Grooved Conductive Monofilament Coating for Durable Static Dissipation

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Solution Overview

Problem

Existing conductive fabrics face limitations in static charge dissipation due to low conductivity and compromised physical properties from high conductive filler loadings, and metal-based fabrics are prone to damage and durability issues.

Innovation Solution

A durable, highly conductive polymeric monofilament with a conductive material coating in longitudinal grooves, protected from wear, providing static dissipation comparable to metal-based fabrics while maintaining physical and thermal properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high loadings of conductive materials are incorporated into monofilaments, then conductivity is improved, but physical properties deteriorate

Engineering Contradiction:

ImproveconductivityVSAvoidphysical properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The conductive coating is applied locally in longitudinal grooves rather than uniformly throughout the monofilament cross-section. This localized application provides sufficient conductivity pathways while preserving the bulk mechanical properties of the polymer matrix.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention creates a composite structure with a polymer monofilament base and a conductive coating layer containing metal particles and binder. This composite approach combines the mechanical advantages of polymer with the electrical conductivity of metal particulates.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conductive coatings are applied to monofilaments, then conductivity is improved, but durability deteriorates

Engineering Contradiction:

ImproveconductivityVSAvoiddurability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The conductive coating is placed in pre-formed longitudinal grooves that protect the coating from wear and mechanical damage. This structural protection beforehand prevents the coating from deteriorating during fabric use and processing.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The conductive material forms a thin film coating within the groove structure, providing electrical conductivity while the groove walls act as a protective shell that prevents coating loss during handling and processing.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If metallic wires are used in fabric construction, then static dissipation is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improvestatic dissipationVSAvoidease of manufacture

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention changes the form factor from discrete metallic wires to a polymer monofilament with surface coating. This parameter change enables conventional textile manufacturing processes to be used while achieving comparable static dissipation performance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the mechanical metallic wire structure with a polymer-based system that uses surface coatings for conductivity. This substitution allows the fabric to be manufactured using standard polymer texturing and coating processes rather than specialized metal fabrication.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If metal-based fabrics are used, then static dissipation is improved, but resistance to damage deteriorates

Engineering Contradiction:

Improvestatic dissipationVSAvoidresistance to damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention creates a polymer-based copy of metal fabric functionality by applying conductive coatings to polymer monofilaments. This copying approach replicates the static dissipation properties of metal fabrics while avoiding their susceptibility to denting and creasing.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The invention changes the material parameter from metal to polymer while maintaining the conductive function through surface coating. This parameter change preserves static dissipation performance while dramatically improving resistance to mechanical damage, denting, and creasing.

Inventive Principle:

Principle #35Parameter changes

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 achieves effective static dissipation and resistance to denting and creasing, with improved durability and conductivity, suitable for various industrial and aerospace applications.

Implementation Method 1

the conductivity of the loaded monofilaments is only in the range of 10^-4 to 10^-2 ohm^-1 cm^-1 and the conductivity is easily lost during subsequent processing and/or use. Other prior art conductive fabrics incorporate conductive coatings

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP2155939B1Conductive monofilament and fabric

Publication Date: 2011.04.06 ALBANY INT CORP

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AI summary

A conductive monofilament and static dissipative fabric having the same wherein the monofilament includes electrically conductive material and binder and has static dissipation properties.