# US 9,434,134 B2 · Formable light weight composites

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- Number: US 9,434,134 B2
- Document ID: US9434134B2
- Status: Granted
- Kind: B2
- Application number: 13/939,666
- Filed: 2013-07-11
- Published: 2014-06-12
- Granted: 2016-09-06
- Earliest claimed: 2008-08-18
- Assignees: Productive Research LLC
- Applicants: Productive Research LLC
- Inventors: Shimon Mizrahi
- Web page: https://patentgrep.com/patent/US9434134B2

## CPC

- B32B 15/085: comprising polyolefins
- B23K 11/11: Spot welding
- B29C 70/025: {with particular filler}
- B29C 70/028: {and with one or more layers of non-plastics material or non-specified material, e.g. supports}
- B29C 70/088: {and with one or more layers of non-plastics material or non-specified material, e.g. supports}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 15/043: {of metal (B32B15/01 takes precedence)}
- B32B 15/08: of synthetic resin
- B32B 15/18: comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/281: {comprising polyimides}
- B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 27/38: comprising epoxy resins
- B32B 27/40: comprising polyurethanes
- B23K 2103/16: Composite materials
- B23K 2103/172: {wherein at least one of the layers is non-metallic}
- B29K 2305/00: Use of metals, their alloys or their compounds, as reinforcement
- B29K 2705/02: Aluminium
- B29K 2705/12: Iron
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2262/103: Metal fibres
- B32B 2264/105: Metal
- B32B 2264/108: Carbon, e.g. graphite particles
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2307/306: Resistant to heat
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2419/00: Buildings or parts thereof
- B32B 2605/00: Vehicles
- B32B 2607/00: Walls, panels
- Y10T 156/1041: Subsequent to lamination
- Y10T 428/12389: having variation in thickness
- Y10T 428/12444: Embodying fibers interengaged or between layers [e.g., paper, etc.]
- Y10T 428/12486: Laterally noncoextensive components [e.g., embedded, etc.]
- Y10T 428/12569: Synthetic resin
- Y10T 428/2495: Thickness [relative or absolute]
- Y10T 428/24967: Absolute thicknesses specified
- Y10T 428/24994: Fiber embedded in or on the surface of a polymeric matrix
- Y10T 428/31678: Of metal
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## 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.

## Claims

### Claim 1

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.

### Claim 2 (depends on 1)

The composite part of claim 1, wherein the thermoplastic polymer includes 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 250° C.

### Claim 3 (depends on 1)

The composite part of claim 1, wherein the composite material wherein the concentration of pores and voids in the polymeric core layer is from 0 to about 10 volume %, based on the total volume of the polymeric core layer.

### Claim 4 (depends on 3)

The composite part of claim 3, wherein the volume ratio of the thermoplastic polymer to the metal fibers is greater than 3:1.

### Claim 5 (depends on 4)

The composite part of claim 4, wherein the thermoplastic polymer has a number average molecular weight greater than about 20,000.

### Claim 6 (depends on 1)

The composite part of claim 1 wherein the core layer includes a grafted polymer including a maleic anhydride grafted polyolefin.

### Claim 7 (depends on 6)

The composite part of claim 6, wherein the concentration of any grafted polymer in the polymeric core layer is up to about 10 wt. %, based on the total weight of the polymeric core layer.

### Claim 8 (depends on 1)

The composite part of claim 1, wherein the first metal foil includes steel, the part is welded to a steel part and the metal fibers include plain carbon steel fibers.

### Claim 9 (depends on 8)

The composite part of claim 8, wherein the thermoplastic polymer has a crystallinity of about 10% or more.

### Claim 10 (depends on 8)

The composite part of claim 8, wherein the metal fibers are chopped fibers and have a weight average length of about 5 μm to 8 mm.

### Claim 11 (depends on 1)

The composite part of claim 1, wherein the polymeric core layer 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.

### Claim 12 (depends on 11)

The composite part of claim 11, wherein metal fibers are present in an amount from about 5 volume percent to 20 volume percent, based on the total volume of the polymeric core layer.

### Claim 13 (depends on 12)

The composite part of claim 12, wherein the first metal foil includes a coating or plating, and the thickness of one or both of the first and second metal foils is 0.15 mm or more.

### Claim 14 (depends on 12)

The composite part of claim 12, wherein the polymeric core layer is in contact with at least 70% of the total surface of the first and second metal foils and wherein there is no visible read through of the fibers on the class A surface.

### Claim 15 (depends on 1)

The composite part of claim 1, wherein
the metal fibers have an aspect ratio of the longest dimension to each perpendicular dimension that is greater than about 10;
the polymeric core layer includes 8 volume percent to 20 volume percent of the metal fibers;
the first metal foil and the second metal foil include at least 40 mole percent iron, or at least 40 mole percent aluminum;
the first metal foil has a generally constant thickness;
the first metal foil has a thickness of at least about 0.10 mm and less than 0.5 mm; and
the polymeric core layer is 50 volume percent to 92 volume percent, based on the total volume of the composite material.

### Claim 16 (depends on 15)

The composite part of claim 15, wherein the thermoplastic polymer is a semi-crystalline polymer having a crystallinity of greater than about 20 weight percent and less than about 68 weight percent.

### Claim 17 (depends on 16)

The composite part of claim 16, wherein the first metal foil includes a high strength steel, a medium strength steel, an ultra-high strength steel, or a stainless steel.

### Claim 18 (depends on 16)

The composite part of claim 16 wherein the composite part is an automotive part selected from the group consisting of a bumper, a wheel house outer, a fender outer, a hood outer, a front door outer, a rear door outer, a decklid outer, a liftgate outer, a back seat panel, a rear shelf panel, a dash cowall, a rear compartment pan, a part having a tub for storage of a spare tire, a part having a tub for stow and go seating, a roof outer, a floor pan, and a body side.

### Claim 19 (depends on 16)

The composite part of claim 16, wherein the aspect ratio of the metal fibers is about 20 or more; the second metal foil has a thickness of at least about 0.10 mm and less than 0.5 mm; and the composite material has a thickness of greater than about 0.7 mm and less than about 2 mm.

### Claim 20 (depends on 19)

The composite part of claim 19, wherein the polymeric core layer is greater than 60 volume percent of the total volume of the composite material.

### Claim 21

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.

### Claim 22 (depends on 21)

The composite part of claim 21, wherein the polymeric core layer is an extrusion; and the thermoplastic polymer includes 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 250° C.

### Claim 23 (depends on 22)

The composite part of claim 22, wherein the metal fibers are plain carbon steel fibers, and at least one of the first or second metal foils is steel.

### Claim 24 (depends on 23)

The composite part of claim 23, wherein the metal fibers have a weight average length from about 5 μm to about 8 mm.

### Claim 25

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.

### Claim 26 (depends on 25)

The composite part of claim 25, wherein the metal fibers have a weight average length from about 5 μm to about 8 mm.