US5028490A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Metal/polymer composites
Assignee: 3M Co
•
Filing: 1988-11-14
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Granted: 1991-07-02
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Expires: 2008-11-14
Abstract
Abstract The present invention provides a discontinuous metal/polymer composite, with a metal layer, formed from a plurality of fine metal strands, which may be used, for example, in static or EMI shielding. The metal layer comprises a plurality of fine metal strands provided on the substrate, the metal strands individually having a cross-section with an area of about 100 to 100,000 μm 2 and the cross-section of the individual metal strands having a flat portion and an arcuate portion. The metal and polymer may be selected so that the composite is capable of being thermoformed without loss of electrical conductivity or transparency.
Inventors
- 👤 David C. Koskenmaki
- 👤 Clyde D. Calhoun
- 👤 Brett E. Huff
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 11:54
CPC Classifications
B; B32; B32B; B32B15/00; B32B15/04; B32B15/08; B32B15/02; H; H05; H05K; H05K9/00; H05K9/0073; H05K9/0079; H05K9/0081; H05K9/009; B32B2305/00; B32B2305/38; B32B2307/00; B32B2307/20; B32B2307/202; B32B2307/40; B32B2307/412; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/4998; Y10T29/49988; Y10T428/00; Y10T428/12; Y10T428/12347; Y10T428/12444; Y10T428/12493; Y10T428/12535; Y10T428/12556; Y10T428/12569; Y10T428/24; Y10T428/24273; Y10T428/24322; Y10T428/24331; Y10T428/249921; Y10T428/249924; Y10T428/24994
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
74 words
A thermoformable metal/polymer composite comprising a polymeric substrate and a discontinuous metal layer, said metal layer comprising a plurality of fine metal strands provided on said substrate, said metal strands individually having a cross-section with an area of about 100 to 100,00 μm 2 and said cross-section having a flat portion and an arcuate portion, said metal strands having a melting point of less than the softening or melting temperature of said polymeric substrate.
Claim 2
Dependent Claim
74 words
A thermoformable metal/polymer composite comprising a polymeric substrate and a discontinuous metal layer, said metal layer comprising a plurality of fine metal strands provided on said substrate, said metal strands individually having a cross-section with an area of about 100 to 100,00 μm 2 and said cross-section having a flat portion and an arcuate portion, said metal strands having a melting point of less than the softening or melting temperature of said polymeric substrate.
Claim 3
Dependent Claim
19 words
The composite of claim 1 wherein the area of said cross-section is about 100 to 10,000 μm 2 .
Claim 4
Dependent Claim
19 words
The composite of claim 1 wherein the area of said cross-section is about 100 to 7500 μm 2 .
Claim 5
Dependent Claim
18 words
The composite of claim 1 wherein said plurality of fine metal strands have a plurality of fused junctions.
Claim 6
Dependent Claim
14 words
The composite of claim 1 wherein said metal layer is transparent and electrically conductive.
Claim 7
Dependent Claim
14 words
The composite of claim 5 wherein said metal layer is in a mesh configuration.
Claim 8
Dependent Claim
30 words
The composite of claim 6 wherein said mesh comprises a plurality of regularly spaced horizontal strands and a plurality of regularly spaced vertical strands substantially perpendicular to said horizontal strands.
Claim 9
Dependent Claim
27 words
The composite of claim 7 wherein said vertical and horizontal strands are regularly spaced at an average spacing of between 2 and about 200 strands per cm.
Claim 10
Dependent Claim
18 words
The composite of claim 5 wherein said metal layer comprises a random, wandering configuration of the metal strands.
Claim 11
Dependent Claim
21 words
The composite of claim 1 wherein said metal is a substantially pure metal or mixture of metals and is substantially undrawn.
Claim 12
Dependent Claim
24 words
The composite of claim 10 wherein said metal is selected from the group consisting of: tin, lead, bismuth, zinc, indium, aluminum, and mixtures thereof.
Claim 13
Dependent Claim
38 words
The composite of claim 1 wherein said polymer is a homopolymer or oligopolymer comprising monomers selected from the group consisting of polyesters, polyamides, polyimides, polyolefins, polyurethanes, polysulfones, polyethers, polycarbonates, cellulose esters, halogenated polyolefins, polyacetals, polystyrenes, and vinyl polymers.
Claim 14
Dependent Claim
37 words
The composite of claim 12 wherein said monomers are polyesters formed from terephthalic acid and one or more diols selected from the group consisting of ethylene glycol, propylene glycol, 1,4 butanediol, 1,6 hexanediol, and 1,4 cyclohexane dimethanol.
Claim 15
Dependent Claim
10 words
The composite of claim 2 wherein said composite is thermoformed.
Claim 16
Dependent Claim
15 words
The composite of claim 14 wherein said composite is stretched at least 50% during thermoforming.
Claim 17
Dependent Claim
15 words
The composite of claim 15 wherein said composite is stretched at least 200% during thermoforming.
Claim 18
Dependent Claim
18 words
The composite of claim 14 wherein said composite is stretched in certain regions at least 200% during thermoforming.
Claim 19
Dependent Claim
18 words
The composite of claim 10 wherein said metal layer blocks less than 5% of visible light transmitted therethrough.
Claim 20
Independent Claim
77 words
A method of forming a thermoformable metal/polymer composite comprising the steps of: (a) providing a polymeric substrate, and (b) squirting a plurality of fine molten metal strands onto said substrate wherein said metal strands individually have a cross-section with an area of about 100 to 100,000 μm 2 and said cross-section having a flat portion and an arcuate portion, said metal having a melting point of less than the softening or melting temperature of said polymeric substrate.
Claim 21
Independent Claim
77 words
A method of forming a thermoformable metal/polymer composite comprising the steps of: (a) providing a polymeric substrate, and (b) squirting a plurality of fine molten metal strands onto said substrate wherein said metal strands individually have a cross-section with an area of about 100 to 100,000 μm 2 and said cross-section having a flat portion and an arcuate portion, said metal having a melting point of less than the softening or melting temperature of said polymeric substrate.
Claim 22
Dependent Claim
14 words
The method of claim 19 wherein said metal layer is transparent and electrically conductive.
Claim 23
Dependent Claim
21 words
The method of claim 20 wherein said metal is a substantially pure metal or mixture of metals and is substantially undrawn.
Claim 24
Dependent Claim
13 words
The method of claim 21 further including the step of thermoforming said composite.
Claim 25
Dependent Claim
15 words
The method of claim 22 wherein said composite is stretched at least 50% during thermoforming.
Claim 26
Dependent Claim
15 words
The method of claim 23 wherein said composite is stretched at least 200% during thermoforming.
Claim 27
Dependent Claim
18 words
The method of claim 22 wherein said composite is stretched in certain regions at least 200% during thermoforming.
Claim 28
Dependent Claim
16 words
The process of claim 22 wherein the composite is shrunk by at least 25% during thermoforming.
Claim 29
Dependent Claim
17 words
The method of claim 19 further including transfering said metal layer to a second similar metal/polymer composite.
Claim 30
Dependent Claim
25 words
The method of claim 19 further including embedding said metal layer into said substrate so that said metal layer becomes substantially flush with said substrate.
Claim 31
Dependent Claim
10 words
A metal/polymer composite made by the method of claim 19.
Claim 32
Dependent Claim
10 words
A metal/polymer composite made by the method of claim 21.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-07-01 | 1994-12-31 | 1995-07-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-07-01 | 1998-12-31 | 1999-07-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-07-01 | 2002-12-31 | 2003-07-02 | $7700.00 | Window Closed / Lapsed |