CN101680130B - 导电单丝及织物 - Google Patents
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Abstract
本发明公开了一种导电单丝和具有导电单丝的静电耗散织物,其中单丝包括导电材料和粘合料,并具有静电耗散性能。
Description
本申请要求以2007年9月10日提交的、美国临时专利申请序号为60/993,158、名称为“导电单丝及织物(ConductiveMonofilament and Fabric)”,以及2007年6月7日提交的、美国临时专利申请序号为60/933,548、名称为“导电单丝及织物(ConductiveMonofilament and Fabric)”的申请为优先权,因此,上述申请所公开的内容在此以引用方式并入本文。
技术领域
本发明涉及一种导电纱线和静电耗散织物结构,特别涉及一种能够有效耗散静电荷同时还具有理想物理性能的导电纱线和静电耗散织物结构。
背景技术
迄今为止,可供用以例如静电耗散的导电织物,以大量的导电材料诸如碳黑或金属颗粒的填料与单丝结合。典型地,这些导电材料或者分散于基质聚合物(诸如聚对苯二甲酸乙二醇酯及聚酰胺)之中,或者结合在涂覆于定位单丝(oriented monofilaments)上的聚合物涂层中。
这些现有技术方法存在某些局限。第一,添加填充料制成的单丝的电导率只在10-4-10-7S/cm范围内,这是有效耗散静电荷的最低要求。不利之处在于,此缺点限制了织物设计的选择,而且还降低织物性能。第二个缺点是,在产品充分添加填充料的情形下,有损单丝物理性能,诸如模量、韧性及伸展性。这是由于超过20%的导电填料的混入造成较高掺杂程度而导致的。这种物理性能缺陷会进一步限制织物设计的选择,并且负面影响织物性能。
其它现有技术的导电织物包括导电涂层、金属线结构物、或在合成结构物中掺有金属纤维的组合设计。然而,这些织物也有相关的缺点。例如:尽管这些现有设计能够耗散静电荷,但应当注意到,带有金属线的结构物很难制造。另一缺点是,以金属为主的织物易于受损,特别是在使用期间会产生不期望的凹痕及折痕。另一方面,现有技术的涂层设计耐用性不足,而且,涂层还会降低开放网眼结构的渗透性。
发明内容
所以,本发明的主要目的是提供一种纱线,其适合于在工业织物中使用并防止出现上述问题,工业织物诸如适合于例如在气流成网、熔喷、纺粘生产中使用的工程织物、以及造纸过程中使用的干燥织物、以及需要或期望静电耗散的其他工业织物。
本发明的另一目的是提供静电耗散纱线,其适合于在诸如油井线缆、大功率输电线等电力电缆的建设中用作接地介质,以防止在电缆建设期间电荷累积,否则这种电荷累积有可能放电而导致设备损坏、人员严重伤害和/或死亡。
本发明的又一目的是提供静电耗散纱线,其适合于在由各种热塑性单丝构成的编织套管的构造中使用,以在高压领域、在航空航天应用方面如飞行器控制、照明及娱乐、以及机动车应用方面,对多用途电线束提供保护、接地和电磁干扰(EMI)屏蔽。
本发明的又一目的是,提供静电耗散纱线,其适合于在室内清洁应用方面所用的针织和/或织造织物中使用。
本发明提供此目的和其他目的及优点。基于此,本发明涉及一种在织物结构中使用的耐用的高电导率聚合物单丝或捻合单丝纱线。有利的是,本发明涉及使用含有特定导电材料的涂层或膜层的功能性单丝或捻合单丝,导电材料包括金属颗粒和粘合料。在一种实施例中,单丝包括一个或多个纵向凹槽,涂层或膜层主要位于凹槽中。在纱线或单丝磨损时,导电材料保持在凹槽中并免遭磨损。结果,该织物具备了此前仅可由以金属为主的织物提供的静电耗散性能,同时还具有与常规工业织物相当的物理性能和热性能。因此,本发明的织物结构克服了与金属织物设计相关的凹痕及折痕,并且能够提供理想的静电耗散。然而,静电耗散量,其取决于涂层厚度、所使用的涂层材料的电导率等级、结构内(表面、内部等)的涂层的面积、单丝网格的间隔、以及其他几个因素,这些在本发明中都予以考虑。附图说明根据下文结合附图进行的详细描述,本发明的这些以及其它的目的和优点将更为明了,其中:图1是根据本发明教导的单丝的横截面图;图2是根据本发明一个方面的织物的平面图;图3a是根据本发明一个方面的单丝的横截面图;图3b是根据本发明一个方面的单丝的横截面图;以及图4是压模涂覆方法(die coating application method)的概略图。
具体实施方式
本发明的优选实施例,以工程织物诸如以气流成网、熔喷、和/或纺粘加工等制造非织造织物中所使用的织物来进行说明,其中当非织造产品在织物上形成,通过消除累积的静电,使非织造产品的释放得以改善。然而,应当注意到,本发明也可以应用于其它工业织物,诸如在造纸过程中使用的干燥织物、以及在要求静电耗散(如通过织物介质)的任何一种“干式”加工中使用的其它织物。此外,由于导电材料也是良好的热导体,在其他需要热传导的应用中也是可行的。可以使用瞬间导电(instant conductive)纱线或静电耗散纱线的一些示例是在诸如油井线缆、大功率输电线等电力电缆的建设中作为接地介质,以避免电缆建设期间电荷累积,否则这种电荷累积可能放电而导致设备损坏、人员严重伤害和/或死亡。另一示例用在由各种热塑性单丝构成的不同编织套管的构造中,以在高压领域、在航空航天应用方面如飞行器控制、照明及娱乐、以及机动车应用方面,对多用途电线束提供保护、接地和电磁干扰(EMI)屏蔽。瞬间静电耗散纱线的又一应用是,用于在室内清洁应用方面所用的针织和/或织造织物。织物结构可以包括:织造、机器方向(MD)或机器横向(CD)纱线阵列、针织物、螺旋连接组件、薄膜或膜状结构、挤出网、以及上述结构材料构成的螺旋缠绕条带。应当注意到,这些工业织物相对较大,而且经常遭遇严酷环境。这些织物可以由单丝、捻合单丝、复丝或捻合复丝合成纱线构成,并且可以是单层、多层、多层织造或叠层。
现在更具体地参照附图,如图1(横截面图)所示,本发明提供的织物由含有导电材料12的功能性单丝或纱线10构成。因此,鉴于导电材料自身强度不足而难以形成为承载负荷的单丝10,本发明的优选实施例将这些导电材料12主要结合在沿单丝10的纵向长度的凹槽14中。有益的是,由这样的单丝10构成的织物,具有此前仅可由金属织物才具有的静电耗散性能,同时又具有与常规工业织物相当的物理性能。此外,带有这些单丝10的织物可避免出现之前金属丝织物易产生的凹痕及折痕。
特别地,本发明在粘合料中加入导电材料12。所用材料优选为导电墨水(ink)或粘合剂,这些可从俄亥俄州43015特拉华市Johnson Drive路132号的Engineered Conductive Materials、LLC、或Engineered Material System有限公司购买。该公司提供许多种导电墨水及粘合剂。特别有用的一种是使用银粒和粘合料制成的导电墨水。优选具有标号CI-1020的产品。带有其他金属颗粒如铜、镍、锌或它们的组合的其他导电墨水也适用于本目的。粘合料可以是环氧树脂、丙烯酸树脂、偏二氯乙烯、它们的共聚物或其他任何一种适用于本目的的粘合料。
导电材料12装填于凹槽14内,但无需将凹槽14填满。然而,导电材料12需要在凹槽14中沿纵向连续构成,以使其有效。图3a图示优选实施例的扫描电子显微镜(SEM)图像,其中将导电材料12以涂层或膜层形式施加于单丝10。该技术包括例如蘸涂或浸泡涂覆、喷涂(spraying)、喷射(jetting)或其它适用于本目的的方法。例如,如图4所示,可以使用压模涂覆方法(die coating applicationmethod),其中在涂层压模(coating die)内周与单丝外周大致相同的情况下,可以控制导电材料12和粘合料的用量,从而在单丝的表面上尤其在凹槽区域中建立膜层。图4特别示出在此工艺中涂覆导电涂层的示例,其中来自供给卷轴18的未涂覆的单丝经过涂层压模(coating die)16,同时将来自导电涂层室22的导电材料12的涂层施加于单丝上。由涂层压模16的尺寸控制用量,而单丝10上的涂层则使用可控的加热垫24进行干燥,该加热垫24设置于干燥室内,使用热风鼓风机26进行加热。随后将单丝10卷绕在输出组件(图中未示出)上。应当注意到,基本为圆形的有槽单丝是优选的,但也可设想使用其他形状,诸如扁平(亦即矩形)、多边形或其它非圆形。然而,这些当中优选的是,成形的单丝带有一个或多个凹槽,以使涂层位于凹槽内。
在有槽单丝中,带有粘合料的导电材料均匀地涂覆凹槽14,这样在凹槽14中提供了导电涂层或膜层的连续通道。图1中示出的三个凹槽仅仅用于说明,也可以使用一个或多个凹槽。
应当注意到,在染料施加过程中,将压模大小调整为单丝的尺寸。这样带来的益处是:由于只需要较少量的材料,所以只需较低的涂层重量和较低的成本。由于导电材料位于可能出现磨损的纤维丝的磨损面之下,因此使凹槽14具有保护导电材料12的增加的功能。在其他应用中,涂层可以位于外表面上。
结果是,由稳定结合的、耐挠曲的、薄层、低成本且受保护的导电涂层构成的单丝,具有与金属纱线相当的电导率。根据所需最终用途,该单丝可以作为单股使用,或者可以使其捻合或缠绕以形成捻合单丝结构。图2示出根据本发明的一个实施例在横机器方向具有单丝10的织物20。
应当注意到,在织物中结合这些单丝,不需要使构成织物的所有纱线具有这些单丝,而只是部分纱线具有这些单丝。对于不同应用,为了耗散静电,可以将它们用在机器方向和/或横机器方向以及任意一种编织图案中。
在图3b的SEM图像中横截面方式示出的实施例,示出了使用导电材料12涂覆带有凹槽的单丝10。有利的是,这样提高了单丝的电导率,同时保持了单丝的物理特性和功能特性。导电材料12沿单丝外周且至少在凹槽的周边之内结合于单丝的表面。即使在单丝10磨损时,这种有槽纱线的布置方式也能够起到保护导电材料12的作用,同时也能够遮蔽并保护导电材料12。如果涂层的耐磨性比单丝自身的耐磨性低,则导电材料12所处的这种保护位置减少了电导率随时间的流失。
应当注意到,单丝可以由任何一种适用于本目的的材料制成,包括聚合物诸如聚酯或聚酰胺或本领域技术人员周知的其他材料。还应当注意到,具有接近或相当于金属纱线的电导率的导电材料可以反复挠曲,同时保持所需的电导率(静电耗散),并且具有对聚合物的良好的附着力,这些聚合物为诸如聚酯、尼龙、聚苯硫醚(PPS)、聚醚醚酮(PEEK)等。
因此,通过本发明可实现其目的及优点,虽然本文详细披露描述了优选实施例,但本发明的范围和目的并不受限于此;本发明范围应由所附权利要求限定。
Claims (21)
1.一种静电耗散织物,其包含多根聚合物单丝,其中所述单丝包括含有金属颗粒的导电材料和粘合料,在织造所述织物之前,所述导电材料和所述粘合料结合在所述单丝上作为涂层或膜层,所述单丝具有静电耗散性能。
2.根据权利要求1所述的织物,其中所述单丝包括一个或多个纵向凹槽,所述导电材料和所述粘合料以连续涂层或膜层位于所述凹槽中。
3.根据权利要求1所述的织物,其中所述粘合料是环氧树脂、丙烯酸树脂、偏二氯乙烯、或其共聚物。
4.根据权利要求1所述的织物,其中所述金属颗粒是银、铜、镍、锌或其组合。
5.根据权利要求1所述的织物,其中所述单丝为圆形或非圆形。
6.根据权利要求1所述的织物,其中通过蘸涂或浸泡涂覆、喷涂、喷射或压模涂覆方法中的一种来施加所述导电材料和所述粘合料。
7.根据权利要求1所述的织物,其中所述织物是织造织物、机器方向或机器横向纱线阵列、针织物、螺旋连接组件、挤出网、或上述结构物构成的螺旋缠绕条带。
8.根据权利要求1所述的织物,其中所述单丝由聚酯、聚酰胺、聚苯硫醚(PPS)或聚醚醚酮(PEEK)制成。
9.根据权利要求1所述的织物,其中所述织物是工程织物、是以气流成网、熔喷或纺粘加工制造非织造织物中使用的织物、或是造纸织物。
10.根据权利要求1所述的织物,其中所述织物是单层、多层、多层织造或叠层。
11.一种聚合物单丝,其上具有导电材料的连续涂层或膜层,所述导电材料由金属颗粒和粘合料组成,所述聚合物单丝具有静电耗散性能,其中,在使用所述聚合物单丝之前,将所述导电材料施加至所述聚合物单丝。
12.根据权利要求11所述的单丝,具有一个或多个纵向凹槽,所述导电材料和所述粘合料以连续涂层或膜层位于所述凹槽中。
13.根据权利要求11所述的单丝,其中所述粘合料是环氧树脂、丙烯酸树脂、偏二氯乙烯、或其共聚物。
14.根据权利要求11所述的单丝,其中所述金属颗粒是银、铜、镍、锌或其组合。
15.根据权利要求11所述的单丝,其中通过蘸涂或浸泡涂覆、喷涂、喷射或压模涂覆方法中的一种来施加所述导电材料和所述粘合料。
16.根据权利要求11所述的单丝,其中所述单丝为圆形或非圆形。
17.根据权利要求11所述的单丝,其中所述单丝由聚酯、聚酰胺、聚苯硫醚(PPS)或聚醚醚酮(PEEK)制成。
18.根据权利要求11所述的单丝,其中所述单丝用于形成工程织物、用于形成以气流成网、熔喷或纺粘加工制造非织造织物中使用的织物、或用于形成造纸织物。
19.根据权利要求11所述的单丝,其中所述织物是单层或多层、多层织造或叠层。
20.根据权利要求11所述的单丝,其中所述单丝用于形成电力电缆、油井线缆、大功率输电线、接地介质、编织套管、电磁干扰(EMI)屏蔽、高压、航空航天应用、机动车应用、或者在室内清洁应用中使用的针织或织造织物。
21.一种工程织物,包括:
多根聚合物单丝,其中所述单丝含有导电材料和粘合料,
其中,在使用所述单丝之前,以涂层方式施加所述导电材料,所述涂层含有具备静电耗散性能的金属颗粒。
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BRPI0812370B1 (pt) | 2019-01-02 |
EP2155939A1 (en) | 2010-02-24 |
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CN101680130A (zh) | 2010-03-24 |
TW200912063A (en) | 2009-03-16 |
PL2155939T3 (pl) | 2011-09-30 |
US20080318483A1 (en) | 2008-12-25 |
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RU2009145295A (ru) | 2011-07-20 |
ATE504678T1 (de) | 2011-04-15 |
CA2689207C (en) | 2015-05-05 |
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