Electrostatic Dissipative Rubber Compound Using Conductive Polyaniline
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Solution Overview
Problem
Existing rubber compounds face challenges in preventing electrostatic charge buildup without using harmful chemical vulcanization agents or causing staining, and they require prolonged vulcanization times, which are environmentally damaging and inefficient.
Innovation Solution
A rubber compound comprising poly(butadiene-co-acrylonitrile), sulfonic acid doped polyaniline as an electrically conductive filler, and antioxidants, vulcanized using high energy electromagnetic radiation, which increases conductivity and tensile strength while eliminating the need for chemical vulcanization agents and reducing processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon black is added as an electrically conductive component, then conductivity increases and electrostatic build-up is prevented, but staining occurs which is undesirable for consumer products
Solution Approach 1:
The patent changes the chemical composition parameter by replacing carbon black with sulfonic acid doped polyaniline, maintaining the conductive function while eliminating the harmful staining effect. This parameter substitution resolves the contradiction between achieving electrostatic dissipation and avoiding staining.
2Reliability
If sulfonic acid doped polyaniline is added to provide conductivity without staining, then electrostatic dissipation is achieved, but crosslinking efficiency is interfered with during chemical vulcanisation
Solution Approach 1:
The patent replaces the chemical vulcanisation system with an electromagnetic radiation-induced vulcanisation system. This substitution eliminates the interference between sulfonic acid doped polyaniline and chemical crosslinking agents, while still achieving effective vulcanisation and maintaining crosslinking efficiency.
Solution Approach 2:
The patent introduces electromagnetic radiation as an intermediary energy source to initiate vulcanisation. This intermediary bypasses the direct chemical interaction between sulfonic acid doped polyaniline and chemical vulcanisation agents, resolving the crosslinking efficiency problem while maintaining the conductive properties.
3Object-generated harmful factors
If low energy electron beam radiation is used for vulcanisation, then chemical vulcanisation agents are eliminated, but penetration depth is limited to only a few millimeters requiring agitation and prolonged time
Solution Approach 1:
The patent changes the energy parameter of electron beam radiation from low energy (100-500 kV) to high energy (2-10 MeV). This parameter change increases the penetration depth from a few millimeters to several centimeters, eliminating the need for agitation and significantly reducing vulcanisation time while maintaining the elimination of chemical residues.
4Reliability
If metallic salts or metal parts are added to increase conductivity, then electrostatic dissipation is improved, but elasticity and durability of the rubber are affected
Solution Approach 1:
The patent changes the material composition parameter by replacing metallic salts or metal parts with sulfonic acid doped polyaniline. This organic conductive polymer provides the necessary conductivity for electrostatic dissipation while being compatible with the rubber matrix, thus preserving elasticity and durability.
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 significantly higher conductivity and tensile strength, preventing electrostatic charge buildup and improving durability, while being environmentally friendly and faster than traditional methods.
Implementation Method 1
the mixture comprising the rubber component, electrically conductive filler and antioxidant is vulcanised by exposure to high energy electromagnetic radiation
Implementation Method 2
an electrically conductive filler component derived from sulfonic acid doped polyaniline... provides an electrical pathway for electrostatic charges to dissipate to the ground
Implementation Method 3
an antioxidant... wherein the mixture comprising the rubber component, electrically conductive filler and antioxidant is vulcanised
Data Source
AI summary
A rubber compound for the manufacture of electrostatic dissipative products comprising a rubber component derived from poly(butadiene-co-acrylonitrile), an electrically conductive filler component derived from sulfonic acid doped polyaniline, and an antioxidant, wherein the mixture comprising the rubber component, electrically conductive filler and antioxidant is vulcanized by exposure to electromagnetic radiation, and the vulcanized rubber compound possesses improved conductivity and tensile strength properties. A method for producing the rubber compound above comprising of providing a rubber component derived from poly(butadiene-co-acrylonitrile), an electrically conductive filler component derived from sulfonic acid doped polyaniline, and an antioxidant, then mixing the rubber component, electrically conductive filler and antioxidant together. The mixture is then molded into a suitable shape and then subjected to an electromagnetic radiation to stimulate vulcanization of the rubber mixture.