Tungsten/powdered metal/polymer high density non-toxic composites

• US 20030164063A1
• Filed: 10/15/2002
• Published: 09/04/2003
• Est. Priority Date: 10/16/2001
• Status: Active Grant

• Current Assignee: Elliott Cartridge Company (Canada), Ltd.
• Original Assignee: International Non-Toxic Composites Corporation
• Inventors: Elliott, Kenneth H.
• Granted Patent: US 6,916,354 B2
• Time in Patent Office: Days
• US Class Current: 75/252
• CPC Class Codes: B22F 1/00 Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
• CPC Class Codes: B22F 1/09 Mixtures of metallic powders
• CPC Class Codes: B22F 1/10 Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
• CPC Class Codes: B22F 2003/145 by warm compacting, below debindering temperature
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/02 Compacting only
• CPC Class Codes: C22C 1/045 Alloys based on refractory metals
• CPC Class Codes: C22C 27/04 Alloys based on tungsten or molybdenum
• CPC Class Codes: C22C 32/0094 with organic materials as the main non-metallic constituent, e.g. resin
• CPC Class Codes: F42B 12/74 of the core or solid body
• CPC Class Codes: F42B 7/046 Pellets or shot therefor

Abstract

Tungsten/polymer composites comprising tungsten powder, another metal powder having a high packing density, and organic binder have high density, good processibility and good malleability. Such composites are useful as lead replacements, particularly in the manufacture of shot.

Claims

1. A composite comprising tungsten powder, another metal powder having a high packing density and an organic binder.

2. The composite according to claim 1, wherein the packing density of the other metal powder is 62 vol % or greater.

3. The composite according to claim 1, wherein the organic binder comprises a thermoplastic elastomer or a blend thereof.

4. The composite according to claim 1, wherein the packing density of the other metal powder is 62 vol % or greater, and wherein the organic binder comprises a thermoplastic elastomer or a blend thereof.

5. The composite according to claim 4, wherein the organic binder comprises a polyether block amide, a polyester elastomer, a melt processible rubber, a chlorinated polyethylene, an ethylene propylene diene monomer (EPDM) rubber, a polyamide elastomer, a polyolefin elastomer, a thermoplastic polyurethane (TPU), or a blend thereof.

6. The composite according to claim 1, wherein the organic binder comprises a polyether block amide or a polyester elastomer.

7. The composite according to claim 4, wherein the organic binder comprises a polyether block amide or a polyester elastomer.

8. The composite according to claim 4, wherein the other metal powder is stainless steel, iron, ferrous alloy or bronze.

9. The composite according to claim 4, wherein the other metal powder is bronze.

10. The composite according to claim 4, wherein the other metal powder is stainless steel.

11. The composite according to claim 4, wherein the tungsten is present in the composite in an amount of from 80-99% by weight of the composite.

12. The composite according to claim 4, wherein the tungsten is present in the composite in an amount of from 80-97% by weight of the composite, the other metal powder is present in the composite in an amount of from 2-15% by weight of the composite, and the organic binder is present in the composite in an amount of from about 1-10% by weight of the composite.

13. The composite according to claim 1 consisting essentially of tungsten powder, another metal powder having a high packing density and an organic binder.

14. The composite according to claim 13, wherein the packing density of the other metal powder is 62 vol % or greater.

15. The composite according to claim 13, wherein the organic binder comprises a thermoplastic elastomer or a blend thereof.

16. The composite according to claim 14, wherein the organic binder comprises a polyether block amide, a polyester elastomer, a melt processible rubber, a chlorinated polyethylene, an ethylene propylene diene monomer (EPDM) rubber, a polyamide elastomer, a polyolefin elastomer, a thermoplastic polyurethane (TPU), or a blend thereof.

17. The composite according to claim 14, wherein the organic binder comprises a polyether block amide or a polyester elastomer.

18. The composite according to claim 16, wherein the tungsten is present in the composite in an amount of from 80-99% by weight.

19. The composite according to claim 16, wherein the tungsten is present in the composite in an amount of from 80-97% by weight of the composite, the other metal powder is present in the composite in an amount of from 2-15% by weight of the composite, and the organic binder is present in the composite in an amount of from about 1-10% by weight of the composite.

21. The article according to claim 12, wherein the packing density of the other metal powder is 62 vol % or greater.

22. The article according to claim 21, wherein the organic binder comprises a thermoplastic elastomer.

23. The article according to claim 21, wherein the organic binder comprises a polyether block amide or a polyester elastomer.

24. The article according to claim 22, wherein the other metal powder is stainless steel, iron, ferrous alloy or bronze.

25. The article according to claim 22, wherein the tungsten is present in the composite in an amount of from 80-97% by weight of the composite, the other metal powder is present in the composite in an amount of from 2-15% by weight of the composite, and the organic binder is present in the composite in an amount of from about 1-10% by weight of the composite.

32. The article according to claim 22 which is ammunition, a weight, radiation shielding or a high-density gyroscopic ballast.

33. The article according to claim 25 which is shot or a bullet core.

20. A finished article of manufacture comprising an unsintered composite comprising tungsten powder, another metal powder having a high packing density and an organic binder.

26. The finished article according to claim 20, wherein the unsintered composite consists essentially of tungsten, another metal powder having a high packing density and an organic binder.

27. The article according to claim 26, wherein the packing density of the other metal powder is 62 vol % or greater.

28. The article according to claim 27, wherein the organic binder comprises a thermoplastic elastomer.

29. The article according to claim 27, wherein the organic binder comprises a polyether block amide or a polyester elastomer.

30. The article according to claim 28, wherein the other metal powder is stainless steel, iron, ferrous alloy or bronze.

31. The article according to claim 28, wherein the tungsten is present in the composite in an amount of from 80-97% by weight of the composite, the other metal powder is present in the composite in an amount of from 2-15% by weight of the composite, and the organic binder is present in the composite in an amount of from about 1-10% by weight of the composite.

34. The article according to claim 28 which is ammunition, a weight, radiation shielding or a high-density gyroscopic ballast.

35. The article according to claim 31 which is shot or a bullet core.