Method of making plastic composite with wire reinforcements

Claim 1

A method of making a plastic composite according to claim 1 wherein the styrene base resin sheath which forms the matrix plastic is selected from the group consisting of polystyrene and acrylonitrile-butadiene-styrene.

Claim 2

A method of making a corrosion resistant plastic composite having a smooth defect free surface comprising: a. coating a plurality of ferrous metal fibers with a surface film of acrylonitrile-butadiene-styrene resin dissolved in an organic solvent and heating the coated fibers to expel the solvent and fuse the remaining film of resin to the surface of the fibers, b. uniformly combining said coated ferrous fibers with a predetermined quantity of a styrene base plastic from the group consisting of polystyrene and acrylonitrile-butadiene-styrene in a manner such that short lengths of the ferrous fibers are encapsulated within the plastic to form ferrous fiber containing plastic pellets, c. combining said pellets of (b) with additional styrene base plastic pellets without included fibers and uniformly blending both sets of plastic pellets together, d. heating said plastic pellets and included ferrous fibers to an elevated temperature, and e. forming the plastic and included ferrous fibers uniformly distributed throughout the plastic into a desired predetermined shape by a hot shaping operation.

Claim 4

A method of making a corrosion resistant plastic composite comprising: a. coating a series of ferrous metal fibers with a surface film of fused acrylonitrile-butadiene-styrene resin; b. coating a series of sacrificial metal fibers having a greater electro negativity than iron with a surface film of fused acrylonitrile-butadiene-styrene resin; c. combining the ferrous and sacrificial metal fibers into a strand of metallic fibers; d. extruding a sheath of a styrene base plastic over the surface of the metallic fibers; e. severing the plastic sheathed strand into a series of short pellets; f. heating the plastic sheathed pellets; and g. forming the heated plastic and included fibers into a desired shape by a molding operation at an elevated temperature.

Claim 9

A method of making a ferrous fiber reinforced plastic composite having ferrous fibers distributed uniformly throughout a plastic matrix comprising: a. passing a linearly extending collection of ferrous fibers through a cleaning operation, b. passing the linearly extending collection of ferrous fibers through a primer composed of a polymeric adhesion inducing material comprised of acrylonitrile-butadiene-styrene in an organic solvent, c. passing the linearly extending collection of ferrous fibers through heating means to evaporate the organic solvent and fuse a thin layer of the polymeric material upon the surface of the ferrous fibers, d. extruding a sheath of a thermoplastic polymer comprising a styrene base plastic compatible with the polymeric film upon the surface of the ferrous fibers about the exterior of the linearly extending collection of ferrous fibers, e. chopping the linearly extending ferrous fibers together with the extruded plastic coatings about said ferrous fibers into pellets, f. heating and blending the pellets to form a uniform mix of matrix plastic and reinforcing fibers, and g. forming the heated plastic by heated plastic forming apparatus into a desired shape having smooth external molded surfaces.