CN106965509A - 一种复合导电海绵及其制备方法 - Google Patents

一种复合导电海绵及其制备方法 Download PDF

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CN106965509A
CN106965509A CN201710300740.0A CN201710300740A CN106965509A CN 106965509 A CN106965509 A CN 106965509A CN 201710300740 A CN201710300740 A CN 201710300740A CN 106965509 A CN106965509 A CN 106965509A
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sponge
cloth
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copper
matrix
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吴中和
吴庆锋
余欢喜
吴曙东
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HUNAN AN-HOME SCIENCE TECHNOLOGY Co Ltd
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HUNAN AN-HOME SCIENCE TECHNOLOGY Co Ltd
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Abstract

本发明公开了一种复合导电海绵及其制备方法，包括裸海绵和裸布，先将裸海绵和裸布通过胶复合或者火贴复合的方式粘附成为整体的海绵布，在海绵布上镀覆镍层或铜层，在镀覆有镍层或铜层的海绵布基体表面直接电镀镍层或先电镀铜层再电镀镍层，经水洗、烘干，得到复合导电海绵。本发明的优点在于整体的海绵布中不需设置导电胶层，可完全杜绝导电胶水的使用，彻底解除了因胶失效而造成产品事故的风险。产品电阻不再受到胶层的干扰，工艺流程短，产品品质的稳定性得以提升。

Description

一种复合导电海绵及其制备方法
技术领域
本发明涉及导电材料领域，具体涉及一种复合导电海绵及其制备方法。
背景技术
复合导电海绵是一种集导电和电磁屏蔽功能于一体的三维网状结构功能材料，由于其导电有效期长，电磁屏蔽效果好，表面电阻值可按实际用途设定等特点而广泛应用于导电材料领域。目前市面上的复合导电海绵一般采用导电海绵成品和导电布成品复合而成，其结构由导电海绵成品、导电胶层和导电布成品组成，存在如下缺陷：目前的导电海绵成品和导电布成品是由厂家分别制备的，而复合导电海绵则需要将这两种不同的材料牢固地结合在一起，因此采用导电胶或热熔胶形成导电胶层作为二者结合的复合中间层，然而导电胶层不环保，且导电胶或热熔胶在高温或长时间使用的情况下，有失效的风险，会导致复合导电海绵的品质不稳定。其次，中部涂覆了导电胶层的复合导电海绵在使用过程中，其产品电阻会受到胶水的干扰，电阻值偏高甚至很难达到国际标准（≦0.1Ω），电阻值一般在0.08-1.5Ω的宽幅区间波动。此外，现有的复合导电海绵制备过程中，导电海绵成品和导电布成品需要分别制备，其中导电海绵成品的制备工序包括裸海绵预处理导电、电镀镍等；导电布成品的制备工序包括裸布预处理导电、电镀镍等；再将分别制成的导电海绵成品和导电布成品热压复合3-5次，整个工艺流程太长，导致产品成本居高不下。并且，在不同工艺环境下、甚至由不同厂家分别生产的导电海绵成品和导电布成品，其品质存在一定偏差，二者作为后期加工复合导电海绵的原材料，不利于产品品质的稳定性。
发明内容
本发明针对上述问题，提供一种复合导电海绵及其制备方法。
为了实现上述目的，本发明采用以下技术方案实现：
一种复合导电海绵，其特征在于，包括裸海绵和裸布，裸海绵和裸布通过胶复合或者火贴复合的方式粘附成为整体的海绵布，采用化学镀或真空磁控溅射在海绵布上镀覆有镍层或铜层，在镀覆有镍层或铜层的海绵布基体表面直接电镀镍层或先电镀铜层再电镀镍层，经水洗、烘干，得到表面电阻≤ 0.1Ω的复合导电海绵。
进一步地，所述裸海绵为三维多孔聚氨酯或PE，所述裸布为聚酯纤维布或无纺布。
一种复合导电海绵的制备方法，其特征在于，包括如下步骤：
（1）取裸海绵和裸布，采用胶转移复合设备，将环保胶粘附或喷涂在裸布或裸海绵基材上，复合走速设定为1-20m/min，喷涂胶点数设定为10-500点/cm2,将裸布或裸海绵复合成为整体的海绵布；或是采用火焰复合设备，对裸海绵表面进行加热烘烤，至海绵软化或轻微燃烧，燃烧量设定为0.5-5m3/min，复合走速设定为1-50m/min，利用聚氨酯海绵本身具有的粘接性能使其与裸布粘接为整体的海绵布；
（2）将步骤（1）复合好的海绵布基体置于pH为8.5±0.2、温度为45±2℃的化学溶液中进行化学镀镍或铜金属，基体走速≤1.35m/min，化学镀后的基体表面电阻≤ 100Ω；或是将复合好的海绵布基体置于磁控真空镀膜设备内，以镍靶或铜靶溅射原理将镍或铜金属粉沫溅射于海绵布基体上，实现海绵布的预导电，其中靶腔内温度设定为60-100℃，基体走速设定为0.5-8 m/min，充气量设定为100-200sccm，压强设定为0.1-0.5Pa,调节溅射需要的电流、速度，控制溅射时的真空度，待溅射过程结束后，取出复合海绵，并校验表面电阻，得到电阻值≤ 100Ω的导电层；
（3）将步骤（2）中镀覆有镍层或铜层的海绵布放入电镀槽中，在基体表面直接连续电镀镍层或先电镀铜层再电镀镍层；设定走速为0.05-0.5 m/min；
（4）将步骤（3）中将电镀后的基体经水洗槽水洗，然后在120-180℃隧道式烘箱炉内烘干，得到表面电阻≤ 0.1Ω的复合导电海绵。
与现有产品及生产工艺相比，本发明的优点在于：1、裸海绵和裸布通过胶复合或者火贴复合的方式粘附成为整体的海绵布，二者之间不需设置导电胶层，产品绿色环保，可完全杜绝导电胶水的使用，彻底解除了因胶失效而造成产品事故的风险。2、产品电阻不再受到胶层的干扰，其电阻平均值能精准控制在0.03-0.08Ω的国际标准下。3、工艺流程短，相较于传统复合导电海绵的制备节省了6个环节，产品品质的稳定性得以提升，并有效地节省了工艺成本、原材料成本、人工成本、以及物流成本，总成本降低40%，还大大提升了产出效率。4、产品不受原材料（现有生产厂家分别制备的导电海绵成品和导电布成品）品质影响，在同一工艺环境下将裸海绵和裸布一次成型，确保了产品品质的稳定性。
附图说明
图1是本发明复合导电海绵的结构示意图
图中：1、裸海绵，2、裸布，3、海绵布，4、化学镀或真空磁控溅射镀覆的镍层或铜层，5、电镀的镍层或铜层。
具体实施方式
下面结合附图对本发明的实施阐述如下。
如图1所示，一种复合导电海绵包括海绵布3、化学镀或真空磁控溅射镀覆的镍层或铜层4、电镀的镍层或铜层5。
实施例一
将三维多孔聚氨酯1和聚酯纤维布2通过胶复合的方式粘附成为整体的海绵布3，即采用胶转移复合设备，将环保胶粘附或喷涂在三维多孔聚氨酯1或聚酯纤维布2的基材上，复合走速设定为10m/min，喷涂胶点数设定为400点/cm2,将三维多孔聚氨酯1和聚酯纤维布2复合成为整体的海绵布3。
采用化学镀在海绵布3上镀覆镍层或铜层4，即将复合好的海绵布3基体置于pH为8.6、温度为44℃的化学溶液中进行化学镀镍或铜金属，基体走速小于1.35m/min，化学镀后的基体表面电阻达到100Ω。
将通过化学镀镀覆有镍层或铜层4的海绵布放入电镀槽中，以0.3m/min的走速直接电镀镍层或铜层5。将电镀后的基体经水洗槽水洗，然后在140℃烘箱内烘干，得到表面电阻小于 0.1Ω的复合导电海绵。
实施例二
将PE1和无纺布2通过火贴复合的方式粘附成为整体的海绵布3，即采用火焰复合设备，将PE1表面进行加热烘烤，至海绵软化或轻微燃烧，燃烧量设定为3m3/min，复合走速设定为45m/min，利用PE海绵1本身具有的粘接性能使其与无纺布2粘接为整体的海绵布3。
采用真空磁控溅射在海绵布3上镀覆镍层或铜层4，即将复合好的海绵布3基体置于磁控真空镀膜设备内，以镍靶或铜靶溅射原理将镍或铜金属粉沫溅射于海绵布3基体上，实现海绵布3的预导电，其中靶腔内温度设定为80℃，基体走速设定为6 m/min，充气量设定为180sccm，压强设定为0.4Pa，调节溅射需要的电流、速度，控制溅射时的真空度，待溅射过程结束后，取出复合海绵，并校验表面电阻，得到电阻值小于 100Ω的导电层。
将通过真空磁控溅射镀覆有镍层或铜层4的海绵布放入电镀槽中，以0.5 m/min的走速先电镀铜层再电镀镍层5。将电镀后的基体经水洗槽水洗，然后在160℃烘箱内烘干，得到表面电阻小于 0.1Ω的复合导电海绵。
采用表面阻抗检测法和垂直阻抗检测法进行检测，经检测，本发明的复合导电海绵与市面上同规格的导电海绵各项性能参数对比如下表所示。
以上记载的仅为本发明的优选实施例，当然不能以此来限定本发明之权利范围，因此依本发明权利要求所作的等同变化，仍属本发明所涵盖的范围。

Claims (3)

1.一种复合导电海绵，其特征在于，包括裸海绵和裸布，裸海绵和裸布通过胶复合或者火贴复合的方式粘附成为整体的海绵布，采用化学镀或真空磁控溅射在海绵布上镀覆有镍层或铜层，在镀覆有镍层或铜层的海绵布基体表面直接电镀镍层或先电镀铜层再电镀镍层，经水洗、烘干，得到表面电阻≤ 0.1Ω的复合导电海绵。
2.如权利要求1所述的复合导电海绵，其特征在于，所述裸海绵为三维多孔聚氨酯或PE，所述裸布为聚酯纤维布或无纺布。
3.如权利要求1所述的复合导电海绵的制备方法，其特征在于，包括如下步骤：
（1）取裸海绵和裸布，采用胶转移复合设备，将环保胶粘附或喷涂在裸布或裸海绵基材上，复合走速设定为1-20m/min，喷涂胶点数设定为10-500点/cm2,将裸布或裸海绵复合成为整体的海绵布；或是采用火焰复合设备，对裸海绵表面进行加热烘烤，至海绵软化或轻微燃烧，燃烧量设定为0.5-5m3/min，复合走速设定为1-50m/min，利用聚氨酯海绵本身具有的粘接性能使其与裸布粘接为整体的海绵布；
（2）将步骤（1）复合好的海绵布基体置于pH为8.5±0.2、温度为45±2℃的化学溶液中进行化学镀镍或铜金属，基体走速≤1.35m/min，化学镀后的基体表面电阻≤ 100Ω；或是将复合好的海绵布基体置于磁控真空镀膜设备内，以镍靶或铜靶溅射原理将镍或铜金属粉沫溅射于海绵布基体上，实现海绵布的预导电，其中靶腔内温度设定为60-100℃，基体走速设定为0.5-8 m/min，充气量设定为100-200sccm，压强设定为0.1-0.5Pa,调节溅射需要的电流、速度，控制溅射时的真空度，待溅射过程结束后，取出复合海绵，并校验表面电阻，得到电阻值≤ 100Ω的导电层；
（3）将步骤（2）中镀覆有镍层或铜层的海绵布放入电镀槽中，在基体表面直接连续电镀镍层或先电镀铜层再电镀镍层；设定走速为0.05-0.5 m/min；
（4）将步骤（3）中将电镀后的基体经水洗槽水洗，然后在120-180℃隧道式烘箱炉内烘干，得到表面电阻≤ 0.1Ω的复合导电海绵。
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