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US 9,115,264 B2Granted
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 16 including a thermoplastic polymer 18 and a metallic fiber 20 and to light weight composite materials 10, 12 which comprise a metallic layer 14 and a polymeric layer, the polymeric layer containing the filled polymeric material 16. The composite materials of the present invention may be formed using conventional stamping equipment at ambient temperatures. Composite materials of the present invention may also be capable of being welded to other metal materials using conventional welding techniques. The composites exhibit resistance to delamination.
Claims29
A composite material comprising:
- a first sheet of metal;
- an optional second sheet of metal;
- and
- an extrusion of a filled polymeric material composite attached to the first sheet of metal, that includes:
- a. a polymeric-based matrix that includes:
- at least one thermoplastic polymer that is an elastomer, an ionomer, or both;
- b. a mass of metallic fibers distributed throughout the polymeric-based matrix to form a filled polymeric material composite mass with the polymeric-based matrix,
- wherein the mass of the metallic fibers is present from about 10 volume percent to about 25 volume percent based on the total volume of the filled polymeric material composite mass, the mass of metallic fibers generally spans the thickness of the filled polymeric material composite mass, and includes a plurality of the metallic fibers that:
- i. are steel fibers;
- ii. have a weight average length from about 0.5 mm to about 7 mm the length being greater than a width and a thickness of the fibers;
- iii. are in the form of ribbon fibers having a generally rectangular cross-section;
- iv. have a ratio of a width to a thickness of about 2 to about 20;
- and
- v. are entangled with one another;
- and
- wherein the composite material has a total thickness of about 0.7 mm to about 10 mm and the filled polymeric material composite mass has a thickness greater than about 20% of the total thickness of the composite material.
13 more elements
A composite material comprising:
- a first sheet of metal;
- a second sheet of metal;
- and
- an extrusion of a filled polymeric material composite attached to the first sheet of metal,
- that includes:
- a. a polymeric-based matrix that includes a blend:
- i. at least one first thermoplastic polymer;
- and
- ii. at least one second thermoplastic polymer that is different from the first thermoplastic polymer and is an elastomer, an ionomer, or both;
- and
- b. a mass of metallic fibers distributed throughout the polymeric-based matrix to form the filled polymeric material composite mass with the polymeric-based matrix,
- wherein the mass of metallic fibers is present from about 10 volume percent to about 25 volume percent based on the total volume of the filled polymeric material composite mass the mass of metallic fibers generally spans the thickness of the filled polymeric material composite mass, and includes a plurality of fibers that:
- i. are steel fibers;
- ii. have a weight average length from about 0.5 mm to about 7 mm;
- iii. are in the form of ribbon fibers having a generally rectangular cross-section;
- iv. have a ratio of a width to a thickness of about 2 to about 20;
- and
- iv. are entangled with one another;
- and
- wherein the composite material has a total thickness of about 0.7 mm to about 10 mm and the filled polymeric material composite mass has a thickness greater than about 20% of the total thickness of the composite material.
17 more elements
A composite material comprising:
- a first sheet of steel;
- an optional second sheet of steel;
- and
- an extrusion of a filled polymeric material composite mass attached to the first sheet of metal, that includes a mixture of:
- a. a polymeric-based matrix that includes a blend of:
- i. a first thermoplastic polymer including a polyolefin selected from a polypropylene and a copolymer including at least 60 wt. % of an α-olefin and at least one additional monomer, wherein the first thermoplastic polymer has an ultimate tensile strength of at least about 50 MPa (per ASTM D882-10), and an ultimate elongation of at least about 500% (per ASTM D882-10);
- and
- ii. a second thermoplastic polymer that is different from the first thermoplastic polymer, and includes an elastomer, an ionomer, or both;
- wherein the second thermoplastic polymer is a non-polar polymer having an ultimate tensile strength (per ASTM D638-08) of at least about 7.5 MPa, an ultimate tensile elongation (per ASTM D638-08) of at least about 700%, and a flexural modulus (per ASTM D790-10, 1% secant) of at least about 13 MPa;
- and when the second polymer includes the elastomer, the elastomer has a tensile modulus at 100% elongation of less than 3 MPa as measured according to ASTM D638-08;
- and
- b. a mass of metallic fibers distributed in a random arrangement throughout the polymeric-based matrix to form the filled polymeric material composite mass with the polymeric-based matrix;
- wherein the mass of metallic fibers is present from about 10 volume percent to about 25 volume percent based on the total volume of the filled polymeric material composite mass, the mass of metallic fibers generally spans the thickness of the filled polymeric material composite mass, and includes a plurality of fibers that:
- i. are carbon steel fibers;
- ii. have a weight average length from about 0.5 mm to about 7 mm;
- iii. are in the form of ribbon fibers having a generally rectangular cross-section;
- and
- iv. are entangled with one another;
- and
- wherein the composite material has a total thickness of about 0.7 mm to about 10 mm and the filled polymeric material composite mass has a thickness greater than about 20% of the total thickness of the composite material;
- wherein the composite material has a maximum draw ratio greater than about 1.2.
18 more elements
Dependencies are inferred from the claim text.