Method for making an abrasion resistant conductive film and gasket

Claim 1

A method of forming a conductive abrasion resistant gasket having electromagnetic interference properties for disposition between adjacent conductive metal surfaces comprising the steps of: a) providing a polymeric film having a reverse side and an obverse side; b) embossing at least the obverse side so as to provide it with a plurality of peaks which upstand from the plane surface of the obverse side, at least one peak characterized by opposed outwardly sloping sides that converge towards a generally flat top; and c) vapor depositing a conductive metal coating onto the obverse side that over lays the peaks and the plane surface of the obverse side so as to form a conductive film for disposition as a gasket between the adjacent conductive metal surfaces and said gasket being unaffected by abrasion of the metal coating from the top of said at least one peak by maintaining contact between the coating on the opposed outwardly sloping sides and the adjacent conductive metal surface.

Claim 2

A method of forming a conductive abrasion resistant gasket having electromagnetic interference properties for disposition between adjacent conductive metal surfaces comprising the steps of: a) providing a polymeric film having a reverse side and an obverse side; b) embossing at least the obverse side so as to provide it with a plurality of peaks which upstand from the plane surface of the obverse side, at least one peak characterized by opposed outwardly sloping sides that converge towards a generally flat top; and c) vapor depositing a conductive metal coating onto the obverse side that over lays the peaks and the plane surface of the obverse side so as to form a conductive film for disposition as a gasket between the adjacent conductive metal surfaces and said gasket being unaffected by abrasion of the metal coating from the top of said at least one peak by maintaining contact between the coating on the opposed outwardly sloping sides and the adjacent conductive metal surface.

Claim 4

A method of forming a conductive abrasion resistant gasket having electromagnetic interference properties for disposition between adjacent conductive metal surfaces comprising the steps of: a) providing a polymeric film having a reverse side and an obverse side; b) embossing at least the obverse side so as to provide it with a plurality of peaks which upstand from the plane surface of the obverse side; and c) vapor depositing a conductive metal coating onto the obverse side that over lays the peaks and the plane surface of the obverse side so as to form a conductive film for disposition as a gasket between the adjacent conductive metal surfaces and said gasket being unaffected by erosion of the metal coating from the tops of said peaks; and comprising vapor depositing onto the obverse side of the film in sequence: a) a first metal as an adhesive layer on the obverse side of the film; b) a second metal onto the first layer, the second layer being an a conductive layer; and c) a third metal layer onto the second layer, the third layer being an abrasion and anti corrosion layer.

Claim 5

A method of forming a conductive abrasion resistant gasket having electromagnetic interference properties for disposition between adjacent conductive metal surfaces comprising the steps of: a) providing a polymeric film having a reverse side and an obverse side; b) embossing at least the obverse side so as to provide it with a plurality of peaks which upstand from the plane surface of the obverse side; and c) vapor depositing a conductive metal coating onto the obverse side that over lays the peaks and the plane surface of the obverse side so as to form a conductive film for disposition as a gasket between the adjacent conductive metal surfaces and said gasket being unaffected by erosion of the metal coating from the tops of said peaks; and comprising vapor depositing onto the obverse side of the film in sequence: a) a first metal as an adhesive layer on the obverse side of the film; b) a second metal onto the first layer, the second layer being an a conductive layer; and c) a third metal layer onto the second layer, the third layer being an abrasion and anti corrosion layer.

Claim 6

A method of forming a conductive abrasion resistant gasket having electromagnetic interference properties for disposition between adjacent conductive metal surfaces comprising the steps of: a) providing a polymeric film having a reverse side and an obverse side; b) embossing at least the obverse side so as to provide it with a plurality of peaks which upstand from the plane surface of the obverse side; and c) vapor depositing a conductive metal coating onto the obverse side that over lays the peaks and the plane surface of the obverse side so as to form a conductive film for disposition as a gasket between the adjacent conductive metal surfaces and said gasket being unaffected by erosion of the metal coating from the tops of said peaks; and comprising vapor depositing onto the obverse side of the film at least three layers including a layer of a conductive metal disposed between inner and outer layers.

Claim 7

A method of forming a conductive abrasion resistant gasket having electromagnetic interference properties for disposition between adjacent conductive metal surfaces comprising the steps of: a) providing a polymeric film having a reverse side and an obverse side; b) embossing at least the obverse side so as to provide it with a plurality of peaks which upstand from the plane surface of the obverse side; and c) vapor depositing a conductive metal coating onto the obverse side that over lays the peaks and the plane surface of the obverse side so as to form a conductive film for disposition as a gasket between the adjacent conductive metal surfaces and said gasket being unaffected by erosion of the metal coating from the tops of said peaks; and comprising vapor depositing onto the obverse side of the film at least three layers including a layer of a conductive metal disposed between inner and outer layers.