Delamination resistant, weldable and formable light weight composites
AssigneeProductive Research LLC
InventorsShimon Mizrahi, Moshe Narkis
Life of this patent
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Abstract
The present invention relates to filled polymeric materials including a thermoplastic polymer and a metallic filler and to light weight composite materials, which comprise a metallic layer and a polymeric layer, the polymeric layer containing the filled polymeric material. The filled polymeric material preferably is an extruded sheet. The composite materials of the present invention may be formed using conventional stamping equipment at ambient temperatures and/pr welded to other metal materials using conventional welding techniques.
Claims17
A sandwich composite material comprising:
- a first sheet of metal having a first thickness;
- a second sheet of metal having a second thickness;
- and
- an extrusion of a filled polymeric material having a thickness attached to the first sheet of metal and interposed between the first sheet of metal and the second sheet of metal, that includes:
- a. a polymeric phase including an ethylene-octene copolymer or an ethylene-hexene copolymer;
- b. b a filler phase including metallic filler,
- wherein the sandwich composite material has a total thickness of less than about 10 mm;
- the combined thickness of the first sheet of metal and the second sheet of metal is about 20 percent to about 70 percent of the total thickness of the sandwich composite material;
- the thickness of the filled polymeric material is greater than about 30 percent of the total thickness of the sandwich composite material;
- the concentration of pores and voids in the filled polymeric material is 0 volume percent to 5 volume percent, based on the total volume of the filled polymeric material;
- and
- the sandwich composite material is capable of being drawn to a draw ratio greater than about 1.5.
A light weight composite material comprising:
- (i) a first metallic layer;
- (ii) a second metallic layer;
- and
- (iii) a filled polymeric layer at least partially interposed between the first metallic layer and the second metallic layer;
- wherein the light weight composite material has a thickness of about 0.4 mm or more, the filled polymeric layer has a thickness that is at least about 30% of the total thickness of the light weight composite material, the filled polymeric layer includes one or more thermoplastics polymers, and a plurality of metallic fibers distributed within the polymer;
- the metallic fibers are present at a concentration greater than about 3% by volume, based on the total volume of the filled polymeric material;
- and
- wherein the shape, size, concentration, and type of the metallic fibers is selected so that the lightweight composite material is weldable;
- wherein the light weight composite material has a static contact resistance ratio of about 0.01 or more,
- wherein the static contact resistance ratio is the ratio of the static contact resistance of a first weld stack consisting of the light weight composite material and a sheet of steel having the same dimensions as the light weight composite, to the static contact resistance of a second weld stack consisting of two sheets of the same steel as in the first weld stack, wherein the static contact resistance is measured using a compressive force of about 500 lbs (about 2224 Nt) applied by two axially aligned electrodes each having a face diameter of about 4.8 mm electrodes.
Dependencies are inferred from the claim text.