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EP0161854A2 Expired / Lapsed EP ⏱️ 0.0 years remaining

Method of adhering metal alloy to metal sheet with resin composition

Assignee: Nitto Denko Corp
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Filing: 1985-04-26
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Granted: —
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Expires: 2005-04-26
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Abstract

Abstract A fixing composition comprises a thermosetting resin, exemplified as an epoxy resin, e.g. a bisphenol A type, optionally with a heat-activated hardener, and one of three additives to maintain the viscosity during melting prior to the resin hardening, namely (a) a powdered metal, e.g. Fe, Ni, (b) a thermoplastic resin, e.g. high molecular wt epoxy resin, or (c) an adhesive material, e.g. an acrylic copolymer of an alkyl-(meth)acrylic acid ester; and other additives optionally. The components are selected so that the residual carbon after heating to metal sintering temperature is at least 0.5 wt %, preferably 1.0 to 10%. A sheet of 0.5 to 5 mm thick of a powdered metal alloy, e.g. a multi-component eutectic alloy and a synthetic resin binder composition, e.g. an acrylic copolymer and an adhesive component, is placed on a metal substrate, e.g. of steel; a molded film or coated layer of 5 to 50 µm thickness of the fixing composition is placed therebetween. The assembly is heated in a non-oxidizing atmosphere to harden the resin and form an adhesive and then to sintering temperature, e.g. 1,000 to 1,150°C at which the adhesive vaporizes and the alloy sinters to the substrate. The alloy sheet is adhered firmly to the substrate during sintering.

Inventors

  • 👤 Takahumi C/O Nitto Electric Sakuramoto
  • 👤 Takashi C/O Nitto Electric Tomigana
  • 👤 Eisha C/O Nitto Electric Asoshina
  • 👤 Ichiro C/O Nitto Electric Ijichi
  • 👤 Kiyohiro C/O Nitto Electric Kamei
  • 👤 Toshiharu C/O Nitto Electric Konishi

Bibliographic Details

Application Number —
Jurisdiction EP
Data Source google_patents
Last Synchronized 2026-11-09 10:34
CPC Classifications
C; C09; C09J; C09J133/00; C09J133/04; C09J133/06; B; B22; B22F; B22F1/00; B22F1/10; B22F1/103; B22F7/00; B22F7/02; B22F7/04; C08; C08K; C08K3/00; C08K3/02; C08K3/08; C08L; C08L101/00; C08L33/00; C08L33/04; C08L33/06; C09J201/00; C09J5/00; C09J5/06; C08L2666/00; C08L2666/02; C08L2666/14; C08L63/00; C09J2463/00

Claims Analysis

Total Claims: 11
Claim 1
Independent Claim 90 words
A composition for use in fixing a molding or sheet formed from a powdered metal alloy and a synthetic resin binder to a metal substrate, and which composition serves to adhere the sheet during heating until the metal alloy is sintered to the substrate comprising a mixture of a thermosetting resin and at least one member selected from finely powdered metal, a thermoplastic resin and an adhesive material, wherein the amount of the residual carbon of the composition after completion of the metal sintering is at least 0.5% by weight.
Claim 2
Dependent Claim 90 words
A composition for use in fixing a molding or sheet formed from a powdered metal alloy and a synthetic resin binder to a metal substrate, and which composition serves to adhere the sheet during heating until the metal alloy is sintered to the substrate comprising a mixture of a thermosetting resin and at least one member selected from finely powdered metal, a thermoplastic resin and an adhesive material, wherein the amount of the residual carbon of the composition after completion of the metal sintering is at least 0.5% by weight.
Claim 3
Dependent Claim 15 words
A composition as claimed in Claim 1, wherein the thermosetting resin is an epoxy resin.
Claim 4
Dependent Claim 32 words
A composition as claimed in Claim 1 or 2, wherein the metal powder is of iron, nickel, cobalt, copper, chromium or silver and has a particle size of 10 um or less.
Claim 5
Dependent Claim 32 words
A composition as claimed in Claim 1 or 2, wherein the thermoplastic resin is a high molecular weight epoxy resin, a polyamide resin, a polyester resin and an ethylene- vinyl acetate copolymer.
Claim 6
Dependent Claim 23 words
A composition as claimed in Claim 1 or 2, wherein the adhesive material is an adhesive comprising a (meth)-acrylic acid alkyl ester-based polymer.
Claim 7
Dependent Claim 21 words
A composition as claimed in any preceding claim, wherein the amount of residual carbon is from 1.0 to 10% by weight.
Claim 8
Dependent Claim 21 words
A composition as claimed in any preceding claim, in the form of a sheet or layer 5 to 50 millimicrons thick.
Claim 9
Dependent Claim 13 words
A composition as claimed in any preceding claim, which includes an organic solvent.
Claim 10
Independent Claim 104 words
A method of sintering a metal alloy to a metal substrate, wherein the alloy is in the form of a molding or sheet formed from a mixture of the alloy and a synthetic resin binder, which comprises placing said sheet or molding on said substrate, interposing a composition as claimed in any preceding claim or a molded layer of the composition between the sheet and substrate, heating the assembly in a non-oxidizing atmosphere so as to form from the composition an adhesive, and continuing heating to the temperature at which the metal alloy is sintered to the substrate and at which the adhesive'formed disappears.
Claim 11
Dependent Claim 45 words
A method as claimed in Claim 9, wherein the alloy is a multi-component eutectic alloy powder containing iron, carbon and at least one of Mo, B or P and the heating is at a substantially constant rate of temperature increase, up to 1,000 to 1,150°C.

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