Electrically conductive composite material
First Claim
1. A composite material comprising:
- a matrix of a nonmetallic material;
a plurality of liberated metallic branching nanostrands formed by minimal shear mixing having an average diameter less than about four microns and an average aspect ratio greater than about ten-to-one, distributed substantially throughout the matrix;
a plurality of fibers distributed substantially throughout the matrix, wherein the fibers have an average diameter greater than about four microns; and
wherein the liberated metallic branching nanostrands formed by minimal shear mixing and the fibers have a total volumetric concentration within the matrix such that there is an electrical conductivity of the composite material that is at least ten times an electrical conductivity of the nonmetallic material alone.
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Accused Products
Abstract
An electrically conductive composite material includes metallic nanostrands distributed throughout a matrix constructed of a polymer, ceramic, or elastomer. The nanostrands may have an average diameter under four microns and an average aspect ratio over ten-to-one. Larger fibers may also be included to enhance electrical conductivity or other properties. The nanostrands and/or fibers may be magnetically oriented to enhance electrical conductivity along one direction. A pressure sensor may be formed by utilizing an elastomer for the matrix. Electrical conductivity through the composite material varies in proportion to deflection of the elastomer. A composite material may be applied to a surface as an electrically conductive paint. Composite materials may be made by cutting a blank of the nanostrands to the desired shape, inserting the matrix, and curing the matrix. Alternatively, a suspension agent may first be used to dispose powdered nanostrands in the desired shape.
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Citations
54 Claims
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1. A composite material comprising:
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a matrix of a nonmetallic material; a plurality of liberated metallic branching nanostrands formed by minimal shear mixing having an average diameter less than about four microns and an average aspect ratio greater than about ten-to-one, distributed substantially throughout the matrix; a plurality of fibers distributed substantially throughout the matrix, wherein the fibers have an average diameter greater than about four microns; and wherein the liberated metallic branching nanostrands formed by minimal shear mixing and the fibers have a total volumetric concentration within the matrix such that there is an electrical conductivity of the composite material that is at least ten times an electrical conductivity of the nonmetallic material alone. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A composite material comprising:
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a matrix of a nonmetallic material; a plurality of liberated metallic branching nanostrands formed by minimal shear mixing having an average diameter less than about four microns and an average aspect ratio greater than about ten-to-one, distributed substantially throughout the matrix; and a plurality of fibers that are oriented generally parallel to each other and wherein the liberated metallic branching nanostrands formed by minimal shear mixing have a total volumetric concentration within the matrix such that there is an electrical conductivity of the composite material that is at least ten times an electrical conductivity of the nonmetallic material alone. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23)
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24. A composite material comprising:
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a matrix formed substantially of a nonmetallic material; and a plurality of liberated metallic branching nanostrands formed by minimal shear mixing having an average diameter less than about four microns and an average aspect ratio greater than about ten-to-one, distributed substantially throughout the matrix; wherein the nonconductive material comprises an elastomer selected such that electrical conductivity through the composite material changes in proportion to deformation of the composite material. - View Dependent Claims (25)
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26. An electrically conductive article comprising:
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a body having a surface; and an electrically conductive mixture coating at least a portion of the surface, the electrically conductive mixture comprising a plurality of liberated metallic branching nanostrands formed by minimal shear mixing, a plurality of fibers, and a matrix, wherein the matrix is formed substantially of a nonmetallic material and the liberated nanostrands and fibers formed by minimal shear mixing are distributed throughout the matrix, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter less than about four microns and the fibers have an average diameter greater than about four microns; wherein the liberated metallic branching nanostrands formed by minimal shear mixing act to convey electric current through the matrix to enhance electrical conductivity of the surface and wherein the liberated metallic branching nanostrands formed by minimal shear mixing have a volumetric concentration within the matrix such that there is an electrical conductivity of the electrically conductive mixture that is at least ten times an electrical conductivity of the body alone. - View Dependent Claims (27, 28, 29)
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30. A composite material comprising:
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a matrix of a nonmetallic material; a plurality of liberated metallic branching nanostrands formed by minimal shear mixing having an average diameter less than about four microns and an average aspect ratio greater than about ten-to-one, distributed substantially throughout the matrix; a plurality of fibers distributed substantially throughout the matrix, wherein the fibers have an average diameter greater than about four microns; and wherein the liberated metallic branching nanostrands formed by minimal shear mixing have a volumetric concentration ranging from about one-half of a percent to about twenty percent. - View Dependent Claims (31, 32, 33, 34, 35, 36, 37, 38)
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39. A composite material comprising:
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a matrix of a nonmetallic material; a plurality of liberated metallic branching nanostrands formed by minimal shear mixing having an average diameter less than about four microns and an average aspect ratio greater than about twenty-to-one, distributed substantially throughout the matrix; and a plurality of fibers distributed substantially throughout the matrix, wherein the fibers have an average diameter greater than about four microns. - View Dependent Claims (40, 41, 42, 43)
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44. A composite material comprising:
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a matrix of a nonmetallic material; a plurality of liberated metallic branching nanostrands formed by minimal shear mixing having an average diameter that ranges from about one tenth of a micron to about four microns and an average aspect ratio greater than about ten-to-one, distributed substantially throughout the matrix; and a plurality of fibers distributed substantially throughout the matrix, wherein the fibers have an average diameter greater than about four microns. - View Dependent Claims (45)
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46. A composite material comprising:
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a matrix of a nonmetallic material; a plurality of liberated metallic branching nanostrands formed by minimal shear mixing having an average diameter less than about four microns and an average aspect ratio greater than about twenty-to-one, distributed substantially throughout the matrix; and wherein a plurality of fibers are distributed substantially throughout the matrix, and wherein the fibers are oriented generally parallel to each other.
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- 47. A liberated metallic branching nanostrand formed by minimal shear mixing having an average diameter less than about four microns and an average aspect ratio greater than about ten-to-one.
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49. An electrically-conductive composite material comprising:
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(a) a matrix of a solidified flowable electrically nonconductive polymeric resin; and (b) a dispersion of liberated metallic branching nanostrands formed by minimal shear mixing and distributed with substantial uniformity throughout the solidified matrix, the liberated metallic branching nanostrands formed by minimal shear mixing retaining substantial lengths, large aspect ratio values, and abundant lateral branchings. - View Dependent Claims (50, 51, 52, 53, 54)
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Specification