Patent ID: 9415568
Filing Date: 2016-08-16
CPC Classification: B32B,C08J,C08K,Y10T

Claim Text:
1. A light weight composite comprising: a first metallic layer; a second metallic layer; and a core layer extrudate including a filled polymeric material having a thickness disposed between the first metallic layer and the second metallic layer; wherein the filled polymeric material includes one or more polymers and a mass of metallic fibers mixed with and distributed within the polymer, wherein at least 70% by weight of the polymer is a thermoplastic that includes a polyethylene copolymer having at least 60% ethylene; the polymer is present at a concentration of about 65 volume percent or more, based on the total volume of the filled polymeric material; the metallic fibers include ribbon fibers having a generally rectangular cross-section in the direction transverse to the length of the fibers; the metallic fibers have a weight average length of 1 mm to 55 mm; the polymer has an elongation at failure of at least about 50% as measured according to ASTM D638-08; the concentration of metallic fibers in the filled polymeric material is from 3 to 25 volume %, based on the total volume of the filled polymeric material; the combined volume of the polymer and the metallic fibers is at least about 90% by volume, based on the total volume of the filled polymeric material; the concentration of pores and voids in the filled polymeric material is from 0 to about 10 volume %, based on the total volume of the filled polymeric material; the metallic fibers are present as a mass of fibers that spans the thickness of the filled polymeric material, and electrically connects the two metallic layers; the composite material has a thickness of 0.3 mm or more and the filled polymeric material has a thickness that is 40% or more of the total volume of the composite material and wherein the composite has a weld current range of 1.5 kA or more and is capable of a draw ratio of at least 1.5 in a stamping operation.