Compositions – Electrically conductive or emissive compositions
Reexamination Certificate
2001-09-28
2004-10-05
Kopec, Mark (Department: 1751)
Compositions
Electrically conductive or emissive compositions
C264S104000
Reexamination Certificate
active
06800221
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a conducting polymer blend and to a process for the preparation thereof. More particularly, the present invention relates to a conductive polymer blend of a major amount of a polyketone polymer and a substantially lesser amount of conducting additive.
BACKGROUND OF THE INVENTION
Electrically conductive materials are of major industrial as well as scientific interest owing to their wide applications in modern electronics and related areas. Conductive materials based on polymers are of even more interest. A particular advantage of polymer based conductive materials is that they exhibit electromagnetic properties similar to metals and also retain their more desirable polymer properties, in particular physical and mechanical properties. Due to their ease of processing, the conducting materials based on polymers are ideal candidates for fabrication of articles intended to facilitate electrostatic discharge such as parts used in home appliances, computers, electronics, and electrical equipment, Unfortunately, not all polymers exhibit enough conductivity as required for some applications. Polyketones for example are relatively recent high performance engineering thermoplastics with established utility in many technologically attractive areas such as the automotive industry. Due to their excellent engineering properties, it would be highly desirable to use materials based on polyketone polymers in a variety of other applications such as electronic instruments, parts of computers and other household appliances. All these and similar applications are expected to facilitate electric discharge in order to prevent electric shock or sparking. A major disadvantage that results in the limited use of polyketone containing materials in such applications is that polyketones are relatively low conducting polymers with conductivities to the order of 10
−13
s/cm or less.
Conducting polyketone materials have been obtained in the prior art by means of blends containing polyketone polymer and inorganic conductive additive such as carbon fiber, metal powder and the like (Byrd, U.S. Pat. No. 5,256,335, to Shell Oil Company). The preparation of polyketone containing conducting materials using even cheaper conductive additives would be a significant advance in the current sate of the art.
The authors of the present invention have comprehensively investigated the possible use of a variety of simple conductive additive materials that can be used in low amounts and still provide better conductive polyketone blends.
OBJECTS OF THE INVENTION
The main object of the invention is to provide a conductive polymer blend comprising of polyketone polymer and a conducting organic polymer.
It is another object of the invention to provide polyketone containing conducting materials using inexpensive conductive additives rendering such blends more economical to manufacture.
Another object of the invention is to provide a process for the preparation of polyketone containing conducting materials using inexpensive conductive additives.
SUMMARY OF THE INVENTION
The present invention provides a conductive polymer blend comprising of polyketones and a conducting organic polymer additive.
Accordingly, the present invention provides a conductive polymer blend comprising of a major amount of a polyketone polymer and a minor amount of a conducting organic polymer as additive.
In one embodiment of the invention, the polyketone polymer is a linear alternating polymer of carbon monooxide and at least one ethylenically unsaturated hydrocarbon.
In another embodiment of the invention, the polyketone polymer is a polymer of the general formula —[—CO—(P—)—]
n
—[CO—(Q)—]
m
wherein n and m are both >0 and P and Q independently consist of unsaturated hydrocarbons selected from the group consisting of ethylene, propylene, styrene, hexene, 1-butene and norbornadiene.
In another embodiment of the invention, the conducting polymer additive is selected from the group consisting of substituted or unsubstituted polyanilines, polyacetylenes, polyvinylpyrrolidine, polyazines, polythiophenes polyphenylene sulfides and polyselenophenes.
In a further embodiment of the invention, the conducting organic polymer is doped with onium salts, iodonium salts, borate salts, organic or inorganic acids or their salts.
The present invention also relates to a process for the preparation of a conductive polymer blend comprising of a major amount of polyketone polymer and a minor amount of a conducting organic polymer additive, said process comprising incorporating the conducting material into the polyketone matrix to uniformly diffuse it therein.
In one embodiment of the invention, the blends are prepared by incorporating the conducting organic polymer additive by melt mixing or solution mixing.
In one embodiment of the invention, the polyketone polymer is a linear alternating polymer of carbon monooxide and at least one ethylenically unsaturated hydrocarbon.
In another embodiment of the invention, the polyketone polymer is a polymer of the general formula —[—CO—(P—)—]
n
—[CO—(Q)—]
m
where n and m are both >0 and P and Q independently consist of unsaturated hydrocarbons selected from the group consisting of ethylene, propylene, styrene, hexene, 1-butene and norbornadiene.
In another embodiment of the invention, the conducting polymer additive is selected from the group consisting of substituted or unsubstituted polyanilines, polyacetylenes, polyvinylpyrrolidine, polyazines, polythiophenes, polyphenylene sulfides and polyselenophenes.
In a further embodiment of the invention, the conducting organic polymer is doped with onium salts, iodonium salts, borate salts, organic or inorganic acids or their salts.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a method for the preparation of conducting polyketone blends consisting of a major amount of polyketone polymer and a minor amount of a conducting additive, preferably a conducting organic polymer.
The polyketone polymers employed in the present invention are preferably linear alternating polymers of carbon monoxide with ethylenically unsaturated hydrocarbons and are represented by the general formula —[—CO—(P—)—]
n
—[CO—(Q)—]
m
where n and m are both >0 and P and Q independently consist of unsaturated hydrocarbons. The ethylenically unsaturated hydrocarbons used may have up to 25 carbon atoms although those having less than 10 carbon atoms are preferred. Examples of such ethylenically unsaturated hydrocarbons include ethylene and other &agr;-olefins such as propylene, 1-butene, 1-hexene, 1-dodecene, and the like. Also suitable are other unsaturated hydrocarbons which have an aryl substituent on an otherwise aliphatic molecule particularly, with an aliphatic or aryl substituent on the carbon atom of the ethylene unsaturation. Examples of the latter class of ethylenically unsaturated hydrocarbons include styrene, 4-methylstyrene, 4-ethylstyrene, and the like. Compounds comprising one of more heteroatoms such as vinyl acetate, methyl methacrylate, acrylonitrile and the like may also be employed. When copolymers are employed, there is no third unsaturated hydrocarbon added. Examples of such polyketone polymers include (ethylene —CO)
n
, (propylene —CO)
n
, (styrene —CO)
n
and the like. Examples of preferred ter-polymers include [(ethylene-(CO)
n
-(propylene —CO)
m
] and the like. In case of ter-polymers, the individual —(—P—CO—)— and —(—Q—CO—)— units may be randomly distributed throughout may be randomly distributed throughout the polymer chain and do not appear to influence the polymer properties to a considerable extent.
Such perfectly alternating polyketones can be prepared using documented literature procedures. For example, U.S. Pat. No. 4,843,144, which is incorporated herein by reference provides a method for the preparation of alternating copolymers of carbon monoxide with at least one ethylenically unsaturated hydrocarbon by using a catalyst based on G
Chaudhari Raghunath Vitthal
Jog Jyoti Prakash
Kulkarni Shrikant Madhukar
L Priya
Burns Doane Swecker & Mathis L.L.P.
Council of Scientific and Industrial Research
Kopec Mark
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