Conductive compositions of conductive polymer and metal coated fiber

Patent metadata

Field	Value
Publication number	US-12417859-B2
Application number	US-202318538042-A
Country	US
Kind code	B2
Filing date	Dec 13, 2023
Priority date	Jun 20, 2018
Publication date	Sep 16, 2025
Grant date	Sep 16, 2025

Abstract

The present disclosure provides compositions including a conductive polymer; and a fiber material comprising one or more metals disposed thereon. The present disclosure further provides a component, such as a vehicle component, including a composition of the present disclosure disposed thereon. The present disclosure further provides methods for manufacturing a component including: contacting a metal coated fiber material with an oxidizing agent and a monomer to form a first composition comprising a metal coated fiber material and a conductive polymer; and contacting the first composition with a polymer matrix or resin to form a second composition.

First claim

What is claimed is:

1. A method for manufacturing a composition, comprising:
forming a coating of a conductive polymer on an oxidized metal-coated carbon fiber, wherein the conductive polymer is selected from the group consisting of a polyaniline (PANI), a poly(ethylenedioxythiophene) (PEDOT), a polypyrrole, a polyfluorene, a polyphenylene, a polypyrene, a polyazulene, a polynaphthalene, a polyacetylene (PAC), a poly(p-phenyl vinylene) (PPV), a polycarbazole, a polyindole, a polyazepine, and a polythiophene, and wherein the oxidized metal-coated carbon fiber comprises about 15 wt % to about 70 wt % of oxidized metal, based on the total weight of the oxidized metal and the carbon fiber; and
contacting the conductive polymer-coated oxidized metal-coated carbon fiber with a polymer matrix or resin to form a composition comprising about 50 wt % to about 99 wt % of the polymer matrix or resin based on the total weight of the composition.

2. The method of claim 1 , further comprising heating the composition to a temperature of from about 40° C. to about 80° C.

3. The method of claim 1 , wherein the conductive polymer is selected from a polyaniline, a poly(ethylenedioxythiophene), a polypyrrole, or mixtures thereof.

4. The method of claim 1 , wherein the metal is selected from nickel, titanium, palladium, iron, cobalt, copper, aluminum, chromium, or mixtures thereof.

5. The method of claim 1 , wherein the polymer matrix or resin is selected from a polyurethane, an epoxy, a thermosetting polymer, a thermoplastic polymer, a rubber, a bismaleimide, a polyimide, a polyaryletherketone, or combinations thereof.

6. The method of claim 5 , wherein the polymer matrix or resin is an epoxy.

7. The method of claim 1 , wherein the conductive polymer-coated oxidized metal-coated carbon fiber is intermingled within the polymer matrix or resin.

8. The method of claim 1 , wherein the carbon fiber comprises carbon fibers having an aspect ratio from about 10 to about 100.

9. The method of claim 1 , wherein the composition comprises a resistance from about 0.1 ohms per square to about 25 Megaohms per square.

10. The method of claim 1 , further comprising casting or spraying the composition onto a vehicle component to form a layer having a thickness of about 1 micron to about 100 microns.

11. The method of claim 1 , further comprising curing the composition at a temperature of about 20° C. to about 300° C.

12. A method, comprising:
forming a coating of a conductive polymer on an oxidized metal-coated carbon fiber, wherein the conductive polymer is selected from the group consisting of a polyaniline, a poly(ethylenedioxythiophene), a polypyrrole, and mixtures thereof, and wherein the oxidized metal-coated carbon fiber comprises about 15 wt % to about 70 wt % of oxidized metal, based on the total weight of the oxidized metal and the carbon fiber; and
contacting the conductive polymer-coated oxidized metal-coated carbon fiber with a polymer matrix or resin to form a composition comprising about 50 wt % to about 99 wt % of the polymer matrix or resin based on the total weight of the composition.

13. The method of claim 12 , further comprising heating the composition to a temperature of from about 40° C. to about 80° C.

14. The method of claim 12 , wherein the metal is selected from nickel, titanium, palladium, iron, cobalt, copper, aluminum, chromium, or mixtures thereof.

15. The method of claim 12 , wherein the polymer matrix or resin is selected from a polyurethane, an epoxy, a thermosetting polymer, a thermoplastic polymer, a rubber, a bismaleimide, a polyimide, a polyaryletherketone, or combinations thereof.

16. The method of claim 12 , further comprising depositing the composition on a metal substrate.

17. The method of claim 16 , wherein the metal substrate is selected from the group consisting of steel, aluminum, titanium, magnesium, tantalum, and copper.

18. The method of claim 16 , further comprising curing the composition deposited on the metal substrate.

19. The method of claim 18 , further comprising curing at a temperature of about 20° C. to about 300° C.

20. The method of claim 16 , wherein the composition is cured under vacuum or pressure after being deposited on the metal substrate.

Assignees

• Boeing Co

Inventors

• Kinlen Patrick J

Classifications

• H01B1/125

  comprising aliphatic main chains, e.g. polyactylenes · CPC title

• H01B1/128

  comprising six-membered aromatic rings in the main chain, e.g. polyanilines, polyphenylenes · CPC title

• C09D163/00

  Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins · CPC title

• H01B1/127

  comprising five-membered aromatic rings in the main chain, e.g. polypyrroles, polythiophenes · CPC title

• H01B1/124

  Intrinsically conductive polymers · CPC title