Method of forming metal fiber mat/polymer composite

Metal working – Method of mechanical manufacture – Combined manufacture including applying or shaping of fluent...

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179 35MS, 428256, 428594, 428608, 428628, B21B 146

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active

052262103

ABSTRACT:
The present invention provides a metal/polymer composite comprising a polymeric substrate and a sintered mat of randomly-oriented metal fibers embedded therein, the fibers having a substantially circular cross-section and a diameter of about 10 to 200 .mu.m. The polymeric substrate is typically a thin, flexible sheet-like material having a pair of planar surfaces. The polymeric substrate is preferably thermoformable. If thermoformability is desired the metal will have a melting point of less than the thermoforming temperature of the polymeric substrate. The thermoformable metal/polymer composite of the present invention may be stretched to at least 20%, and often can be stretched at least 200% of its original dimensions, at least in certain regions, without loss of electrical continuity or EMI shielding properties. The present invention also provides a method of making a metal/polymer composite and a sintered mat of randomly-oriented metal fibers.

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