Electroless plated fiber material, manufacturing method, and manufacturing system therefor
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Solution Overview
Problem
The existing electroless plating methods for fiber materials require large amounts of processing solutions containing precious metals, leading to high manufacturing costs and environmental hazards, with inefficiencies in conductivity, film thickness, and manufacturing efficiency.
Innovation Solution
A method involving electrostatic spraying of catalyst and reducing agent solutions onto a fiber material, followed by electrostatic spraying of metal ion and reducing agent solutions in the same electric field to form a plated film, reducing the amount of processing solution used and enhancing conductivity and film thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the fiber material is immersed in processing solutions using batch processing in tanks, then the electroless plating can be performed, but the manufacturing cost increases and manufacturing efficiency decreases
Solution Approach 1:
The patent replaces the mechanical immersion batch processing system with an electrostatic spraying system. The electrostatic spraying apparatus uses electric fields to deposit processing solutions onto the fiber material, eliminating the need for large tanks and mechanical immersion operations. This substitution enables continuous processing and significantly improves manufacturing efficiency while reducing apparatus complexity and cost.
2Ease of manufacture
If large amounts of processing solutions containing precious metals are used, then the electroless plating processing can be performed, but the manufacturing cost increases and environmental hazards increase
Solution Approach 1:
The electrostatic spraying system applies processing solutions locally and precisely to the fiber material surface. The electric field concentrates the sprayed solutions only where needed on the material, preventing waste and reducing the total amount of precious metal-containing solutions required. This localized application minimizes both manufacturing costs and environmental hazards associated with waste disposal.
Solution Approach 2:
The patent changes the physical state and application method of the processing solutions from bulk immersion to electrostatically-controlled spraying. By controlling the electric field parameters, the system optimizes solution deposition efficiency, reducing the quantity of precious metals needed while maintaining plating quality.
3Reliability
If the fiber material is immersed in processing solutions, then the electroless plating can be performed, but the amount of processing solution used increases leading to higher waste disposal costs
Solution Approach 1:
The patent replaces the mechanical immersion system with an electrostatic spraying system that deposits processing solutions efficiently. This substitution ensures reliable plating formation while minimizing solution usage and waste generation, thereby reducing disposal costs and environmental impact.
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 approach decreases the amount of processing solution needed, increases the quality and conductivity of the electroless plated fiber material, reduces manufacturing costs, and minimizes environmental impact while improving efficiency.
Implementation Method 1
an electrostatic spraying step of electrostatically spraying a catalyst solution containing a catalyst precursor onto a fiber material
Implementation Method 2
an electrostatic spraying step of electrostatically spraying a first reducing agent solution containing a reducing agent of the catalyst precursor onto the fiber material
Implementation Method 3
an electroless plating step of electrostatically spraying each of a metal ion solution containing metal ions and a second reducing agent solution containing a reducing agent of the metal ions, each in a state of being electrically charged to a positive potential or a negative potential in a similar manner, onto the catalyst-applied fiber material
Implementation Method 4
such that the metal ion solution and the second reducing agent solution react with each other in the same electric field on the catalyst-applied fiber material, to thereby generate metal particles in the fiber material
Data Source
AI summary
The amount of a processing solution used is reduced, and the quality of an electroless plated fiber material is improved. The present invention relates to a manufacturing method for an electroless plated fiber material A4. The manufacturing method includes a step S5 of electrostatically spraying a solution B containing a catalyst precursor in a state of being electrically charged to a positive potential onto a fiber material A2 while grounding the fiber material A2 and moistening the fiber material A2, and electrostatically spraying a solution C containing a reducing agent in a state of being electrically charged to a positive potential onto the fiber material A2, and a step S7 of electrostatically spraying each of a solution D containing metal ions and a solution E containing a reducing agent each in a state of being electrically charged to a positive potential onto the fiber material A3 such that the solution D containing metal ions and the solution E containing the reducing agent react with each other in the same electric field on the fiber material A3 while grounding the fiber material A3 to which a catalyst is given and moistening the fiber material A3. The present invention relates to the electroless plated fiber material A4 manufactured by the manufacturing method. The present invention relates to a manufacturing system of the electroless plated fiber material A4.