WO2002002686A2 - Composites comprising fibers dispersed in a polymer matrix having improved shielding - Google Patents
Composites comprising fibers dispersed in a polymer matrix having improved shielding Download PDFInfo
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- WO2002002686A2 WO2002002686A2 PCT/US2001/015966 US0115966W WO0202686A2 WO 2002002686 A2 WO2002002686 A2 WO 2002002686A2 US 0115966 W US0115966 W US 0115966W WO 0202686 A2 WO0202686 A2 WO 0202686A2
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K9/00—Screening of apparatus or components against electric or magnetic fields
- H05K9/0073—Shielding materials
- H05K9/0081—Electromagnetic shielding materials, e.g. EMI, RFI shielding
- H05K9/009—Electromagnetic shielding materials, e.g. EMI, RFI shielding comprising electro-conductive fibres, e.g. metal fibres, carbon fibres, metallised textile fibres, electro-conductive mesh, woven, non-woven mat, fleece, cross-linked
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/02—Fibres or whiskers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K9/00—Use of pretreated ingredients
- C08K9/04—Ingredients treated with organic substances
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/20—Conductive material dispersed in non-conductive organic material
- H01B1/22—Conductive material dispersed in non-conductive organic material the conductive material comprising metals or alloys
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/20—Conductive material dispersed in non-conductive organic material
- H01B1/24—Conductive material dispersed in non-conductive organic material the conductive material comprising carbon-silicon compounds, carbon or silicon
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/249927—Fiber embedded in a metal matrix
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/249933—Fiber embedded in or on the surface of a natural or synthetic rubber matrix
- Y10T428/249938—Composite or conjugate fiber [e.g., fiber contains more than one chemically different material in monofilament or multifilament form, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/249933—Fiber embedded in or on the surface of a natural or synthetic rubber matrix
- Y10T428/249939—Two or more layers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
- Y10T428/24995—Two or more layers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
- Y10T428/24995—Two or more layers
- Y10T428/249952—At least one thermosetting synthetic polymeric material layer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2904—Staple length fiber
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2918—Rod, strand, filament or fiber including free carbon or carbide or therewith [not as steel]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2933—Coated or with bond, impregnation or core
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2933—Coated or with bond, impregnation or core
- Y10T428/2938—Coating on discrete and individual rods, strands or filaments
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2933—Coated or with bond, impregnation or core
- Y10T428/294—Coated or with bond, impregnation or core including metal or compound thereof [excluding glass, ceramic and asbestos]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2933—Coated or with bond, impregnation or core
- Y10T428/2964—Artificial fiber or filament
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
- Y10T428/2991—Coated
- Y10T428/2998—Coated including synthetic resin or polymer
Definitions
- the present invention relates to composites useful for shielding electromagnetic radiation and their manufacture.
- the composites of the present invention comprise conductive fibers which are highly dispersed in a polymer matrix.
- the invention also relates to pellets and their manufacture. Such pellets are useful in the manufacture of composites comprising highly dispersed conductive fibers in a polymer matrix.
- electromagnetic shielded composites have been developed to: 1) protect the user of an electronic device, 2) protect an electronic device, and 3) protect surrounding electronic devices.
- electromagnetic shielded materials which may be incorporated into electronic products.
- Plastic articles formed with electrically conductive materials are particularly convenient as compared to traditional metal materials because they are light weight, easily produced using injection molding techniques, and of low cost.
- these electrically conductive materials are composites of plastics and conductive fibers.
- Various conventional techniques have been employed when incorporating electrically conductive fibers into a polymer matrix to make electromagnetic shielded composites. A drawback to these techniques is their inability to provide for adequate dispersions of conductive fibers within the composites. A technique which yields poor dispersions of conductive fibers in a composite requires the use of larger amounts of fibers in order to obtain effective electromagnetic shielding. To solve this problem, conventional techniques have employed several mechanical means to intimately mix conductive fibers a polymer to make a composite product.
- conductive fibers with a polymer are stressful and causes damage to the fibers such as fracture or breakage. These damaged fibers impart reduced electromagnetic shielding properties due to their reduced ability to conduct electricity through the composite article.
- An example of a basic technique for making an electromagnetic shielded composite involves heating a thermoplastic to a molten temperature and then kneading in the conductive powders fibers.
- the fibers are often broken due to the cutting action by the kneading screw and by the shearing of the resin. These fibers are broken into smaller and smaller segments such that the resulting composite article contains only shorter length broken fibers.
- Such shortened fibers impart reduced electromagnetic shielding properties to the composite article due to their reduced ability to conduct electricity through the composite article.
- Composite articles formed with broken fibers require the use of higher amounts fiber and may lead to embrittlement of the composite article thus formed. Additionally, operators working directly with the cut fibers and powders can experience pain or itchiness in handling the materials.
- an impregnation technique involves the use of a conductive tow comprised of a plurality of strands.
- the tow is mechanically splayed allowing for the impregnation of a polymer between the strands and then the strands subsequently gathered together into an impregnated tow which is cooled and chopped into pellets.
- impregnation techniques are relatively slow and cumbersome. Additionally, impregnation techniques often do not provide adequate integration of polymer and fiber. Impregnated fibers often fray when cut into pellets and can become separated from the resin.
- At most the final polymer sheathed pellet should comprise no more than 8 wt. % of the chemical treated and preferably no more than 5 wt. %. Amounts greater than 8 wt. % may lead to problems such as off gassing and drool during injection molding.
- the polymer sheath may comprise any polymer such as thermoset or thermoplastic polymers. If the chemically treated strand is encased in a thermoset polymer, the thermoset polymer is left uncured or partially cured.
- the thermoset polymer should be convertible by heat or light, alone or in combination with catalysts, accelerators, cross-linking agents, to form the electronic shielded composites of the invention.
- some of the polymers useful as a polymer sheath of the invention include: polyesters, polyethers, polycarbonates, epoxies, phenolics, epoxy- novolacs, epoxy-polyurethanes, urea-type resins, phenol-formaldehyde resins, melamine resins, melamine thiourea resins, urea-aldehyde resins, alkyd resins, polysulfide resins, vinyl organic prepolymers, multifunctional vinyl ethers, cyclic ethers, cyclic esters, polycarbonate-coesters, polycarbonate-co-silicones, polyetheresters, polyimides, bismalemides, polyamides, polyetherimides, polyamideimides, polyetherimides, and polyvinyl chlorides.
- the sheathing polymer is applied to a chemically treated strand so that the strand is thoroughly coated with the polymer resulting in a material comprising a core of chemically treated conductive strand encased in a polymer sheath of relatively uniform thickness.
- Conventional wire coating methods may be employed to encase the chemically treated strands of this invention. Such methods include passing a chemically treated strand into a single hole extrusion die which is supplied with molten polymer to encase the strand. Preferable wire coating methods are those described in U.S. Patent No. 6,099,910.
- Figure 1 shows a comparison of the electromagnetic shielding properties of composites made with conventional methods as compared to composites which may be obtained according to the present invention.
- a linear fit line is drawn through the plotted comparative samples which includes the point 0,0.
- two inventive samples of electromagnetic shielded composites made in accordance with the present invention are made according to the methods outlined under the heading inchlnventive Sample inch as Examples 30-31 below.
- composites made in accordance with the present invention generally show increased shielding properties at any given fiber content.
- the heated fibers are then allowed to pass over a chemical treatment application device which may be fabricated by machining an .125 inch (3.175 centimeter (cm)) wide groove into a 6 inch (15.24 cm) by .50 inch (1.27 cm) by 1 inch (2.54 cm) piece of brass bar stock.
- the groove depth varies from .50 inch (1.27 cm) deep on the ends to .25 inch (0.63 cm) deep in the middle.
- at the bottom of the groove are two holes through which the chemical treatment is pumped.
- One suitable pump is a Zenith model HPB, delivering 0.297 cc per revolution and is available from the Zenith Pumps Division of the Parker Hannifin Corporation, Sanford, North Carolina.
- Suitable conductive fibers for the present invention are available from a number of suppliers.
- Stainless steel fibers may be obtained from Bekaert Corporation/Bekaert Fibre Technologies Marietta, Georgia, product numbers Beki-Shield BU08/5000 CR E, and Beki-Shield BU08/12000 CR E.
- One type of electroplated metal-coated carbon fibers may be obtained from Composite Material, L.L.C., Mamaroneck, New York, product numbers, PPO-1200-NiCuNi, PPO-1200-NiCu, and PPO-1200-Ni.
- Another type of electroplated metal-coated carbon fiber may be obtained from Toho Carbon Fiber, Inc. Irvine, California, product number, G30-500 12K A203 MC.
- metal- coated carbon fibers may be obtained from Inco Special Products Wyckoff, New Jersey, Product Numbers, INCOFEBER® 12K20 Nickel Coated Carbon Fiber, and LNCOFIBER® 12K50 Nickel Coated Carbon Fiber. Carbon fiber is available as Besfight G30-500 HTA 7C NS01 from Toho Carbon Fiber, Inc. Irvine, California or as Grafil 34- 700 12K from Grafil Inc. Sacramento, Ca.
- Suitable conductive strands for the present invention may be made by conventional methods known in the art.
- a tow consisting of forty filaments of copper wire was prepared from ten spools of awg-41 bare copper wire available from Elektrisola of Boscawen, New Hampshire, by collecting the ten individual wires from the ten spools into a single tow often filaments by winding them onto a single spool.
- THQ toluhydroquinone
- PG propyleneglycol
- FA fumaric acid
- ST stearic acid
- the mixture under a nitrogen atmosphere, was heated to 390°F (199°C) for five hours.
- the resulting 4 inch (10.16 cm) diameter X 2 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 49db as measured by the ASTM D4935 test.
- Example 4 A 4.38 molal solution was prepared by adding 1.5 kg, 6.57 moles of bisphenol-A to 1.5 kg of bisphenol- A-propoxylate in a one gallon metal paint can. This chemical treatment mixture was then heated in an oven at 130°F (54.4°C) for three hours. Once at thermal equilibrium, the container with the now homogeneous chemical treatment was placed on the hot plate of the process apparatus described in the above general section and the temperature was maintained at 120°F (48.9°C). At this temperature, the solution had a viscosity of 40 cps (.04 Pa.s).
- the conductive fiber used was Ni Cu with an average yield of 1.37 grams per meter and was heated by passing it through the tube furnace. Under these conditions, 13 kg of conductive fiber was coated with 1.95 kg of chemical treatment and the mixture was then encapsulated with 84.72 kg of thermoplastic resin affording 99.67 kg of composite pellets having the composition of 13.04 % Ni Cu fiber, 1.96%) bis-A-diol / bisphenol-A chemical treatment, and 85% PC-ABS, with the chemically treated metallized fiber tow comprising 15% of the finished composite compound.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 75db as measured by the ASTM D4935 test and a surface resistivity of 0.6 - 52 ohm/sq.
- a 0.19 molal solution was prepared by adding 1.5 kg, 0.29 moles of sorbitan monostearate to 1.5 kg of bisphenol- A-propoxylate in a one gallon metal paint can. This chemical treatment mixture was then heated in an oven at 130°F (54.4°C) for three hours. Once at thermal equilibrium, the container with the now homogeneous chemical treatment was placed on the hot plate of the process apparatus described in the above general section and the temperature was maintained at 120°F (48.9°C). At this temperature, the solution had a viscosity of 40 cps (.04 Pa.s).
- the conductive fiber used was Ni Cu with an average yield of 1.37 grams per meter and was heated by passing it through the tube furnace. Under these conditions, 13 kg of conductive fiber was coated with 1.95 kg of chemical treatment and the mixture was then encapsulated with 84.72 kg of thermoplastic resin affording 99.67 kg of composite pellets having the composition of 13.04 % Ni Cu fiber, 1.96% bis-A-diol / sorbitan monostearate chemical treatment, and 85% PC-ABS, with the chemically treated metallized fiber tow comprising 15% of the finished composite compound.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 75db as measured by the ASTM D4935 test.
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 13db as measured by the ASTM D4935 test.
- Example 7 A 1.30 molal solution was prepared by adding 0.6 kg, 3.12 moles of citric acid to
- the conductive fiber used was Ni Cu with an average yield of 1.26 grams per meter and was heated by passing it through the tube furnace. Under these conditions, 13 kg of conductive fiber was coated with 1.95 kg of chemical treatment and the mixture was then encapsulated with 84.72 kg of thermoplastic resin affording 99.67 kg of composite pellets having the composition of 13.04 % Ni Cu fiber, 1.96% bis-A-diol / citric acid chemical treatment, and 85% polycarbonate, with the chemically treated metallized fiber tow comprising 15% of the finished composite compound.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 81db as measured by the ASTM D4935 test and a surface resistivity of 0.2 - 93 oh /sq.
- a 0.19 molal solution was prepared by adding 1.5 kg, 0.29 moles of sorbitan monostearate to 1.5 kg of bisphenol- A-propoxylate in a one gallon metal paint can. This chemical treatment mixture was then heated in an oven at 130°F (54.4°C) for three hours. Once at thermal equilibrium, the container with the now homogeneous chemical treatment was placed on the hot plate of the process apparatus described in the above general section and the temperature was maintained at 120°F (48.9°C). At this temperature, the solution had a viscosity of 40 cps (.040 Pa.s).
- the conductive fiber used was Ni Cu with an average yield of 1.37 grams per meter and was heated by passing it through the tube furnace. Under these conditions, 13 kg of conductive fiber was coated with 1.95 kg of chemical treatment and the mixture was then encapsulated with 84.72 kg of thermoplastic resin affording 99.67 kg of composite pellets having the composition of 13.04 % Ni Cu fiber, 1.96% bis-A-diol / sorbitan monostearate chemical treatment, and 85% polycarbonate, with the chemically treated metallized fiber tow comprising 15% of the finished composite compound.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 82db as measured by the ASTM D4935 test and a surface resistivity of 0.4 — 11.1 ohm/sq.
- the conductive fiber used was Ni Cu with an average yield of 1.42 grams per meter and was heated by passing it through the tube furnace. Under these conditions, 13 kg of conductive fiber was coated with 1.95 kg of chemical treatment and the mixture was then encapsulated with 84.72 kg of thermoplastic resin affording 99.67 kg of composite pellets having the composition of 13.04 % Ni Cu fiber, 1.96% sorbitan monostearate chemical treatment, and 85% polycarbonate, with the chemically treated metallized fiber tow comprising 15% of the finished composite compound.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 84db as measured by the ASTM D4935 test and a surface resistivity of 0.2 - 1.2 ohm/sq.
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 21db as measured by the ASTM D4935 test.
- Example 11 A 0.19 molal solution was prepared by adding 1.5 kg, 0.29 moles of sorbitan monostearate to 1.5 kg of bisphenol- A-propoxylate in a one gallon metal paint can. This chemical treatment mixture was then heated in an oven at 130°F (54.4°C) for three hours. Once at thermal equilibrium, the container with the now homogeneous chemical treatment was placed on the hot plate of the process apparatus described in the above general section and the temperature was maintained at 120°F (48.9°C). At this temperature, the solution had a viscosity of less than 1 cps (.001 Pa.s).
- the conductive fiber used was Ni Cu with an average yield of 1.37 grams per meter and was heated by passing it through the tube furnace.
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 71db as measured by the ASTM D4935 test and a surface resistivity of 0.9 - 35 ohm/sq.
- the conductive fiber used was Ni Cu with an average yield of 1.53 grams per meter and was heated by passing it through the tube furnace. Under these conditions, 13 kg of conductive fiber was coated with 1.95 kg of chemical treatment and the mixture was then encapsulated with 84.72 kg of thermoplastic resin affording 99.67 kg of composite pellets having the composition of 13.04 % Ni Cu fiber, 1.96% butoxyethylstearate chemical treatment, and 85% polybutyleneterephthalate, with the chemically treated metallized fiber tow comprising 15% of the finished composite compound.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 560°F (293°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 73db as measured by the ASTM D4935 test and a surface resistivity of 4.4 - 999 ohm/sq.
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 79db as measured by the ASTM D4935 test and a surface resistivity of 1.2 - 41 ohm/sq.
- the pellets were injection molded at a melt temperature of 535°F (279°C) into a tool at 130°F (54.4°C).
- the resulting 4 inch (10.16 cm) diameter X 2 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 70db as measured by the ASTM D4935 test and a surface resistivity of 5 - 25 ohm/sq.
- the conductive fiber used was Ni Cu with an average yield of 1.45 grams per meter and was heated by passing it through the tube furnace. Under these conditions, 13 kg of conductive fiber was coated with 1.95 kg of chemical treatment and the mixture was then encapsulated with 84.72 kg of thermoplastic resin affording 99.67 kg of composite pellets having the composition of 13.04 % Ni Cu fiber, 1.96% bis-A-diol / citric acid chemical treatment, and 85%) polypropylene, with the chemically treated metallized fiber tow comprising 15% of the finished composite compound.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 535°F (279°C) into a tool at 130°F (54.4°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 85db as measured by the ASTM D4935 test and a surface resistivity of 0.6 - 9.6 ohm/sq.
- Example 16 A 2.19 molal solution was prepared by adding 0.75 kg, 3.29 moles of bisphenol-A to 2.25 kg of bisphenol- A-propoxylate in a one gallon metal paint can. This chemical treatment mixture was then heated in an oven at 330°F (165°C) for three hours. Once at thermal equilibrium, the container with the now homogeneous chemical treatment was placed on the hot plate of the process apparatus described in the above general section and the temperature was maintained at 120°F (48.9°C). At this temperature, the solution had a viscosity of less than 1 cps (.001 Pa.s).
- the conductive fiber used was Ni Cu with an average yield of 1.45 grams per meter and was heated by passing it through the tube furnace. Under these conditions, 13 kg of conductive fiber was coated with 1.95 kg of chemical treatment and the mixture was then encapsulated with 84.72 kg of thermoplastic resin affording 99.67 kg of composite pellets having the composition of 13.04 % Ni Cu fiber, 1.96% bis-A-diol / bisphenol-A chemical treatment, and 85% Nylon, with the chemically treated metallized fiber tow comprising 15% of the finished composite compound.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 77db as measured by the ASTM D4935 test and a surface resistivity of 2.9 - 450 ohm/sq.
- Example 17 Example 17
- the resulting 4 inch (10.16 cm) diameter X 2 mm disk test specimens had conductive fibers moderately well dispersed throughout the composite. Occasional undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 73db as measured by the ASTM D4935 test and a surface resistivity of 8 - 50 ohm/sq.
- Example 20 A 4.38 molal solution was prepared by adding 1.5 kg, 6.57 moles of bisphenol-A to 1.5 kg of bisphenol- A-propoxylate in a one gallon metal paint can. This chemical treatment mixture was then heated in an oven at 130°F (54.4°C) for three hours. Once at thermal equilibrium, the container with the now homogeneous chemical treatment was placed on the hot plate of the process apparatus described in the above general section and the temperature was maintained at 120°F (48.9°C). At this temperature, the solution had a viscosity of 40 cps (.040 Pa.s).
- the conductive fiber used was stainless steel with an average yield of 1.48 grams per meter and was heated by passing it through the tube furnace. Under these conditions, 13 kg of conductive fiber was coated with 1.95 kg of chemical treatment and the mixture was then encapsulated with 84.72 kg of thermoplastic resin affording 99.67 kg of composite pellets having the composition of 13.04 % stainless steel fiber, 1.96% bis-A-diol / bisphenol-A chemical treatment, and 85% PC-ABS, with the chemically treated metallized fiber tow comprising 15% of the finished composite compound.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 53db as measured by the ASTM D4935 test and a surface resistivity of greater than 20 ohm/sq.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 45db as measured by the ASTM D4935.
- Plated nickel coated carbon conductive fiber having an average yield of 1.39 grams per meter, was processed as described in Example 20.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 74db as measured by the ASTM D4935 test and a surface resistivity of 1 - 14 ohm/sq.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 61db as measured by the ASTM D4935.
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 80db as measured by the ASTM D4935 test and a surface resistivity of 0.3 - 48 ohm/sq.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 73 db as measured by the ASTM D4935.
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 71db as measured by the ASTM D4935.
- the conductive fiber used was nickel plated carbon fiber with an average yield of 2.01 grams per meter and was heated by passing it through the tube furnace.
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 80db as measured by the ASTM D4935 test and a surface resistivity of less than 3.1 ohm/sq.
- a 4.38 molal solution was prepared by adding 1.5 kg, 6.57 moles of bisphenol-A to 1.5 kg of bisphenol- A-propoxylate in a one gallon metal paint can. This chemical treatment mixture was then heated in an oven at 130°F (54.4°C) for three hours. Once at thermal equilibrium, the container with the now homogeneous chemical treatment was placed on the hot plate of the process apparatus described in the above general section and the temperature was maintained at 120°F (48.9°C). At this temperature, the solution had a viscosity of 40 cps (.040 Pa.s).
- the conductive fiber used was nickel plated carbon fiber with an average yield of 2.01 grams per meter and was heated by passing it through the tube furnace. Under these conditions, 8.7 kg of nickel coated carbon conductive fiber was coated with 1.31 kg of chemical treatment and the mixture was then encapsulated with 77.0 kg of thermoplastic resin affording 87.0 kg of composite pellets having the composition of 10.0 % nickel coated carbon fiber, 1.5% bis-A-diol / bisphenol- A chemical treatment, and 88.5% PC-ABS, with the chemically treated metallized fiber tow comprising 11.5% of the finished composite compound.
- the pellets were of uniform size and shape with the fiber bundle anchored and well centered in the thermoplastic sheath.
- the pellets were injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C).
- the resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed.
- the composite exhibited a shielding effectiveness value of 60db as measured by the ASTM D4935 test and a surface resistivity of less than 3.1 ohm/sq.
- the material used for this example is LNCOSHIELDTM PMMA Long Fiber Nickel Concentrate available from Inco Special Products, 681 Lawlins Rd., Wyckoff, NJ 07481. Following the product literature instructions, 1.13 kg of the long fiber nickel concentrate was mixed with 3.4 kg of dried PC/ABS in Littleford Mixer model FM-130D, available from Littleford Bros., Inc. of Florence, KY 41042. The pellet mixture was injection molded at a melt temperature of 570°F (299°C) into a tool at 150°F (65.5°C). The resulting 4 inch (10.16 cm) diameter X 1 mm disk test specimens had conductive fibers well dispersed throughout the composite. No undispersed bundles of fibers were observed. The composite exhibited a shielding effectiveness value of 64db as measured by the ASTM D4935 test and a surface resistivity of less than 21 ohm/sq.
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- Organic Chemistry (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Dispersion Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Electromagnetism (AREA)
- Textile Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Shielding Devices Or Components To Electric Or Magnetic Fields (AREA)
- Reinforced Plastic Materials (AREA)
- Conductive Materials (AREA)
- Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
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Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP01935640A EP1297064A2 (en) | 2000-06-30 | 2001-05-16 | Composites comprising fibers dispersed in a polymer matrix having improved shielding |
JP2002507934A JP2004502816A (en) | 2000-06-30 | 2001-05-16 | Composites comprising fibers dispersed in a polymer matrix having improved shielding with less amount of conductive fibers |
AU2001261717A AU2001261717A1 (en) | 2000-06-30 | 2001-05-16 | Composites comprising fibers dispersed in a polymer matrix having improved shielding with lower amounts of conductive fiber |
CA2413040A CA2413040C (en) | 2000-06-30 | 2001-05-16 | Composites comprising fibers dispersed in a polymer matrix having improved shielding with lower amounts of conductive fiber |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/607,864 | 2000-06-30 | ||
US09/607,864 US7078098B1 (en) | 2000-06-30 | 2000-06-30 | Composites comprising fibers dispersed in a polymer matrix having improved shielding with lower amounts of conducive fiber |
Publications (2)
Publication Number | Publication Date |
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WO2002002686A2 true WO2002002686A2 (en) | 2002-01-10 |
WO2002002686A3 WO2002002686A3 (en) | 2002-03-21 |
Family
ID=24434045
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2001/015966 WO2002002686A2 (en) | 2000-06-30 | 2001-05-16 | Composites comprising fibers dispersed in a polymer matrix having improved shielding |
Country Status (8)
Country | Link |
---|---|
US (1) | US7078098B1 (en) |
EP (1) | EP1297064A2 (en) |
JP (1) | JP2004502816A (en) |
KR (1) | KR20030063122A (en) |
CN (1) | CN1293135C (en) |
AU (1) | AU2001261717A1 (en) |
CA (1) | CA2413040C (en) |
WO (1) | WO2002002686A2 (en) |
Cited By (7)
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WO2003043028A2 (en) * | 2001-11-13 | 2003-05-22 | Dow Global Technologies Inc. | Electrically conductive thermoplastic polymer composition |
FR2868355A1 (en) * | 2004-03-31 | 2005-10-07 | Canada Majesty In Right Of | PROCESS AND APPARATUS FOR MANUFACTURING POLYMER-COATED FIBERS |
WO2007050467A1 (en) * | 2005-10-24 | 2007-05-03 | Ocv Intellectual Capital, Llc | Long fiber thermoplastic process for conductive composites and composites formed thereby |
WO2010033814A1 (en) | 2008-09-20 | 2010-03-25 | The Boeing Company | Varied glass density reinforcement of composites |
WO2011039521A1 (en) * | 2009-10-02 | 2011-04-07 | Technical Fibre Products Limited | Magnetic woven material |
US9242897B2 (en) | 2009-05-18 | 2016-01-26 | Ppg Industries Ohio, Inc. | Aqueous dispersions and methods of making same |
US10615508B2 (en) | 2013-05-30 | 2020-04-07 | Daicel Polymer Ltd. | Thermoplastic resin composition for molded article having capability of shielding millimeter waves |
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US20050191788A1 (en) * | 2001-02-15 | 2005-09-01 | Integral Technologies, Inc. | Low cost magnetic brakes and motion control devices manufactured from conductive loaded resin-based materials |
US20120321836A1 (en) * | 2001-02-15 | 2012-12-20 | Integral Technologies, Inc. | Variable-thickness elecriplast moldable capsule and method of manufacture |
JP2009532867A (en) * | 2006-03-31 | 2009-09-10 | パーカー.ハニフィン.コーポレイション | Conductive article |
US8359965B2 (en) * | 2007-09-17 | 2013-01-29 | Oxford J Craig | Apparatus and method for broad spectrum radiation attenuation |
JP5658418B2 (en) * | 2012-03-14 | 2015-01-28 | 帝人株式会社 | Molding material and molded body |
WO2014039509A2 (en) | 2012-09-04 | 2014-03-13 | Ocv Intellectual Capital, Llc | Dispersion of carbon enhanced reinforcement fibers in aqueous or non-aqueous media |
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US11129312B2 (en) | 2017-11-20 | 2021-09-21 | Ticona Llc | Electronic module for use in an automotive vehicle |
CN111372987A (en) | 2017-11-20 | 2020-07-03 | 提克纳有限责任公司 | Fiber reinforced polymer composition for use in electronic modules |
EP3867310A4 (en) * | 2018-10-16 | 2022-07-20 | Avient Corporation | Conductive long fiber thermoplastic compounds for electromagnetic shielding |
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- 2001-05-16 CN CNB018121306A patent/CN1293135C/en not_active Expired - Fee Related
- 2001-05-16 WO PCT/US2001/015966 patent/WO2002002686A2/en active Application Filing
- 2001-05-16 CA CA2413040A patent/CA2413040C/en not_active Expired - Fee Related
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Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2003043028A2 (en) * | 2001-11-13 | 2003-05-22 | Dow Global Technologies Inc. | Electrically conductive thermoplastic polymer composition |
WO2003043028A3 (en) * | 2001-11-13 | 2003-12-18 | Dow Global Technologies Inc | Electrically conductive thermoplastic polymer composition |
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WO2007050467A1 (en) * | 2005-10-24 | 2007-05-03 | Ocv Intellectual Capital, Llc | Long fiber thermoplastic process for conductive composites and composites formed thereby |
WO2010033814A1 (en) | 2008-09-20 | 2010-03-25 | The Boeing Company | Varied glass density reinforcement of composites |
US8490348B2 (en) | 2008-09-20 | 2013-07-23 | The Boeing Company | Varied glass density reinforcement of composites |
US9242897B2 (en) | 2009-05-18 | 2016-01-26 | Ppg Industries Ohio, Inc. | Aqueous dispersions and methods of making same |
WO2011039521A1 (en) * | 2009-10-02 | 2011-04-07 | Technical Fibre Products Limited | Magnetic woven material |
US10615508B2 (en) | 2013-05-30 | 2020-04-07 | Daicel Polymer Ltd. | Thermoplastic resin composition for molded article having capability of shielding millimeter waves |
Also Published As
Publication number | Publication date |
---|---|
CA2413040C (en) | 2010-07-20 |
US7078098B1 (en) | 2006-07-18 |
JP2004502816A (en) | 2004-01-29 |
CN1293135C (en) | 2007-01-03 |
KR20030063122A (en) | 2003-07-28 |
WO2002002686A3 (en) | 2002-03-21 |
AU2001261717A1 (en) | 2002-01-14 |
EP1297064A2 (en) | 2003-04-02 |
CN1440440A (en) | 2003-09-03 |
CA2413040A1 (en) | 2002-01-10 |
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