US5397608A — Plastic article containing electrically conductiv…

Claim 1

Independent Claim 83 words

A thread, comprised of a bundle of between 1000 and 35000 adjacent conductive metal coated fibers embedded and anchored in plastic comprising a polymer of relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, wherein the fiber diameter ranges from 0.002 mm to about 0.015 mm and wherein the fiber conductivity is at least 0.5% of the copper standard.

Claim 2

Dependent Claim 83 words

A thread, comprised of a bundle of between 1000 and 35000 adjacent conductive metal coated fibers embedded and anchored in plastic comprising a polymer of relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, wherein the fiber diameter ranges from 0.002 mm to about 0.015 mm and wherein the fiber conductivity is at least 0.5% of the copper standard.

Claim 3

Dependent Claim 13 words

A thread according to claim 1 whereby it has a flattened cross section.

Claim 4

Dependent Claim 21 words

A thread according to claim 1 or 2 whereby the fiber content therein is between about 30 and 70 volume percent.

Claim 5

Dependent Claim 24 words

A thread according to claim 1 whereby the plastic in which the bundle is embedded comprises a thermoplastic polymer of relatively low molecular weight.

Claim 6

Dependent Claim 26 words

A thread according to claim 1 wherein the plastic is able to promote the gradual disintegration of the bundle while mixing and working at high temperature.

Claim 7

Dependent Claim 16 words

A fiber and plastic composite granule obtained by chopping pieces from the thread of claim 1.

Claim 8

Dependent Claim 16 words

A granule according to claim 6 having a length of between 3 mm and 15 mm.

Claim 9

Dependent Claim 14 words

A granule according to claim 6 wherein the conductive fibers are stainless steel fibers.

Claim 10

Dependent Claim 15 words

A molding material comprising natural synthetic resin pellets blended with granules according to claim 6.

Claim 11

Dependent Claim 15 words

A molding material comprising granules according to claim 6 blended with granules containing reinforcing fibers.

Claim 12

Dependent Claim 15 words

A molded article characterised by superior EMI shielding properties derived from granules of claim 6.

Claim 13

Dependent Claim 79 words

A thread comprising a bundle of conductive fibers, each fiber having a diameter of at most 0.015 mm, the fiber bundle being embedded in a polymer with a relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, said embedded bundle being dried to solidify the polymer and thereafter provided with a sheath of plastic material.

Claim 14

Dependent Claim 79 words

A thread comprising a bundle of conductive fibers, each fiber having a diameter of at most 0.015 mm, the fiber bundle being embedded in a polymer with a relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, said embedded bundle being dried to solidify the polymer and thereafter provided with a sheath of plastic material.

Claim 15

Dependent Claim 24 words

A thread according to claim 12 wherein the sheath of plastic material is different from the polymer in which the fiber bundle is embedded.

Claim 16

Dependent Claim 11 words

A thread according to claim 12 having a flattened cross section.

Claim 17

Dependent Claim 16 words

A thread according to claim 12 whereby the fiber bundle contains between 1000 and 35000 fibers.

Claim 18

Dependent Claim 21 words

A thread according to claim 12 whereby the fiber content therein is between about 30 volume percent and 70 volume percent.

Claim 19

Dependent Claim 11 words

A thread as in claim 12 has a round cross-sectional shape.

Claim 20

Dependent Claim 12 words

A granule obtained by chopping pieces from the thread of claim 17.

Claim 21

Dependent Claim 16 words

A fiber and plastic composite granule obtained by chopping pieces from the thread of claim 12.

Claim 22

Dependent Claim 16 words

A granule according to claim 19 having a length of between 3 mm and 15 mm.

Claim 23

Dependent Claim 27 words

A granule according to claim 19 wherein the plastic material is able to stimulate the gradual disintegration of the bundle while mixing and working at high temperature.

Claim 24

Dependent Claim 14 words

A granule according to claim 19 wherein the conductive fibers are stainless steel fibers.

Claim 25

Dependent Claim 14 words

A granule according to claim 19 wherein the conductive fibers are metal coated fibers.

Claim 26

Dependent Claim 15 words

A molding material comprising natural synthetic resin pellets blended with granules according to claim 19.

Claim 27

Dependent Claim 15 words

A molding material comprising granules according to claim 19 blended with granules containing reinforcing fibers.

Claim 28

Dependent Claim 20 words

A molding material according to any of the claims 10 or 25 comprising further including synthetic resin pellets blended therewith.

Claim 29

Dependent Claim 14 words

A molded article characterised by superior EMI shielding properties from granules of claim 19.

Claim 30

Dependent Claim 83 words

A thread comprising a bundle of conductive fibers, each fiber having a diameter of at most 0.015 mm, the fiber bundle being embedded in a polymer having a relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, said embedded bundle being provided with a sheath of plastic material different from the polymer in which the fiber bundle is embedded.

Claim 31

Dependent Claim 83 words

A thread comprising a bundle of conductive fibers, each fiber having a diameter of at most 0.015 mm, the fiber bundle being embedded in a polymer having a relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, said embedded bundle being provided with a sheath of plastic material different from the polymer in which the fiber bundle is embedded.

Claim 32

Dependent Claim 14 words

A thread as in claim 28, wherein the thread has a round cross-sectional shape.

Claim 33

Dependent Claim 14 words

A thread as in claim 28, wherein the thread has a flattened cross section.

Claim 34

Dependent Claim 16 words

A thread as in claim 28, wherein the fiber bundle contains between 1,000 and 35,000 fibers.

Claim 35

Dependent Claim 21 words

A thread as in claim 28, wherein the fiber content therein is between about 30 volume percent and 70 volume percent.

Claim 36

Dependent Claim 13 words

A thread as in claim 28 wherein the conductive fibers are stainless steel.

Claim 37

Dependent Claim 15 words

A fiber and plastic segment formed by subdividing the thread of claim 28 into granules.

Claim 38

Dependent Claim 22 words

A fiber and plastic composite as in claim 34, wherein the granule has a length of between 3 mm and 15 mm.

Claim 39

Dependent Claim 30 words

A fiber and plastic composite as in claim 34, wherein the plastic material is able to stimulate the gradual disintegration of the bundle while mixing and working at high temperatures.

Claim 40

Dependent Claim 13 words

A segment as in claim 34 wherein the conductive fibers are stainless steel.

Claim 41

Dependent Claim 35 words

A thread as in claim 28 wherein the conductive fibers have an electrical conductivity of at least 0.5% of the CU-Standard and further including reinforcing fibers embedded so as to extend along the length thereof.

Claim 42

Dependent Claim 15 words

A fiber and plastic segment formed by subdividing the thread of claim 38 into granules.

Claim 43

Dependent Claim 12 words

A molding material comprising the fiber and plastic composite of claim 39.

Claim 44

Dependent Claim 20 words

A thread as in claim 38 wherein the conductive fibers are disposed in a side-to-side disposition with the reinforcing fibers.

Claim 45

Dependent Claim 15 words

A fiber and plastic segment formed by subdividing the thread of claim 41 into granules.

Claim 46

Dependent Claim 12 words

A molding material comprising the fiber and plastic composite of claim 42.

Claim 47

Dependent Claim 21 words

Molded articles comprising conductive fibers and reinforcing fibers dispersed therein derived from the molding material according to claim 40 or 43.

Claim 48

Dependent Claim 91 words

A fiber and plastic composite granule obtained by cutting pieces from an elongated thread comprised of a bundle of between 1,000 and 35,000 adjacent conductive, metal coated fibers embedded in a polymeric plastic material having a relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from said granule, the diameter of said conductive fibers being at most about 0.015 mm and exhibiting a fiber conductivity of at least 0.5% of the copper standard.

Claim 49

Dependent Claim 91 words

A fiber and plastic composite granule obtained by cutting pieces from an elongated thread comprised of a bundle of between 1,000 and 35,000 adjacent conductive, metal coated fibers embedded in a polymeric plastic material having a relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from said granule, the diameter of said conductive fibers being at most about 0.015 mm and exhibiting a fiber conductivity of at least 0.5% of the copper standard.

Claim 50

Dependent Claim 15 words

A composite granule as in claim 45 further including an outer sheath of plastic material.

Claim 51

Dependent Claim 20 words

A composite granule as in claim 45, wherein the equivalent diameter of said fibers range from 0.002 to 0.008 mm.

Claim 52

Dependent Claim 17 words

A fiber and plastic composite as in claim 45, wherein the thread has a flattened cross section.

Claim 53

Dependent Claim 24 words

A fiber and plastic composite as in claim 45 or 48, wherein the fiber content therein is between about 30 and 70 volume percent.

Claim 54

Dependent Claim 27 words

A fiber and plastic composite as in claim 45, wherein the plastic in which the bundle is embedded comprises a thermoplastic polymer of relatively low molecular weight.

Claim 55

Dependent Claim 29 words

A fiber and plastic composite as in claim 45, wherein the plastic is able to promote the gradual disintegration of the bundle while mixing and working at high temperatures.

Claim 56

Dependent Claim 22 words

A fiber and plastic composite as in claim 45, wherein the granule has a length of between 3 mm and 15 mm.

Claim 57

Dependent Claim 84 words

A fiber and plastic composite granule obtained by cutting pieces from an elongated thread comprised of a bundle of conductive, metal coated fibers, each fiber having a diameter of at most 0.015 mm, the fiber bundle being embedded in a polymer with a relatively low molecular weight which will enable even distribution of the conductive fibers under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from said granule, said embedded bundle being provided with a sheath of plastic material.

Claim 58

Dependent Claim 84 words

A fiber and plastic composite granule obtained by cutting pieces from an elongated thread comprised of a bundle of conductive, metal coated fibers, each fiber having a diameter of at most 0.015 mm, the fiber bundle being embedded in a polymer with a relatively low molecular weight which will enable even distribution of the conductive fibers under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from said granule, said embedded bundle being provided with a sheath of plastic material.

Claim 59

Dependent Claim 17 words

A fiber and plastic composite as in claim 53, wherein the thread has a round cross-sectional shape.

Claim 60

Dependent Claim 17 words

A fiber and plastic composite as in claim 53, wherein the thread has a flattened cross section.

Claim 61

Dependent Claim 19 words

A fiber and plastic composite as in claim 53, wherein the fiber bundle contains between 1,000 and 35,000 fibers.

Claim 62

Dependent Claim 24 words

A fiber and plastic composite as in claim 53, wherein the fiber content therein is between about 30 volume percent and 70 volume percent.

Claim 63

Dependent Claim 22 words

A fiber and plastic composite as in claim 53, wherein the granule has a length of between 3 mm and 15 mm.

Claim 64

Dependent Claim 30 words

A fiber and plastic composite as in claim 53, wherein the plastic material is able to stimulate the gradual disintegration of the bundle while mixing and working at high temperatures.

Claim 65

Dependent Claim 132 words

A granule with a length of 3 to 15 mm chopped from a composite thread for use in the moldings of an article capable of shielding against electromagnetic waves, said composite thread comprising from 1000 to 35000 electrically conductive fibers with a conductivity of at least 0.5% of the Cu-standard and a diameter of not more than 75 mm, embedded as a bundle in a relative low molecular weight polymer, said embedded bundle being sheathed with a layer comprising a different polymer said low molecular weight polymer enabling a gradual disintegration of the granule with minimal shear force on the conductive fibers so as to avoid substantial fiber breakage while the granule is kneaded during molding of the article, thus permitting an even electromagnetic shielding dispersion of the fibers throughout the article.

Claim 66

Dependent Claim 132 words

A granule with a length of 3 to 15 mm chopped from a composite thread for use in the moldings of an article capable of shielding against electromagnetic waves, said composite thread comprising from 1000 to 35000 electrically conductive fibers with a conductivity of at least 0.5% of the Cu-standard and a diameter of not more than 75 mm, embedded as a bundle in a relative low molecular weight polymer, said embedded bundle being sheathed with a layer comprising a different polymer said low molecular weight polymer enabling a gradual disintegration of the granule with minimal shear force on the conductive fibers so as to avoid substantial fiber breakage while the granule is kneaded during molding of the article, thus permitting an even electromagnetic shielding dispersion of the fibers throughout the article.

Claim 67

Dependent Claim 49 words

An article molded from granules of claim 60 having improved EMI shielding properties and including conductive fibers that form a substantially continuous conductive network in the molded article to thereby increase the conductivity of the molded article without substantially modifying the physical and mechanical properties of the molded article.

Claim 68

Dependent Claim 95 words

A molding material comprising natural synthetic resin pellets blended with granules obtained by cutting pieces from a thread comprised of a bundle containing between 1,000-35,000 adjacent conductive fibers, each said fiber having a diameter of at most 0.015 mm, the fiber bundle being embedded in a polymer having a relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, said embedded bundle being provided with an outer sheath of a plastic material.

Claim 69

Dependent Claim 95 words

A molding material comprising natural synthetic resin pellets blended with granules obtained by cutting pieces from a thread comprised of a bundle containing between 1,000-35,000 adjacent conductive fibers, each said fiber having a diameter of at most 0.015 mm, the fiber bundle being embedded in a polymer having a relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, said embedded bundle being provided with an outer sheath of a plastic material.

Claim 70

Dependent Claim 15 words

A molding material according to claim 62 wherein the conductive filler is a metal fiber.

Claim 71

Dependent Claim 32 words

A molding material according to claim 62 wherein a bundle of the conductive filler has a coating layer on a surface thereof of a material stimulating the gradual disintegration of the bundle.

Claim 72

Dependent Claim 23 words

A molding material according to claim 62 or 64, wherein the bundle of the conductive filler consists of a plurality of individual bundles.

Claim 73

Dependent Claim 27 words

A molding material according to claim 62 wherein the mixing ratio of the granules to the natural pellets is in the range of from 1:6 to 1:20.

Claim 74

Dependent Claim 29 words

A molding material according to claim 62 wherein a resin of the cylindrical synthetic resin layer and the synthetic resin of the natural pellets are of the same type.

Claim 75

Dependent Claim 19 words

A molding material according to claim 67 comprising natural synthetic resin pellets blended with granules according to claim 18.

Claim 76

Dependent Claim 13 words

A molding material according to claim 62 wherein the granules are shaped flat.

Claim 77

Dependent Claim 16 words

A molding material as in claim 62, wherein the plastic material is different from the polymer.

Claim 78

Dependent Claim 17 words

A molding material as in claim 62, wherein the conductive fibers are comprised of stainless steel fibers.

Claim 79

Dependent Claim 15 words

A molding material as in claim 62, wherein the conductive fibers are metal coated fibers.

Claim 80

Dependent Claim 19 words

Molded articles derived from the molding material according to any one of claims 9, 10, 24-26, 63-68 or 69.

Claim 81

Dependent Claim 46 words

A molding material comprising synthetic resin pellets blended with granules comprising a bundle of a number of strands of fibrous conductive filler provided inside a synthetic resin layer in a longitudinal direction thereof, wherein the conductive filler is a non-metallic fiber coated with a metal layer.

Claim 82

Dependent Claim 46 words

A molding material comprising synthetic resin pellets blended with granules comprising a bundle of a number of strands of fibrous conductive filler provided inside a synthetic resin layer in a longitudinal direction thereof, wherein the conductive filler is a non-metallic fiber coated with a metal layer.

Claim 83

Dependent Claim 73 words

A thread comprising a bundle of conducive, metal coated fibers, each having a diameter of at most 0.015 mm, the fiber bundle being embedded in a polymer with a relative low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, said embedded bundle being provided with a sheath of plastic material.

Claim 84

Dependent Claim 73 words

A thread comprising a bundle of conducive, metal coated fibers, each having a diameter of at most 0.015 mm, the fiber bundle being embedded in a polymer with a relative low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, said embedded bundle being provided with a sheath of plastic material.

Claim 85

Independent Claim 106 words

A method of continuously forming granules, which comprises the steps of continuously coating a bundle of fibrous conductive fillers with a polymer having a relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, drying the polymer, passing the coated bundle through an extruder for sheathing a synthetic resin layer around the coated bundle, and cutting the bundle sheathed with resin for providing granules, said coating being capable of stimulating the gradual disintegration of the bundle while mixing and working at high temperatures.

Claim 86

Independent Claim 106 words

A method of continuously forming granules, which comprises the steps of continuously coating a bundle of fibrous conductive fillers with a polymer having a relatively low molecular weight which will enable even distribution of the conductive fibers, under minimal shear force and without substantial fiber breakage, within molded plastic articles formed from granules cut from the thread, drying the polymer, passing the coated bundle through an extruder for sheathing a synthetic resin layer around the coated bundle, and cutting the bundle sheathed with resin for providing granules, said coating being capable of stimulating the gradual disintegration of the bundle while mixing and working at high temperatures.

Claim 87

Dependent Claim 125 words

A process for forming plastic articles having at least predetermined conductive portions including the steps of: (a) providing a fiber/plastic composite having a conductive fibers content ranging from about 30 to about 70% vol. and having a substantially parallel fiber arrangement therein, wherein the conductive fibers are anchored in a polymeric plastic compatible with and of lower melting point, softening point and molecular weight than substantially pure polymeric plastic material to be admixed therewith (b) admixing this fiber/plastic composite from step (a) with a predetermined volume of substantially pure polymeric plastic material, and (c) heating said mixture and working the heated mixture while maintaining low shear conditions to avoid breakage of the fibers, but with sufficient shear to evenly distribute the fibers within the plastic.

Claim 88

Dependent Claim 125 words

A process for forming plastic articles having at least predetermined conductive portions including the steps of: (a) providing a fiber/plastic composite having a conductive fibers content ranging from about 30 to about 70% vol. and having a substantially parallel fiber arrangement therein, wherein the conductive fibers are anchored in a polymeric plastic compatible with and of lower melting point, softening point and molecular weight than substantially pure polymeric plastic material to be admixed therewith (b) admixing this fiber/plastic composite from step (a) with a predetermined volume of substantially pure polymeric plastic material, and (c) heating said mixture and working the heated mixture while maintaining low shear conditions to avoid breakage of the fibers, but with sufficient shear to evenly distribute the fibers within the plastic.

Claim 89

Dependent Claim 23 words

A process according to claim 77 including the further step of forming the article by extrusion through a die of the worked mixture.

Claim 90

Dependent Claim 20 words

A process according to claim 77 including the further step of forming the article by injection molding the worked mixture.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1998-03-13	1998-09-12	1999-03-14	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2002-03-13	2002-09-12	2003-03-14	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2006-03-13	2006-09-12	2007-03-14	$7700.00	Window Closed / Lapsed

Plastic article containing electrically conductive fibers

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