Systems, compositions, and methods for enhanced electromagnetic shielding and corrosion resistance

Patent metadata

Field	Value
Publication number	US-11414555-B2
Application number	US-201916697296-A
Country	US
Kind code	B2
Filing date	Nov 27, 2019
Priority date	Aug 5, 2019
Publication date	Aug 16, 2022
Grant date	Aug 16, 2022

Abstract

Aspects of the present disclosure provide a coating composition that includes a polymer material comprising an electrically conductive polymer; and a coated or partially coated magnetic material comprising a magnetic material and an antioxidant material. Aspects of the present disclosure further provide a method of making a coating composition that includes introducing, under first conditions, a magnetic material to a passivation solution comprising an antioxidant to form a coated (or partially coated) magnetic material; and introducing, under second conditions, the coated (or partially coated) magnetic material to a mixture comprising a polymer material to form a coating composition. Aspects of the present disclosure further provide a coated substrate that includes a film and a substrate, the film including a coating composition that includes an electrically conductive polymer, a magnetic material, and an antioxidant.

First claim

What is claimed is:

1. A coating composition, comprising:
a polymer material comprising an electrically conductive polymer; and
a coated or partially coated magnetic material comprising a magnetic material and an antioxidant material, the antioxidant material comprising cerium oxide, aluminum oxide, chromium oxide, yttrium oxide, iron oxide, titanium oxide, or a combination thereof,
a dopant selected from the group consisting of sulfonyl diphenol (SDP), p-toluenesulfonic acid (p-TSA), m-cresol, 2-(2-hydroxyphenyl)benzene-1,4-diol, 2-(2-hydroxyethyl)benzene-1,4-diol, 3-ethylphenol, 1-dodecanesulfonic acid, d-camphorsulfonic acid, 2-dodecylbenzenesulfonic acid, 1-anthrol, 2-chlorophenol, benzenesulfonic acid, 2-naphthol, 2-fluorophenol, 3-isopropylphenol, 2-methylbenzenesulfonic acid, phenyl dodecane-1-sulfonate, and combinations thereof.

2. The coating composition of claim 1 , wherein the magnetic material comprises iron, an iron alloy, nickel, a nickel alloy, cobalt, a cobalt alloy, an iron oxide, a hexagonal ferrite, or a combination thereof.

3. The coating composition of claim 1 , wherein the polymer material includes a polyaniline, a polypyrrole, a polyacetylene, a polythiophene, or a combination thereof.

4. The coating composition of claim 1 , further comprising an acid.

5. The coating composition of claim 4 , wherein:
a total amount of the polymer material and the acid in the coating composition is from 40 wt % to 99 wt % based on a total weight of the coating composition; and
an amount of the magnetic material in the coating composition is from 1 wt % to 60 wt % based on the total weight of the coating composition.

6. The coating composition of claim 1 , wherein an amount of the dopant in the coating composition is from 1 wt % to about 80 wt % based on a total weight of the coating composition.

7. The coating composition of claim 1 , wherein an amount of the antioxidant material in the coating composition is from 0.01 wt % to 1 wt % based on a total weight of the coating composition.

8. The coating composition of claim 1 , wherein the coating composition has a resistance less than 1 MΩ.

9. The coating composition of claim 1 , wherein an amount of the dopant in the coating composition is from 10 wt % to 60 wt % based on a total weight of the coating composition.

10. The coating composition of claim 1 , wherein the coating composition has a resistance that is from about 10Ω to about 250Ω.

11. The coating composition of claim 1 , wherein the antioxidant material comprises cerium oxide.

12. A coating composition, comprising:
a polymer material comprising a polyaniline, a polypyrrole, a polyacetylene, a polythiophene, or a combination thereof;
an acid comprising dinonylnaphthalene sulfonic acid, dodecylbenzene sulfonic acid, camphorsulfonic acid, dibutylnaphthalene sulfonic acid, polystyrene sulfonic acid, or a combination thereof;
an antioxidant material selected from the group consisting of cerium oxide, aluminum oxide, chromium oxide, yttrium oxide, iron oxide, titanium oxide, and combinations thereof; and
a magnetic material at least partially coated with the antioxidant material.

13. The coating composition of claim 12 , wherein a total amount of the polymer material and the acid in the coating composition is from about 40 wt % to about 99 wt % based on a total weight of the coating composition.

14. The coating composition of claim 12 , further comprising a dopant selected from the group consisting of sulfonyl diphenol (SDP), p-toluenesulfonic acid (p-TSA), m-cresol, 2-(2-hydroxyphenyl)benzene-1,4-diol, 2-(2-hydroxyethyl)benzene-1,4-diol, 3-ethylphenol, 1-dodecanesulfonic acid, d-camphorsulfonic acid, 2-dodecylbenzenesulfonic acid, 1-anthrol, 2-chlorophenol, benzenesulfonic acid, 2-naphthol, 2-fluorophenol, 3-isopropylphenol, 2-methylbenzenesulfonic acid, phenyl dodecane-1-sulfonate, and combinations thereof.

15. The coating composition of claim 14 , wherein an amount of the dopant in the coating composition is from about 35 wt % to about 55 wt % based on a total weight of the coating composition.

16. The coating composition of claim 12 , wherein the magnetic material comprises iron, an iron alloy, nickel, a nickel alloy, cobalt, a cobalt alloy, an iron oxide, a hexagonal ferrite, or a combination thereof.

17. A coating composition comprising:
a polymer material comprising polyaniline;
an antioxidant material selected from the group consisting of cerium oxide, aluminum oxide, chromium oxide, yttrium oxide, iron oxide, titanium oxide, and combinations thereof;
a magnetic material at least partially coated with the antioxidant material; and
a dopant selected from the group consisting of sulfonyl diphenol (SDP), p-toluenesulfonic acid (p-TSA), m-cresol, 2-(2-hydroxyphenyl)benzene-1,4-diol, 2-(2-hydroxyethyl)benzene-1,4-diol, 3-ethylphenol, 1-dodecanesulfonic acid, d-camphorsulfonic acid, 2-dodecylbenzenesulfonic acid, 1-anthrol, 2-chlorophenol, benzenesulfonic acid, 2-naphthol, 2-fluorophenol, 3-isopropylphenol, 2-methylbenzenesulfonic acid, phenyl dodecane-1-sulfonate, and combinations thereof.

18. The coating composition of claim 17 , wherein an amount of the dopant in the coating composition is from about 35 wt % to about 55 wt % based on a total weight of the coating composition.

19. The coating composition of claim 17 , wherein the coating composition has a resistance that is from about 10Ω to about 250Ω.

20. The coating composition of claim 17 , wherein:
the antioxidant material comprises cerium oxide; and
the magnetic material comprises iron, an iron alloy, an iron oxide, a hexagonal ferrite, or combinations thereof.

Assignees

• Boeing Co

Inventors

• Kinlen Patrick John

Classifications

• H01B1/22

  the conductive material comprising metals or alloys · CPC title

• H01B1/124

  Intrinsically conductive polymers · CPC title

• C09D5/24 Primary

  Electrically-conducting paints {(conductive materials H01B1/00)} · CPC title

• C09D7/62

  modified by treatment with other compounds · CPC title

• C08K9/10

  Encapsulated ingredients · CPC title