Microlayer Coextrusion for Thin Conductive Laminates
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Solution Overview
Problem
Existing microlayer extrusion processes face limitations in creating conductive structures with anisotropic electrical properties, particularly in achieving thin layers with conductive pathways and maintaining conductivity when layers approach particle thickness.
Innovation Solution
A method and system for microlayer extrusion involving multiple stages of dividing, compressing, and overlapping ribbon-shaped flow streams to multiply laminations, forming thin layers with conducting materials, and using non-rotating extrusion assemblies to create tubular products with nano-sized features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If microlayer extrusion is used to create thin conductive layers, then electrical conductivity is improved, but layer thickness must be precisely controlled to maintain conductivity
Solution Approach 1:
The conductive layer is segmented into multiple thin sub-layers separated by insulating layers, allowing each sub-layer to be thinner than the particle thickness while collectively maintaining conductivity through multiple pathways. This segmentation resolves the contradiction by enabling thin overall layer thickness while preserving electrical conductivity through the distributed conductive network.
Solution Approach 2:
Different regions of the composite material have different properties: conductive regions contain metal particles for electrical conductivity, while insulating regions provide separation and structural integrity. This local differentiation allows the material to achieve both thin overall thickness and maintained conductivity by concentrating conductive elements in specific local zones rather than requiring uniform thickness throughout.
2Reliability
If multiple metal particles are used to ensure conductivity, then electrical properties are improved, but metal usage increases
Solution Approach 1:
The conductive layer is designed with a porous structure containing voids and channels that reduce the amount of metal particles needed while maintaining conductivity pathways. The porous architecture allows electrical conduction through fewer, strategically positioned particles, thereby reducing overall metal usage while preserving electrical properties.
Solution Approach 2:
The invention uses composite materials combining metal particles with polymer matrices and insulating layers to achieve conductivity with reduced metal content. The composite structure leverages the synergistic effects of different materials, where the polymer and insulating layers provide structural support and particle spacing, allowing metal particles to be used more efficiently for electrical conduction.
3Length of stationary object
If layer thickness is reduced to achieve thin films, then product dimension is improved, but conductivity is lost when thickness approaches particle thickness
Solution Approach 1:
The invention transitions from relying on through-thickness conductivity to in-plane conductivity within thin conductive sub-layers. By creating a laminated structure where conductivity occurs within the plane of thin conductive layers rather than through the thickness direction, the overall film can be very thin while maintaining electrical properties through alternative conduction pathways.
Solution Approach 2:
The conductive layer is divided into multiple thin conductive sub-layers separated by insulating layers. Each sub-layer is thin enough to achieve the desired overall film thickness but contains sufficient conductive particles to maintain in-plane conductivity. The segmentation allows the total thickness to be reduced while preserving electrical properties through the distributed conductive network.
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
Enables the production of conductive products with enhanced electrical properties and reduced metal usage, achieving thin layers with improved conductivity and tensile strength, suitable for various applications including EMI shielding and lithium ion batteries.
Implementation Method 1
filled and unfilled polymers are combined into unique structures with many alternating layers of two or more components
Implementation Method 2
Filled layers with 10% (v/v) copper flakes or 15% (v/v) nickel flakes were conductive only if the filled layers were thick compared to the thickness of the flake particles
Data Source
AI summary
A method and system for extruding multiple laminated flow streams using microlayer extrusion, and in particular to creating and forming products with electrical properties that are formed from layers and particles with dimensions in the micro to nanometer range.