Weldable Light-Weight Composite Materials
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Solution Overview
Problem
Current composite materials fail to meet the requirements of being lightweight, weldable, and resistant to delamination and corrosion, while also being stampable and cost-effective, making them unsuitable as direct substitutes for steel in many applications.
Innovation Solution
A composite material comprising a polymeric-based matrix with a mixture of thermoplastic polymers and metallic fibers, where the metallic fibers are distributed throughout the matrix, providing excellent bond strength and resistance to delamination, and can be welded using conventional techniques, even in the absence of polar polymers, and is suitable for use in sandwich composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If sandwich composites are used to reduce weight, then weight savings are achieved, but bonding integrity between layers deteriorates
Solution Approach 1:
The patent employs a multi-layer composite structure consisting of a polymeric layer, a metallic layer, and an interlayer comprising thermoplastic elastomer particles dispersed in a thermoplastic polymer matrix. This composite approach combines the advantages of different materials: the polymeric layer provides corrosion resistance and formability, the metallic layer provides strength and stiffness, and the interlayer with thermoplastic elastomer particles enhances bonding integrity between layers while maintaining flexibility and impact resistance
Solution Approach 2:
The interlayer is designed with localized thermoplastic elastomer particles concentrated at the interface between the polymeric and metallic layers. This local quality enhancement targets specifically the bonding interface where delamination occurs, providing improved adhesion and damage tolerance precisely where needed, while the bulk materials maintain their inherent properties for weight savings
2Weight of moving object
If conventional steel materials are used, then strength and durability are maintained, but weight increases
Solution Approach 1:
The patent modifies the polymeric layer by incorporating thermoplastic elastomer particles and adjusting the thermoplastic polymer matrix composition to achieve a balance of properties. The interlayer composition is specifically tuned with thermoplastic elastomer particle content and size distribution to enable both formability (ease of manufacture) and bonding integrity, allowing the composite to be manufactured using conventional processes while achieving weight savings compared to steel
3Ease of operation
If materials are optimized for stampability, then formability improves, but weldability deteriorates
Solution Approach 1:
The patent creates functional differentiation within the composite structure: the polymeric layer with thermoplastic elastomer particles provides enhanced formability and stampability for complex shapes, while the metallic layer provides weldability for joining operations. The interlayer facilitates both operations by providing a transition zone that accommodates the different requirements of forming and welding processes
Data Source
AI summary
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/or welded to other metal materials using conventional welding techniques.