Selective Metallization of Polymer Structures

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Solution Overview

Problem

Current metallizing processes for polymer structures are limited by their inability to uniformly coat complex geometries and components, often resulting in partially metallized products that are discarded due to uncontrollable variations and line-of-sight coverage restrictions, which restricts their application to specific sizes and architectures.

Innovation Solution

A method for manufacturing partially metallized polymer structures by selectively metallizing regions using electro- or electroless-plating, where different polymer compositions are used to create regions receptive and unreceptive to metal plating, involving processes like conditioning, etching, catalyzing, and immersion in inhibitor solutions, allowing for the formation of interconnected lattice structures with controlled metal deposition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If traditional metallizing processes are used to coat polymer structures, then uniform coating is achieved on simple geometries, but complex geometries and three-dimensional structures cannot be fully coated due to line-of-sight coverage restrictions

Engineering Contradiction:

Improvecoated surface areaVSAvoidcoating uniformity

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The patent segments the polymer structure into multiple regions with different metallization receptivity by using different polymer compositions or curing states in different zones. This allows selective metallization of specific areas while leaving others uncoated, resolving the contradiction between achieving complete coverage and maintaining coating uniformity on complex geometries.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by creating regions with distinct metallization properties throughout the polymer structure. Different zones are engineered to be either receptive or unreceptive to metal deposition, enabling precise control over where metallization occurs and achieving both complete area coverage and uniform coating quality in targeted regions.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If traditional metallizing processes are used, then complete metallization is achieved, but partial metallization results are discarded due to uncontrollable variations

Engineering Contradiction:

Improvemetallization controlVSAvoidyield rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent performs preliminary action by pre-engineering the polymer structure with regions of different metallization receptivity before the metallization process. This predetermined segmentation allows controlled and predictable metallization outcomes, eliminating uncontrollable variations and enabling consistent production of partially metallized components without discarding defective parts.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If selective metallization regions are created using different polymer compositions, then localized metallization is achieved, but manufacturing process complexity increases

Engineering Contradiction:

Improveselective metallizationVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies the nested doll principle by incorporating multiple polymer compositions or curing states within a single integrated polymer structure. This nested arrangement of different material zones within one component allows selective metallization to be achieved through the structure itself rather than through complex external manufacturing processes, thereby reducing overall process complexity while maintaining selective metallization capability.

Inventive Principle:

Principle #7Nested doll (Nesting)

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

Enables the creation of three-dimensional structures with localized metallization, enhancing structural reinforcement, corrosion resistance, and aesthetic properties while allowing for variable wave propagation and energy absorption, overcoming the limitations of existing metallizing techniques.

Implementation Method 1

etching the polymer structure

Methodology Applied

Scientific EffectEtching:

Implementation Method 2

catalyzing the polymer structure

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

immersing the polymer structure in an accelerator, and immersing the polymer structure in an electroless bath

Methodology Applied

Scientific EffectElectroless plating:

Implementation Method 4

forming the polymer structure by irradiating one or more photo-monomers with a series of light beams

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS10775534B2Structures having selectively metallized regions and methods of manufacturing the same

Publication Date: 2020.09.15 HRL LAB

AI summary

Methods of manufacturing a structure having at least one plated region and at least one unplated region. The method includes plating a metal on a polymer structure having a first region accepting the metal and a second region unreceptive to the metal plating. The first region may include fully-cured polymer optical waveguides and the second region may include partially-cured polymer optical waveguides. The first region may include a first polymer composition and the second region may include a second polymer composition different than the first polymer composition.