Conformal coatings comprising carbon nanotubes

• US 20040071949A1
• Filed: 07/24/2002
• Published: 04/15/2004
• Est. Priority Date: 07/27/2001
• Status: Active Grant

• Current Assignee: Eikos, Inc.
• Original Assignee: Eikos, Inc.
• Inventors: Conroy, Jeffrey L., Landrau, Nelson, Glatkowski, Paul J., Piche, Joseph W., Landis, David H. Jr.
• Granted Patent: US 7,118,693 B2
• Time in Patent Office: Days
• US Class Current: 428/313.3
• CPC Class Codes: B05D 5/12 to obtain a coating with specific electrical properties
• CPC Class Codes: B05D 7/52 Two layers
• CPC Class Codes: B82Y 10/00 Nanotechnology for information processing, storage or transmission, e.g. quantum computing or single electron logic
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C08K 3/04 Carbon
• CPC Class Codes: C08K 3/041 Carbon nanotubes
• CPC Class Codes: C08K 3/045 Fullerenes
• CPC Class Codes: C09D 175/04 Polyurethanes
• CPC Class Codes: C09D 179/08 Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
• CPC Class Codes: C09D 5/00 Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced electrically insulating plastics, resins or waxes H01B3/30; Filling pastes
• CPC Class Codes: C09D 5/24 Electrically-conducting paints conductive materials H01B1/00
• CPC Class Codes: C09D 7/62 modified by treatment with other compounds
• CPC Class Codes: C09D 7/70 characterised by shape, e.g. fibres, flakes or microspheres
• CPC Class Codes: G21F 1/10 Organic substances; Dispersions in organic carriers
• CPC Class Codes: H01B 1/24 the conductive material comprising carbon-silicon compounds, carbon or silicon
• CPC Class Codes: H05K 9/0086 comprising a single discontinuous metallic layer on an electrically insulating supporting structure, e.g. metal grid, perforated metal foil, film, aggregated flakes, sintering
• CPC Class Codes: Y10S 428/922 Static electricity metal bleed-off metallic stock
• CPC Class Codes: Y10S 428/924 Composite
• CPC Class Codes: Y10S 977/742 Carbon nanotubes, CNTs
• CPC Class Codes: Y10S 977/75 Single-walled
• CPC Class Codes: Y10T 428/1393 : Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/249971 : Preformed hollow element-containing
• CPC Class Codes: Y10T 428/249978 : Voids specified as micro
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

The invention is directed to conformal coatings that provide excellent shielding against electromagnetic interference (EMI). A conformal coating comprises an insulating layer and a conducting layer containing electrically conductive material. The insulating layer comprises materials for protecting a coated object. The conducting layer comprises materials that provide EMI shielding such as carbon black, carbon buckeyballs, carbon nanotubes, chemically-modified carbon nanotubes and combinations thereof. The insulating layer and the conductive layer may be the same or different, and may be applied to an object simultaneously or sequentially. Accordingly, the invention is also directed to objects that are partially or completely coated with a conformal coating that provides EMI shielding.

Claims

1. A conformal coating that provides EMI shielding, wherein said coating comprises:

an insulating layer; and

a conductive layer wherein said conductive layer comprises an electrically conductive material.

2. The conformal coating of claim 1, wherein said insulating layer comprises a material selected from the group consisting of polyurethanes, parylene, acrylics, epoxy, silicone and mixtures thereof.

3. The conformal coating of claim 1, wherein the conducting layer provides EMI shielding properties in the 10-70 dB attenuation range.

4. The conformal coating of claim 1, wherein the conducting layer has a surface resistance in the range of less than about 10⁴ ohms/square.

5. The conformal coating of claim 1, wherein the conductive layer is over-coated with a polymeric layer comprising a conformal coating material selected from the group consisting of polyurethanes, parylene, acrylics, epoxies and silicone.

6. The conformal coating of claim 1, wherein the conductive layer contains an electrically conductive material selected from the group consisting of carbon black, an electrically conductive metal, carbon nanotubes, chemically-modified carbon nanotubes and combinations thereof.

7. The conformal coating of claim 6, wherein the electrically conductive material comprises carbon nanotubes.

8. The conformal coating of claim 7, wherein the carbon nanotubes are selected from the group consisting of single-walled nanotubes, double-walled nanotubes, multi-walled nanotubes, and mixtures thereof.

9. The conformal coating of claim 7, wherein the carbon nanotubes are substantially single-walled nanotubes.

10. The conformal coating of claim 7, wherein the carbon nanotubes are present in said nanotube-containing layer at about 0.1 to about 0.5%.

11. The conformal coating of claim 7, wherein the carbon nanotubes are oriented.

12. The conformal coating of claim 7, wherein the carbon nanotubes are chemically modified.

13. The conformal coating of claim 1, wherein the conductive layer further comprises a polymeric material, wherein the polymeric material comprises a material selected from the group consisting of thermoplastics, thermosetting polymers, elastomers, conducting polymers and combinations thereof.

14. The conformal coating of claim 1, wherein the conductive layer further comprises a polymeric material, wherein the polymeric material comprises a material selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, styrenic, polyurethane, polyimide, polycarbonate, polyethylene terephthalate, cellulose, gelatin, chitin, polypeptides, polysaccharides, polynucleotides and mixtures thereof.

15. The conformal coating of claim 1, wherein the conductive layer further comprises a polymeric material, wherein the polymeric material comprises a material selected from the group consisting of ceramic hybrid polymers, phosphine oxides, chalcogenides, and combinations thereof.

16. The conformal coating of claim 1, wherein the conductive layer further comprises a conformal coating material selected from the group consisting of polyurethanes, parylene, acrylics, epoxies, silicone and combinations thereof.

17. The conformal coating of claim 1, wherein the conductive layer further comprises a polymeric material wherein the nanotubes are dispersed substantially homogenously throughout the polymeric material.

18. The conformal coating of claim 1, wherein the conductive layer further comprises an additive selected from the group consisting of a dispersing agent, a binder, a cross-linking agent, a stabilizer agent, a coloring agent, a UV absorbent agent, a charge adjusting agent and combinations thereof.

19. The conformal coating of claim 1, wherein the conductive layer has a transmittance of at least about 60%.

20. A coated substrate with EMI shielding comprising:

a) a substrate; and

b) conformal coating disposed on said substrate that provides EMI shielding, wherein said coating comprises;

an insulating layer; and

a carbon nanotube-containing layer disposed on said insulating layer, wherein said carbon nanotube-containing layer comprises a plurality of carbon nanotubes.

21. The coated substrate of claim 20, wherein the substrate is part of a device component selected from the group consisting of keypads, catheters, integrated circuits, printed wire boards, printed circuit boards, hybrids, transducers, sensors, cores, accelerometers, catheters, coils, fiber optic components, heat exchangers, pacemakers, implants, flow meters, magnets, photoelectric cells, electrosurgical instruments, and plastic encapsulated microcircuits.

22. The coated substrate of claim 20, wherein the insulating layer comprises a material selected from the group consisting of polyurethanes, parylene, acrylics, epoxy and silicone.

23. The coated substrate of claim 20, wherein the carbon nanotubes are selected from the group consisting of single-walled nanotubes, double-walled nanotubes, multi-walled nanotubes, and mixtures thereof.

24. The coated substrate of claim 20, wherein the carbon nanotube-containing layer further comprises a conformal coating material selected from the group consisting of polyurethanes, parylene, acrylics, epoxies and silicone.

25. The coated substrate of claim 20, wherein the carbon nanotubes are substantially single-walled nanotubes.

26. The coated substrate of claim 20, wherein the carbon nanotube-containing layer has a surface resistance in the range of less than about 104 ohms/square.

27. The coated substrate of claim 20, wherein the carbon nanotube-containing layer further comprises an additive selected from the group consisting of a dispersing agent, a binder, a cross-linking agent, a stabilizer agent, a coloring agent, a UV absorbent agent, and a charge adjusting agent.

28. The coated substrate of claim 20, wherein the carbon nanotube-containing layer has a total transmittance of at least about 60%.

29. The coated substrate of claim 20, wherein the carbon nanotubes are oriented.

30. The coated substrate of claim 20, wherein the carbon nanotube-containing layer is over-coated with a polymeric layer comprising a conformal coating material selected from the group consisting of polyurethanes, parylene, acrylics, epoxies and silicone.

31. The coated substrate of claim 20, wherein the carbon nanotube-containing layer provides EMI shielding properties in the 10-70 dB attenuation range.

32. The coated substrate of claim 20, wherein the carbon nanotubes are chemically modified.

33. A method for imparting EMI shielding to a substrate, comprising coating said substrate with a conformal coating wherein said conformal coating comprises:

an insulating layer; and

a nanotube-containing layer disposed on said insulating layer, wherein said nanotube-containing layer comprises a plurality of carbon nanotubes.

34. The method of claim 33, wherein the substrate is part of a device component selected from the group consisting of keypads, catheters, integrated circuits, printed circuit boards, printed wire boards, hybrids, transducers, sensors, cores, accelerometers, catheters, coils, fiber optic components, heat exchangers, pacemakers, implants, flow meters, magnets, photoelectric cells, electrosurgical instruments, and plastic encapsulated microcircuits.

35. The method of claim 33, wherein the insulating layer comprises a material selected from the group consisting of polyurethanes, parylene, acrylics, epoxy and silicone.

36. The method of claim 33, wherein the carbon nanotubes are selected from the group consisting of single-walled nanotubes, double-walled nanotubes, multi-walled nanotubes, and mixtures thereof.

37. The method of claim 33, wherein the carbon nanotubes are substantially single-walled nanotubes.

38. The method of claim 33, wherein the nanotube-containing layer further comprises a polymeric material, wherein the polymeric material comprises a material selected from the group consisting of thermoplastics, thermosetting polymers, elastomers, conducting polymers and combinations thereof.

39. The method of claim 33, wherein the carbon nanotube-containing layer further comprises a polymeric material, wherein the polymeric material comprises a material selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, styrenic, polyurethane, polyimide, polycarbonate, polyethylene terephthalate, cellulose, gelatin, chitin, polypeptides, polysaccharides, polynucleotides and mixtures thereof.

40. The method of claim 33, wherein the carbon nanotube-containing layer further comprises a polymeric material, wherein the polymeric material comprises a material selected from the group consisting of ceramic hybrid polymers, phosphine oxides and chalcogenides.

41. The method of claim 33, wherein the carbon nanotube-containing layer further comprises a conformal coating material selected from the group consisting of polyurethanes, parylene, acrylics, epoxies and silicone.

42. The method of claim 33, wherein the carbon nanotube-containing layer further comprises an additive selected from the group consisting of a dispersing agent, a binder, a cross-linking agent, a stabilizer agent, a coloring agent, a UV absorbent agent, and a charge adjusting agent.

43. The method of claim 33, wherein the carbon nanotube-containing layer has a total transmittance of at least about 60%.

44. The method of claim 33, wherein the carbon nanotubes are oriented.

45. The method of claim 33, wherein the coating further comprises an over-coat comprising a conformal coating material selected from the group consisting of polyurethanes, parylene, acrylics, epoxies and silicone.

46. The method of claim 33, wherein the carbon nanotube-containing layer provides EMI shielding properties in the 10-70 dB attenuation range.

47. The method of claim 33, wherein the carbon nanotubes are chemically modified.

48. A conformal coating that provides EMI shielding, wherein said coating comprises a plurality of carbon nanotubes and a polymer selected from the group consisting of acrylics, epoxies, silicone, polyurethane, and parylene.

49. The conformal coating of claim 48, wherein the carbon nanotubes are selected from the group consisting of single-walled nanotubes, double-walled nanotubes, multi-walled nanotubes, and mixtures thereof.

50. The conformal coating of claim 48, wherein the carbon nanotubes are substantially single-walled nanotubes.

51. The conformal coating of claim 48, wherein the coating has a surface resistance in the range of less than about 104 ohms/square.

52. The conformal coating of claim 48, wherein the film has a surface resistance in the range of less than about 103 ohms/square.

53. The conformal coating of claim 48, wherein the film has a surface resistance in the range of about 10⁻

2-10⁰ ohms/square.

54. The conformal coating of claim 48, wherein the coating provides EMI shielding properties in the 10-70 dB attenuation range.

55. The conformal coating of claim 48, wherein the carbon nanotubes are chemically modified.

56. The conformal coating of claim 48, wherein the carbon nanotubes are present on a surface of said conformal coating.

57. A dispersion comprising a plurality of carbon nanotubes and a conformal coating material selected from the group consisting of polyurethanes, parylene, acrylics, epoxies and silicone.

58. The dispersion of claim 57, wherein the carbon nanotubes are selected from the group consisting of single-walled nanotubes, double-walled nanotubes, multi-walled nanotubes, and mixtures thereof.

59. The dispersion of claim 57, wherein the carbon nanotubes are substantially single-walled nanotubes.

60. The dispersion of claim 57, further comprising a polymeric material, wherein the polymeric material comprises a material selected from the group consisting of thermoplastics, thermosetting polymers, elastomers, conducting polymers and combinations thereof.

61. The dispersion of claim 57, further comprising a plasticizer, softening agent, filler, reinforcing agent, processing aid, stabilizer, antioxidant, dispersing agent, binder, a cross-linking agent, a coloring agent, a UV absorbent agent, or a charge adjusting agent.

62. The dispersion of claim 57, further comprising conductive organic particles, inorganic particles or combinations or mixtures thereof.

63. The dispersion of claim 62, wherein the conductive organic particles are selected from the group consisting of buckeyballs, carbon black, fullerenes, and combinations and mixtures thereof.

64. The dispersion of claim 62, wherein the conductive inorganic particles are selected from the group consisting of nickel, silver and copper.

65. The dispersion of claim 62, wherein the dispersion can form a coating, wherein the coating provides EMI shielding properties in the 10-70 dB attenuation range.