Laser-Induced Graphene Plating for Conductive Polymer Composites

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Solution Overview

Problem

Polymer composites in the aerospace industry face challenges with surface wear and abrasion, and the inability to incorporate metallic plating due to their insulative nature, which increases costs and limits their adoption, especially when electrical conductivity is required for applications like EMI shielding and static protection.

Innovation Solution

A method involving laser-induced graphene formation on polymeric substrates to create a conductive surface, allowing for the bonding of a metallic layer via electroplating, which facilitates traditional plating techniques and enhances electrical conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If polymer composites are used to reduce weight, then weight is reduced, but electrical conductivity is lost

Engineering Contradiction:

Improvecomponent weightVSAvoidelectrical conductivity

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent creates a composite structure by forming a graphene layer on the polymer composite surface through laser irradiation. This graphene-polymer composite provides both the weight advantage of polymers and the electrical conductivity of graphene, resolving the contradiction between weight reduction and conductivity requirements.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the surface properties of the polymer composite by applying laser energy, which transforms the insulating polymer surface into conductive graphene. This parameter change in surface composition and electrical properties allows the component to maintain bulk polymer weight advantages while achieving surface conductivity.

Inventive Principle:

Principle #35Parameter changes

2Strength

If metallic plating is applied to polymer composites, then wear resistance is improved, but manufacturing cost increases due to additional processing

Engineering Contradiction:

Improvewear resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent performs preliminary action by forming a graphene layer on the polymer surface before applying metallic plating. This pre-treatment creates a conductive and adhesive surface that enables direct plating processes, eliminating the need for expensive intermediate metal strike layers and reducing overall manufacturing complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The graphene layer serves as an intermediary between the polymer composite and the metallic plating. It provides both electrical conductivity for plating process initiation and enhanced adhesion for the metal coating, replacing the traditional need for multiple intermediate layers and simplifying the manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If traditional plating methods are used on non-conductive surfaces, then metallic coating can be applied, but additional metal strike layers are required significantly increasing costs

Engineering Contradiction:

Improveplating process simplicityVSAvoidnumber of processing layers

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent extracts the essential function of the metal strike layer (providing conductivity and adhesion) and replaces it with a graphene layer formed directly on the polymer surface. This eliminates the need for separate strike layer deposition processes and reduces the total number of processing steps required.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent substitutes the mechanical/chemical process of depositing metal strike layers with a laser-induced graphical transformation process. The laser energy directly converts surface polymer into conductive graphene, replacing multi-step metal deposition with a single energy-based transformation step.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach enables the use of non-conductive polymer composites in high-wear areas while reducing manufacturing costs and providing improved thermal transport and EMI shielding, allowing for the expansion of composite components in aerospace applications.

Implementation Method 1

treating a surface of a polymeric substrate with a laser to photothermally convert the insulative polymer on the surface to a porous graphene

Methodology Applied

Scientific EffectPhotothermal conversion: Laser

Implementation Method 2

laser scribing the surface with a carbon dioxide laser source

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 3

bonding a metallic layer is comprised of electroplating

Methodology Applied

Scientific EffectElectroplating: Electroplating

Implementation Method 4

disposing the anode and the polymeric component in an electrolyte solution, and supplying a current via the power source

Methodology Applied

Scientific EffectElectrolysis: Electrolysis

Data Source

PatentEP4089209A1Laser induced graphene as pretreatment to plate non-conductive composites

Publication Date: 2022.11.16 GOODRICH CORP

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Figure 2A~2D
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AI summary

A method of manufacture can comprise: treating a surface of a polymeric substrate (210) with a laser induced graphene; and bonding a metallic layer (218) to the laser induced graphene.