Weldable laminated structure and method of welding

Abstract

A laminate structure and method of welding the laminate structure is provided. The laminate structure includes a first metal sheet having a first thickness, a second metal sheet having a second thickness, and an adhesive core made of an adhesive material also described as a viscoelastic adhesive material. The adhesive core is disposed between and bonded to the first and second metal sheets. The first and second metal sheets are made of an aluminum based material. The adhesive core includes a plurality of electrically conductive filler particles dispersed in the adhesive materials. The filler particles are made of a first filler material and at least a second filler material which is a different material than the first filler material.

1 . A laminate structure comprising:
 a first metal sheet;   a second metal sheet;   wherein the first and second metal sheets are made of an aluminum based material characterized by an aluminum electrical resistivity;   an adhesive core;   wherein the adhesive core is disposed between and bonded to the first and second metal sheets such that the adhesive core is coextensive with each of the first and second metal sheets;   wherein the first metal sheet, the second metal sheet, and the adhesive core are laminated together to form the laminate sheet;   wherein the adhesive core includes a plurality of electrically conductive filler particles dispersed in an adhesive material;   wherein the filler particles are made of a first filler material and a second filler material which is a different material than the first filler material;   wherein at least one the first and second filler materials has a filler electrical resistivity greater than the aluminum electrical resistivity;   wherein the plurality of electrically conductive filler particles defines a conduction path by which an electrical current applied to one of the first and second metal sheets is conducted through the adhesive core to the other of the first and second metal sheets to generate a resistive heat; and   wherein a percentage weight of the filler particles is in a range of about 5% to 49% of a total weight of the adhesive core.   
     
     
         2 . The laminate structure of  claim 1 , wherein the resistive heat is sufficient to at least partially melt the first and second metal sheets in a weld zone including the conduction path. 
     
     
         3 . The laminate structure of  claim 1 , wherein:
 the first filler material is a first iron phosphide compound;   the second filler material is second iron phosphide compound; and   the first iron phosphide compound is different than the second iron phosphide compound.   
     
     
         4 . The laminate structure of  claim 1 , wherein:
 the first filler material is zinc;   the second filler material is aluminum particles; and   wherein the filler particles are formed by coating the aluminum particles with the zinc.   
     
     
         5 . The laminate structure of  claim 4 , wherein the aluminum particles are deoxidized prior to being coated by the zinc. 
     
     
         6 . The laminate structure of  claim 4 , wherein a percentage weight of the filler particles is in a range of about 5% to 37.5% of a total weight of the adhesive core. 
     
     
         7 . The laminate structure of  claim 1 , wherein:
 the first filler material is one of zinc, silver, and nickel;   the second filler material is a plurality of carrier objects; and   wherein the filler particles are formed by coating the carrier objects with the one of the zinc, silver, and nickel.   
     
     
         8 . The laminate structure of  claim 7 , wherein the carrier object is made of one of a glass and a ceramic material. 
     
     
         9 . The laminate structure of  claim 8 , wherein the carrier object is a hollow object. 
     
     
         10 . The laminate structure of  claim 7 , wherein the carrier object is a spherical object having an object diameter;
 wherein the adhesive core has a core thickness; and   wherein the core thickness and the object diameter are substantially the same.   
     
     
         11 . The laminate structure of  claim 7 , wherein a percentage weight of the filler particles is in a range of about 8% to 30% of a total weight of the adhesive core. 
     
     
         12 . The laminate structure of  claim 1 , wherein:
 the first filler material is one of magnesium, zinc, silicon, and copper; and   the second filler material is an oxide of the one of magnesium, zinc, silicon, and copper.   
     
     
         13 . The laminate structure of  claim 1 , wherein:
 the first filler material is magnesium;   the second filler material is manganese dioxide.   
     
     
         14 . The laminate structure of  claim 1 , wherein the filler particles include a third filler material which is a different material than the first and second filler materials. 
     
     
         15 . The laminate structure of  claim 14 , wherein:
 the first filler material is manganese dioxide;   the second filler material is magnesium and silicon; and   the third filler material is one of aluminum and zinc.   
     
     
         16 . A method of welding a laminate structure, the method comprising:
 providing a laminate structure, wherein the laminate structure includes:
 a first metal sheet; 
 a second metal sheet; 
 wherein the first and second metal sheets are made of an aluminum based material characterized by an aluminum electrical resistivity; 
 an adhesive core; 
 wherein:
 the adhesive core is disposed between and bonded to the first and second metal sheets such that the adhesive core is coextensive with each of the first and second metal sheets; 
 the first metal sheet, the second metal sheet, and the adhesive core are laminated together to form the laminate sheet; 
 the adhesive core includes a plurality of electrically conductive filler particles dispersed in an adhesive material; 
 the filler particles are made of a first filler material and a second filler material which is a different material than the first filler material; and 
 at least one the first and second filler materials has a filler electrical resistivity greater than the aluminum electrical resistivity; 
 wherein the plurality of electrically conductive filler particles defines a conduction path by which an electrical current applied to one of the first and second metal sheets is conducted through the adhesive core to the other of the first and second metal sheets to generate a resistive heat; 
 wherein a percentage weight of the filler particles is in a range of about 5% to 49% of a total weight of the adhesive core; 
 
   providing a metal component;   stacking the laminate structure and the metal component;   flowing an electrical current through a weld zone defined by the stacked laminate structure and the metal component;   wherein the plurality of electrically conductive filler particles defines a conduction path by which the electrical current is conducted through the adhesive core to generate a resistive heat; and   wherein the resistive heat is sufficient to at least partially melt the first and second metal sheets and the metal component to form a weld in the weld zone.   
     
     
         17 . A laminate structure comprising:
 a first metal sheet;   a second metal sheet;   wherein the first and second metal sheets are made of an aluminum based material characterized by an aluminum electrical resistivity;   an adhesive core;   wherein the adhesive core is disposed between and bonded to the first and second metal sheets;   wherein the adhesive core includes a plurality of electrically conductive filler particles dispersed in an adhesive material;   wherein the filler particles are made of a first filler material and a second filler material;   wherein the first filler material is one of magnesium, zinc, silicon, and copper;   wherein the second filler material is an oxide of the one of magnesium, zinc, silicon, and copper; and   wherein the plurality of electrically conductive filler particles defines a conduction path by which an electrical current applied to one of the first and second metal sheets is conducted through the adhesive core to the other of the first and second metal sheets to generate a resistive heat.