Method of forming and processing conductive polymer composites

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252518, B32B 516

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active

052215792

ABSTRACT:
A processable thermoplastic conductive composite resin is formed by coating polypyrrole onto the surface of microbeads by in situ oxidative polymerization. The microbeads, generally having an average diameter from about 0.5 to about 500 microns, are coated with polypyrrole by combining pyrrole, oxidizing agent and the beads in a protic solvent such as water, methanol, ethanol, ethylene glycol and the like. The pyrrole polymerizes on the surface of the microbeads. The microbeads, which are thermoplastic, can then be processed and the conductivity of the processed polymer remains high, generally about 0.1 to about 10 S/cm. This is suitable for use as a conductive film. By incorporating a sulfonate counterion, the conductivity of the composite is significantly improved. Further, by incorporating a heat activated cross-linking agent such as a peroxide, the tensile strength of the processed polymer is significantly improved.

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