Deposition of high melting temperature and variable resistance metal materials on plastic and metal surfaces using a combination of kinetic and thermal spray processes

摘要

A method for deposition of a metal layer onto plastic materials is disclosed. The method allows for formation of long length strain gauges and deposition of high melting temperature metals onto plastic materials. The method comprises initially depositing a pattern of powder particles onto the plastic material using a kinetic spray process. Then the high melting temperature metal layer is deposited using a thermal spray process. The metal layer only adheres to the pattern of the powder particles and not to the plastic substrate. To form a stain gauge the powder particles are deposited in a discontinuous non-electrically conductive density on the plastic material. Then a metal layer is deposited using a thermal spray process and a metal having a variable resistance. The metal forms a continuous and electrically conductive pathway having a resistance that changes as stress is applied to the substrate.