Method of continuous metal plating of textile material, device to carry out the method, metal plated textile material and its use
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Solution Overview
Problem
Current methods for continuous metal plating of textile materials are inefficient, with high induction start-up times, non-homogeneous plating, low electrical conductivity, and high consumption of expensive reagents, making them unsuitable for industrial production of metal plated textile materials with high electrical conductivity.
Innovation Solution
A two-stage chemical reduction process in the roll-to-roll mode, involving primary and secondary chemical metal plating with specific reaction solutions and conditions to achieve rapid and homogeneous deposition of metal nanoparticles, followed by electrochemical reinforcement, optimizing the kinetics and compatibility with continuous processing speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional chemical metal plating methods are used, then metal deposition occurs, but the induction start-up time is high and plating rate is slow
Solution Approach 1:
The textile material undergoes preliminary activation treatment with palladium or other catalytic metals before the main metal plating process. This preliminary action creates active sites on the fiber surface that immediately catalyze the metal deposition reaction when the plating solution is applied, eliminating the induction period and enabling instant high-rate plating.
Solution Approach 2:
The patent modifies the chemical parameters of the plating solution, specifically using strong reducing agents like sodium borohydride at controlled pH levels (9-12) and temperatures (20-40°C). These parameter changes accelerate the reduction kinetics of metal ions, transforming the slow conventional plating into rapid deposition that keeps pace with continuous textile processing speeds.
2Reliability
If conventional metal plating is applied, then metal layer is formed, but the electrical conductivity is low
Solution Approach 1:
The patent creates non-uniform metal distribution at the micro-scale, with higher metal concentration and density at critical contact points and along fiber surfaces where conductivity is most needed. This local quality enhancement achieves high electrical conductivity without requiring uniform thick metal coating across the entire textile, reducing material consumption and cost.
Solution Approach 2:
The invention produces composite textile structures with multiple metal layers (e.g., palladium-copper, nickel-copper combinations) that combine the catalytic properties of noble metals with the high conductivity and low cost of base metals. This composite approach optimizes both electrical conductivity and cost efficiency.
3Productivity
If continuous roll-to-roll processing is implemented, then production speed increases, but the plating homogeneity deteriorates
Solution Approach 1:
The patent employs dynamic application methods where the plating solution is continuously applied and processed during textile movement through the production line. The system is designed to maintain optimal residence time and solution flow rates that ensure uniform metal deposition even at high processing speeds, adapting the chemistry to the kinetic conditions of continuous processing.
4Productivity
If high-speed continuous plating is achieved, then productivity increases, but reagent consumption increases
Solution Approach 1:
The patent extracts and removes excess plating solution and unreacted chemicals from the textile material through squeezing rollers, washing stages, or other separation devices immediately after the plating reaction. This recovery process reduces reagent waste and allows for potential recycling of valuable metals and chemicals, decreasing overall consumption despite high-speed continuous operation.
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 enables high-speed, continuous, and cost-effective production of metal plated textile materials with enhanced electrical conductivity and adhesion, overcoming previous limitations of slow plating rates and material inefficiencies.
Implementation Method 1
primary chemical metal plating, which consists of: a reaction of the aqueous solution no. 1 of inorganic salts of metallic ions with the aqueous solution no. 2 of reductant
Implementation Method 2
the final electrochemical reinforcement of the metallic layer
Data Source
Figure 1
Figure 2
AI summary
A treatment method of textile material to increase its absorption and reflectivity of electromagnetic radiation, electrical and thermal conductivity, antimicrobial characteristics wherein it is characterized in that continuously moving textile material is gradually surface treated (using chemical and also plasmatic treatment as necessary), chemically modified with a defined quantity of adsorbed nanoparticles of metals and/or their alloys, and subsequently electrochemically treated with metals and their alloys, or possibly metal oxides, and finally treated with an organic protective layer if necessary. Device to carry out the method, produced metal plated textile material and its use are also provided.