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US 9,434,134 B2Granted
Formable light weight composites
AssigneeProductive Research LLC
InventorShimon Mizrahi
Life of this patent
Estimating the term…
Abstract
The present invention relates to light weight composite materials which comprise a metallic layer and a polymeric layer, the polymeric layer containing a filled thermoplastic polymer which includes a thermoplastic polymer and a metallic fiber. 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 a resistance welding process such as resistance spot welding.
Claims26
A composite part comprising:
- a composite material having
- (i) a first metal foil;
- (ii) a second metal foil;
- and
- (iii) an extruded polymeric core layer interposed between the first and second metal foils;
- wherein the polymeric core layer includes greater than 40 volume percent of a thermoplastic polymer, based on the total volume of the polymeric core layer and from about 3 volume percent to less than about 30 volume percent metal fibers based on the total volume of the polymeric core layer;
- wherein the polymeric core layer has an apparent modulus of rigidity according to ASTM D1043-02 of at least about 200 MPa over a temperature range of about −40° C. to about 50° C.;
- wherein the polymeric core layer includes a synthetic elastomer having either or both of a tensile modulus at 100% elongation of less than about 3 MPa, a tensile elongation at break greater than about 110%, both measured according to ASTM D638-08 at a nominal strain rate of about 0.1 s−1;
- wherein the metal fibers have a weight average length from about 5 μm to about 25 mm;
- wherein the metal fibers are oriented in a plurality of directions, some of the metal fibers being entangled with each other and being attached to polymer of the polymeric core layer;
- and
- wherein the composite part is stamped and welded to a metal material.
9 more elements
A composite part comprising:
- a composite material having
- (i) a first metal foil;
- (ii) a second metal foil;
- (iii) a polymeric core layer interposed between the first and second metal foils;
- wherein the polymeric core layer includes greater than 40 volume percent of a thermoplastic polymer, based on the total volume of the polymeric core layer and from about 3 volume percent to less than about 30 volume percent metal fibers based on the total volume of the polymeric core layer, and wherein the volume ratio of the thermoplastic polymer to the metal fibers is greater than 3:1;
- wherein the polymeric core layer has an apparent modulus of rigidity according to ASTM D1043-02 of at least about 200 MPa over a temperature range of about −40° C. to about 50° C. and has an elongation at break greater than 50%, as measured according to ASTM D638-08 at a nominal strain rate of about 0.1 s−1;
- wherein the polymeric core layer includes:
- (a) a synthetic elastomer having either or both of a tensile at modulus 100% elongation of less than about 3 MPa, a tensile elongation at break greater than about 110%, both measured according to ASTM D638-08 at a nominal strain rate of about 0.1 s−1;
- and
- (b) a grafted polymer including a maleic anhydride grafted polyolefin and the concentration of the grafted polymer in the polymeric core layer is up to about 10 wt. %, based on the total weight of the polymeric core layer;
- wherein the metal fibers:
- (a) have a weight average length from about 5 μm to about 25 mm;
- and
- (b) are oriented in a plurality of directions, some of the metal fibers being entangled with each other and being attached to polymer of the polymeric core layer;
- wherein the composite part is stamped and welded to a metal material.
12 more elements
A composite part comprising:
- a composite material having
- (i) a first steel foil;
- (ii) a second steel foil;
- (iii) an extruded polymeric core layer interposed between the first and second steel foils;
- wherein the polymeric core layer includes greater than 40 volume percent of a thermoplastic polymer, based on the total volume of the polymeric core layer and from about 3 volume percent to less than about 30 volume percent metal fibers based on the total volume of the polymeric core layer, and wherein the volume ratio of the thermoplastic polymer to the metal fibers is greater than 3:1;
- wherein the polymeric core layer exhibits:
- (a) an apparent modulus of rigidity according to ASTM D1043-02 of at least about 200 MPa over a temperature range of about −40° C. to about 50° C.;
- and
- (b) a concentration of pores and voids from 0 to about 10 volume %, based on the total volume of the polymeric core layer;
- wherein the polymeric core layer includes:
- (a) a synthetic elastomer having either or both of a tensile modulus at 100% elongation of less than about 3 MPa, a tensile elongation at break greater than about 110%, both measured according to ASTM D638-08 at a nominal strain rate of about 0.1 s−1;
- (b) a polyethylene copolymer of one or more α-olefins and optionally one or more additives wherein the thermoplastic polymer forms a polymeric matrix and the metal fibers are dispersed in the polymeric matrix;
- and the polyethylene copolymer includes at least about 80 weight % ethylene polymer and has a peak melting temperature (as measured according to ASTM D3418-08) or a glass transition temperature (as measured according to ASTM D3418-08) above about 80° C. and below about 150° C.;
- and
- (c) a grafted polymer including a maleic anhydride grafted polyolefin and the concentration of the grafted polymer in the polymeric core layer is up to about 10 wt. %, based on the total weight of the polymeric core layer;
- wherein the metal fibers:
- (a) have a weight average length from about 5 μm to about 25 mm;
- (b) are oriented in a plurality of directions, some of the metal fibers being entangled with each other and being attached to polymer of the polymeric core layer;
- and
- wherein the composite part is stamped and welded to define a weld joint with a monolithic steel sheet.
17 more elements
Dependencies are inferred from the claim text.