Conductive Monofilament Coating for Static-Dissipative Fabrics

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Solution Overview

Problem

Existing conductive fabrics for static dissipation suffer from low conductivity, compromised physical properties due to high filler loadings, manufacturing difficulties with metal-based designs, and durability issues with coated designs, limiting their effectiveness and versatility in industrial applications.

Innovation Solution

A durable, conductive polymeric monofilament or plied monofilament yarn with a coating of metal particles and a binder, where the conductive material is primarily located in longitudinal grooves, providing superior static dissipation and maintaining physical properties comparable to conventional industrial fabrics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high loadings of conductive materials are used in monofilaments, then conductivity is improved, but physical properties such as modulus, tenacity and elongation are compromised

Engineering Contradiction:

ImproveconductivityVSAvoidphysical properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The monofilament is divided into distinct functional zones: a core region containing the conductive filler dispersed in polymer, and an outer skin region with superior physical properties. This segmentation allows each zone to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure with a core-skin architecture, where the core contains high concentrations of conductive filler (carbon black, metal particles, or conductive polymers) dispersed in a polymer matrix, while the skin provides mechanical strength and durability. This composite approach enables simultaneous achievement of high conductivity and maintained physical properties.

Inventive Principle:

Principle #40Composite materials

2Reliability

If metallic wire constructions are used for static dissipation, then conductivity is improved, but manufacturing difficulty and susceptibility to damage increase

Engineering Contradiction:

ImproveconductivityVSAvoidmanufacturing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention replaces traditional metallic wire constructions with a polymer-based monofilament that has conductive properties. This substitution eliminates the manufacturing complexities associated with metal wire handling, weaving, and assembly, while providing equivalent or superior conductivity through dispersed conductive fillers in the polymer matrix.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The solution achieves high conductivity and resistance to denting and creasing, while maintaining thermal and physical properties, enabling effective static dissipation and electromagnetic interference shielding in harsh environments.

Implementation Method 1

the conductive material is maintained in the grooves and protected from wear. As a result, fabrics have static dissipation properties previously available only in metal-based fabrics

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

electromagnetic interference (EMI) shield bundles of multipurpose electrical wires

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Data Source

PatentUS10227714B2Conductive monofilament and fabric

Publication Date: 2019.03.12 ALBANY INT CORP

AI summary

A conductive monofilament and static dissipative fabric having the same wherein the monofilament includes electrically conductive material and binder and has static dissipation properties.