Resin-Impregnated Conductive Paper for Heat-Resistant Strength
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Solution Overview
Problem
Conventional conductive paper lacks sufficient electrical conductivity, strength, and heat resistance, leading to issues like electrolytic corrosion and electromagnetic compatibility problems in electric vehicles, and poor performance in oil environments.
Innovation Solution
Conductive paper comprising a paper substrate with carbon fibers and fibrillated fibers, impregnated with a cured thermosetting resin, enhancing electrical conductivity, strength, and heat resistance through controlled fiber ratios and impregnation methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional conductive paper is used to ensure sufficient electrical conductivity, then the area and applied load must be increased, but this results in increased drag torque and decreased durability
Solution Approach 1:
The invention changes the material parameters by using carbon fibers with specific diameter ranges (5-20 μm) and aspect ratios (50-200), and controlling the fiber content (30-80 wt%) to achieve high electrical conductivity without increasing area or load. This resolves the contradiction by optimizing intrinsic material properties rather than increasing system size
Solution Approach 2:
The invention creates a composite structure by combining carbon fibers with inorganic fibers (such as glass fibers, ceramic fibers) and organic fibers in specific ratios. This composite approach provides both high electrical conductivity through carbon fiber networks and enhanced mechanical strength/durability through the reinforcing fiber components, eliminating the need to increase area or applied load
2Reliability
If conventional conductive paper is used to provide conductive path, then it lacks strength against shear deformation and heat resistance to withstand sliding heat
Solution Approach 1:
The invention employs a composite material system where carbon fibers provide electrical conductivity while inorganic fibers (glass fibers, ceramic fibers with alumina content 50-90 wt%) provide high-temperature strength and shear resistance. The synergistic combination allows the conductive paper to withstand sliding heat and mechanical stress without compromising conductivity
Solution Approach 2:
The invention optimizes the aspect ratio of carbon fibers to 50-200 and controls fiber diameter within specific ranges to enhance the network structure's ability to resist shear deformation. The controlled fiber morphology creates a more robust conductive network that maintains integrity under thermal and mechanical stress
3Strength
If resin is used to reinforce conductive paper, then strength is improved, but the resin softens due to sliding heat and strength decreases
Solution Approach 1:
The invention replaces thermoplastic resin with inorganic fibers having high melting points and thermal stability. The inorganic fiber reinforcement maintains strength at elevated temperatures because these materials do not soften like thermoplastic resins, providing stable mechanical properties throughout the operating temperature range
Solution Approach 2:
The invention creates a fiber-reinforced composite where inorganic fibers substitute for resin binders in critical load-bearing functions. This composite structure eliminates the temperature-dependent softening behavior of resins while maintaining structural integrity and strength through the high-temperature stability of inorganic fiber networks
4Reliability
If conductive paper with high carbon fiber content is used, then electrical conductivity is improved, but mechanical strength and wear resistance decrease
Solution Approach 1:
The invention balances the composite composition by combining carbon fibers (providing conductivity) with inorganic fibers such as glass fibers and ceramic fibers (providing mechanical strength). This balanced composite formulation achieves both high electrical conductivity and adequate mechanical strength without requiring excessive carbon fiber content that would compromise structural integrity
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 conductive paper exhibits excellent electrical conductivity, strength, and heat resistance, effectively addressing electrolytic corrosion and electromagnetic compatibility issues, while maintaining durability and oil film removability.
Implementation Method 1
a cured product of a thermosetting resin at least partially impregnated into the paper substrate
Data Source
AI summary
The present invention provides conductive paper with excellent electrical conductivity, strength, and heat resistance, and a method for producing the same,the conductive paper including: a paper substrate containing at least a carbon fiber and a fibrillated fiber, and in which an amount of the fibrillated fiber is from 10 to 120% by mass with respect to the carbon fiber; and a cured product of a thermosetting resin at least partially impregnated into the paper substrate; andthe method for producing conductive paper, the method including the steps of: preparing a slurry containing at least a carbon fiber and a fibrillated fiber, and in which an amount of the fibrillated fiber is from 10 to 120% by mass with respect to the carbon fiber; obtaining a paper substrate by subjecting the slurry to a papermaking process; impregnating the paper substrate with a thermosetting resin; and heating the paper substrate impregnated with the thermosetting resin to cure the thermosetting resin.