阅读说明：本技术 传导性复合材料和制备传导性复合材料的方法 (Conductive composite and method of making a conductive composite ) 是由 A·达斯汀 X·关 A·E·索伦森 A·P·诺瓦克 R·E·沙普 于 2021-05-06 设计创作，主要内容包括：本发明的名称为传导性复合材料和制备传导性复合材料的方法。传导性复合材料包括第一弹性聚合物层、在第一弹性聚合物层上的传导性氟流体层和在传导性氟流体层上的第二弹性聚合物层。(The invention relates to a conductive composite and a method of making a conductive composite. The conductive composite includes a first elastic polymer layer, a conductive fiuidic layer on the first elastic polymer layer, and a second elastic polymer layer on the conductive fiuidic layer.)

1. A conductive composite (2) comprising:

a first elastic polymer layer (4);

a conductive fluorine fluid layer (6) on the first elastic polymer layer (4); and

a second elastomeric polymer layer (8) on the conductive fiuidic layer (6).

2. The conductive composite (2) of claim 1, wherein the conductive fiuidic layer (6) comprises a fluorinated component and a conductive additive.

3. The conductive composite (2) of claim 2, wherein the fluorinated component comprises at least one of a perfluoropolyether, a fluorinated acrylate oligomer, or a combination thereof.

4. The conductive composite (2) according to claim 2 or 3, wherein the fluorinated component has a viscosity in the range of about 2,000cP to about 10,000,000 cP.

5. The conductive composite (2) of claim 2 or 3, wherein the aspect ratio of the conductive additive is less than about 2.

6. The conductive composite (2) of claim 2 or 3, wherein the conductive additive has an aspect ratio of at least about 2.

7. The conductive composite (2) of claim 2 or 3, wherein the conductive additive comprises at least one of carbon fiber, coated carbon fiber, and a metallic material.

8. The conductive composite (2) of claim 1 or 2, wherein the conductive fiuidic layer (6) further comprises a compatibilizing agent.

9. The conductive composite (2) according to claim 1 or 2, further comprising an additive that increases thermo-oxidative stability.

10. The conductive composite (2) of claim 1 or 2, wherein the first elastic polymer layer (4) comprises at least one of a thermoplastic polymer, a thermoset polymer, and combinations thereof.

11. The conductive composite (2) of claim 1 or 2, wherein the second elastic polymer layer (8) comprises at least one of a thermoplastic polymer, a thermoset polymer, and combinations thereof.

12. The conductive composite (2) of claim 1 or 2, further comprising a reinforcing mesh (10) in contact with the conductive fiuidic layer (6), wherein the reinforcing mesh (10) comprises a fabric selected from at least one of: knitted fabrics, woven fabrics, and combinations thereof.

13. The conductive composite (2) of claim 1 or 2, wherein the conductive composite comprises an edge length of an elastic polymer surrounding the conductive fiuidic layer, the edge length sealing conductive fiuidic within the conductive composite.

14. The conductive composite (2) of claim 1 or 2, being a part of an aircraft comprising at least one of at least a portion of a wing, at least a portion of a fuselage, a seal, and a gasket.

15. A method for preparing a conductive composite, the method comprising:

forming a first elastic polymer layer;

forming a conductive fluorine fluid layer on the first elastic polymer layer; and

forming a second elastic polymer layer on the conductive fiuidic layer.

Background

In a broad sense, a conductive composite is any composite having significant electrical and/or thermal conductivity. Such conductive composites have a wide range of uses in telecommunications, power generation and distribution, defense, aerospace, medical and other fields.

The properties are typically obtained by combining polymeric materials with solid conductive particles to prepare conductive composites and/or by combining polymeric materials with solid conductive particles. To obtain sufficient conductivity, i.e. to achieve percolation (percolation), high particle loadings, typically in excess of 45% by volume, are generally required. Polymers with these levels of particle loading are generally rigid materials. Thus, these particle loading levels result in conductive films and coatings having properties that make them unsuitable or difficult to use, such as elongation at break, tensile strength, and thermal stability.

Accordingly, those skilled in the art continue to research and develop in the field of conductive composites.

Disclosure of Invention

In one embodiment, a conductive composite includes a first elastic polymer layer, a conductive fiuidic layer on the first elastic polymer layer, and a second elastic polymer layer on the conductive fiuidic layer.

In another embodiment, a method for making a conductive composite comprises: forming a first elastic polymer layer; forming a conductive fluorine fluid layer on the first elastic polymer layer; and forming a second elastic polymer layer on the conductive fluorine fluid layer.

Other embodiments of the disclosed conductive composites and methods for making conductive composites will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

Drawings

Fig. 1 is a perspective view of an exemplary conductive composite according to one exemplary embodiment of the present description.

Fig. 2 is a cross-sectional perspective view of the exemplary conductive composite of fig. 1 taken along section lines a-a and B-B shown in fig. 1.

Fig. 3A-3C are perspective views illustrating steps for preparing the exemplary conductive composite of fig. 1 and 2.

FIG. 4 is a flow chart of an aircraft manufacturing and service method.

FIG. 5 is a block diagram of an aircraft.

Detailed Description

Fig. 1 is a perspective view of an exemplary conductive composite according to an exemplary embodiment of the present description. Fig. 2 is a cross-sectional perspective view of the exemplary conductive composite of fig. 1 taken along section lines a-a and B-B shown in fig. 1.

As shown in fig. 1 and 2, the conductive composite 2 includes a first elastic polymer layer 4, a conductive fiuidic layer 6 on the first elastic polymer layer 4, and a second elastic polymer layer 8 on the conductive fiuidic layer 6, and an optional reinforcing mesh 10 in contact with the conductive fiuidic layer 6.

In embodiments, the conductive composites of the present invention provide conductivity without rigidity; low viscosity conductive fluids without the use of common room temperature liquid metals and alloys (e.g., gallium); and/or increased viscosity and fluidity to prevent leakage of the conductive filler paste during use of the composite. Also, in embodiments, the conductive composites of the present invention allow for the minimization of the amount of conductive slurry required and the potential for slurry leaching. Further, in embodiments, the conductive composite provides additional conductivity and/or structural integrity without sacrificing elongation.

Elastomeric polymers are polymers that exhibit elasticity at high strain levels. In one aspect, the elastomeric polymers of the present description are polymers that exhibit an elongation at break of greater than about 50%. In another aspect, the elastomeric polymers of the present description are polymers that exhibit an elongation at break of greater than about 100%. In another aspect, the elastomeric polymers of the present invention are polymers that exhibit an elongation at break of greater than about 200%. Elongation at break is measured as the percentage of strain of a material after application of tension before breaking. The percentage of the original length is used to represent the elongation at break.

In one aspect, the elastomeric polymer of the present description is an electrical insulator. In one aspect, the elastomeric polymers of the present description are those having an electrical conductivity of less than about 1X 10^-8S/m electrical insulation. In another aspect, the elastomeric polymers of the present disclosure are those having an electrical conductivity of less than about 1X 10^-9S/m electrical insulation. In another aspect, the elastomeric polymers of the present description are those having an electrical conductivity of less than about 1X 10^-10S/m electrical insulation.

The first and second elastic polymer layers 4, 8 may include at least one of a thermoplastic polymer, a thermoset polymer, and combinations thereof. In one aspect, suitable elastomeric polymers for first elastomeric polymer layer 4 and second elastomeric polymer layer 8 have a viscosity of from about 1,000 to about 100,000cP under typical processing conditions. In another aspect, suitable elastomeric polymers for first elastomeric polymer layer 4 and second elastomeric polymer layer 8 have a viscosity of from about 1,000 to about 25,000cP under typical processing conditions. In another aspect, suitable elastomeric polymers for first elastomeric polymer layer 4 and second elastomeric polymer layer 8 have a viscosity of from about 25,000 to about 50,000cP under typical processing conditions. In another aspect, suitable elastomeric polymers for first elastomeric polymer layer 4 and second elastomeric polymer layer 8 have a viscosity of from about 50,000 to about 75,000cP under typical processing conditions. In another aspect, suitable elastomeric polymers for first elastomeric polymer layer 4 and second elastomeric polymer layer 8 have a viscosity of from about 75,000 to about 100,000cP under typical processing conditions. In certain examples, the thermoplastic elastomers suitable for use herein have a viscosity of from about 1,000 to about 50,000cP under typical processing conditions. As used herein, the term "typical processing conditions" includes temperatures of about room temperature (about 25 ℃) to about 400 ℃, about room temperature to about 200 ℃, or about room temperature to about 100 ℃. Measurement techniques for measuring viscosity may include viscometers, rheometers, or other suitable viscosity measuring equipment. Such thermoplastic elastomers facilitate the preparation of flexible materials.

Suitable elastomeric polymers for the first and second elastomeric polymer layers 4, 8 include thermoplastic elastomeric polymers, thermoset elastomeric polymers, and combinations thereof. For example, suitable elastomeric polymers for the first and second elastomeric polymer layers 4, 8 include silicone, fluorosilicone, perfluoropolyether, polybutadiene, polyester, polycarbonate, polyurethane, polyurea, polyurethane-urea, epoxy, acrylate, natural rubber, butyl rubber, polyacrylonitrile, Ethylene Propylene Diene Monomer (EPDM) rubber, or combinations thereof. The first elastic polymer layer 4 and the second elastic polymer layer 8 may be formed of the same or different polymer compositions.

In one aspect, at least one of the first elastic polymer layer 4 and the second elastic polymer layer 8 may include a conductive additive to create an electrical connection through the entire laminate. For example, the conductive additive may include particles (e.g., rods) added to the at least one elastic polymer layer, wires added to the at least one elastic polymer layer, or particles (e.g., rods) and wires added to the at least one elastic polymer layer. By including the conductive additive into the elastomeric polymer layer, an electrical connection to the conductive fiuidic layer 6 may be achieved, which may be desirable for certain applications.

In the context of this specification, a conductive fluorine fluid is a high viscosity fluid. The conductive fluorine fluid of the present specification is not cured or hardened to a solid state. In contrast, the conductive fluorine fluid of the present specification maintains a high viscosity fluid state. In one aspect, the viscosity of the conductive fluoro-fluid of the present description is in the range of about 2,000 to about 10,000,000 cP. In another aspect, the viscosity of the conductive fluoro-fluid of the present description is in the range of about 2,000 to about 5,000,000 cP. In another aspect, the viscosity of the conductive fluoro-fluid of the present description is in the range of about 2,000 to about 1,000,000 cP.

The conductive fluorine fluid is a fluorine fluid capable of carrying an electric current. In one aspect, the conductivity of the conductive fluorine fluids of the present description is greater than about 1 x 10¹And (5) S/m. In another aspect, the conductivity of the conductive fluorine fluids of the present description is greater than about 1 x 10²And (5) S/m. In another aspect, the conductivity of the conductive fluorine fluids of the present description is greater than about 1 x 10³And (5) S/m. In another aspect, the conductivity of the conductive fluorine fluids of the present description is greater than about 1 x 10⁴And (5) S/m. In another aspect, the conductivity of the conductive fluorine fluids of the present description is greater than about 1 x 10⁵And (5) S/m. The conductive fluorine fluid layer (6) may be homogeneous or heterogeneous.

In one aspect, the conductive fluorine fluid includes a fluorinated component and a conductive additive. The fluorinated component may include, for example, at least one of a perfluoropolyether, a fluorinated acrylate oligomer, and combinations thereof.

In one aspect, the fluorinated component has a viscosity in the range of about 2,000 to about 10,000,000 cP. In another aspect, the fluorinated component has a viscosity in the range of about 2,000 to about 5,000,000 cP. In another aspect, the fluorinated component has a viscosity in the range of about 2,000 to about 1,000,000 cP. However, the fluorinated component may have a lower viscosity, and the viscosity of the conductive fluorine fluid may be increased by a conductive additive or thickener.

In certain examples, the conductive additive has an average aspect ratio (average aspect ratio) in a range from 1 to about 2. The low aspect ratio conductive additive may take the form of, for example, a powder. The average largest dimension of the low aspect ratio conductive additive may be, for example, in the range of about 0.1 to about 500 μm, such as in the range of about 50 to about 150 μm. In other examples, the conductive additive has an average aspect ratio greater than about 2, such as in a range from about 2 to about 2,000. The high aspect ratio conductive additive may take the form of, for example, a rod or wire. The average largest dimension of the high aspect ratio conductive additive may be in a range of, for example, about 0.1mm to about 10 mm.

The conductive additives used herein may also act as viscosity modifiers to help resist or minimize flow of the fluorine fluid itself, and may help resist or minimize flow of the fluorine fluid within the conductive fluorine fluid layer. The conductive additive used herein may be, for example, an inorganic material. The conductive additive remains a solid when mixed with the fluorinated component. The conductive additive is typically used as particles in the shape of, for example, rods, wires, substantially spherical particles, or mixtures thereof, and the particle size determines the ease with which the conductive additive is homogenized with the fluorine fluid.

The conductive additive has electrical conductivity. The conductivity additive increases the conductivity of the resulting conductive composite 2 or enables a reduction in the amount of conductive fluorine fluid 6 required to achieve the same conductivity. By adjusting the amount of fluorine fluid or the amount of conductivity additive, the overall conductivity can be adjusted.

In one aspect, the conductive additive includes, for example, at least one of carbon fiber, coated carbon fiber, and a metallic material, such as, for example, stainless steel, brass, and at least one of a metal or alloy of at least one of iron, nickel, titanium, aluminum, copper, silver, gold, platinum, palladium, and zinc, and combinations thereof. As a specific example, the conductive additive includes nickel-coated carbon fibers.

In certain examples, the conductive additive comprises particles of the conductive additive, such as rods or wires, having an average aspect ratio greater than about 2 (i.e., wherein the length is at least about twice the width). The average aspect ratio can be measured using a microscope.

In other examples, the conductive additive includes particles, e.g., substantially spherical particles, of the conductive additive having an average aspect ratio of less than about 2 (i.e., wherein the length is at most about twice the width). In certain examples, the conductive additive comprises substantially spherical particles of the conductive additive having an average particle size of about 0.1 to about 500 μm (about 100 to about 500,000 nm). In certain examples, the conductive additive comprises substantially spherical particles having an average particle size of from about 1 to about 25 μm, or from about 25 to about 50 μm, or from about 50 to about 75 μm, or from about 75 to about 100 μm, or from about 100 to about 150 μm, or from about 150 to about 200 μm, or from about 200 to about 250 μm, or from about 250 to about 300 μm, or from about 300 to about 350 μm, or from about 350 to about 400 μm, or from about 450 to about 500 μm. In other examples, the conductivity additive includes substantially spherical particles of the conductivity additive having an average particle size of about 50 to about 150 μm. In certain examples, the particles of the conductive additive have an average particle size of about 0.1 to about 5 μm. Particle size can be measured using a Coulter Counter or Multisizer.

In one example, the conductive additive has an average aspect ratio greater than about 2 and includes rods or wires having a length of about 0.01 to about 10 mm. In certain examples, the conductive additive rods have a length of about 0.01 to about 0.5mm, or about 0.05 to about 10mm, or about 0.01 to about 10mm, or about 0.1 to about 1mm, or about 1 to about 5mm, or about 5 to about 10 mm. The use of conductive rods or wires contributes to the conductivity of the final composite to a greater extent than typical spherical conductive particles.

In certain examples, the conductive additive comprises a powder having particles with a mixture of rods or wires and substantially spherical particles, or a mixture comprising rods, wires, and substantially spherical particles.

The conductive additive may act as a thickener. In such a case, the conductive additive may be used in an amount to produce an appropriate viscosity and/or to adjust the conductive properties of the resulting composite. When a powder having particles in the shape of rods or wires is used as the conductive additive, the amount of the conductive additive can be reduced. Suitable amounts of the rod or wire conductive additive in the conductive fluorine fluid range from about 2% to about 40% by volume of the conductive fluorine fluid. In certain examples, the amount of conductive additive is about 2% to about 5%, or about 5 to about 10%, or about 10 to about 15%, or about 15 to about 20%, about 20 to about 25%, or about 25 to about 30%, or about 30 to about 40% by volume of the conductive fluorine fluid.

Suitable electrical conductivity can be achieved in the conductive composites disclosed herein without the need for large amounts of conductive additives in the conductive fiuidic fluid, i.e., loadings of such particles greater than about 45 volume percent. However, the conductive composites of the present description are not limited to particle loading levels of less than about 45 volume percent. Thus, particle loading levels above about 45 volume percent can be used in the conductive fluorine fluid.

In one aspect, the conductive fluorine fluid layer may further comprise a non-conductive thickener. The thickener may include, for example, at least one of an organic thickener, an inorganic thickener, and combinations thereof.

In certain examples, the thickener has an average aspect ratio of 1 to about 2. The low aspect ratio thickener may take the form of, for example, a powder. The low aspect ratio thickener may have an average largest dimension, for example, in the range of about 0.1 to about 500 μm, such as in the range of about 50 to about 150 μm. In other examples, the thickener has an average aspect ratio greater than about 2, such as in the range of about 2 to about 2,000. The high aspect ratio thickener may take the form of, for example, a rod or wire. The high aspect ratio thickener may have an average largest dimension, for example, in the range of about 0.1 to about 10 mm.

The thickening agent used herein acts as a viscosity modifier and may help to resist or minimize the flow of fluorine fluid within the conductive fluorine fluid layer. The thickener used herein may be an inorganic or organic material. The thickener remains a solid when mixed with the conductive fluorine fluid. Thickeners are typically used as particles in shapes such as rods, strands, substantially spherical particles or mixtures thereof, and the particle size determines the ease with which the powder can be homogenized with the fluorine fluid. Generally, a thickener with a higher surface area will be a better thickener than a thickener with a lower surface area.

In examples where the conductive fluorine fluid also includes a thickener, the thickener may be used in an amount to produce an appropriate viscosity.

In certain examples, the thickener used to prepare the conductive composite is an organic thickener. Examples of such compounds are maltol, phenol, naphthalene, 1-naphthol, 2-naphthol, 4-pyridone and carbon, including for example graphite and carbon black. When the organic thickener is a compound having a phenolic hydroxyl group, the compound may react with the isocyanate group of a diisocyanate or polyisocyanate through the hydroxyl group, but the reaction will be slower than the reaction to form a urethane or urea. Suitably used, such compounds may be used to modify the properties of the resulting thickener. The thickener may be a mixture of at least one organic thickener and at least one inorganic thickener.

In one aspect, the conductive fluorine fluid layer includes a compatibilizing agent. The compatibilizing agent may include, for example, at least one of an organic compatibilizing agent, an inorganic compatibilizing agent, and combinations thereof. When the compatibilizing agent comprises an organic compatibilizing agent, the organic compatibilizing agent may comprise, for example, a surfactant, such as an ionic surfactant, a nonionic surfactant, and combinations thereof. When the compatibilizing agent comprises an inorganic compatibilizing agent, the inorganic compatibilizing agent may comprise, for example, a metal nanoparticle.

The compatibilizing agent used herein improves the processability (e.g., flowability, ease of application) of the conductive fluorine fluid.

In certain examples, the compatibilizing agent used herein may also be used to thicken the conductive fluorine fluid, i.e., to increase the viscosity of the conductive fluorine fluid.

In certain examples, the conductive fluorine fluid used to form the conductive composite comprises a fluorine fluid and a compatibilizing agent in a weight ratio of fluorine fluid to compatibilizing agent of about 5: 1 to about 50: 1, or about 10: 1 to about 30: 1, or about 15: 1 to about 25: 1, or about 20: 1 to about 25: 1. thus, the amount of compatibilizing agent as a percentage of the fluorine fluid is from about 2 weight percent to about 20 weight percent. Particularly useful amounts of compatibilizing agents are about 4 wt.% to about 10 wt.%. Weight percent refers to the weight of the compatibilizing agent relative to the total weight of the conductive fluorine fluid. Phase separation should be avoided. At higher levels of compatibilizing agent, phase separation may occur, which can be addressed using the thickeners disclosed elsewhere herein.

In certain examples, the compatibilizing agent comprises inorganic nanoparticles, such as metal nanoparticles, having an average particle size in any linear dimension of less than about 100nm, or less than about 90nm, or less than about 80nm, or less than about 70nm, less than about 60nm, or less than about 50nm, or less than about 40nm, or less than about 30nm, or less than about 20 nm. For example, the particle size referred to herein may be measured using a Coulter Counter or Multisizer. Suitable nanoparticles include metals that are insoluble, i.e., do not dissolve, in the conductive fluorine fluid. Examples of suitable metals for use herein as nanoparticle-compatible agents include metals or alloys of silver, copper, brass, bronze, nickel, stainless steel, carbon, coated carbon, titanium, tungsten, and combinations thereof.

In certain examples, the compatibilizing agent is a nonionic amphiphilic compound or a mixture of nonionic amphiphilic compounds. Suitable nonionic amphiphilic compounds include: fatty alcohol alkoxylates, including fatty alcohol ethoxylates; alkylphenol alkoxylates, including alkylphenol ethoxylates; fatty acid alkoxylates, including fatty acid ethoxylates; alkoxylated amines, including ethoxylated amines; a fatty acid amide; polyoxyethylene-polyoxypropylene copolymers; fatty acid esters of polyhydroxy compounds; glycerol fatty acid esters; sorbitan fatty acid esters; sucrose fatty acid ester; an alkyl polyglucoside; an aliphatic amine oxide; a sulfoxide; organic phosphine oxides and mixtures thereof.

In certain examples, the compatibilizing agent is an ionic compound. Suitable ionic amphiphilic compounds include anionic compounds and cationic compounds. Representative anionic compounds are alkyl sulfates, alkyl ether sulfates, alkyl sulfonates, alkyl ether sulfonates, alkyl phosphates, and alkyl carboxylates. Representative cationic compounds are quaternary ammonium compounds, monoalkylammonium salts, dialkyl ammonium salts and trialkyl ammonium salts.

The selection and amount of the particular anionic compound (or mixture thereof) or cationic compound (or mixture thereof) used to form the conductive fluorine fluid layer will be determined by the particular elastomeric polymer used to prepare the conductive composite. The type and amount of anionic or cationic compound is selected to avoid degradation or depolymerization of the elastomeric polymer.

In certain examples, the compatibilizing agent is a surfactant.

In certain examples, the compatibilizing agent is a nonionic amphiphilic compound or mixture of such compounds. Particularly useful nonionic amphiphilic compounds are alkylphenol ethoxylates. Representative of alkylphenol ethoxylates are octylphenol ethoxylates, such as Triton^TMX-100 (polyethylene glycol p- (1,1,3, 3-tetramethylbutyl) -phenyl ether with an average of 9.5 ethylene oxide units) and nonylphenol ethoxylate.

Other particularly useful nonionic amphiphilic compounds are poloxamers (poloxamers), which are triblock copolymers of poly (ethylene oxide) -poly (propylene oxide) -poly (ethylene oxide) (PEO-PPO-PEO). For example, PLURONIC nonionic amphiphilic compounds are suitable.

The conductive composites of the present description may also include additional materials to impart other characteristics to the conductive composites. In one aspect, the conductive composite includes an additive that increases thermal oxidation stability. When the conductive composite includes an additive that increases thermal oxidation stability, the additive that increases thermal oxidation stability can include, for example, at least one of a phosphate, an iron oxide, a phenol, an antioxidant, a metal deactivator, and combinations thereof. A thermo-oxidative stabilizer is a material or additive that increases the thermo-oxidative stability. A thermal oxidation stabilizer may be included in the conductive fiuidic composition or added to the elastic polymer layer prior to forming the conductive composite. The thermal oxidation stabilizer may be a phosphate, an iron oxide, a phenolic antioxidant, a metal deactivator, or a combination thereof, depending on the properties desired in the conductive composite and the environment in which the conductive composite is to be deployed. The addition of a thermo-oxidative stabilizer to the conductive composites disclosed herein extends the operating temperature range of the conductive composites. Suitable metal deactivators include nitrates such as nitric acid; citrates such as citric acid; a tungstate salt; a molybdate; chromates and mixtures thereof.

The preparation of the conductive fluorine fluid can be accomplished by mixing the fluorinated component, the conductive additive, and any optional components, such as via a centrifugal planetary mixer or a shear mixing capability. The resulting conductive fluorine fluid may be stored for future use.

In certain examples, the conductive fiuids disclosed herein and useful for making conductive composites can have a loss modulus (G ") that is greater than the storage modulus (G'), i.e., the conductive fiuids have tan δ values greater than 1. Thus, the conductive fluorine fluid compositions of the present disclosure behave more like a liquid than a solid. The conductive fluoro-fluid compositions of the present disclosure may have a viscosity of about 500Cp to about 1,000,000Cp at 1Hz, when measured using a dynamic shear rheometer according to ASTM D7175.

The thickness of each layer of the conductive composite 2 can be adjusted as desired to obtain the desired properties of the final product. In one aspect, as shown in fig. 2, the first elastic polymer layer 4 has a first thickness 14 and the second elastic polymer layer 8 has a second thickness 12. The first thickness 14 and the second thickness 12 may each be in the range of about 0.01mm to about 100 mm. In another aspect, the first thickness 14 and the second thickness 12 may each be in a range of about 0.1mm to about 10 mm. For example, the first thickness 14 and the second thickness 12 may each be about 1 mm. The first thickness 14 may be the same as or different from the second thickness 12. The conductive fluorine fluid layer has a third thickness 16, and the third thickness 16 may be less than or equal to at least one of the first thickness 14 and the second thickness 12. Third thickness 16 may be greater than at least one of first thickness 14 and second thickness 12. In one aspect, the third thickness 16 is less than the sum of the first thickness 14 and the second thickness 12. In another aspect, the third thickness 16 is less than at least one of the first thickness 14 and the second thickness 12. For example, the first thickness 14 and the second thickness 12 may be about 1mm, and the third thickness 16 may be less than about 1 mm. The total thickness of the conductive composite 2 may range from about 0.03mm to about 200 mm. In one aspect, the total thickness of the conductive composite 2 may be in the range of about 0.1mm to about 100 mm. In another aspect, the total thickness of the conductive composite 2 may be in a range from about 0.5mm to about 10 mm.

The conductive composite 2 may include one or more additional elastomeric polymer layers and one or more additional conductive fluorine fluid layers. For example, the conductive composite may comprise a total of five layers, three elastomeric polymer layers alternating with two conductive fluorine fluid layers.

In one aspect, the conductive composite 2 is in the form of a laminate in which a continuous conductive fluorine fluid layer 6 is sandwiched between a first elastic polymer layer 4 and a second elastic polymer layer 8. The continuous conductive fluorine fluid layer 6 may be flat or curved. In one expression, the length of the continuous conductive fluorine fluid layer 6 is much greater than the thickness of the continuous conductive fluorine fluid layer 6. In one aspect, the length of the continuous conductive fluorine fluid layer 6 is at least five times the length of the continuous conductive fluorine fluid layer 6. On the other hand, the length of the continuous conductive fluorine fluid layer 6 is at least twenty times the thickness of the continuous conductive fluorine fluid layer 6. On the other hand, the length of the continuous conductive fluorine fluid layer 6 is at least fifty times the thickness of the continuous conductive fluorine fluid layer 6. In another expression, the length and width of the continuous conductive fluorine fluid layer 6 is much greater than the thickness of the continuous conductive fluorine fluid layer 6. In one aspect, the length and width of the continuous conductive fluorine fluid layer 6 is at least five times the thickness of the continuous conductive fluorine fluid layer 6. On the other hand, the length and width of the continuous layer of conductive fluorine fluid 6 is at least twenty times the thickness of the continuous layer of conductive fluorine fluid 6. In another aspect, the length and width of the continuous layer of conductive fluorine fluid 6 is at least fifty times greater than the thickness of the continuous layer of conductive fluorine fluid 6.

The edges of the conductive composite 2 surrounding the conductive fluorine fluid layer 6 may be sealed in any manner. In one aspect, the edges of the conductive composite 2 may be sealed by contacting the second elastic polymer layer 8 with the first elastic polymer layer 4. For example, the first elastic polymer layer 4 and the second elastic polymer layer 8 may be separated by the conductive fiuidic layer 6 except for the edges of the conductive composite 2 surrounding the conductive fiuidic layer 6 where the first elastic polymer layer 4 and the second elastic polymer layer 8 are in contact with each other. The second elastomeric polymer layer 8 may be capable of curing to the first elastomeric polymer layer 4 to form an effective sealant. The edge length 18 of the edge of the conductive composite 2 surrounding the conductive fiuidic layer prevents overstressing the bond between the first elastic polymer layer 4 and the second elastic polymer layer 8. In one aspect, the edge length 18 is greater than at least one of the first thickness 14 and the second thickness 12.

The conductive fluorine fluid layer 6 of the present description provides conductivity to the conductive composite 2 without requiring rigidity, and the high viscosity of the conductive fluorine fluid layer inhibits leakage of the conductive fluorine fluid during coating or use. As shown in fig. 2 and 3B, the present description also includes a reinforcing mesh 10 in contact with the conductive fluorine fluid layer 6. The reinforcing mesh 10 in contact with the conductive fluorine fluid layer 6 alters the flow characteristics of the conductive fluorine fluid 6 to further reduce the likelihood of leaching and better retain the conductive fluorine fluid 6 within the conductive composite 2. The reinforcing mesh 10 also improves the elongation and recovery of the overall conductive composite and minimizes its hysteresis.

The reinforcing mesh 10 may be free to move relative to the first and second elastic polymer layers 4, 8 to avoid a reduction in elasticity of the conductive composite 2, or the reinforcing mesh 10 may be attached to one of the first or second elastic polymer layers 4, 8 to provide additional structural integrity.

The reinforcing mesh 10 may be electrically conductive or non-conductive. The conductive reinforcing mesh 10 increases the conductivity of the resulting conductive composite 2, or reinforcing mesh 10 enables a reduction in the amount of conductive fluorine fluid 6 that achieves the same conductivity. Reducing conductivity in composite materials 2The amount of conductive fluorine fluid 6 may further reduce the likelihood of leaching and better retain the conductive fluorine fluid 6 within the conductive composite 2. In one aspect, the conductive web has a conductivity greater than about 1 x 10³And (5) S/m. In another aspect, the conductive web has a conductivity greater than about 1 x 10⁴And (5) S/m. In another aspect, the conductive web has a conductivity greater than about 1 x 10⁵S/m。

In one aspect, the reinforcing mesh 10 is a continuous reinforcing mesh layer in contact with the continuous conductive fiuidic layer 6. In one expression, the length of the continuous reinforcing web layer is substantially greater than the thickness of the continuous reinforcing web layer. In one aspect, the length of the continuous reinforced web layer is at least five times the thickness of the continuous reinforced web layer. In another aspect, the length of the continuous reinforced web layer is at least twenty times the thickness of the continuous reinforced web layer. In another aspect, the length of the continuous reinforced web layer is at least fifty times the thickness of the continuous reinforced web layer. In another expression, the length and width of the continuous reinforced web layer are substantially greater than the thickness of the continuous reinforced web layer. In one aspect, the length and width of the continuous reinforced web layer is at least five times the thickness of the continuous reinforced web layer. In another aspect, the length and width of the continuous reinforced web layer is at least twenty times the thickness of the continuous reinforced web layer. In another aspect, the length and width of the continuous reinforced web layer is at least fifty times the thickness of the continuous reinforced web layer. The length and width of the reinforcing mesh 10 may be greater than, equal to, or less than the continuous conductive fluorine fluid layer 6.

Additionally, if the conductive composite 2 is in the form of a laminate, the laminate structure allows the continuous conductive fiuorofluid layer 6 and continuous reinforcing web layer 10 to be co-located, with the continuous conductive fiuorofluid layer 6 and continuous reinforcing web layer 10 sandwiched between the first elastic polymer layer 4 and the second elastic polymer layer 8.

The reinforcing mesh 10 may be or include a fabric, such as a knit, a woven, or a combination thereof. The fabric may be a non-conductive fabric, a conductive fabric, or a combination thereof. The conductive fabric increases the conductivity of the resulting conductive composite 2.

The nonconductive fabric may be or include, for example, a polyether polyurea copolymer, latex, poly-p-phenylene terephthalamide, aramid, nylon, polyester, or combinations thereof. However, any fabric chemically suitable for use with the conductive fluorine fluid 6 may be used. The non-conductive fabric may be coated with a conductive material to create a conductive fabric.

The conductive fabric may comprise or be formed from conductive filaments, coated non-conductive fabric, or a combination thereof. Exemplary conductive wires include silver wire, copper wire, brass wire, nickel wire, stainless steel wire, aluminum wire, carbon wire, coated carbon wire, titanium wire, tungsten wire, tin wire, zinc wire, and combinations thereof. Exemplary coated nonconductive fabrics include metal coated polyether-polyurea copolymers, metal coated latex, metal coated poly-p-phenylene terephthalamide, metal coated aramid, metal coated nylon, metal coated polyester, carbon coated polyether-polyurea copolymers, carbon coated latex, carbon coated poly-p-phenylene terephthalamide, carbon coated aramid, carbon coated nylon, carbon coated polyester, and combinations thereof.

In certain examples, the conductive composites 2 of the present description exhibit a minimum sheet resistance of less than about 100 Ohm/sq. The sheet resistance of a particular conductive composite will depend on the end use. For example, when the conductive composite is used to shield electrical components from electromagnetic radiation, such as to minimize electromagnetic interference that may damage or harm sensitive electronic devices, a minimum sheet resistance of less than about 100Ohm/sq is preferred. Sheet resistivity can be determined during fabrication or prior to final packaging using, for example, a four-point probe.

In certain examples, the conductive composite 2 of the present description exhibits an elongation at break of greater than or equal to about 10%. In other examples, the conductive composite 2 of the present description exhibits an elongation at break of greater than or equal to about 25%. In other examples, the conductive composite 2 of the present description exhibits an elongation at break of greater than or equal to about 50%. Elongation at break is measured as the percentage of strain of a material after application of tension before breaking. The percentage of the original length is used to represent the elongation at break.

In certain examples, the conductive composites 2 of the present description exhibit a tensile strength of greater than or equal to about 3 MPa.

In certain examples, the conductive composite 2 of the present description has a density of less than about 7g/mL, less than about 6g/mL, less than about 5g/mL, or less than about 4 g/mL. In certain examples, the conductive composite has a density of between about 2 and about 10 g/mL. In other examples, the conductive composite has a density between about 10 to about 20 g/mL. In other examples, the density of the conductive composite is between about 1 to about 5g/mL, or between about 3 to about 8 g/mL. This parameter can be easily measured by determining the mass of a known volume or measuring the volume of water displaced by a known mass.

In certain examples, the conductive composite 2 of the present description exhibits about 5 x 10 at 20 ℃⁵Maximum bulk conductivity (maximum bulk conductivity) of S/m.

In certain examples, the conductive composite is flexible. In certain examples, the conductive composite has a tensile strength of greater than or equal to about 3 MPa. In certain examples, the conductive composite is flexible and has a tensile strength of greater than or equal to about 3 MPa.

The present disclosure also provides products, articles, and structures comprising a substrate with a conductive composite layer as disclosed herein. Such products, articles, and structures can be prepared by heating and applying a thermoplastic or thermoset conductive composite as disclosed herein to a substrate. In some examples, the conductive composite may be a portion of an aircraft, such as all or a portion of at least one of a wing and a fuselage of the aircraft. In some examples, the conductive composite may be at least one of a seal and a gasket.

As shown in fig. 3A, 3B, and 3C, the conductive composite 2 of the present description may be prepared by forming a first elastic polymer layer 4 (see fig. 3A) and forming a conductive fluorine fluid layer 6 (see fig. 3B) on the first elastic polymer layer 4. The conductive fluorine fluid layer 6 may be reinforced with a reinforcing mesh 10 before or after forming the conductive fluorine fluid layer 6. Then, a second elastic polymer layer 8 is formed on the conductive fluorine fluid layer 6 (see fig. 3C).

In one aspect, the step of forming the first elastomeric polymer layer includes curing the first elastomeric polymer layer. The step of curing the first elastomeric polymer layer may comprise curing the first elastomeric polymer layer.

In certain examples, the step of forming the conductive fluorine fluid layer includes mixing a fluorinated component and a conductive additive. In other examples, the step of forming the conductive fluorine fluid layer includes mixing a fluorinated component, a conductive additive, and a compatibilizing agent. In other examples, the step of forming the conductive fluorine fluid layer includes mixing a fluorinated component, a conductive additive, and an additive that increases thermal oxidation stability, and optionally a compatibilizing agent. In one aspect, the step of forming the conductive fluorine fluid layer includes mixing the conductive fluorine fluid using shear mixing. Shear mixing may be performed at a speed of about 25 to about 2,000rpm, such as at a speed of about 25 to about 125 rpm. In another aspect, the step of forming the conductive fluorine fluid layer includes infiltrating reinforcing mesh 10 with a conductive fluorine fluid.

In some examples, the step of forming the second elastomeric polymer layer includes curing the second elastomeric polymer layer. The step of curing the second elastic polymer layer may include bonding the second elastic polymer layer to the first elastic polymer layer.

After forming the second elastomeric polymer layer, the methods of the present description may include trimming the conductive composite around the conductive fiuidic layer. In one aspect, the trimming leaves an edge length around the conductive fluorine fluid layer.

For example, the conductive composites of the present disclosure can be prepared by laminating a conductive fiuidic onto a surface of a first cured or partially cured elastic polymer and by laminating a second elastic polymer thereon.

In another embodiment, the conductive composite of the present disclosure may be prepared by dispensing a conductive fluorine fluid onto a non-tacky surface, applying an uncured elastomeric polymer over the conductive fluorine fluid, and then curing the elastomeric polymer. The conductive composite can then be conveniently removed from the non-tacky surface by peeling the conductive composite from the non-tacky surface. After removal from the non-tacky surface, another layer of cured or uncured elastomeric polymer can be added over the conductive fluorine fluid, if needed or desired, and cured as needed to create a sandwich or laminate structure.

The laminate composite of the present disclosure may be prepared by laminating a conductive fiuorofluid onto a surface of a first elastic polymer and applying a second elastic polymer layer over the conductive fiuorofluid layer. The second elastomeric polymer may be the same or different from the first elastomeric polymer. The addition of a second elastomeric polymer layer will encapsulate the conductive fluorocarbon fluid layer.

The laminated conductive composites of the present disclosure can also be prepared by dispensing a conductive fluorine fluid onto a non-tacky surface, coating an uncured elastomeric polymer onto the conductive fluorine fluid, and then curing the elastomeric polymer. The conductive composite can then be conveniently removed from the non-tacky surface by peeling the conductive composite from the non-tacky surface. If desired, a second elastomeric polymer (which may be the same or different from the first elastomeric polymer) may optionally be applied over the conductive fiuidic layer. The addition of a second elastomeric polymer layer will encapsulate the conductive fluorocarbon fluid layer.

The non-stick surface may be any suitable non-stick material. Examples of suitable non-stick materials include polytetrafluoroethylene, anodized aluminum, ceramic, and enameled cast iron.

The present disclosure also provides products, articles, and structures that include a substrate bearing a layer of conductive composite material as disclosed herein, and in certain examples, a flexible conductive composite as disclosed herein. Such products, articles, and structures can be prepared by heating and applying a thermoplastic or thermoset conductive composite as disclosed herein to a substrate. Alternatively, the flexible conductive composite may be bonded to a substrate.

The conductive fluorine fluid composition can be prepared by mixing a fluorinated component with a conductive additive and thoroughly mixing the resulting mixture to form a uniform conductive fluorine fluid. Mixing may be accomplished with a shear mixer at about 25 to about 2500 rpm. In certain examples, the shear mixing is performed at about 25 to about 125rpm, or at about 125 to about 250rpm, or at about 250 to about 400rpm, or at about 400 to about 700rpm, or at about 700 to about 1500rpm, or at about 1500 to about 2500rpm to form the conductive fluorine fluid composition. Alternatively, the mixing may be performed using a centrifugal planetary mixer. The resulting conductive fluorine fluid may be stored for future use.

In addition, the surface of the elastic polymer layer facing the conductive fluorine fluid layer may be treated to improve the wettability of the liquid metal. This may include ultraviolet treatment, plasma treatment or corona discharge treatment. In addition, a surfactant may be applied to the elastic polymer layer facing the conductive fluorine fluid layer to improve wettability.

The following experiments illustrate other features and properties of the conductive composites of the present description.

Material

A98 benzoyl peroxide was purchased from Sigma Aldrich and used as received. Stainless steel wire (3 mm. times.2 μm) and nickel wire (10 μm x 0.25mm, 10 μm x 1mm and 10 μm x 3mm) were purchased from intramicon and used as received. Stainless steel powder (type 316) was purchased from Atlantic Equipment Engineers and washed with acetone prior to use. Sylgard 184 silicone elastic kit was purchased from Dow Corning and used as received. NuSil R21-2615 silicone was purchased from Nusil and used as received. Silver knitted fabrics were prepared. Polyethylene glycol dimethacrylate (SR210) was obtained from Sartomer and used as received.DMPT cure accelerator was purchased from Albemarle and used as received.PFPE E10-H，AD1700 andHC/04 was obtained from Solvay and used as received. Nickel powder was purchased from Vale and used as received. FlexSeal Clear Liquid was purchased from a local household store and used as received.

Comparative example 1: nusil R21-2615 control

10g of NuSil R21-2615A portion and 10g of NuSil R21-2615B portion were mixed for 1 minute at 2300rpm using a flaktek mixer. The resulting homogeneous mixture of elastomeric polymers was poured on top of the Mylar release film and cast with a glass rod. The elastic polymer film was then heat cured at 60 ℃ for 2 hours according to the manufacturer's instructions.

Example 2: FlexSeal control

A 10g aliquot of the FlexSeal solution was cast on top of the Mylar release film and cast with a glass rod. The resulting elastic polymer film was cured overnight (about 18 hours) at room temperature according to the manufacturer's instructions.

Example 3: nickel-fluorine gel (Nickel fluorogel) and laminated composite material prepared therefrom

Preparation of conductive fluorine fluid: 131.25g E10-H and 18.75g SR210 were mixed at 2300rpm for 1 minute. 90g of nickel powder from Vale was divided into 3 portions and added to the acrylate fluoro-solvent mixture using a flactek mixer at 2300rpm for 1 minute. 60g of nickel wire (10. mu. m x 0.25.25 mm) were mixed by Flactek mixing at 2300rpm for several minutes. The resulting nickel-fluorine solvent mixture was homogenized and no lumps were visible. In a separate vessel, 2 wt.% benzoyl peroxide (relative to SR210) was added to 2mL MEK solvent, vortexed for a few minutes until it was completely dissolved. The benzoyl peroxide MEK solution was added to the Ni-acrylate fluoro solvent mixture and mixed by a Flactek mixer at 2300rpm for 1 minute. 375 mu L of the extractDMPT curing Accelerator additionTo the mixture and mixed by a Flactek mixer at 2300rpm for 1 minute. The resulting homogeneous mixture was heated in a heating mantle at 110 ℃. Polymerization took place within 5 minutes. The nickel fluoro gel was solidified and formed into large pieces which were then broken into smaller pieces with a spatula and then mixed centrifugally at 2300rpm for 20 seconds. The resulting nickel-fluorine gel was spreadable/flowable.

Preparation of laminate composite: a-30 mil thick nickel fluoro gel was cast onto a cured FlexSeal Clear Liquid film. Additional FlexSeal Clear Liquid was cast on top of the nickel-fluorine gel to fully encapsulate the laminated composite and cured overnight at room temperature. The composite had a thickness of about 100 mils.

Example 4: nickel-fluorine gel with silver knitted fabric and laminated composite material prepared by same

Preparation of conductive fluorine fluid: 131.25g E10-H and 18.75g SR210 were mixed at 2300rpm for 1 minute. 38.6g of nickel powder from Vale was added to the acrylate fluorous solvent mixture using a flactek mixer at 2300 rpm. 25.7g of nickel wire (10. mu. m x 0.25.25 mm) were mixed by Flactek mixing at 2300rpm for several minutes. The resulting nickel-fluorine solvent mixture was homogenized and no lumps were visible. In a separate vessel, 2 wt.% benzoyl peroxide (relative to SR210) was added to 2mL MEK solvent, vortexed for a few minutes until it was completely dissolved. The benzoyl peroxide MEK solution was added to the Ni-acrylate fluoro solvent mixture and mixed by a Flactek mixer at 2300rpm for 1 minute. 375 mu L of the extractThe DMPT cure accelerator was added to the mixture and mixed by the flatek mixer at 2300rpm for 1 minute. The resulting homogeneous mixture was heated in a heating mantle at 110 ℃. Polymerization took place within 5 minutes. The nickel-fluorine gel was solidified and formed into large pieces, which were then broken into smaller pieces, and then centrifugally mixed at 2300rpm for 20 seconds. The resulting nickel-fluorine gel is spreadable/flowable and can be easily coated on fabrics.

Preparation of the penetration enhancement net: uniformly spreading the nickel-fluorine gel on the silver knitted fabric with a spatula to form a conductive silver knitted fabric filled with nickel-fluorine gel:

preparation of laminate composite: a nickel fluoro gel filled silver knit was placed on the cured FlexSeal Clear Liquid film. Additional FlexSeal Clear Liquid was cast onto the nickel fluoro gel filled silver knit fabric to fully encapsulate the laminate and cured overnight at room temperature. The composite had a thickness of about 100 mils.

Example 5: nickel-fluorine gel with longer nickel wire and laminated composite material prepared by same

Preparation of conductive fluorine fluid: 131.25g E10-H and 18.75g SR210 were mixed at 2300rpm for 1 minute. 25.7g of Ni strands (10 μm x 1mm) were mixed by an overhead shear mixer at speed 2 to the mixture overnight and then rapidly mixed at speed 8 for 1 hour. Next, 4g of nickel wire (8 μm. times.3 mm) was mixed by an overhead shear mixer at speed 2 until the mixture was overnight, and then centrifuged at 2300rpm for 1 minute. The resulting nickel-fluorine solvent mixture was homogenized and no lumps were visible. 38.6g of nickel powder from Vale was added to the mixture and mixed at 2300rpm for 2 minutes. In a separate vessel, 2 wt.% benzoyl peroxide (relative to SR210) was added to 2mL MEK solvent, vortexed for a few minutes until completely dissolved. The benzoyl peroxide MEK solution was added to the nickel acrylate fluoro solvent mixture and mixed by a flatek mixer at 2300rpm for 1 minute. 375 mu L of the extractThe DMPT cure accelerator was added to the mixture and mixed by the flatek mixer at 2300rpm for 1 minute. The resulting homogeneous mixture was heated in a heating mantle at 110 ℃. Polymerization took place within 5 minutes. The nickel fluoro gel was solidified and formed into large pieces which were then broken into smaller pieces with a spatula and then mixed centrifugally at 2300rpm for 20 seconds. The resulting nickel-fluorine gel was spreadable/flowable.

Preparation of laminate composite: a-30 mil thick nickel fluoro gel was cast onto a cured FlexSeal Clear Liquid film. Additional FlexSeal Clear Liquid was cast on top of the nickel-fluorine gel to fully encapsulate the laminated composite and cured overnight at room temperature. The composite had a thickness of about 100 mils.

Example 6: nickel-fluorine gel (fluoroacrylate) with silver knit fabric and laminated composite material prepared therefrom

Preparation of conductive fluorine fluid: 70g HC/04 and 40g nickel powder from Vale were mixed at 1500rpm for 1 minute. 6g of Ni wire (8 μm x 3mm) was mixed by an overhead shear mixer at speed 2 to the mixture overnight and then rapidly mixed at speed 8 for 1 hour. An additional 20g of nickel powder from Vale was added to the mixture and mixed at 1500rpm for 1 minute. Next, 14g of AD1700 (fluoroacrylate) and 14g of n-butyl acetate were added to the mixture and mixed at 1500rpm for 1 minute. The resulting nickel-fluorine solvent mixture was homogenized and no lumps were visible. Additional 40g of nickel powder from Vale was added to the mixture and mixed at 1500rpm for 2 minutes. In a separate container, 2 wt.% benzoyl peroxide (relative to AD1700) was added to 2mL MEK solvent, vortexed for a few minutes, until completely dissolved. The benzoyl peroxide MEK solution was added to the nickel acrylate fluoro solvent mixture and mixed by the Flactek mixer at 1500rpm for 1 minute. 280 microliter of the extractThe DMPT cure accelerator was added to the mixture and mixed by the flatek mixer at 1500rpm for 1 minute. The resulting homogeneous mixture was heated in a heating mantle at 110 ℃. Polymerization took place within 5 minutes. The resulting nickel-fluorine gel is spreadable and processable.

Preparation of conductive fluoro gel filled conductive Ag knit laminate composite: the flowable conductive fluoro-gel paste was spread into the silver knit fabric with a spatula.

Nusil vacuum infiltration: nusil R21-2615 liquid silicone rubber is a two-part translucent silicone system with a mixing ratio of part a to part B of 1: 1, and has a rapid thermosetting property. Equal portions were weighed into a Flacktek vessel and mixed at 2300rpm for 1 minute. The resulting homogeneous resin was poured on top of the panel with Mylar release film and a 30mil thick film was cast using a glass rod. The nickel-fluorine gel filled silver knit was placed on top of the NuSil film and the remaining NuSil mixture was poured on top of the knit and evenly distributed using a glass rod. The top panel, Mylar peel film side down, is placed on top of the resin, and a vent hole is placed on the top panel. Prior to sealing, a vacuum connector was placed inside the vacuum bag, a 0.5 inch slit was cut into the vacuum bag, and a vacuum hose was connected through the slit. Immediately after sealing the system, the vacuum pump was turned on and the pressure was maintained at-25 inches of mercury. The entire vacuum bagging apparatus was placed on top at a high temperature of 60 ℃ to perform a rapid thermal cure of about 40 minutes. After 1 hour the composite was removed from the apparatus. Additional NuSil R21-2615 was added/sprayed on the composite surface to ensure that the nickel-fluorine gel was fully encapsulated. The composite material has a thickness of about 60-120 mils.

Example 7: nickel-fluorine gel (uncured fluorinated acrylate web) with Ag knit, and laminated composite material prepared therefrom

Nickel-fluorine gel synthesis: 70g HC/04 and 30g nickel powder from Vale were mixed at 1500rpm for 1 minute. 4g of nickel wire (8 μm x 3mm) was mixed by an overhead shear mixer at speed 2 to the mixture overnight and then rapidly mixed at speed 8 for 1 hour. An additional 30g of nickel powder from Vale was added to the mixture and mixed at 1500rpm for 1 minute. Next, 11g AD1700 (fluoroacrylate) and 14g n-butyl acetate were added to the mixture and mixed at 1500rpm for 1 minute. The resulting nickel-fluorine gel mixture should be homogenized without visible lumps. An additional 30g of nickel powder from Vale was added to the mixture and mixed at 1500rpm for 2 minutes. The homogenized mixture was not subjected to a polymerization step. The mixture is spreadable/flowable.

Preparation of conductive fluoro gel filled conductive Ag knit laminate composite: the flowable conductive fluoro-gel paste was spread into the silver knit fabric with a spatula.

Nusil vacuum infiltration: nusil R21-2615 liquid silicone rubber is a two-part translucent silicone system with a mixing ratio of part a to part B of 1: 1, and has a rapid thermosetting property. Equal portions were weighed into a Flacktek vessel and mixed at 2300rpm for 1 minute. The resulting homogeneous resin was poured on top of the panel with Mylar release film and a 30mil thick film was cast using a glass rod. The nickel-fluorine gel filled silver knit was placed on top of the NuSil film and the remaining NuSil mixture was poured on top of the knit and evenly distributed using a glass rod. The top panel, Mylar peel film side down, is placed on top of the resin, and a vent hole is placed on the top panel. Prior to sealing, a vacuum connector was placed inside the vacuum bag, a 0.5 inch slit was cut into the vacuum bag, and a vacuum hose was connected through the slit. Immediately after sealing the system, the vacuum pump was turned on and the pressure was maintained at-25 inches of mercury. The entire vacuum bagging apparatus was placed on top at a high temperature of 60 ℃ to perform a rapid thermal cure of about 40 minutes. After 1 hour the composite was removed from the apparatus. Additional NuSil R21-2615 was added/sprayed on the composite surface to ensure that the nickel-fluorine gel was fully encapsulated. The composite material has a thickness of about 60-120 mils.

Examples of the present disclosure may be described in the context of aircraft preparation and service method 1000 as shown in FIG. 4 and aircraft 1002 as shown in FIG. 5. During pre-production, aircraft preparation and service method 1000 may include specification and design 1004 of aircraft 1002 and material procurement 1006. During production, component/subassembly preparation 1008 and system integration 1010 of aircraft 1002 occurs. Thereafter, aircraft 1002 may go through certification and delivery 1012 in order to be placed in service 1014. During service by a customer, aircraft 1002 is scheduled for routine maintenance and service 1016, which may also include modification, reconfiguration, refurbishment, and so on.

Each of the processes of method 1000 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For ease of illustration, the system integrators may include, but are not limited to, any number of aircraft manufacturers and major system subcontractors; the third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; the operator may be an airline, leasing company, military entity, service organization, and so on.

The conductive composite of the present disclosure may be used during any one or more stages of aircraft manufacturing and service method 1000, including specification and design 1004 of aircraft 1002, material procurement 1006, component/subassembly preparation 1008, system integration 1010, certification and delivery 1012, aircraft service 1014, and routine maintenance and service 1016.

Further, the present disclosure includes embodiments according to the following clauses:

clause 1. a conductive composite (2) comprising:

a first elastic polymer layer (4);

a conductive fluorine fluid layer (6) on the first elastic polymer layer (4); and

a second elastomeric polymer layer (8) on the conductive fiuorofluid layer (6).

Clause 2. the conductive composite (2) of clause 1, wherein the conductive fiuidic layer (6) comprises a fluorinated component and a conductive additive.

Clause 3. the conductive composite (2) of clause 2, wherein the fluorinated component comprises at least one of a perfluoropolyether, a fluorinated acrylate oligomer, a combination thereof.

Clause 4. the conductive composite (2) of clause 2 or 3, wherein the fluorinated component has a viscosity in the range of about 2,000cP to about 10,000,000 cP.

Clause 5. the conductive composite (2) of any one of clauses 2-4, wherein the fluorinated component has a viscosity of about 2,000cP to about 5,000,000 cP.

Clause 6. the conductive composite (2) of any of clauses 2-5, wherein the fluorinated component has a viscosity of about 2,000cP to about 1,000,000 cP.

Clause 7. the conductive composite (2) of any of clauses 2-6, wherein the aspect ratio of the conductive additive is less than about 2.

Clause 8. the conductive composite (2) of any of clauses 2-7, wherein the conductive additive has an aspect ratio of at least about 2.

Clause 9. the conductive composite (2) of any one of clauses 2 to 8, wherein the conductive additive includes at least one of carbon fiber, coated carbon fiber, and a metallic material.

Clause 10. the conductive composite (2) of any one of clauses 2 to 9, wherein the conductive additive comprises a metallic material, wherein the metallic material comprises at least one of stainless steel, brass, iron, nickel, titanium, aluminum, copper, silver, gold, platinum, palladium, and zinc.

Clause 11. the conductive composite (2) of any one of clauses 1-10, wherein the conductive fiuidic layer (6) further comprises a compatibilizing agent.

Clause 12. the conductive composite (2) of any of clauses 1-10, wherein the conductive fluorine fluid layer (6) further comprises a compatibilizing agent, and wherein the compatibilizing agent comprises at least one of an organic compatibilizing agent, an inorganic compatibilizing agent, and combinations thereof.

Clause 13. the conductive composite (2) of any of clauses 1-12, wherein the conductive fluorine fluid layer (6) further comprises an organic compatibilizing agent, and wherein the organic compatibilizing agent comprises a surfactant.

Clause 14. the conductive composite (2) of any of clauses 1-13, wherein the conductive fiuidic layer (6) further comprises an organic compatibilizing agent, and wherein the organic compatibilizing agent comprises at least one of an ionic surfactant, a nonionic surfactant, and a combination thereof.

Clause 15. the conductive composite (2) of any one of clauses 1 to 14, further comprising an additive that increases thermo-oxidative stability.

Clause 16. the conductive composite (2) of any of clauses 1 to 15, further comprising an additive that increases thermo-oxidative stability, wherein the additive comprises at least one of a phosphate, an iron oxide, a phenolic, an antioxidant, a metal deactivator, and combinations thereof.

Clause 17. the conductive composite (2) of any one of clauses 1 to 16, wherein the first elastic polymer layer (4) comprises at least one of a thermoplastic polymer, a thermoset polymer, and combinations thereof.

Clause 18. the conductive composite (2) of any of clauses 1-17, wherein the first elastic polymer layer (4) comprises at least one of silicone, fluorosilicone, perfluoropolyether, polybutadiene, polyester, polycarbonate, polyurethane, polyurea, polyurethane-urea, epoxy, acrylate, natural rubber, butyl rubber, polyacrylonitrile, Ethylene Propylene Diene Monomer (EPDM) rubber, and combinations thereof.

Clause 19. the conductive composite (2) of any one of clauses 1 to 18, wherein the second elastic polymer layer (8) comprises at least one of a thermoplastic polymer, a thermoset polymer, and combinations thereof.

Clause 20. the conductive composite (2) of any one of clauses 1-19, wherein the second elastic polymer layer (8) comprises at least one of silicone, fluorosilicone, perfluoropolyether, polybutadiene, polyester, polycarbonate, polyurethane, polyurea, polyurethane-urea, epoxy, acrylate, natural rubber, butyl rubber, polyacrylonitrile, Ethylene Propylene Diene Monomer (EPDM) rubber, and combinations thereof.

Clause 21. the conductive composite (2) of any one of clauses 1-20, wherein the first elastic polymer layer (4) has a thickness in the range of about 0.01mm to about 100 mm.

Clause 22. the conductive composite (2) of any one of clauses 1 to 21, wherein the first elastic polymer layer (4) has a thickness in the range of about 0.1mm to about 10 mm.

Clause 23. the conductive composite (2) of any one of clauses 1 to 22, wherein the thickness of the second elastic polymer layer (8) is in the range of about 0.01mm to about 100 mm.

Clause 24. the conductive composite (2) of any one of clauses 1 to 23, wherein the thickness of the second elastic polymer layer (8) is in the range of about 0.1mm to about 10 mm.

Clause 25. the conductive composite (2) of any of clauses 1-24, wherein the thickness of the conductive fiuidic layer (6) is less than or equal to at least one of the thickness of the first elastic polymer layer (4) and the thickness of the second elastic polymer layer (8).

Clause 26. the conductive composite (2) of any one of clauses 1 to 25, wherein the thickness of the conductive fiuidic layer (6) is greater than at least one of the thickness of the first elastic polymer layer (4) and the thickness of the second elastic polymer layer (8).

Clause 27. the conductive composite (2) of any one of clauses 1 to 26, wherein the thickness of the conductive fiuorofluid layer (6) is greater than the sum of the thickness of the first elastic polymer layer (4) and the thickness of the second elastic polymer layer (8).

Clause 28. the conductive composite (2) of any one of clauses 1 to 27, wherein the conductive fluorine fluid layer (6) is homogeneous.

Clause 29. the conductive composite (2) of any one of clauses 1 to 28, wherein the conductive fluorine fluid layer (6) is heterogeneous.

Clause 30. the conductive composite (2) of any one of clauses 1 to 29, further comprising a reinforcing mesh (10) in contact with the conductive fluorine fluid layer (6).

Clause 31. the conductive composite (2) of clause 30, wherein the reinforcing mesh (10) comprises a fabric.

Clause 32. the conductive composite (2) of clause 30 or 31, wherein the reinforcing mesh (10) comprises at least one of a knit fabric, a woven fabric, and combinations thereof.

Clause 33. the conductive composite (2) of any one of clauses 30 to 32, wherein the reinforcing mesh (10) comprises at least one of a non-conductive fabric, a conductive fabric, and combinations thereof.

Clause 34. the conductive composite (2) of any one of clauses 30 to 33, wherein the reinforcing mesh (10) comprises a non-conductive fabric comprising at least one of a polyether-polyurea copolymer, a latex, a poly-p-phenylene terephthalamide, an aramid, a nylon, a polyester, and combinations thereof.

Clause 35. the conductive composite (2) of any one of clauses 30 to 34, the reinforcing mesh (10) comprising a conductive fabric comprising at least one of conductive filaments, a coated nonconductive fabric, and combinations thereof.

Clause 36. the conductive composite (2) of any one of clauses 30 to 35, wherein the reinforcing mesh (10) comprises a conductive fabric comprising conductive filaments, wherein the conductive filaments comprise at least one of silver filaments, copper filaments, brass filaments, nickel filaments, stainless steel filaments, aluminum filaments, carbon filaments, coated carbon filaments, titanium filaments, tungsten filaments, tin filaments, zinc filaments, and combinations thereof.

Clause 37. the conductive composite (2) of any of clauses 30 to 36, wherein the reinforcing mesh (10) comprises a conductive fabric comprising a coated nonconductive fabric, wherein the coated nonconductive fabric comprises at least one of a metal coated polyether-polyurea copolymer, a metal coated latex, a metal coated poly-p-phenylene terephthalamide, a metal coated aramid, a metal coated nylon, a metal coated polyester, a carbon coated polyether-polyurea copolymer, a carbon coated latex, a carbon coated poly-p-phenylene terephthalamide, a carbon coated aramid, a carbon coated nylon, a carbon coated polyester, and combinations thereof.

Clause 38. the conductive composite (2) of any one of clauses 1 to 37, including an edge length of the elastic polymer surrounding the conductive fiuid layer, the edge length of the elastic polymer sealing the conductive fiuid within the conductive composite.

Clause 39. the conductive composite (2) of any one of clauses 1 to 38, wherein the edge length is greater than or equal to at least one of the thickness of the first elastic polymer layer and the thickness of the second elastic polymer layer.

Clause 40. the conductive composite (2) of any one of clauses 1 to 39, wherein the second elastic polymer layer is bonded to the first elastic polymer layer.

Clause 41. the conductive composite (2) of any one of clauses 1-40, wherein the conductive composite (2) exhibits a minimum sheet resistance of less than about 100 Ohm/sq.

Clause 42. the conductive composite (2) of any one of clauses 1-41, wherein the conductive composite (2) exhibits an elongation at break of greater than or equal to about 10%.

Clause 43. the conductive composite (2) of any one of clauses 1-42, wherein the conductive composite (2) exhibits an elongation at break of greater than or equal to about 15%.

Clause 44. the conductive composite (2) of any one of clauses 1-43, wherein the conductive composite (2) exhibits an elongation at break of greater than or equal to about 50%.

Clause 45. the conductive composite (2) of any one of clauses 1-44, wherein the conductive composite (2) exhibits a tensile strength of greater than or equal to about 3 MPa.

Clause 46. the conductive composite (2) of any one of clauses 1-45, wherein the conductive composite (2) has a density of less than about 7 g/mL.

Clause 47. the conductive composite (2) of any one of clauses 1-46, wherein the conductive composite (2) has a density of less than about 6 g/mL.

Clause 48. the conductive composite (2) of any one of clauses 1 to 47, wherein the conductive composite (2) has a density of less than about 5 g/mL.

Clause 49. the conductive composite (2) of any one of clauses 1-48, wherein the conductive composite (2) has a density of less than about 4 g/mL.

Clause 50. the conductive composite (2) of any of clauses 1-49, wherein the loss modulus (G ") of the conductive fiuidic fluid is greater than the storage modulus (G').

Clause 51 the conductive composite (2) of any one of clauses 1 to 50 is part of an aircraft.

Clause 52. the conductive composite (2) of any one of clauses 1 to 51 is at least a portion of at least one of a wing and a fuselage of an aircraft.

Clause 53 the conductive composite (2) of any of clauses 1-52 is at least one of a seal and a gasket.

Clause 54. a method of making a conductive composite, the method comprising:

forming a first elastic polymer layer;

forming a conductive fluorine fluid layer on the first elastic polymer layer; and

a second elastomeric polymer layer is formed on the conductive fiuidic layer.

Clause 55. the method of clause 54, wherein the step of forming the first elastomeric polymer layer comprises curing the first elastomeric polymer layer.

Clause 56. the method of clause 54 or 55, wherein the step of forming the conductive fluorine fluid layer comprises mixing a fluorinated component and a conductive additive.

Clause 57 the method of any one of clauses 54 to 56, wherein the step of forming the conductive fluorine fluid layer comprises mixing a fluorinated component, a conductive additive, and a compatibilizing agent.

Clause 58. the method of any one of clauses 54 to 57, wherein the step of forming the conductive fluorine fluid layer comprises mixing a fluorinated component, a conductive additive, and an additive that increases thermal oxidation stability.

Clause 59. the method of any one of clauses 54 to 58, wherein the step of forming the conductive fluorine fluid layer comprises mixing the conductive fluorine fluid using at least one of shear mixing and centrifugal mixing.

Clause 60. the method of any one of clauses 54 to 59, wherein the step of forming the conductive fluorine fluid layer comprises mixing the conductive fluorine fluid using shear mixing, wherein the shear mixing is performed at a rotational speed of about 25 to about 2,000 rpm.

Clause 61. the method of any one of clauses 54 to 60, wherein the step of forming the conductive fluorine fluid layer comprises mixing the conductive fluorine fluid using shear mixing, wherein the shear mixing is performed at a rotational speed of about 25 to about 125 rpm.

Clause 62. the method of any one of clauses 54 to 61, wherein the step of forming the conductive fluorine fluid layer comprises infiltrating a reinforcing mesh with the conductive fluorine fluid layer.

Clause 63. the method of any one of clauses 54 to 62, wherein the step of forming the second elastomeric polymer layer comprises curing the second elastomeric polymer layer.

Clause 64. the method of clause 63, wherein the step of curing the second elastomeric polymer layer comprises bonding the second elastomeric polymer layer to the first elastomeric polymer layer.

Clause 65 the method of any one of clauses 54 to 64, wherein the first elastic polymer layer and the second elastic polymer layer encapsulate the conductive fiuidic layer.

Clause 66. the method of any one of clauses 54 to 65, further comprising trimming the conductive composite around the conductive fiuidic layer.

Clause 67 the method of any one of clauses 54 to 66, wherein trimming the conductive composite around the conductive fiuidic layer leaves an edge length around the conductive fiuidic layer, thereby sealing the conductive fiuidic in the conductive composite.

Clause 68. the method of clause 67, wherein the edge length is greater than or equal to at least one of the thickness of the first elastic polymer layer and the thickness of the second elastic polymer layer.

As shown in fig. 5, aircraft 1002 produced by example method 1000 may include an airframe 1018 with a plurality of systems 1020 and an interior 1022. Examples of the plurality of systems 1020 may include one or more of a propulsion system 1024, an electrical system 1026, a hydraulic system 1028, and an environmental system 1030. Any number of other systems may be included. The conductive composite of the present disclosure may be used in any system of aircraft 1002.

While various examples of the disclosed conductive composites and methods for making conductive composites have been shown and described, modifications may occur to those skilled in the art upon reading the specification. This application includes such modifications and is limited only by the scope of the claims.