Delamination resistant, weldable and formable light weight composites

{
  "publication_number": "US2013136944A1",
  "country": "US",
  "kind": "A1",
  "title": "Delamination resistant, weldable and formable light weight composites",
  "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.",
  "claims": [
    "1. (canceled) 2. The composite material of claim 7, wherein the at least one first thermoplastic polymer includes at least one polyolefinic polymer. 3. The composite material of claim 7, wherein the at least one first thermoplastic polymer includes a linear low density polyethylene. 4. The composite material of claim 3, wherein the second thermoplastic polymer is selected from a thermoplastic elastomer (e.g., one that includes ethylene-octene), and ionomer or a combination thereof. 5. (canceled) 6. A composite material comprising: a. a polymeric-based matrix that includes a mixture of: i. at least one first thermoplastic polymer; and ii. at least one second thermoplastic polymer that is different from the first thermoplastic polymer; and b. a mass of metallic fibers distributed throughout the matrix to form a filled polymeric material composite mass when the polymeric-based matrix, the mass of metallic fibers: i. including a plurality of metallic fibers having at least one generally flat surface, and ii. being present in concentration greater than about 3% by volume, based on the total volume of the filled polymeric material composite mass; wherein the filled polymeric material composite mass is attached to a metal sheet. 7. A composite material comprising: a. a polymeric-based matrix that includes a mixture of: i. at least one first thermoplastic polymer; and ii. at least one second thermoplastic polymer that is different from the first thermoplastic polymer; and b. a mass of metallic fibers distributed throughout the matrix to form a filled polymeric material composite mass with the polymeric-based matrix, the mass of metallic fibers; i. including a plurality of metallic fibers having at least one generally flat surface, and ii. being present in concentration greater than about 3% by volume, based on the total volume of the filled polymeric material composite mass; wherein the filled polymeric material composite mass is sandwiched between opposing metal sheets. 8. The composite material of claim 7, wherein the filled polymeric material composite mass is sandwiched between opposing metal sheets that are coated on at least one major surface of the sheet with a coating for resisting corrosion. 9. The composite material of claim 7, wherein the filled polymeric material composite mass is sandwiched between opposing metal sheets that are coated on opposing major surfaces of the sheet with one or more coatings that include zinc, phosphate, or both. 10. The composite material of claim 7, wherein the filled polymeric material composite mass is attached to one or more of aluminum, a plain carbon steel, a high strength steel, or a steel that includes an alloying ingredient selected from nickel, manganese, copper, niobium, vanadium, chromium, molybdenum, titanium, calcium, one or more rare earth elements, zirconium, nitrogen or any combination. 11. The composite material of claim 10, wherein the mass of metallic fibers includes a plurality of fibers that have a layer on them with a composition for resisting corrosion. 12. (canceled) 13. (canceled) 14. The composite material of claim 10, wherein the metallic fibers include fibers that are at least partially coated with aluminum, zinc, phosphate or any combination thereof. 15. The composite material of claim 7, wherein the mass of metallic fibers includes a plurality of fibers that are in the form of a ribbon; and the polymeric-based matrix include a polymer that is capable of cross-linking. 16. (canceled) 17. (canceled) 18. A composite material comprising: a. a polymeric-based matrix that includes a mixture of: i. at least one first thermoplastic polymer; and ii. at least one second thermoplastic polymer that is different from the first thermoplastic polymer; and b. a mass of metallic fibers distributed throughout the matrix to form a filled polymeric material composite mass with the polymeric-based matrix, the mass of metallic fibers; i. including a plurality of metallic fibers having at least one generally flat surface, and ii. being present in concentration greater than about 3% by volume, based on the total volume of the filled polymeric material composite mass: wherein the composite mass is bonded sufficiently to any metal layer so that upon being subjected to peel testing under DIN 11339, the composite exhibits at least about 40% cohesive failure and/or upon being subjected to lap shear testing under DIN 11465, the composite exhibits at least 40% cohesive failure. 19. (canceled) 20. A sandwich composite formed using the composite material of claim 6, wherein the yield strength of the sandwich composite is about 100 MPa or more, the tensile strength of the sandwich composite is about 160 MPa or more, the sandwich composite has a thickness of 0.4 mm or more, and the filled polymeric material composite mass has a thickness that is at least about 30% of the thickness of the sandwich composite. 21. (canceled) 22. (canceled) 23. A welded article comprising a composite material of claim 7. 24. A welded article comprising a composite material of claim 7, wherein the shape, size, concentration, and type of the metallic fibers is selected so that a weld stack consisting of the composite material and a sheet of galvannealed steel having approximately the same thickness as the composite material, exhibits a static contact resistance of 0.0020 Ω or less, as measured using a comprehensive force of about 500 lbs applied by two axially aligned electrodes each having a face diameter of about 4.8 mm electrodes. 25. A welded article comprising a composite material of claim 7, wherein the shape, size, concentration, and type of metallic fibers is selected so that the light weight composite has a static contact resistance ratio of about 0.01 or more, wherein the static contact resistance ratio is the ratio of: (i) the static contact resistance of the first weld stack consisting of the composite material and a sheet of steel having approximately the same thickness as the composite material, to (ii) 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 applied by two axially aligned electrodes each having a face diameter of about 4.8 mm electrodes. 26. A method of making an article, comprising the steps of plastically deforming the composite material of claim 7, to a draw ratio of at least about 1.5. 27. (canceled) 28. (canceled) 29. A method of making an article, comprising a step of welding a sandwich composite formed using the composite material of claim 7, to a metallic body. 30. The married of making an article of claim 29, wherein the welding includes the steps of: i) applying pressure to a weld stack; ii) applying an initial weld current to the weld stack while the pressure is applied, wherein the initial weld current is about 0.8 kA or less; iii) incrementally increasing or continuously ramping the welding current for an upslope time until the weld current reaches a second weld current; wherein the second weld current is at least about 0.5 kA higher than the first weld current, and the upslope time is about 0.01 seconds or more, and wherein the process optionally includes a step of holding the weld current at the second weld current for at least 0.06 seconds. 31. (canceled) 32. An article made according to the method of claim 29. 33. (canceled) 34. (canceled)"
  ],
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  ],
  "assignees": [
    "MIZRAHI SHIMON",
    "NARKIS MOSHE",
    "PRODUCTIVE RES LLC"
  ],
  "filing_date": "2011-08-05",
  "publication_date": "2013-05-30",
  "priority_date": "2010-02-15",
  "application_number": "US-201113814352-A",
  "family_id": "43877009",
  "citations": [
    "US2010040902A1",
    "US4313996A"
  ]
}