EMI Shielded plastic composites

Claim 2

An article comprising a first subpart characterized by electrically conductive fibers embedded in a continuous plastic matrix and a second subpart characterized by electrically conductive fibers embedded in a continuous plastic matrix, said subparts being joined together along a fusion line, and an electrically conductive insert embedded in said first subpart and said second subpart along the fusion line which contacts the electrically conductive fibers in the first subpart and the second subpart and establishes continuity between the electrically conductive fibers in the first subpart and the electrically conductive fibers in the second subpart.

Claim 3

An article as in claim 1 wherein the plastic matrix comprises a thermoplastic matrix and the electrically conductive insert comprises electrically conductive wires or fibers in the form of a mat, a fabric or a screen.

Claim 4

An article as in claim 2 wherein the electrically conductive fibers or wires extending across the fusion line are sunk into the surfaces of the subparts.

Claim 5

An article as in claim 3 wherein the electrically conductive fibers or wires are selected from the group consisting of metal whiskers, metal wires, metal fibers, metallized fibers, and carbon fibers.

Claim 6

An article as in claim 4 wherein the thermoplastic matrix of the subparts is selected from the group consisting of polyethylene, polypropylene, polyester, polyamide, polystyrene, acrylonitrile-butadiene-styrene polymers, acrylic polymers and copolymers, polyethers, polyamides, polyvinylchlorides, polycarbonates, and poly(arylene sulfide)s.

Claim 7

An article as in claim 4 wherein the thermoplastic matrix comprises a poly(arylene sulfide) selected from the group consisting of poly(phenylene sulfide), poly(phenylene sulfide phenylene sulfone), poly(phenylene sulfide phenylene ketone), and poly(biphenylene sulfide).

Claim 8

An article comprising a continuous plastic matrix containing electrically conductive fibers and having an electrically conductive insert forming a portion of the surface of said article, said electrically conductive insert being sunk into said article so as to contact the electrically conductive fibers therein and establish continuity between the electrically conductive fibers and the surface of said object.

Claim 9

An article comprising a continuous plastic matrix containing electrically conductive fibers and having an electrically conductive insert forming a portion of the surface of said article, said electrically conductive insert being sunk into said article so as to contact the electrically conductive fibers therein and establish continuity between the electrically conductive fibers and the surface of said object.

Claim 10

An article as in claim 7 wherein the electrically conductive insert is embedded in the surface of the article and contains carbon fibers or metal.

Claim 11

An article as in claim 8 further comprising a fastener extending through the article, said fastener being formed from an electrically conductive material and having a head portion which contacts the electrically conductive insert and a shank portion which is connected to a means for grounding said fastener.

Claim 12

An article as in claim 8 wherein the insert embedded into the surface of the article is selected from the group consisting of electrically conductive fibers or wires in the form of a mat, a fabric, or a screen.

Claim 13

An article as in claim 10 wherein the thermoplastic matrix comprises a poly(arylene sulfide) and the conductive fibers or wires comprise metallized carbon fibers.

Claim 14

An article as in claim 11 wherein the thermoplastic matrix comprises a poly(phenylene sulfide).

Claim 15

A process for connecting a first subpart containing electrically conductive fibers in a continuous thermoplastic matrix with a second subpart containing electrically conductive fibers in a continuous thermoplastic matrix to form an article, said process comprising contacting said first thermoplastic subpart with said second thermoplastic subpart along corresponding edges of the first subpart and the second subpart; bridging the contacting edges of the first subpart and the second subpart with an electrically conductive object; heating said first subpart and said second subpart along said contacting edges sufficiently to soften the thermoplastic matrix of the first subpart and the second subpart; fusing the first subpart to the second subpart along the contacting edges; pressing the electrically conductive object into the softened thermoplastic matrix along the contacting edges sufficiently to establish electrical continuity between the electrically conductive fibers in the first subpart and the electrically conductive fibers in the second subpart; and cooling the resulting article.

Claim 16

A process for connecting a first subpart containing electrically conductive fibers in a continuous thermoplastic matrix with a second subpart containing electrically conductive fibers in a continuous thermoplastic matrix to form an article, said process comprising contacting said first thermoplastic subpart with said second thermoplastic subpart along corresponding edges of the first subpart and the second subpart; bridging the contacting edges of the first subpart and the second subpart with an electrically conductive object; heating said first subpart and said second subpart along said contacting edges sufficiently to soften the thermoplastic matrix of the first subpart and the second subpart; fusing the first subpart to the second subpart along the contacting edges; pressing the electrically conductive object into the softened thermoplastic matrix along the contacting edges sufficiently to establish electrical continuity between the electrically conductive fibers in the first subpart and the electrically conductive fibers in the second subpart; and cooling the resulting article.

Claim 17

A process as in claim 13 wherein the electrically conductive objective comprises a network of electrically conductive fibers or wires.

Claim 18

A process as in claim 14 wherein the electrically conductive fibers embedded in the continuous thermoplastic matrix comprise metallized carbon fibers and the network of conductive fibers or wires comprises a mat, a fabric, or a screen.

Claim 19

A process as in claim 13 wherein the thermoplastic matrix comprises a poly(arylene sulfide) and the first subpart and the second subpart are heated at a temperature of at least 500° F. in order to soften the matrix sufficiently to fuse the first subpart to the second subpart.

Claim 20

A process as in claim 16 wherein the first subpart and the second subpart are in the form of sheets.

Claim 21

A process comprising (a) heating at least a portion of an article containing electrically conductive fibers in a continuous thermoplastic matrix sufficiently to soften the continuous thermoplastic matrix; (b) embedding an electrically conductive insert in the thus softened thermoplastic matrix sufficiently to establish electrical continuity between the electrically conductive fibers embedded in the continuous thermoplastic matrix and the thus embedded insert; and (c) cooling the article containing the thus embedded insert.

Claim 22

A process comprising (a) heating at least a portion of an article containing electrically conductive fibers in a continuous thermoplastic matrix sufficiently to soften the continuous thermoplastic matrix; (b) embedding an electrically conductive insert in the thus softened thermoplastic matrix sufficiently to establish electrical continuity between the electrically conductive fibers embedded in the continuous thermoplastic matrix and the thus embedded insert; and (c) cooling the article containing the thus embedded insert.

Claim 23

A process as in claim 18 further comprising positioning said article adjacent to an electrically grounded metal object and inserting an electrically conductive fastener through said article and into said electrically grounded metal object in a manner so that said fastener contacts a portion of the electrically conductive insert embedded in the article, thereby establishing electrical conductance between the conductive fibers embedded in the article and the grounded object.

Claim 24

A process as in claim 19 wherein the article comprises electrically conductive fibers in a continuous poly(arylene sulfide) matrix and the insert embedded in said article contains an electrically conductive metal.