TWM663384U - Fiber with conductive layer - Google Patents

Abstract

This invention relates to a fiber with a conductive layer, which includes a fiber substrate and a conductive layer. The conductive layer is coated on the outer surface of the fiber substrate, and the conductive layer has an anti-settling agent, a bonding resin and a conductive material, wherein the conductive material is single-walled carbon nanotubes, multi-walled carbon nanotubes or metal particles; the conductive layer is completely coated on the outer surface of the fiber substrate to have good conductive properties.

Description

Fiber with conductive layer

This invention is related to a fiber with a conductive layer, in which a conductive layer is coated on the outer surface of a fiber substrate by a coating method, so that the fiber has a conductive layer completely covered by a conductive material.

Currently, textile products such as thermostatic clothing, physiological sensing clothing and embedded electronic clothing have been developed. They combine conductive materials with textile fibers, weave the fibers into conductive fabrics, and finally make various clothing, so that the clothing worn on the human body can receive and send electronic signals. Such clothing is called smart textiles and can be applied to sports and fitness, medical care, home life, fashion and entertainment, and military security. In addition to directly combining conductive materials with fibers to make conductive fabrics, there is also a method of combining conductive inks or conductive films with clothing. It can be seen that the research and development of smart textiles has gradually become a trend in the future textile industry.

US Patent Publication No. US 20180187077 A1 discloses a conductive fiber with a metal coating, which first deposits a nickel metal layer on the fiber by chemical plating, and then electroplates one or more layers of metal materials such as tin, nickel, copper, silver or gold on the nickel metal layer. Although the metal material can be plated on the surface of the fiber material by chemical plating and electroplating, the electroplating process itself will produce industrial wastewater, which contains toxic heavy metals and cyanide. Therefore, the industrial wastewater produced by electroplating needs to be treated by back-end equipment before it can be discharged or recycled, which will lead to a significant increase in manufacturing costs.

Furthermore, in the past, when making conductive fabrics, a whole piece of fabric is usually coated with conductive materials to make the surface of the fabric have a conductive layer, and then cut into pieces to make clothing. However, the conductive fabric that has been cut does not have a conductive layer formed on the cut surface, and its conductivity is relatively insufficient. Therefore, how to provide a fiber material that can be completely coated with conductive materials, which can be environmentally friendly and reduce manufacturing costs during manufacturing, is the direction that the creator of this invention has been thinking about.

Today, the creator has found that the above-mentioned existing conductive fibers still have many deficiencies in actual implementation, so he improved them with his rich professional knowledge and many years of practical experience, and developed this creation based on this.

The main purpose of this invention is to provide a fiber with a conductive layer, in which the conductive layer is coated on the outer surface of the fiber substrate, so that the fiber will not be cut or weaved, and the scope of the conductive layer coating is reduced. This invention has better conductivity.

In order to achieve the above-mentioned implementation purpose, the present invention provides a fiber with a conductive layer, which includes a fiber substrate having an outer surface; and a conductive layer having an anti-settling agent, a bonding resin and a conductive material, the conductive layer is coated on the outer surface of the fiber substrate, and the conductive material is single-walled carbon nanotubes, multi-walled carbon nanotubes or metal particles.

In one embodiment of the present invention, the thickness of the conductive layer is 5 μm-300 μm.

In one embodiment of the present invention, the resistance of the conductive layer is 10 ^-4 -10 ⁸ Ω/cm.

In one embodiment of the present invention, the Denier number of the fiber substrate coated with the conductive layer increases by 5-300% compared to the fiber substrate not coated with the conductive layer.

In one embodiment of the present invention, the conductive layer further comprises a conductive polymer material.

In one embodiment of the present invention, the conductive polymer material is poly(3,4-ethylenedioxythiophene): poly(styrenesulfonate), PEDOT:PSS.

In one embodiment of the present invention, the conductive layer further includes a dye.

In one embodiment of the present invention, the fiber substrate is natural fiber, synthetic fiber, woven fabric, non-woven fabric or film, and the fiber substrate is dyed or undyed.

In one embodiment of the present invention, at least one of the anti-settling agents is selected from the group consisting of sodium carboxyethyl cellulose (CMC), ammonium salt of polycarboxylic acid, polysulfonate, polyether salts, hydrogenated nitrile rubber (H-NBR), sodium salt of polynaphthalene sulphonic acid (NNO), gamma-butyrolactone (GBL), isophorone, butyl acetate and ethyl acetate.

In one embodiment of the present invention, the adhesive resin is at least one selected from the group consisting of waterborne polyurethane, thermoplastic polyurethane, polyester resin, poly(ethyl acrylate), polyacrylic acid resin, poly(butyl acrylate), unsaturated polyester resins, polyamide resin, polyvinyl acetate (PVA), water-based rubber and water-based epoxy resin.

Please refer to FIG. 1 and FIG. 2 . The fiber 1 with a conductive layer of the present invention mainly comprises a fiber substrate 11 and a conductive layer 13 completely covering the outer surface 12 of the fiber substrate 11 , as shown in FIG. 1 . The conductive layer 13 comprises an anti-settling agent 131 , an adhesive resin 132 and a conductive material 133 .

When manufacturing the fiber 1 of this invention, the steps S1 to S3 are performed in sequence, as shown in FIG2 . Step S1: Use water as a solvent, add an anti-settling agent 131 into the water and mix them evenly, then add a bonding resin 132 to the mixture of water and the anti-settling agent 131. The bonding resin 132 is thick, so it needs to be placed in an ultrasonic oscillator. After ultrasonic oscillation, the bonding resin 132, water and the anti-settling agent 131 are evenly mixed, and then a conductive material 133 is added to the water, the anti-settling agent 131 and the bonding resin 132. 2, since the conductive material 133 is in a granular form, the mixed liquid to which the conductive material 133 is added needs to be placed in a bead mill, and the grinding beads of the bead mill grind the conductive material 133 and evenly disperse it in the mixed liquid. The anti-settling agent 131 allows the conductive material 133 to be more easily and evenly dispersed in the adhesive resin 132, thereby improving the overall conductive effect. The mixed liquid is then taken out of the bead mill to prepare a liquid phase resin.

Step S2: Take a fiber substrate 11, which may be, for example, natural fiber, synthetic fiber, woven fabric, nonwoven fabric or film, and transport the fiber substrate 11 at a speed of 10-200 m/min. Apply a liquid resin to the outer surface 12 of the fiber substrate 11 by a coating method. Then, through a thickness control procedure, control the thickness of the liquid resin on the outer surface 12 of the fiber substrate 11 to be 5 μm-300 μm.

Step S3: Continuously perform a high temperature carbonization process or a metallization process, subjecting the fiber substrate 11 coated with the liquid phase resin to a first high temperature carbonization treatment or a metallization treatment in a reaction chamber at a temperature of 100°C-180°C, and then stretching the fiber substrate 11, and then transporting it to a reaction chamber at a temperature of 100°C-180°C for a second high temperature carbonization treatment or a metallization treatment, and then stretching the fiber substrate 11, so that the liquid phase resin coated on the outer surface 12 of the fiber substrate 11 is completely cured and fixed, so as to obtain a fiber substrate 11 with a conductive layer 13 on the outer surface 12, and finally the fiber substrate 11 is rolled up and stored by a winder.

In the step S1 of preparing the liquid phase resin, in addition to adding the adhesive resin 132 to the mixture of water and the anti-settling agent 131, a conductive polymer material may be added to increase the electrical performance of the liquid phase resin, as shown in FIG. 3 .

Furthermore, in step S1, a dye can be added at the same time as the conductive material 133 is added. After being mixed and dispersed in a bead mill, the liquid phase resin takes on the color of the dye, so that the conductive layer 13 coated with the fiber substrate 11 has a color, which can be applied to different textile designs, as shown in FIG4 ; wherein the dye is a nylon dye or a polyester dye. The conductive layer 13 with the dye can also be matched with the color of the fiber substrate 11, so that the fiber 1 takes on different colors.

Thus, the conductive layer 13 of the fiber 1 with a conductive layer may include not only the anti-settling agent 131, the adhesive resin 132 and the conductive material 133, but also a conductive polymer material (not shown) and a dye (not shown).

The raw materials used for the conductive layer 13 of this invention are all water-based, and the liquid resin is coated on the fiber substrate 11 by a coating method, which can avoid the generation of industrial wastewater and does not require the construction of additional equipment to treat industrial wastewater. This invention has the advantages of both environmental protection and low manufacturing cost.

The following provides various embodiments to illustrate the application of the anti-settling agent 131, the adhesive resin 132, the conductive material 133, the conductive polymer material and the dye of the creative fiber 1.

Embodiment 1

The liquid resin of Example 1 includes 65-90 wt % of water, 1-5 wt % of an anti-settling agent 131, 1-5 wt % of a binder resin 132, and 5-15 wt % of a conductive material 133.

Preferably, the composition is 75-85 wt% water, 1.5-3.5 wt% sodium carboxymethyl cellulose, 2-4 wt% water-based rubber and polyacrylic acid resin, and 7-13 wt% multi-walled carbon nanotubes.

The size of the multi-walled carbon nanotubes is 2-200 μm and the color is black. After the high-temperature carbonization process, the conductive layer 13 of the outer surface 12 of the fiber substrate 11 appears black. Therefore, the first embodiment is suitable for matching with a dark fiber substrate 11. If it is matched with a blue or red fiber substrate 11, the color of the fiber 1 is dark blue or dark red.

The fiber substrate 11 is made of dark synthetic fiber PET (Polyethylene terephthalate), which is a synthetic fiber yarn or woven fabric, and is coated with the liquid phase resin of Example 1. Its electrical resistance is 10 ¹ -10 ² Ω/cm, and its color fastness to washing according to the AATCC 61 test standard reaches level 4-5, and its color fastness to light according to the AATCC 16.3 test standard is level 4. Compared with the fiber substrate 11 not coated with the conductive layer 13, the denier number is increased by 10-20%.

Embodiment 2

The liquid resin of Example 2 contains 88.5-98.9 wt % of water, 0.01-2 wt % of an anti-settling agent 131, 1-10 wt % of a binder resin 132, and 0.005-1.0 wt % of a conductive material 133. Example 2 provides four different formulations.

Preferably, the composition is 89.5-97.5 wt% water, 0.03-1.5 wt% naphthalenesulfonic acid formaldehyde condensation polymer sodium salt, 2-6 wt% water-based rubber and unsaturated polyester resin, and 0.006-0.04 wt% single-walled carbon nanotubes.

Preferably, the composition is 89-95 wt% water, 0.05-1.5 wt% naphthalenesulfonic acid formaldehyde condensation polymer sodium salt, 2-8 wt% water-based rubber and unsaturated polyester resin, and 0.008-0.8 wt% single-walled carbon nanotubes.

Preferably, the composition is 90-96 wt% water, 0.02-1.2 wt% sodium carboxymethyl cellulose, 2-8 wt% water-based rubber and unsaturated polyester resin, and 0.01-0.04 wt% single-walled carbon nanotubes.

Preferably, the composition is 89-96 wt% water, 0.2-1.2 wt% sodium carboxymethyl cellulose, 2-7 wt% water-based rubber and unsaturated polyester resin, and 0.009-0.8 wt% single-walled carbon nanotubes.

The size of the single-walled carbon nanotubes is 2-200 μm and the color is black. Depending on the amount used and after the high-temperature carbonization process, the conductive layer 13 of the outer surface 12 of the fiber substrate 11 will appear black or light gray. Therefore, if the second embodiment is matched with a blue or red fiber substrate 11, the color of the fiber 1 is dark blue, light blue, dark red or light red.

The fiber substrate 11 is made of a plurality of synthetic fiber PET, which is a synthetic fiber yarn or a woven fabric, and is coated with the liquid phase resin of Example 2. Its electrical resistance is 10 ² -10 ⁷ Ω/cm, and its color fastness to washing according to the AATCC 61 test standard reaches level 4-5, and its color fastness to light according to the AATCC 16.3 test standard is level 4. Compared with the fiber substrate 11 not coated with the conductive layer 13, the denier number is increased by 10-20%.

Embodiment 3

The liquid resin of Example 3 includes 70-90 wt% of water, 0.001-0.5 wt% of an anti-settling agent 131, 1-10 wt% of a binder resin 132, 5-30 wt% of a conductive polymer material, and 0.005-0.05 wt% of a conductive material 133.

The preferred composition is 72-85 wt% water, 0.005-0.3 wt% naphthalenesulfonic acid formaldehyde condensate sodium salt, 2-7 wt% waterborne polyurethane and polyester resin, 10-25 wt% poly(ethylenedioxythiophene):polystyrenesulfonic acid, and 0.009-0.04 wt% single-walled carbon nanotubes.

The amount of single-walled carbon nanotubes in the liquid phase resin is relatively small, and after the high-temperature carbonization process, the conductive layer 13 of the outer surface 12 of the fiber substrate 11 appears light gray. Therefore, the third embodiment can be used with a fiber substrate 11 of any color. If it is used with a blue or red fiber substrate 11, the color of the fiber 1 is light blue or light red.

The fiber substrate 11 is made of a plurality of synthetic fiber PET, which is a synthetic fiber yarn or a woven fabric, and is coated with the liquid phase resin of Example 3. Its electrical resistance is 10 ⁴ -10 ⁵ Ω/cm, and its color fastness to washing according to the AATCC 61 test standard reaches level 4-5, and its color fastness to light according to the AATCC 16.3 test standard is level 4. Compared with the fiber substrate 11 not coated with the conductive layer 13, the denier number is increased by 10-15%.

Embodiment 4

The liquid resin of Example 4 includes 10-20 wt% of water, 0.001-0.5 wt% of an anti-settling agent 131, 1-10 wt% of a bonding resin 132, 70-90 wt% of a conductive polymer material, and 0.005-0.05 wt% of a conductive material 133.

The preferred composition is 12-18 wt% water, 0.005-0.4 wt% naphthalenesulfonic acid formaldehyde condensate sodium salt, 2-8 wt% waterborne polyurethane and polyester resin, 75-88 wt% poly(ethylenedioxythiophene):polystyrenesulfonic acid, and 0.008-0.03 wt% single-walled carbon nanotubes.

The amount of single-walled carbon nanotubes in the liquid phase resin is relatively small, and after the high-temperature carbonization process, the conductive layer 13 of the outer surface 12 of the fiber substrate 11 appears light gray. Therefore, the fourth embodiment can be used with a fiber substrate 11 of any color. If it is used with a blue or red fiber substrate 11, the color of the fiber 1 is light blue or light red.

The fiber substrate 11 is made of a plurality of synthetic fiber PET or PA6 (Polyamide 6), which is a synthetic fiber yarn or woven fabric, and is coated with the liquid phase resin of Example 4. The resistivity is 10 ¹ -10 ³ Ω/cm, the color fastness to washing according to the AATCC 61 test standard reaches level 4-5, and the color fastness to light according to the AATCC 16.3 test standard is level 4. Compared with the fiber substrate 11 not coated with the conductive layer 13, the denier number is increased by 10-20%.

Embodiment 5

The liquid resin of Example 5 includes 10-40 wt % of water, 0.001-0.5 wt % of an anti-settling agent 131, 1-10 wt % of a binder resin 132, 5-20 wt % of a conductive polymer material, 0.001-0.05 wt % of a conductive material 133, and 40-70 wt % of a dye.

Preferably, the composition is 15-35 wt% water, 0.005-0.35 wt% naphthalenesulfonic acid formaldehyde condensate sodium salt, 2-8 wt% waterborne polyurethane and polyester resin, 8-18 wt% poly(ethylenedioxythiophene):polystyrenesulfonic acid, 0.001-0.03 wt% single-walled carbon nanotubes and 45-65 wt% titanium dioxide (TiO ₂ ).

The amount of single-walled carbon nanotubes in the liquid phase resin is relatively small, and titanium dioxide is used as a dye. After a high-temperature carbonization process, the conductive layer 13 on the outer surface 12 of the fiber substrate 11 will appear white. Example 5 is suitable for matching with a white fiber substrate 11.

The fiber substrate 11 is made of white synthetic fiber PET and coated with the liquid resin of Example 5. Its electrical resistance is 10 ⁶ -10 ⁷ Ω/cm, and its color fastness to washing according to the AATCC 61 test standard reaches level 4-5. Its color fastness to light according to the AATCC 16.3 test standard is level 3. Compared with the fiber substrate 11 not coated with the conductive layer 13, its denier number increases by 25-40%.

Embodiment 6

The liquid resin of Example 6 includes 0.1-10 wt% of water, 15-40 wt% of an anti-settling agent 131, 3-15 wt% of a binder resin 132, and 20-80 wt% of a conductive material 133. The conductive material 133 of Example 6 is made of metal particles with a particle size of 0.5-20 μm, such as gold, silver, copper, nickel, tin, cobalt, aluminum, zinc, and tungsten. Example 6 provides three different formulations.

Preferably, the composition comprises 1.5-8.5 wt% of water, 16-36 wt% of γ-butyrolactone, isophorone, n-butyl acetate and ethyl acetate, 4-10 wt% of waterborne polyurethane and polyester resin or polyamide resin, and 50-80 wt% of metal particles, wherein the metal particles are composed of 10-20 wt% of silver and 50-60 wt% of copper.

Preferably, the composition is 2-8 wt% water, 15-35 wt% n-butyl acetate and ethyl acetate, 4-10 wt% waterborne polyurethane and polyester resin or polyamide resin, and 55-75 wt% silver.

Preferably, the composition is 2-8 wt% water, 15-35 wt% n-butyl acetate and ethyl acetate, 4-10 wt% waterborne polyurethane and polyester resin or polyamide resin, and 55-75 wt% copper.

The metal particles have an original metal color. After the metallization process, the conductive layer 13 on the outer surface 12 of the fiber substrate 11 presents the metal color of the selected metal particles. Therefore, if the sixth embodiment is matched with a fiber substrate 11 of any color, the fiber 1 will present the metal color of the selected metal particles.

The fiber substrate 11 is made of a plurality of synthetic fiber PET or PA6, which are synthetic fiber yarns or woven fabrics, and is coated with the liquid phase resin of Example 6. The resistivity is 10 ^-4 -10 ^-1 Ω/cm, the color fastness to washing according to the AATCC 61 test standard reaches level 4-5, and the color fastness to light according to the AATCC 16.3 test standard is level 4. Compared with the fiber substrate 11 not coated with the conductive layer 13, the denier number is increased by 110-120%.

From the above implementation description, it can be seen that compared with the prior art, this invention has the following advantages:

1. This invention has a conductive layer of fiber. The conductive layer is completely coated on the outer surface of the fiber substrate. After subsequent cutting or weaving processes, the fiber will not reduce the coverage of the conductive layer, and can provide good conductivity. It can be applied to EMI protection, military and police supplies, electronic equipment, smart clothing, aerospace technology, medical peripherals and server computing.

2. This invention has a conductive layer of fiber, which contains an anti-settling agent, which allows the conductive material to be dispersed more easily and evenly in the adhesive resin to provide a better conductive effect.

1: Fiber 11: Fiber substrate 12: Outer surface 13: Conductive layer 131: Anti-settling agent 132: Adhesive resin 133: Conductive material S1~S3: Steps

Figure 1 is a structural cross-sectional view of the present invention; Figure 2 is a manufacturing flow chart of the present invention; Figure 3 is a manufacturing flow chart of the conductive polymer material of the present invention; and Figure 4 is a manufacturing flow chart of the dye of the present invention.

1: Fiber

11: Fiber substrate

12: External surface

13: Conductive layer

131: Anti-settling agent

132: Adhesive resin

133: Conductive materials

Claims (10)

A fiber with a conductive layer comprises: a fiber substrate having an outer surface; and a conductive layer having an anti-settling agent, a bonding resin and a conductive material, wherein the conductive layer is coated on the outer surface of the fiber substrate, and the conductive material is single-walled carbon nanotubes, multi-walled carbon nanotubes or metal particles. The fiber with a conductive layer as described in claim 1, wherein the thickness of the conductive layer is 5 µm-300 µm. The fiber having a conductive layer as claimed in claim 1, wherein the resistance of the conductive layer is 10 ^-4 -10 ⁸ Ω/cm. The fiber with a conductive layer as described in claim 1, wherein the Denier number of the fiber substrate coated with the conductive layer is increased by 5-300% compared to the fiber substrate not coated with the conductive layer. The fiber with a conductive layer as described in claim 1, wherein the conductive layer further comprises a conductive polymer material. The fiber with a conductive layer as described in claim 5, wherein the conductive polymer material is poly(3,4-ethylenedioxythiophene): poly(styrenesulfonate), PEDOT:PSS. The fiber having a conductive layer as described in claim 1, wherein the conductive layer further comprises a dye. The fiber with a conductive layer as described in claim 1, wherein the fiber substrate is natural fiber, synthetic fiber, woven fabric, non-woven fabric or film, and the fiber substrate is dyed or undyed. The fiber with a conductive layer as described in claim 1, wherein the anti-settling agent is at least one selected from the group consisting of sodium carboxyethyl cellulose (CMC), ammonium salt of polycarboxylic acid, polysulfonate, polyether salts, hydrogenated nitrile rubber (H-NBR), sodium salt of polynaphthalene sulphonic acid (NNO), gamma-butyrolactone (GBL), isophorone, butyl acetate and ethyl acetate. The fiber with a conductive layer as described in claim 1, wherein the adhesive resin is at least one selected from the group consisting of waterborne polyurethane, thermoplastic polyurethane, polyester resin, poly(ethyl acrylate)), polyacrylic acid resin, poly(butyl acrylate)), unsaturated polyester resin, polyamide resin, polyvinyl acetate (PVA), water-based rubber and water-based epoxy resin.

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