CONDUCTIVE/ABSORBTIVE SHEET MATERIALS WITH ENHANCED PROPERTIES

• US 20090176074A1
• Filed: 04/30/2007
• Published: 07/09/2009
• Est. Priority Date: 05/05/2006
• Status: Abandoned Application

• Current Assignee: Onyx Specialty Papers, Inc.
• Original Assignee: Meadwestvaco (WestRock Company)
• Inventors: Sotendahl, Steve, Maggio, Stephen P., Bushhouse, Steve
• Application Number:
  US12/297,775
• Publication Number:
  US 20090176074A1
• Time in Patent Office: Days
• US Class Current: 428/208
• CPC Class Codes: D21H 15/00 Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution
• CPC Class Codes: D21H 27/30 Multi-ply for surface covering D21H27/18; making on paper-making machines D21F9/00, D21F11/00
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24893 including particulate material
• CPC Class Codes: Y10T 428/24909 Free metal or mineral containing

Abstract

An electrically conductive/electromagnetic energy absorptive sheet material is provided comprising cellulosic fibers mixed with conductive/absorptive fibers or particles. The material may have additional useful properties such as compressibility, biodegradability, and fire retardance.

Claims

1. An electrically conductive/electromagnetic energy absorptive sheet material comprising

nonconductive fibers;

and

conductive/absorptive fibers or particles sufficient to give useful conductive/absorptive properties, wherein said conductive/absorptive fibers or particles are interspersed with or mixed together with said nonconductive fibers.

2. The conductive/absorptive sheet material of claim 1, wherein said nonconductive fibers comprise cellulose fibers.

3. The conductive/absorptive sheet material of claim 1, wherein said nonconductive fibers comprise synthetic fibers.

4. The conductive/absorptive sheet material of claim 1, wherein said nonconductive fibers comprise a mixture of cellulose and synthetic fibers.

5. The conductive/absorptive sheet of claim 1, wherein said conductive/absorptive fibers or particles and said nonconductive fibers are biodegradable.

6. The conductive/absorptive sheet of claim 1, wherein said conductive/absorptive fibers or particles are carbon and said nonconductive fibers are cellulose or biodegradable synthetic fibers.

7. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles are comprised of metal, metal plated metal, carbon, metal plated carbon, ferrite powder, iron-based powder, metal plated glass, or synthetic fibers that are metal plated or contain conductive/absorptive particles or fibrets within.

8. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles comprise stainless steel fibers, copper fibers, aluminum fibers, nickel plated copper fibers, silver plated copper fibers, or tin plated copper fibers.

9. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles comprise about 1% to 80% of the total dry weight of the sheet.

10. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles are provided in the slurry feed to a headbox.

11. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles are provided in the slurry feed to a primary headbox.

12. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles are provided in the slurry feed to a secondary headbox.

13. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles are provided through a slot or curtain coater.

14. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles are provided through a sprayer.

15. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles are distributed evenly throughout said sheet.

16. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles are distributed preferentially to at least one surface of said sheet.

17. The conductive/absorptive sheet of claim 1, formed in more than one layer of fibers.

18. The conductive/absorptive sheet material of claim 1, wherein said conductive/absorptive fibers or particles are contained between two nonconductive fiber layers.

19. The conductive/absorptive sheet of claim 1, further comprising a fire retardant material.

20. The conductive/absorptive sheet of claim 1, further comprising expansible microspheres.

21. The conductive/absorptive sheet of claim 1, further comprising a binder.

22. The conductive/absorptive sheet of claim 1, further comprising a biodegradable binder.

23. The conductive/absorptive sheet of claim 1, further comprising an adhesive on at least one side.

24. The conductive/absorptive sheet of claim 1, formed into a tape.

25. The conductive/absorptive sheet material of claim 1, having a surface resistance suitable for at least one of electromagnetic shielding, electromagnetic interference shielding, radio frequency shielding, radio frequency interference shielding, microwave shielding, microwave interference shielding, electrostatic discharge protection, or resistance heating.

26. The conductive/absorptive sheet material of claim 1, comprising conductive/absorptive fibers or particles in an amount sufficient to provide electromagnetic shielding.

27. The conductive/absorptive sheet material of claim 1, comprising conductive/absorptive fibers or particles in an amount sufficient to provide radio frequency shielding.

28. The conductive/absorptive sheet material of claim 1, comprising conductive/absorptive fibers or particles in an amount sufficient to provide microwave frequency shielding.

29. The conductive/absorptive sheet material of claim 1, comprising conductive/absorptive fibers or particles in an amount sufficient to provide electrostatic discharge protection.

30. The conductive/absorptive sheet material of claim 1, comprising conductive/absorptive fibers or particles in ah amount sufficient to provide resistance heating.

31. The conductive/absorptive sheet material of claim 1, used in a laminate structure.

32. The conductive/absorptive sheet material of claim 1, used in a thermoformed structure.

33. The absorptive sheet material of claim 1, used as a cavity resonance suppressing material for circuit board covers.

34. The absorptive sheet material of claim 1, used as an interference absorber for electric cables.

35. The conductive/absorptive sheet material of claim 1, used in lining or covering at least a portion of an enclosure for electronic circuitry, or electrical or electronic components.

36. The conductive/absorptive sheet material of claim 1, used as a conductive/absorptive gasket material for shielding applications.

37. The conductive/absorptive sheet material of claim 1, used as a conductive/absorptive sheet material for architectural shielding applications.

38. A process for making a conductive/absorptive sheet material, comprising:

providing a slurry of both conductive/absorptive fibers or particles and nonconductive fibers; and

applying said slurry onto a porous support and draining the liquid from said slurry to form a mat or web; and

drying said mat or web to form a sheet with conductive/absorptive properties.

39. The process of claim 38, wherein said nonconductive/absorptive fibers comprise cellulose fibers.

40. The process of claim 38, wherein said nonconductive fibers comprise synthetic fibers.

41. The process of claim 38, wherein said nonconductive fibers comprise a mixture of cellulose and synthetic fibers.

42. The process of claim 38, wherein said conductive/absorptive fibers or particles and said nonconductive fibers are biodegradable.

43. The process of claim 38, wherein said conductive/absorptive fibers or particles are carbon and said nonconductive fibers are cellulose or biodegradable synthetic fibers.

44. The process of claim 38, wherein said conductive/absorptive fibers or particles are comprised of metal, carbon, nickel plated carbon, ferrite powder, iron-based powder or synthetic fibers that contain conductive/absorptive carbon particles or fibrets within.

45. The process of claim 38, wherein said conductive/absorptive fibers or particles comprise stainless steel fibers, copper fibers, aluminum fibers, nickel plated copper fibers, silver plated copper fibers, or tin plated copper fibers.

46. The process of claim 38, wherein said conductive/absorptive fibers or particles comprise about 1% to 80% of the total dry weight of said mat or web.

47. The process of claim 38, wherein said conductive/absorptive fibers or particles are provided in a slurry feed to a headbox.

48. The process of claim 38, wherein said conductive/absorptive fibers or particles are provided in a slurry feed to a primary headbox.

49. The process of claim 38, wherein said conductive/absorptive fibers or particles are provided in a slurry feed to a secondary headbox.

50. The process of claim 38, wherein said conductive/absorptive fibers or particles are provided through a slot or curtain coater.

51. The process of claim 38, wherein said conductive/absorptive fibers or particles are provided through a sprayer.

52. The process of claim 38, wherein said conductive/absorptive fibers or particles are distributed evenly throughout said mat or web

53. The process of claim 38, wherein said conductive/absorptive fibers or particles are distributed unevenly throughout said mat or web.

54. The process of claim 38, wherein said conductive/absorptive fibers or particles are distributed preferentially to at least one surface of said mat or web.

55. The process of claim 38, wherein said conductive/absorptive fibers or particles are contained between two nonconductive fiber layers.

56. The process of claim 38, further comprising the addition of a fire retardant material to said slurry or as a coating.

57. The process of claim 38, further comprising an addition of expansible microspheres to the mat or web.

58. The process of claim 38 further comprising the addition of a binder material to said slurry.

59. The process of claim 38, further comprising a lamination step applied to the mat or web produced thereby.

60. The process of claim 38, further comprising a thermoforming step applied to the mat or web produced thereby.

61. The process of claim 38, further comprising a step of binder application or saturation carried out On the mat or web produced thereby.

62. A process for making a conductive/absorptive sheet material, comprising:

providing a first slurry comprising at least nonconductive fibers and optionally conductive/absorptive fibers or particles;

providing a second slurry comprising at least conductive/absorptive fibers or particles and optionally nonconductive fibers;

applying said first slurry onto a porous support and draining at least a portion of the liquid from said first slurry to form a mat or web;

applying said second slurry onto said mat or web; and

drying said mat or web to form a sheet with conductive/absorptive properties.

63. The process of claim 62, wherein said nonconductive/absorptive fibers comprise cellulose fibers.

64. The process of claim 62, wherein said nonconductive fibers comprise synthetic fibers.

65. The process of claim 62, wherein said nonconductive fibers comprise a mixture of cellulose and synthetic fibers.

66. The process of claim 62, wherein said conductive/absorptive fibers or particles and said nonconductive fibers are biodegradable.

67. The process of claim 62, wherein said conductive/absorptive fibers or particles are carbon and said nonconductive fibers are cellulose or biodegradable synthetic fibers.

68. The process of claim 62, wherein said conductive/absorptive fibers or particles are comprised of metal, carbon, nickel plated carbon, ferrite powder, iron-based powder or synthetic fibers that contain conductive/absorptive carbon particles or fibrets within.

69. The process of claim 62, wherein said conductive/absorptive fibers or particles comprise stainless steel fibers, copper fibers, aluminum fibers, nickel plated copper fibers, silver plated copper fibers, or tin plated copper fibers.

70. The process of claim 62, wherein said conductive/absorptive fibers or particles comprise about 1% to 80% of the total dry weight of said mat or web.

71. The process of claim 62, wherein said conductive/absorptive fibers or particles are provided in a slurry feed to a headbox.

72. The process of claim 62, wherein said conductive/absorptive fibers or particles are provided in a slurry feed to a primary headbox.

73. The process of claim 62, wherein said conductive/absorptive fibers or particles. are provided in a slurry feed to a secondary headbox.

74. The process of claim 62, wherein said conductive/absorptive fibers or particles are provided through a slot or curtain coater.

75. The process of claim 62, wherein said conductive/absorptive fibers or particles are provided through a sprayer.

76. The process of claim 62, wherein said conductive/absorptive fibers or particles are distributed evenly throughout said mat or web

77. The process of claim 62, wherein said conductive/absorptive fibers or particles are distributed unevenly throughout said mat or web.

78. The process of claim 62, wherein said conductive/absorptive fibers or particles are distributed preferentially to at least one surface of said mat or web.

79. The process of claim 62, wherein said conductive/absorptive fibers or particles are contained between two nonconductive fiber layers.

80. The process of claim 62, further comprising the addition of a fire retardant material to said first or second slurry or as a coating.

81. The process of claim 62, further comprising an addition of expansible microspheres to the mat or web.

82. The process of claim 62 further comprising the addition of a binder material to said first or second slurry.

83. The process of claim 62, further comprising a lamination step applied to the mat or web produced thereby.

84. The process of claim 62, further comprising a thermoforming step applied to the mat or web produced thereby.

85. The process of claim 62, further comprising a step of binder application or saturation carried out on the mat or web produced thereby.