Method of making synthetic resin composites with magnetic fillers

Claim 1

A METHOD OF IMPROVING THE MECHANICAL PROPERTIES INCLUDING TENSILE AND FLEXURE STRENGTHS AND TENSILE AND FLEXURE MODULUS IN SYNTHETIC RESIN, MAGNETIC PARTICLE REINFORCED, COMPOSITES COMPRISING: A. PROVIDING SYNTHETIC RESIN SELECTED FROM THE GROUP CONSISTING OF THERMOSETTING POLYESTER POLYMERS AND THERMOPLASTIC ACRYLONITRILE-BUTADIENE-STYRENE POLYMERS IN A LOW VISCOSITY FLUID STATE, COMBINING WITH SAID FLUID SYNTHETIC RESIN PARTICULATE MAGNETIC FUME MATERIAL DERIVED FROM A STEELMAKING OPERATION OF AN AVERAGE PARTICLE SIZE NO GREATER THAN ABOUT 20 MICRONS AND IN AMOUNTS BY VOLUME NOT TO EXCEED ABOUT 80% OF THE TOTAL VOLUME OF THE CONPOSITE, B. APPLYING TO SAID FLUID SYNTHETIC RESIN AND SAID PARTICULATE MAGNETIC FUME MATERIAL A MAGNETIC FORCE IN SUBSTANTIALLY THE DIRECTION IN WHICH IMPROVEMENT IN THE PROPERTIES OF THE FINAL PLASTIC COMPOSITE IS DESIRED OF SUFFICIENT STRENGTH, AND MAINTAINING SAID MAGNETIC FORCE FOR A TIME SUFFICIENT TO MAGNETICALLY ALIGN THE MAGNETIC FUME MATERIAL IN SAID RESIN IN PLANES PARALLEL TO SAID MAGNETIC FORCE, AND C. CONVERTING SAID RESIN FROM A FLUID TO A RIGID STATE WHILE MAINTAINING THE PARTICLE ALIGNMENT TO FORM AN INTEGRAL RIGID COMPOSITE WHEREIN SAID TENSILE AND FLEXURE STRENGTH AND TENSILE AND FLEXURE MODULUS OF SAID COMPOSITE ARE INCREASED.

Claim 2

A METHOD OF IMPROVING THE MECHANICAL PROPERTIES INCLUDING TENSILE AND FLEXURE STRENGTHS AND TENSILE AND FLEXURE MODULUS IN SYNTHETIC RESIN, MAGNETIC PARTICLE REINFORCED, COMPOSITES COMPRISING: A. PROVIDING SYNTHETIC RESIN SELECTED FROM THE GROUP CONSISTING OF THERMOSETTING POLYESTER POLYMERS AND THERMOPLASTIC ACRYLONITRILE-BUTADIENE-STYRENE POLYMERS IN A LOW VISCOSITY FLUID STATE, COMBINING WITH SAID FLUID SYNTHETIC RESIN PARTICULATE MAGNETIC FUME MATERIAL DERIVED FROM A STEELMAKING OPERATION OF AN AVERAGE PARTICLE SIZE NO GREATER THAN ABOUT 20 MICRONS AND IN AMOUNTS BY VOLUME NOT TO EXCEED ABOUT 80% OF THE TOTAL VOLUME OF THE CONPOSITE, B. APPLYING TO SAID FLUID SYNTHETIC RESIN AND SAID PARTICULATE MAGNETIC FUME MATERIAL A MAGNETIC FORCE IN SUBSTANTIALLY THE DIRECTION IN WHICH IMPROVEMENT IN THE PROPERTIES OF THE FINAL PLASTIC COMPOSITE IS DESIRED OF SUFFICIENT STRENGTH, AND MAINTAINING SAID MAGNETIC FORCE FOR A TIME SUFFICIENT TO MAGNETICALLY ALIGN THE MAGNETIC FUME MATERIAL IN SAID RESIN IN PLANES PARALLEL TO SAID MAGNETIC FORCE, AND C. CONVERTING SAID RESIN FROM A FLUID TO A RIGID STATE WHILE MAINTAINING THE PARTICLE ALIGNMENT TO FORM AN INTEGRAL RIGID COMPOSITE WHEREIN SAID TENSILE AND FLEXURE STRENGTH AND TENSILE AND FLEXURE MODULUS OF SAID COMPOSITE ARE INCREASED.

Claim 4

A method of improving the mechanical properties including tensile and flexure strengths and tensile and flexure modulus in synthetic resin, magnetic particle reinforced, composites comprising: a. providing synthetic resin material selected from the group consisting of thermoplastic acrylonitrile-butadiene-styrene type and thermosetting polyester type polymers in a fluid state, combining said fluid synthetic resin with particulate fume material derived from a steelmaking operation and having an average particle size no greater than about 20 microns and in amounts by volume not to exceed about 80% of the total volume of the composite, b. applying to said synthetic resin and particulate fume mixture a magnetic force of sufficient strength and maintaining said magnetic force for a time sufficient to magnetically align the fume material in said resin in planes parallel to said magnetic forces, and c. converting said resin from a fluid to a substantially rigid state while maintaining the fume particle alignment to form an integral rigid composite wherein said tensile and flexure strength and tensile and flexure modulus of said composite are increased.

Claim 5

A method of improving the mechanical properties including tensile and flexure strengths and tensile and flexure modulus in synthetic resin, magnetic particle reinforced, composites comprising: a. providing synthetic resin material selected from the group consisting of thermoplastic acrylonitrile-butadiene-styrene type and thermosetting polyester type polymers in a fluid state, combining said fluid synthetic resin with particulate fume material derived from a steelmaking operation and having an average particle size no greater than about 20 microns and in amounts by volume not to exceed about 80% of the total volume of the composite, b. applying to said synthetic resin and particulate fume mixture a magnetic force of sufficient strength and maintaining said magnetic force for a time sufficient to magnetically align the fume material in said resin in planes parallel to said magnetic forces, and c. converting said resin from a fluid to a substantially rigid state while maintaining the fume particle alignment to form an integral rigid composite wherein said tensile and flexure strength and tensile and flexure modulus of said composite are increased.