ALUMINUM POLY(ARYL ETHER KETONE) LAMINATE, METHODS OF MANUFACTURE THEREOF, AND ARTICLES COMPRISING THE SAME
A laminate having excellent bond strength, and comprising a tempered aluminum layer comprising aluminum in an amount of 95 to less than 99 wt %, and at least one of cobalt, copper, lithium, magnesium, manganese, nickel, platinum, and silicon in a total amount of at least 0.5 wt %; and a poly(aryl ether ketone) layer, wherein at least a portion layer and the poly(aryl ether ketone) layer are in direct contact.
1 . A laminate comprising:
a tempered aluminum layer comprising aluminum in an amount of 95 to less than 99 wt %, and at least one of cobalt, copper, lithium, magnesium, manganese, nickel, platinum, and silicon in a total amount of at least 0.5 wt %; and
a poly(aryl ether ketone) layer, wherein at least a portion layer and the poly(aryl ether ketone) layer are in direct contact.
2 . The laminate of claim 1 , wherein the tempered aluminum layer comprises aluminum in an amount of at least 98 wt %, and silicon and iron in a total amount of at least 0.5 wt %.
3 . The laminate of claim 2 , wherein the aluminum is tempered to a designation of H1.
4 . The laminate of claim 3 , wherein the aluminum is tempered to a designation of H18.
5 . The laminate of any one of claim 2 , wherein the aluminum comprises
98 to 99.49 wt % of aluminum,
0.50 to 1.5 wt % of iron, and
0.01 to 0.50 wt % of silicon.
6 . The laminate of claim 5 , wherein the aluminum comprises
98.1 to 99.39 wt % of aluminum,
0.60 to 1.5 wt % of iron, and
0.02 to 0.40 wt % of silicon.
7 . The laminate of claim 6 , wherein the aluminum comprises
98.40 to 99.25 wt % of aluminum,
0.70 to 1.3 wt % of iron, and
0.05 to 0.30 wt % of silicon.
8 . The laminate of claim 7 , wherein the aluminum further comprises other elements in a total amount of less than or equal to 0.25 wt %.
9 . The laminate of claim 8 , wherein the aluminum further comprises less than or equal to 0.05 wt % of copper, less than or equal to 0.0003 wt % of magnesium, and less than or equal to 0.05 wt % of titanium.
10 . The laminate of claim 2 , wherein the aluminum is tempered Aluminum 8079 with the tempering designation H18.
11 . The laminate of claim 1 , wherein the poly 1 (aryl ether ketone) is poly(ether ether ketone).
12 . The laminate of claim 1 , wherein the poly(aryl ether ketone) layer further comprises a particulate filler in an amount of 1 to 80 wt %, based on the total weight of the poly(aryl ether ketone) layer.
13 . The laminate of claim 12 , wherein the particulate filler is a talc.
14 . The laminate of claim 1 , wherein the poly(aryl ether ketone) layer further comprises a glass fiber reinforcement.
15 . A method of manufacturing a laminate, the method comprising:
directly contacting a least portion of a tempered aluminum layer comprising aluminum in an amount of 95 to less than 99 wt %, and at least one of cobalt, copper, lithium, magnesium, manganese, nickel, platinum, and silicon in a total amount of at least 0.5 wt %, with at least a portion of a poly(aryl ether ketone) layer; and
heat-bonding the aluminum layer and the poly(aryl ether ketone) layer under conditions effective to manufacture the laminate.
16 . The method of claim 15 , wherein the aluminum comprises aluminum in an amount of at least 98 wt %, and silicon and iron in a total amount of at least 0.5 wt %.
17 . The method of claim 15 , wherein the aluminum comprises
98.40 to 99.25 wt % of aluminum,
0.70 to 1.3 wt % of iron, and
0.05 to 0.30 wt % of silicon
18 . The method of claim 17 , wherein the aluminum is tempered Aluminum 8079, tempered to a designation of H18.
19 . The method of claim 15 , wherein the heat bonding is at 200 to 450° C. while compressing under a pressure of 2 to 10 megaPascals.
20 . An article comprising the laminate of claim 1 .