CNT-Coated Polymeric Particles for Conductive Extrusion
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Solution Overview
Problem
Current methods for producing conductive polymeric composite materials with high electrical conductivity are not compatible with industrial-scale extrusion processes, requiring high loading of conductive additives and resulting in non-homogeneous distributions of carbon nano-tubes within the polymeric matrix.
Innovation Solution
Development of core-shell particles comprising a thermoplastic polymeric core coated with a shell of carbon nano-tubes (CNTs), allowing for a homogeneous dispersion and improved physical stability during extrusion, enabling the production of conductive composite materials with controlled CNT distribution and enhanced electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high loading of conductive additives is used to achieve high electrical conductivity, then electrical conductivity is improved, but manufacturing complexity and process compatibility worsen
Solution Approach 1:
The conductive additive (carbon nanotubes) is segmented and pre-coated onto polymeric particles to form core-shell structured particles. This segmentation allows the CNTs to be pre-distributed on particle surfaces before extrusion, enabling industrial-scale production without requiring high loading amounts while maintaining good electrical conductivity and avoiding aggregation issues
Solution Approach 2:
The carbon nanotubes are pre-coated onto the polymeric particles before the extrusion process. This preliminary action ensures homogeneous distribution of CNTs within the polymeric matrix during extrusion, eliminating the need for high loading and complex post-processing while achieving desired electrical conductivity
2Reliability
If high loading of conductive additives is used to achieve high electrical conductivity, then electrical conductivity is improved, but homogeneity of distribution worsens
Solution Approach 1:
The conductive additive is segmented and pre-coated onto individual polymeric particles, creating discrete core-shell structures. This segmentation ensures that CNTs are distributed as individual entities or small clusters on particle surfaces, preventing aggregation and ensuring homogeneous distribution throughout the final composite material
Solution Approach 2:
The carbon nanotubes are concentrated at the surface layer of each polymeric particle, creating a local high-density CNT region. This local quality ensures that when particles are mixed and extruded, the CNTs are uniformly distributed throughout the bulk material, achieving both high conductivity and homogeneous distribution
3Reliability
If melt-mixing of conductive additives with polymer in molten state is used to achieve high conductivity, then electrical conductivity is improved, but physical stability during extrusion worsens
Solution Approach 1:
The carbon nanotubes are pre-coated onto the polymeric particles before extrusion, forming a stable shell structure. This preliminary action protects the CNTs from aggregation and ensures they remain uniformly distributed during the extrusion process, maintaining physical stability while achieving the desired electrical conductivity in the final product
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The core-shell particle approach facilitates the production of composite materials with improved electrical conductivity and physical stability, enabling the formation of articles with uniform CNT distribution, suitable for industrial-scale extrusion processes, and achieving enhanced EMI attenuation properties.
Implementation Method 1
composite materials comprising electrically conductive additives (such as carbon nano-tubes, carbon fiber and metallic particles) dispersed within polymeric insulating matrices and characterized by an enhanced electrical conductivity
Data Source
AI summary
A composition comprising a plurality of microsized core-shell particles is provided, wherein the shell comprises CNT and further comprises a surfactant, and wherein the core comprises a polymer. Further, articles derived from the compositions of the invention are provided.