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3714 |
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Thursday, May 22, 2014, Hall A 9:00 AM Cold Gas Spraying 2 |
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Integration of electrical functionality by transplantation of cold sprayed electrical conductive Cu tracks via injection moulding |
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Christiane Schulz / Surface Engineering Institute, RWTH Aachen University, Germany Kirsten Bobzin / Surface Engineering Institute, Germany Mehmet Öte/ Surface Engineering Institute, Germany Thomas Frederik Linke*/ Surface Engineering Institute, Germany Christian Hopmann/ Institute of Plastics Processing, Germany Johannes Wunderle/ Institute of Plastics Processing, Germany |
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To increase the efficiency in manufacturing the cold spraying process is integrated into an injection moulding process in order to produce hybrid plastics/metal products in a single process step. Therefore, a cold sprayed copper track is applied to the surface of an injection mould insert. Subsequent, the metal layer is overmoulded and transferred to the surface of the injected polymer. By the new process complex injection moulded parts with electrical functionality such as electrically conductive tracks or improved electromagnetic compatibility can be produced. Especially in the production for automotive and consumer electronics multi-stage processes can be substituted by this new process. The transferability of the copper track greatly depends on the bond strength to the mould insert, which is influenced by the surface pretreatment of the mould insert, the mould insert material as well as the cold spray parameters. The bond strength is investigated regarding the particle velocity, the hardness of the mould insert material and the applied pre-treatment method. The achieved bond strength is correlated with the percentage of transfer and the electrical conductivity of the copper track. Moreover, the influence of voids, oxidation and cohesion of particles on the electrical conductivity is examined. |