Substrate-Free Conductive Surface Covering for Static Dissipation
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Solution Overview
Problem
Substrate-free surface coverings lack static control properties, making them unsuitable for electrostatic-free environments, particularly in electronic manufacturing industries, and the addition of varnish layers further exacerbates electrical insulation issues.
Innovation Solution
A substrate-free conductive surface covering is developed with a core layer of unfused particles embedded in a polymer matrix containing electrically conductive materials, featuring a conductive primer and varnish layers to enhance static control properties, and a process involving heat treatment and compaction in a double belt press without a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If substrate-free surface coverings are used, then manufacturing simplicity and homogeneous structure are improved, but static control properties deteriorate (poor static control, insulating behavior)
Solution Approach 1:
The patent applies composite materials by incorporating conductive particles (metal, metal oxide, carbon, or conductive polymers) into the polymer matrix of the substrate-free surface covering. This creates a composite structure that maintains the manufacturing simplicity of substrate-free coverings while adding static control properties through the conductive phase distributed within the insulating polymer matrix.
Solution Approach 2:
The patent applies local quality by creating regions with different electrical properties within the surface covering. The conductive particles are distributed locally throughout the polymer matrix, creating conductive pathways in specific regions while maintaining the overall homogeneous structure. This allows static control properties to be introduced without changing the entire material composition or manufacturing process fundamentally.
2Strength
If varnish layer is applied to improve cleaning and maintenance properties, then surface durability is improved, but electrical insulation increases (worsening static control)
Solution Approach 1:
The patent applies composite materials in the varnish layer by incorporating conductive particles into the polyurethane-based varnish. This creates a conductive varnish composite that maintains the protective and cleaning properties of the varnish coating while adding static control functionality. The conductive particles in the varnish layer provide electrical pathways that counteract the insulating effect of the varnish binder.
Solution Approach 2:
The patent applies multi-functionality by designing the varnish layer to serve multiple purposes: providing surface durability and protection, enabling easy cleaning and maintenance, and simultaneously providing static control properties. The conductive varnish coating combines the protective functions of traditional varnishes with the electrostatic dissipation function, making the surface covering suitable for electronic manufacturing environments.
3Reliability
If conductive particles are incorporated into the polymer matrix, then static control properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-mixing the conductive particles with the polymer powder before the forming process. The conductive particles are incorporated into the polymer matrix during the powder preparation stage, so that when the powder is deposited and heated, the conductive particles are already uniformly distributed. This eliminates the need for separate steps to add conductive materials after forming, keeping the manufacturing process relatively simple.
Solution Approach 2:
The patent applies the extraction principle by removing the substrate step from traditional multi-layer constructions. By using a substrate-free approach with conductive particles embedded in the polymer matrix, the patent simplifies the overall structure while maintaining static control functionality. The conductive particles themselves provide the necessary electrical pathways without requiring a separate conductive substrate layer.
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 provides a substrate-free surface covering with improved static control properties, reducing static charge generation and allowing for effective charge dissipation, while maintaining mechanical properties and aesthetic considerations.
Implementation Method 1
said particles or said polymer matrix, or both comprises an electrically conductive material
Implementation Method 2
passed through a heating zone, compacted and welded under pressure
Implementation Method 3
compacted and welded under pressure
Data Source
AI summary
The present invention relates to a substrate-free conductive surface covering, and a process to manufacture such covering, said surface covering comprising a core layer of sheet particles which are agglomerated and embedded in a polymer matrix, wherein the particles or the polymer matrix, or both, comprise an electrically conductive material.