integrity even when the top layer is damaged, offering enhanced protection and maintaining the characteristic color tones of copper or copper alloys.

Implementation Method 1

the corrosion protection layer is applied directly to the color layer using Physical Vapor Deposition (PVD)

Methodology Applied

Scientific EffectPhysical Vapor Deposition: Physical Vapour Deposition

Data Source

PatentEP4261246A1Improvement of the corrosion resistance of copper-based metallization layers and production of components with such layers

Publication Date: 2023.10.18 WEIDPLAS

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AI summary

A component with a corrosion-resistant copper coating is described, comprising a plastic substrate (1), a colored layer (3) applied to the substrate (1), a translucent or transparent corrosion protection layer (4) applied to the colored layer (3), and a topcoat (5, 6) applied to the corrosion protection layer (4). The colored layer (3) is made of copper or a copper alloy with a copper content of at least 30%, such as bronze or brass. The corrosion protection layer (4) is translucent or transparent and is made of one or more of the elements Al, Sc, V, Fe, Nb, Mo, Cr, Zr, Ti, Ag, Hf, Ta, W, Au, Pt, or their alloys. The topcoat (5, 6) is translucent or transparent. The corrosion protection layer (4) is applied directly to the colored layer (3). Furthermore, a method for manufacturing such a corrosion-resistant component is described.