Patent ID: 7413691
Filing Date: 2008-08-19
Classification: B29C,B29K,B29L,Y10T

Abstract:
1. A method of forming a net shape molded component having a metallic layer about an exterior surface thereof, the method comprising the steps of: providing a polymer resin, said polymer resin having a usable molten state that exists between a first temperature and a second temperature higher than said first temperature; providing a granular metal having a melting temperature that is greater than said first temperature and less than said second temperature; heating said polymer resin to a temperature that is greater than said first temperature and less than said melting temperature of said granular metal, thereby causing said polymer resin to become molten; uniformly dispersing said granular metal throughout said molten polymer resin to form a composition; further heating said composition to a temperature that is greater than said melting temperature of said granular metal, thereby causing said granular metal to become molten metal; injecting said composition under pressure into a mold cavity, having cavity walls; separating the molten metal from said polymer, said metal migrating toward said cavity walls and said polymer migrating toward the interior of said cavity; and cooling said composition to form a component having a metallic layer surrounding a polymer core.