US 11,998,978 B1
Thermoplastic-encapsulated functionalized metal or metal alloy powders
Jacob M. Hundley, Thousand Oaks, CA (US); John H. Martin, Oxnard, CA (US); Brennan Yahata, Los Angeles, CA (US); Julie Miller, Los Angeles, CA (US); Randall C. Schubert, Santa Monica, CA (US); and Tobias A. Schaedler, Oak Park, CA (US)
Assigned to HRL Laboratories, LLC, Malibu, CA (US)
Filed by HRL Laboratories, LLC, Malibu, CA (US)
Filed on Jan. 28, 2019, as Appl. No. 16/259,642.
Application 16/259,642 is a continuation in part of application No. 15/880,488, filed on Jan. 25, 2018, granted, now 11,117,193.
Application 15/880,488 is a continuation in part of application No. 15/880,474, filed on Jan. 25, 2018, granted, now 11,052,460.
Claims priority of provisional application 62/649,121, filed on Mar. 28, 2018.
Claims priority of provisional application 62/463,952, filed on Feb. 27, 2017.
Claims priority of provisional application 62/463,991, filed on Feb. 27, 2017.
Claims priority of provisional application 62/452,989, filed on Feb. 1, 2017.
Int. Cl. B29C 64/165 (2017.01); B22F 1/054 (2022.01); B22F 1/16 (2022.01); B22F 1/18 (2022.01); B22F 3/22 (2006.01); B22F 10/00 (2021.01); B33Y 70/00 (2020.01); B33Y 10/00 (2015.01)
CPC B22F 1/16 (2022.01) [B22F 1/056 (2022.01); B22F 1/18 (2022.01); B22F 3/225 (2013.01); B22F 10/00 (2021.01); B29C 64/165 (2017.08); B33Y 70/00 (2014.12); B33Y 10/00 (2014.12)] 14 Claims
OG exemplary drawing
 
1. A functionalized composite material comprising:
(a) a thermoplastic polymer binder matrix disposed in a distinct volume;
(b) a plurality of discrete metal or metal alloy particles dispersed in said thermoplastic polymer matrix, wherein said discrete metal or metal alloy particles comprise an element selected from the group consisting of aluminum, iron, titanium, nickel, and alloys or intermetallics thereof, and wherein said discrete metal or metal alloy particles have an average particle size from about 1 micron to about 1 centimeter; and
(c) a plurality of discrete particulates fully assembled on surfaces of said discrete metal or metal alloy particles in the form of an intermittent coating of said discrete particulates, wherein said discrete particulates comprise a material selected from the group consisting of metals, ceramics, polymers, carbon, and nitrides, hydrides, carbides, oxides, or alloys thereof, and combinations of any of the foregoing, wherein said discrete particulates are in contact with said thermoplastic polymer binder matrix, wherein said discrete particulates occupy from about 1 vol % to about 25 vol % of said distinct volume, wherein said discrete particulates are smaller than said discrete metal or metal alloy particles in at least one dimension, wherein said discrete particulates are compositionally different than said discrete metal or metal alloy particles, and wherein said discrete particulates have an average particulate size from about 5 nanometers to about 1000 nanometers,
wherein said discrete particulates fully assembled on surfaces of said discrete metal or metal alloy particles structurally establish surface-functionalized discrete metal or metal alloy particles,
and wherein said thermoplastic polymer binder matrix entirely and continuously surrounds said surface-functionalized discrete metal or metal alloy particles.