Fabrication, composition and application of conductive polymer / rubber composite

Abstract

A conductive coating composition may be produced by forming a conductive polymer in situ in a rubber latex. The conductive polymer may be polypyrrole. The coating may be crosslinked. The composition may further include a peroxide-containing crosslinking agent, an epoxy-containing crosslinking agent, a carbodiimide crosslinking agent, and / or an aziridine-containing crosslinking agent.

Description

Fabrication, Composition and Application ofConductive PolyMER / Rubber Composite

[0001] This application claims priority to U.S. Provisional Application Serial Nos. 63 / 710,076, filed October 22, 2024 and 63 / 902,618, filed October 21, 2025, the contents of which are incorporated by reference herein.BACKGROUND

[0002] The buildup of static charges on products, such as tires, textiles, rubbers, and plastics, is a potential risk and may cause severe harm or damage in various industries. To address these issues, anti-static or semiconducting materials have been developed to avoid the accumulated static charge and avoid sparking flammable or explosive materials. In comparison to using bulk conductive materials, a conductive coating is an appealing solution. It only interacts on the surface of the materials and improves the surface conductivity of the insulator, enabling dissipative antistatic behavior, while being a coating can significantly decrease the materials' expense and maintain the integrity of bulk substrates. However, it is challenging to prepare flexible conductive coatings due to the trade-offs between high flexibility, high electrical conductivity, and low cost.

[0003] Moreover, it is challenging to achieve robust coatings with good interfacial adhesion, conductivity and wear resistance. Especially for eco-friendly water-based rubber latex, vulcanization methods using sulfur and activators may exhibit poor compatibility with aqueous solutions.BRIEF DESCRIPTION

[0004] The present disclosure relates to a conductive coating composition containing polypyrrole and a rubber latex. The polypyrrole may be formedin situin the rubber latex. Non-limiting examples of rubbers include styrene butadiene rubber, natural rubber, epoxidized natural rubber, acrylic rubber, acrylonitrile butadiene rubber, and hydrogenated acrylonitrile butadiene rubber. The composition may include additives such as surfactants and oxidizing agents. The conductive coating solution is stable and offers good conductivity, adhesion, and mechanical flexibility after being coated onto a substrate (e.g., rubber, paper).

[0005] Disclosed, in some embodiments, is a conductive coating composition containing: a conductive polymer and a rubber latex. The conductive polymer was formed in situ in the rubber latex. The conductive polymer may be polypyrrole. In some embodiments, the rubber latex comprises a carboxylate functional group and / or a polar functional group. The rubber latex may include one or more of styrene butadiene rubber, natural rubber, epoxidized natural rubber, acrylic rubber, hydrogenated acrylonitrile butadiene rubber, a carboxylated nitrile rubber, and a carboxylated styrene butadiene rubber. The conductive polymer may be included in the coating composition in an amount of from about 0.1 to about 100 phr, from about 0.5 to about 50 phr, from about 1 to about 20 phr, from about 5 to about 15 phr, or from about 8 to about 10 phr. In some embodiments, the coating composition further contains at least one additive selected from surfactants, adhesion promoters, oxidizing agents, and pigments.

[0006] Disclosed, in other embodiments, is a process for forming a conductive coating composition. The process includes polymerizing a monomer in situ in a composition comprising a rubber latex to form a conductive polymer. The monomer may be pyrrole. In some embodiments, the composition further contains one or more additives selected from surfactants, adhesion promoters, oxidizing agents, and pigments. The rubber latex may include a carboxylate functional group and / or a polar functional group. In some embodiments, the rubber latex includes one or more of styrene butadiene rubber, natural rubber, epoxidized natural rubber, styrene butadiene rubber, acrylic rubber, hydrogenated acrylonitrile butadiene rubber, a carboxylated nitrile rubber, and a carboxylated styrene butadiene rubber. In some embodiments, the conductive polymer is included in the coating composition in an amount of from about 0.1 to about 100 phr, from about 0.5 to about 50 phr, from about 1 to about 20 phr, from about 5 to about 15 phr, or from about 8 to about 10 phr.

[0007] Also disclosed are coated articles having a substrate and a conductive layer formed from the conductive coating composition on the substrate. Non-limiting examples of articles include tires, textiles, rubbers, and plastics. The substrate may be selected from paper, glass, rubber, and plastic.

[0008] Further disclosed are methods for coating a substrate. The methods include applying the coating composition to the substrate. Optionally, the coating composition is dried after being applied to the substrate. The substrate may be selected from paper, glass, rubber, and plastic.

[0009] The present disclosure further relates to a method of crosslinking PPy / rubber composite latex for durable conductive composite coating. The composite coating composed of a conductive filler, a flexible rubber matrix, and a crosslinker. These components are homogeneously dispersed in water, leading to a stable latex that can be easily sprayed on the surfaces of non-conductive polymeric materials. The resultant coating can be further crosslinked to produce a conductive and flexible coating with enhanced interfacial adhesion, mechanical properties, and wear resistance.

[0010] Disclosed, in some embodiments, is a conductive coating composition containing: a conductive polymer, a rubber latex, and a crosslinker. The conductive polymer may be formed in situ in the rubber latex. The conductive polymer may be polypyrrole. In some embodiments, the rubber latex comprises a carboxylate functional group and / or a polar functional group. The rubber latex may include one or more of styrene butadiene rubber, natural rubber, epoxidized natural rubber, styrene butadiene rubber, acrylic rubber, hydrogenated acrylonitrile butadiene rubber, a carboxylated nitrile rubber, and a carboxylated styrene butadiene rubber. The conductive polymer may be included in the coating composition in an amount of from about 0.1 to about 100 phr, from about 0.5 to about 50 phr, from about 1 to about 20 phr, from about 5 to about 15 phr, or from about 8 to about 10 phr. In some embodiments, the coating composition further contains at least one additive selected from surfactants, adhesion promoters, oxidizing agents, and pigments.

[0011] Disclosed, in other embodiments, is a process for forming a conductive coating composition. The process includes polymerizing a monomer in situ in a composition comprising a rubber latex to form a conductive polymer. The composition further includes a crosslinking agent and may be applied to an article and subsequently crosslinked. The monomer may be pyrrole. In some embodiments, the composition further contains one or more additives selected from surfactants, adhesion promoters, oxidizing agents, and pigments. The rubber latex may include a carboxylate functional group and / or a polar functional group. In some embodiments, the rubber latex includes one or more of styrene butadiene rubber, natural rubber, epoxidized natural rubber, styrene butadiene rubber, acrylic rubber, hydrogenated acrylonitrile butadiene rubber, a carboxylated nitrile rubber, and a carboxylated styrene butadiene rubber. In some embodiments, the conductive polymer is included in the coating composition in an amount of from about 0.1 to about 100 phr, from about 0.5 to about 50 phr, from about 1 to about 20 phr, from about 5 to about 15 phr, or from about 8 to about 10 phr.

[0012] Also disclosed are coated articles having a substrate and a conductive layer formed from the conductive coating composition on the substrate and curing the composition. Non-limiting examples of articles include tires, textiles, rubbers, and plastics. The substrate may be selected from paper, glass, rubber, and plastic.

[0013] Further disclosed are methods for coating a substrate. The methods include applying the coating composition to the substrate and crosslinking the applied composition. Optionally, the coating composition is dried after being applied to the substrate. The substrate may be selected from paper, glass, rubber, and plastic.

[0014] These and other non-limiting characteristics are more particularly described below.DETAILED DESCRIPTION

[0015] The present disclosure may be understood more readily by reference to the following detailed description of desired embodiments included therein. In the following specification and the claims which follow, reference will be made to a number of terms which shall be defined to have the following meanings.

[0016] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In case of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or equivalent can be used in practice or testing of the present disclosure. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. The materials, methods, and articles disclosed herein are illustrative only and not intended to be limiting.

[0017] The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0018] As used in the specification and in the claims, the term “comprising” may include the embodiments “consisting of” and “consisting essentially of.” The terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases that require the presence of the named ingredients / steps and permit the presence of other ingredients / steps. However, such description should be construed as also describing compositions, mixtures, or processes as “consisting of” and “consisting essentially of” the enumerated ingredients / steps, which allows the presence of only the named ingredients / steps, along with any impurities that might result therefrom, and excludes other ingredients / steps.

[0019] Unless indicated to the contrary, the numerical values in the specification should be understood to include numerical values which are the same when reduced to the same number of significant figures and numerical values which differ from the stated value by less than the experimental error of the conventional measurement technique of the type used to determine the particular value.

[0020] All ranges disclosed herein are inclusive of the recited endpoint and independently combinable (for example, the range of “from 2 to 10” is inclusive of the endpoints, 2 and 10, and all the intermediate values). The endpoints of the ranges and any values disclosed herein are not limited to the precise range or value; they are sufficiently imprecise to include values approximating these ranges and / or values.

[0021] As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” may not be limited to the precise value specified, in some cases. The modifier “about” should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4.” The term “about” may refer to plus or minus 10% of the indicated number. For example, “about 10%” may indicate a range of 9% to 11%, and “about 1” may mean from 0.9-1.1.

[0022] For the recitation of numeric ranges herein, each intervening number there between with the same degree of precision is explicitly contemplated. For example, for the range of 6-9, the numbers 7 and 8 are contemplated in addition to 6 and 9, and for the range 6.0-7.0, the number 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are explicitly contemplated.

[0023] As used herein, “phr” is “parts per hundred parts of rubber by weight.” For example, the composition referenced in various figures as “XSBR / 10PPy” contains 10 parts by weight of PPy (polypyrrole) per 100 parts by weight XSBR (carboxylated styrene butadiene rubber).

[0024] The present disclosure relates to conductive coating compositions, methods for producing the compositions, methods for producing coated articles using the compositions, and coated articles including a conductive layer formed from the compositions. The coating compositions contain a rubber latex and a conductive polymer formed in situ in the rubber latex. The rubber latex may be a water-borne latex.

[0025] The rubber latex may include a rubber having a carboxylate functional group and / or a different polar group. Non-limiting examples of suitable rubbers include styrene butadiene rubber, natural rubber, epoxidized natural rubber, styrene butadiene rubber, acrylic rubber, hydrogenated acrylonitrile butadiene rubber, a carboxylated nitrile rubber, and a carboxylated styrene butadiene rubber.

[0026] The conductive polymer is formed in situ in the rubber latex. For example, monomer is polymerized in the rubber latex to form a conductive polymer.

[0027] The rubber may provide a flexible elastomeric matrix which hosts the conductive polymer.

[0028] Non-limiting examples of conductive polymers include polypyrroles, polyacetylenes, polyphenylene vinylenes, polythiophene, polyanilines, polyacenes, and polyphenylene sulfides. The conductive polymer may be a homopolymer or a copolymer.

[0029] The conductive polymer is included in the coating composition in an amount of from about 0.1 to about 100 phr, from about 0.5 to about 50 phr, from about 1 to about 20 phr, from about 5 to about 15 phr, or from about 8 to about 10 phr.

[0030] The compositions may include a crosslinking agent and the resultant cured coating may exhibit improved conductivity.

[0031] Non-limiting examples of curing strategies may utilize sulfur-triggered carbon-sulfur network, peroxide-initiated double bond crosslinking, epoxy-containing crosslinkers, carbodiimide-containing crosslinkers, and / or aziridine-containing crosslinkers.

[0032] Non-limiting examples of sulfur-based crosslinking agents include elemental sulfur, thiazoles, thiurams, dithiocarbamates, and sulfenamides.

[0033] In some embodiments, the crosslinking agent includes one or more of elemental sulfur, mercaptobenzothiazole (MBT), mercaptobenzothiazole disulfide (MBTS), N-cyclohexylbenzothiazol-2-sulfenamide (CBS), tetramethyl thiuram disulfide (TMTD), dipentamethylene thiuram tetrasulfide (DPTT), zinc diethyl dithiocarbamate (ZDEC), zinc dimethyldithiocarbamate (ZDMC), N-cyclohexyl benzothiazole-2-sulfenamide (CBS), N-tert-butylbenzothiazole-2-sulfenamide (TBBS), 4,4′-dithiodimorpholine (DTDM), and thiocarbamyl sulfenamide (OTOS).

[0034] However, in some embodiments, the crosslinking agent is not a sulfur-based crosslinking agent.

[0035] Non-limiting examples of peroxide crosslinking agents include dicumyl peroxide (DCP), benzoyl peroxide (BPO), 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane, bis(tert-butylperoxyisopropyl)benzene (BIPB), 2,5-di(tert-butylperoxy)-2,5-dimethyl-3-hexyne, and 3,3,5,7,7-pentamethyl-1,2,4-trioxepane.

[0036] In some embodiments, the peroxide includes one or more of hydrogen peroxide and organoperoxides such as alkyl hydroperoxides, dialkyl peroxides, and diacyl peroxides. Examples for the peroxide include, but are not limited to, an organic peroxide selected from the group consisting of di-t-butyl peroxide, t-butyl cumyl peroxide, dicumyl peroxide, 2,5-dimethyl-2,5-di(t-butyl-peroxy)hexyne-3, l,3-bis(t-butyl- peroxy-isopropyl)benzene, n-butyl-4,4-bis(t-butyl-peroxy)valerate, benzoyl peroxide, t-butylperoxybenzoate, t-butylperoxy isopropyl carbonate, t-butylperbenzoate, bis(2-methylbenzoyl)peroxide, bis(4-methylbenzoyl)peroxide, t-butyl peroctoate, cumene hydroperoxide, methyl ethyl ketone peroxide, lauryl peroxide, tert-butyl peracetate, di-t-amyl peroxide, t-amyl peroxybenzoate, 1, 1 -bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, a,a'-bis(t-butylperoxy)-1,3- diisopropylbenzene, a,a'-bis(t-butylpexoxy)-l,4-diisopropylbenzene, 2,5-bis(t-butylperoxy)-2,5- dimethylhexane, 2,5-Dimethyl-2,5-di-(tert-butylperoxy)-hexane, 2,5-bis(t-butylperoxy)-2,5- dimethy 1-3 -hexyne, 2,4-dichlorobenzoyl peroxide, and combinations thereof.

[0037] Non-limiting examples of epoxy crosslinking agents include ethylene glycol diglycidyl ether (EGDGE), poly(ethylene glycol) diglycidyl ether (PEG-DE), and polyethylene glycol diacrylate (PEGDA).

[0038] Non-limiting examples of carbodiimide-containing crosslinking agents include 1-ethyl-3-(3-dimethylaminopropyl) carbodiimide (EDC), 1-cyclohexyl-3-(2-morpholinoethyl)carbodiimide methyl p-toluenesulfonate (CMC), and dicyclohexylcarbodiimide (DCC).

[0039] Non-limiting examples of aziridine crosslinking agents include bis-aziridines and tris-aziridines. In some embodiments, the aziridine crosslinking agent includes a (meth)acryloyl-aziridine.

[0040] Curing may be performed using chemicals, UV light, and / or heat.

[0041] A surfactant may be included before, during, and / or after the polymerization. The surfactant may be anionic, cationic, non-ionic, or zwitterionic.

[0042] The surfactant may be included in the coating composite in an amount of from about 2 to about 70 phr, from about 10 to about 50 phr, or from about 24 to about 35 phr.

[0043] Non-limiting examples of anionic surfactants include 2-acrylamido-2-methylpropane sulfonic acid, alkylbenzene sulfonate, ammonium lauryl sulfate, ammonium perfluorononanoate, chlorosulfolipid, disodium cocoamphodiacetate, magnesium laureth sulfate, alpha-olefin sulfonate, perfluorobutanesulfonic acid, perfluorodecanoic acid, perfluorohexanesulfonic acid, perfluorononanoic acid, perfluorooctanesulfonic acid, perfluorooctanoic acid, perfluoropropanesulfonic acid, phospholipid, potassium lauryl sulfate, sodium dodecyl sulfate, sodium laurate, sodium laureth sulfate, sodium lauroyl sarcosinate, sodium myreth sulfate, sodium nonanoyloxybenzenesulfonate, sodium pareth sulfate, sodium stearate, sodium sulfosuccinate esters, sodium tallowate, sodium tetradecyl sulfate, and sulfolipid.

[0044] Non-limiting examples of cationic surfactant include behentrimonium chloride, benzalkonium chloride, benzethonium chloride, benzododecinium bromide, carbethopendecinium bromide, cetalkonium chloride, cetrimide, cetrimonium bromide, cetrimonium chloride, cetylpyridinium chloride, didecyldimethylammonium chloride, dimethyldioctadecylammonium bromide, dimethyldioctadecylammonium chloride, dioleoyl-3-trimethylammonium propane, domiphen bromide, ethyl lauroyl arginate, hexadecyltrimethylammonium bromide, lauryl methyl gluceth-10 hydroxypropyl dimonium chloride, octenidine dihydrochloride, olaflur, n-oleyl-1,3-propanediamine, stearalkonium chloride, tetramethylammonium hydroxide, and thonzonium bromide.

[0045] Non-limiting examples of non-ionic surfactants include alkyl polyglycoside, Brij 35, cetostearyl alcohol, cetyl alcohol, cocamide DEA, cocamide MEA, decyl glucoside, decyl polyglucose, glycerol monostearate, lauryl glucoside, maltoside, monolaurin, mycosubtilin, narrow-range ethoxylate, octaethylene glycol monododecyl ether, n-octyl β-D-thioglucopyranoside, octyl glucoside, oleyl alcohol, pentaethylene glycol monododecyl ether, polidocanol, poloxamer, polyethoxylated tallow amine, polyethylene glycol cetyl ether, polyglycerol polyricinoleate, polysorbate, polysorbate 20, polysorbate 80, polyvinylpyrrolidone, sorbitan, sorbitan monolaurate, sorbitan monostearate, sorbitan tristearate, stearyl alcohol, Triton X-100, and Tween 80.

[0046] Non-limiting examples of zwitterionic surfactants include cocamidopropyl betaine, cocamidopropyl hydroxysultaine, dipalmitoylphosphatidylcholine, hydroxysultaine, lecithin, miltefosine, and sodium lauroamphoacetate.

[0047] An oxidizing agent may be included to initiate the polymerization of the conductive polymer. In some embodiments, the oxidizing agent is a persulfate oxidizing agent. Non-limiting examples include potassium persulfate and ammonium persulfate.

[0048] Non-limiting examples of oxidizing agents may include ammonium persulphate (APS), ferric chloride, iron(III) sulfate hydrate, iron(III) nitrate, iron(III) citrate, iron(III) dodecylbenzesulfonate, iron(III) butyl naphthalene sulfonate, silver nitrate, cupric nitrate, cupric chloride, hydrogen peroxide, potassium dichromate, pyridinium chlorochromate.

[0049] The oxidizing agent may be included in the coating composite in an amount of from about 2 to about 70 phr, from about 16 to about 50 phr, or from about 25 to about 34 phr.

[0050] An adhesion promoter may be included before, during, and / or after the polymerization. Dopamine hydrochloride is one non-limiting example of a suitable adhesion promoter.

[0051] For applications where the color of the coating is critical, one or more pigments may be included.

[0052] The coating composition may be formed by adding monomer to a solution including a surfactant for form a first mixture, mixing the first mixture and a rubber latex to form a second mixture, introducing an oxidizing agent to initiate polymerization of the monomer, and maintaining the reaction. The various mixtures may be stirred or otherwise agitated during any of these steps. The reaction may be maintained at a temperature of about 5°C and / or for a time period of at least about 14 hours. The reaction temperature may vary in ranges of from about 0°C to about 20 °C, from about 0°C to about 12°C, or from about 3°C to about 8°C.

[0053] Coated articles may be formed by applying the composition to a substrate and optionally drying the applied composition. The substrate may be selected from paper, glass, rubber, and plastic. Non-limiting examples of articles include tires, textiles, rubbers, and plastics.

[0054] The following examples are provided to illustrate the devices and methods of the present disclosure. The examples are merely illustrative and are not intended to limit the disclosure to the materials, conditions, or process parameters set forth therein.EXAMPLES

[0055] Example 1

[0056] The PPy / XSBR latex was synthesized in a flat-bottom beaker equipped with a mechanical stirrer and / or bath ultrasonication. In a typical experiment, 1.8 g of Py monomer were dispersed in 30 mL (8wt%) SDS solution. Then, 25 g of XSBR (48 wt% solid content), and 30 mL of water were sequentially added to the above solution under vigorous stirring for at least 20 mins at a reaction temperature maintained at 5oC. In the end, 20 g of 25 wt% APS solution were dropwise added to the latex, and the latex was kept stirring overnight. The obtained black composite latex was directly used as the coating without further treatment.

[0057] Example 2

[0058] The black latex prepared by in-situ method was drop-casted onto natural rubber using a syringe with an 18-gauge needle. The cast black latex was dried naturally in air, resulting in a coating formed on the top of the rubber that is dense and uniform. The interfacial morphology between natural rubber and coating was observed by SEM, showing intimate contact between them.

[0059] Example 3

[0060] The electrical resistivity of coating was measured by a four-point probe setup. The probe spacing is 1 mm. The resistivity was calculated by using a standard equation:

[0061]

[0062] where t, I, and V represent the film thickness, applied current, and read-out voltage. In our experiment, the coating on the glass substrate is 75 x 25 mm (Length x width). The thickness of the coating varies between 50 μm and 80 μm. V / I was read from the four-point setup.

[0063] Example 4

[0064] The adhesion properties of the coating were characterized by 180opeeling test. To avoid largely mechanical deformation of coating (or breaking) during stretching, a 20 mm-wide strip of 304 stainless steel woven wire with 200 × 200 mesh size and 0.075 mm hole was used as the backing in peeling test. The latex was spread evenly onto the substrate and mesh, and the mesh was buried into the coating. The peeling strengths of the coating were all recorded by peeling the mesh off of different substrates (glass and rubber) at 180oat a constant speed of 50 mm / min. The peel adhesion (N cm-1) was calculated by the ratio of peeling-off force and width of mesh. The peel adhesion increases with the displacement, and then levels off. The maximum peeling strength is attributed to the coating adhesion on the substrates.

[0065] Example 5

[0066] ENR latex is prepared as below: 40 mL of deionized water was added to 40 g of natural rubber (NR, 60wt%) latex in 250 mL single-neck round-bottom flask to dilute its content to 30wt%. Then, 1.92 g surfactant (TERGITOLTM15-S-15) was added into the latex with magnetic stirring for 20 min to stabilize the diluted latex. Following that, 3.2 g of formic acid and 28 g of hydrogen peroxide were dripped into the flask and kept for stirring at 50oC for 12h. After that, 2M sodium hydroxide aqueous solution was used to adjust the latex pH to between 10 and 11. The generated oxygen gas was removed by vacuum oven at room temperature. The obtained ENR latex was kept for further use.

[0067] Example 6

[0068] The PPy / NR and PPy / ENR composite latex were synthesized according to Example 1. The obtained black composite emulsion was destabilized by adding acetone. The precipitate was collected by filtration and washed for several times until the washing has no bubble. Then, the black solid was dried in the oven at 70oC overnight. The prepared black rubber is conductive and flexible.

[0069] Example 7

[0070] XNBR latex was used as the conductive rubber matrix. PPy / XNBR latex was synthesized in a flat-bottom beaker equipped with a mechanical stirrer. In a typical experiment, 2 g of polyvinylpyrrolidone (PVP, Mw~55000 g / mol) were dissolved in 30 mL deionized water. Then, 1.24 mL of Py monomer were added into PVP solution and was stirred for at least 1h. After that, 26 g of XNBR (46.2 wt% solid content), and 30 mL of water were sequentially added to the above solution under vigorous stirring for at least 20 mins at a reaction temperature maintained at 5oC. In the end, 16 g of 25 wt% APS solution were dropwise added to the latex, and the latex was kept stirring overnight. The obtained black composite latex was directly used as the coating without further treatment.

[0071] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Claims

A conductive coating composition comprising:a conductive polymer anda rubber latex.The conductive coating composition of claim 1, wherein the conductive polymer was formed in situ in the rubber latex.The conductive coating composition of any one of claims 1 and 2, wherein the conductive polymer comprises polypyrrole.The conductive coating composition of any one of claims 1-3, wherein the rubber latex comprises a carboxylate functional group.The conductive coating composition of any one of claims 1-4, wherein the rubber latex comprises a polar functional group.The conductive coating composition of any one of claims 1-5, wherein the rubber latex comprises styrene butadiene rubber.The conductive coating composition of any one of claims 1-5, wherein the rubber latex comprises natural rubber.The conductive coating composition of any one of claims 1-5, wherein the rubber latex comprises epoxidized natural rubber.The conductive coating composition of any one of claims 1-5, wherein the rubber latex comprises acrylic rubber and / or hydrogenated acrylonitrile butadiene rubber.

10. The conductive coating composition of any one of claims 1-5, wherein the rubber latex comprises a carboxylated nitrile rubber.

11. The conductive coating composition of any one of claims 1-5, wherein the rubber latex comprises a carboxylated styrene butadiene rubber.

12. The conductive coating composition of any one of claims 1-11, wherein the coating composition comprises from about 0.1 to about 100 phr of the conductive polymer.

13. The conductive coating composition of any one of claims 1-11, wherein the coating composition comprises from about 0.5 to about 50 phr of the conductive polymer.

14. The conductive coating composition of any one of claims 1-11, wherein the coating composition comprises from about 1 to about 20 phr of the conductive polymer.

15. The conductive coating composition of any one of claims 1-11, wherein the coating composition comprises from about 5 to about 15 phr of the conductive polymer.

16. The conductive coating composition of any one of claims 1-11, wherein the coating composition comprises from about 8 to about 10 phr of the conductive polymer.

17. The conductive coating composition of any one of claims 1-16, further comprising:a surfactant.

18. The conductive coating composition of any one of claims 1-17, further comprising:an adhesion promoter.

19. The conductive coating composition of any one of claims 1-18, further comprising:an oxidizing agent.

20. The conductive coating composition of any one of claims 1-19, further comprising:a pigment.The conductive coating composition of any one of claims 1-20, further comprising:a crosslinking agent.The conductive coating composition of claim 21, wherein the crosslinking agent is not sulfur-based.The conductive coating composition of claim 21, wherein the crosslinking agent is a peroxide-containing crosslinking agent.

24. The conductive coating composition of claim 21, wherein the crosslinking agent is an aziridine-containing crosslinking agent.

25. The conductive coating composition of claim 21, wherein the crosslinking agent is an epoxy-containing crosslinking agent.

26. The conductive coating composition of claim 21, wherein the crosslinking agent is a carbodiimide-containing crosslinking agent.The conductive coating composition of any one of claims 21-26, wherein the crosslinking agent is included in the coating composition in an amount of from about 1 phr to about 50 phr.

28. The conductive coating composition of any one of claims 21-26, wherein the crosslinking agent is included in the coating composition in an amount of from about 5 phr to about 30 phr.

29. The conductive coating composition of any one of claims 21-26, wherein the crosslinking agent is included in the coating composition in an amount of from about 10 phr to about 20 phr.The conductive coating composition of any one of claims 1-29, wherein the pH is from about 0.5 to about 12.

31. The conductive coating composition of any one of claims 1-29, wherein the pH is from about 1 to about 10.

32. The conductive coating composition of any one of claims 1-29, wherein the pH is from about 1.5 to about 5.The conductive coating composition of any one of claims 1-32, wherein the solids content is from about 1% to about 30%.

34. The conductive coating composition of any one of claims 1-32, wherein the solids content is from about 4% to about 20%.

35. The conductive coating composition of any one of claims 1-32, wherein the solids content is from about 6% to about 15%.

36. A process for forming a conductive coating composition comprising:polymerizing a monomer in situ in a composition comprising a rubber latex to form a conductive polymer.

37. The process of claim 36, wherein the monomer is pyrrole.

38. The process of any one of claims 36 and 37, wherein the composition further comprises a surfactant.

39. The process of any one of claims 36-38, wherein the composition further comprises an adhesion promoter.

40. The process of any one of claims 36-39, wherein the composition further comprises an oxidizing agent.

41. The process of any one of claims 36-40, wherein the composition further comprises a pigment.

42. The process of any one of claims 36-41, wherein the rubber latex comprises a carboxylate functional group.

43. The process of any one of claims 36-41, wherein the rubber latex comprises a polar functional group.

44. The process of any one of claims 36-41, wherein the rubber latex comprises styrene butadiene rubber.

45. The process of any one of claims 36-41, wherein the rubber latex comprises natural rubber.

46. The process of any one of claims 36-41, wherein the rubber latex comprises epoxidized natural rubber.

47. The process of any one of claims 36-41, wherein the rubber latex comprises acrylic rubber and / or hydrogenated acrylonitrile butadiene rubber.

48. The process of any one of claims 36-41, wherein the rubber latex comprises a carboxylated nitrile rubber.

49. The process of any one of claims 36-41, wherein the rubber latex comprises a carboxylated styrene butadiene rubber.

50. The process of any one of claims 36-49, wherein the coating composition comprises from about 0.1 to about 100 phr of the conductive polymer.

51. The process of any one of claims 36-49, wherein the coating composition comprises from about 0.5 to about 50 phr of the conductive polymer.

52. The process of any one of claims 36-49, wherein the coating composition comprises from about 1 to about 20 phr of the conductive polymer.

53. The process of any one of claims 36-49, wherein the coating composition comprises from about 5 to about 15 phr of the conductive polymer.

54. The process of any one of claims 36-49, wherein the coating composition comprises from about 8 to about 10 phr of the conductive polymer.

55. The process of any one of claims 36-54, wherein the coating composition further comprises:a crosslinking agent.

56. The process of claim 55, wherein the crosslinking agent is not sulfur-based.

57. The process of claim 55, wherein the crosslinking agent is a peroxide-containing crosslinking agent.

58. The process of claim 55, wherein the crosslinking agent is an aziridine-containing crosslinking agent.

59. The process of claim 55, wherein the crosslinking agent is an epoxy-containing crosslinking agent.

60. The process of claim 55, wherein the crosslinking agent is a carbodiimide-containing crosslinking agent.

61. The process of any one of claims 55-60, wherein the crosslinking agent is included in the coating composition in an amount of from about 1 phr to about 50 phr.

62. The process of any one of claims 55-60, wherein the crosslinking agent is included in the coating composition in an amount of from about 5 phr to about 30 phr.

63. The process of any one of claims 55-60, wherein the crosslinking agent is included in the coating composition in an amount of from about 10 phr to about 20 phr.

64. The process of any one of claims 55-63, wherein the pH is from about 0.5 to about 12.

65. The process of any one of claims 55-63, wherein the pH is from about 1 to about 10.

66. The process of any one of claims 55-63, wherein the pH is from about 1.5 to about 5.

67. The process of any one of claims 36-66, wherein the solids content is from about 1% to about 30%.

68. The process of any one of claims 36-66, wherein the solids content is from about 4% to about 20%.

69. The process of any one of claims 36-66, wherein the solids content is from about 6% to about 15%.

70. A coated article comprising:a substrate; anda conductive layer formed from the conductive coating composition of any one of claims 1-35.

71. The coated article of claim 70, wherein the article is selected from the group consisting of tires, textiles, rubbers, and plastics.

72. The coated article of claim 70, wherein the substrate is selected from the group consisting of paper, glass, rubber, and plastic.The coated article of any one of claims 70-72, wherein the conductive layer has a thickness of from about 1 µm to about 80 µm.

74. The coated article of any one of claims 70-72, wherein the conductive layer has a thickness of from about 5 µm to about 50 µm.

75. The coated article of any one of claims 70-72, wherein the conductive layer has a thickness of from about 10 µm to about 30 µm.The coated article of any one of claims 70-75, wherein a surface resistance of the conductive layer is from about 10-4Ω / sq to about 10-7Ω / sq.

77. The coated article of any one of claims 70-75, wherein a surface resistance of the conductive layer is from about 10-5Ω / sq to about 10-6Ω / sq.The coated article of any one of claims 70-77, wherein a tensile strength of the conductive layer is from about 0.5 MPa to about 50 MPa.

79. The coated article of any one of claims 70-77, wherein a tensile strength of the conductive layer is from about 1 MPa to about 40 MPa.

80. The coated article of any one of claims 70-77, wherein a tensile strength of the conductive layer is from about 6 MPa to about 20 MPa.The coated article of any one of claims 70-80, wherein an elongation at break of the conductive layer is from about 5% strain to about 500% strain.

82. The coated article of any one of claims 70-80, wherein an elongation at break of the conductive layer is from about 20% strain to about 400% strain.

83. The coated article of any one of claims 70-80, wherein an elongation at break of the conductive layer is from about 40% strain to about 300% strain.The coated article of any one of claims 70-83, wherein the conductive layer can resist a normal force varying from about 1 g to about 10,000 g.

85. The coated article of any one of claims 70-83, wherein the conductive layer can resist a normal force varying from about 100 g to about 8000 g.

86. The coated article of any one of claims 70-83, wherein the conductive layer can resist a normal force varying from about 1000 g to about 5000 g.A method for coating a substrate comprising:applying the coating composition of any one of claims 1-35 to the substrate.

88. The method of claim 87, further comprising: drying the coating composition.

89. The method of claim 87, further comprising: curing the coating composition.

90. The method of claim 89, wherein the coating composition is cured at a temperature of from about 22 °C to about 170 °C.

91. The method of claim 89, wherein the coating composition is cured at a temperature of from about 70 °C to about 150 °C.

92. The method of claim 89, wherein the coating composition is cured at a temperature of from about 100 °C to about 140 °C.

93. The method of any one of claims 89-92, wherein curing time is from about 1 minute to about 24 hours.

94. The method of any one of claims 89-92, wherein curing time is from about 5 minutes to about 15 hours.

95. The method of any one of claims 89-92, wherein curing time is from about 1 hour to about 7 hours.

96. The method of any one of claims 87-95, wherein the substrate is selected from the group consisting of paper, glass, rubber, and plastic.

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