Conductive Rubber Mat Composition for Non-Marking Static Dissipation
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Solution Overview
Problem
Conventional conductive rubber mats using carbon black as an additive are limited to black coloration and leave black residue, which can mark equipment and surfaces, posing issues in clean environments.
Innovation Solution
Manufacture conductive rubber mats using carbon nanostructures, such as carbon nanotubes, with a composition including nitrile rubber, PVC plastic, and PVC stabilizer, and employ a mixing process involving controlled temperature and speed to achieve non-marking, electrically conductive mats with a resistivity of 10^6 Ohms per centimeter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon black is used as the conductive additive, then electrical conductivity is achieved, but the matting is limited to black color and leaves black residue on equipment and surfaces
Solution Approach 1:
The patent changes the physical and chemical parameters of the conductive additive by replacing carbon black with carbon nanotubes. This substitution maintains the electrical conductivity function while altering the color properties and surface interaction characteristics, enabling non-black coloration and eliminating black residue transfer to equipment and surfaces.
Solution Approach 2:
The patent creates a composite rubber matting material incorporating carbon nanotubes within the rubber matrix. This composite structure provides the necessary electrical conductivity through the carbon nanotube network while allowing the base rubber and pigment components to determine the final color, thus achieving both conductivity and color versatility.
2Reliability
If carbon black pigment is used in rubber mats, then conductivity is provided, but the pigment marks on workers' shoes and spreads to floors and surfaces
Solution Approach 1:
The patent extracts the harmful black pigment property from the conductive additive function. By using carbon nanotubes instead of carbon black, the conductive function is separated from the black coloring and residue-transfer properties, allowing the matting to provide conductivity without generating black markings on shoes, floors, or equipment.
Solution Approach 2:
The patent replaces the problematic carbon black material with carbon nanotubes that do not transfer residue. This substitution eliminates the need for frequent cleaning and maintenance associated with black residue accumulation, reducing the operational overhead of dealing with marked surfaces and equipment.
3Ease of manufacture
If conventional mixing processes are used, then manufacturing is simple, but the rubber compound does not achieve optimal conductivity and homogeneity
Solution Approach 1:
The patent introduces dynamic control elements to the mixing process, including variable mixing speeds and temperature adjustments during different mixing stages. This dynamic approach ensures proper dispersion of carbon nanotubes and optimal vulcanization, achieving both high conductivity and homogeneity while maintaining reasonable manufacturing complexity through systematic process control.
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 provides non-marking, electrically conductive rubber mats that can be colored other than black and effectively dissipate static electricity without leaving residue, suitable for sensitive equipment protection in various environments.
Implementation Method 1
the carbon nanostructures do not include carbon black
Implementation Method 2
in response to a measured temperature in the internal mixer reaching a first threshold temperature
Data Source
AI summary
Examples provide a method for manufacturing electrically conductive rubber matting. The method includes charging, into an internal mixer, a set of ingredients for forming a rubber compound. The set of ingredients include 63.2 weight percent (wt %) to 73.2 wt % nitrile rubber, 25.0 wt % to 35.0 wt % polyvinyl chloride (PVC) plastic, 0.02 wt % to 1.0 wt % PVC stabilizer, and 0.8 wt % to 2.6 wt % carbon nanostructures not including carbon black. The ingredients are mixed at a first speed at least until a measured temperature in the internal mixer reaches a first threshold temperature. The ingredients are mixed at a second speed that is greater than the first speed at least until the measured temperature in the internal mixer reaches a second threshold temperature that is greater than the first threshold temperature. After mixing, the rubber compound is discharged the rubber compound from the internal mixer and shaped.