Noise dampening energy efficient tape and gasket material

Abstract

A noise dampening tape and gasket material for reducing or preventing unwanted electromagnetic interference from escaping or entering an enclosure. The noise dampening gasket includes an inner core section, a carbon material layer surrounding the inner core section, an insulating layer surrounding the carbon material layer, and a metal shield layer surrounding the insulating layer. The noise dampening tape includes a metal shield layer, an insulating layer adjacent to and in contact with the metal shield layer, a carbon material layer adjacent to and in contact with the insulating layer, and an adhesive layer disposed on a surface of the carbon material layer. A second adhesive layer can be disposed on a surface of the metal shield layer. The carbon fibers can be coated with silicone or polytetrafluoroethylene to enhance mechanical and electrical properties of the carbon material layer.

1 . A carbon fiber textile with enhanced mechanical and electromagnetic properties comprising:
 a plurality of carbon fibers aligned to form one or more tows of the carbon fibers;   a coating of polytetrafluoroethylene on the carbon fibers which electrically insulates the carbon fibers individually;   the one or more tows of polytetrafluoroethylene-coated carbon fibers arranged to form a polytetrafluoroethylene-coated carbon fiber textile;   the polytetrafluoroethylene-coated carbon fiber textile having a specific sheet resistance of the carbon fibers of less than or equal to 100 ohms per centimeter squared; and   the polytetrafluoroethylene-coated carbon fiber textile is resistant to breakage and spalling of the individual carbon fibers.   
     
     
         2 . The carbon fiber textile of  claim 1 , wherein the polytetrafluoroethylene-coated carbon fiber textile has memory and returns to an original shape after a mechanical force is removed. 
     
     
         3 . The carbon fiber textile of  claim 1 , wherein the specific resistivity is equal to or less than 1.0 ohms per centimeter squared along the aligned, polytetrafluoroethylene-coated carbon fibers. 
     
     
         4 . The carbon fiber textile of  claim 1 , wherein the polytetrafluoroethylene-coated carbon fiber textile are less breakable than untreated carbon fibers under mechanical stress. 
     
     
         5 . The carbon fiber textile of  claim 4 , wherein a 3 k tow of polytetrafluoroethylene-coated carbon fiber resists breakage at about 7 kg of pull. 
     
     
         6 . The carbon fiber textile of  claim 1 , wherein the polytetrafluoroethylene-coated carbon fibers are woven, non-woven, basket-woven, piled or aligned to form the polytetrafluoroethylene-coated carbon fiber textile. 
     
     
         7 . The carbon fiber textile of  claim 1 , wherein the polytetrafluoroethylene-coated carbon fiber textile attenuates radio frequency electromagnetic radiation. 
     
     
         8 . The carbon fiber textile of  claim 1 , wherein the enhanced mechanical properties comprise the ability to bend without breaking. 
     
     
         9 . A carbon fiber textile with enhanced mechanical and electromagnetic properties comprising:
 a plurality of carbon fibers aligned to form one or more tows of the carbon fibers;   a coating of silicone on the carbon fibers which electrically insulates the carbon fibers individually;   the one or more tows of polytetrafluoroethylene-coated carbon fibers are arranged to form a polytetrafluoroethylene-coated carbon fiber textile; and   the polytetrafluoroethylene-coated carbon fiber textile having sufficient resistivity of the aligned polytetrafluoroethylene-coated carbon fibers to attenuate radio frequency electromagnetic radiation.   
     
     
         10 . The carbon fiber textile of  claim 9 , wherein the polytetrafluoroethylene-coated carbon fiber textile is incorporated into a quilted textile. 
     
     
         11 . The carbon fiber textile of  claim 10 , wherein the quilted textile comprises the polytetrafluoroethylene-coated carbon fiber textile with at least one conductive layer. 
     
     
         12 . The carbon fiber textile of  claim 11 , wherein the conductive layer is comprised of a metallic layer. 
     
     
         13 . The carbon fiber textile of  claim 11 , wherein the conductive layer is comprised of a textile containing conductive threads. 
     
     
         14 . The carbon fiber textile of  claim 9 , wherein the polytetrafluoroethylene-coated carbon fiber textile is arranged in a laminate with at least one metal layer. 
     
     
         15 . The carbon fiber textile of  claim 9 , wherein the polytetrafluoroethylene-coated carbon fiber textile is between at least two layers of conductive textile. 
     
     
         16 . A method for forming a carbon fiber textile with enhanced electromagnetic and mechanical properties, comprising:
 aligning a plurality of carbon fibers to form one or more tows of the carbon fibers;   coating the carbon fibers with polytetrafluoroethylene which electrically insulates the carbon fibers individually;   arranging one or more tows of the polytetrafluoroethylene-coated carbon fibers to form a polytetrafluoroethylene-coated carbon fiber textile; and   the polytetrafluoroethylene-coated carbon fiber textile having sufficient resistivity of the aligned silicone-coated carbon fibers to attenuate radio frequency electromagnetic radiation.   
     
     
         17 . The method of  claim 16 , further comprising the polytetrafluoroethylene-coated carbon fiber textile having a specific sheet resistance of less than or equal to 1.0 ohms per centimeter squared and an increased tolerance for bending around a radius. 
     
     
         18 . The method of  claim 16 , further comprising the polytetrafluoroethylene-coated carbon fiber textile having a specific sheet resistance of 1.0 ohms per centimeter squared along the aligned, polytetrafluoroethylene-coated carbon fibers. 
     
     
         19 . The method of  claim 16 , further comprising coating the carbon fibers with polytetrafluoroethylene by at least one of the following methods: spray, brush, and immersion. 
     
     
         20 . The method of  claim 19 , further comprising treating polytetrafluoroethylene-coated carbon fibers by compaction or sintering. 
     
     
         21 . The method of  claim 16 , further comprising incorporating the polytetrafluoroethylene-coated carbon fiber textile into a quilted textile. 
     
     
         22 . The method of  claim 16 , further comprising joining the polytetrafluoroethylene-coated carbon fiber textile to a conductive layer. 
     
     
         23 . The carbon fiber textile of  claim 16 , further comprising forming a laminate incorporating the polytetrafluoroethylene-coated carbon fiber textile.