Conductive Polymer Compositions with Oxidized Carbon Fillers

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Solution Overview

Problem

Polymeric materials lack inherent electrical and thermal conductivity, requiring high filler loadings that compromise physical properties and introduce processing difficulties, especially in applications where metal-based conductive inks are expensive and prone to oxidation.

Innovation Solution

Compositions comprising a carbonaceous filler, a polymeric binder, and an organic compound with charged functional groups, such as ammonium salts or sulfates, which enhance electrical conductivity while maintaining desirable material properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high loadings of carbonaceous fillers are added to polymers to achieve electrical conductivity, then electrical conductivity is improved, but physical properties and processability deteriorate

Engineering Contradiction:

Improveelectrical conductivityVSAvoidphysical properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the chemical parameter of the carbonaceous filler by using oxidized carbonaceous materials (such as oxidized carbon nanotubes, oxidized carbon black, or graphite oxide) instead of conventional carbon fillers. This chemical modification allows achieving electrical conductivity at lower loadings (5-50 wt%) while maintaining the physical properties of the polymer matrix, thereby resolving the contradiction between conductivity and strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining oxidized carbonaceous filler with the polymer matrix. The oxidized surface of the carbon filler provides better interfacial adhesion and dispersion within the polymer, enabling effective conductivity at lower concentrations without compromising the mechanical integrity of the composite material.

Inventive Principle:

Principle #40Composite materials

2Reliability

If high loadings of carbonaceous fillers are added to polymers to achieve electrical conductivity, then electrical conductivity is improved, but processing difficulty increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmelt processing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The oxidation treatment of carbonaceous fillers changes their surface chemistry and physical properties, including reduced aggregation and improved dispersibility. This allows processing at lower loadings where the filler does not interfere with polymer chain mobility and melt flow, thus maintaining ease of manufacture while achieving conductivity.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If metal particles are used to impart electrical conductivity to polymer coatings, then electrical conductivity is achieved, but cost increases and oxidation susceptibility occurs

Engineering Contradiction:

Improveelectrical conductivityVSAvoidoxidation resistance

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent replaces expensive metal particles with carbonaceous materials that are chemically stable and resistant to oxidation. Although carbon fillers have been used before, the use of oxidized carbonaceous materials at lower loadings provides comparable or superior conductivity with enhanced chemical stability and lower cost, eliminating the need for protective coatings or sintering processes.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Reliability

If conventional carbon black is used to make conductive polymer compositions, then some electrical conductivity is achieved, but conductivity is insufficient and filler loading must be high

Engineering Contradiction:

Improveelectrical conductivityVSAvoidfiller loading

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent applies oxidation treatment to carbonaceous fillers, which fundamentally changes their electrical properties by introducing oxygen-containing functional groups on the surface. This parameter change enables the filler to provide effective conductivity pathways at much lower loadings compared to conventional carbon black, resolving the contradiction between achieving sufficient conductivity and minimizing filler quantity.

Inventive Principle:

Principle #35Parameter changes

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 compositions achieve improved electrical conductivity with reduced filler loadings, maintaining physical properties and simplifying processing, and can be used in various forms like coatings and films for flexible devices.

Implementation Method 1

at least one organic compound having at least one charged functional group

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Data Source

PatentUS9117568B2Polymer compositions containing carbonaceous fillers

Publication Date: 2015.08.25 VORBECK MATERIALS CORP

AI summary

Compositions comprising carbonaceous filler, polymeric binder, and at least one organic compound having at least one charged functional group.