ELECTRICALLY CONDUCTIVE POLYMER COMPOSITES

• US 20090189125A1
• Filed: 01/28/2009
• Published: 07/30/2009
• Est. Priority Date: 01/28/2008
• Status: Active Grant

• Current Assignee: Yazaki Corporation
• Original Assignee: Yazaki Corporation
• Inventors: Chen, Chorng-Jeou, Grigorian, Leonid
• Granted Patent: US 8,597,547 B2
• Time in Patent Office: Days
• US Class Current: 252/511
• CPC Class Codes: H01B 1/06 mainly consisting of other non-metallic substances
• CPC Class Codes: H01B 1/24 the conductive material comprising carbon-silicon compounds, carbon or silicon

Abstract

This invention relates to a process for preparing an electrically conductive composite comprising the weight ratio of carbon to polymer of greater than 0.11. The process comprises the steps of mixing non-predispersed carbon with an emulsion comprising a polymer in a liquid solvent to obtain a dispersion of the carbon within the polymer matrix, wherein the weight ratio of carbon to polymer is greater than 0.11; and removing the liquid solvent from the dispersion. The invention also relates to conductive polymer composites prepared by the process.

Claims

1. A process for preparing an electrically conductive composite comprising the steps of:

mixing non-predispersed carbon with an emulsion comprising a polymer in a liquid solvent to obtain a dispersion of the carbon within the polymer matrix, wherein the weight ratio of carbon to the polymer is greater than 0.11; and

removing the liquid solvent from the dispersion,

whereby an electrically conductive composite comprising the weight ratio of carbon to the polymer of greater than 0.11 is obtained.

2. The process according to claim 1, wherein said carbon is graphite, carbon fibers, carbon nanotubes, or a mixture thereof.

3. The process according to claim 2, wherein said carbon is expanded graphite nanoplatelets.

4. The process according to claim 1, wherein said polymer is selected from the group consisting of polypropylene, polyethylene, acrylic, vinyl acrylic, styrene acrylic, vinyl ester, vinyl acetate, starches, epoxies, natural rubbers, synthetic rubbers, latexes, and a mixture thereof.

5. The process according to claim 1, wherein said polymer is polypropylene.

6. The process according to claim 1, wherein the weight ratio of carbon to polymer is equal to or greater than about 0.25.

7. The process according to claim 6, wherein the weight ratio of carbon to polymer is about 0.25-1.0.

8. The process according to claim 6, wherein the weight ratio of carbon to polymer is about 0.25-0.43.

9. The process according to claim 1, wherein the liquid is water.

10. The process according to claim 1, wherein the mixing is by mechanical agitation or by sonication.

11. An electrically conductive composite prepared according to claim 1.

12. The electrically conductive composite according to claim 11, wherein said carbon is graphite, carbon fibers, carbon nanotubes, or a mixture thereof.

13. The electrically conductive composite according to claim 12, wherein said carbon is expanded graphite nanoplatelets.

14. The electrically conductive composite according to claim 11, wherein said polymer is selected from the group consisting of polypropylene, polyethylene, acrylic, vinyl acrylic, styrene acrylic, vinyl ester, vinyl acetate, starches, epoxies, natural rubbers, synthetic rubbers, latexes, and a mixture thereof.

15. The electrically conductive composite according to claim 14, wherein said polymer is polypropylene.

16. The electrically conductive composite according to claim 11, wherein the weight ratio of carbon to polymer is equal to or greater than 0.25.

17. The electrically conductive composite according to claim 16, wherein the weight ratio of carbon to polymer is 0.25-0.43.

18. The electrically conductive composite according to claim 16, wherein the weight ratio of carbon to polymer is 0.25-1.0.

19. The electrically conductive composite according to claim 11, wherein the liquid is water.