Method of forming a conductive gasket material
View Patent ↗A method of forming a conductive gasket material by layering at least one conductive web layer having a blended mixture of conductive fibers and low melting point nonconductive fibers onto a foam core, and needlepunching the conductive web layer and the foam core forming a conductive composite gasket material having a plurality of conductive fibers interspersed through the foam core.
1. A method of forming a conductive gasket material comprising:
layering at least one conductive web layer comprising a blended mixture of conductive fibers and bi-component nonconductive fibers having a blend ratio of at least 1 to 1 of conductive fibers to nonconductive fibers onto a foam core; and
needlepunching said conductive web layer and said foam core forming a conductive composite gasket material having a plurality of conductive fibers interspersed through said foam core.
2. The method of claim 1 further comprising heating said conductive composite to the softening point of said nonconductive fibers.
3. The method of claim 1 further comprising layering a second conductive web layer onto an opposite side of said foam core.
4. The method of claim 3 further comprising needlepunching said second conductive web layer and said foam core.
5. The method of claim 1 further comprising layering a nonconductive web layer comprising nonconductive fibers between said at least one conductive web layer and said foam core before said needlepunching step.
6. The method of claim 5 further comprising thermoforming Mid conductive composite gasket material.
7. The method of claim 1 further comprising blending a plurality of conductive fibers and a plurality of bi-component nonconductive fibers forming said conductive web layer.
8. The method of claim 7 wherein said blending step includes blending said plurality of conductive fibers and said plurality of nonconductive fibers in a blend ratio about 1 to 1 to about 3 to 1 of conductive fibers to nonconductive fibers.