US20140329045A1 - Building materials - Google Patents
Building materials Download PDFInfo
- Publication number
- US20140329045A1 US20140329045A1 US14/128,252 US201214128252A US2014329045A1 US 20140329045 A1 US20140329045 A1 US 20140329045A1 US 201214128252 A US201214128252 A US 201214128252A US 2014329045 A1 US2014329045 A1 US 2014329045A1
- Authority
- US
- United States
- Prior art keywords
- core
- outer layer
- conductive polymer
- building material
- metal
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000004566 building material Substances 0.000 title claims abstract description 51
- 229910052751 metal Inorganic materials 0.000 claims description 50
- 239000002184 metal Substances 0.000 claims description 49
- 229920001940 conductive polymer Polymers 0.000 claims description 47
- 238000000034 method Methods 0.000 claims description 34
- 239000000243 solution Substances 0.000 claims description 19
- 238000009713 electroplating Methods 0.000 claims description 18
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 17
- 239000010949 copper Substances 0.000 claims description 16
- 229910052802 copper Inorganic materials 0.000 claims description 16
- 229910045601 alloy Inorganic materials 0.000 claims description 15
- 239000000956 alloy Substances 0.000 claims description 15
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 13
- YLQBMQCUIZJEEH-UHFFFAOYSA-N Furan Chemical compound C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 claims description 12
- KAESVJOAVNADME-UHFFFAOYSA-N Pyrrole Chemical compound C=1C=CNC=1 KAESVJOAVNADME-UHFFFAOYSA-N 0.000 claims description 12
- YTPLMLYBLZKORZ-UHFFFAOYSA-N Thiophene Chemical compound C=1C=CSC=1 YTPLMLYBLZKORZ-UHFFFAOYSA-N 0.000 claims description 12
- 229920001169 thermoplastic Polymers 0.000 claims description 9
- 239000004416 thermosoftening plastic Substances 0.000 claims description 9
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 8
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical group [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 8
- 239000000843 powder Substances 0.000 claims description 8
- 239000011701 zinc Substances 0.000 claims description 8
- 229910052725 zinc Inorganic materials 0.000 claims description 8
- 238000001746 injection moulding Methods 0.000 claims description 7
- 229910052759 nickel Inorganic materials 0.000 claims description 7
- 239000002245 particle Substances 0.000 claims description 7
- 125000001140 1,4-phenylene group Chemical group [H]C1=C([H])C([*:2])=C([H])C([H])=C1[*:1] 0.000 claims description 6
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 6
- HSFWRNGVRCDJHI-UHFFFAOYSA-N alpha-acetylene Natural products C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 claims description 6
- 229920001577 copolymer Polymers 0.000 claims description 6
- 125000005549 heteroarylene group Chemical group 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 6
- 239000000178 monomer Substances 0.000 claims description 6
- 229920001197 polyacetylene Polymers 0.000 claims description 6
- 229920000767 polyaniline Polymers 0.000 claims description 6
- 229920000015 polydiacetylene Polymers 0.000 claims description 6
- 229920000128 polypyrrole Polymers 0.000 claims description 6
- 229920000123 polythiophene Polymers 0.000 claims description 6
- 229930192474 thiophene Natural products 0.000 claims description 6
- 229910000906 Bronze Inorganic materials 0.000 claims description 5
- 239000010974 bronze Substances 0.000 claims description 5
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 claims description 5
- 238000001125 extrusion Methods 0.000 claims description 5
- 239000011133 lead Substances 0.000 claims description 5
- 229910001369 Brass Inorganic materials 0.000 claims description 4
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 4
- 239000010951 brass Substances 0.000 claims description 4
- 229920001971 elastomer Polymers 0.000 claims description 4
- 239000000806 elastomer Substances 0.000 claims description 4
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 4
- 229910052737 gold Inorganic materials 0.000 claims description 4
- 239000010931 gold Substances 0.000 claims description 4
- 229910052709 silver Inorganic materials 0.000 claims description 4
- 239000004332 silver Substances 0.000 claims description 4
- 229910000679 solder Inorganic materials 0.000 claims description 4
- 229920001187 thermosetting polymer Polymers 0.000 claims description 4
- 239000011135 tin Substances 0.000 claims description 4
- 239000006229 carbon black Substances 0.000 claims description 3
- 238000000748 compression moulding Methods 0.000 claims description 3
- 239000000835 fiber Substances 0.000 claims description 3
- 229910021389 graphene Inorganic materials 0.000 claims description 3
- 229910002804 graphite Inorganic materials 0.000 claims description 3
- 239000010439 graphite Substances 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 229910021645 metal ion Inorganic materials 0.000 claims description 3
- 238000000465 moulding Methods 0.000 claims description 3
- 230000015572 biosynthetic process Effects 0.000 claims description 2
- 230000000903 blocking effect Effects 0.000 claims description 2
- 239000002041 carbon nanotube Substances 0.000 claims description 2
- 229910021393 carbon nanotube Inorganic materials 0.000 claims description 2
- 239000012811 non-conductive material Substances 0.000 claims description 2
- 229920000642 polymer Polymers 0.000 description 13
- 239000004033 plastic Substances 0.000 description 10
- 229920003023 plastic Polymers 0.000 description 10
- 239000002585 base Substances 0.000 description 9
- 150000001450 anions Chemical class 0.000 description 4
- 239000004020 conductor Substances 0.000 description 4
- 150000002739 metals Chemical class 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 150000001768 cations Chemical class 0.000 description 3
- 239000002131 composite material Substances 0.000 description 3
- 238000004070 electrodeposition Methods 0.000 description 3
- 238000007772 electroless plating Methods 0.000 description 3
- 238000007747 plating Methods 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- JPVYNHNXODAKFH-UHFFFAOYSA-N Cu2+ Chemical compound [Cu+2] JPVYNHNXODAKFH-UHFFFAOYSA-N 0.000 description 2
- VEQPNABPJHWNSG-UHFFFAOYSA-N Nickel(2+) Chemical compound [Ni+2] VEQPNABPJHWNSG-UHFFFAOYSA-N 0.000 description 2
- PTFCDOFLOPIGGS-UHFFFAOYSA-N Zinc dication Chemical compound [Zn+2] PTFCDOFLOPIGGS-UHFFFAOYSA-N 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 210000003195 fascia Anatomy 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 238000004184 polymer manufacturing process Methods 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- JIAARYAFYJHUJI-UHFFFAOYSA-L zinc dichloride Chemical compound [Cl-].[Cl-].[Zn+2] JIAARYAFYJHUJI-UHFFFAOYSA-L 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 238000001994 activation Methods 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 230000000536 complexating effect Effects 0.000 description 1
- 229910001431 copper ion Inorganic materials 0.000 description 1
- ORTQZVOHEJQUHG-UHFFFAOYSA-L copper(II) chloride Chemical compound Cl[Cu]Cl ORTQZVOHEJQUHG-UHFFFAOYSA-L 0.000 description 1
- ARUVKPQLZAKDPS-UHFFFAOYSA-L copper(II) sulfate Chemical compound [Cu+2].[O-][S+2]([O-])([O-])[O-] ARUVKPQLZAKDPS-UHFFFAOYSA-L 0.000 description 1
- 229910000366 copper(II) sulfate Inorganic materials 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000003487 electrochemical reaction Methods 0.000 description 1
- 238000005323 electroforming Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000004794 expanded polystyrene Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 230000005499 meniscus Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000005555 metalworking Methods 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 229910001453 nickel ion Inorganic materials 0.000 description 1
- LGQLOGILCSXPEA-UHFFFAOYSA-L nickel sulfate Chemical compound [Ni+2].[O-]S([O-])(=O)=O LGQLOGILCSXPEA-UHFFFAOYSA-L 0.000 description 1
- 229910000363 nickel(II) sulfate Inorganic materials 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 229910001174 tin-lead alloy Inorganic materials 0.000 description 1
- -1 type 2500 Chemical compound 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 239000011592 zinc chloride Substances 0.000 description 1
- 235000005074 zinc chloride Nutrition 0.000 description 1
- NWONKYPBYAMBJT-UHFFFAOYSA-L zinc sulfate Chemical compound [Zn+2].[O-]S([O-])(=O)=O NWONKYPBYAMBJT-UHFFFAOYSA-L 0.000 description 1
- 229910000368 zinc sulfate Inorganic materials 0.000 description 1
- 239000011686 zinc sulphate Substances 0.000 description 1
Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0866—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/54—Contact plating, i.e. electroless electrochemical plating
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/02—Electroplating: Baths therefor from solutions
- C25D3/38—Electroplating: Baths therefor from solutions of copper
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/02—Electroplating of selected surface areas
- C25D5/022—Electroplating of selected surface areas using masking means
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/54—Electroplating of non-metallic surfaces
- C25D5/56—Electroplating of non-metallic surfaces of plastics
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/12—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of metal or with an outer layer of metal or enameled metal
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00439—Physico-chemical properties of the materials not provided for elsewhere in C04B2111/00
- C04B2111/00465—Heat conducting materials
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/90—Electrical properties
- C04B2111/94—Electrically conducting materials
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/18—Electroplating using modulated, pulsed or reversing current
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/23—Sheet including cover or casing
- Y10T428/239—Complete cover or casing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31533—Of polythioether
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
- Y10T428/31692—Next to addition polymer from unsaturated monomers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
- Y10T428/31692—Next to addition polymer from unsaturated monomers
- Y10T428/31696—Including polyene monomers [e.g., butadiene, etc.]
Definitions
- the present invention relates to building materials.
- the present invention relates to building materials for placement on the exterior of buildings.
- the present invention also relates to methods of producing such building materials.
- Modern building methods call for a variety of building materials to inter alia suit aesthetic preferences and provide weather resistance over a number of years.
- Vulcan Supply Corp.TM sell roofing products, e.g. roof tiles, which consist of copper.
- the copper is said to provide aesthetic properties to roofs, be waterproof and be environmentally friendly.
- metallic building materials e.g. those mentioned above, stand up to strong weather conditions, they use a large amount of metal raw material. This results in high raw material cost, when compared to, for example, ceramic tiles, and generally high density, leading to higher transport costs, when compared to, for example, ceramic tiles.
- the inclusion of large amounts of metal raw material means that metallic building materials are heavy for their size, relative to plastic panels for example, because metals generally have a high density. Heavier panels for roofing, for example, place limits on design freedom in buildings, increases transportation costs and places tough limits on structures, e.g. with a particularly heavy roof walls would have to be thicker and foundations built to be more robust.
- U.S. Pat. No. 5,417,838 discloses the preparation of building panels, e.g. roofing panels, by placing a layer of copper over a preformed plastics structural base.
- the plastics structural base is generally an insulator.
- the surface of the plastics structural base was subjected to an oxidising process by a high voltage corona discharge to render the surface conductive.
- the structural base was then placed in an electrodeposition bath and a thin layer of copper metal was deposited on the surface of the base.
- U.S. Pat. No. 5,417,838 discloses the deposition of copper metal on a plastics structural base, the copper metal is a very thin layer and the panels produced are not suitable for most environments.
- the metal layers of the panels produced in U.S. Pat. No. 5,417,838 erode quickly to expose the plastics base layer because the plastics structural bases are poor conductors and have limited ability to electroplate.
- the metal layer in the panels disclosed in U.S. Pat. No. 5,417,838 has a tendency to separate from the plastics structural base due to differences in coefficient of thermal expansion between the two materials.
- an insulating polymer provides a supporting role as the host material for conducting material, the conducting material being placed within holes in the host material.
- the conductivity is provided by a network of conductive particles, metal powders, graphite and/or carbon black to form an electrically conductive network.
- “Filled resin” materials have very limited ability to electroplate effectively and the adhesion of the deposited metal to the thermoplastic substrate is weak; the surface and appearance finish are poor. This is because the insulating plastic on the surface has no electrical potential. Only the parts of the surface which are conductive have any electrical potential.
- a building material comprising:
- the outer layer surrounds the core.
- the outer layer partially surrounds the core.
- the intrinsically conductive polymer comprises an electrically conductive thermoplastic, a conductive thermoset plastic, a conductive elastomer, and/or a conductive polymer blend.
- the intrinsically conductive polymer comprises any one or more of polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene, where heteroarylene can be thiophene, furan or pyrrole, poly-p-phenylene, polyphenylene-sulphide, polyperinaphthalene, polyphthalocyanine, and their derivatives formed from monomers substituted with side chains or groups, or their copolymers.
- the core comprising a conductive polymer further comprises a non-conductive material.
- the intrinsically conductive polymer is filled and/or mixed with conductive particles.
- the conductive particles are one or more of carbon black, graphite, graphene, carbon nanotubes and metal powders or fibers.
- the outer layer is zinc, copper, nickel, bronze, brass, solder, chrome, tin, lead, gold, silver and any other metallic metal or alloy, or combination of metallic metal and/or alloy, preferably, wherein the outer layer is copper.
- the building material is a panel, a facade panel, a rainscreen, a tile, a door, a fascia, a soffit, a weatherboard, a garage door, door furniture, fencing, a building detailing, a flashing, guttering, piping, a window frame or an ancillary of any shape and/or size for a particular building function.
- a method of making a building material for use on the exterior of a building, the building material comprising a core comprising an intrinsically conductive polymer, and, an outer layer, wherein the outer layer is metallic, wherein the method comprises:
- the step of electroplating the outer layer over the core is by electrochemical means.
- the intrinsically conductive polymer is an electrically conductive thermoplastic, a conductive thermoset plastic, a conductive elastomer, or a conductive polymer blend.
- the intrinsically conductive polymer comprises any one or more of polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene, where heteroarylene can be thiophene, furan or pyrrole, poly-p-phenylene, polyphenylene-sulphide, polyperinaphthalene, polyphthalocyanine, and their derivatives formed from monomers substituted with side chains or groups, or their copolymers.
- the core comprising a conductive polymer is formed by a polymer manufacturing processes, preferably, compression moulding, extrusion, intrusion or injection moulding.
- the step of forming a core comprising a conductive polymer comprises the step of over moulding the conductive polymer over another material, optionally wherein the other material is a non-conductive polymer, further optionally wherein the step of over moulding includes bi-injection moulding and/or co-extrusion.
- electroplating the outer layer over the core by electrochemical means comprises:
- the method comprises the further step of affixing a blocking structure to the core, prior to electroplating, so as to prevent formation of an outer layer at one or more positions on the core.
- a building material obtainable by a method according to any one of the above methods.
- FIG. 1 is a schematic representation of a building material according to the present invention.
- FIG. 2 is a cross-section along line A-A of FIG. 1 .
- FIG. 3 is a schematic representation of a method of manufacturing a building material according to the present invention.
- the building material 1 is a tile which could be placed on a roof or on an external surface of a building.
- the building material item could be a panel (optionally, a façade panel), a rainscreen, a tile, a door, a fascia, a soffit, a weatherboard, a garage door, door furniture, fencing, a building detailing, a flashing, guttering, piping, a window frame or an ancillary of any shape and/or size for a particular building function.
- FIG. 2 shows the building material 1 in cross section along the line A-A.
- FIG. 2 shows that the building material 1 has a core 3 and an outer layer 2 surrounding the core 3 .
- the core 3 comprises an intrinsically conductive polymer, for example an intrinsically conductive thermoplastic.
- the outer layer 2 is a metallic layer.
- intrinsically conductive polymer(s) refers to organic polymers which have poly-conjugated it-electron systems (e.g. double bonds or aromatic rings).
- examples of such polymers include, but are not limited to, polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene (where heteroarylene can be thiophene, furan or pyrrole), poly-p-phenylene, polyphenylene-sulphide, polyperinaphthalene, polyphthalocyanine, and other known intrinsically conductive polymers, and their derivatives (formed for example from monomers substituted with side chains or groups), their copolymers and their physical compounds.
- the intrinsically conductive polymer of the core 3 may be over-moulded over another polymer or material, which may not be electrically conductive.
- the core 3 is formed by initially forming a composite part from a first polymer and/or other generally inert material, e.g. a non-electrically conductive polymer (which may be relatively cheaper and/or lighter than the electrically conductive polymer, e.g. epoxy resin, expanded polystyrene, polymer foams) and/or glass materials, and subsequently forming the intrinsically conductive polymer over the composite part formed of the first polymer.
- a non-electrically conductive polymer which may be relatively cheaper and/or lighter than the electrically conductive polymer, e.g. epoxy resin, expanded polystyrene, polymer foams
- Examples of metals and alloys which in different embodiments make up the outer layer 2 include zinc, copper, nickel, bronze, brass, solder, chrome, tin, lead, gold, silver and any other metallic metal or alloy, or a combination of metallic metal and/or alloy.
- the presence of the core 3 reduces the amount of metal required in the building material item 3 , as compared with building materials made entirely of metal.
- the building material 1 can, in one embodiment, be made by a method as discussed with reference to FIG. 3 .
- FIG. 3 shows electroplating of a metallic outer layer 2 on top of a core 3 , the core 3 being made of an intrinsically conductive polymer, for example, but not limited to, polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene (where heteroarylene can be thiophene, furan or pyrrole), poly-p-phenylene, polyphenylene-sulphide, polyperinaphthalene, polyphthalocyanine, and other known intrinsically conductive polymers, and their derivatives (formed for example from monomers substituted with side chains or groups), their copolymers and their physical compounds.
- an intrinsically conductive polymer for example, but not limited to, polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene (
- the core 3 of intrinsically conductive polymer can be made by known polymer manufacturing processes, such as compression moulding, extrusion, intrusion or injection moulding. Using these known processes, the core 3 can be shaped for its desired function. Alternatively, in other non-limiting embodiments, the core 3 , comprising an intrinsically conductive polymer and a separate composite part formed of another material can be formed together by bi-injection or co-extrusion.
- the cathode is the core 3 .
- the anode 4 is a metallic element made up of metal atoms which are to be layered on top of the core 3 .
- the cathode and the anode 4 are both connected to an external supply of direct current 5 , e.g. a battery or a rectifier.
- the anode 4 is connected to the positive terminal of the external supply of direct current 5 and the cathode is connected to the negative terminal.
- the external supply of direct current 5 is turned on, the metal at the anode is oxidised to form cations which have a positive charge and go into the solution 6 , which has a meniscus 7 .
- the cations M n+ associate with anions A n ⁇ in solution.
- the cations are reduced at the cathode and deposit in the metallic state. In other words, by way of this electroplating process, a metallic outer layer 2 forms over the core 3 .
- the cathode can be made from any intrinsically conductive polymer, e.g. intrinsically conductive thermoplastics.
- intrinsically conductive thermoplastics include, but are not limited to, polymers currently on the market and sold by Cool Polymers®, Inc. as their E-series polymers, such as E2, E4501, E4505 and E5101.
- the intrinsically conductive polymer of the core can be selected to match the thermal expansion coefficient of the metal which is deposited on and/or over the core.
- the co-efficient of thermal expansion of E4505 is 33 ppm/° C.
- Metallic zinc has a similar co-efficient of thermal expansion at 30 ppm/° C. Therefore, a core comprising E4505 and an outer layer of zinc is a particularly preferred example.
- the thermal expansion coefficient of the core is often between two or three times the thermal expansion coefficient of most metals, e.g. zinc and copper.
- the co-efficient of thermal expansion of the core and the metallic outer layer prefferably be the same, or at least a similar co-efficient of thermal expansion within 20,10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 ppm/° C.
- the core 3 mentioned above can additionally include injection moulding metal powders, particles or fibers, and/or graphene, to make an intrinsically conductive polymer and metal blend or matrix.
- injection moulding metal powders include, but are not limited to, bronze granules and flake metal copper powder (e.g. type 2500, as currently sold by AVL Metal Powders NV, Kortrijk, Belgium).
- the injection moulding metal powders include stainless steel fibres, particles or powders (e.g. Advanced Metalworking Practices, LLC product range ADVAMET®).
- the passive oxide film of the stainless steel exposed on the surface of the thermoplastic matrix must be cleaned by chemical cleaning and activation processes, such as nickel strike, chloride pre cleaning, e.g. Zinc chloride or copper chloride strikes.
- the anode can be made from any metal or alloy, i.e. an alloy which can undergo the electroplating process, from which it is desired to form the outer layer 2 over the core 3 .
- metals and alloys which can form the anode include, but are not limited to, zinc, copper, nickel, bronze, brass, solder, chrome, tin, lead, gold, silver and any other metallic metal or alloy, or combination of metallic metal and/or alloy.
- the solution 6 contains a dissolved mixture of metallic salt which is complementary to the metal forming the anode 4 .
- the solution 6 can be a solution of CuSO 4 , so the anion, A n ⁇ , is SO 4 2 ⁇ and the copper ions in solution are Cu 2+ .
- the solution 6 can be a solution of ZnSO 4 , so the anion, A n ⁇ , is SO 4 2 ⁇ and the zinc ions in solution are Zn 2+ .
- the solution 6 can be a solution of NiSO 4 , so the anion, A n ⁇ , is SO 4 2 ⁇ and the nickel ions in solution are Ni 2+ .
- the anode is often of the same metal to be deposited but not always.
- the anode can consist of a non-consumable alternative metal.
- lead can be used as the anode when it is desired to reduce the g/l of copper content in the copper plating solution.
- tin-lead alloy anodes can be employed for chromium plating, for example with chrome flakes directly added according to the usage of the bath as opposed to a reduction of the anode.
- the intrinsically conductive polymer which makes up the core 3 is selected to allow sufficient electrodeposition of the chosen metal or alloy.
- the conductive polymer will have an electrical resistance of 10000 per square or less, including each and every integer below 10000 per square, preferably an electrical resistance of 400 per square or less.
- the units of ⁇ per square are commonly used when referring to sheet resistance. Referring to sheet resistance as simply ⁇ could be taken out of context and misinterpreted as bulk resistance.
- Electroplating can be carried out using reverse pulse plating to reduce the effect of intrinsically conductive polymers' electrical resistance on the current density during electroplating.
- the whole of the core 3 is covered with the metallic outer layer 2 .
- the metallic outer layer 2 e.g. only the part of the building material 1 which is to be exposed to the elements when the building material is in use.
- Electroless plating is an auto-catalytic process for depositing a metal and/or alloy on an object, for example, a plastic object. Electroless plating utilises a reducing agent to react with metal ions in solution to deposit metal on the object.
- the building materials according to the present invention provide building materials with similar wear properties to known metallic building materials with at least the advantage that the building materials of the present invention use less raw metallic material. This saves on raw material cost and also reduces the weight of the building materials, thereby reducing, for example, transportation cost.
- the building materials according to the present invention provide building materials with thicker metallic layers over the core than previous building materials formed by electrodeposition over a generally insulating polymeric core after the core has been subjected to an oxidising process to render the surface at least partially conductive.
- the core is weakly conducting so only a very thin layer of metal can be economically deposited.
- the metallic layer formed on a generally insulating core after the generally insulating polymeric core has been oxidised is only weakly attached and is more akin to electroforming, where a metallic layer can be formed on a surface by mechanical (e.g. by screws or bolts), or adhesive (e.g. glue), means.
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Abstract
The present invention relates to building materials, particularly building materials for placement on the outside of buildings.
Description
- The present invention relates to building materials. In particular, the present invention relates to building materials for placement on the exterior of buildings. The present invention also relates to methods of producing such building materials.
- Modern building methods call for a variety of building materials to inter alia suit aesthetic preferences and provide weather resistance over a number of years.
- Various different materials have been used in the past to provide desired finishes to buildings. Common building materials include bricks and mortar for walls and slates for roofs. Metallic panels for exterior walls and/or tiles for roofs are now quite regularly used to provide hard wearing building materials which can come in a variety of colours. Panels and tiles can be provided with matching flashings and ancillaries to provide a desired finish. Examples of metallic panels are provided in the UK by Kingspan Benchmark™ and by KME™. In addition, Rockwool™ sell imitation metallic panels.
- Vulcan Supply Corp.™ sell roofing products, e.g. roof tiles, which consist of copper. The copper is said to provide aesthetic properties to roofs, be waterproof and be environmentally friendly.
- Although known metallic building materials, e.g. those mentioned above, stand up to strong weather conditions, they use a large amount of metal raw material. This results in high raw material cost, when compared to, for example, ceramic tiles, and generally high density, leading to higher transport costs, when compared to, for example, ceramic tiles. The inclusion of large amounts of metal raw material means that metallic building materials are heavy for their size, relative to plastic panels for example, because metals generally have a high density. Heavier panels for roofing, for example, place limits on design freedom in buildings, increases transportation costs and places tough limits on structures, e.g. with a particularly heavy roof walls would have to be thicker and foundations built to be more robust.
- It would, therefore, be preferable to have building materials which provide the aesthetic and weather resistant properties of known metallic building materials, whilst using less metal.
- U.S. Pat. No. 5,417,838 discloses the preparation of building panels, e.g. roofing panels, by placing a layer of copper over a preformed plastics structural base. The plastics structural base is generally an insulator. However, in one example the surface of the plastics structural base was subjected to an oxidising process by a high voltage corona discharge to render the surface conductive. The structural base was then placed in an electrodeposition bath and a thin layer of copper metal was deposited on the surface of the base.
- Although U.S. Pat. No. 5,417,838 discloses the deposition of copper metal on a plastics structural base, the copper metal is a very thin layer and the panels produced are not suitable for most environments. In other words, the metal layers of the panels produced in U.S. Pat. No. 5,417,838 erode quickly to expose the plastics base layer because the plastics structural bases are poor conductors and have limited ability to electroplate. Additionally, the metal layer in the panels disclosed in U.S. Pat. No. 5,417,838 has a tendency to separate from the plastics structural base due to differences in coefficient of thermal expansion between the two materials.
- In “filled resins”, coated with metallic layers, an insulating polymer provides a supporting role as the host material for conducting material, the conducting material being placed within holes in the host material. The conductivity is provided by a network of conductive particles, metal powders, graphite and/or carbon black to form an electrically conductive network.
- “Filled resin” materials have very limited ability to electroplate effectively and the adhesion of the deposited metal to the thermoplastic substrate is weak; the surface and appearance finish are poor. This is because the insulating plastic on the surface has no electrical potential. Only the parts of the surface which are conductive have any electrical potential.
- In a first aspect of the present invention, there is provided a building material, comprising:
-
- a core comprising an intrinsically conductive polymer, and,
- an outer layer, wherein the outer layer is metallic.
- Preferably, wherein the outer layer surrounds the core.
- Further preferably, wherein the outer layer partially surrounds the core.
- Advantageously, wherein the intrinsically conductive polymer comprises an electrically conductive thermoplastic, a conductive thermoset plastic, a conductive elastomer, and/or a conductive polymer blend.
- Preferably, wherein the intrinsically conductive polymer comprises any one or more of polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene, where heteroarylene can be thiophene, furan or pyrrole, poly-p-phenylene, polyphenylene-sulphide, polyperinaphthalene, polyphthalocyanine, and their derivatives formed from monomers substituted with side chains or groups, or their copolymers.
- Further preferably, wherein the core comprising a conductive polymer further comprises a non-conductive material.
- Advantageously, wherein the intrinsically conductive polymer is filled and/or mixed with conductive particles.
- Preferably, wherein the conductive particles are one or more of carbon black, graphite, graphene, carbon nanotubes and metal powders or fibers.
- Further preferably, wherein the outer layer is zinc, copper, nickel, bronze, brass, solder, chrome, tin, lead, gold, silver and any other metallic metal or alloy, or combination of metallic metal and/or alloy, preferably, wherein the outer layer is copper.
- Advantageously, wherein the building material is a panel, a facade panel, a rainscreen, a tile, a door, a fascia, a soffit, a weatherboard, a garage door, door furniture, fencing, a building detailing, a flashing, guttering, piping, a window frame or an ancillary of any shape and/or size for a particular building function.
- In a further aspect of the present invention, there is provided a method of making a building material, for use on the exterior of a building, the building material comprising a core comprising an intrinsically conductive polymer, and, an outer layer, wherein the outer layer is metallic, wherein the method comprises:
-
- forming a core comprising an intrinsically conductive polymer, and,
- electroplating the outer layer over the core.
- Preferably, wherein the step of electroplating the outer layer over the core is by electrochemical means.
- Further preferably, wherein the intrinsically conductive polymer is an electrically conductive thermoplastic, a conductive thermoset plastic, a conductive elastomer, or a conductive polymer blend.
- Advantageously, wherein the intrinsically conductive polymer comprises any one or more of polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene, where heteroarylene can be thiophene, furan or pyrrole, poly-p-phenylene, polyphenylene-sulphide, polyperinaphthalene, polyphthalocyanine, and their derivatives formed from monomers substituted with side chains or groups, or their copolymers.
- Preferably, wherein the core comprising a conductive polymer is formed by a polymer manufacturing processes, preferably, compression moulding, extrusion, intrusion or injection moulding.
- Further preferably, wherein the step of forming a core comprising a conductive polymer comprises the step of over moulding the conductive polymer over another material, optionally wherein the other material is a non-conductive polymer, further optionally wherein the step of over moulding includes bi-injection moulding and/or co-extrusion.
- Advantageously, further comprising the step of, after forming the core and before electroplating the outer layer over the core, working the core so that it adopts a suitable shape.
- Preferably, wherein electroplating the outer layer over the core by electrochemical means comprises:
-
- placing the core in a solution of metal ions, the core being configured to act as a cathode,
- placing an anode comprising metal atoms, the metal atoms being for the outer layer, in the solution, and,
- providing a voltage across the core and the anode so that there is a net movement of metal atoms from the anode to the cathode to form the outer layer.
- Further preferably, wherein the method comprises the further step of affixing a blocking structure to the core, prior to electroplating, so as to prevent formation of an outer layer at one or more positions on the core.
- Advantageously, further comprising a washing step at any point.
- Preferably, further comprising a working step after electroplating the core to work the outer layer into a desired shape.
- In a further aspect of the present invention, there is provided a building material obtainable by a method according to any one of the above methods.
- Embodiments of the invention are described below with reference to the accompanying drawings, in which:
-
FIG. 1 is a schematic representation of a building material according to the present invention. -
FIG. 2 is a cross-section along line A-A ofFIG. 1 . -
FIG. 3 is a schematic representation of a method of manufacturing a building material according to the present invention. - Referring to
FIG. 1 , abuilding material 1 is shown. In the embodiment shown inFIG. 1 , thebuilding material 1 is a tile which could be placed on a roof or on an external surface of a building. In other embodiments, the building material item could be a panel (optionally, a façade panel), a rainscreen, a tile, a door, a fascia, a soffit, a weatherboard, a garage door, door furniture, fencing, a building detailing, a flashing, guttering, piping, a window frame or an ancillary of any shape and/or size for a particular building function. -
FIG. 2 shows thebuilding material 1 in cross section along the line A-A.FIG. 2 shows that thebuilding material 1 has acore 3 and anouter layer 2 surrounding thecore 3. Thecore 3 comprises an intrinsically conductive polymer, for example an intrinsically conductive thermoplastic. Theouter layer 2 is a metallic layer. - The term “intrinsically conductive polymer(s)” refers to organic polymers which have poly-conjugated it-electron systems (e.g. double bonds or aromatic rings). Examples of such polymers include, but are not limited to, polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene (where heteroarylene can be thiophene, furan or pyrrole), poly-p-phenylene, polyphenylene-sulphide, polyperinaphthalene, polyphthalocyanine, and other known intrinsically conductive polymers, and their derivatives (formed for example from monomers substituted with side chains or groups), their copolymers and their physical compounds. They can exist in various states, each described by different empirical formulae, which can generally be converted reversibly into one another by electrochemical reactions such as oxidation, reduction, acid/alkali reaction or complexing. These reactions are also occasionally known as “doping” or “compensation” in the art, or can be regarded as “charging” and “discharging” in analogy with the electrochemical processes in batteries. At least one of the possible states is a very good conductor of electricity, e.g. has a conductivity of more than 1 Siemens/cm (in pure form).
- In one embodiment, the intrinsically conductive polymer of the
core 3 may be over-moulded over another polymer or material, which may not be electrically conductive. In this embodiment, thecore 3 is formed by initially forming a composite part from a first polymer and/or other generally inert material, e.g. a non-electrically conductive polymer (which may be relatively cheaper and/or lighter than the electrically conductive polymer, e.g. epoxy resin, expanded polystyrene, polymer foams) and/or glass materials, and subsequently forming the intrinsically conductive polymer over the composite part formed of the first polymer. - Examples of metals and alloys which in different embodiments make up the
outer layer 2 include zinc, copper, nickel, bronze, brass, solder, chrome, tin, lead, gold, silver and any other metallic metal or alloy, or a combination of metallic metal and/or alloy. - The presence of the
core 3 reduces the amount of metal required in thebuilding material item 3, as compared with building materials made entirely of metal. - The
building material 1 can, in one embodiment, be made by a method as discussed with reference toFIG. 3 . -
FIG. 3 shows electroplating of a metallicouter layer 2 on top of acore 3, thecore 3 being made of an intrinsically conductive polymer, for example, but not limited to, polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene (where heteroarylene can be thiophene, furan or pyrrole), poly-p-phenylene, polyphenylene-sulphide, polyperinaphthalene, polyphthalocyanine, and other known intrinsically conductive polymers, and their derivatives (formed for example from monomers substituted with side chains or groups), their copolymers and their physical compounds. Thecore 3 of intrinsically conductive polymer can be made by known polymer manufacturing processes, such as compression moulding, extrusion, intrusion or injection moulding. Using these known processes, thecore 3 can be shaped for its desired function. Alternatively, in other non-limiting embodiments, thecore 3, comprising an intrinsically conductive polymer and a separate composite part formed of another material can be formed together by bi-injection or co-extrusion. - In
FIG. 3 , the cathode is thecore 3. Theanode 4 is a metallic element made up of metal atoms which are to be layered on top of thecore 3. The cathode and theanode 4 are both connected to an external supply of direct current 5, e.g. a battery or a rectifier. Theanode 4 is connected to the positive terminal of the external supply of direct current 5 and the cathode is connected to the negative terminal. When the external supply of direct current 5 is turned on, the metal at the anode is oxidised to form cations which have a positive charge and go into thesolution 6, which has ameniscus 7. The cations Mn+ associate with anions An− in solution. The cations are reduced at the cathode and deposit in the metallic state. In other words, by way of this electroplating process, a metallicouter layer 2 forms over thecore 3. - In the above process, the cathode can be made from any intrinsically conductive polymer, e.g. intrinsically conductive thermoplastics. Particularly preferred examples of intrinsically conductive thermoplastics include, but are not limited to, polymers currently on the market and sold by Cool Polymers®, Inc. as their E-series polymers, such as E2, E4501, E4505 and E5101.
- The intrinsically conductive polymer of the core can be selected to match the thermal expansion coefficient of the metal which is deposited on and/or over the core. For example, the co-efficient of thermal expansion of E4505 is 33 ppm/° C. Metallic zinc has a similar co-efficient of thermal expansion at 30 ppm/° C. Therefore, a core comprising E4505 and an outer layer of zinc is a particularly preferred example. Using insulating polymers, or insulating polymers comprising conduction portions, the thermal expansion coefficient of the core is often between two or three times the thermal expansion coefficient of most metals, e.g. zinc and copper. It is preferable for the co-efficient of thermal expansion of the core and the metallic outer layer to be the same, or at least a similar co-efficient of thermal expansion within 20,10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 ppm/° C. By selecting materials for the core and the metallic outer layer so that they have a similar co-efficient of thermal expansion, the risk of catastrophic failure is minimised because the bond between the core and the metallic outer layer is put under minimal strain under different temperature conditions.
- Other examples of combinations of intrinsically conductive polymers, coated with a metallic layer and for use in building materials, include, but are not limited to:
-
- Cool Polymers®, Inc.'s Coolpoly E2 (which has a linear co-efficient of thermal expansion of 9.1 ppm/° C.) electroplated with nickel (which has a linear co-efficient of thermal expansion of 13 ppm/° C.).
- Cool Polymers®, Inc.'s Coolpoly E5101 (which has a linear co-efficient of thermal expansion of 14 ppm/° C.) electroplated with copper (which has a linear co-efficient of thermal expansion of 17 ppm/° C.).
- In an alternative embodiment, the
core 3 mentioned above can additionally include injection moulding metal powders, particles or fibers, and/or graphene, to make an intrinsically conductive polymer and metal blend or matrix. Examples of injection moulding metal powders include, but are not limited to, bronze granules and flake metal copper powder (e.g. type 2500, as currently sold by AVL Metal Powders NV, Kortrijk, Belgium). In other non-limiting examples, the injection moulding metal powders include stainless steel fibres, particles or powders (e.g. Advanced Metalworking Practices, LLC product range ADVAMET®). When using stainless steel, the passive oxide film of the stainless steel exposed on the surface of the thermoplastic matrix must be cleaned by chemical cleaning and activation processes, such as nickel strike, chloride pre cleaning, e.g. Zinc chloride or copper chloride strikes. - In the above process, the anode can be made from any metal or alloy, i.e. an alloy which can undergo the electroplating process, from which it is desired to form the
outer layer 2 over thecore 3. Examples of metals and alloys which can form the anode include, but are not limited to, zinc, copper, nickel, bronze, brass, solder, chrome, tin, lead, gold, silver and any other metallic metal or alloy, or combination of metallic metal and/or alloy. - In the above process, the
solution 6 contains a dissolved mixture of metallic salt which is complementary to the metal forming theanode 4. For example, when the anode is copper, thesolution 6 can be a solution of CuSO4, so the anion, An−, is SO4 2− and the copper ions in solution are Cu2+. Another example, when the anode is zinc, thesolution 6 can be a solution of ZnSO4, so the anion, An−, is SO4 2− and the zinc ions in solution are Zn2+. Another example, when the anode is nickel, thesolution 6 can be a solution of NiSO4, so the anion, An−, is SO4 2− and the nickel ions in solution are Ni2+. - As with known electroplating processes, the anode is often of the same metal to be deposited but not always. The anode can consist of a non-consumable alternative metal. For example, lead can be used as the anode when it is desired to reduce the g/l of copper content in the copper plating solution. In another example, tin-lead alloy anodes can be employed for chromium plating, for example with chrome flakes directly added according to the usage of the bath as opposed to a reduction of the anode.
- Generally, the intrinsically conductive polymer which makes up the
core 3 is selected to allow sufficient electrodeposition of the chosen metal or alloy. The conductive polymer will have an electrical resistance of 10000 per square or less, including each and every integer below 10000 per square, preferably an electrical resistance of 400 per square or less. The units of Ω per square are commonly used when referring to sheet resistance. Referring to sheet resistance as simply Ω could be taken out of context and misinterpreted as bulk resistance. - Electroplating can be carried out using reverse pulse plating to reduce the effect of intrinsically conductive polymers' electrical resistance on the current density during electroplating.
- In the example shown in
FIG. 3 , only part of thecore 3 is shown in thesolution 6. In a preferred embodiment, the whole of thecore 3 is covered with the metallicouter layer 2. In other embodiments, only part of thecore 3 is covered with the metallicouter layer 2, e.g. only the part of thebuilding material 1 which is to be exposed to the elements when the building material is in use. - An alternative method of covering the core with a metal and/or alloy is by way of electroless plating. Electroless plating is an auto-catalytic process for depositing a metal and/or alloy on an object, for example, a plastic object. Electroless plating utilises a reducing agent to react with metal ions in solution to deposit metal on the object.
- The building materials according to the present invention provide building materials with similar wear properties to known metallic building materials with at least the advantage that the building materials of the present invention use less raw metallic material. This saves on raw material cost and also reduces the weight of the building materials, thereby reducing, for example, transportation cost.
- The building materials according to the present invention provide building materials with thicker metallic layers over the core than previous building materials formed by electrodeposition over a generally insulating polymeric core after the core has been subjected to an oxidising process to render the surface at least partially conductive. After subjecting a generally insulating polymeric core to an oxidising process, the core is weakly conducting so only a very thin layer of metal can be economically deposited. Furthermore, the metallic layer formed on a generally insulating core after the generally insulating polymeric core has been oxidised is only weakly attached and is more akin to electroforming, where a metallic layer can be formed on a surface by mechanical (e.g. by screws or bolts), or adhesive (e.g. glue), means.
- When used in this specification and claims, the terms “comprises” and “comprising” and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.
- The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.
Claims (23)
1. A building material, comprising:
a core comprising an intrinsically conductive polymer, and,
an outer layer, wherein the outer layer is metallic.
2. The building material of claim 1 , wherein the outer layer surrounds the core.
3. The building material of claim 1 , wherein the outer layer partially surrounds the core.
4. The building material of claim 1 wherein the intrinsically conductive polymer comprises an electrically conductive thermoplastic, a conductive thermoset plastic, a conductive elastomer, and/or a conductive polymer blend.
5. The building material of claim 1 , wherein the intrinsically conductive polymer comprises any one or more of polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene, where heteroarylene can be thiophene, furan or pyrrole, poly-p-phenylene, polyphenylene-sulphide, polyperinaphthalene, polyphthalocyanine, and their derivatives formed from monomers substituted with side chains or groups, or their copolymers.
6. The building material of claim 1 , wherein the core comprising a conductive polymer further comprises a non-conductive material.
7. The building material of claim 4 , wherein the intrinsically conductive polymer is filled and/or mixed with conductive particles.
8. The building material of claim 7 , wherein the conductive particles are one or more of carbon black, graphite, graphene, carbon nanotubes and metal powders or fibers.
9. The building material of claim 1 , wherein the outer layer is zinc, copper, nickel, bronze, brass, solder, chrome, tin, lead, gold, silver or other metallic metal or alloy, or combination of metallic metal and/or alloy.
10. (canceled)
11. A method of making a building material, for use on the exterior of a building, the building material comprising a core comprising an intrinsically conductive polymer, and, an outer layer, wherein the outer layer is metallic, wherein the method comprises:
forming a core comprising an intrinsically conductive polymer, and,
electroplating the outer layer over the core.
12. The method of claim 11 , wherein the step of electroplating the outer layer over the core is by electrochemical means.
13. The method of claim 11 , wherein the intrinsically conductive polymer is an electrically conductive thermoplastic, a conductive thermoset plastic, a conductive elastomer, or a conductive polymer blend.
14. The method of claim 11 , wherein the intrinsically conductive polymer comprises any one or more of polydiacetylene, polyacetylene, polypyrrole, polyaniline, polythiophene, polyisothianaphthene, polyheteroarylenvinylene, where heteroarylene can be thiophene, furan or pyrrole, poly-p-phenylene, polyphenylene-sulphide, polyperinaphthalene, polyphthalocyanine, and their derivatives formed from monomers substituted with side chains or groups, or their copolymers.
15. The method of claim 11 , wherein the core comprising a conductive polymer is formed by compression moulding, extrusion, intrusion or injection moulding.
16. The method of claim 11 , wherein the step of forming a core comprising a conductive polymer comprises the step of over moulding the conductive polymer over another material.
17. The method of claim 11 , further comprising the step of, after forming the core and before electroplating the outer layer over the core, working the core so that it adopts a suitable shape.
18. The method of claim 11 , wherein electroplating the outer layer over the core by electrochemical means comprises:
placing the core in a solution of metal ions, the core being configured to act as a cathode,
placing an anode comprising metal atoms, the metal atoms being for the outer layer, in the solution, and,
providing a voltage across the core and the anode so that there is a net movement of metal atoms from the anode to the cathode to form the outer layer.
19. The method of claim 11 , wherein the method comprises the further step of affixing a blocking structure to the core, prior to electroplating, so as to prevent formation of an outer layer at one or more positions on the core.
20. (canceled)
21. The method of claim 11 , further comprising a working step after electroplating the core to work the outer layer into a desired shape.
22. A building material obtainable by a method according to claim 11 .
23.-24. (canceled)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1110808.1A GB2493492A (en) | 2011-06-27 | 2011-06-27 | A building material comprising a conductive polymer core and an outer metallic layer |
GB1110808.1 | 2011-06-27 | ||
PCT/GB2012/051493 WO2013001286A1 (en) | 2011-06-27 | 2012-06-26 | Building materials |
Publications (1)
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US20140329045A1 true US20140329045A1 (en) | 2014-11-06 |
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Family Applications (1)
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US14/128,252 Abandoned US20140329045A1 (en) | 2011-06-27 | 2012-06-26 | Building materials |
Country Status (5)
Country | Link |
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US (1) | US20140329045A1 (en) |
EP (1) | EP2723953A1 (en) |
AU (1) | AU2012277587A1 (en) |
GB (1) | GB2493492A (en) |
WO (1) | WO2013001286A1 (en) |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
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US20150267022A1 (en) * | 2012-09-28 | 2015-09-24 | Xiao Hu | Methods of producing foams and nanocomposites of phthalonitrile based resins, and foams and nanocomposites produced thereof |
WO2017080569A1 (en) * | 2015-11-11 | 2017-05-18 | Knauf Gips Kg | Building products with graphene or graphene oxide |
WO2017092778A1 (en) * | 2015-11-30 | 2017-06-08 | Knauf Gips Kg | Building products comprising graphene or graphene oxide in the bulk material and method for producing such building products |
US20200109482A1 (en) * | 2018-10-09 | 2020-04-09 | Lacks Enterprises, Inc. | 2-shot molded article with multiple electrical current pathways |
US11745439B2 (en) * | 2015-11-12 | 2023-09-05 | Cytec Industries Inc. | Hybrid veil as interlayer in composite materials |
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US5417838A (en) * | 1990-07-06 | 1995-05-23 | Tube Technology Pty. Ltd. | Formation of contoured building panels by direct electrodeposition from leachates of copper ores |
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DE2924314A1 (en) * | 1979-06-15 | 1980-12-18 | Franz Zambelli | Recovery of sheet metal waste - by dissolving in electrolyte and depositing it on cathode former to make angle pieces for guttering |
JPS6448962A (en) * | 1987-08-17 | 1989-02-23 | Ig Tech Res Inc | Snow melting roof material |
JPH05138802A (en) * | 1991-11-15 | 1993-06-08 | Kobe Steel Ltd | Composite type vibration damping material excellent in spot-weldability and adherence |
US5415762A (en) * | 1993-08-18 | 1995-05-16 | Shipley Company Inc. | Electroplating process and composition |
GB0323539D0 (en) * | 2003-10-08 | 2003-11-12 | Inditherm Plc | Heating of surface areas |
JP3141702U (en) * | 2008-02-29 | 2008-05-22 | グッドウイン株式会社 | Snow melting panel for roof |
CN101294439B (en) * | 2008-06-16 | 2011-12-21 | 吴绍元 | Multifunctional energy-saving decorative board |
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- 2011-06-27 GB GB1110808.1A patent/GB2493492A/en not_active Withdrawn
-
2012
- 2012-06-26 EP EP12733194.0A patent/EP2723953A1/en not_active Withdrawn
- 2012-06-26 US US14/128,252 patent/US20140329045A1/en not_active Abandoned
- 2012-06-26 WO PCT/GB2012/051493 patent/WO2013001286A1/en active Application Filing
- 2012-06-26 AU AU2012277587A patent/AU2012277587A1/en not_active Abandoned
Patent Citations (1)
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US5417838A (en) * | 1990-07-06 | 1995-05-23 | Tube Technology Pty. Ltd. | Formation of contoured building panels by direct electrodeposition from leachates of copper ores |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20150267022A1 (en) * | 2012-09-28 | 2015-09-24 | Xiao Hu | Methods of producing foams and nanocomposites of phthalonitrile based resins, and foams and nanocomposites produced thereof |
IL258427B (en) * | 2015-11-11 | 2022-07-01 | Knauf Gips Kg | Building products with graphene or graphene oxide |
WO2017080569A1 (en) * | 2015-11-11 | 2017-05-18 | Knauf Gips Kg | Building products with graphene or graphene oxide |
US11891806B2 (en) | 2015-11-11 | 2024-02-06 | Knauf Gips Kg | Building products with graphene or graphene oxide |
JP2018535338A (en) * | 2015-11-11 | 2018-11-29 | クナーフ ギプス カーゲーKnauf Gips Kg | Building material products containing graphene or graphene oxide |
US11745439B2 (en) * | 2015-11-12 | 2023-09-05 | Cytec Industries Inc. | Hybrid veil as interlayer in composite materials |
IL258560A (en) * | 2015-11-30 | 2018-06-28 | Knauf Gips Kg | Building products comprising graphene or graphene oxide in the bulk material and method for producing such building products |
US10836679B2 (en) | 2015-11-30 | 2020-11-17 | Knauf Gips Kg | Building products comprising graphene or graphene oxide in the bulk material and method for producing such building products |
JP2019502619A (en) * | 2015-11-30 | 2019-01-31 | クナーフ ギプス カーゲーKnauf Gips Kg | Building material product containing graphene or graphene oxide in bulk material, and method for producing such building material product |
US20180354856A1 (en) * | 2015-11-30 | 2018-12-13 | Knauf Gips Kg | Building products comprising graphene or graphene oxide in the bulk material and method for producing such building products |
WO2017092778A1 (en) * | 2015-11-30 | 2017-06-08 | Knauf Gips Kg | Building products comprising graphene or graphene oxide in the bulk material and method for producing such building products |
US20200109482A1 (en) * | 2018-10-09 | 2020-04-09 | Lacks Enterprises, Inc. | 2-shot molded article with multiple electrical current pathways |
US11802347B2 (en) * | 2018-10-09 | 2023-10-31 | Lacks Enterprises, Inc. | 2-shot molded article with multiple electrical current pathways |
Also Published As
Publication number | Publication date |
---|---|
GB201110808D0 (en) | 2011-08-10 |
GB2493492A (en) | 2013-02-13 |
AU2012277587A1 (en) | 2014-01-16 |
WO2013001286A1 (en) | 2013-01-03 |
EP2723953A1 (en) | 2014-04-30 |
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