US2014322532A1PendingUtilityA1

Variable-thickness elecriplast moldable capsule and method of manufacture

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Assignee: INTEGRAL TECHNOLOGIES INCPriority: Feb 15, 2001Filed: Jul 9, 2014Published: Oct 30, 2014
Est. expiryFeb 15, 2021(expired)· nominal 20-yr term from priority
Inventors:Thomas Aisenbrey
B29B 9/14D06M 15/19B29K 2995/0005Y10T428/2933B29C 59/14B29K 2105/0023B29C 48/154Y10T428/2913B29C 48/06B29K 2995/0013B29C 2793/009B29C 48/08
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Claims

Abstract

A moldable capsule device ( 1 ) includes a bundle of micron conductive fiber ( 3 ) and a resin-based material layer ( 5 ) overlying the bundle along the length (L) of the capsule wherein thickness of the resin-based material layer is not uniform (T 1 and T 2 ). A method ( 100 ) to form a moldable capsule ( 1 ) including extruding/pultruding a resin-based material layer ( 5 ) onto the length (L) of a bundle of micron conductive fiber ( 3 ). The resin-based material layer ( 5 ) has a first thickness (T 1 ) and a second thickness (T 2 ). The first thickness (T 1 ) is disposed around multiple first surfaces ( 7 ) of the bundle. The second thickness (T 2 ) is disposed around multiple second surfaces ( 9 ) of the bundle. The second thickness (T 2 ) is at least twice that of the first thickness (T 1 ). The extruded/pultruded resin-based material and bundle are section into moldable capsules.

Claims

exact text as granted — not AI-modified
1 . A capsule comprising:
 a plurality of conductive fibers having a length and a central axis; and   a resin-based material overlying the plurality of conductive fibers along the length of the plurality of conductive fibers and having a radial thickness as measured along a line perpendicular to the central axis, wherein the radial thickness of the resin-based material at a point along the central axis is not uniform.   
     
     
         2 . The capsule according to  claim 1  wherein the resin-based material has a first thickness and a second thickness and wherein the second thickness is at least twice that of the first thickness. 
     
     
         3 . The capsule according to  claim 2  wherein the first thickness is disposed around a first surface of the plurality of conductive fibers and the second thickness is disposed around a second surface of the plurality of conductive fibers. 
     
     
         4 . The capsule according to  claim 2  wherein the first thickness is disposed around multiple first surfaces of the plurality of conductive fibers and the second thickness is disposed around multiple second surfaces of the plurality of conductive fibers. 
     
     
         5 . The capsule according to  claim 1  wherein the cross-section of the moldable capsule is bowtie-shaped. 
     
     
         6 . The capsule according to  claim 1  wherein the cross-section of the moldable capsule is gear-shaped. 
     
     
         7 . The capsule according to  claim 1  wherein the cross-section of the moldable capsule is star-shaped. 
     
     
         8 . The capsule of  claim 1  wherein the resin-based material further comprises a conductive powder. 
     
     
         9 . The capsule of  claim 1  wherein the plurality of conductive fibers further comprises conductive powder. 
     
     
         10 . The capsule of  claim 1  wherein the plurality of conductive fibers is between about 5% and 50% of the weight of the capsule. 
     
     
         11 . The capsule of  claim 1  wherein the plurality of conductive fibers is between about 20% and 50% of the weight of the capsule. 
     
     
         12 . The capsule of  claim 1  wherein the plurality of conductive fibers is between about 1% and 50% of the volume of the capsule. 
     
     
         13 . The capsule of  claim 1  wherein the plurality of conductive fibers is between about 4% and 10% of the weight of the capsule. 
     
     
         14 . A capsule comprising:
 a plurality of conductive fibers having a length and a central axis; and   a resin-based material overlying the plurality of conductive fibers along the length of the plurality of conductive fibers and having radial thickness as measured along a line perpendicular to the central axis;   wherein the resin-based material has a first thickness and a second thickness at a point along the central axis, and   wherein the second thickness is at least twice that of the first thickness.   
     
     
         15 . The capsule according to  claim 14  wherein the cross-section of the capsule is bowtie-shaped. 
     
     
         16 . The capsule according to  claim 14  wherein the cross-section of the moldable capsule is gear-shaped. 
     
     
         17 . The capsule according to  claim 14  wherein the cross-section of the moldable capsule is star-shaped. 
     
     
         18 . The capsule of  claim 14  wherein the resin-based material further comprises a conductive powder. 
     
     
         19 . The capsule of  claim 14  wherein the plurality of conductive fibers further comprises conductive powder. 
     
     
         20 . The capsule of  claim 14  wherein the plurality of conductive fibers is between about 5% and 50% of the weight of the capsule. 
     
     
         21 . The capsule of  claim 14  wherein the plurality of conductive fibers is between about 20% and 50% of the weight of the capsule. 
     
     
         22 . The capsule of  claim 14  wherein the plurality of conductive fibers is between about 1% and 50% of the volume of the capsule. 
     
     
         23 . The capsule of  claim 14  wherein the plurality of conductive fibers is between about 4% and 10% of the weight of the capsule. 
     
     
         24 - 37 . (canceled) 
     
     
         38 . The capsule of  claim 1  wherein the conductive fibers each have diameters of between about 3 microns and about 12 microns. 
     
     
         39 . The capsule of  claim 1  wherein the plurality of conductive fibers are in essentially parallel orientation to each other along the length of the capsule. 
     
     
         40 . The capsule of  claim 1  wherein the combination of the plurality of conductive fibers and the resin-based material can be extruded to form an article. 
     
     
         41 . The capsule of  claim 1  wherein the combination of the plurality of conductive fibers and the resin-based material can be thermally molded to form an article. 
     
     
         42 . The capsule of  claim 1  wherein the cross-section of the capsule is rectangular. 
     
     
         43 . The capsule of  claim 14  wherein the conductive fibers each have diameters of between about 3 microns and about 12 microns. 
     
     
         44 . The capsule of  claim 14  wherein the plurality of conductive fibers are in essentially parallel orientation to each other along the length of the capsule. 
     
     
         45 . The capsule of  claim 14  wherein the combination of the plurality of conductive fibers and the resin-based material can be extruded to form an article. 
     
     
         46 . The capsule of  claim 14  wherein the combination of the plurality of conductive fibers and the resin-based material can be thermally molded to form an article. 
     
     
         47 . The capsule of  claim 14  wherein the cross-section of the capsule is rectangular.

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