Electrically conductive composite material

• US 7,935,415 B1
• Filed: 04/15/2003
• Issued: 05/03/2011
• Est. Priority Date: 04/17/2002
• Status: Active Grant

• Current Assignee: Conductive Composites Company, LLC
• Original Assignee: Conductive Composites Company, LLC
• Inventors: Hansen, Lauren, Jenkin, William C., Hansen, George Clayton
• Primary Examiner(s): Tarazano; D. Lawrence
• Assistant Examiner(s): Thompson; Camie S
• Application Number:
  US10/414,266
• Time in Patent Office: 2,940 Days
• Field of Search: 524/495, 524/439, 524/441, 524/440, 428/328, 428/292.1
• US Class Current: 428/292.1
• CPC Class Codes: B29C 70/14 oriented
• CPC Class Codes: B29C 70/882 partly or totally electrically conductive, e.g. for EMI shielding conductive floors or floor coverings H05F3/025; EMI shielding in general H05K9/00
• CPC Class Codes: D04H 5/00 Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
• CPC Class Codes: G01K 2211/00 Thermometers based on nanotechnology
• CPC Class Codes: G01K 5/50 arranged for free expansion or contraction
• CPC Class Codes: Y10S 977/754 Dendrimer, i.e. serially branching or "tree-like" structure
• CPC Class Codes: Y10S 977/778 within specified host or matrix material, e.g. nanocomposite films
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/249931 Free metal or alloy fiber
• CPC Class Codes: Y10T 428/249933 Fiber embedded in or on the surface of a natural or synthetic rubber matrix
• CPC Class Codes: Y10T 428/256 Heavy metal or aluminum or compound thereof

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.

Claims

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.

2. The composite material of claim 1, 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.

3. The composite material of claim 1, wherein the fibers are formed of a material selected to cooperate with the liberated metallic branching nanostrands to synergistically improve an electrical conductivity of the composite material.

4. The composite material of claim 1, wherein the fibers are selected to enhance a mechanical strength of the composite material.

5. The composite material of claim 1, wherein the liberated metallic branching nanostrands formed by minimal shear mixing are constructed substantially of nickel.

6. The composite material of claim 1, wherein the matrix is formed substantially of a nonconductive material selected from the group consisting of elastomers and ceramics.

7. The composite material of claim 6, wherein the matrix is formed substantially of an elastomer, wherein the liberated metallic branching nanostrands formed by minimal shear mixing provide an electrical conductivity of the composite material that varies generally in proportion to a magnitude of deformation of the elastomer.

8. The composite material of claim 1, wherein the fibers are oriented generally parallel to each other.

9. The composite material of claim 1, wherein the matrix coats at least a portion of a surface of a body, 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.

10. The composite material of claim 1, wherein the liberated metallic branching nanostrands formed by minimal shear mixing are formed through a process selected to provide a comparatively high degree of branching of the liberated metallic branching nanostrands.

11. The composite material of claim 1, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average aspect ratio greater than about twenty-to-one.

12. The composite material of claim 11, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average aspect ratio greater than about fifty-to-one.

13. The composite material of claim 1, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter that ranges from about one tenth of a micron to about four microns.

14. The composite material of claim 1, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter that ranges from about one-half micron to about two microns.

15. The composite material of claim 1, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter less than about two microns and an average aspect ratio greater than about twenty-to-one.

16. 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; 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.

17. The composite material of claim 16, wherein the liberated metallic branching nanostrands formed by minimal shear mixing are constructed substantially of nickel.

18. The composite material of claim 16, wherein the matrix is formed substantially of a nonconductive material selected from the group consisting of elastomers and ceramics.

19. The composite material of claim 16, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average aspect ratio greater than about twenty-to-one.

20. The composite material of claim 19, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average aspect ratio greater than about fifty-to-one.

21. The composite material of claim 16, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter that ranges from about one tenth of a micron to about four microns.

22. The composite material of claim 16, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter that ranges from about one-half micron to about two microns.

23. The composite material of claim 16, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter less than about two microns and an average aspect ratio greater than about twenty-to-one.

24. A composite material comprising:

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.

25. The composite material of claim 24, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter less than about two microns and an average aspect ratio greater than about twenty-to-one.

26. An electrically conductive article comprising:

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.

27. The electrically conductive article of claim 26, wherein the nonmetallic material comprises a polymer selected to permit application of the electrically conductive mixture to the surface in the form of a paint.

28. The electrically conductive article of claim 26, wherein the liberated metallic branching nanostrands formed by minimal shear mixing are constructed substantially of nickel.

29. The composite material of claim 26, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter less than about two microns and an average aspect ratio greater than about twenty-to-one.

30. 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 have a volumetric concentration ranging from about one-half of a percent to about twenty percent.

31. The composite material of claim 30, wherein the fibers are formed of a material selected to cooperate with the liberated metallic branching nanostrands formed by minimal shear mixing to synergistically improve an electrical conductivity of the composite material.

32. The composite material of claim 30, wherein the fibers are selected to enhance a mechanical strength of the composite material.

33. The composite material of claim 30, wherein the liberated metallic branching nanostrands formed by minimal shear mixing are constructed substantially of nickel.

34. The composite material of claim 30, wherein the matrix is formed substantially of a nonconductive material selected from the group consisting of elastomers and ceramics.

35. The composite material of claim 34, wherein the matrix is formed substantially of an elastomer, wherein the liberated metallic nanostrands formed by minimal shear mixing provide an electrical conductivity of the composite material that varies generally in proportion to a magnitude of deformation of the elastomer.

36. The composite material of claim 30, wherein the fibers are oriented generally parallel to each other.

37. The composite material of claim 30, wherein the matrix coats at least a portion of a surface of a body, 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.

38. The composite material of claim 30, wherein the liberated metallic branching nanostrands formed by minimal shear mixing are formed through a process selected to provide a comparatively high degree of branching of the liberated metallic branching nanostrands.

39. 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 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.

40. The composite material of claim 39, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average aspect ratio greater than about fifty-to-one.

41. The composite material of claim 39, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter that ranges from about one tenth of a micron to about four microns.

42. The composite material of claim 39, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter that ranges from about one-half micron to about two microns.

43. The composite material of claim 39, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average diameter less than about two microns and an average aspect ratio greater than about twenty-to-one.

44. 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 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.

45. The composite material of claim 44, wherein the liberated metallic branching nanostrands formed by minimal shear mixing have an average aspect ratio greater than about twenty-to-one.

46. 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 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.

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.

48. The liberated metallic branching nanostrand of claim 47 constructed substantially of nickel.

49. An electrically-conductive composite material comprising:

(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.

50. An electrically-conductive composite material as recited in claim 49, wherein the resin comprises a medium viscosity quick-set epoxy resin.

51. An electrically-conductive composite material as recited in claim 49, wherein the liberated metallic branching nanostrands formed by minimal shear mixing are comprised of pure metallic nickel.

52. An electrically-conductive composite material as recited in claim 49, wherein the liberated metallic branching nanostrands formed by minimal shear mixing are of sub-micron diameter.

53. An electrically-conductive composite material as recited in claim 49, wherein the volume resistivity of the composite material in an ASTM 2793 test method is less than about 1.00 E+08 ohm-centimeters.

54. An electrically-conductive composite material as recited in claim 49, wherein the volume resistivity of the composite material in an ASTM 257 test method is less than about 1.00 E+05 ohm-centimeters.