Graphene-Polymer Coating for Low-Temperature Curing

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Solution Overview

Problem

Existing surface coatings require high curing temperatures, which can be detrimental to substrates like papers and polymers, and often rely on conductive additives that increase weight and cost, while polymeric materials lack intrinsic conductivity.

Innovation Solution

A method of coating substrates with graphene sheets and a polymer binder having a melting point or glass transition temperature no greater than 100°C, cured at temperatures no higher than 135°C, to form a conductive and thermally conductive coating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high curing temperatures are used to form conductive coatings, then electrical conductivity is achieved, but substrate integrity is compromised

Engineering Contradiction:

Improveelectrical conductivityVSAvoidsubstrate damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the curing temperature parameter from conventional high temperatures (typically >150°C) to low temperatures (≤100°C), enabling substrate-compatible curing while maintaining coating conductivity through optimized polymer selection and graphene content

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials combining conductive additives (graphene, carbon nanotubes, or metal particles) with polymeric binders to achieve electrical conductivity without requiring high curing temperatures, thus protecting temperature-sensitive substrates

Inventive Principle:

Principle #40Composite materials

2Reliability

If conductive additives are added to polymeric materials, then electrical conductivity is improved, but material cost and weight increase

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent optimizes the concentration and distribution parameters of conductive additives within the polymeric matrix, achieving effective conductivity at lower loadings through improved dispersion techniques and selective additive selection

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent develops composite material formulations that efficiently combine conductive fillers with polymeric binders, optimizing the ratio and type of components to achieve desired conductivity at reduced material costs compared to conventional approaches

Inventive Principle:

Principle #40Composite materials

3Reliability

If high loadings of conductive additives are used, then electrical conductivity is achieved, but processability and physical properties deteriorate

Engineering Contradiction:

Improveelectrical conductivityVSAvoidprocessability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the loading parameter of conductive additives to optimized lower levels, and compensates for conductivity requirements through improved particle distribution, morphology selection, and polymer matrix composition

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent designs composite materials with optimized filler-polymer interfaces and balanced compositions that maintain processability while achieving adequate conductivity through synergistic interactions between components

Inventive Principle:

Principle #40Composite materials

4Ease of operation

If conventional polymeric materials are used for coating, then flexibility and processability are maintained, but intrinsic conductivity is insufficient

Engineering Contradiction:

ImproveflexibilityVSAvoidelectrical conductivity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent creates composite coatings combining conventional flexible polymeric materials with conductive additives, preserving the flexibility and processability of the polymer while imparting electrical conductivity through the dispersed conductive phase

Inventive Principle:

Principle #40Composite materials

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 allows for the formation of electrically and thermally conductive coatings without the need for high curing temperatures, preserving substrate integrity and reducing material costs, while maintaining flexibility and processability.

Implementation Method 1

at least one polymer having a melting point or glass transition temperature no greater than about 100° C.

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

at least one polymer having a melting point or glass transition temperature no greater than about 100° C.

Methodology Applied

Scientific EffectGlass transition:

Implementation Method 3

graphene sheets and at least one polymer binder... to form a conductive and thermally conductive coating

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 4

graphene sheets and at least one polymer binder... to form a conductive and thermally conductive coating

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9540498B1Method of coating a substrate with a graphene containing composition

Publication Date: 2017.01.10 SCHEFFER DAN

AI summary

A method of coating a substrate wherein a composition comprising graphene sheets and at least one polymer having a melting point or glass transition temperature of no greater than about 100° C. is applied to the substrate and the composition is cured at a temperature no greater than about 135° C. to form a coating.