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US5382384A
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US
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Conductive polymer composition
Assignee: Raychem Corp
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Filing: 1993-06-29
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Granted: 1995-01-17
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Expires: 2013-06-29
Abstract
Abstract A conductive polymer composition in which a particulate conductive filler is dispsered in a polymeric component which is a mixture of an essentially amorphous thermoplastic resin and a thermosetting resin. In preferred compositions, the amorphous thermoplastic resin and the thermosetting resin are substantially mutually soluble. In order to improve the thermal stability of the composition on exposure to successive thermal cycles, it is preferred that the composition be cured by heating the uncured mixture of amorphous thermoplastic resin, thermosetting resin, and particulate conductive filler at a rate of at least 15° C./minute to the cure temperature.
Inventors
- 👤 Stephen Baigrie
- 👤 Edward F. Chu
- 👤 George B. Park
- 👤 Vijay N. Reddy
- 👤 James A. Rinde
- 👤 Robert P. Saltman
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 13:05
CPC Classifications
H; H01; H01B; H01B1/00; H01B1/20; H01B1/22; C; C08; C08K; C08K3/00; C08K3/02; C08K3/04; C08K3/08; H01B1/24; H01C; H01C7/00; H01C7/02; H01C7/027
Claims Analysis
Total Claims: 17
Claim 1
Independent Claim
152 words
A process for preparing a conductive polymer composition, said process comprising (1) mixing together to form a mixture (A) a polymeric component which comprises (i) 10 to 75 parts by weight of the total polymer component of an essentially amorphous thermoplastic resin, and (ii) 90 to 25 parts by weight of the total polymeric component of a thermosetting resin, (B) a curing agent which has a curing temperature T cure , and (C) a particulate conductive filler dispersed in the polymeric component which is 5 to 65% by volume of the polymeric component; (2) shaping the mixture at a temperature less than T cure to form a shaped mixture; and (3) heating the shaped mixture at a rate of at least 15° C./minute to a temperature of at least T cure and maintaining the shaped mixture at the temperature of at least T cure for a time sufficient to cure the mixture.
Claim 2
Dependent Claim
152 words
A process for preparing a conductive polymer composition, said process comprising (1) mixing together to form a mixture (A) a polymeric component which comprises (i) 10 to 75 parts by weight of the total polymer component of an essentially amorphous thermoplastic resin, and (ii) 90 to 25 parts by weight of the total polymeric component of a thermosetting resin, (B) a curing agent which has a curing temperature T cure , and (C) a particulate conductive filler dispersed in the polymeric component which is 5 to 65% by volume of the polymeric component; (2) shaping the mixture at a temperature less than T cure to form a shaped mixture; and (3) heating the shaped mixture at a rate of at least 15° C./minute to a temperature of at least T cure and maintaining the shaped mixture at the temperature of at least T cure for a time sufficient to cure the mixture.
Claim 3
Dependent Claim
15 words
A process according to claim 1 wherein the heating rate is at least 30° C./minute.
Claim 4
Dependent Claim
19 words
A process according to claim 1 wherein the heating step is conducted while the shaped mixture is under pressure.
Claim 5
Dependent Claim
15 words
A process according to claim 2 wherein the heating rate is at least 40° C./minute.
Claim 6
Dependent Claim
14 words
A process according to claim 1 wherein the mixture is shaped by compression molding.
Claim 7
Dependent Claim
19 words
A process according to claim 1 wherein the amorphous thermoplastic resin and the thermosetting resin are substantially mutually soluble.
Claim 8
Dependent Claim
14 words
A process according to claim 1 wherein the conductive polymer composition exhibits PTC behavior.
Claim 9
Dependent Claim
14 words
A process according to claim 1 wherein the particulate conductive filler comprises carbon black.
Claim 10
Dependent Claim
14 words
A process according to claim 1 wherein the particulate conductive filler comprises a metal.
Claim 11
Dependent Claim
187 words
A process for preparing an electrical device which comprises a conductive polymer composition, said process comprising (A) preparing a resistive element which comprises a conductive polymer by (1) mixing together to form a mixture of the conductive polymer composition (a) a polymeric component which comprises (i) 10 to 75 parts by weight of the total polymeric component of an essentially amorphous thermoplastic resin, and (ii) 90 to 25 parts by weight of the total polymeric component of a thermosetting resin, (b) a curing agent which has a curing temperature T cure , and (c) a particulate conductive filler dispersed in the polymeric component which is 5 to 65% by volume of the polymeric component; (2) shaping the mixture at a temperature less than T cure to form a shaped mixture; and (3) heating the shaped mixture at a rate of at least 15° C./minute to a temperature of at least T cure and maintaining the shaped mixture at the temperature of at least T cure for a time sufficient to cure the mixture and form the resistive element, and (B) attaching two electrodes to the resistive element.
Claim 12
Dependent Claim
187 words
A process for preparing an electrical device which comprises a conductive polymer composition, said process comprising (A) preparing a resistive element which comprises a conductive polymer by (1) mixing together to form a mixture of the conductive polymer composition (a) a polymeric component which comprises (i) 10 to 75 parts by weight of the total polymeric component of an essentially amorphous thermoplastic resin, and (ii) 90 to 25 parts by weight of the total polymeric component of a thermosetting resin, (b) a curing agent which has a curing temperature T cure , and (c) a particulate conductive filler dispersed in the polymeric component which is 5 to 65% by volume of the polymeric component; (2) shaping the mixture at a temperature less than T cure to form a shaped mixture; and (3) heating the shaped mixture at a rate of at least 15° C./minute to a temperature of at least T cure and maintaining the shaped mixture at the temperature of at least T cure for a time sufficient to cure the mixture and form the resistive element, and (B) attaching two electrodes to the resistive element.
Claim 13
Dependent Claim
15 words
A process according to claim 10 wherein the heating rate is at least 30° C./minute.
Claim 14
Dependent Claim
15 words
A process according to claim 11 wherein the heating rate is at least 40° C./minute.
Claim 15
Dependent Claim
19 words
A process according to claim 10 wherein the heating step is conducted while the shaped mixture is under pressure.
Claim 16
Dependent Claim
15 words
A process according to claim 10 wherein the electrical device is a circuit protection device.
Claim 17
Dependent Claim
13 words
A process according to claim 10 wherein the electrical device is a heater.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1998-01-16 | 1998-07-18 | 1999-01-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-01-16 | 2002-07-18 | 2003-01-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-01-16 | 2006-07-18 | 2007-01-17 | $7700.00 | Window Closed / Lapsed |