Conductive composite material and method for preparing conductive composite material

Abstract

The name of the present invention is a conductive composite material and a method for preparing a conductive composite material. The conductive composite material includes a first elastic polymer layer, a conductive fluorinated fluid layer on the first elastic polymer layer, and a second elastic polymer layer on the conductive fluorinated fluid layer.

Description

BACKGROUND OF THE INVENTION

[0001] Broadly speaking, a conductive composite material is any composite material having significant electrical conductivity and / or thermal conductivity. Such conductive composite materials have a wide range of uses in telecommunications, power generation and distribution, defense, aerospace, medicine, and other fields.

[0002] Conductive composite materials are typically prepared by combining a polymeric material with solid conductive particles and / or by combining a polymeric material with solid conductive particles to obtain properties. To obtain sufficient conductivity, i.e., to reach percolation, a high particle loading of typically more than 45 volume % is usually required. Polymers having these particle loading levels are typically rigid materials. Thus, these particle loading levels result in conductive films and coatings having properties (such as elongation at break, tensile strength, and thermal stability) that make them unsuitable or difficult to use.

[0003] Therefore, those skilled in the art continue to conduct research and development in the field of conductive composite materials. SUMMARY OF THE INVENTION

[0004] In one embodiment, a conductive composite material includes a first elastic polymer layer, a conductive fluorinated fluid layer on the first elastic polymer layer, and a second elastic polymer layer on the conductive fluorinated fluid layer.

[0005] In another embodiment, a method for preparing a conductive composite material includes: forming a first elastic polymer layer; forming a conductive fluorinated fluid layer on the first elastic polymer layer; and forming a second elastic polymer layer on the conductive fluorinated fluid layer.

[0006] Other embodiments of the disclosed conductive composite materials and methods for preparing conductive composite materials will become apparent from the following detailed description, the drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a perspective view of an exemplary conductive composite material according to an exemplary embodiment of the present specification.

[0008] Figure 2 is Figure 1 of the exemplary conductive composite material along Figure 1 section lines A - A and B - B shown in the cross-sectional perspective view.

[0009] Figures 3A to 3C is a perspective view showing the steps for preparing Figure 1 and Figure 2 of the exemplary conductive composite material.

[0010] Figure 4 is a flow chart of a method for manufacturing and servicing an aircraft.

[0011] Figure 5 is a block diagram of an aircraft. Detailed Description

[0012] Figure 1 is a perspective view of an exemplary conductive composite material according to an exemplary embodiment of the present specification. Figure 2 is Figure 1 of the exemplary conductive composite material along Figure 1 section lines A - A and B - B shown in the cross - sectional perspective view.

[0013] As Figure 1 and Figure 2 shown, the conductive composite material 2 includes a first elastic polymer layer 4, a conductive fluorinated fluid layer 6 on the first elastic polymer layer 4, a second elastic polymer layer 8 on the conductive fluorinated fluid layer 6, and an optional reinforcing mesh 10 in contact with the conductive fluorinated fluid layer 6.

[0014] In an embodiment, the conductive composite material of the present invention provides conductivity without rigidity; a low - viscosity conductive fluid without using common room - temperature liquid metals and alloys (such as gallium); and / or increased viscosity and fluidity to prevent leakage of the conductive filling paste during the use of the composite material. Also, in an embodiment, the conductive composite material of the present invention allows the amount of the required conductive paste and the possibility of paste leaching to be minimized. Further, in an embodiment, the conductive composite material provides additional conductivity and / or structural integrity without sacrificing elongation.

[0015] An elastic polymer is a polymer that exhibits elasticity at high strain levels. On the one hand, the elastic polymer of the present specification is a polymer that exhibits an elongation at break of greater than about 50%. On the other hand, the elastic polymer of the present specification is a polymer that exhibits an elongation at break of greater than about 100%. On the other hand, the elastic polymer of the present invention is a polymer that exhibits an elongation at break of greater than about 200%. The elongation at break is measured as the percentage of strain of the material before it breaks after the application of tension. The percentage of the original length is used to represent the elongation at break.

[0016] On the one hand, the elastic polymer of the present specification is an electrical insulator. On the one hand, the elastic polymer of the present specification is an electrical insulator with a conductivity of less than about 1×10 -8 S / m. On the other hand, the elastic polymer of the present specification is an electrical insulator with a conductivity of less than about 1×10 -9 S / m. On the other hand, the elastic polymer of the present specification is an electrical insulator with a conductivity of less than about 1×10 -10 S / m.

[0017] The first elastic polymer layer 4 and the second elastic polymer layer 8 may include at least one of a thermoplastic polymer, a thermosetting polymer, and combinations thereof. In one aspect, suitable elastic polymers for the first elastic polymer layer 4 and the second elastic polymer layer 8 have a viscosity of from about 1,000 to about 100,000 cP under typical processing conditions. In another aspect, suitable elastic polymers for the first elastic polymer layer 4 and the second elastic polymer layer 8 have a viscosity of from about 1,000 to about 25,000 cP under typical processing conditions. In another aspect, suitable elastic polymers for the first elastic polymer layer 4 and the second elastic polymer layer 8 have a viscosity of from about 25,000 to about 50,000 cP under typical processing conditions. In another aspect, suitable elastic polymers for the first elastic polymer layer 4 and the second elastic polymer layer 8 have a viscosity of from about 50,000 to about 75,000 cP under typical processing conditions. In another aspect, suitable elastic polymers for the first elastic polymer layer 4 and the second elastic polymer layer 8 have a viscosity of from about 75,000 to about 100,000 cP under typical processing conditions. In certain instances, the thermoplastic elastomers suitable for use herein have a viscosity of from about 1,000 to about 50,000 cP under typical processing conditions. As used herein, the term "typical processing conditions" includes temperatures from about room temperature (about 25 °C) to about 400 °C, from about room temperature to about 200 °C, or from about room temperature to about 100 °C. Measurement techniques for measuring viscosity may include viscometers, rheometers, or other suitable viscosity testing equipment. Such thermoplastic elastomers are convenient for preparing flexible materials.

[0018] Suitable elastic polymers for the first elastic polymer layer 4 and the second elastic polymer layer 8 include thermoplastic elastic polymers, thermosetting elastic polymers, and combinations thereof. For example, suitable elastic polymers for the first elastic polymer layer 4 and the second elastic polymer layer 8 include siloxanes, fluorosiloxanes, perfluoropolyethers, polybutadienes, polyesters, polycarbonates, polyurethanes, polyureas, polyurethane-ureas, epoxy resins, acrylates, natural rubbers, butyl rubbers, polyacrylonitriles, ethylene propylene diene monomer (EPDM) rubbers, or combinations thereof. The first elastic polymer layer 4 and the second elastic polymer layer 8 may be formed of the same or different polymers.

[0019] In one aspect, at least one of the first elastic polymer layer 4 and the second elastic polymer layer 8 may include a conductive additive to create an electrical connection across the entire laminate. For example, the conductive additive may include particles (e.g., rods) added to at least one elastic polymer layer, wires added to at least one elastic polymer layer, or particles (e.g., rods) and wires added to at least one elastic polymer layer. By including the conductive additive in the elastic polymer layer, an electrical connection to the conductive fluorinated fluid layer 6 can be achieved, which is desirable for certain applications.

[0020] In the context of this specification, the conductive fluorinated fluid is a high-viscosity fluid. The conductive fluorinated fluid of this specification is not cured or hardened into a solid state. Instead, the conductive fluorinated fluid of this specification remains in a high-viscosity fluid state. On the one hand, the viscosity of the conductive fluorinated fluid of this specification ranges from about 2,000 to about 10,000,000 cP. On the other hand, the viscosity of the conductive fluorinated fluid of this specification ranges from about 2,000 to about 5,000,000 cP. On the other hand, the viscosity of the conductive fluorinated fluid of this specification ranges from about 2,000 to about 1,000,000 cP.

[0021] A conductive fluorinated fluid is a fluorinated fluid capable of carrying an electric current. On the one hand, the conductivity of the conductive fluorinated fluid of this specification is greater than about 1×10 1 S / m. On the other hand, the conductivity of the conductive fluorinated fluid of this specification is greater than about 1×10 2 S / m. On the other hand, the conductivity of the conductive fluorinated fluid of this specification is greater than about 1×10 3 S / m. On the other hand, the conductivity of the conductive fluorinated fluid of this specification is greater than about 1×10 4 S / m. On the other hand, the conductivity of the conductive fluorinated fluid of this specification is greater than about 1×10 5 S / m. The conductive fluorinated fluid layer (6) can be homogeneous or inhomogeneous.

[0022] On the one hand, the conductive fluorinated fluid includes a fluorinated component and a conductive additive. The fluorinated component can include, for example, at least one of perfluoropolyether, fluorinated acrylate oligomer, and combinations thereof.

[0023] On the one hand, the viscosity of the fluorinated component ranges from about 2,000 to about 10,000,000 cP. On the other hand, the viscosity of the fluorinated component ranges from about 2,000 to about 5,000,000 cP. On the other hand, the viscosity of the fluorinated component ranges from about 2,000 to about 1,000,000 cP. However, the fluorinated component can have a lower viscosity, and the viscosity of the conductive fluorinated fluid can be increased by a conductive additive or a thickening agent.

[0024] In some instances, the average aspect ratio of the conductive additive is in the range of 1 to about 2. The conductive additive with a low aspect ratio can take the form of, for example, powder. The average maximum size of the conductive additive with a low aspect ratio can be, for example, in the range of about 0.1 to about 500 μm, such as in the range of about 50 to about 150 μm. In other instances, the average aspect ratio of the conductive additive is greater than about 2, such as in the range of about 2 to about 2,000. The conductive additive with a high aspect ratio can take the form of, for example, rods or wires. The average maximum size of the conductive additive with a high aspect ratio can be in the range of, for example, about 0.1 mm to about 10 mm.

[0025] The conductive additive used herein can also act as a viscosity modifier, thus helping to resist or minimize the flow of the fluorine fluid itself and can help to resist or minimize the flow of the fluorine fluid within the conductive fluorine fluid layer. The conductive additive used herein can be, for example, an inorganic material. When mixed with the fluorinated component, the conductive additive remains solid. The conductive additive is generally used as particles in the shape of, for example, rods, wires, substantially spherical particles, or a mixture thereof, and the particle size determines the ease of homogenization of the conductive additive with the fluorine fluid.

[0026] The conductive additive has electrical conductivity. The conductive additive increases the conductivity of the resulting conductive composite 2 or enables a reduction in the amount of the conductive fluorine fluid 6 required to achieve the same conductivity. By adjusting the amount of the fluorine fluid or the amount of the conductive additive, the overall conductivity can be adjusted.

[0027] In one aspect, the conductive additive includes at least one of, for example, carbon fibers, coated carbon fibers, and metal materials, such as at least one of metals or alloys of, for example, stainless steel, brass, and at least one of iron, nickel, titanium, aluminum, copper, silver, gold, platinum, palladium, and zinc, and combinations thereof. As a specific example, the conductive additive includes nickel-coated carbon fibers.

[0028] In some instances, the conductive additive includes particles of a conductive additive having an average aspect ratio greater than about 2 (i.e., where the length is at least about twice the width), such as rods or wires. The average aspect ratio can be measured using a microscope.

[0029] In other instances, the conductive additive includes particles of a conductive additive having an average aspect ratio of less than about 2 (i.e., where the length is at most about twice the width), e.g., substantially spherical particles. In certain instances, the conductive additive includes substantially spherical particles of a conductive additive having an average particle size of about 0.1 to about 500 μm (about 100 to about 500,000 nm). In certain instances, the conductive additive includes substantially spherical particles having an average particle size of about 1 to about 25 μm, or about 25 to about 50 μm, or about 50 to about 75 μm, or about 75 to about 100 μm, or about 100 to about 150 μm, or about 150 to about 200 μm, or about 200 to about 250 μm, or about 250 to about 300 μm, or about 300 to about 350 μm, or about 350 to about 400 μm, or about 450 to about 500 μm. In other instances, the conductive additive includes substantially spherical particles of a conductive additive having an average particle size of about 50 to about 150 μm. In certain instances, the particles of the conductive additive have an average particle size of about 0.1 to about 5 μm. The particle size can be measured using a Coulter Counter or Multisizer.

[0030] In one instance, the conductive additive has an average aspect ratio greater than about 2 and includes rods or wires having a length of about 0.01 to about 10 mm. In certain instances, the length of the conductive additive rods is about 0.01 to about 0.5 mm, or about 0.05 to about 10 mm, or about 0.01 to about 10 mm, or about 0.01 to about 10 mm, or about 0.01 to about 10 mm, or about 0.1 to about 1 mm, or about 0.1 to about 1 mm, or about 1 to about 5 mm, or about 5 to about 10 mm. The use of conductive rods or wires contributes to the conductivity of the final composite material to a greater extent compared to conventional spherical conductive particles.

[0031] In certain instances, the conductive additive includes a powder having particles with a mixture of rods or wires and substantially spherical particles, or includes a mixture of rods, wires, and substantially spherical particles.

[0032] Conductive additives can act as thickeners. In such cases, the conductive additives can be used in amounts that produce an appropriate viscosity and / or regulate the conductive properties of the resulting composite material. When using a powder of particles having a rod or wire shape as the conductive additive, the amount of the conductive additive can be reduced. The suitable amount range of the rod or wire conductive additive in the conductive fluorinated fluid is from about 2% to about 40% by volume of the conductive fluorinated fluid. In certain examples, the amount of the conductive additive is from about 2% to about 5%, or about 5 to about 10%, or about 10 to about 15%, or about 15 to about 20%, about 20 to about 25%, or about 25 to about 30%, or about 30 to about 40% by volume of the conductive fluorinated fluid.

[0033] Suitable conductivity can be achieved in the conductive composite materials disclosed herein without the need for a large amount of conductive additive in the conductive fluorinated fluid, i.e., a loading of such particles greater than about 45% by volume. However, the conductive composite materials of this specification are not limited to a particle loading level of less than about 45% by volume. Thus, a particle loading level of greater than about 45% by volume can be used in the conductive fluorinated fluid.

[0034] In one aspect, the conductive fluorinated fluid layer can further include a non-conductive thickener. The thickener can include, for example, at least one of an organic thickener, an inorganic thickener, and combinations thereof.

[0035] In certain examples, the average aspect ratio of the thickener is from 1 to about 2. The low aspect ratio thickener can take the form of, for example, a powder. The low aspect ratio thickener can have, for example, an average maximum size in the range of about 0.1 to about 500 μm, such as in the range of about 50 to about 150 μm. In other examples, the thickener has an average aspect ratio greater than about 2, such as in the range of about 2 to about 2,000. The high aspect ratio thickener can take the form of, for example, a rod or a wire. The high aspect ratio thickener can have, for example, an average maximum size in the range of about 0.1 to about 10 mm.

[0036] The thickeners used herein act as viscosity regulators and can help resist or minimize the flow of the fluorinated fluid within the conductive fluorinated fluid layer. The thickeners used herein can be inorganic or organic materials. When mixed with the conductive fluorinated fluid, the thickeners remain solid. The thickeners are generally used as particles in the shape of, for example, rods, wires, substantially spherical particles, or mixtures thereof, and the particle size determines the ease of homogenization of the powder with the fluorinated fluid. Generally, thickeners with a higher surface area will be better thickeners compared to thickeners with a lower surface area.

[0037] In examples where the conductive fluorinated fluid further includes a thickener, the thickener can be used in an amount that produces an appropriate viscosity.

[0038] In some instances, the thickening agent used to prepare the conductive composite material is an organic thickening agent. Examples of such compounds are maltol, phenol, naphthalene, 1-naphthol, 2-naphthol, 4-pyridone, and carbon, including, for example, graphite and carbon black. When the organic thickening agent is a compound having a phenolic hydroxyl group, the compound can react through the hydroxyl group with the isocyanate group of a diisocyanate or polyisocyanate, but this reaction will be slower than the reaction to form a carbamate or urea. Used appropriately, such a compound can be used to modify the properties of the resulting thickening agent. The thickening agent can be a mixture of at least one organic thickening agent and at least one inorganic thickening agent.

[0039] In one aspect, the conductive fluorinated fluid layer includes a compatibility agent. The compatibility agent can include at least one of, for example, an organic compatibility agent, an inorganic compatibility agent, and combinations thereof. When the compatibility agent includes an organic compatibility agent, the organic compatibility agent can include, for example, surfactants such as ionic surfactants, nonionic surfactants, and combinations thereof. When the compatibility agent includes an inorganic compatibility agent, the inorganic compatibility agent can include, for example, metal nanoparticles.

[0040] The compatibility agent used herein improves the processability (e.g., flowability, ease of application) of the conductive fluorinated fluid.

[0041] In some instances, the compatibility agent used herein can also be used to thicken the conductive fluorinated fluid, i.e., to increase the viscosity of the conductive fluorinated fluid.

[0042] In some instances, the conductive fluorinated fluid used to form the conductive composite material comprises a fluorinated fluid and a compatibility agent, and the weight ratio of the fluorinated fluid to the compatibility agent is from about 5:1 to about 50:1, or from about 10:1 to about 30:1, or from about 15:1 to about 25:1, or from about 20:1 to about 25:1. Thus, the amount of the compatibility agent, as a percentage of the fluorinated fluid, is from about 2 wt% to about 20 wt%. A particularly useful amount of the compatibility agent is from about 4 wt% to about 10 wt%. The weight percentage refers to the weight of the compatibility agent relative to the total weight of the conductive fluorinated fluid. Phase separation should be avoided. At higher levels of the compatibility agent, phase separation may occur, which can be addressed using the thickening agents disclosed elsewhere herein.

[0043] In some instances, the compatibilizing agent includes inorganic nanoparticles having an average particle size less than about 100 nm, or less than about 90 nm, or less than about 80 nm, or less than about 70 nm, less than about 60 nm, or less than about 50 nm, or less than about 40 nm, or less than about 30 nm, or less than about 20 nm in any linear dimension, such as metal nanoparticles. For example, the particle sizes mentioned herein can be measured using a Coulter Counter or Multisizer. Suitable nanoparticles include metals that are insoluble, i.e., not dissolved, in the conductive fluorinated fluid. Examples of suitable metals used as nanoparticle compatibilizing agents herein include silver, copper, brass, bronze, nickel, stainless steel, carbon, coated carbon, titanium, tungsten, and combinations thereof as metals or alloys.

[0044] In some instances, the compatibilizing agent is a nonionic amphiphilic compound or a mixture of nonionic amphiphilic compounds. Suitable nonionic amphiphilic compounds include: fatty alcohol alkoxylates, including fatty alcohol ethoxylates; alkylphenol alkoxylates, including alkylphenol ethoxylates; fatty acid alkoxylates, including fatty acid ethoxylates; alkoxylated amines, including ethoxylated amines; fatty acid amides; polyoxyethylene-polyoxypropylene copolymers; fatty acid esters of polyhydroxy compounds; glycerol fatty acid esters; sorbitan fatty acid esters; sucrose fatty acid esters; alkyl polyglucosides; fatty amine oxides; sulfoxides; organophosphine oxides, and mixtures thereof.

[0045] In some instances, the compatibilizing agent is an ionic compound. Suitable ionic amphiphilic compounds include anionic compounds and cationic compounds. Representative anionic compounds are alkyl sulfates, alkyl ether sulfates, alkyl sulfonates, alkyl ether sulfonates, alkyl phosphates, and alkyl carboxylates. Representative cationic compounds are quaternary ammonium compounds, monoalkylammonium salts, dialkylammonium salts, and trialkylammonium salts.

[0046] The selection of the specific anionic compound (or mixture thereof) or cationic compound (or mixture thereof) for forming the conductive fluorinated fluid layer and its amount will be determined by the specific elastomeric polymer used to prepare the conductive composite. The type and amount of the anionic or cationic compound are selected to avoid degradation or depolymerization of the elastomeric polymer.

[0047] In some instances, the compatibilizing agent is a surfactant.

[0048] In some instances, the compatibilizing agent is a nonionic amphiphilic compound or a mixture of such compounds. A particularly useful nonionic amphiphilic compound is alkylphenol ethoxylate. A representative alkylphenol ethoxylate is octylphenol ethoxylate, such as Triton TMX-100 (polyethylene glycol p-(1,1,3,3-tetramethylbutyl)-phenyl ether having an average of 9.5 ethylene oxide units) and nonylphenol ethoxylate.

[0049] Other particularly useful nonionic amphiphilic compounds are poloxamers, which are triblock copolymers of poly(ethylene oxide)-poly(propylene oxide)-poly(ethylene oxide) (PEO-PPO-PEO). For example, PLURONIC nonionic amphiphilic compounds are suitable.

[0050] The conductive composite materials of the present specification may also include additional materials to impart other characteristics to the conductive composite materials. In one aspect, the conductive composite materials include additives that increase thermal oxidative stability. When the conductive composite materials include additives that increase thermal oxidative stability, the additives that increase thermal oxidative stability may include, for example, at least one of phosphates, iron oxides, phenols, antioxidants, metal deactivators, and combinations thereof. A thermal oxidative stabilizer is a material or additive that increases thermal oxidative stability. The thermal oxidative stabilizer may be included in the conductive fluorinated fluid composition before forming the conductive composite material or added to the elastomeric polymer layer. Depending on the desired characteristics in the conductive composite material and the environment in which the conductive composite material will be deployed, the thermal oxidative stabilizer may be a phosphate, an iron oxide, a phenolic antioxidant, a metal deactivator, or a combination thereof. Adding a thermal oxidative stabilizer to the conductive composite materials disclosed herein expands the operating temperature range of the conductive composite materials. Suitable metal deactivators include nitrates such as nitric acid; citrates such as citric acid; tungstates; molybdates; chromates; and mixtures thereof.

[0051] The preparation of the conductive fluorinated fluid can be accomplished, for example, by mixing the fluorinated components, the conductive additives, and any optional components via a centrifugal planetary mixer or a shear mixing capability. The resulting conductive fluorinated fluid can be stored for future use.

[0052] In certain instances, the conductive fluorinated fluid disclosed herein and useful for preparing a conductive composite material may have a loss modulus (G") greater than the storage modulus (G'), i.e., the tanδ value of the conductive fluorinated fluid is greater than 1. Thus, the conductive fluorinated fluid compositions of the present disclosure behave more like a liquid than a solid. When measured using a dynamic shear rheometer according to ASTM D7175, the conductive fluorinated fluid compositions of the present disclosure may have a viscosity of from about 500 Cp to about 1,000,000 Cp at 1 Hz.

[0053] The thickness of each layer of the conductive composite material 2 can be adjusted as needed to obtain the desired characteristics of the final product. In one aspect, as Figure 2As shown, the first elastic polymer layer 4 has a first thickness 14, and the second elastic polymer layer 8 has a second thickness 12. The first thickness 14 and the second thickness 12 can each be in the range of about 0.01 mm to about 100 mm. In another aspect, the first thickness 14 and the second thickness 12 can each be in the range of about 0.1 mm to about 10 mm. For example, the first thickness 14 and the second thickness 12 can each be about 1 mm. The first thickness 14 can be the same as or different from the second thickness 12. The conductive fluorinated fluid layer has a third thickness 16, and the third thickness 16 can be less than or equal to at least one of the first thickness 14 and the second thickness 12. The third thickness 16 can be greater than at least one of the first thickness 14 and the second thickness 12. In one aspect, the third thickness 16 is less than the sum of the first thickness 14 and the second thickness 12. In another aspect, the third thickness 16 is less than at least one of the first thickness 14 and the second thickness 12. For example, the first thickness 14 and the second thickness 12 can be about 1 mm, and the third thickness 16 can be less than about 1 mm. The total thickness of the conductive composite material 2 can be in the range of about 0.03 mm to about 200 mm. In one aspect, the total thickness of the conductive composite material 2 can be in the range of about 0.1 mm to about 100 mm. In another aspect, the total thickness of the conductive composite material 2 can be in the range of about 0.5 mm to about 10 mm.

[0054] The conductive composite material 2 can include one or more additional elastic polymer layers and one or more additional conductive fluorinated fluid layers. For example, the conductive composite material can include a total of five layers, with three elastic polymer layers alternating with two conductive fluorinated fluid layers.

[0055] In one aspect, the conductive composite material 2 is in the form of a laminate, wherein a continuous conductive fluorinated fluid layer 6 is sandwiched between a first elastomeric polymer layer 4 and a second elastomeric polymer layer 8. The continuous conductive fluorinated fluid layer 6 can be flat or curved. In one expression, the length of the continuous conductive fluorinated fluid layer 6 is much greater than the thickness of the continuous conductive fluorinated fluid layer 6. In one aspect, the length of the continuous conductive fluorinated fluid layer 6 is at least five times the thickness of the continuous conductive fluorinated fluid layer 6. In another aspect, the length of the continuous conductive fluorinated fluid layer 6 is at least twenty times the thickness of the continuous conductive fluorinated fluid layer 6. In yet another aspect, the length of the continuous conductive fluorinated fluid layer 6 is at least fifty times the thickness of the continuous conductive fluorinated fluid layer 6. In another expression, the length and width of the continuous conductive fluorinated fluid layer 6 are much greater than the thickness of the continuous conductive fluorinated fluid layer 6. In one aspect, the length and width of the continuous conductive fluorinated fluid layer 6 are at least five times the thickness of the continuous conductive fluorinated fluid layer 6. In another aspect, the length and width of the continuous conductive fluorinated fluid layer 6 are at least twenty times the thickness of the continuous conductive fluorinated fluid layer 6. In yet another aspect, the length and width of the continuous conductive fluorinated fluid layer 6 are at least fifty times the thickness of the continuous conductive fluorinated fluid layer 6.

[0056] The edges of the conductive composite material 2 surrounding the conductive fluorinated fluid layer 6 can be sealed in any manner. In one aspect, the edges of the conductive composite material 2 can be sealed by bringing the second elastomeric polymer layer 8 into contact with the first elastomeric polymer layer 4. For example, the first elastomeric polymer layer 4 and the second elastomeric polymer layer 8 can be separated by the conductive fluorinated fluid layer 6, except at the edges of the conductive composite material 2 surrounding the conductive fluorinated fluid layer 6 where the first elastomeric polymer layer 4 and the second elastomeric polymer layer 8 are in contact with each other. The second elastomeric polymer layer 8 can be capable of curing to the first elastomeric polymer layer 4 to form an effective sealant. The edge length 18 of the edges of the conductive composite material 2 surrounding the conductive fluorinated fluid layer prevents overstressing of the bond between the first elastomeric polymer layer 4 and the second elastomeric polymer layer 8. In one aspect, the edge length 18 is greater than at least one of the first thickness 14 and the second thickness 12.

[0057] The conductive fluorinated fluid layer 6 of the present specification provides conductivity to the conductive composite material 2 without rigidity, and the high viscosity of the conductive fluorinated fluid layer inhibits leakage of the conductive fluorinated fluid during coating or use. As Figure 2 and 3B shown, the present specification further includes a reinforcing mesh 10 in contact with the conductive fluorinated fluid layer 6. The reinforcing mesh 10 in contact with the conductive fluorinated fluid layer 6 changes the flow characteristics of the conductive fluorinated fluid 6, thereby further reducing the possibility of leaching and better retaining the conductive fluorinated fluid 6 within the conductive composite material 2. The reinforcing mesh 10 can also improve the elongation and recovery rates of the entire conductive composite material and minimize its hysteresis.

[0058] The reinforcing mesh 10 can move freely relative to the first elastic polymer layer 4 and the second elastic polymer layer 8 to avoid a reduction in the elasticity of the conductive composite material 2, or the reinforcing mesh 10 can be attached to one of the first elastic polymer layer 4 or the second elastic polymer layer 8 to provide additional structural integrity.

[0059] The reinforcing mesh 10 can be conductive or non-conductive. The conductive reinforcing mesh 10 increases the conductivity of the resulting conductive composite material 2, or the reinforcing mesh 10 enables a reduction in the amount of the conductive fluorinated fluid 6 required to achieve the same conductivity. Reducing the amount of the conductive fluorinated fluid 6 in the conductive composite material 2 can further reduce the likelihood of leaching and better retain the conductive fluorinated fluid 6 within the conductive composite material 2. In one aspect, the conductivity of the conductive mesh is greater than about 1×10 3 S / m. In another aspect, the conductivity of the conductive mesh is greater than about 1×10 4 S / m. In another aspect, the conductivity of the conductive mesh is greater than about 1×10 5 S / m.

[0060] In one aspect, the reinforcing mesh 10 is a continuous reinforcing mesh layer in contact with the continuous conductive fluorinated fluid layer 6. In one expression, the length of the continuous reinforcing mesh layer is much greater than the thickness of the continuous reinforcing mesh layer. In one aspect, the length of the continuous reinforcing mesh layer is at least five times the thickness of the continuous reinforcing mesh layer. In another aspect, the length of the continuous reinforcing mesh layer is at least twenty times the thickness of the continuous reinforcing mesh layer. In another aspect, the length of the continuous reinforcing mesh layer is at least fifty times the thickness of the continuous reinforcing mesh layer. In another expression, the length and width of the continuous reinforcing mesh layer are much greater than the thickness of the continuous reinforcing mesh layer. In one aspect, the length and width of the continuous reinforcing mesh layer are at least five times the thickness of the continuous reinforcing mesh layer. In another aspect, the length and width of the continuous reinforcing mesh layer are at least twenty times the thickness of the continuous reinforcing mesh layer. In another aspect, the length and width of the continuous reinforcing mesh layer are at least fifty times the thickness of the continuous reinforcing mesh layer. The length and width of the reinforcing mesh 10 can be greater than, equal to, or less than the continuous conductive fluorinated fluid layer 6.

[0061] Additionally, if the conductive composite material 2 is in the form of a laminate, the laminate structure allows the continuous conductive fluorinated fluid layer 6 and the continuous reinforcing mesh layer 10 to be in the same position, where the continuous conductive fluorinated fluid layer 6 and the continuous reinforcing mesh layer 10 are sandwiched between the first elastic polymer layer 4 and the second elastic polymer layer 8.

[0062] The reinforcing mesh 10 can be or include a fabric, such as a knitted fabric, a woven fabric, or a combination thereof. The fabric can be a non-conductive fabric, a conductive fabric, or a combination thereof. The conductive fabric increases the conductivity of the resulting conductive composite material 2.

[0063] The non-conductive fabric can be or include, for example, a polyether-polyurea copolymer, latex, poly-p-phenylene terephthalamide, aromatic polyamide, nylon, polyester, or a combination thereof. However, any fabric that is chemically suitable for use with the conductive fluorinated fluid 6 can be used. The non-conductive fabric can be coated with a conductive material to produce a conductive fabric.

[0064] The conductive fabric can include, be formed of, or be a combination of conductive filaments, coated non-conductive fabrics, or both. Exemplary conductive filaments include silver wire, copper wire, brass wire, nickel wire, stainless steel wire, steel wire, aluminum wire, carbon wire, coated carbon wire, titanium wire, tungsten wire, tin wire, zinc wire, and combinations thereof. Exemplary coated non-conductive fabrics include metal-coated polyether-polyurea copolymer, metal-coated latex, metal-coated poly-p-phenylene terephthalamide, metal-coated aromatic polyamide, metal-coated nylon, metal-coated polyester, carbon-coated polyether-polyurea copolymer, carbon-coated latex, carbon-coated poly-p-phenylene terephthalamide, carbon-coated aromatic polyamide, carbon-coated nylon, carbon-coated polyester, and combinations thereof.

[0065] In certain instances, the conductive composite material 2 of the present specification exhibits a minimum sheet resistance of less than about 100 Ohm / sq. The sheet resistance of a particular conductive composite will depend on its end use. For example, when the conductive composite is used to shield electrical components from electromagnetic radiation, such as to minimize electromagnetic interference that could damage or harm sensitive electronic devices, a minimum sheet resistance of less than about 100 Ohm / sq is preferred. The sheet resistivity can be determined, for example, using a four-point probe during fabrication or prior to final encapsulation.

[0066] In certain instances, the conductive composite material 2 of the present specification exhibits an elongation at break of greater than or equal to about 10%. In other instances, the conductive composite material 2 of the present specification exhibits an elongation at break of greater than or equal to about 25%. In other instances, the conductive composite material 2 of the present specification exhibits an elongation at break of greater than or equal to about 50%. The elongation at break is measured as the percentage of strain of the material before it breaks after the application of tension. The percentage of the original length is used to represent the elongation at break.

[0067] In certain instances, the conductive composite material 2 of the present specification exhibits a tensile strength of greater than or equal to about 3 MPa.

[0068] In some instances, the conductive composite material 2 of the present specification has a density of less than about 7 g / mL, less than about 6 g / mL, less than about 5 g / mL, or less than about 4 g / mL. In some instances, the density of the conductive composite material is between about 2 and about 10 g / mL. In other instances, the conductive composite material has a density between about 10 and about 20 g / mL. In other instances, the density of the conductive composite material is between about 1 and about 5 g / mL, or between about 3 and about 8 g / mL. This parameter can be easily measured by determining the mass of a known volume or measuring the volume of water displaced by a known mass.

[0069] In some instances, the conductive composite material 2 of the present specification exhibits a maximum bulk conductivity of about 5×10 5 S / m at 20 °C.

[0070] In some instances, the conductive composite material is flexible. In some instances, the conductive composite material has a tensile strength greater than or equal to about 3 MPa. In some instances, the conductive composite material is flexible and has a tensile strength greater than or equal to about 3 MPa.

[0071] The present disclosure also provides products, articles, and structures including a substrate having a layer of the conductive composite material disclosed herein. Such products, articles, and structures can be prepared by heating a thermoplastic or thermosetting conductive composite material as disclosed herein and applying it to a substrate. In some instances, the conductive composite material can be a part of an aircraft, such as all or part of at least one of the wings and fuselage of an aircraft. In some instances, the conductive composite material can be at least one of seals and gaskets.

[0072] As Figure 3A 、 3B and shown in 3C, the conductive composite material 2 of the present specification can be prepared by forming a first elastic polymer layer 4 (see Figure 3A ) and forming a conductive fluorinated fluid layer 6 on the first elastic polymer layer 4 (see Figure 3B ). The conductive fluorinated fluid layer 6 can be reinforced with a reinforcing mesh 10 before or after forming the conductive fluorinated fluid layer 6. Then, a second elastic polymer layer 8 is formed on the conductive fluorinated fluid layer 6 (see Figure 3C ).

[0073] In one aspect, the step of forming the first elastic polymer layer includes curing the first elastic polymer layer. The step of curing the first elastic polymer layer can include curing the first elastic polymer layer.

[0074] In some instances, the step of forming the conductive fluorinated fluid layer includes mixing a fluorinated component and a conductive additive. In other instances, the step of forming the conductive fluorinated fluid layer includes mixing a fluorinated component, a conductive additive, and a compatibilizing agent. In other instances, the step of forming the conductive fluorinated fluid layer includes mixing a fluorinated component, a conductive additive, an additive that increases thermal oxidative stability, and optionally a compatibilizing agent. In one aspect, the step of forming the conductive fluorinated fluid layer includes using shear mixing to mix the conductive fluorinated fluid. Shear mixing can be performed at a rotational speed of from about 25 to about 2,000 rpm, such as from about 25 to about 125 rpm. In another aspect, the step of forming the conductive fluorinated fluid layer includes permeating a reinforcing mesh 10 with the conductive fluorinated fluid.

[0075] In some instances, the step of forming the second elastomeric polymer layer includes curing the second elastomeric polymer layer. The step of curing the second elastomeric polymer layer can include bonding the second elastomeric polymer layer to the first elastomeric polymer layer.

[0076] After forming the second elastomeric polymer layer, the method of the present specification can include trimming the conductive composite material around the conductive fluorinated fluid layer. In one aspect, the trimming leaves an edge length around the conductive fluorinated fluid layer.

[0077] For example, the conductive composite material of the present disclosure can be prepared by laminating a conductive fluorinated fluid layer onto the surface of a first cured or partially cured elastomeric polymer and by laminating a second elastomeric polymer thereon.

[0078] In another embodiment, the conductive composite material of the present disclosure can be prepared by spreading a conductive fluorinated fluid onto a non-stick surface, applying an uncured elastomeric polymer over the conductive fluorinated fluid, and then curing the elastomeric polymer. The conductive composite material can then be conveniently removed from the non-stick surface by peeling it off the non-stick surface. After removal from the non-stick surface, if desired or needed, another layer of cured or uncured elastomeric polymer can be added over the conductive fluorinated fluid and cured if needed to produce a sandwich structure or a laminated structure.

[0079] The laminated composite material of the present disclosure can be prepared by laminating a conductive fluorinated fluid layer onto the surface of a first elastomeric polymer and applying a second elastomeric polymer layer over the conductive fluorinated fluid layer. The second elastomeric polymer can be the same as or different from the first elastomeric polymer. Adding the second elastomeric polymer layer will encapsulate the conductive fluorinated fluid layer.

[0080] The laminated conductive composite of the present disclosure can also be prepared by spreading a conductive fluorinated fluid onto a non-stick surface, coating an uncured elastic polymer over the conductive fluorinated fluid, and then curing the elastic polymer. The conductive composite can then be conveniently removed from the non-stick surface by peeling it off the non-stick surface. Optionally, a second elastic polymer (which can be the same as or different from the first elastic polymer) can be applied onto the conductive fluorinated fluid layer. Adding a second elastic polymer layer will encapsulate the conductive fluorinated fluid layer.

[0081] The non-stick surface can be any suitable non-stick material. Examples of suitable non-stick materials include polytetrafluoroethylene, anodized aluminum, ceramics, and enameled cast iron.

[0082] The present disclosure also provides products, articles, and structures that include a substrate with a layer of the conductive composite disclosed herein, and in certain instances, a flexible conductive composite as disclosed herein. Such products, articles, and structures can be prepared by heating a thermoplastic or thermosetting conductive composite as disclosed herein and applying it to a substrate. Optionally, the flexible conductive composite can be adhered to a substrate.

[0083] A conductive fluorinated fluid composition can be prepared by mixing a fluorinated component with a conductive additive and thoroughly mixing the resulting mixture to form a uniform conductive fluorinated fluid. The mixing can be done with a shear mixer at about 25 to about 2500 rpm. In certain instances, shear mixing is performed at about 25 to about 125 rpm, or at about 125 to about 250 rpm, or at about 250 to about 400 rpm, or at about 400 to about 700 rpm, or at about 700 to about 1500 rpm, or at about 1500 to about 2500 rpm to form the conductive fluorinated fluid composition. Optionally, a centrifugal planetary mixer can be used for mixing. The resulting conductive fluorinated fluid can be stored for future use.

[0084] Additionally, the surface of the elastic polymer layer facing the conductive fluorinated fluid layer can be treated to improve the wettability of the liquid metal. This can include ultraviolet treatment, plasma treatment, or corona discharge treatment. Additionally, a surfactant can be applied to the elastic polymer layer facing the conductive fluorinated fluid layer to improve wettability.

[0085] The following experimental examples illustrate other features and properties of the conductive composites of this specification.

[0086] Materials

[0087] Benzoyl peroxide A98 was purchased from Sigma Aldrich and used as received. Stainless steel wires (3 mm x 2 μm) and nickel wires (10 μm x 0.25 mm, 10 μm x 1 mm, and 10 μm x 3 mm) were purchased from Intramicron and used as received. Stainless steel powder (type 316) was purchased from Atlantic Equipment Engineers and washed with acetone before use. Sylgard 184 silicone elastomer kit was purchased from Dow Corning and used as received. NuSil R21-2615 silicone was purchased from Nusil and used as received. Silver needle fabric was prepared. Polyethylene glycol dimethacrylate (SR210) was obtained from Sartomer and used as received. The DMPT curing accelerator was purchased from Albemarle and used as received. PFPE E10-H, AD1700 and HC / 04 were obtained from Solvay and used as received. Nickel powder was purchased from Vale and used as received. FlexSeal Clear Liquid was purchased from a local home improvement store and used as received.

[0088] Control Example 1: Nusil R21-2615 control

[0089] Using a flacktek mixer, 10 g of Part A of NuSil R21-2615 and 10 g of Part B of NuSil R21-2615 were mixed at 2300 rpm for 1 minute. The resulting homogeneous mixture of the elastic polymer was poured on top of a Mylar release film and cast with a glass rod. Then, the elastic polymer film was thermally cured at 60 °C for ~2 hours according to the manufacturer's instructions.

[0090] Example 2: FlexSeal control

[0091] A 10 g aliquot of the FlexSeal solution was cast on top of a Mylar release film and cast with a glass rod. The resulting elastic polymer film was cured overnight (about 18 hours) at room temperature according to the manufacturer's instructions.

[0092] Example 3: Nickel fluorogel and laminated composites prepared therefrom

[0093] Preparation of Conductive Fluorinated Fluid: 131.25 g of E10-H and 18.75 g of SR210 were mixed at 2300 rpm for 1 minute. 90 g of nickel powder from Vale was divided into 3 parts and added to the acrylate fluorinated solvent mixture at 2300 rpm using a flactek mixer for 1 minute. 60 g of nickel wire (10 μm x 0.25 mm) was mixed at 2300 rpm for several minutes by Flactek mixing. The resulting nickel fluorinated solvent mixture was homogenized with no visible lumps. In a separate container, 2 wt.% benzoyl peroxide (relative to SR210) was added to 2 mL of MEK solvent and vortexed for several minutes until it was completely dissolved. The benzoyl peroxide MEK solution was added to the Ni-acrylate fluorinated solvent mixture and mixed at 2300 rpm using a flactek mixer for 1 minute. 375 μL of DMPT curing accelerator was added to the mixture and mixed at 2300 rpm using a flactek mixer for 1 minute. The resulting homogeneous mixture was heated in a heating hood at 110 °C. Polymerization occurred within 5 minutes. The nickel fluorinated gel was cured and formed into a large mass, which was then broken into smaller pieces with a spatula and then centrifugally mixed at 2300 rpm for 20 seconds. The resulting nickel fluorinated gel was spreadable / flowable.

[0094] Preparation of Laminated Composite: The ~30 mil thick nickel fluorinated gel was cast onto a cured FlexSeal ClearLiquid film. Additional FlexSeal Clear Liquid was cast on top of the nickel fluorinated gel to completely encapsulate the laminated composite and cured overnight at room temperature. The thickness of the composite was approximately 100 mil.

[0095] Example 4: Nickel Fluorinated Gel with Silver Needle Fabric and Laminated Composite Prepared Therefrom

[0096] Preparation of Conductive Fluorinated Fluid: 131.25 g of E10-H and 18.75 g of SR210 were mixed at 2300 rpm for 1 minute. 38.6 g of nickel powder from Vale was added to the acrylate fluorinated solvent mixture at 2300 rpm using a flactek mixer. 25.7 g of nickel wire (10 μm x 0.25 mm) was mixed at 2300 rpm for several minutes by Flactek mixing. The resulting nickel fluorinated solvent mixture was homogenized with no visible lumps. In a separate container, 2 wt.% benzoyl peroxide (relative to SR210) was added to 2 mL of MEK solvent and vortexed for several minutes until it was completely dissolved. The benzoyl peroxide MEK solution was added to the Ni-acrylate fluorinated solvent mixture and mixed at 2300 rpm using a flactek mixer for 1 minute. 375 μL The DMPT curing accelerator was added to the mixture and mixed for 1 minute at 2300 rpm by a Flactek mixer. The resulting homogeneous mixture was heated in a heating hood at 110 °C. Polymerization occurred within 5 minutes. The nickel fluoride gel was cured and formed into a large mass, which was then broken into smaller pieces and then centrifugally mixed at 2300 rpm for 20 seconds. The resulting nickel fluoride gel was spreadable / flowable and capable of being easily coated on the fabric.

[0097] Preparation of the permeability-enhancing network: The nickel fluoride gel was evenly spread on the silver needle fabric with a spatula to form a conductive silver needle fabric filled with the nickel fluoride gel:

[0098] Preparation of the laminated composite: The silver needle fabric filled with the nickel fluoride gel was placed on the cured FlexSeal ClearLiquid film. Additional FlexSeal Clear Liquid was cast on the silver needle fabric filled with the nickel fluoride gel to completely encapsulate the laminated composite and cured overnight at room temperature. The thickness of this composite was approximately 100 mil.

[0099] Example 5: Nickel fluoride gel with longer nickel wire and laminated composite prepared therefrom

[0100] Preparation of the conductive fluorinated fluid: 131.25 g of E10-H and 18.75 g of SR210 were mixed at 2300 rpm for 1 minute. 25.7 g of Ni wire (10 μm x 1 mm) was mixed into the mixture at speed 2 by an overhead shear mixer overnight and then quickly mixed at speed 8 for 1 hour. Next, 4 g of nickel wire (8 μm × 3 mm) was mixed into the mixture at speed 2 by an overhead shear mixer overnight and then centrifugally mixed at 2300 rpm for 1 minute. The resulting nickel fluoride solvent mixture was homogenized with no visible lumps. 38.6 g of nickel powder from Vale was added to the mixture and mixed at 2300 rpm for 2 minutes. In a separate container, 2 wt.% benzoyl peroxide (relative to SR210) was added to 2 mL of MEK solvent and vortexed for several minutes until completely dissolved. The benzoyl peroxide MEK solution was added to the nickel acrylate fluorinated solvent mixture and mixed at 2300 rpm by a Flactek mixer for 1 minute. 375 μL The DMPT curing accelerator was added to the mixture and mixed for 1 minute at 2300 rpm by a Flactek mixer. The resulting homogeneous mixture was heated in a heating hood at 110 °C. Polymerization occurred within 5 minutes. The nickel fluoride gel was cured and formed into a large mass, which was then broken into smaller pieces with a spatula and then centrifugally mixed at 2300 rpm for 20 seconds. The resulting nickel fluoride gel was spreadable / flowable.

[0101] Preparation of the laminated composite: Cast a ~30 mil thick nickel fluoride gel onto a cured FlexSeal Clear Liquid film. Cast additional FlexSeal Clear Liquid on top of the nickel fluoride gel to completely encapsulate the laminated composite and cure overnight at room temperature. The thickness of the composite is approximately 100 mil.

[0102] Example 6: Nickel fluoride gel (fluorinated acrylate) with silver needle fabric and a laminated composite prepared therefrom

[0103] Preparation of the conductive fluorinated fluid: Mix 70 g of HC / 04 and 40 g of nickel powder from Vale at 1500 rpm for 1 minute. Mix 6 g of Ni wire (8 μm x 3 mm) into the mixture at speed 2 overnight through an overhead shear mixer, then mix rapidly at speed 8 for 1 hour. Add an additional 20 g of nickel powder from Vale to the mixture and mix at 1500 rpm for 1 minute. Next, add 14 g of AD1700 (fluorinated acrylate) and 14 g of n-butyl acetate to the mixture and mix at 1500 rpm for 1 minute. Homogenize the resulting nickel fluoride solvent mixture until there are no visible lumps. Add an additional 40 g of nickel powder from Vale to the mixture and mix at 1500 rpm for 2 minutes. In a separate container, add 2 wt.% benzoyl peroxide (relative to AD1700) to 2 mL of MEK solvent and vortex for several minutes until completely dissolved. Add the benzoyl peroxide MEK solution to the nickel acrylate fluoride solvent mixture and mix at 1500 rpm for 1 minute using a Flactek mixer. Add 280 μL of DMPT curing promoter to the mixture and mix at 1500 rpm for 1 minute using a Flactek mixer. Heat the resulting homogeneous mixture in a heating hood at 110 °C. Polymerization occurs within 5 minutes. The resulting nickel fluoride gel is spreadable and processable.

[0104] Preparation of the conductive Ag knitted laminated composite filled with the conductive fluorinated gel: Spread the flowable conductive fluorinated gel paste into the silver needle fabric using a spatula.

[0105] Nusil Vacuum Infiltration: Nusil R21-2615 liquid silicone rubber is a two-part translucent silicone system with a mixing ratio of part A to part B of 1:1 and has rapid thermal curing. Equal parts are weighed into a Flacktek container and mixed at 2300 rpm for 1 minute. The resulting homogeneous resin is poured on top of a panel with a Mylar release film, and a 30-mil thick film is cast using a glass rod. A nickel fluoride gel-filled silver needle fabric is placed on top of the NuSil film, the remaining NuSil mixture is poured on top of the needle fabric, and evenly distributed using a glass rod. The top panel, with the Mylar release film side down, is placed on top of the resin, and a vent hole is placed on the top panel. Before sealing, a vacuum connector is placed inside the vacuum bag, a 0.5-inch slit is cut in the vacuum bag, and a vacuum hose is connected through this slit. The vacuum pump is turned on immediately after sealing the system, and the pressure is maintained at -25 inches of mercury. The entire vacuum bagging device is placed on top of a 60°C hot spot for approximately 40 minutes of rapid thermal curing. The composite material is removed from the device after 1 hour. Additional NuSil R21-2615 is added / sprayed on the surface of the composite material to ensure that the nickel fluoride gel is completely encapsulated. The thickness of this composite material is approximately 60-120 mils.

[0106] Example 7: Nickel fluoride gel (uncured fluorinated acrylate network) with Ag needle fabric, and a laminated composite material prepared therefrom

[0107] Nickel Fluoride Gel Synthesis: 70 g of HC / 04 and 30 g of nickel powder from Vale are mixed at 1500 rpm for 1 minute. 4 g of nickel wire (8 μm x 3 mm) is mixed into the mixture at speed 2 overnight using an overhead shear mixer, and then quickly mixed at speed 8 for 1 hour. Another 30 g of nickel powder from Vale is added to the mixture and mixed at 1500 rpm for 1 minute. Next, 11 g of AD1700 (fluorinated acrylate) and 14 g of n-butyl acetate are added to the mixture and mixed at 1500 rpm for 1 minute. The resulting nickel fluoride gel mixture should be homogenized with no visible lumps. Another 30 g of nickel powder from Vale is added to the mixture and mixed at 1500 rpm for 2 minutes. The homogenized mixture does not go through a polymerization step. The mixture is spreadable / flowable.

[0108] Preparation of Conductive Fluoride Gel-Filled Conductive Ag Knit Laminated Composite Material: The flowable conductive fluoride gel paste is spread into the silver needle fabric using a spatula.

[0109] Nusil Vacuum Infusion: Nusil R21-2615 liquid silicone rubber is a two-part translucent silicone system with a 1:1 mixing ratio of Part A to Part B and has rapid thermal curing. Equal parts are weighed into a Flacktek container and mixed for 1 minute at 2300 rpm. The resulting homogeneous resin is poured onto the top of a panel with a Mylar release film, and a 30-mil thick film is cast using a glass rod. A silver needle fabric filled with nickel fluoride gel is placed on top of the NuSil film, the remaining NuSil mixture is poured on top of the needle fabric, and evenly distributed using a glass rod. The top panel, with the Mylar release film side down, is placed on top of the resin, and a vent hole is placed on the top panel. Before sealing, a vacuum connector is placed inside the vacuum bag, a 0.5-inch slit is cut in the vacuum bag, and a vacuum hose is connected through the slit. The vacuum pump is turned on immediately after the system is sealed, and the pressure is maintained at -25 inches of mercury. The entire vacuum bagging apparatus is placed on top of a 60°C hot spot for approximately 40 minutes of rapid thermal curing. The composite material is removed from the apparatus after 1 hour. Additional NuSil R21-2615 is added / sprayed onto the surface of the composite material to ensure that the nickel fluoride gel is fully encapsulated. The thickness of this composite material is approximately 60-120 mils.

[0110] Examples of the present disclosure can be described in the context of an aircraft preparation and repair method 1000 as shown in Figure 4 and an aircraft 1002 as shown in Figure 5 . During pre-production, the aircraft preparation and service method 1000 can include the specification and design 1004 of the aircraft 1002 and the material procurement 1006. During production, the component / sub-assembly preparation 1008 and system integration 1010 of the aircraft 1002 are performed. Thereafter, the aircraft 1002 can be certified and delivered 1012 for service 1014. During service by a customer, the aircraft 1002 is scheduled for routine maintenance and servicing 1016, which can also include modifications, reconfigurations, refurbishments, etc.

[0111] Each process of the method 1000 can be performed or executed by a system integrator, a third party, and / or an operator (e.g., a customer). For ease of explanation, the system integrator can include, but is not limited to, any number of aircraft manufacturers and prime system subcontractors; the third party can include, but is not limited to, any number of vendors, subcontractors, and suppliers; the operator can be an airline, a leasing company, a military entity, a service organization, etc.

[0112] The conductive composite materials of the present disclosure can be used in any one or more stages of the aircraft manufacturing and repair method 1000, including the specification and design 1004 of the aircraft 1002, material procurement 1006, component / sub-assembly preparation 1008, system integration 1010, certification and delivery 1012, aircraft service 1014, and routine maintenance and servicing 1016.

[0113] In addition, the present disclosure includes embodiments according to the following clauses:

[0114] Clause 1. A conductive composite material (2), comprising:

[0115] A first elastic polymer layer (4);

[0116] A conductive fluorinated fluid layer (6) on the first elastic polymer layer (4); and

[0117] A second elastic polymer layer (8) on the conductive fluorinated fluid layer (6).

[0118] Clause 2. The conductive composite material (2) of Clause 1, wherein the conductive fluorinated fluid layer (6) comprises a fluorinated component and a conductive additive.

[0119] Clause 3. The conductive composite material (2) of Clause 2, wherein the fluorinated component comprises at least one of perfluoropolyether, fluorinated acrylate oligomer, and combinations thereof.

[0120] Clause 4. The conductive composite material (2) of Clause 2 or 3, wherein the viscosity of the fluorinated component is in the range of about 2,000 cP to about 10,000,000 cP.

[0121] Clause 5. The conductive composite material (2) of any one of Clauses 2 to 4, wherein the viscosity of the fluorinated component is about 2,000 cP to about 5,000,000 cP.

[0122] Clause 6. The conductive composite material (2) of any one of Clauses 2 to 5, wherein the viscosity of the fluorinated component is about 2,000 cP to about 1,000,000 cP.

[0123] Clause 7. The conductive composite material (2) of any one of Clauses 2 to 6, wherein the aspect ratio of the conductive additive is less than about 2.

[0124] Clause 8. The conductive composite material (2) of any one of Clauses 2 to 7, wherein the conductive additive has an aspect ratio of at least about 2.

[0125] Clause 9. The conductive composite material (2) of any one of Clauses 2 to 8, wherein the conductive additive comprises at least one of carbon fiber, coated carbon fiber, and metallic material.

[0126] Clause 10. Conductive composite material (2) of any one of Clauses 2 to 9, wherein the conductive additive comprises a metallic material, and the metallic material comprises at least one of stainless steel, brass, iron, nickel, titanium, aluminum, copper, silver, gold, platinum, palladium, and zinc.

[0127] Clause 11. Conductive composite material (2) of any one of Clauses 1 to 10, wherein the conductive fluorinated fluid layer (6) further comprises a compatibility reagent.

[0128] Clause 12. Conductive composite material (2) of any one of Clauses 1 to 10, wherein the conductive fluorinated fluid layer (6) further comprises a compatibility reagent, and the compatibility reagent comprises at least one of an organic compatibility reagent, an inorganic compatibility reagent, and combinations thereof.

[0129] Clause 13. Conductive composite material (2) of any one of Clauses 1 to 12, wherein the conductive fluorinated fluid layer (6) further comprises an organic compatibility reagent, and the organic compatibility reagent comprises a surfactant.

[0130] Clause 14. Conductive composite material (2) of any one of Clauses 1 to 13, wherein the conductive fluorinated fluid layer (6) further comprises an organic compatibility reagent, and the organic compatibility reagent comprises at least one of an ionic surfactant, a non-ionic surfactant, and combinations thereof.

[0131] Clause 15. Conductive composite material (2) of any one of Clauses 1 to 14, further comprising an additive for increasing thermal oxidation stability.

[0132] Clause 16. Conductive composite material (2) of any one of Clauses 1 to 15, further comprising an additive for increasing thermal oxidation stability, and the additive comprises at least one of phosphate, iron oxide, phenols, antioxidants, metal deactivators, and combinations thereof.

[0133] Clause 17. Conductive composite material (2) of any one of Clauses 1 to 16, wherein the first elastic polymer layer (4) comprises at least one of a thermoplastic polymer, a thermosetting polymer, and combinations thereof.

[0134] Clause 18. Conductive composite material (2) of any one of Clauses 1 to 17, wherein the first elastic polymer layer (4) comprises at least one of siloxane, fluorosiloxane, perfluoropolyether, polybutadiene, polyester, polycarbonate, polyurethane, polyurea, polyurethane-urea, epoxy resin, acrylate, natural rubber, butyl rubber, polyacrylonitrile, ethylene propylene diene monomer (EPDM) rubber, and combinations thereof.

[0135] Clause 19. The conductive composite material (2) according to any one of Clauses 1 to 18, wherein the second elastic polymer layer (8) comprises at least one of a thermoplastic polymer, a thermosetting polymer, and combinations thereof.

[0136] Clause 20. The conductive composite material (2) according to any one of Clauses 1 to 19, wherein the second elastic polymer layer (8) comprises at least one of siloxane, fluorosiloxane, perfluoropolyether, polybutadiene, polyester, polycarbonate, polyurethane, polyurea, polyurethane-urea, epoxy resin, acrylate, natural rubber, butyl rubber, polyacrylonitrile, ethylene propylene diene monomer (EPDM) rubber, and combinations thereof.

[0137] Clause 21. The conductive composite material (2) according to any one of Clauses 1 to 20, wherein the thickness of the first elastic polymer layer (4) is in the range of about 0.01 mm to about 100 mm.

[0138] Clause 22. The conductive composite material (2) according to any one of Clauses 1 to 21, wherein the thickness of the first elastic polymer layer (4) is in the range of about 0.1 mm to about 10 mm.

[0139] Clause 23. The conductive composite material (2) according to any one of Clauses 1 to 22, wherein the thickness of the second elastic polymer layer (8) is in the range of about 0.01 mm to about 100 mm.

[0140] Clause 24. The conductive composite material (2) according to any one of Clauses 1 to 23, wherein the thickness of the second elastic polymer layer (8) is in the range of about 0.1 mm to about 10 mm.

[0141] Clause 25. The conductive composite material (2) according to any one of Clauses 1 to 24, wherein the thickness of the conductive fluorinated fluid layer (6) is less than or equal to at least one of the thickness of the first elastic polymer layer (4) and the thickness of the second elastic polymer layer (8).

[0142] Clause 26. The conductive composite material (2) according to any one of Clauses 1 to 25, wherein the thickness of the conductive fluorinated fluid layer (6) is greater than at least one of the thickness of the first elastic polymer layer (4) and the thickness of the second elastic polymer layer (8).

[0143] Clause 27. The conductive composite material (2) according to any one of Clauses 1 to 26, wherein the thickness of the conductive fluorinated fluid layer (6) is greater than the sum of the thickness of the first elastic polymer layer (4) and the thickness of the second elastic polymer layer (8).

[0144] Clause 28. The conductive composite material (2) according to any one of Clauses 1 to 27, wherein the conductive fluorinated fluid layer (6) is homogeneous.

[0145] Clause 29. The conductive composite material (2) of any one of Clauses 1 to 28, wherein the conductive fluorine fluid layer (6) is heterogeneous.

[0146] Clause 30. The conductive composite material (2) of any one of Clauses 1 to 29, further comprising a reinforcing mesh (10) in contact with the conductive fluorine fluid layer (6).

[0147] Clause 31. The conductive composite material (2) of Clause 30, wherein the reinforcing mesh (10) comprises a fabric.

[0148] Clause 32. The conductive composite material (2) of Clause 30 or 31, wherein the reinforcing mesh (10) comprises at least one of a knitted fabric, a woven fabric, and combinations thereof.

[0149] Clause 33. The conductive composite material (2) of any one of Clauses 30 to 32, wherein the reinforcing mesh (10) comprises at least one of a non-conductive fabric, a conductive fabric, and combinations thereof.

[0150] Clause 34. The conductive composite material (2) of any one of Clauses 30 to 33, wherein the reinforcing mesh (10) comprises a non-conductive fabric, and the non-conductive fabric comprises at least one of a polyether-polyurea copolymer, latex, poly-p-phenylene terephthalamide, aromatic polyamide, nylon, polyester, and combinations thereof.

[0151] Clause 35. The conductive composite material (2) of any one of Clauses 30 to 34, the reinforcing mesh (10) comprises a conductive fabric, and the conductive fabric comprises at least one of a conductive filament, a coated non-conductive fabric, and combinations thereof.

[0152] Clause 36. The conductive composite material (2) of any one of Clauses 30 to 35, wherein the reinforcing mesh (10) comprises a conductive fabric containing a conductive filament, and the conductive filament comprises at least one of a silver wire, a copper wire, a brass wire, a nickel wire, a stainless steel wire, a steel wire, an aluminum wire, a carbon wire, a coated carbon wire, a titanium wire, a tungsten wire, a tin wire, a zinc wire, and combinations thereof.

[0153] Clause 37. The conductive composite material (2) of any one of Clauses 30 to 36, wherein the reinforcing mesh (10) comprises a conductive fabric containing a coated non-conductive fabric, and the coated non-conductive fabric comprises at least one of a metal-coated polyether-polyurea copolymer, a metal-coated latex, a metal-coated poly-p-phenylene terephthalamide, a metal-coated aromatic polyamide, a metal-coated nylon, a metal-coated polyester, a carbon-coated polyether-polyurea copolymer, a carbon-coated latex, a carbon-coated poly-p-phenylene terephthalamide, a carbon-coated aromatic polyamide, a carbon-coated nylon, a carbon-coated polyester, and combinations thereof.

[0154] Clause 38. Conductive composite material (2) of any one of Clauses 1 to 37, the conductive composite material comprising an edge length of an elastic polymer surrounding a layer of conductive fluorinated fluid, the edge length of the elastic polymer sealing the conductive fluorinated fluid within the conductive composite material.

[0155] Clause 39. Conductive composite material (2) of any one of Clauses 1 to 38, wherein the edge length is greater than or equal to at least one of the thickness of the first elastic polymer layer and the thickness of the second elastic polymer layer.

[0156] Clause 40. Conductive composite material (2) of any one of Clauses 1 to 39, wherein the second elastic polymer layer is bonded to the first elastic polymer layer.

[0157] Clause 41. Conductive composite material (2) of any one of Clauses 1 to 40, wherein the conductive composite material (2) exhibits a minimum sheet resistance of less than about 100 Ohm / sq.

[0158] Clause 42. Conductive composite material (2) of any one of Clauses 1 - 41, wherein the conductive composite material (2) exhibits an elongation at break of greater than or equal to about 10%.

[0159] Clause 43. Conductive composite material (2) of any one of Clauses 1 - 42, wherein the conductive composite material (2) exhibits an elongation at break of greater than or equal to about 15%.

[0160] Clause 44. Conductive composite material (2) of any one of Clauses 1 - 43, wherein the conductive composite material (2) exhibits an elongation at break of greater than or equal to about 50%.

[0161] Clause 45. Conductive composite material (2) of any one of Clauses 1 - 44, wherein the conductive composite material (2) exhibits a tensile strength of greater than or equal to about 3 MPa.

[0162] Clause 46. Conductive composite material (2) of any one of Clauses 1 to 45, wherein the conductive composite material (2) has a density of less than about 7 g / mL.

[0163] Clause 47. Conductive composite material (2) of any one of Clauses 1 - 46, wherein the conductive composite material (2) has a density of less than about 6 g / mL.

[0164] Clause 48. Conductive composite material (2) of any one of Clauses 1 to 47, wherein the conductive composite material (2) has a density of less than about 5 g / mL.

[0165] Clause 49. Conductive composite material (2) of any one of Clauses 1 - 48, wherein the conductive composite material (2) has a density of less than about 4 g / mL.

[0166] Clause 50. Conductive composite material (2) of any one of Clauses 1 - 49, wherein the loss modulus (G") of the conductive fluorinated fluid is greater than the storage modulus (G').

[0167] Clause 51. The conductive composite material (2) of any one of Clauses 1 to 50 is part of an aircraft.

[0168] Clause 52. The conductive composite material (2) of any one of Clauses 1 to 51 is at least a part of at least one of the wing and fuselage of an aircraft.

[0169] Clause 53. The conductive composite material (2) of any one of Clauses 1 - 52 is at least one of a seal and a gasket.

[0170] Clause 54. A method for preparing a conductive composite material, the method comprising:

[0171] Forming a first elastic polymer layer;

[0172] Forming a conductive fluorinated fluid layer on the first elastic polymer layer; and

[0173] Forming a second elastic polymer layer on the conductive fluorinated fluid layer.

[0174] Clause 55. The method of Clause 54, wherein the step of forming the first elastic polymer layer includes curing the first elastic polymer layer.

[0175] Clause 56. The method of Clause 54 or 55, wherein the step of forming the conductive fluorinated fluid layer includes mixing a fluorinated component and a conductive additive.

[0176] Clause 57. The method of any one of Clauses 54 to 56, wherein the step of forming the conductive fluorinated fluid layer includes mixing a fluorinated component, a conductive additive, and a compatibility reagent.

[0177] Clause 58. The method of any one of Clauses 54 to 57, wherein the step of forming the conductive fluorinated fluid layer includes mixing a fluorinated component, a conductive additive, and an additive for increasing thermal oxidation stability.

[0178] Clause 59. The method of any one of Clauses 54 to 58, wherein the step of forming the conductive fluorinated fluid layer includes mixing the conductive fluorinated fluid using at least one of shear mixing and centrifugal mixing.

[0179] Clause 60. The method of any one of Clauses 54 to 59, wherein the step of forming the conductive fluorinated fluid layer includes using shear mixing to mix the conductive fluorinated fluid, and the shear mixing is performed at a rotational speed of about 25 to about 2,000 rpm.

[0180] Clause 61. The method of any one of Clauses 54 to 60, wherein the step of forming the conductive fluorinated fluid layer includes using shear mixing to mix the conductive fluorinated fluid, and the shear mixing is performed at a rotational speed of about 25 to about 125 rpm.

[0181] Clause 62. The method of any one of Clauses 54 to 61, wherein the step of forming the conductive fluorinated fluid layer includes permeating the conductive fluorinated fluid layer through a reinforcing mesh.

[0182] Clause 63. The method of any one of Clauses 54 to 62, wherein the step of forming the second elastic polymer layer includes curing the second elastic polymer layer.

[0183] Clause 64. The method of Clause 63, wherein the step of curing the second elastic polymer layer includes bonding the second elastic polymer layer to the first elastic polymer layer.

[0184] Clause 65. The method of any one of Clauses 54 to 64, wherein the first elastic polymer layer and the second elastic polymer layer encapsulate the conductive fluorinated fluid layer.

[0185] Clause 66. The method of any one of Clauses 54 to 65, which further includes trimming the conductive composite material around the conductive fluorinated fluid layer.

[0186] Clause 67. The method of any one of Clauses 54 to 66, wherein trimming the conductive composite material around the conductive fluorinated fluid layer leaves an edge length around the conductive fluorinated fluid layer, thereby sealing the conductive fluorinated fluid in the conductive composite material.

[0187] Clause 68. The method according to Clause 67, wherein the edge length is greater than or equal to at least one of the thickness of the first elastic polymer layer and the thickness of the second elastic polymer layer.

[0188] As Figure 5 shown, the aircraft 1002 produced by the exemplary method 1000 may include a fuselage 1018 having a plurality of systems 1020 and an interior 1022. Examples of the plurality of systems 1020 may include one or more of a propulsion system 1024, an electrical system 1026, a hydraulic system 1028, and an environmental system 1030. Any number of other systems may be included. The conductive composite material of the present disclosure can be used in any system of the aircraft 1002.

[0189] Although various examples of the disclosed conductive composites and methods for preparing conductive composites have been shown and described, modifications may be made by those skilled in the art upon reading the specification. This application includes such modifications and is limited only by the scope of the claims.

Claims

1. A conductive composite material (2), comprising: A first elastic polymer layer (4); A composite fluid layer (6) on the first elastic polymer layer (4), wherein the composite fluid comprises a fluorine fluid that has not been cured or hardened into a solid state and a solid conductive additive; and A second elastic polymer layer (8) on the composite fluid layer (6), Wherein the edge of the conductive composite material seals around the composite fluid layer.

2. The conductive composite material (2) according to claim 1, wherein the fluorine fluid comprises at least one of perfluoropolyether, fluorinated acrylate oligomer, and combinations thereof.

3. The conductive composite material (2) according to claim 1 or 2, wherein the viscosity of the fluorine fluid is in the range of 2,000 cP to 10,000,000 cP.

4. The conductive composite material (2) according to claim 1 or 2, wherein the aspect ratio of the solid conductive additive is less than 2.

5. The conductive composite material (2) according to claim 1 or 2, wherein the solid conductive additive has an aspect ratio of at least 2.

6. The conductive composite material (2) according to claim 1 or 2, wherein the solid conductive additive comprises at least one of carbon fiber, coated carbon fiber, and metal material.

7. The conductive composite material (2) according to claim 1, wherein the composite fluid layer (6) further comprises a compatibility reagent.

8. The conductive composite material (2) according to claim 1, which further comprises an additive for increasing thermal oxidation stability.

9. The conductive composite material (2) according to claim 1, wherein the first elastic polymer layer (4) comprises at least one of a thermoplastic polymer, a thermosetting polymer, and combinations thereof.

10. The conductive composite material (2) according to claim 1, wherein the second elastic polymer layer (8) comprises at least one of a thermoplastic polymer, a thermosetting polymer, and combinations thereof.

11. The conductive composite material (2) according to claim 1, further comprising a reinforcing mesh (10) in contact with the composite fluid layer (6), wherein the reinforcing mesh (10) comprises a fabric selected from at least one of the following: knitted fabric, woven fabric, and combinations thereof.

12. The conductive composite material (2) according to claim 1, wherein the conductive composite material comprises an edge length of the elastic polymer around the composite fluid layer, and the edge length seals the composite fluid within the conductive composite material.

13. The conductive composite material (2) according to claim 1, which is part of an aircraft, including at least part of a wing, at least part of a fuselage, at least one of a seal and a gasket.

14. A method for preparing a conductive composite material, the method comprising: Forming a first elastic polymer layer; Forming a composite fluid layer on the first elastic polymer layer, wherein the composite fluid comprises a fluorine fluid that has not been cured or hardened into a solid state and a solid conductive additive; and Forming a second elastic polymer layer on the composite fluid layer, The edge of the conductive composite material seals around the composite fluid layer.

Images