US20050170177A1 - Conductive filament - Google Patents
Conductive filament Download PDFInfo
- Publication number
- US20050170177A1 US20050170177A1 US10/767,668 US76766804A US2005170177A1 US 20050170177 A1 US20050170177 A1 US 20050170177A1 US 76766804 A US76766804 A US 76766804A US 2005170177 A1 US2005170177 A1 US 2005170177A1
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- US
- United States
- Prior art keywords
- component
- yarn
- conductive
- carbon nanotubes
- filament
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 52
- 239000002041 carbon nanotube Substances 0.000 claims abstract description 34
- 229910021393 carbon nanotube Inorganic materials 0.000 claims abstract description 34
- 239000000203 mixture Substances 0.000 claims abstract description 16
- 239000000463 material Substances 0.000 claims abstract description 14
- 229910052799 carbon Inorganic materials 0.000 claims description 18
- 229920000642 polymer Polymers 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 13
- -1 polypropylene Polymers 0.000 claims description 12
- 239000002952 polymeric resin Substances 0.000 claims description 11
- 229920003002 synthetic resin Polymers 0.000 claims description 11
- 229920000728 polyester Polymers 0.000 claims description 8
- 229920005989 resin Polymers 0.000 claims description 7
- 239000011347 resin Substances 0.000 claims description 7
- 239000004952 Polyamide Substances 0.000 claims description 6
- 229920002647 polyamide Polymers 0.000 claims description 6
- 239000004696 Poly ether ether ketone Substances 0.000 claims description 5
- 239000004698 Polyethylene Substances 0.000 claims description 5
- 239000004734 Polyphenylene sulfide Substances 0.000 claims description 5
- 239000004743 Polypropylene Substances 0.000 claims description 5
- JUPQTSLXMOCDHR-UHFFFAOYSA-N benzene-1,4-diol;bis(4-fluorophenyl)methanone Chemical compound OC1=CC=C(O)C=C1.C1=CC(F)=CC=C1C(=O)C1=CC=C(F)C=C1 JUPQTSLXMOCDHR-UHFFFAOYSA-N 0.000 claims description 5
- 229920002530 polyetherether ketone Polymers 0.000 claims description 5
- 229920000573 polyethylene Polymers 0.000 claims description 5
- 229920000069 polyphenylene sulfide Polymers 0.000 claims description 5
- 229920001155 polypropylene Polymers 0.000 claims description 5
- 229920002994 synthetic fiber Polymers 0.000 claims 2
- 239000003575 carbonaceous material Substances 0.000 claims 1
- 239000004744 fabric Substances 0.000 description 7
- 239000000835 fiber Substances 0.000 description 6
- SZUVGFMDDVSKSI-WIFOCOSTSA-N (1s,2s,3s,5r)-1-(carboxymethyl)-3,5-bis[(4-phenoxyphenyl)methyl-propylcarbamoyl]cyclopentane-1,2-dicarboxylic acid Chemical compound O=C([C@@H]1[C@@H]([C@](CC(O)=O)([C@H](C(=O)N(CCC)CC=2C=CC(OC=3C=CC=CC=3)=CC=2)C1)C(O)=O)C(O)=O)N(CCC)CC(C=C1)=CC=C1OC1=CC=CC=C1 SZUVGFMDDVSKSI-WIFOCOSTSA-N 0.000 description 5
- 238000000576 coating method Methods 0.000 description 5
- 229940126543 compound 14 Drugs 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 4
- 239000007977 PBT buffer Substances 0.000 description 3
- XRWSZZJLZRKHHD-WVWIJVSJSA-N asunaprevir Chemical compound O=C([C@@H]1C[C@H](CN1C(=O)[C@@H](NC(=O)OC(C)(C)C)C(C)(C)C)OC1=NC=C(C2=CC=C(Cl)C=C21)OC)N[C@]1(C(=O)NS(=O)(=O)C2CC2)C[C@H]1C=C XRWSZZJLZRKHHD-WVWIJVSJSA-N 0.000 description 3
- 229940125961 compound 24 Drugs 0.000 description 3
- 239000004020 conductor Substances 0.000 description 3
- 239000002071 nanotube Substances 0.000 description 3
- 229920001707 polybutylene terephthalate Polymers 0.000 description 3
- 229920002215 polytrimethylene terephthalate Polymers 0.000 description 3
- FDSYTWVNUJTPMA-UHFFFAOYSA-N 2-[3,9-bis(carboxymethyl)-3,6,9,15-tetrazabicyclo[9.3.1]pentadeca-1(15),11,13-trien-6-yl]acetic acid Chemical compound C1N(CC(O)=O)CCN(CC(=O)O)CCN(CC(O)=O)CC2=CC=CC1=N2 FDSYTWVNUJTPMA-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 210000001367 artery Anatomy 0.000 description 1
- 238000009954 braiding Methods 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 239000002482 conductive additive Substances 0.000 description 1
- 229920001940 conductive polymer Polymers 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
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- 239000004417 polycarbonate Substances 0.000 description 1
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- 239000004753 textile Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Images
Classifications
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/09—Addition of substances to the spinning solution or to the melt for making electroconductive or anti-static filaments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D11/00—Other features of manufacture
- D01D11/06—Coating with spinning solutions or melts
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/40—Yarns in which fibres are united by adhesives; Impregnated yarns or threads
- D02G3/404—Yarns or threads coated with polymeric solutions
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/44—Yarns or threads characterised by the purpose for which they are designed
- D02G3/441—Yarns or threads with antistatic, conductive or radiation-shielding properties
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2101/00—Inorganic fibres
- D10B2101/10—Inorganic fibres based on non-oxides other than metals
- D10B2101/12—Carbon; Pitch
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2933—Coated or with bond, impregnation or core
Definitions
- Filament a shaped body, usually formed of polymeric material, of relatively small cross section and of indefinite length.
- Multi-Component Yarn A yarn formed of two or more different materials and/or of two or more different yarns.
- Carbon nanotubes which have recently been developed, are essentially very fine carbon fibers. This nano size allows the use of a low percentage of carbon in a polymeric composition while providing for the requisite conductive properties.
- Another object of the invention is a multi-component conductive yarn in which no component includes more than 20% carbon by weight.
- Another object of the invention is a multi-component conductive yarn which contains less than 10% carbon by weight.
- Another object of the invention is a multi-component conductive yarn which includes a plurality of components, at least one of which is a conductive filament.
- Another object of the invention is the provision of a multi-component yarn with a conductive sheath secured to a non-conductive core.
- Another object of the invention is a multi-component conductive yarn in which multiple components include carbon nanotubes which form the electrical conductor.
- Another object of the invention is a multi-component conductive yarn which is physically resilient.
- the invention is intended for use in a variety of applications including, but not limited to, lay belts, conveyor belts, braiding, industrial textiles, filtration, paper machine clothing, IFBC shipping bags, upholstery, home furnishings, hook and loop, carpets, apparel, nonwovens, brushes and process forming belts.
- the invention is directed to a multi-component conductive yarn and the method of forming.
- the yarn comprises a primary component and a secondary component.
- the primary component consists of an elongated filament formed from polymeric material.
- the secondary component consists of a fiber of a polymeric material and carbon nanotubes which is bonded with the primary component along its length.
- the carbon included in the secondary component includes up to 20% by mass of carbon nanotubes.
- the secondary component when combined with the first component provides a conductive yarn which comprises no more than 10% carbon nanotubes by weight.
- the polymeric material forming the primary component may be one of any melt-spinnable polymer, preferred is one of or a blend of polyester (such as PET, PTT, PBT, PCTA, Polycarbonate, etc.), polyamide, PPS, polypropylene, polyethylene and/or PEEK.
- the polymeric material of said secondary component includes at least 80% of one of polyester, polyamide, PTT, PBT, PPS, polypropylene, polyethylene and PEEK while carbon nanotubes comprise the remainder of the makings of the component.
- the secondary component may comprise a sheath surrounding the filament of the primary component.
- the secondary component may comprise an elongated filament bonded with the filament of the primary component along its length.
- the secondary component may wrap around the primary component as it extends along its length.
- the secondary component may comprise between 0.5% and 50% by weight of the multi-component yarn while the carbon nanotubes may comprise up to 20% by weight, preferred no more than 15% by weight, of the secondary component.
- the primary component may be a yarn which has been stretched and heat set prior to being combined with the secondary component.
- the first and second components may be extruded simultaneously and joined forming the multi-component yarn.
- the so formed yarn may then be stretched and heat set.
- Such a yarn is called a heterofilament yarn.
- the invention further includes a method of forming a conductive multi-component yarn.
- the method includes the steps of providing at least a first component consisting of at least one elongated filament of polymeric material. Also, providing at least a second component consisting of a composition including a polymeric resin and carbon nanotubes. Limiting the carbon nanotubes to between 0.5% to 20% of the composition of the second component. Passing the first component through a crosshead extruder in the form of a filament while the second component is extruded onto the first component causing it to bond therewith forming the composite yarn as a core filament comprised of the first component with a conductive sheath formed there about. This type of yarn is called a coated yarn.
- the method may comprise simultaneously extruding the first and second components forming multiple filaments and causing the filaments to bond together along their length. This type of yarn is called bonded filaments.
- FIG. 1 is a schematic view showing a process forming a multi-component yarn of the invention. It is the coating process of the first component with a second component by a crosshead extruder.
- FIG. 2 is a schematic view showing another process for forming a multi-component yarn of the invention.
- FIG. 3A is a cross sectional view of a multi-component yarn of the invention.
- FIG. 3B is a cross sectional view of another multi-component yarn of the invention.
- FIG. 3C is a cross sectional view of another multi-component yarn of the invention.
- FIG. 3D is a cross sectional view of another multi-component yarn of the invention.
- FIG. 3E is a cross-sectional view of another multi-component yarn of the invention.
- FIG. 3F is a cross-sectional view of another multi-component yarn of the invention.
- FIG. 3G is a cross-sectional view of another multi-component yarn of the invention.
- FIG. 4 is a diagrammatic view showing aligned nanotubes.
- Carbon nanotubes are extremely small conductive elements which have found use with polymers as a conductive additive.
- a primary advantage of carbon nanotubes is that they possess a higher aspect ratio than carbon black particles or chopped carbon which allows for a lower additive loading while maintaining adequate levels of conductivity.
- Carbon nanotubes comprise elongated particles which tend to intertwine and have a low sensitivity to shear fields. This provides the capability of elongating the polymeric resin containing carbon nanotubes without entirely severing the carbon nanotube agglomerates which are formed within the polymer.
- FIG. 4 schematically shows generally the manner in which carbon nanotubes can be distributed in a polymeric resin.
- the instant invention provides to overcome these drawbacks by providing a conductive multi-component yarn which retains the desired physical characteristics, is flexible and does not peel or crack.
- a supply 10 comprising a set filament 12 is seen being passed through at least one but preferably a plurality of extruder dies which extrude a coating or adhering resin compound 14 onto the filament 12 as it passes.
- Resin compound 14 in this instance, forms a sheath 16 about filament 12 .
- sheath 16 is allowed to solidify and the multi-component yarn 18 is simply rewound for shipment.
- the multi-component yarn could be passed between draw rolls and through an oven where the yarn is stretched, relaxed, or both and then heat set.
- the multi-component yarn 18 may comprise a core usually formed of a polyester (such as PET, PTT, PBT, PCTA, etc) or a polyamide fiber.
- the core could alternatively be polypropylene, polyethylene, PPS, PEEK or other melt-spinnable polymers or a blend of these polymers.
- the core may comprise one or a plurality of filaments. It can also be a yarn made of natural fibers and staple fibers.
- the sheath comprises a polymer, again usually a polyester or a polyamide combined with carbon nanotubes. Again, the above listed resins could also comprise the polymer forming the sheath.
- Resin compound 14 comprises between 0.5% to 20% carbon nanotubes and between 80% to 99.5% polyester or other polymer or blend of polymers.
- Sheath 16 comprises between 0.5% to 50% of the mass of the multi-component yarn while core 12 forms between 50% to 99.5% of the multi-component yarn.
- the nanotubes within resin 14 are interspersed along the length of the sheath and about the core providing a conductive artery along the length of the multi-component yarn.
- the percentage of the multi-component yarn consisting of carbon nanotubes is between 0.5% and 15%. Such a low percentage of carbon allows the resins forming the compound 14 to maintain substantially all of their normal features such as elasticity, strength and elongation. Normally the core of the multi-component yarn retains all of its usual characteristics as it is formed of 100% polymer.
- yarn 12 is pre-formed but not set.
- Yarn 12 is drawn from supply 10 and passes through the extruders extruding compound 14 producing yarn 18 as earlier described.
- the just formed multi-component yarn is passed between draw rolls and through an oven where the yarn is stretched, relaxed, or both and then heat set. Both the core 12 and sheath 16 are treated and then set. This is possible due to the innate characteristics of carbon nanotubes which are not so easily separated but remain substantially in contact and because of the limited percentage of nanotubes present in the sheath 16 .
- FIG. 2 Other arrangements are shown in FIG. 2 .
- a pair of extruders 20 , 22 are shown. Extruder 20 extrudes the core yarn 12 while extruder 22 extrudes the second component 24 .
- the extruders are controlled in known manner which allows the second component 24 to adhere to core 12 along its length in the form of an elongated filament 28 .
- FIG. 2 also represents the heterofilament process. In this case both components are molten in their extruders 20 and 22 and pressed into a special designed spinhead in which both components are simultaneously spun into a multi-component yarn 28 .
- the multi-component yarn 28 shown in FIG. 3 is passed between draw rolls 30 , stretched and/or relaxed and then heat set by heater 32 .
- component 24 may be dispensed in the form of sheath 16 as shown in FIG. 3A which encases the core along its length.
- the extruded compound 24 can be controlled to attach to the core 12 in the form of a wedge shaped filament 26 or an additional filament 26 which extends along the length and is wrapped about its axis of core 12 as shown in FIGS. 3B and 3E .
- Another arrangement could be for core 12 to be arranged on opposed sides of compound 24 which assumes the form of a conductive strip 26 ′ which extends along the length of core 12 as shown in FIG. 3C .
- the extruded compound 24 could form a plurality of wedge shaped filaments 26 or additional filaments 26 which are arranged along the length of core 12 as shown in FIGS.
- FIG. 3D and 3F Another arrangement could be for core 12 to be first coated by sheath 36 and then by conductive sheath 16 .
- Sheath 36 which is preferably a low melt polymer, adhesive type polymer, co-polyester or other suitable material, provides an intermediate layer which provides increased adhesion between the core 12 and the conductive sheath 16 .
- filaments 26 and strips 26 ′ form a conductive filament which is adhered with core 12 along its length.
- the percentage of the first component or core polymer and the percentage of the second component or conductive polymer+carbon nanotubes remains within the set forth limits.
- the core could consist of a plurality of filaments which are preferably but not necessarily of the same polymer.
- the core could consist of a blend of polymers.
- the sheath or conductive filament could consist of a blend of polymers combined with the carbon nanotubes.
- the multi-component conductive yarn of the invention is intended for use with a multiple of fabric types such as woven fabrics, knitted fabrics, braided fabrics, non-woven fabrics, interlaid fabrics and composite fabrics.
- the yarn is intended to comprise varying selected percents of yarns forming these fabrics. Also, the yarn is intended for use with any combination of the above fabric types.
Abstract
Description
- Filament—a shaped body, usually formed of polymeric material, of relatively small cross section and of indefinite length.
- Yarn—here: A product formed of at least one filament (=monofilament) or an assembly of filaments (=multifilament)
- Multi-Component Yarn—A yarn formed of two or more different materials and/or of two or more different yarns.
- Conductivity—definition of what is considered to be conductive
- It has long been known to produce conductive yarns from thermoplastic polymers which are combined with a conductive material such as carbon. In many instances the carbon is combined with the yarn as a coating. This is not wholly acceptable because carbon or carbon loaded polymeric resin does not adhere well which causes flaking or peeling. Another concern is the mass of carbon required in order to generate an acceptable level of conductivity. Because relatively large percentages of carbon must be combined with the polymer resin to make it conductive, the yarn properties are severely compromised. Historically, the carbon content necessary to provide adequate conductivity is more than 25% by weight. The technical properties of yarns containing this level of carbon content is severely affected.
- Carbon nanotubes, which have recently been developed, are essentially very fine carbon fibers. This nano size allows the use of a low percentage of carbon in a polymeric composition while providing for the requisite conductive properties.
- It is the primary object of the instant invention to provide a multi-component yarn which is conductive, does not flake, is not brittle and has good physical properties.
- Another object of the invention is a multi-component conductive yarn in which no component includes more than 20% carbon by weight.
- Another object of the invention is a multi-component conductive yarn which contains less than 10% carbon by weight.
- Another object of the invention is a multi-component conductive yarn which includes a plurality of components, at least one of which is a conductive filament.
- Another object of the invention is the provision of a multi-component yarn with a conductive sheath secured to a non-conductive core.
- Another object of the invention is a multi-component conductive yarn in which one component includes carbon nanotubes which form the electrical conductor.
- Another object of the invention is a multi-component conductive yarn in which multiple components include carbon nanotubes which form the electrical conductor.
- Another object of the invention is a multi-component conductive yarn which is physically resilient.
- The invention is intended for use in a variety of applications including, but not limited to, lay belts, conveyor belts, braiding, industrial textiles, filtration, paper machine clothing, IFBC shipping bags, upholstery, home furnishings, hook and loop, carpets, apparel, nonwovens, brushes and process forming belts.
- The invention is directed to a multi-component conductive yarn and the method of forming. The yarn comprises a primary component and a secondary component. The primary component consists of an elongated filament formed from polymeric material. The secondary component consists of a fiber of a polymeric material and carbon nanotubes which is bonded with the primary component along its length. The carbon included in the secondary component includes up to 20% by mass of carbon nanotubes. The secondary component when combined with the first component provides a conductive yarn which comprises no more than 10% carbon nanotubes by weight.
- The polymeric material forming the primary component may be one of any melt-spinnable polymer, preferred is one of or a blend of polyester (such as PET, PTT, PBT, PCTA, Polycarbonate, etc.), polyamide, PPS, polypropylene, polyethylene and/or PEEK. The polymeric material of said secondary component includes at least 80% of one of polyester, polyamide, PTT, PBT, PPS, polypropylene, polyethylene and PEEK while carbon nanotubes comprise the remainder of the makings of the component.
- The secondary component may comprise a sheath surrounding the filament of the primary component. Alternatively, the secondary component may comprise an elongated filament bonded with the filament of the primary component along its length.
- The secondary component may wrap around the primary component as it extends along its length.
- The secondary component may comprise between 0.5% and 50% by weight of the multi-component yarn while the carbon nanotubes may comprise up to 20% by weight, preferred no more than 15% by weight, of the secondary component.
- The primary component may be a yarn which has been stretched and heat set prior to being combined with the secondary component. Alternatively, the first and second components may be extruded simultaneously and joined forming the multi-component yarn. The so formed yarn may then be stretched and heat set. Such a yarn is called a heterofilament yarn.
- The invention further includes a method of forming a conductive multi-component yarn. The method includes the steps of providing at least a first component consisting of at least one elongated filament of polymeric material. Also, providing at least a second component consisting of a composition including a polymeric resin and carbon nanotubes. Limiting the carbon nanotubes to between 0.5% to 20% of the composition of the second component. Passing the first component through a crosshead extruder in the form of a filament while the second component is extruded onto the first component causing it to bond therewith forming the composite yarn as a core filament comprised of the first component with a conductive sheath formed there about. This type of yarn is called a coated yarn. Alternately, the method may comprise simultaneously extruding the first and second components forming multiple filaments and causing the filaments to bond together along their length. This type of yarn is called bonded filaments.
- The construction designed to carry out the invention will hereinafter be described, together with other features thereof.
- The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:
-
FIG. 1 is a schematic view showing a process forming a multi-component yarn of the invention. It is the coating process of the first component with a second component by a crosshead extruder. -
FIG. 2 is a schematic view showing another process for forming a multi-component yarn of the invention. -
FIG. 3A is a cross sectional view of a multi-component yarn of the invention. -
FIG. 3B is a cross sectional view of another multi-component yarn of the invention. -
FIG. 3C is a cross sectional view of another multi-component yarn of the invention. -
FIG. 3D is a cross sectional view of another multi-component yarn of the invention. -
FIG. 3E is a cross-sectional view of another multi-component yarn of the invention. -
FIG. 3F is a cross-sectional view of another multi-component yarn of the invention. -
FIG. 3G is a cross-sectional view of another multi-component yarn of the invention. -
FIG. 4 is a diagrammatic view showing aligned nanotubes. - Referring now in more detail to the drawings, the invention will now be described in more detail.
- Carbon nanotubes are extremely small conductive elements which have found use with polymers as a conductive additive. A primary advantage of carbon nanotubes is that they possess a higher aspect ratio than carbon black particles or chopped carbon which allows for a lower additive loading while maintaining adequate levels of conductivity.
- Carbon nanotubes comprise elongated particles which tend to intertwine and have a low sensitivity to shear fields. This provides the capability of elongating the polymeric resin containing carbon nanotubes without entirely severing the carbon nanotube agglomerates which are formed within the polymer.
FIG. 4 schematically shows generally the manner in which carbon nanotubes can be distributed in a polymeric resin. - In a conductive yarn it has been most difficult to produce a yarn which retains most of the desired fiber characteristics normally achieved from the original polymer resin due to the negative impact of the carbon. A major contributor to this problem is the amount of carbon necessary to provide for the fiber to be sufficiently conductive. If the carbon additive is combined with the polymer in the form of a coating, the coating has the tendency to peel and crack.
- The instant invention provides to overcome these drawbacks by providing a conductive multi-component yarn which retains the desired physical characteristics, is flexible and does not peel or crack.
- Turning now to
FIG. 1 , asupply 10 comprising aset filament 12 is seen being passed through at least one but preferably a plurality of extruder dies which extrude a coating or adheringresin compound 14 onto thefilament 12 as it passes.Resin compound 14, in this instance, forms asheath 16 aboutfilament 12. Also, in this instance, asfilament 12 is already stretched and heat set,sheath 16 is allowed to solidify and themulti-component yarn 18 is simply rewound for shipment. Alternatively, the multi-component yarn could be passed between draw rolls and through an oven where the yarn is stretched, relaxed, or both and then heat set. - The
multi-component yarn 18 may comprise a core usually formed of a polyester (such as PET, PTT, PBT, PCTA, etc) or a polyamide fiber. The core could alternatively be polypropylene, polyethylene, PPS, PEEK or other melt-spinnable polymers or a blend of these polymers. The core may comprise one or a plurality of filaments. It can also be a yarn made of natural fibers and staple fibers. - The sheath comprises a polymer, again usually a polyester or a polyamide combined with carbon nanotubes. Again, the above listed resins could also comprise the polymer forming the sheath.
-
Resin compound 14 comprises between 0.5% to 20% carbon nanotubes and between 80% to 99.5% polyester or other polymer or blend of polymers.Sheath 16 comprises between 0.5% to 50% of the mass of the multi-component yarn whilecore 12 forms between 50% to 99.5% of the multi-component yarn. - The nanotubes within
resin 14 are interspersed along the length of the sheath and about the core providing a conductive artery along the length of the multi-component yarn. The percentage of the multi-component yarn consisting of carbon nanotubes is between 0.5% and 15%. Such a low percentage of carbon allows the resins forming thecompound 14 to maintain substantially all of their normal features such as elasticity, strength and elongation. Normally the core of the multi-component yarn retains all of its usual characteristics as it is formed of 100% polymer. - In a second arrangement for forming the multi-component yarn,
yarn 12 is pre-formed but not set.Yarn 12 is drawn fromsupply 10 and passes through theextruders extruding compound 14 producingyarn 18 as earlier described. In the alternative arrangement, the just formed multi-component yarn is passed between draw rolls and through an oven where the yarn is stretched, relaxed, or both and then heat set. Both thecore 12 andsheath 16 are treated and then set. This is possible due to the innate characteristics of carbon nanotubes which are not so easily separated but remain substantially in contact and because of the limited percentage of nanotubes present in thesheath 16. - Other arrangements are shown in
FIG. 2 . In a first arrangement a pair ofextruders Extruder 20 extrudes thecore yarn 12 whileextruder 22 extrudes thesecond component 24. The extruders are controlled in known manner which allows thesecond component 24 to adhere tocore 12 along its length in the form of anelongated filament 28.FIG. 2 also represents the heterofilament process. In this case both components are molten in theirextruders multi-component yarn 28. - The
multi-component yarn 28 shown inFIG. 3 is passed between draw rolls 30, stretched and/or relaxed and then heat set byheater 32. - It is noted that
component 24 may be dispensed in the form ofsheath 16 as shown inFIG. 3A which encases the core along its length. The extrudedcompound 24 can be controlled to attach to the core 12 in the form of a wedge shapedfilament 26 or anadditional filament 26 which extends along the length and is wrapped about its axis ofcore 12 as shown inFIGS. 3B and 3E . Another arrangement could be forcore 12 to be arranged on opposed sides ofcompound 24 which assumes the form of aconductive strip 26′ which extends along the length ofcore 12 as shown inFIG. 3C . The extrudedcompound 24 could form a plurality of wedge shapedfilaments 26 oradditional filaments 26 which are arranged along the length ofcore 12 as shown inFIGS. 3D and 3F . Another arrangement could be forcore 12 to be first coated bysheath 36 and then byconductive sheath 16.Sheath 36, which is preferably a low melt polymer, adhesive type polymer, co-polyester or other suitable material, provides an intermediate layer which provides increased adhesion between the core 12 and theconductive sheath 16. In each of thearrangements sheath 16,filaments 26 and strips 26′ form a conductive filament which is adhered withcore 12 along its length. - In all arrangements, the percentage of the first component or core polymer and the percentage of the second component or conductive polymer+carbon nanotubes remains within the set forth limits.
- It is noted that the core could consist of a plurality of filaments which are preferably but not necessarily of the same polymer. The core could consist of a blend of polymers. Also the sheath or conductive filament could consist of a blend of polymers combined with the carbon nanotubes.
- The multi-component conductive yarn of the invention is intended for use with a multiple of fabric types such as woven fabrics, knitted fabrics, braided fabrics, non-woven fabrics, interlaid fabrics and composite fabrics. The yarn is intended to comprise varying selected percents of yarns forming these fabrics. Also, the yarn is intended for use with any combination of the above fabric types.
- While a preferred embodiment of the invention has been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.
Claims (19)
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/767,668 US20050170177A1 (en) | 2004-01-29 | 2004-01-29 | Conductive filament |
JP2004297349A JP2005213718A (en) | 2004-01-29 | 2004-10-12 | Electroconductive yarn |
EP04030556A EP1559815B1 (en) | 2004-01-29 | 2004-12-23 | Conductive yarn, method of manufacture and use thereof |
ES04030556T ES2308098T3 (en) | 2004-01-29 | 2004-12-23 | DRIVING THREAD, MANUFACTURING METHOD AND USE OF THE SAME. |
DE602004014587T DE602004014587D1 (en) | 2004-01-29 | 2004-12-23 | Electrically conductive yarn and method of making and using same |
PT04030556T PT1559815E (en) | 2004-01-29 | 2004-12-23 | Conductive yarn, method of manufacture and use thereof |
PL04030556T PL1559815T3 (en) | 2004-01-29 | 2004-12-23 | Conductive yarn, method of manufacture and use thereof |
AT04030556T ATE399222T1 (en) | 2004-01-29 | 2004-12-23 | ELECTRICALLY CONDUCTIVE YARN AND METHOD FOR THE PRODUCTION AND USE OF THE SAME |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/767,668 US20050170177A1 (en) | 2004-01-29 | 2004-01-29 | Conductive filament |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050170177A1 true US20050170177A1 (en) | 2005-08-04 |
Family
ID=34654357
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/767,668 Abandoned US20050170177A1 (en) | 2004-01-29 | 2004-01-29 | Conductive filament |
Country Status (8)
Country | Link |
---|---|
US (1) | US20050170177A1 (en) |
EP (1) | EP1559815B1 (en) |
JP (1) | JP2005213718A (en) |
AT (1) | ATE399222T1 (en) |
DE (1) | DE602004014587D1 (en) |
ES (1) | ES2308098T3 (en) |
PL (1) | PL1559815T3 (en) |
PT (1) | PT1559815E (en) |
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WO2013155571A1 (en) * | 2012-04-19 | 2013-10-24 | Commonwealth Scientific And Industrial Research Organisation | Polymeric composites containing highly aligned carbon nanotubes and method for making them |
WO2016001640A1 (en) * | 2014-07-01 | 2016-01-07 | Sensor Spol. S.R.O | Conducting mesh |
EP3759266A4 (en) * | 2018-03-02 | 2021-12-01 | Mesomat Inc. | Nanomaterial-coated fibers |
US20220220641A1 (en) * | 2019-05-30 | 2022-07-14 | Lintec Corporation | Modeling material for 3d printers and shaped article |
DE102019132028B3 (en) * | 2019-11-26 | 2021-04-15 | Deutsche Institute Für Textil- Und Faserforschung Denkendorf | Piezoresistive force sensor |
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Also Published As
Publication number | Publication date |
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EP1559815A2 (en) | 2005-08-03 |
ES2308098T3 (en) | 2008-12-01 |
JP2005213718A (en) | 2005-08-11 |
EP1559815A3 (en) | 2006-06-21 |
DE602004014587D1 (en) | 2008-08-07 |
PT1559815E (en) | 2008-09-12 |
EP1559815B1 (en) | 2008-06-25 |
PL1559815T3 (en) | 2008-12-31 |
ATE399222T1 (en) | 2008-07-15 |
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