Devices comprising conductive polymers
First Claim
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1. An electrical device which comprises (1) an element composed of a conductive polymer composition;
- (2) a flame-sprayed layer of a material which at 25°
C. has a resistivity of at most 5×
10-2 ohm.cm, said layer being at least one mil thick; and
(3) a foraminous element at the interface between said conductive polymer element (1) and said flame-sprayed layer (2);
there being electrical and direct physical contact between said conductive polymer element (1) and said flame-sprayed layer (2) in interstices of said foraminous element (2).
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Abstract
Electrical devices comprise a conductive polymer element and, in electrical contact therewith, a flame-sprayed layer of a metal or other highly conductive material. Electrical leads can readily be attached to the flame-sprayed layer. Particularly valuable devices are those in which at least part of the conductive polymer element is a PTC or NTC conductive polymer. The flame-sprayed layer can be formed directly by flame-spraying a suitable material onto the device, or by flame-spraying the material onto a carrier and then laminating the layer, on the carrier, to the device.
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Citations
43 Claims
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1. An electrical device which comprises (1) an element composed of a conductive polymer composition;
- (2) a flame-sprayed layer of a material which at 25°
C. has a resistivity of at most 5×
10-2 ohm.cm, said layer being at least one mil thick; and
(3) a foraminous element at the interface between said conductive polymer element (1) and said flame-sprayed layer (2);
there being electrical and direct physical contact between said conductive polymer element (1) and said flame-sprayed layer (2) in interstices of said foraminous element (2). - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
- (2) a flame-sprayed layer of a material which at 25°
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25. A method of providing a highly conductive layer on a surface of a device which comprises an element composed of a conductive polymer composition and a foraminous element, said surface being provided by the foraminous element and by the conductive polymer composition in interstices of the foraminous element, which method comprises flame-spraying onto the surface of the device a material which at 25°
- C. has a resistivity of at most 5×
10-2 ohm.cm, to form a layer of said material which is in electrical contact and in direct physical contact with said element. - View Dependent Claims (26, 27, 28, 29, 30, 31)
- C. has a resistivity of at most 5×
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32. A method of providing a highly conductive layer on a surface of a device which comprises an element composed of a conductive polymer composition, which method comprises
(a) flame-spraying, onto the surface of a carrier member, a material which at 25° - C. has a resistivity of at most 5×
10-2 ohm.cm, to form a layer of said material which is at least 1 mil thick; and(b) contacting said flame-sprayed layer, on said carrier member, and a surface of said device which comprises an element composed of a conductive polymer composition, under conditions of heat and pressure, to form a layer of said material which is in electrical contact and in physical contact with said element. - View Dependent Claims (33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43)
- C. has a resistivity of at most 5×
Specification