Vacuum pretreatment process for durable electroplated coatings on ABS and PPO plastics

Claim 1

A method of forming adherent electrodeposited coatings onto a surface of a thermoplastic polymer selected from the class consisting of ABS and PPO comprising the steps of exposing the polymer surface to an RF oxidizing glow discharge equivalent to at least about 3 minutes at a power setting of at least about 50 watts, vacuum depositing onto the so-exposed surface a first thin film of a metal selected from the class consisting of nickel, chromium, titanium, molybdenum, silicon, zirconium, aluminum and alloys thereof to form a blanket metal layer strongly bonded to the so-exposed surface, vacuum depositing a blanket thin film of a readily electroplatable metal strongly bonded to the first thin film, and then electrodepositing an overlayer onto the last-mentioned vacuum deposited thin film, without producing peeling or blistering of the films or the overlayer on them.

Claim 2

A method of forming adherent electrodeposited coatings onto a surface of a thermoplastic polymer selected from the class consisting of ABS and PPO comprising the steps of exposing the polymer surface to an RF oxidizing glow discharge equivalent to at least about 3 minutes at a power setting of at least about 50 watts, vacuum depositing onto the so-exposed surface a first thin film of a metal selected from the class consisting of nickel, chromium, titanium, molybdenum, silicon, zirconium, aluminum and alloys thereof to form a blanket metal layer strongly bonded to the so-exposed surface, vacuum depositing a blanket thin film of a readily electroplatable metal strongly bonded to the first thin film, and then electrodepositing an overlayer onto the last-mentioned vacuum deposited thin film, without producing peeling or blistering of the films or the overlayer on them.

Claim 3

A method of forming an adherent electrodeposited coating onto a surface of a thermoplastic polymer selected from the class consisting of ABS and PPO comprising establishing a vacuum over the polymer surface and successively exposing the polymer surface to an RF oxidizing glow discharge equivalent to at least about 3 minutes at a power setting of at least about 50 watts, vacuum depositing a continuous nickel film onto the co-exposed surface, and vacuum depositing a blanket thin film of copper onto the nickel thin film, exposing the film covered surface to atmospheric air, and then electrodepositing successive layers of copper, nickel and chromium onto the vacuum deposited films without producing peeling or blistering of the films or the overlayers on them.

Claim 4

A method of forming an adherent electrodeposited coating onto a surface of a thermoplastic polymer selected from the class consisting of ABS and PPO comprising establishing a vacuum over the polymer surface and successively exposing the polymer surface to an RF oxidizing glow discharge equivalent to at least about 3 minutes at a power setting of at least about 50 watts, vacuum depositing a continuous nickel film onto the co-exposed surface, and vacuum depositing a blanket thin film of copper onto the nickel thin film, exposing the film covered surface to atmospheric air, and then electrodepositing successive layers of copper, nickel and chromium onto the vacuum deposited films without producing peeling or blistering of the films or the overlayers on them.

Claim 5

A method of forming adherent electrodeposited coatings on a surface of a thermoplastic polymer selected from the class consisting of ABS and PPO without using liquid process steps for pretreatment of the polymer surface comprising the steps of activating and etching the polymer surface in an oxidizing RF glow discharge equivalent to an Rf oxygen glow discharge at a pressure of about 1-2 Torr for about 3-10 minutes at a power setting of about 35-150 watts, vacuum depositing a first coating of a first metal selected from the class consisting of nickel, chromium, titanium, molybdenum, silicon, zirconium, aluminum and alloys thereof to form a first metal layer highly adherent to the activated and etched plastic surface, vacuum depositing onto the first metal layer a coating of a readily electroplatable metal that is highly adherent to the first metal layer, and then electrodepositing at least one subsequent metal layer onto the second vacuum deposited metal layer without producing peeling or blistering of the first or second metal layers.

Claim 6

A method of forming adherent electrodeposited coatings on a surface of a thermoplastic polymer selected from the class consisting of ABS and PPO without using liquid process steps for pretreatment of the polymer surface comprising the steps of activating and etching the polymer surface in an oxidizing RF glow discharge equivalent to an Rf oxygen glow discharge at a pressure of about 1-2 Torr for about 3-10 minutes at a power setting of about 35-150 watts, vacuum depositing a first coating of a first metal selected from the class consisting of nickel, chromium, titanium, molybdenum, silicon, zirconium, aluminum and alloys thereof to form a first metal layer highly adherent to the activated and etched plastic surface, vacuum depositing onto the first metal layer a coating of a readily electroplatable metal that is highly adherent to the first metal layer, and then electrodepositing at least one subsequent metal layer onto the second vacuum deposited metal layer without producing peeling or blistering of the first or second metal layers.

Claim 7

A method of forming an adherent electrodeposited coating onto a surface of a plastic selected from the class consisting of ABS and PPO polyphenylene oxide mixtures thereof performing the following steps on the plastic surface while continuously maintaining a vacuum over the plastic surface, treating the plastic surface in an RF oxygen glow discharge equivalent to treatment for about 3-10 minutes at a pressure of about 1-2 Torr at a power setting of about 35-150 watts, vacuum depositing a first coating of nickel and alloys thereof onto said surface to form a first metal layer strongly bonded to the plastic surface, and vacuum depositing a coating of copper onto the first metal layer to form a strongly bonded readily electroplatable metal coating on the first metal layer, thereafter exposing the thus coated plastic surface to ambient atmospheric conditions and electrodepositing successive layers of copper and nickel onto the vacuum deposited copper layer.

Claim 8

A method of forming an adherent electrodeposited coating onto a surface of a plastic selected from the class consisting of ABS and PPO polyphenylene oxide mixtures thereof performing the following steps on the plastic surface while continuously maintaining a vacuum over the plastic surface, treating the plastic surface in an RF oxygen glow discharge equivalent to treatment for about 3-10 minutes at a pressure of about 1-2 Torr at a power setting of about 35-150 watts, vacuum depositing a first coating of nickel and alloys thereof onto said surface to form a first metal layer strongly bonded to the plastic surface, and vacuum depositing a coating of copper onto the first metal layer to form a strongly bonded readily electroplatable metal coating on the first metal layer, thereafter exposing the thus coated plastic surface to ambient atmospheric conditions and electrodepositing successive layers of copper and nickel onto the vacuum deposited copper layer.

Claim 9

A method of forming an adherent base coating on a surface of a polymer selected from the class of ABS and PPO, which coating is not only readily electroplatable but is also resistant to blistering and peeling during electroplating metal overlayers onto them, comprising the steps of etching the polymer surface and bonding oxygen atoms thereto in an RF oxygen glow discharge, vacuum depositing a coating onto the etched oxygen bonded polymer surface of a metal having a strong affinity for oxygen, and without breaking vacuum after depositing the aforesaid metal coating, vacuum depositing an overlayer of a readily electroplatable metal onto the metal having a strong affinity for oxygen.

Claim 10

A method of forming an adherent base coating on a surface of a polymer selected from the class of ABS and PPO, which coating is not only readily electroplatable but is also resistant to blistering and peeling during electroplating metal overlayers onto them, comprising the steps of etching the polymer surface and bonding oxygen atoms thereto in an RF oxygen glow discharge, vacuum depositing a coating onto the etched oxygen bonded polymer surface of a metal having a strong affinity for oxygen, and without breaking vacuum after depositing the aforesaid metal coating, vacuum depositing an overlayer of a readily electroplatable metal onto the metal having a strong affinity for oxygen.

Claim 11

A method of forming an adherent base coating on a surface of an acrylonitrile-butadiene-styrene polymer, which coating is not only readily electroplatable but is also resistant to blistering and peeling during electroplating conditions, comprising the steps of etching the polymer surface and bonding oxygen atoms thereto in an RF oxygen glow discharge, vacuum depositing a nickel coating onto the etched and oxygen bonded polymer surface, and without breaking vacuum after depositing the nickel coating, vacuum depositing an overlayer of copper onto the nickel coating.

Claim 12

A method of forming an adherent base coating on a surface of an acrylonitrile-butadiene-styrene polymer, which coating is not only readily electroplatable but is also resistant to blistering and peeling during electroplating conditions, comprising the steps of etching the polymer surface and bonding oxygen atoms thereto in an RF oxygen glow discharge, vacuum depositing a nickel coating onto the etched and oxygen bonded polymer surface, and without breaking vacuum after depositing the nickel coating, vacuum depositing an overlayer of copper onto the nickel coating.