Formable light weight composites

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.

2. 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.

3. 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.

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

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

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

7. 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.

8. 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.

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

10. 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.

11. 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 .

12. 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.

13. 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.

14. 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.

15. 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.

16. 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.

17. 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.

18. 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.

19. 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.

20. 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.

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.

22. 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.

23. 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.

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

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.

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