High-Temperature Conductive Elastomer Composition With Stable Resistivity

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Solution Overview

Problem

There is a need for high temperature conductive elastomers that meet the performance and service requirements of aerospace applications, as existing fluoroelastomer resins are no longer being manufactured, and there are concerns about supply chain assurance and material availability.

Innovation Solution

A polydimethylsiloxane-based resin formulation with metal-coated carbon fiber fillers and neoalkoxy titanate additives is developed, which includes a planetary mixer process to create a stable and consistent conductivity and resistivity, using solvents like low molecular weight silicone and methylisobutyl ketone, and can be applied via spraying.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fluoroelastomer resins are used for high temperature conductive elastomers, then service requirements are met, but supply chain assurance and material availability deteriorate

Engineering Contradiction:

Improveservice requirementsVSAvoidmaterial availability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces discontinued fluoroelastomer resins with a new formulation based on polydimethylsiloxane-based resins that can be readily manufactured. This new material system ensures continued availability while meeting the same high temperature service requirements, effectively substituting an unavailable material with an accessible alternative that performs equally well in aerospace applications.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If existing fluoroelastomer formulations are used, then conductivity requirements are met, but supply chain assurance deteriorates

Engineering Contradiction:

Improveconductivity requirementsVSAvoidsupply chain assurance

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent modifies the chemical composition parameters by transitioning from fluoroelastomer-based formulations to polydimethylsiloxane-based formulations with specific conductive filler loadings (10-25 volume percent). This parameter change maintains the electrical conductivity performance while ensuring the material can be continuously supplied through established manufacturing channels, resolving the supply chain uncertainty.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If new polydimethylsiloxane-based formulations are developed, then material availability improves, but formulation complexity increases

Engineering Contradiction:

Improvematerial availabilityVSAvoidformulation complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent creates a composite material system combining polydimethylsiloxane-based resins with electrically conductive fillers (carbon nanotubes, nickel graphite, tungsten carbide, or functionalized fullerene) and organometallic additives. This composite approach achieves the desired conductivity and high temperature performance while using commercially available base materials, thereby maintaining manufacturing simplicity despite the multi-component formulation.

Inventive Principle:

Principle #40Composite materials

4Reliability

If conductive fillers are coated with organometallic compounds, then interfacial interactions improve, but manufacturing process complexity increases

Engineering Contradiction:

Improveinterfacial interactionsVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies organometallic compounds (such as titanium-based additives) as pre-coatings on the conductive filler particles before final compound formulation. This preliminary surface treatment enhances the interfacial bonding between filler and matrix, improving overall material reliability. The coating step is integrated into the existing mixing process, minimizing additional manufacturing complexity while achieving superior interfacial adhesion.

Inventive Principle:

Principle #10Preliminary action

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 formulation achieves stable conductivity and resistivity over time, suitable for electronic service applications, with improved interfacial interactions and corrosion resistance, making it suitable for aerospace components.

Implementation Method 1

the additive may include an organometallic compound including titanium... improved interfacial interactions

Methodology Applied

Scientific EffectInterfacial interaction enhancement:

Implementation Method 2

the electrically conductive filler is coated with a treatment which may include a metal... improved corrosion resistance

Methodology Applied

Scientific EffectCorrosion resistance:

Implementation Method 3

a planetary mixer process to create a stable and consistent conductivity and resistivity

Methodology Applied

Scientific EffectMechanical mixing and dispersion:

Data Source

PatentUS20250346738A1High temperature conductive elastomers and methods thereof

Publication Date: 2025.11.13 THE BOEING CO

AI summary

An electrically conductive composition is disclosed, including a polydimethylsiloxane-based resin, an electrically conductive filler, coated with an additive, and where the electrically conductive filler is coated with a treatment that may include a metal, and where the additive may include an organometallic compound including titanium. In examples, the electrically conductive composition can include carbon nanotubes, nickel graphite, functionalized carbon nanotubes, tungsten carbide, functionalized fullerene, graphene, nickel powder or a combination thereof. A coated article and a method for coating the article are also disclosed.