Conductive Elastomer Coating via Reactive Topcoat Thinning
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Solution Overview
Problem
Existing methods for applying conductive coatings to elastomeric substrates, such as those using volatile organic compounds (VOCs), pose health and environmental hazards and fail to ensure effective bonding and flexibility of the conductive layer.
Innovation Solution
A method involving the use of a reactive topcoat to thin conductive ink, allowing it to be spray-coated onto elastomeric substrates without VOCs, ensuring bonding and maintaining substrate flexibility, using a mixture like liquid silicone rubber topcoat TP3719A and TP3719B with silver 102-32 paste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If VOCs are used to thin conductive ink for spray coating, then the conductive coating can be applied to the elastomeric substrate, but hazardous emissions occur and bonding effectiveness is compromised
Solution Approach 1:
The patent changes the chemical composition parameters of the conductive ink by replacing VOC-based solvents with water-based or solvent-free alternatives. This parameter change eliminates hazardous emissions while maintaining the ink's sprayability and bonding effectiveness to the elastomeric substrate.
Solution Approach 2:
The patent converts the previously harmful VOC solvents into beneficial water-based or solvent-free formulations. This transformation eliminates the harmful effects of hydrocarbon off-gassing while preserving the functional benefits of spray coating application.
2Ease of manufacture
If VOCs are used to thin conductive ink, then the coating can be sprayed onto the substrate, but the bonding between conductive layer and substrate is ineffective
Solution Approach 1:
The patent changes the chemical composition parameters by using water-based or solvent-free conductive inks that contain bonding promoters or adhesion enhancers. These compositional changes enable effective bonding between the conductive layer and elastomeric substrate while maintaining spray coating feasibility.
3Ease of manufacture
If VOCs are used in the conductive solution, then the coating can be applied, but the substrate flexibility is adversely affected
Solution Approach 1:
The patent changes the solvent system parameters from VOC-based to water-based or solvent-free formulations. This parameter change eliminates the stiffening effect on the elastomeric substrate while preserving the ability to apply conductive coatings through spray coating processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces hazardous emissions, enhances bonding between the conductive layer and substrate, and maintains the flexibility of the elastomeric material, creating a highly conductive and flexible skin without hydrocarbon off-gassing.
Implementation Method 1
A method involving the use of a reactive topcoat to thin conductive ink
Implementation Method 2
allowing it to be spray-coated onto elastomeric substrates
Implementation Method 3
wherein the first conductive topcoat structure is configured to propagate a first signal; and a second conductive topcoat structure bonded to the elastomeric structure
Data Source
AI summary
A cable is provided, the cable includes: a conductor configured to propagate a signal; an elastomeric layer surrounding the center conductor; and a conductive topcoat layer surrounding and bonded to the elastomeric layer. The conductive topcoat layer includes a suspension of conductive particles. The conductive topcoat layer is formed by curing a topcoat and conductive paste mixture applied to the elastomeric layer.