CN1778156A - 多平面emi屏蔽衬垫及其制造方法 - Google Patents
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Abstract
多平面、导电衬垫材料具有泡沫芯、包括导电纤维和绝缘纤维的混合物的导电网层、加强织物和大量散布穿过泡沫芯和加强织物的混合纤维。混合纤维被热定形在衬垫材料内。
Description
发明背景
1.技术领域
本发明总体上涉及EMI屏蔽衬垫。具体地,本发明涉及整个衬垫均具有导电性的EMI屏蔽衬垫。
2.背景技术
EMI屏蔽衬垫用于在电学上密封封装电子元件的金属外壳中的间隙。在面板、开口等和外壳之间的间隙向EMI/RFI提供了不合需要的通过衬垫的机会。间隙还干扰来自EMI/RFI能量的、沿外壳表面流过的电流,EMI/RFI能量被吸收并被传导给大地。间隙降低了接地传导通路的效率,甚至可导致衬垫成为EMI/RFI泄漏的第二来源。
在过去已开发了多种衬垫结构来封闭间隙以实现对接地传导电流的最少可能的干扰。这些衬垫均寻求建立跨间隙的、尽可能连续的导电通路。其中一些衬垫结构仅在静态应用中有用,而其它衬垫结构可用在静态和动态应用中。静态应用是指元件在固定高度工作且加载力是恒量。动态应用是指元件在从最大到最小限制之间变化的高度下工作,且加载的力将反比于高度进行变化。动态应用的例子如板、开口等被再三地分隔并重新连接到外壳。
为了维修外壳内的电子元件,包容各个电子元件的外壳必须时常地打开和关闭。为经受住大量的外壳打开和关闭,EMI屏蔽衬垫必须适于动态应用。遗憾地是在下述因素之间要进行不可避免的折衷:衬垫平滑且彻底地与邻近间隙的外壳接合并与其相符的能力、衬垫的传导能力、衬垫的易安装性、衬垫经受磨损和撕扯及反复压缩和张驰的能力、及衬垫的制造成本。在现有技术中已公开了多种EMI屏蔽衬垫。
美国专利6,309,742 B1(2002年授予Clupper等)公开了EMI/RFI屏蔽衬垫。导电衬垫具有带骨架结构的金属化的、开孔泡沫衬底及沉积在骨架结构上的金属涂层。衬垫在低压下既可复原也可实质变形。泡沫的金属化采用泡沫的骨架结构上的金属涂层的形式。金属涂层通过开孔泡沫衬底沉积在骨架结构的大部分表面上。Clupper装置的缺点在于金属化过程必须被小心地控制以通过泡沫衬底用金属充分地涂覆衬垫,从而提供适当的通体超导性,但又不能用金属过分涂覆从而使得金属化的泡沫很难压缩和/或不够有弹性。
美国专利6,395,402 B1(2002年授予Lambert等)公开了制备导电聚合泡沫的方法。该方法包括步骤:(a)使聚合泡沫与表面活性剂溶液接触;(b)使聚合泡沫与敏化溶液接触;(c)使聚合泡沫与活化溶液接触;及(d)最后用无电镀工艺在聚合泡沫上形成一金属层。
Laird Technologies新产品公报公开了阻燃导电泡沫,其提供X、Y和Z轴传导性以增强屏蔽效应。Laird导电泡沫的缺点在于其设计用于非动态、低压力区域如输入/输出屏蔽及其它标准连接器结构。
美国专利6,465,731(2002年授予Stanley Miska)公开了通体导电的EMI屏蔽。Miska装置使用导电的芯,其或具有嵌入在芯内的镀金属的纤维或具有镀金属的泡沫芯。该装置的缺点在于金属镀层可能因反复的压缩和张驰而破裂,从而导致衬垫的通体传导性的降级。
上述镀金属的导电泡沫不可再次使用在动态应用中,因为已置放在泡沫的网眼内的镀金属的表面是刚硬的。这些刚硬的金属表面在初次压缩之后即被损坏。
因此,需要这样一种EMI屏蔽衬垫,其是柔韧且不可变形的以用于动态应用。还需要一种EMI屏蔽衬垫材料,其提供泡沫芯的通体电导但不具有刚性的金属涂层成分。还需要这样一种EMI屏蔽衬垫材料,其提供遍及X、Y和Z轴的电导。此外,还需要制备EMI屏蔽衬垫的方法,其成本较低且保持泡沫芯的弹性和适应特性。
发明内容
本发明的目标在于提供可用在动态应用中的EMI屏蔽衬垫。本发明的目标还在于提供在其再使用的压缩和张驰周期期间可保持其相当高的电导的EMI屏蔽衬垫。本发明的目标还在于对再使用提供实质上相似的屏蔽效应。本发明的另一目标是提供在三维中屏蔽X、Y和Z轴的EMI屏蔽衬垫。本发明的目标还在于提供制造EMI屏蔽衬垫的方法,其成本较低且可保持泡沫芯的弹性和适应特性。
本发明通过提供多平面EMI屏蔽衬垫来实现这些及其它目标,其具有柔韧的泡沫芯、在泡沫芯的至少一侧上的导电纤维网、大量交织贯穿泡沫芯的混合导电纤维。本发明的优选实施例还包括支靠泡沫芯的加强织物,其中大量混合导电纤维也被交织穿过加强织物。大量混合导电纤维从泡沫芯的顶面延伸,通过泡沫芯的内部,并从泡沫芯的底面向外凸出。由于上面、下面及贯穿泡沫芯的混合导电纤维的存在,EMI屏蔽衬垫展现出X、Y和Z轴传导性。
多平面EMI屏蔽衬垫的泡沫芯由传统的聚合柔韧多孔状泡沫体组成。泡沫芯可以是开孔的、部分开孔的、或封闭孔的泡沫芯,取决于具体应用的需要。传统的聚合柔韧多孔状泡沫体包括但不限于热塑性弹性体(TPE)如SANTOPRENE、NEOPRENE,或含有聚氨酯的材料如聚酯、聚醚、聚氨酯或其结合。泡沫最好具有在约0.5到约50毫米之间的厚度。
多平面EMI屏蔽衬垫的导电纤维网由大量导电和绝缘纤维的同质混合物组成。纤维网的导电纤维通常在1-15丹尼尔(Denier)大小和1-5英寸长的尼龙短纤维上包含银、银/铜或银/镍。纤维网的绝缘纤维通常由低软化点纤维组成如大小为1-15丹尼尔、长度为1-5英寸的双组分聚酯纤维,但最好由醇化聚酯(PETG)纤维组成。本发明的导电和绝缘纤维以典型的约75/25的比例进行混合,该比例可向上或向下调节,其取决于所想要的最终产品的传导性和屏蔽效应(SE)。优选的组分包括绝缘阻燃纤维,从而使得混合物具有这样的典型比例:约65%的导电纤维、约20%的绝缘粘性纤维和约15%的绝缘阻燃纤维。
导电纤维网通过将导电和绝缘纤维混合为同质混合物、然后将混合的纤维馈送到织物梳理机或随机化的纤维纺织机而形成。该工艺生产40-80英寸宽的网,其具有每平方码在10-200克之间的重量,具体数字取决于所希望的成品传导性和屏蔽效应。
硬挺织物可可选地添加在泡沫芯和导电纤维网之间以产生更硬的EMI衬垫材料。当泡沫芯具有5毫米以下的厚度时,可能必须添加硬挺织物。在衬垫产品的成品片的芯厚度小于5毫米从而缺乏必须的坚固性、硬度或刚性时可以使用硬挺织物。
为了增加本发明的导电衬垫的传导性和屏蔽效应,可在进行针刺法操作之前在导电纤维网和柔韧的聚氨酯泡沫芯之间插入一薄层铝箔。铝箔层最好具有在0.0005-0.002英寸之间的厚度,其可从罗得岛州Pawtucket的Neptco公司获得。薄铝箔层的添加改善了EMI衬垫片或冲切输入/输出衬垫的屏蔽性能。
为了改善片式衬垫经受十字方向剪切作用的能力,片式衬垫或输入/输出衬垫的整个背面均被覆盖以特殊的蜂巢状、压敏粘合剂。特殊的蜂巢式样具有钻石形状的孔,其允许多平面衬垫的导电背面与其所连接的表面之间的连通性。该技术允许使用绝缘的、成本较低的PSA粘合剂产品如可从康涅狄格州Windsor的Scapa North America在产品号RX650ULT下获得的产品。整个衬垫或I/O表面被稳固地粘合到提供高级十字剪切作用的小盒子(cabinet box)或封装门(enclosure door)。
尽管多平面EMI屏蔽衬垫材料的一实施例是通过将导电纤维网沉积在聚合、柔韧、多孔状泡沫体上而形成,但最好是通过将导电纤维网和加强织物沉积在聚合、柔韧、多孔状泡沫体上而形成多平面EMI屏蔽衬垫材料。首选的导电纤维网、聚合泡沫及加强织物的组合接着被呈现给针织机。织机针刺导电纤维网的混合纤维以使其穿过泡沫和加强织物。为避免撕碎泡沫和织物,使用特殊凿形针尖的针。织机针的凿形针尖在自凿形针尖的预定距离内沿针杆具有多个角度的倒钩。倒钩通常具有5度的角度,但也可使用具有更大角度倒钩的织机针。倒钩角度越大,则从导电纤维网带过泡沫的纤维的数量越大。
由于针织机上的针刺工艺趋向于产生与导电纤维网特征类似的“地毯绒头”,半成品被热定形以将纤维锁定在适当位置。热定形工艺包括将半成品加热到绝缘粘性纤维的软化点,所述软化点低于导电纤维的软化点。绝缘纤维的软化点通常在约110℃-138℃之间。对于双组分聚酯纤维,其在约115℃-138℃之间。对于PETG纤维,其为约110℃。
本发明结构提供了传统产品不可能达到的柔韧性和转弯能力。其没有硬的、金属化的机织织物,也没有用于将泡沫粘结到导电织物的涂层或粘合剂,这使得本发明可紧密地接触电子外壳,从而给出近乎完美的EMI密封。需要临界特性以用于未来的具有超细电波幅的高时钟脉冲速度。
此外,制造的简单性及所使用的原材料的低成本大大节省了成品的成本。另外,简单的制造方法向用户提供更宽范围的应用。
附图说明
图1为本发明多平面EMI衬垫材料的放大立体图。
图2为本发明一实施例的部分成形的EMI衬垫材料片的断面图。
图3为本发明第二实施例的部分成形的EMI衬垫材料片的断面图。
图4为本发明第三实施例的断面图,其示出了在泡沫芯和导电纤维网之间添加有硬挺织物的部分成形的EMI衬垫材料片。
图5为使用本发明的衬垫材料的多个加热成形形状的断面图。
图6A和6B为使用在形成本发明的多平面EMI衬垫材料的针刺机织工艺中的针的侧视图。
图7为产生本发明的多平面EMI衬垫材料的加热成形生产线的侧视图。
图8为示出本发明的具有加强织物的多平面EMI衬垫材料的放大立体图。
图9为根据本发明的优选实施例的、部分成形的EMI衬垫材料片的断面图。
具体实施方式
图1-9示出了本发明的优选实施例。图1为一片多平面EMI衬垫材料100的透视图。多平面EMI衬垫材料100具有聚合泡沫芯20、在泡沫芯20的至少一侧上的一层导电纤维网40、及大量散布的完全穿过泡沫芯20的导电纤维43。聚合泡沫芯20具有顶面22和底面24,且有大量散布的细孔(未示出)贯穿泡沫芯20。大量散布的纤维43从泡沫芯20的底面24凸出并保持与导电纤维网40的电气连接。用作泡沫芯20的可接受的材料的例子如可从新泽西州East Rutherford的Foamex International获得的Foamex Ether泡沫型号YCC240-115。然而,任何低密度和低压缩尿烷和硅树脂泡沫的选择均虑及对EMI多平面衬垫施以非常低的闭合力或压力,其小于2.0psi(140.61g/cm2)。
导电纤维网40是大量导电和绝缘纤维的混合物。导电纤维和绝缘纤维被混合为同质混合物,继而被馈送给织物梳理机或随机化的纤维纺织机。该工艺生产40-80英寸宽的网,其具有每平方码在10-200克之间的重量,网的重量取决于所希望的传导性和屏蔽效应。当在混合物内包括阻燃纤维时,还可实现导电纤维网40的另一改进。
导电纤维通常在1-15丹尼尔大小、1-5英寸长的尼龙短纤维上包括银、银/铜、或银/镍。在一实施例中,绝缘纤维为不导电的双组分聚酯纤维,其可从纽约Albany的Stein Limited获得。导电和绝缘纤维的典型混合比为约3∶1(75/25)。然而,可根据最终产品的传导性和屏蔽效应要求而调整混合比。
图2为制造一实施例的EMI衬垫材料100的针织机工艺的横断面图。导电纤维网40按与泡沫芯20呈分层的关系带进从而形成多平面组件50。多平面组件50接着经过针织机500,其按非常类似于制造地毯的工艺处理多平面组件50。针织机500将网40的各个纤维43从网40散布穿过泡沫芯20,使得大量单独的纤维43凸出底面24。针织机工艺使纤维网40与泡沫芯20互锁或结合从而形成多平面芯90,而不需要粘合剂。
参见图3,其示出了制造第二实施例的EMI衬垫材料100的针织机工艺的横断面图。如上所述,导电纤维网40按与泡沫芯20呈分层的关系带进从而形成多平面组件50。多平面组件50接着经过针织机500,其处理多平面组件50。针织机500将网40的各个纤维43从网40散布穿过泡沫芯20,使得大量单独的纤维43凸出底面24。针织机工艺使纤维网40与泡沫芯20互锁或结合从而形成多平面芯90。第二导电纤维网40’接着按与在底面24的泡沫芯20呈分层关系带进从而形成多平面组件50’,其有多平面芯90和第二导电纤维网组成40’。多平面组件50’接着经过第二针织机500’,其处理多平面组件50’。针织机500’将网40’的各个纤维43’从网40’散布穿过泡沫芯20,使得大量单独的纤维43’凸出并与导电网40接触。第二针织机工艺使纤维网40’与多平面芯90互锁从而形成多平面芯90’ 。
在泡沫芯20的厚度太薄如厚度小于5毫米的情况下,衬垫材料100可能缺少某些必须的坚固性、硬度或刚性。图4为制造第三实施例的EMI衬垫材料100的针织机工艺的横断面图。绝缘硬挺织物30按分层关系置于导电纤维网40和泡沫芯20之间从而形成多平面组件150。多平面组件150接着经过针织机500,其处理多平面组件150。针织机500将网40的各个纤维43从网40散布穿过硬挺织物30和泡沫芯20,使得大量单独的纤维43凸出底面24。针织机工艺使纤维网40与硬挺织物30和泡沫芯20互锁或结合从而形成多平面芯190。
硬挺织物30最好是绝缘纤维网,其具有按约4∶1(80/20)混合的双组分聚酯纤维与常规聚酯纤维。双组分聚酯纤维通常具有约240-280°F的软化点。组合硬挺织物30的额外好处在于在各个三维断面中使用硬挺织物的加热成形特性,从而提供更好的屏蔽片和输入/输出衬垫。图5提供了各种形状的示例性例子,但不应被视为仅限于这些示出的形状。每一形状均包括泡沫芯20、硬挺织物30、导电纤维网40、和大量穿透泡沫芯30的导电纤维43,如先前所公开的那样。
为增加衬垫材料100的传导性和屏蔽效应,可在导电纤维网40和泡沫芯20之间插入铝箔层。图4可用于图示增强的衬垫材料100,因为硬挺织物30简单地被铝箔层代替。其余针刺法操作均一样。应注意的是,也可使用硬挺织物30和铝箔层的组合。在这种情况下,铝箔层最好与硬挺织物30相邻。
图6A和6B为在针织机500中使用的针的两个示例性的例子的侧视图。图6A和6B示出了针刺法所使用的针510a和510b。针510a和510b均具有曲柄部分512a、512b,胫部514a、514b,锥形部分516a、516b,倒钩部分518a、518b,及凿形针尖部分520a、520b。针510a的倒钩部分518a具有多个5度角的倒钩519a。针510b的倒钩部分518b具有多个20度角的倒钩519b。倒钩上的角度数越大,则由针携带穿过泡沫芯20的纤维的数量越大。针510a、510b可从Foster Needles Company购买,且型号为15x18x40x3 CBA F56-3B/CP的特殊6倒钩针。针510a、510b的特别重要的特征在于针允许穿透泡沫的断面而不会撕开泡沫,且针携带各个纤维43穿过泡沫芯20从而到达另一侧。
本发明的另一重要特征在于使用导电纤维和绝缘的且熔点更低的纤维的纤维混合物。绝缘的熔点较低的纤维为双组分聚酯(如前所述)并具有约240-280°F的软化点。尽管多平面芯90和90’具有必要的导电衬垫材料质量,多平面芯90和90’中的纤维趋向于产生导电纤维屑。该导电纤维屑是有害的,特别是在松散导电纤维可能导致电路的意外短路的电子应用中更是如此。为阻止这种情况发生,多平面芯90和90’经受热处理过程。
参见图7,其示出了所述热处理过程的一个例子。加热成形工艺700包括一卷多平面芯90或90’,加热室720、冷成型模730、拉紧带740和切断机构750。多平面芯90或90’被展开并馈送在滚筒710上以进入加热室720。加热室720包括加热滚筒如textile calendar或两个加热带,其使得多平面芯90或90’达到绝缘双组分聚酯纤维的软化点,所述软化点通常为约240-280°F。该加热过程将导电纤维锁定在适当位置并避免了任何随后的导电纤维移动或损失,同时保持衬垫的弹性和适应特性。所得到的材料形成多平面EMI衬垫材料,其不仅在X和Y轴中导电,而且在穿过衬垫的X轴也导电。
在这里,衬垫材料100可被保存以用于以后的冲切或可在通过加热室720之后进行冲切。如果冲切被执行为加热成形过程700的一部分,则衬垫材料100在通过冷成型模730之前被冷却到室温。冷成型模730按所需的样板冲模切割或切削衬垫材料100,接着通过拉紧带740并移动到切断机构750,冲切后的衬垫在这里被剪切为适当长度。
本发明及方法提供了柔韧的多孔状泡沫体的连续护层,其具有传导电流并在3轴(X-Y-Z)结构中提供EMI屏蔽的能力。本发明是基本的导电衬垫材料,其可用于制造非常小及非常宽宽度的片式衬垫,也可用于制造具有非常小及非常大表面积的输入/输出衬垫。应该理解的是,通过针刺法穿过泡沫的导电纤维的合成物可以各种纤维密度及泡沫厚度进行制造,这取决于应用。本发明的导电衬垫材料还可被分为多个单独的片以用于制造连续的片式衬垫。此外,如上所述,使用一层由双组分聚酯制成的硬挺织物可提供产生多种热压模衬垫形状的能力。
现在参考图8,其示出了一片优选实施例的多平面EMI衬垫材料的透视图。多平面EMI衬垫材料200在多平面EMI衬垫材料100的基础上提供了增强的性能。具体地,多平面EMI衬垫材料200对松散纤维保存提供了更好的控制、降低了X、Y和Z轴的电阻、增加了阻燃性、增加了抗磨损性、降低了原材料成本、降低了压缩力要求、提供了更好的拉伸控制和改善的强度。
多平面EMI衬垫材料200具有聚合泡沫芯220、在泡沫芯200的至少一侧上的一层导电纤维网240、加强织物260、及大量散布的完全穿过泡沫芯220和加强织物260的导电纤维243。
导电纤维网240是大量导电和绝缘纤维的混合物。导电纤维和绝缘纤维被混合为同质混合物,继而被馈送给织物梳理机或随机化的纤维纺织机,所有的均如在此所述。当在混合物内包括阻燃纤维时,还可实现导电纤维网240的另一改进。
导电纤维通常在1-15丹尼尔大小、1-5英寸长的尼龙短纤维上包括银、银/铜、或银/镍。传统的导电纤维具有导电金属成分,约占18%。当微处理器速度达到4.0千兆赫级时,屏蔽衬垫必须能够是极其传导的,以适当地用作该应用中的有效EMI衬垫。这意味着X、Y和Z轴电阻必须达到10毫欧以下的级别。
当使用传统的导电纤维(约含18%金属成分)时,衬垫必须从其原始厚度压缩50%或更多以达到10毫欧的电阻率级别。这样高的压缩要求在组装过程期间对EMI衬垫的效力产生不确定的可再现性因素。本发明的EMI衬垫材料200已用含约27%的金属的导电纤维生产,其提供的衬垫能够在EMI衬垫材料200仅压缩20%时就可提供10毫欧范围内的X、Y和Z轴电阻率。该较低的压缩要求在计算机系统的组装期间提供了更可再生产的和更坚实的EMI保护。
在先前的混合物配方包括使用可从纽约Albany的Stein Limited获得的绝缘双组分聚酯纤维的同时,醇化聚酯纤维(PETG)如可从Foss Manufacturing获得的T110粘合纤维的使用提供了增强的混合纤维保存。相较于双组分纤维,PETG纤维具有更高的粘合剂含量和增加的抗磨损性。更高的粘合剂含量使纤维从织物结构脱落的可能性最小。在导电纤维网240中优选的PETG纤维含量被发现为约含20%PETG纤维。该百分比被发现是首选的数量,以能在多平面EMI衬垫材料200中在锁定所有混合纤维和保持足够的X、Y和Z轴电传导性之间进行平衡。
为进一步改善多平面EMI衬垫材料200的阻燃性,阻燃腈氯纶(Kanecaron)纤维作为绝缘纤维添加到混合物配方中。在混合物中添加约15%的阻燃纤维,向EMI衬垫材料200提供以更好的抗UL94 HB(水平燃烧)测试能力。EMI衬垫材料200的优选实施例为导电纤维、粘性纤维和阻燃纤维按65∶20∶15的比例形成的纤维混合物。然而,根据最终产品的传导性和屏蔽效应要求,也可调整混合比。
当切割为小的衬垫断面时,EMI衬垫具有更小的机械稳定性。为了使EMI衬垫材料200的拉伸最小并改善其机械稳定性,包括了加强织物260。加强织物260不应与先前公开的硬挺织物30混淆。如前所述,硬挺织物30是绝缘纤维的网,其具有约4∶1(80/20)的低熔点双组分聚酯和常规聚酯的混合物。正是硬挺织物的加热成形特性使得可形成图5所示的各种三维形状。
加强织物260是较硬挺织物30具有更高软化点的织物。加强织物260也被使用针刺法纺织在导电纤维、粘性纤维和阻燃纤维的混合物中。加强织物260提供与硬挺织物30的形状形成能力相对的机械稳定性。多种材料可用作加强织物260,包括但不限于机织玻纤筛网织物、纺粘非机织聚酯织物、经编织物等。机织玻纤筛网织物可从宾夕法尼亚州Mt.Wolf的New York Wire Co.在产品号1816011下获得。纺粘非机织聚酯织物可从田纳西州Nashville的BBA Fiberweb获得,其为每平方米43克的纺粘聚酯织物。经编织物可从北卡罗来纳州Greensboro的Guilford Technical Textiles在类型号37879下获得。
除了使用前面所述的阻燃纤维以外,加强纤维260在两侧均被涂覆以阻燃PVC(聚氯乙烯)涂层。这进一步增加了EMI衬垫200的阻燃性并使得EMI衬垫200的额定燃烧接近于UL94 VO垂直燃烧级别。
图9为制造优选实施例的EMI衬垫材料200的针织机工艺的横断面图。导电纤维网240以分层关系置放到泡沫芯220的一侧222上,加强织物260以分层关系置放在泡沫芯220的另一侧224上从而形成多平面组件。多平面组件250接着经过针织机500,其以非常相似于制造地毯的工艺处理多平面组件250。针织机500将网240的各个纤维243从网240散布穿过泡沫芯220和加强织物260,使得大量单独的纤维243凸出底面225。针织机工艺将纤维网240和加强织物260与泡沫芯220互锁或结合从而形成多平面芯290,而不需要粘合剂。与先前的实施例一样,EMI衬垫材料200经受加热过程以将导电纤维锁定在适当位置。
尽管本发明的优选实施例已在此描述,上面的描述仅是示例性的。对于各个领域的技术人员,可对在此公开的本发明进行进一步的修改,且所有这些修改均被视为在本发明的范围之内。
Claims (32)
1、多平面导电衬垫材料,包括:
泡沫芯;
至少一导电网层,其包括布置在所述泡沫芯的第一侧上的大量导电和绝缘纤维的混合物;
预定数量的所述大量导电和绝缘纤维的所述混合物完全延伸穿过所述泡沫芯。
2、根据权利要求1所述的导电衬垫材料,还包括布置在所述泡沫芯上的加强织物。
3、根据权利要求2所述的导电衬垫材料,其中所述预定数量的所述大量导电和绝缘纤维的所述混合物延伸穿过所述加强织物。
4、根据权利要求1所述的导电衬垫材料,还包括布置在所述至少一导电网层和所述泡沫芯之间的硬挺织物。
5、根据权利要求1所述的导电衬垫材料,还包括布置在所述泡沫芯的第二侧上的第二导电网层。
6、根据权利要求1所述的导电衬垫材料,其中所述大量导电和绝缘纤维的所述混合物被热定形以使导电纤维的移动最小。
7、根据权利要求1所述的导电衬垫材料,其中所述至少一导电网材料中所述导电纤维和所述绝缘纤维具有约1∶1~约3∶1的混合比。
8、根据权利要求1所述的导电衬垫材料,其中所述至少一导电网材料中所述导电纤维和所述绝缘纤维具有至少1∶1的混合比。
9、根据权利要求4所述的导电衬垫材料,所述大量导电和绝缘纤维被热定形以使导电纤维的移动最小。
10、根据权利要求9所述的导电衬垫材料,其中所述热定形包括将所述衬垫材料热压模为预定的形状。
11、根据权利要求1所述的导电衬垫材料,其中所述绝缘纤维包括粘性纤维和阻燃纤维。
12、根据权利要求11所述的导电衬垫材料,其中所述粘性纤维为低熔点纤维。
13、根据权利要求11所述的导电衬垫材料,其中所述导电网层的混合物具有65%∶20%∶15%的导电纤维、粘性纤维和阻燃纤维。
14、根据权利要求1所述的导电衬垫材料,其中所述加强织物具有布置于其上的阻燃涂层。
15、根据权利要求1所述的导电衬垫材料,其中所述导电纤维具有约18%~27%范围内的金属含量。
16、根据权利要求1所述的导电衬垫材料,其中所述导电纤维具有预定量的金属以在压缩约50%或更小时足以使所述导电衬垫材料具有约10毫欧的电阻。
17、形成导电衬垫材料的方法,包括:
将至少一包括导电纤维和绝缘纤维的混合物的导电网层层压在泡沫芯上;及
使用针刺法处理所述导电网层和所述泡沫芯以形成导电合成衬垫材料,其使大量导电纤维散布穿过所述泡沫芯和所述加强织物。
18、根据权利要求17所述的方法,还包括将加强织物层压在所述泡沫芯上。
19、根据权利要求18所述的方法,其中所述针刺法处理步骤还包括针刺穿过所述加强织物。
20、根据权利要求17所述的方法,其中所述导电网层压步骤包括层压包括导电纤维、低软化点纤维和阻燃纤维的混合物的导电网层。
21、根据权利要求17所述的方法,还包括将所述导电合成物加热到所述绝缘纤维的软化点。
22、根据权利要求1 7所述的方法,还包括将第二导电网层层压在所述泡沫芯的另一侧上。
23、根据权利要求22所述的方法,还包括使用针刺法处理所述第二导电网层和所述泡沫芯。
24、根据权利要求17所述的方法,还包括在所述针刺步骤之前在所述至少一导电网层和所述泡沫芯之间层压包括绝缘纤维的绝缘网层。
25、根据权利要求24所述的方法,还包括加热定形所述导电合成衬垫材料。
26、根据权利要求17所述的方法,还包括混合大量导电纤维和大量绝缘纤维以形成所述导电网层。
27、根据权利要求26所述的方法,其中所述混合步骤包括以约1∶1~约3∶1的导电纤维和绝缘纤维混合比混合所述大量导电纤维和所述大量绝缘纤维。
28、根据权利要求26所述的方法,其中所述混合步骤包括以至少约1∶1的导电纤维和绝缘纤维混合比混合所述大量导电纤维和所述大量绝缘纤维。
29、根据权利要求20所述的方法,其中所述方法还包括以约65%的导电纤维、约20%的低软化点纤维和约15%的阻燃纤维的比例混合所述纤维混合物。
30、根据权利要求17所述的方法,还包括在所述加强织物上布置阻燃涂层。
31、根据权利要求17所述的方法,还包括以约18%~约27%范围内的导电金属含量配制所述导电纤维。
32、根据权利要求17所述的方法,还包括以预定量的金属配制所述导电纤维以在压缩约50%或更小时足以使所述导电衬垫材料具有约10毫欧的电阻。
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-
2004
- 2004-04-13 US US10/822,952 patent/US7081292B2/en not_active Expired - Lifetime
- 2004-04-14 ES ES04759855T patent/ES2336449T3/es not_active Expired - Lifetime
- 2004-04-14 JP JP2006510028A patent/JP4939930B2/ja not_active Expired - Lifetime
- 2004-04-14 WO PCT/US2004/011500 patent/WO2004093855A2/en active Application Filing
- 2004-04-14 BR BRPI0409587-1A patent/BRPI0409587B1/pt active IP Right Grant
- 2004-04-14 KR KR1020057019904A patent/KR100903226B1/ko active IP Right Grant
- 2004-04-14 DE DE200460024408 patent/DE602004024408D1/de not_active Expired - Lifetime
- 2004-04-14 MX MXPA05011382A patent/MXPA05011382A/es active IP Right Grant
- 2004-04-14 EP EP20040759855 patent/EP1654917B1/en not_active Expired - Lifetime
- 2004-04-14 CN CNB2004800107215A patent/CN100512615C/zh not_active Expired - Lifetime
- 2004-04-14 AT AT04759855T patent/ATE451006T1/de not_active IP Right Cessation
-
2005
- 2005-11-18 NO NO20055473A patent/NO334849B1/no unknown
-
2006
- 2006-01-06 US US11/306,675 patent/US7353597B2/en not_active Expired - Lifetime
- 2006-02-03 US US11/307,370 patent/US7622407B2/en not_active Expired - Lifetime
- 2006-11-14 HK HK06112497A patent/HK1090794A1/xx not_active IP Right Cessation
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102912509A (zh) * | 2008-05-28 | 2013-02-06 | 瑟尔瑞株式会社 | 带状导电垫 |
CN105472955A (zh) * | 2014-09-26 | 2016-04-06 | 莱尔德电子材料(上海)有限公司 | 屏蔽设备及其制造方法 |
CN113966183A (zh) * | 2019-07-03 | 2022-01-21 | 氧气合伙人有限责任公司 | 抗静电纤维泡沫鞋内底及其制造方法 |
Also Published As
Publication number | Publication date |
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US20040209064A1 (en) | 2004-10-21 |
US7622407B2 (en) | 2009-11-24 |
NO20055473D0 (no) | 2005-11-18 |
MXPA05011382A (es) | 2006-01-30 |
US20060208426A1 (en) | 2006-09-21 |
NO334849B1 (no) | 2014-06-16 |
CN100512615C (zh) | 2009-07-08 |
ES2336449T3 (es) | 2010-04-13 |
BRPI0409587A (pt) | 2006-04-18 |
DE602004024408D1 (de) | 2010-01-14 |
JP4939930B2 (ja) | 2012-05-30 |
ATE451006T1 (de) | 2009-12-15 |
EP1654917A2 (en) | 2006-05-10 |
US20040209065A1 (en) | 2004-10-21 |
US7081292B2 (en) | 2006-07-25 |
WO2004093855A3 (en) | 2005-02-03 |
JP2006524917A (ja) | 2006-11-02 |
NO20055473L (no) | 2005-11-28 |
US20060199458A1 (en) | 2006-09-07 |
US7353597B2 (en) | 2008-04-08 |
KR100903226B1 (ko) | 2009-06-17 |
WO2004093855A2 (en) | 2004-11-04 |
BRPI0409587B1 (pt) | 2017-10-31 |
EP1654917B1 (en) | 2009-12-02 |
US7022405B2 (en) | 2006-04-04 |
KR20060003036A (ko) | 2006-01-09 |
HK1090794A1 (en) | 2006-12-29 |
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