Processes for welding composite materials and articles therefrom
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
F16B-005/08
B23K-011/11
B23K-011/16
B23K-031/02
B32B-015/08
B32B-015/18
B32B-027/30
B32B-027/32
B32B-027/34
B32B-027/36
B23K-011/00
B23K-026/32
출원번호
US-0295822
(2014-06-04)
등록번호
US-9239068
(2016-01-19)
발명자
/ 주소
Mizrahi, Shimon
출원인 / 주소
PRODUCTIVE RESEARCH LLC
대리인 / 주소
The Dobrusin Law Firm, P.C.
인용정보
피인용 횟수 :
0인용 특허 :
139
초록▼
The invention is directed at a method for welding a composite material and to welded structures thus prepared. The method includes a step of contacting a substrate material with a composite material, wherein the composite material includes a pair of spaced apart steel sheets and a core layer between
The invention is directed at a method for welding a composite material and to welded structures thus prepared. The method includes a step of contacting a substrate material with a composite material, wherein the composite material includes a pair of spaced apart steel sheets and a core layer between the sheets; the volume of the core layer is about 25 volume % or more, based on the total volume of the composite material; the core layer includes a plurality of steel fibers arranged in one or more masses of fibers that extend the thickness of the core layer so that the core layer is in electrical communication with the steel sheets; and the steel fibers have a cross sectional area perpendicular to the length of the fibers from about 1×10−5 mm2 to about 2.5×10−2 mm2.
대표청구항▼
1. A process of forming a weld joint comprising the steps of: providing a substrate material, wherein the substrate material is a metallic material;providing a light weight composite material having a stamped configuration, a roll formed configuration, a bent configuration, or a punched configuratio
1. A process of forming a weld joint comprising the steps of: providing a substrate material, wherein the substrate material is a metallic material;providing a light weight composite material having a stamped configuration, a roll formed configuration, a bent configuration, or a punched configuration;forming a weld stack including at least the substrate material and the light weight composite material; andwelding the light weight composite material directly to the substrate material;wherein the step of welding includes a step of applying a weld current to the substrate material and the light weight composite material using electrodes of a resistance welding apparatus to weld the substrate material with the light weight composite material; the step of welding includes a first weld stage having an upslope weld current starting at an initial weld current followed by an increase to the weld current;wherein the light weight composite material includes a pair of spaced apart steel sheets and a core layer including a filled polymeric material between the steel sheets, wherein the core layer has a thickness;the filled polymeric material is present at a concentration from about 30 volume % to about 75 volume %, based on the total volume of the light weight composite material;the core layer includes a polymeric matrix and a plurality of steel fibers arranged in one or more masses of fibers that extend the thickness of the core layer so that the core layer is in electrical communication with the steel sheets,the polymer matrix includes one or more polymers, and the polymer(s) and steel fibers are present at a volume ratio of polymer(s) to steel fiber of about 19:1 to about 2.2:1;the steel fibers have a length of about 200 μm or more and less than 7 mm; andthe steel fibers have a generally rectangular cross-section perpendicular to the length of the fibers. 2. The process of claim 1, wherein the step of applying a weld current includes applying a weld current from about 2.5 kA to about 25 kA to the substrate and the light weight composite material to weld the substrate with the light weight composite material so that a weld is achieved characterized by a weld button having an area of about 1 mm2 or more. 3. The process of claim 2; wherein the concentration of metallic fibers is from about 10 percent by volume to about 30 percent by volume, based on the total volume of the core layer of the light weight composite material. 4. The process of claim 3, wherein the polymeric matrix includes at least one polymer selected from the group consisting of a polyolefin, a polyamide, a polyester, a polyether, a polystyrene, a polymer including an acrylonitrile, a polymer including an acrylic acid, a polymer including an acrylate, a polyimide, a polycarbonate, an ionomer, and a copolymer including one or more of the above polymers. 5. The process of claim 3, wherein the thickness of the light weight composite material is from about 0.4 to about 4 mm; and the polymeric matrix includes a polyethylene including about 70 wt. % or more ethylene. 6. The process of claim 5, wherein the combined thickness of the pair of metallic sheets of the light weight composite material is about 1.5 mm or less and is less than about 75% of the total thickness of the light weight composite material. 7. The process of claim 6, wherein the core layer includes from about 10 volume percent to about 30 volume percent metallic fibers, wherein the metallic fibers have a cross-section in the direction perpendicular to the length of the fibers having a cross-sectional area of about 8×10−5 mm2 or more, wherein the static resistance of the light weight composite material is about 1.5 mOhm or less, as measured between two electrodes each having a face diameter of about 3.8 mm using a load of about 2200 kN and a sample coupon width of about 25 mm and length of about 25 mm. 8. A weld joint prepared according to the method of claim 1. 9. A welded article prepared according to claims 1, comprising i) the light weight composite material;ii) the steel substrate; andiii) a weld joint characterized by at least one of the following: a) a weld button size of about 2 mm2 or more;b) a tensile strength of about 1 kN or more; orc) a weld free of metal expulsion. 10. A process of forming a weld joint comprising the steps of: providing a substrate material, wherein the substrate material is a metallic material;providing a light weight composite material having a stamped configuration, a roll formed configuration, a bent configuration, or a punched configuration;forming a weld stack including at least the substrate material and the light weight composite material; andwelding the light weight composite material directly to the substrate material;wherein the step of welding includes a step of applying a weld current to the substrate material and the light weight composite material using electrodes of a resistance welding apparatus to weld the substrate material with the light weight composite material;wherein the light weight composite material includes a pair of spaced apart steel sheets and a core layer including a filled polymeric material between the steel sheets, wherein the core layer has a thickness;the filled polymeric material is present at a concentration from about 30 volume % to about 75 volume %, based on the total volume of the light weight composite material;the core layer includes a polymeric matrix and a plurality of steel fibers arranged in one or more masses of fibers that extend the thickness of the core layer so that the core layer is in electrical communication with the steel sheets, wherein the fraction of the steel fibers that contact a steel sheet along at least half of the length of the fiber is about 0.3 or less;the polymer matrix includes one or more polymers, and the polymer(s) and steel fibers are present at a volume ratio of polymer(s) to steel fiber of about 19:1 to about 2.2:1; andthe steel fibers have a length of about 200 μm or more and less than 7 mm. 11. The process of claim 10; wherein the concentration of metallic fibers is from about 10 percent by volume to about 30 percent by volume, based on the total volume of the core layer of the light weight composite material. 12. The process of claim 11, wherein the polymeric matrix includes at least one polymer selected from the group consisting of a polyolefin, a polyamide, a polyester, a polyether, a polystyrene, a polymer including an acrylonitrile, a polymer including an acrylic acid, a polymer including an acrylate, a polyimide, a polycarbonate, an ionomer, and a copolymer including one or more of the above polymers. 13. The process of claim 11, wherein the thickness of the light weight composite material is from about 0.4 to about 4 mm and the polymeric matrix includes a polyethylene including about 70 wt. % or more ethylene. 14. The process of claim 13, wherein the combined thickness of the pair of metallic sheets of the light weight composite material is about 0.6 mm or less and is less than about 75% of the total thickness of the light weight composite material; and wherein the step of welding includes a first weld stage having an upslope weld current starting at an initial weld current followed by an increase to the weld current. 15. A welded article prepared according to claims 10, comprising i) the light weight composite material;ii) the steel substrate; andiii) a weld joint characterized by at least one of the following: a) a weld button size of about 2 mm2 or more;b) a tensile strength of about 1 kN or more; orc) a weld free of metal expulsion. 16. A process of forming a weld joint comprising the steps of: providing a substrate material, wherein the substrate material is a metallic material;providing a light weight composite material;forming a weld stack including at least the substrate material and the light weight composite material; andwelding the light weight composite material directly to the substrate material;wherein the step of welding includes a step of applying a weld current to the substrate material and the light weight composite material using electrodes of a resistance welding apparatus to weld the substrate material with the light weight composite material;wherein the light weight composite material includes a pair of spaced apart steel sheets and a core layer including a filled polymeric material between the steel sheets, wherein the core layer has a thickness;the filled polymeric material is present at a concentration from about 30 volume % to about 75 volume %, based on the total volume of the light weight composite material;the core layer includes a polymeric matrix and a plurality of steel fibers arranged in one or more masses of fibers that extend the thickness of the core layer so that the core layer is in electrical communication with the steel sheets, wherein from about 0% to 40% of the steel fibers individually span the thickness of the core layer;the polymer matrix includes one or more polymers, and the polymer(s) and steel fibers are present at a volume ratio of polymer(s) to steel fiber of about 19:1 to about 2.2:1;the steel fibers have a length of about 200 μm or more and less than 7 mm; andthe steel fibers have a generally rectangular cross-section perpendicular to the length of the fibers. 17. The process of claim 1 wherein the polymeric matrix includes at least one polymer selected from the group consisting of a polyolefin, a polyamide, a polyester, a polyether, a polystyrene, a polymer including an acrylonitrile, a polymer including an acrylic acid, a polymer including an acrylate, a polyimide, a polycarbonate, an ionomer, and a copolymer including one or more of the above polymers. 18. The process of claim 17, wherein the thickness of the light weight composite material is from about 0.4 to about 4 mm; the polymeric matrix includes a polyethylene including about 70 wt. % or more ethylene; and the metallic fibers are present at a concentration from about 10 percent by volume to about 30 percent by volume based on the total volume of the core layer of the light weight composite material. 19. The process of claim 18, wherein the combined thickness of the pair of metallic sheets of the light weight composite material is about 0.6 mm or less and is less than about 75% of the total thickness of the light weight composite material. 20. A welded article prepared according to claim 16, comprising i) the light weight composite material;ii) the steel substrate; andiii) a weld joint characterized by at least one of the following: a) a weld button size of about 2 mm2 or more;b) a tensile strength of about 1 kN or more; orc) a weld free of metal expulsion. 21. The process of claim 6, wherein from about 0% to 40% of the steel fibers individually span the thickness of the core layer. 22. The process of claim 14, wherein from about 0% to 40% of the steel fibers individually span the thickness of the core layer. 23. The process of claim 19, wherein from about 0% to 40% of the steel fibers individually span the thickness of the core layer.
Behr, Friedrich; Gall, Hans-Dieter; Nazikkol, Cetin, Composite material made of two steel cover sheets resistance-welded together and an intermediate layer.
Schmit, Francis; Sanadres, Michel; Charbonnet, Philippe, Composite sheet intended for drawing, comprising a main sheet and at least one adhesively bonded patching sheet blank as a patch.
Tina L. Grubb ; Catherine A. Kleckner ; William E. Wertz ; Michael C. Siminski ; Andrew T. Daly ; Jeno Muthiah, Corrosion- and chip-resistant coatings for high tensile steel.
Arthurs Trevor C. (Nova Scotia CAX) Kelly Peter Y. (Ontario CAX) Boocock John R. B. (Ontario CAX) Bryce Wayne F. (Ontario CAX), Cross-linkable adhesive polymers.
Nelson A. Dwayne, Damped laminates having welded through holes and/or edges with decreased spring back and improved fastener force retention and, a method of making.
McCutcheon Jeffrey W. (Eagan MN) Landin Donald T. (Eagan MN), Damped laminates with improved fastener force retention, a method of making, and novel tools useful in making.
Patil Ram S. (Munster IN) Johnson Donald F. (Hammond IN) Quasney John T. (East Chicago IN), Differentially coated galvanized steel strip and method and apparatus for producing same.
Friedrich Behr DE; Klaus Blumel DE; Horst Mittelstadt DE; Cetin Nazikkol DE; Werner Hufenbach DE; Frank Adam DE, Double sheet metal consisting of two covering metal sheets and an intermediate layer.
Swift Joseph A. (Union Hill NY) Orlowski Thomas E. (Fairport NY) Wallace Stanley J. (Victor NY) Peck Wilbur M. (Rochester NY) Courtney John E. (Macedon NY) Rollins David E. (Lyons NY), Fibrillated pultruded electronic components and static eliminator devices.
Sanmartin Marie-Louise (Semeac FRX) Lepoetre Pierre H. (Soissons FRX), Lightweight sandwich designed for making multilayer structures resistant to impact and thermal aggressions.
Wick, Robert J.; Hoppe, Karl M.; Cagle, Greg S., Long fiber-reinforced thermoplastic compositions, articles made therefrom and methods of making the same.
Zweben Carl H. (Devon PA) Mogle Rodman A. (Clinton NY) Rodini ; Jr. Benjamin T. (Wayne PA) Thaw Charles L. (Phoenixville PA), Low-thermal-expansion, heat conducting laminates having layers of metal and reinforced polymer matrix composite.
Hedrick Ross M. (St. Louis MO) Woodbrey James C. (Chesterfield MO) Gabbert James D. (St. Louis MO) Erickson Floyd B. (Webster Groves MO), Metal-thermoplastic-metal laminates.
Hedrick Ross M. (St. Louis MO) Woodbrey James C. (Chesterfield MO) Gabbert James D. (St. Louis MO) Erickson Floyd B. (Webster Groves MO), Metal-thermoplastic-metal laminates.
Loth Michael R. (Palos Hills IL) Millar Ronald L. (Wheaton IL) Moore Thomas E. (Perrysburg OH) Vydra Edward J. (Northbrook IL) Rogers James A. (Milford MI), Method of forming noise-damping composite with externally galvanized surfaces and composite formed thereby.
Koga Hitoshi (Iwakuni JPX) Noborio Takehisa (Iwakuni JPX) Nishimoto Masushi (Yamaguchi JPX), Method of welding laminates each having the structure of metal layer/thermally softenable insulating layer/metal layer.
Colombier Gabriel (St. Egreve FRX) Gimenez Philippe (Echirolles FRX) Drapier Claude (Vaucresson FRX) Moreau Michel (Clichy FRX), Multi-layer material comprising flexible graphite which is reinforced mechanically, electrically and thermally by a meta.
Squire, Kevin R.; Oshinski, Alan J.; Robinson, Kevin D.; Mehnert, Christian Peter; Arvedson, Marsha M.; Poole, Beverly J.; Patil, Abhimanyu Onkar; Baugh, Lisa Saunders; Colle, Karla Schall, Polymer compositions comprising cyclic olefin polymers, polyolefin modifiers, and fillers.
Schwab, Thomas J.; Schwartz, Steven A.; Botros, Maged G.; Holland, Charles S.; Weber, Robert S.; Sylvester, Richard T. E.; Morris, Neil W., Polyolefin-metal laminate.
Sakayori Seigo (Koga JA) Kuro Tomoyosi (Izumi JA) Morita Kazuyuki (Sowa JA) Hinooka Nobuya (Iwakuni JA) Niimi Hirozi (Waki JA) Komatsu Kensuke (Iwakuni JA), Process for the formation of a polyolefin coating layer onto a metal surface.
Imai Ryuusuke (Toukai JPX) Nashiwa Michio (Toukai JPX) Oomura Yasuhiro (Toukai JPX) Matsuda Ryouichi (Toukai JPX) Satou Michio (Toukai JPX) Takeuchi Tamayuki (Toukai JPX), Resin-sandwiched metal laminate, process and apparatus for producing the same and process for producing resin film for t.
Kritchevsky Gina R. (Scotch Plains NJ) Gregor John A. (Basking Ridge NJ) Gruendig Manfred W. (Long Valley NJ) Sellers Gregory J. (Clinton NJ) Liss Barbara (Verona NJ), Stampable polymeric composite containing an EMI/RFI shielding layer.
Still ; Jr. Robert D. (Bartlesville OK) Boeke Paul J. (Bartlesville OK), Stampable sheets of bonded laminate of metal sheet and fiber mat reinforced poly(arylene sulfide) and method of preparat.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.