Composites having improved interlayer adhesion and methods thereof

摘要

The invention relates to multi-layered composite materials and methods for making multi-layered composite materials having good adhesion between the layers. The adhesion between a polymer layer and a metal layer of a multi-layered composite material may be improved by a process including a step of pre-treating a surface of the metal layer prior to contacting the metal surface with the polymer layer, and by including filler particles in the polymer layer. Using this approach, it is possible to increase the peel strength by about 10% or more, by about 20% or more, by about 40% or more, or by about 100% or more, compared with an otherwise identical composite material that does not include both of these features.

主权项

1. A process for preparing a composite material comprising the steps of:
i) contacting a surface of a first aluminum foil with a metal phosphate for cleaning the surface, for coating the surface, or both; ii) contacting the surface of the first aluminum foil with a filled polymeric core material; and iii) adhering the filled polymeric core material to the surface of the first aluminum foil using heat, pressure, or both; wherein the filled polymeric core material includes about 2 volume percent to about 50 volume percent metal fibers; and about 50 volume percent to about 98 volume percent of one or more polyolefin resins, wherein the polyolefin resin includes about 65 weight percent or more of an α-olefin; wherein the aluminum is free of a polymeric coating prior to the step of adhering the aluminum to the polymeric core layer; the polyolefin resin includes a polyethylene copolymer; the composite material is a sandwich composite including the filled polymeric core material interposed between the first aluminum foil and a second aluminum foil.