Conductive composite material and method for manufacturing the conductive composite material

Abstract

To provide a conductive composite that can achieve both high particle loading and properties required for rigid materials, namely, elongation at break, tensile strength and thermal stability, and a method for manufacturing the same.SOLUTION: The conductive composite includes a first layer of elastic polymer, a layer of conductive fluoro-fluid on the first layer of elastic polymer, and a second layer of elastic polymer on the layer of conductive fluoro-fluid.SELECTED DRAWING: None

Description

Background Art

[0001] Conductive composites are broadly defined as any composite material having a high conductivity and / or thermal conductivity. Such conductive composites have a wide range of applications in fields such as telecommunications, power generation and supply, defense, aerospace, medicine, and other fields.

[0002] Conductive composites are typically manufactured by incorporating a polymer material having solid conductive particles, and / or their properties are realized by incorporating a polymer material having solid conductive particles. To achieve sufficient conductivity, i.e., to reach percolation, typically a high particle loading exceeding 45 volume % is often required. The polymers used with these particle loading levels are usually rigid materials. Eventually, 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 inappropriate or difficult to use.

[0003] Therefore, those skilled in the art are continuously engaged in research and development in the field of conductive composites.

Summary of the Invention

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

[0005] In another embodiment, a method for manufacturing a conductive composite includes forming a first layer of an elastic polymer, forming a layer of a conductive fluorinated fluid on the first layer of the elastic polymer, and forming a second layer of an elastic polymer on the layer of the conductive fluorinated fluid.

[0006] Other embodiments of the conductive composite material and the method for manufacturing the conductive composite material of the present disclosure will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3A

Figure 3B

Figure 3C

Figure 4

Figure 5

Embodiments for Carrying Out the Invention

[0008] FIG. 1 is a perspective view of an exemplary conductive composite material according to an exemplary embodiment of the present description. FIG. 2 is a cross-sectional perspective view of the exemplary conductive composite material of FIG. 1, cut along lines A-A and B-B shown in FIG. 1.

[0009] As shown in FIGS. 1 and 2, the conductive composite material 2 includes a first layer of an elastic polymer 4, a layer of a conductive fluorinated fluid 6 on the first layer of the elastic polymer 4, a second layer of an elastic polymer 8 on the layer of the conductive fluorinated fluid 6, and an optional reinforcing mesh 10 in contact with the layer of the conductive fluorinated fluid 6.

[0010] In an embodiment, the present conductive composite provides conductivity without rigidity, provides a low-viscosity conductive fluid without the use of common room-temperature liquid metals and alloys such as gallium, and / or provides an increased viscosity and flow characteristics to prevent leakage of the conductive filling paste during use of the composite. Also, in an embodiment, the present conductive composite enables minimization of the amount of conductive paste required and the possibility of paste leaching. Further, in an embodiment, the conductive composite provides additional conductivity and / or structural integrity without sacrificing elongation rate.

[0011] An elastic polymer is a polymer that exhibits elasticity at high strain levels. In one aspect, the elastic polymers of this description are polymers that exhibit an elongation at break of greater than about 50%. In another aspect, the elastic polymers of this description are polymers that exhibit an elongation at break of greater than about 100%. In yet another aspect, the elastic polymers of this description are polymers that exhibit an elongation at break of greater than about 200%. The elongation at break is measured as the percentage by which a material deforms before it breaks when a tensile force is applied. The percentage of the original length is used to express the elongation at break.

[0012] In one aspect, the elastic polymers of this description are electrical insulators. In one aspect, the elastic polymers of this description are electrical insulators having a conductivity of less than about 1×10 -8 S / m. In another aspect, the elastic polymers of this description are electrical insulators having a conductivity of less than about 1×10 -9 S / m. In yet another aspect, the elastic polymers of this description are electrical insulators having a conductivity of less than about 1×10 -10 S / m.

[0013] The first layer of elastic polymer 4 and the second layer of elastic polymer 8 can include at least one of a thermoplastic polymer, a thermosetting polymer, and combinations thereof. In one aspect, suitable elastic polymers for the first layer of elastic polymer 4 and the second layer of elastic polymer 8 are from about 1,000 to 100,000 under typical processing conditions mPa·shas a viscosity. In another aspect, a suitable elastomer for the first layer of elastomer 4 and the second layer of elastomer 8 has a viscosity of from about 1,000 to 25,000 under typical processing conditions mPa·s has a viscosity. In yet another aspect, a suitable elastomer for the first layer of elastomer 4 and the second layer of elastomer 8 has a viscosity of from about 25,000 to 50,000 under typical processing conditions mPa·s has a viscosity. In yet another aspect, a suitable elastomer for the first layer of elastomer 4 and the second layer 8 of the elastomer has a viscosity of from about 50,000 to 75,000 under typical processing conditions mPa·s has a viscosity. In yet another aspect, a suitable elastomer for the first layer of elastomer 4 and the second layer of elastomer 8 has a viscosity of from about 75,000 to 100,000 under typical processing conditions mPa·s has a viscosity. In certain embodiments, a thermoplastic elastomer suitable for use herein has a viscosity of from about 1,000 to about 50,000 under typical processing conditions mPa·s has a viscosity. As used herein, the term "typical processing conditions" includes temperatures from about room temperature (about 25 degrees Celsius) to about 400 degrees Celsius, from about room temperature to about 200 degrees Celsius, or from about room temperature to about 100 degrees Celsius. The measurement technique for measuring viscosity can include a viscometer, a rheometer, or other suitable viscosity testing instruments. Such thermoplastic elastomers are convenient for making flexible materials.

[0014] Suitable elastic polymers for the first layer of elastic polymer 4 and the second layer of elastic polymer 8 include thermoplastic elastic polymers, thermosetting elastic polymers, and combinations thereof. For example, suitable elastic polymers for the first layer of elastic polymer 4 and the second layer of elastic polymer 8 include siloxanes, fluorosiloxanes, perfluoropolyethers, polybutadienes, polyesters, polycarbonates, polyurethanes, polyureas, polyurethane-ureas, epoxies, acrylates, natural rubbers, butyl rubbers, polyacrylonitriles, ethylene propylene diene monomer (EPDM) rubbers, or combinations thereof. The first layer of elastic polymer 4 and the second layer of elastic polymer 8 can be formed from the same or different polymer compositions.

[0015] In one aspect, at least one of the first layer of elastic polymer 4 and the second layer of elastic polymer 8 can include a conductive additive to create an electrical connection through the entire laminate. For example, the conductive additive can 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 a conductive additive in the elastic polymer layer, an electrical connection to the layer of conductive fluorinated fluid 6 becomes possible. This is desirable for some applications.

[0016] In the context of this description, the conductive fluorinated fluid is a high-viscosity fluid. The conductive fluorinated fluid of this description is not cured or solidified into a solid state. Rather, the conductive fluorinated fluid of this description retains the state of a high-viscosity fluid. In one aspect, the conductive fluorinated fluid of this description has a viscosity in the range of about 2,000 to about 10,000,000 mPa·s Another aspect, the conductive fluorinated fluid of this description has a viscosity in the range of about 2,000 to about 5,000,000 mPa·s In yet another aspect, the conductive fluorinated fluid of this description has a viscosity in the range of about 2,000 to about 1,000,000 mPa·s

[0017] ​A conductive fluorinated fluid is a fluorinated fluid that can carry an electric current. In one aspect, the conductive fluorinated fluid described herein has a conductivity greater than about 1×10 1 S / m. In another aspect, the conductive fluorinated fluid described herein has a conductivity greater than about 1×10 2 S / m. In yet another aspect, the conductive fluorinated fluid described herein has a conductivity greater than about 1×10 3 S / m. In yet another aspect, the conductive fluorinated fluid described herein has a conductivity greater than about 1×10 4 S / m. In yet another aspect, the conductive fluorinated fluid described herein has a conductivity greater than about 1×10 5 S / m. The layer of the conductive fluorinated fluid (6) may be uniform or non-uniform.

[0018] In one aspect, the conductive fluorinated fluid includes a fluorinated component and a conductive additive. The fluorinated component may include, for example, at least one of perfluoropolyether, fluorinated acrylate oligomer, and combinations thereof.

[0019] In one aspect, the fluorinated component has a viscosity in the range of about 2,000 to about 10,000,000 mPa·s In another aspect, the fluorinated component has a viscosity in the range of about 2,000 to about 5,000,000 mPa·s In yet another aspect, the fluorinated component has a viscosity in the range of about 2,000 to about 1,000,000 mPa·s However, the fluorinated component may have a lower viscosity, and the viscosity of the conductive fluorinated fluid can be increased by a conductive additive or a thickening agent.

[0020] In certain embodiments, the conductive additive has an average aspect ratio in the range of from 1 to about 2. The low aspect ratio conductive additive can, for example, take the form of a powder. The low aspect ratio conductive additive can have an average maximum dimension in the range of from about 0.1 to about 500 μm, such as in the range of from about 50 to about 150 μm. In other embodiments, the conductive additive has an average aspect ratio greater than about 2, such as in the range of from about 2 to about 2,000. The high aspect ratio conductive additive can, for example, take the form of a rod or a wire. The high aspect ratio conductive additive can have an average maximum dimension in the range of from about 0.1 to about 10 mm.

[0021] The conductive additive used herein also functions as a viscosity modifier and helps to resist or minimize the flow of the fluorinated fluid itself and to resist or minimize the flow of the fluorinated fluid within the layer of the conductive fluorinated fluid. The conductive additive used herein can be, for example, an inorganic material. The conductive additive remains solid when mixed with the fluorinated component. The conductive additive is typically used as particles in the shape of, for example, rods or wires, substantially spherical particles, or a mixture thereof, and the size of the particles determines how the conductive additive immediately homogenizes the fluorinated fluid.

[0022] The conductive additive is electrically conductive. The conductive additive increases the conductivity of the resulting conductive composite 2 or enables a reduction in the amount of the conductive fluorinated fluid 6 required to achieve the same conductivity. The overall conductivity can be adjusted by adjusting either the amount of the fluorinated fluid or the amount of the conductive additive.

[0023] In one aspect, the conductive additive includes at least one of, for example, carbon fibers, coated carbon fibers, and metal materials. The metal material is, for example, at least one of stainless steel, brass, and at least one metal or alloy of iron, nickel, titanium, aluminum, copper, silver, gold, platinum, palladium, and zinc, or a combination thereof, or at least one of the like. As a specific example, the conductive additive includes carbon fibers coated with nickel.

[0024] In a specific example, the conductive additive includes particles of a conductive additive having an average aspect ratio greater than about 2, that is, particles in which the length is at least about 2 times the width, such as rods or wires. The average aspect ratio can be measured using a microscope.

[0025] In other examples, the conductive additive includes particles of a conductive additive having an average aspect ratio of less than about 2, that is, particles in which the length is at most about 2 times the width, such as substantially spherical particles. In a specific example, the conductive additive includes substantially spherical particles having an average particle size of about 0.1 to about 500 μm (about 100 to about 500,000 nm). In a specific example, 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 examples, the conductive additive includes substantially spherical particles having an average particle size of about 50 to about 150 μm. In a specific example, 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 a Multisizer.

[0026] In one embodiment, the conductive additive includes rods or wires having an average aspect ratio greater than about 2 and a length from 0.01 to about 10 mm. In certain embodiments, the rods of the conductive additive are from about 0.01 to about 0.5 mm, or from about 0.05 to about 10 mm, or from about 0.01 to about 10 mm, or from about 0.01 to about 0.1 mm, or from about 0.1 to about 1 mm, or from about 0.1 to about 1 mm, or from about 1 to about 5 mm, or from about 5 to about 10 mm in length. The use of conductive rods or wires generally contributes to the conductivity of the final composite over a wider range than spherical conductive particles.

[0027] In certain embodiments, the conductive additive includes a powder having particles that are a mixture of rods or wires and substantially spherical particles, or includes a mixture of rods, wires, and substantially spherical particles.

[0028] The conductive additive can act as a thickening agent. In this case, the conductive additive can be used in an amount that produces an appropriate viscosity and / or adjusts the conductive properties of the resulting composite. The amount of the conductive additive can be reduced when a powder of particles in the form of rods or wires is used as the conductive additive. The appropriate amount of the conductive additive of rods or wires in the conductive fluorinated fluid is in the range of about 2 to about 40% relative to the volume of the conductive fluorinated fluid. In certain embodiments, the amount of the conductive additive is about 2% to about 5%, or about 5 to about 10%, or about 10 to about 15%, or about 15 to about 20%, or about 20 to about 25%, or about 25 to about 30%, or about 30 to about 40% relative to the volume of the conductive fluorinated fluid.

[0029] Appropriate conductivity can be achieved in the conductive composites disclosed herein without requiring a large amount of conductive additive, i.e., filling of such particles in excess of about 45 volume percent, in the conductive fluorinated fluid. However, the conductive composites of this description are not limited to particle loading levels less than about 45 volume percent. Thus, particle loading levels in excess of about 45 volume percent can also be used in the conductive fluorinated fluid.

[0030] In one aspect, the layer of conductive fluorinated fluid may further include a non-conductive thickening agent. The thickening agent may include, for example, at least one of an organic thickening agent, an inorganic thickening agent, and combinations thereof.

[0031] In certain embodiments, the thickening agent has an average aspect ratio in the range from 1 to about 2. The low aspect ratio thickening agent may, for example, take the form of a powder. The low aspect ratio thickening agent may have an average maximum dimension in the range from about 0.1 to about 500 μm, such as in the range from about 50 to about 150 μm. In other embodiments, the thickening agent has an average aspect ratio greater than about 2, such as in the range from about 2 to about 2,000. The high aspect ratio thickening agent may, for example, take the form of a rod or a wire. The high aspect ratio thickening agent may have an average maximum dimension in the range from about 0.1 to about 10 mm.

[0032] The thickening agent used herein functions as a viscosity modifier and can help resist or minimize the flow of the fluorinated fluid within the layer of conductive fluorinated fluid. The thickening agent used herein may be an inorganic or organic material. The thickening agent remains solid when mixed with the conductive fluorinated fluid. The thickening agent is typically used, for example, as particles in the shape of rods or wires, substantially spherical particles, or a mixture thereof, and the size of the particles determines how well the thickening agent homogenizes the fluorinated fluid immediately. Typically, thickening agents with a larger surface area seem to be superior to those with a smaller surface area.

[0033] In embodiments where the conductive fluorinated fluid also includes a thickening agent, the thickening agent may be used in an amount that produces an appropriate viscosity.

[0034] In certain embodiments, the thickening agent used to make the conductive composite 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 reacts with the isocyanate groups of diisocyanate or polyisocyanate via the hydroxy, but the reaction is slower than the urethane or urea formation reaction. When used appropriately, such compounds can be used to adjust the properties of the resulting thickening agent. The thickening agent may be a mixture of at least one organic thickening agent and at least one inorganic thickening agent.

[0035] In one aspect, the layer of the conductive fluorinated fluid contains a compatibilizing agent. The compatibilizing agent may include, for example, at least one of an organic compatibilizing agent, an inorganic compatibilizing agent, and combinations thereof. When the compatibilizing agent includes an organic compatibilizing agent, the organic compatibilizing agent may include surfactants such as, for example, ionic surfactants, non-ionic surfactants, and combinations thereof. When the compatibilizing agent includes an inorganic compatibilizing agent, the inorganic compatibilizing agent may include, for example, metal nanoparticles.

[0036] The compatibilizing agent used herein improves the workability (e.g., fluidity, ease of addition) of the conductive fluorinated fluid.

[0037] In certain embodiments, the compatibilizing agent used herein may also be used to increase the viscosity of the conductive fluorinated fluid, i.e., to increase the viscosity of the conductive fluorinated fluid.

[0038] In certain embodiments, the conductive fluorinated fluid used to form the conductive composite contains a fluorinated fluid and a compatibilizer in a weight ratio of 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 compatibilizer as a percentage of the fluorinated fluid is in the range of from about 2 wt% to about 20 wt%. A particularly useful amount of the compatibilizer is in the range of from about 4 wt% to about 10 wt%. The weight percent refers to the weight of the compatibilizer relative to the total weight of the conductive fluorinated fluid. Phase separation must be avoided. At higher levels of the compatibilizer, phase separation can occur. This can be addressed using the types of thickeners disclosed elsewhere herein.

[0039] In certain embodiments, the compatibilizer includes inorganic (e.g., metal) nanoparticles. It has an average particle size of less than about 100 nm, or less than about 90 nm, or less than about 80 nm, or less than about 70 nm, or 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. The particle sizes described herein can be measured, for example, using a Coulter counter or a multisizer. Suitable nanoparticles include metals that are insoluble (i.e., do not dissolve) in the conductive fluorinated fluid. Examples of metals suitable for use as nanoparticle compatibilizers herein include metals or alloys of silver, copper, brass, bronze, nickel, stainless steel, carbon, coated carbon, titanium, tungsten, and combinations thereof.

[0040] In certain embodiments, the compatibilizer 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 sorbate compounds, glycerol titanates, glycerol fatty acid esters, sucrose fatty acid esters, alkyl polyglucosides, fatty amine oxides, sulfoxides, organophosphine oxides, and mixtures thereof.

[0041] In certain embodiments, the compatibilizer 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, monoalkyl ammonium salts, dialkyl ammonium salts, and trialkyl ammonium salts.

[0042] The particular anionic compound (or mixtures thereof) or cationic compound (or mixtures thereof) and their amounts used to form the layer of the conductive fluorinated fluid will be determined by the particular elastic polymer used to manufacture the conductive composite. The type and amount of the anionic or cationic compound can be selected to avoid degradation and depolymerization of the elastic polymer.

[0043] In certain embodiments, the compatibilizer is a surfactant.

[0044] In certain embodiments, the compatibilizer is a nonionic amphiphilic compound or a mixture of such compounds. Particularly useful nonionic amphiphilic compounds are alkylphenol ethoxylates. Representative alkylphenol ethoxylates include octylphenol ethoxylates and nonylphenol ethoxylates such as Triton™ X-100 (a polyethylene glycol p-(1,1,3,3-tetramethylbutyl)-phenyl ether with an average of 9.5 ethylene oxide units).

[0045] 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.

[0046] The conductive composite materials of this description may also include additional materials that impart other properties to the conductive composite. In one aspect, the conductive composite includes an additive for enhancing thermal oxidative stability. When the conductive composite includes an additive for enhancing thermal oxidative stability, the additive for enhancing thermal oxidative stability may include, for example, at least one of phosphates, iron oxides, phenols, antioxidants, metal passivators, and combinations thereof. A thermal oxidative stabilizer is a material or additive that enhances thermal oxidative stability. The thermal oxidative stabilizer is included in the composition of the conductive fluorinated fluid and is added to the elastic polymer layer before forming the conductive composite. Depending on the properties desired in the conductive composite and the environment in which the conductive composite may be deployed, the thermal oxidative stabilizer may be a phosphate, an iron oxide, a phenolic antioxidant, a metal passivator, or a combination thereof. The addition of the thermal oxidative stabilizer disclosed herein to the conductive composite broadens the operating temperature range of the conductive composite. Suitable metal passivators include nitrates such as nitric acid, citrates such as citric acid, tungstates, molybdates, chromates, and mixtures thereof.

[0047] The preparation of the conductive fluorinated fluid can be achieved, for example, by mixing a fluorinated component, a conductive additive, and any components in a centrifugal planetary mixer or a shear mixer. The resulting conductive composite can be stored for future use.

[0048] In certain embodiments, the conductive fluorinated fluid disclosed herein and useful for the preparation of conductive composites can have a loss modulus (G”) greater than the storage modulus (G’), and the tangent delta value of the conductive fluorinated fluid is greater than 1. The composition of the conductive fluorinated fluid of the present disclosure thus exhibits behavior more like a liquid than a solid. The composition of the conductive fluorinated fluid of the present disclosure, when measured using a dynamic shear rheometer according to ASTM D7175, can have a viscosity of about 500 mPa·s to about 1,000,000 mPa·s at 1 Hz.

[0049] The thickness of each layer of the conductive composite 2 can be adjusted as needed to achieve the desired properties of the final product. As shown in FIG. 2, in one aspect, the first layer of the elastic polymer 4 has a first thickness 14, and the second layer of the elastic polymer 8 has a second thickness 12. The first thickness 14 and the second thickness 12 may each be in the range of from about 0.01 mm to about 100 mm. In another aspect, the first thickness 14 and the second thickness 12 may each be in the range of from about 0.1 mm to about 10 mm. For example, the first thickness 14 and the second thickness 12 may each be about 1 mm. The first thickness 14 may be the same as or different from the second thickness 12. The layer of the conductive fluorinated fluid has a third thickness 16. It may be less than or equal to at least one of the first thickness 14 and the second thickness 12. Alternatively, the third thickness 16 may 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 may be about 1 mm, and the third thickness 16 may be less than about 1 mm. The overall thickness of the conductive composite 2 may be in the range of from about 0.03 mm to about 200 mm. In one aspect, the overall thickness of the conductive composite 2 may be in the range of from about 0.1 mm to about 100 mm. In another aspect, the overall thickness of the conductive composite 2 may be in the range of from about 0.5 mm to about 10 mm.

[0050] The conductive composite 2 may include one or more additional layers of an elastic polymer and one or more additional layers of a conductive fluorinated fluid. For example, the conductive composite may comprise a total of five layers, namely three layers of an elastic polymer and two layers of a conductive fluorinated fluid arranged alternately.

[0051] In one aspect, the conductive composite material 2 is in the form of a laminate. In that case, a continuous layer of the conductive fluoropolymer fluid 6 is sandwiched between a first layer of the elastic polymer 4 and a second layer of the elastic polymer 8. The continuous layer of the conductive fluoropolymer fluid 6 may be flat or curved. In one expression, the continuous layer of the conductive fluoropolymer fluid 6 has a length that is considerably larger than the thickness of the continuous layer of the conductive fluoropolymer fluid 6. In one aspect, the length of the continuous layer of the conductive fluoropolymer fluid 6 is at least 5 times the thickness of the continuous layer of the conductive fluoropolymer fluid 6. In another aspect, the length of the continuous layer of the conductive fluoropolymer fluid 6 is at least 20 times the thickness of the continuous layer of the conductive fluoropolymer fluid 6. In yet another aspect, the length of the continuous layer of the conductive fluoropolymer fluid 6 is at least 50 times the thickness of the continuous layer of the conductive fluoropolymer fluid 6. In another expression, the continuous layer of the conductive fluoropolymer fluid 6 has a length and a width that are considerably larger than the thickness of the continuous layer of the conductive fluoropolymer fluid 6. In one aspect, the length and the width of the continuous layer of the conductive fluoropolymer fluid 6 are at least 5 times the thickness of the continuous layer of the conductive fluoropolymer fluid 6. In another aspect, the length and the width of the continuous layer of the conductive fluoropolymer fluid 6 are at least 20 times the thickness of the continuous layer of the conductive fluoropolymer fluid 6. In yet another aspect, the length and the width of the continuous layer of the conductive fluoropolymer fluid 6 are at least 50 times the thickness of the continuous layer of the conductive fluoropolymer fluid 6.

[0052] The edges of the conductive composite 2 can be sealed in any manner around the layer of the conductive fluoropolymer fluid 6. In one aspect, the edges of the conductive composite 2 can be sealed by contact of the first layer of the elastic polymer 4 with the second layer of the elastic polymer 8. For example, the first layer of the elastic polymer 4 and the second layer of the elastic polymer 8 can be separated by the layer of the conductive fluoropolymer fluid 6, except for the edges of the conductive composite 2 around the layer of the conductive fluoropolymer fluid 6. At those edges, the first layer of the elastic polymer 4 and the second layer of the elastic polymer 8 are in contact with each other. The second layer of the elastic polymer 8 can cure against the first layer of the elastic polymer 4 to form an effective encapsulant. The edge length 18 of the edges of the conductive composite 2 around the layer of the conductive fluoropolymer fluid prevents excessive stress from being applied to the joint between the first layer of the elastic polymer 4 and the second layer of the elastic polymer 8. In one aspect, the edge length 18 is greater than at least one of the first thickness 14 and the second thickness 12.

[0053] The layer of the conductive fluoropolymer fluid 6 of this description provides conductivity to the conductive composite 2 without requiring rigidity, and the high viscosity of the layer of the conductive fluoropolymer fluid inhibits leakage of the conductive fluoropolymer fluid during coating or use. This description further includes a reinforcing mesh 10 in contact with the layer of the conductive fluoropolymer fluid 6, as shown in FIGS. 2 and 3B. The reinforcing mesh 10 in contact with the layer of the conductive fluoropolymer fluid 6 changes the flow characteristics of the layer of the conductive fluoropolymer fluid 6 to further reduce the possibility of leaching and better retain the layer of the conductive fluoropolymer fluid 6 within the conductive composite 2. The reinforcing mesh 10 can also improve the elongation and recovery of the entire conductive composite and minimize hysteresis.

[0054] The reinforcing mesh 10 can move freely with respect to the first layer of the elastic polymer 4 and the second layer of the elastic polymer 8, avoiding reduction of the elasticity of the conductive composite 2, or the reinforcing mesh 10 can be attached to one of the first layer of the elastic polymer 4 and the second layer of the elastic polymer 8 to provide further structural integrity.

[0055] The reinforcing mesh 10 may be conductive or non-conductive. The conductive reinforcing mesh 10 increases the conductivity of the resulting conductive composite 2, or the reinforcing mesh 10 enables a reduction in the amount of the conductive fluorinated fluid 6 to achieve the same conductivity. By reducing the amount of the conductive fluorinated fluid 6 in the conductive composite 2, the possibility of leaching is further reduced, and the conductive fluorinated fluid 6 can be better retained in the conductive composite 2. In one aspect, the conductivity of the conductive mesh is about 1×10 3 S / m or more. In another aspect, the conductivity of the conductive mesh is about 1×10 4 S / m or more. In yet another aspect, the conductivity of the conductive mesh is about 1×10 5 S / m or more.

[0056] In one aspect, the reinforcing mesh 10 is a continuous reinforcing layer in contact with a continuous layer of the conductive fluorinated fluid 6. In one expression, the continuous reinforcing mesh layer has a length that is considerably larger than the thickness of the continuous reinforcing mesh layer. In one aspect, the length of the continuous reinforcing mesh layer is at least 5 times the thickness of the continuous reinforcing mesh layer. In another aspect, the length of the continuous reinforcing mesh layer is at least 20 times the thickness of the continuous reinforcing mesh layer. In yet another aspect, the length of the continuous reinforcing mesh layer is at least 50 times the thickness of the continuous reinforcing mesh layer. In another expression, the continuous reinforcing mesh layer has a length and a width that are considerably larger than the thickness of the continuous reinforcing mesh layer. In another aspect, the length and the width of the continuous reinforcing mesh layer are at least 5 times the thickness of the continuous reinforcing mesh layer. In another aspect, the length and the width of the continuous reinforcing mesh layer are at least 20 times the thickness of the continuous reinforcing mesh layer. In yet another aspect, the length and the width of the continuous reinforcing mesh layer are at least 50 times the thickness of the continuous reinforcing mesh layer. The reinforcing mesh 10 may have a length and a width that are larger than, equal to, or less than the continuous layer of the conductive fluorinated fluid 6.

[0057] Furthermore, when the conductive composite 2 is in the form of a laminate, the laminate can be constructed by arranging a continuous layer of the conductive fluorinated fluid 6 and a continuous layer of the reinforcing mesh 10 in the same position. In that case, the continuous layer of the conductive fluorinated fluid 6 and the continuous layer of the reinforcing mesh 10 are sandwiched between a first layer of the elastic polymer 4 and a second layer of the elastic polymer 8.

[0058] The reinforcing mesh 10 can be or include a fabric such as a knitted or woven fabric or a combination thereof. The fabric can be a non-conductive fabric, a conductive fabric, or a combination thereof. The conductive fabric enhances the conductivity of the resulting conductive composite 2.

[0059] The non-conductive fabric can be or include, for example, a polyether polyurea copolymer, latex, polyparaphenylene terephthalamide, aramid, 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 provide a conductive fabric.

[0060] The conductive cloth may include, or may be formed from, conductive filaments, coated non-conductive cloth, or combinations thereof. Exemplary conductive filaments include silver filaments, copper filaments, brass filaments, nickel filaments, stainless steel filaments, steel filaments, aluminum filaments, carbon filaments, coated carbon filaments, titanium filaments, tungsten filaments, tin filaments, zinc filaments, and combinations thereof. Exemplary coated non-conductive cloths include polyester-polyurea copolymers coated with metal, latex coated with metal, polyparaphenylene terephthalamide coated with metal, aramid coated with metal, nylon coated with metal, polyester coated with metal, polyether-polyurea copolymers coated with carbon, latex coated with carbon, polyparaphenylene terephthalamide coated with carbon, aramid coated with carbon, nylon coated with carbon, polyester coated with carbon, and combinations thereof.

[0061] In certain embodiments, the conductive composite 2 of this description exhibits a minimum sheet resistance value of less than about 100 ohms / sq. The sheet resistance value of a particular conductive composite can depend on the end use. For example, a minimum sheet resistance value of less than about 100 ohms / sq is suitable when the conductive composite is used to block electronic components from electromagnetic radiation, such as to minimize electromagnetic interference that could interfere with or damage delicate electronics. The sheet resistance value is determined, for example, using a four-point probe during the manufacturing process or prior to final encapsulation.

[0062] In certain embodiments, the conductive composite 2 of this description exhibits an elongation at break of about 10% or more. In other embodiments, the conductive composite 2 of this description exhibits an elongation at break of about 25% or more. In still other embodiments, the conductive composite 2 of this description exhibits an elongation at break of about 50% or more. The elongation at break is measured as the percentage by which the material deforms before it breaks when tension is applied. The percentage of the original length is used to express the elongation at break.

[0063] In certain embodiments, the conductive composite 2 of this description exhibits a tensile strength of about 3 MPa or more.

[0064] In certain embodiments, the conductive composite 2 of this description 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 certain embodiments, the conductive composite has a density between about 2 and about 10 g / mL. In other embodiments, the conductive composite has a density between about 10 and about 20 g / mL. In still other embodiments, the conductive composite has a density 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 by measuring the volume of water displaced by a known mass.

[0065] In certain embodiments, the conductive composite 2 of this description has a maximum bulk conductivity of about 5×10 5 S / m at 20 degrees Celsius.

[0066] In certain embodiments, the conductive composite is flexible. In certain embodiments, the conductive composite has a tensile strength of about 3 MPa or more. In certain embodiments, the conductive composite is flexible and has a tensile strength of about 3 MPa or more.

[0067] The present disclosure also provides products, items, and structures comprising a substrate that supports a layer of the conductive composite disclosed herein. Such products, items, and structures can be made by heating the thermoplastic or thermosetting conductive composite disclosed herein and applying it to a substrate. In certain embodiments, the conductive composite can be all or part of an aircraft, for example, at least one of an aircraft wing and fuselage. In certain embodiments, the conductive composite can be at least one of a seal and a gasket.

[0068] As shown in FIGS. 3A, 3B, and 3C, the conductive composite material 2 of the present disclosure can be produced by forming a first layer of the elastic polymer 4 (see FIG. 3A) and forming a layer of the conductive fluorinated fluid 6 on the first layer of the elastic polymer 4 (see FIG. 3B). The layer of the conductive fluorinated fluid 6 can be reinforced with the reinforcing mesh 10 either before or after forming the layer of the conductive fluorinated fluid 6. Then, a second layer of the elastic polymer 8 is formed on the layer of the conductive fluorinated fluid 6 (see FIG. 3C).

[0069] In one aspect, the step of forming the first layer of the elastic polymer includes curing the first layer of the elastic polymer. The step of curing the first layer of the elastic polymer may include curing the first layer of the elastic polymer.

[0070] In certain embodiments, the step of forming the layer of the conductive fluorinated fluid includes mixing a fluorinated component and a conductive additive. In other embodiments, the step of forming the layer of the conductive fluorinated fluid includes mixing a fluorinated component, a conductive additive, and a compatibilizer. In other embodiments, the step of forming the layer of the conductive fluorinated fluid includes mixing a fluorinated component, a conductive additive, and an additive for enhancing thermal oxidative stability, and optionally a compatibilizer. In one aspect, the step of forming the layer of the conductive fluorinated fluid includes mixing the conductive fluorinated fluid using shear mixing. The shear mixing can be performed at a rotational speed in the range of about 25 to about 2,000 rpm, such as about 25 to about 125 rpm. In another aspect, the step of forming the layer of the conductive fluorinated fluid includes impregnating the reinforcing mesh 10 with the conductive fluorinated fluid.

[0071] In certain embodiments, the step of forming the second layer of the elastic polymer includes curing the second layer of the elastic polymer. The step of curing the second layer of the elastic polymer may include bonding the second layer of the elastic polymer to the first layer of the elastic polymer.

[0072] After forming the second layer of the elastic polymer, the method of the present description may include trimming the conductive composite around the layer of the conductive fluorinated fluid. In one aspect, the trimming leaves a marginal length around the layer of the conductive fluorinated fluid.

[0073] As an example, the conductive composite of the present disclosure is made by laminating a conductive fluorinated fluid on the surface of a first cured or partially cured elastic polymer and then laminating a second elastic polymer thereon.

[0074] In another example, the conductive composite of the present disclosure can be made by spreading a conductive fluorinated fluid on a non-stick surface, adding an uncured elastic polymer on the conductive fluorinated fluid, and then curing the elastic polymer layer. The conductive composite can then be conveniently removed from the non-stick surface by peeling the conductive composite from the non-stick surface. After being removed from the non-stick surface, an additional layer of cured or uncured elastic polymer may be added on the conductive fluorinated fluid as needed or desired, and a sandwich or laminate structure may be generated as needed.

[0075] The laminated composite of the present disclosure can be made by laminating a conductive fluorinated fluid on the surface of a first elastic polymer and adding a layer of a second elastic polymer on the layer of the conductive fluorinated fluid. The second elastic polymer may be the same as or different from the first elastic polymer. Adding the layer of the second elastic polymer will encapsulate the layer of the conductive fluorinated fluid.

[0076] The laminated conductive composites of the present disclosure can also be made by spreading a conductive fluorinated fluid on a non-stick surface, adding an uncured elastic polymer on top of the conductive fluorinated fluid, and then curing the elastic polymer layer. The conductive composite can then be conveniently removed from the non-stick surface by peeling the conductive composite from the non-stick surface. Optionally, a second elastic polymer (which may be the same as or different from the first elastic polymer) can be optionally added on top of the layer of conductive fluorinated fluid. Adding a layer of the second elastic polymer will encapsulate the layer of conductive fluorinated fluid.

[0077] The non-stick surface can be any suitable non-stick material. Examples of suitable non-stick materials include polytetrafluoroethylene, anodized aluminum, ceramic, and enameled cast iron.

[0078] The present disclosure also provides products, items, and structures comprising a substrate that supports a layer of the conductive composites disclosed herein and, in certain embodiments, a flexible conductive composite as disclosed herein. Such products, items, and structures can be made by heating the thermoplastic or thermosetting conductive composites disclosed herein and adding them to a substrate. Alternatively, a flexible conductive composite can be adhesively bonded to the substrate.

[0079] The composition of the conductive fluorinated fluid can be prepared by combining a fluorinated component with a conductive additive and thoroughly mixing the resulting mixture to produce a uniform conductive fluorinated fluid. Mixing can be achieved using a shear mixer at about 25 to about 2500 rpm. In certain embodiments, shear mixing to produce the composition of the conductive fluorinated fluid is performed at about 25 to about 125 rpm, or about 125 to about 250 rpm, or 250 to about 400 rpm, or about 400 to about 700 rpm, or about 700 to about 1500 rpm, or about 1500 to about 2500 rpm. Alternatively, mixing can be performed using a centrifugal planetary mixer. The resulting conductive composite can be stored for future use.

[0080] Furthermore, the surface of the elastic polymer layer facing the layer of the conductive fluorinated fluid can be treated to improve the wetting of the liquid metal. This can include ultraviolet treatment, plasma treatment, or corona discharge treatment. Further, a surfactant is added to the elastic polymer layer facing the layer of the conductive fluorinated fluid to improve wetting.

[0081] The following experimental examples illustrate further features and properties of the conductive composites of this description.

[0082] Materials Luperox® A98 benzoyl peroxide was purchased from SigmaAldrich and used as received. Stainless steel wires (3 mm × 2 μm) and nickel wires (10 μm × 0.25 mm, 10 μm × 1 mm, and 10 μm × 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 DowCorning and used as received. NuSil R21-2615 silicone was obtained from Nusil and used as received. Silver nitrite was produced. Polyethylene glycol dimethacrylate (SR210) was obtained from Sartomer and used as received. FIRSTCURE® DMPT curing promoter was purchased from Albemarle and used as received. Fluorolink® PFPE E10-H , Fluorolink® AD1700 and Fomblin® 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.

[0083] Control Example 1: Nusil R21-2615 Control 10 g of NuSil R21-2615 Part A and 10 g of NuSil R21-2615 Part B were mixed at 2300 rpm for 1 minute using a flacktek mixer. The resulting homogeneous mixture of the elastic polymer was poured onto a Mylar release film and cast with a glass rod. The thin film of the elastic polymer was then thermally cured at 60 degrees Celsius for about 2 hours according to the manufacturer's instructions.

[0084] Example 2: FlexSeal Control 10 g of an aliquot of FlexSeal solution was cast onto a Mylar release film and cast with a glass rod. The resulting thin film of the elastic polymer was cured at room temperature overnight (about 18 hours) according to the manufacturer's instructions.

[0085] Example 3: Nickel Fluorogel and the Laminated Composite Prepared Therefrom Preparation of Conductive Fluoro 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 the veil was divided into three parts and added to the acrylate fluoro solvent mixture at 2300 rpm for 1 minute using a fracturing mixer. 60 g of nickel wire (10 μm × 0.25 mm) was mixed into the mixture by Flactek mixing at 2300 rpm for several minutes. The resulting nickel fluoro solvent mixture was homogenized and had 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 completely dissolved. The benzoyl peroxide MEK solution was added to the Ni-acrylate fluoro solvent mixture and mixed at 2300 rpm for 1 minute via a Flactek mixer. 375 μL of FIRSTCURE® DMPT curing promoter was added to the mixture and mixed at 2300 rpm for 1 minute via a Flactek mixer. The resulting homogenized mixture was heated in a heating mantle at 110 degrees Celsius. Polymerization occurred within 5 minutes. The nickel fluoro gel was cured to form large lumps, which were then crushed into small pieces with a spatula and then centrifugally mixed at 2300 rpm for 20 seconds. The resulting nickel fluoro gel was diffusible / fluid.

[0086] Preparation of Laminated Composite: Nickel fluoro gel up to about 30 mils thick was cast onto a cured FlexSeal ClearLiquid film. Additional FlexSeal Clear Liquid was cast on top of the nickel fluoro gel to completely encapsulate the laminated composite and cured overnight at room temperature. The thickness of this composite was about 100 mils.

[0087] Example 4: Nickel Fluoro Gel, Silver Nitride, and Laminated Composite Prepared Therefrom Preparation of Conductive Fluoro 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 a veil was added to an acrylate fluoro solvent mixture that had been mixed at 2300 rpm for 1 minute using a fracturing mixer. 25.7 g of nickel wire (10 μm × 0.25 mm) was mixed into the mixture by Flactek mixing at 2300 rpm for several minutes. The resulting nickel fluoro solvent mixture was homogenized and had 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 completely dissolved. The benzoyl peroxide MEK solution was added to the Ni-acrylate fluoro solvent mixture and mixed at 2300 rpm for 1 minute via a Flactek mixer. 375 μL of FIRSTCURE® DMPT curing promoter was added to the mixture and mixed at 2300 rpm for 1 minute via a Flactek mixer. The resulting homogenized mixture was heated in a heating mantle at 110 degrees Celsius. Polymerization occurred within 5 minutes. The nickel fluorogel was cured to form large lumps, then crushed into smaller fragments, and then centrifugally mixed at 2300 rpm for 20 seconds. The resulting nickel fluorogel was diffusible / flowable and could be easily applied onto a cloth.

[0088] Preparation of Impregnated Reinforcing Mesh: Using a spatula, the nickel fluorogel was evenly spread onto a silver knit to form a conductive silver knit filled with the nickel fluorogel.

[0089] Preparation of Laminated Composite: The silver knit filled with nickel fluorogel was placed on a cured FlexSeal ClearLiquid film. Additional FlexSeal Clear Liquid was cast on top of the silver knit filled with nickel fluorogel to completely encapsulate the laminated composite and cured overnight at room temperature. The thickness of this composite was approximately 100 mils.

[0090] Example 5: Nickel fluorogel with a longer nickel wire and a laminated composite material prepared therefrom Preparation of Conductive Fluoro 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 × 1 mm) was mixed overnight at speed 2 via an overhead shear mixer and then mixed at high speed for 1 hour at speed 8. Next, 4 g of nickel wire (8 μm × 3 mm) was mixed overnight at speed 2 via an overhead shear mixer and then centrifugally mixed at 2300 rpm for 1 minute. The resulting nickel fluoro-solvent mixture was homogenized and had no visible lumps. 38.6 g of additional 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 it was completely dissolved. The benzoyl peroxide MEK solution was added to the nickel-acrylate fluoro-solvent mixture and mixed at 2300 rpm for 1 minute via a Flactek mixer. 375 μL of FIRSTCURE® DMPT curing promoter was added to the mixture and mixed at 2300 rpm for 1 minute via a Flactek mixer. The resulting homogenized mixture was heated at 110 degrees Celsius in a heating mantle. Polymerization occurred within 5 minutes. The nickel fluorogel was cured to form large lumps, then crushed into small pieces with a spatula and then centrifugally mixed at 2300 rpm for 20 seconds. The resulting nickel fluorogel was diffusible / fluid.

[0091] Preparation of Laminated Composite Material: Nickel fluorogel up to about 30 mils thick was cast onto a cured FlexSeal ClearLiquid film. Additional FlexSeal Clear Liquid was cast on top of the nickel fluorogel to completely encapsulate the laminated composite material and cured overnight at room temperature. The thickness of this composite material was about 100 mils.

[0092] Example 6: Nickel fluorogel (fluorinated acrylate), silver nitrile, and a laminated composite material prepared therefrom Preparation of Conductive Fluoro Fluid: 70 g of HC / 04 from Vale and 40 g of nickel powder were mixed at 1500 rpm for 1 minute. 6 g of Ni wire (8 μm × 3 mm) was mixed overnight at speed 2 via an overhead shear mixer and then mixed at high speed for 1 hour at speed 8. An additional 20 g of nickel powder from Vale was added to the mixture and mixed at 1500 rpm for 1 minute. Next, 14 g of AD1700 (fluorinated acrylate) and 14 g of n-butyl acetate were added to the mixture and mixed at 1500 rpm for 1 minute. The resulting nickel fluoro-solvent mixture was homogenized and there were no visible lumps. An additional 40 g of nickel powder from Vale was added to the mixture and mixed at 1500 rpm for 2 minutes. In a separate container, 2 wt% benzoyl peroxide (relative to AD1700) 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 nickel-acrylate fluoro-solvent mixture and mixed at 1500 rpm for 1 minute via a Flactek mixer. 280 μL of FIRSTCURE® DMPT curing accelerator was added to the mixture and mixed at 1500 rpm for 1 minute via a Flactek mixer. The resulting homogenized mixture was heated at 110 degrees Celsius in a heating mantle. Polymerization occurred within 5 minutes. The resulting nickel fluorogel was diffusible and workable.

[0093] Preparation of Conductive Ag Nitrile Laminated Composite Material Filled with Conductive Fluorogel Using a spatula, the flowable conductive fluorogel paste was spread onto the silver nitrile.

[0094] Nusil Vacuum Infiltration: Nusil R21-2615 liquid silicone rubber is a two-component translucent silicone system that cures rapidly with a 1:1 mixing ratio of A and B. Equal parts were weighed into a Flacktek container and mixed at 2300 rpm for 1 minute. The resulting homogeneous resin was poured onto a panel equipped with a Mylar release film, and a 30-mil-thick film was cast using a glass rod. A silver nitrile filled with nickel fluorogel was placed on top of the NuSil film, and the remaining NuSil mixture was poured on top of the nitrile and dispersed evenly using a glass rod. A top panel with the Mylar release film side facing down was placed on top of the resin, and a breather sheet was placed on top of the panel. Before sealing, a vacuum connector was placed inside the vacuum bag, a 0.5-inch slit was cut into the vacuum bag, and a vacuum hose was connected to the slit. As soon as the system was sealed and the pressure was maintained at -25 inches Hg, the vacuum pump was turned on. The entire vacuum bag setup was placed on top of a location at a high temperature of 60 degrees Celsius and rapidly heat-cured for approximately 40 minutes. The composite material was removed from the setup after 1 hour. Additional NuSil R21-2615 was added / painted onto the composite surface to confirm that the nickel fluorogel was completely encapsulated. The thickness of this composite material was approximately 60-120 mils.

[0095] Example 7: Nickel fluorogel (uncured fluorinated acrylate network), silver nitrile, and a laminated composite material prepared therefrom Ni Fluorogel Synthesis: 70 g of HC / 04 and 30 g of nickel beryllium powder were mixed at 1500 rpm for 1 minute. 4 g of nickel wire (8 μm × 3 mm) was mixed overnight at speed 2 via an overhead shear mixer and then mixed at high speed at speed 8 for 1 hour. An additional 30 g of nickel beryllium powder was 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 were added to the mixture and mixed at 1500 rpm for 1 minute. The resulting nickel fluorosolvent mixture should be homogenized and should have no visible lumps. An additional 30 g of nickel beryllium powder was added to the mixture and mixed at 1500 rpm for 2 minutes. The homogenized mixture did not undergo a polymerization process. The mixture was diffusible / flowable.

[0096] Preparation of Conductive Ag Nit Knit Laminated Composite Filled with Conductive Fluorogel: Using a spatula, the fluid conductive fluorogel paste was spread onto the silver knit.

[0097] Nusil Vacuum Infiltration: Nusil R21-2615 liquid silicone rubber is a two-component translucent silicone system that cures rapidly with a 1:1 mixing ratio of A and B. Equal parts were weighed into a Flacktek container and mixed for 1 minute at 2300 rpm. The resulting homogeneous resin was poured onto a panel equipped with a Mylar release film, and a 30-mil-thick film was cast using a glass rod. A silver knit filled with nickel fluorogel was placed on top of the NuSil film, and the remaining NuSil mixture was poured on top of the knit and dispersed evenly using a glass rod. A top panel with the Mylar release film side facing down was placed on top of the resin, and a breather sheet was placed on top of the panel. Before sealing, a vacuum connector was placed inside the vacuum bag, a 0.5-inch slit was cut into the vacuum bag, and a vacuum hose was connected to the slit. As soon as the system was sealed and the pressure was maintained at -25 inches Hg, the vacuum pump was turned on. The entire vacuum bag setup was placed on top of a location at a high temperature of 60 degrees Celsius and rapidly heat cured for approximately 40 minutes. The composite material was removed from the setup after 1 hour. Additional NuSil R21-2615 was added / painted onto the composite surface to confirm that the nickel fluorogel was completely encapsulated. The thickness of this composite material was approximately 60-120 mils.

[0098] The examples of the present disclosure can be described in light of the aircraft manufacturing and maintenance method 1000 shown in FIG. 4 and the aircraft 1002 shown in FIG. 5. The aircraft manufacturing and maintenance method 1000 may include, in the pre-manufacturing stage, the specifications and design 1004 of the aircraft 1002 and the procurement 1006 of materials. In the manufacturing stage, the manufacturing 1008 of the components / subassemblies of the aircraft 1002 and the system integration 1010 are performed. Thereafter, the aircraft 1002 can be subjected to operation 1014 through approval and delivery 1012. During the period of operation by the customer, the aircraft 1002 is scheduled for regular maintenance and servicing 1016, which may also include modifications, reconfigurations, repairs, etc.

[0099] Each process of method 1000 can be implemented or executed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, the system integrator can include, but is not limited to, any number of aircraft manufacturers and subcontractors of major systems, the third party can include, but is not limited to, any number of vendors, subcontractors, and suppliers, and the operator can be an airline, a leasing company, a military organization, a service agency, etc.

[0100] The conductive composite material of the present disclosure can be employed at any one or more stages of the aircraft manufacturing and maintenance method 1000, including the specification and design 1004 of the aircraft 1002, the procurement 1006 of materials, the manufacture 1008 of components / subassemblies, the system integration 1010, the approval and delivery 1012, the placement into the operation 1014 of the aircraft, and the regular servicing and maintenance 1016.

[0101] Furthermore, the present disclosure includes embodiments according to the following clauses. Clause 1. A first layer of an elastic polymer (4), A layer of a conductive fluorinated fluid (6) on the first layer of the elastic polymer (4), and A second layer of an elastic polymer (8) on the layer of the conductive fluorinated fluid (6), a conductive composite material (2). Clause 2. The layer of the conductive fluorinated fluid (6) contains a fluorinated component and a conductive additive, the conductive composite material (2) according to Clause 1. Clause 3. The fluorinated component contains at least one of perfluoropolyether, fluorinated acrylate oligomer, and combinations thereof, the conductive composite material (2) according to Clause 2. Clause 4. The fluorinated component has a viscosity in the range of about 2,000 mPa·s to about 10,000,000 mPa·s the conductive composite material (2) according to Clause 2 or 3. Clause 5. The fluorinated component has a viscosity in the range of about 2,000 mPa·s to about 5,000,000mPa·s The conductive composite material (2) according to any one of clauses 2 to 4, having the viscosity of mPa·s . Clause 6. The fluorinated component has a viscosity of about 2,000 mPa·s to about 1,000,000 mPa·s The conductive composite material (2) according to any one of clauses 2 to 5, having the viscosity of mPa·s . Clause 7. The conductive additive has an aspect ratio of less than about 2, and the conductive composite material (2) according to any one of clauses 2 to 6. Clause 8. The conductive additive has an aspect ratio of at least about 2, and the conductive composite material (2) according to any one of clauses 2 to 7. Clause 9. The conductive additive includes at least one of carbon fiber, coated carbon fiber, and metal material, and the conductive composite material (2) according to any one of clauses 2 to 8. Clause 10. The conductive additive includes a metal material, and the metal material includes at least one of stainless steel, brass, iron, nickel, titanium, aluminum, copper, silver, gold, platinum, palladium, and zinc, and the conductive composite material (2) according to any one of clauses 2 to 9. Clause 11. The layer of the conductive fluorinated fluid (6) further includes a compatibilizer, and the conductive composite material (2) according to any one of clauses 1 to 10. Clause 12. The layer of the conductive fluorinated fluid (6) further includes a compatibilizer, and the compatibilizer includes at least one of an organic compatibilizer, an inorganic compatibilizer, and a combination thereof, and the conductive composite material (2) according to any one of clauses 1 to 10. Clause 13. The layer of the conductive fluorinated fluid (6) further includes an organic compatibilizer, and the organic compatibilizer includes a surfactant, and the conductive composite material (2) according to any one of clauses 1 to 12. Clause 14. The layer of the conductive fluorinated fluid (6) further contains an organic compatibilizer, and the organic compatibilizer includes at least one of an ionic surfactant, a nonionic surfactant, and combinations thereof. The conductive composite material (2) according to any one of clauses 1 to 13. Clause 15. The conductive composite material (2) according to any one of clauses 1 to 14, further containing an additive for enhancing thermal oxidation stability. Clause 16. The conductive composite material (2) according to any one of clauses 1 to 15, further containing an additive for enhancing thermal oxidation stability, and the additive includes at least one of a phosphate, iron oxide, phenol, antioxidant, metal passivator, and combinations thereof. Clause 17. The first layer of the elastic polymer (4) includes at least one of a thermoplastic polymer, a thermosetting polymer, and combinations thereof. The conductive composite material (2) according to any one of clauses 1 to 16. Clause 18. The first layer of the elastic polymer (4) includes at least one of a siloxane, a fluorosiloxane, a perfluoropolyether, a polybutadiene, a polyester, a polycarbonate, a polyurethane, a polyurea, a polyurethane-urea, an epoxy, an acrylate, a natural rubber, a butyl rubber, a polyacrylonitrile, an ethylene propylene diene monomer (EPDM) rubber, and combinations thereof. The conductive composite material (2) according to any one of clauses 1 to 17. Clause 19. The second layer of the elastic polymer (8) includes at least one of a thermoplastic polymer, a thermosetting polymer, and combinations thereof. The conductive composite material (2) according to any one of clauses 1 to 18. Clause 20. The second layer of the elastic polymer (8) is the conductive composite material (2) according to any one of clauses 1 to 19, including at least one of siloxane, fluorosiloxane, perfluoropolyether, polybutadiene, polyester, polycarbonate, polyurethane, polyurea, polyurethane-urea, epoxy, acrylate, natural rubber, butyl rubber, polyacrylonitrile, ethylene propylene diene monomer (EPDM) rubber, and combinations thereof. Clause 21. The conductive composite material (2) according to any one of clauses 1 to 20, wherein the thickness of the first layer of the elastic polymer (4) is in the range of about 0.01 mm to about 100 mm. Clause 22. The conductive composite material (2) according to any one of clauses 1 to 21, wherein the thickness of the first layer of the elastic polymer (4) is in the range of about 0.1 mm to about 10 mm. Clause 23. The conductive composite material (2) according to any one of clauses 1 to 22, wherein the thickness of the second layer of the elastic polymer (8) is in the range of about 0.01 mm to about 100 mm. Clause 24. The conductive composite material (2) according to any one of clauses 1 to 23, wherein the thickness of the second layer of the elastic polymer (8) is in the range of about 0.1 mm to about 10 mm. Clause 25. The conductive composite material (2) according to clauses 1 to 24, wherein the thickness of the layer of the conductive fluorinated fluid (6) is less than or equal to at least one of the thickness of the first layer of the elastic polymer (4) and the thickness of the second layer of the elastic polymer (8). Clause 26. The conductive composite material (2) according to clauses 1 to 25, wherein the thickness of the layer of the conductive fluorinated fluid (6) is greater than at least one of the thickness of the first layer of the elastic polymer (4) and the thickness of the second layer of the elastic polymer (8). Clause 27. The conductive composite material (2) according to clauses 1 to 26, wherein the thickness of the layer of the conductive fluorinated fluid (6) is greater than the sum of the thickness of the first layer of the elastic polymer (4) and the thickness of the second layer of the elastic polymer (8). Article 28. The layer of the conductive fluorinated fluid (6) is the conductive composite material (2) according to any one of Articles 1 to 27, which is uniform. Article 29. The layer of the conductive fluorinated fluid (6) is the conductive composite material (2) according to any one of Articles 1 to 28, which is non-uniform. Article 30. The conductive composite material (2) according to any one of Articles 1 to 29, further comprising a reinforcing mesh (10) in contact with the layer of the conductive fluorinated fluid (6). Article 31. The reinforcing mesh (10) is the conductive composite material (2) according to Article 30, which includes cloth. Article 32. The reinforcing mesh (10) is the conductive composite material (2) according to Article 30 or 31, which includes at least one of knitted fabric, woven fabric, and combinations thereof. Article 33. The reinforcing mesh (10) is the conductive composite material (2) according to any one of Articles 30 to 32, which includes at least one of non-conductive cloth, conductive cloth, and combinations thereof. Article 34. The reinforcing mesh (10) is the conductive composite material (2) according to any one of Articles 30 to 33, which includes non-conductive cloth and includes at least one of polyether-polyurea copolymer, latex, polyparaphenylene terephthalamide, aramid, nylon, polyester, and combinations thereof. Article 35. The reinforcing mesh (10) is the conductive composite material (2) according to any one of Articles 30 to 34, which includes conductive cloth and includes at least one of conductive filaments, coated non-conductive cloth, and combinations thereof. Article 36. The reinforcing mesh (10) includes a conductive cloth containing a conductive filament, and the conductive filament includes at least one of a silver filament, a copper filament, a brass filament, a nickel filament, a stainless steel filament, a steel filament, an aluminum filament, a carbon filament, a coated carbon filament, a titanium filament, a tungsten filament, a tin filament, a zinc filament, and combinations thereof, and is the conductive composite material (2) according to any one of clauses 30 to 35. Clause 37. The reinforcing mesh (10) includes a conductive cloth containing a coated non-conductive cloth, and the coated non-conductive cloth includes at least one of a polyester-polyurea copolymer coated with a metal, a latex coated with a metal, a polyparaphenylene terephthalamide coated with a metal, an aramid coated with a metal, a nylon coated with a metal, a polyester coated with a metal, a polyether-polyurea copolymer coated with carbon, a latex coated with carbon, a polyparaphenylene terephthalamide coated with carbon, an aramid coated with carbon, a nylon coated with carbon, a polyester coated with carbon, and combinations thereof, and is the conductive composite material (2) according to any one of clauses 30 to 36. Clause 38. The conductive composite material includes an edge length of an elastic polymer around a layer of the conductive fluorinated fluid that seals the conductive fluorinated fluid within the conductive composite material, and is the conductive composite material (2) according to any one of clauses 1 to 37. Clause 39. The edge length is at least one of the thickness of the first layer of the elastic polymer and the thickness of the second layer of the elastic polymer, and is the conductive composite material (2) according to any one of clauses 1 to 38. Clause 40. The second layer of the elastic polymer is joined to the first layer of the elastic polymer, and is the conductive composite material (2) according to any one of clauses 1 to 39. Clause 41. The conductive composite material (2) is the conductive composite material (2) according to any one of clauses 1 to 40, which exhibits a minimum sheet resistance value of less than about 100 ohms / sq. Clause 42. The conductive composite material (2) is the conductive composite material (2) according to any one of clauses 1 to 41, which exhibits an elongation at break rate of about 10% or more. Clause 43. The conductive composite material (2) is the conductive composite material (2) according to any one of clauses 1 to 42, which exhibits an elongation at break rate of about 15% or more. Clause 44. The conductive composite material (2) is the conductive composite material (2) according to any one of clauses 1 to 43, which exhibits an elongation at break rate of about 50% or more. Clause 45. The conductive composite material (2) is the conductive composite material (2) according to any one of clauses 1 to 44, which exhibits a tensile strength of about 3 MPa or more. Clause 46. The conductive composite material (2) is the conductive composite material (2) according to any one of clauses 1 to 45, which has a density of less than about 7 g / mL. Clause 47. The conductive composite material (2) is the conductive composite material (2) according to any one of clauses 1 to 46, which has a density of less than about 6 g / mL. Clause 48. The conductive composite material (2) is the conductive composite material (2) according to any one of clauses 1 to 47, which has a density of less than about 5 g / mL. Clause 49. The conductive composite material (2) is the conductive composite material (2) according to any one of clauses 1 to 48, which has a density of less than about 4 g / mL. Clause 50. The conductive composite material (2) is the conductive composite material (2) according to any one of clauses 1 to 49, which has a loss modulus (G”) greater than the storage modulus (G’). Clause 51. The conductive composite material (2) is a part of an aircraft, and is the conductive composite material (2) according to any one of clauses 1 to 50. Clause 52. The conductive composite material (2) according to any one of clauses 1 to 51, which is at least a part of at least one of the main wing and the fuselage of an aircraft. Clause 53. The conductive composite material (2) according to any one of clauses 1 to 52, which is at least one of a seal and a gasket. Clause 54. A method for manufacturing a conductive composite material, forming a first layer of an elastic polymer, forming a layer of a conductive fluorinated fluid on the first layer of the elastic polymer, and forming a second layer of an elastic polymer on the layer of the conductive fluorinated fluid. Clause 55. The method according to clause 54, wherein the step of forming the first layer of the elastic polymer includes curing the first layer of the elastic polymer. Clause 56. The method according to clause 54 or 55, wherein the step of forming the layer of the conductive fluorinated fluid includes mixing a fluorinated component and a conductive additive. Clause 57. The method according to any one of clauses 54 to 56, wherein the step of forming the layer of the conductive fluorinated fluid includes mixing a fluorinated component, a conductive additive, and a compatibilizer. Clause 58. The method according to any one of clauses 54 to 57, wherein the step of forming the layer of the conductive fluorinated fluid includes mixing a fluorinated component, a conductive additive, and an additive for enhancing thermal oxidation stability. Clause 59. The method according to any one of clauses 54 to 58, wherein the step of forming the layer of the conductive fluorinated fluid includes mixing the conductive fluorinated fluid using at least one of shear mixing and centrifugal mixing. Clause 60. The step of forming the layer of the conductive fluorinated fluid includes mixing the conductive fluorinated fluid using shear mixing, and the shear mixing is performed at a rotational speed in the range of about 25 to about 2,000 rpm, the method according to any one of clauses 54 to 59. Clause 61. The step of forming the layer of the conductive fluorinated fluid includes mixing the conductive fluorinated fluid using shear mixing, and the shear mixing is performed at a rotational speed in the range of about 25 to 125 rpm, the method according to any one of clauses 54 to 60. Clause 62. The step of forming the layer of the conductive fluorinated fluid includes impregnating the layer of the conductive fluorinated fluid into a reinforcing mesh, the method according to clauses 54 to 61. Clause 63. The step of forming the second layer of the elastic polymer includes curing the second layer of the elastic polymer, the method according to any one of clauses 54 to 62. Clause 64. The step of curing the second layer of the elastic polymer includes joining the second layer of the elastic polymer to the first layer of the elastic polymer, the method according to clause 63. Clause 65. The first layer of the elastic polymer and the second layer of the elastic polymer enclose the layer of the conductive fluorinated fluid, the method according to any one of clauses 54 to 64. Clause 66. The method according to any one of clauses 54 to 65 further includes trimming the conductive composite material around the layer of the conductive fluorinated fluid. Clause 67. Trimming the conductive composite material around the layer of the conductive fluorinated fluid seals the conductive fluorinated fluid within the conductive composite material and leaves an edge length around the layer of the conductive fluorinated fluid, the method according to any one of clauses 54 to 66. Clause 68. The method according to clause 67, wherein the edge length is at least one or more of the thickness of the first layer of the elastic polymer and the thickness of the second layer of the elastic polymer.

[0102]

[0001]

[0103]

[0002] As shown in FIG. 5, an aircraft 1002 manufactured by an 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 also be included. The conductive composite material of the present disclosure may be employed in any of the plurality of systems of the aircraft 1002.

[0104]

[0003] Although various embodiments of the conductive composite material of the present disclosure and methods for manufacturing the conductive composite material have been illustrated and described, those skilled in the art will be able to envision variations by reading this specification. This application includes such variations and is limited only by the claims.

Claims

**Claim 1**: A conductive composite material comprising: a first layer of an elastic polymer, a layer of a conductive fluorinated fluid on the first layer of the elastic polymer, and a second layer of an elastic polymer on the layer of the conductive fluorinated fluid wherein the conductive composite material includes an edge length of the elastic polymer around the layer of the conductive fluorinated fluid that seals the conductive fluorinated fluid within the conductive composite material. **Claim 2**: The conductive composite material according to claim 1, wherein the layer of the conductive fluorinated fluid includes a fluorinated component and a conductive additive. **Claim 3**: The conductive composite material according to claim 2, wherein the fluorinated component includes at least one of perfluoropolyether, fluorinated acrylate oligomer, or a combination thereof. **Claim 4**: The conductive composite material according to claim 2 or 3, wherein the fluorinated component has a viscosity in the range of 2,000 mPa·s to 10,000,000 mPa·s. **Claim 5**: The conductive composite material according to any one of claims 2 to 4, wherein the conductive additive has an aspect ratio of less than 2. **Claim 6**: The conductive composite material according to any one of claims 2 to 4, wherein the conductive additive has an aspect ratio of at least 2. **Claim 7**: The conductive composite material according to any one of claims 2 to 6, wherein the conductive additive includes at least one of carbon fiber, coated carbon fiber, and a metal material. **Claim 8**: The conductive composite material according to any one of claims 1 to 7, wherein the layer of the conductive fluorinated fluid further includes a compatibilizer. **Claim 9**: The conductive composite material according to any one of claims 1 to 8, further including an additive for enhancing thermal oxidation stability. **Claim 10**: The conductive composite material according to any one of claims 1 to 9, wherein the first layer of the elastic polymer includes at least one of a thermoplastic polymer, a thermosetting polymer, and a combination thereof. **Claim 11**: The conductive composite material according to any one of claims 1 to 10, wherein the second layer of the elastic polymer includes at least one of a thermoplastic polymer, a thermosetting polymer, and a combination thereof. **Claim 12**: The conductive composite material according to any one of claims 1 to 11, further comprising a reinforcing mesh in contact with the layer of the conductive fluorinated fluid, wherein the reinforcing mesh includes a cloth selected from at least one of a knitted fabric, a woven fabric, and a combination thereof.

13. The conductive composite material according to any one of claims 1 to 12, wherein the conductive fluorinated fluid has a conductivity exceeding 10 S / m.

14. The conductive composite material according to any one of claims 1 to 13, which is a part of an aircraft, including at least one of at least a part of a main wing, at least a part of a fuselage, a seal, and a gasket.

15. A method for manufacturing a conductive composite material, forming a first layer of an elastic polymer, forming a layer of a conductive fluorinated fluid on the first layer of the elastic polymer, and forming a second layer of an elastic polymer on the layer of the conductive fluorinated fluid including, wherein the first layer of the elastic polymer and / or the second layer of the elastic polymer are formed to include the edge length of the elastic polymer around the layer of the conductive fluorinated fluid that seals the conductive fluorinated fluid within the conductive composite material.

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