Electrically conductive compositions and method of manufacture thereof

1. A method of manufacturing an electrically conductive composition comprising:

reducing the viscosity of a molten masterbatch to form a reduced viscosity molten masterbatch; and

mixing the reduced viscosity molten masterbatch with a polymer to form the electrically conductive composition.

2. The method of claim 1 , wherein the viscosity of the molten masterbatch is reduced by mixing it with a diluent, a plasticizer, a polymer having a melt viscosity that is lower than the viscosity of the molten masterbatch, or a combination thereof.

3. A method of manufacturing an electrically conductive composition comprising:

mixing a molten masterbatch with a first polymer in a first extruder, wherein the first polymer has a melt viscosity that is lower than the melt viscosity of the molten masterbatch;

reducing the melt viscosity of the molten masterbatch to form a reduced viscosity molten masterbatch; and

mixing the reduced viscosity molten masterbatch with a second polymer in a second extruder to form the electrically conductive composition.

4. The method of claim 3 , wherein the molten masterbatch comprises a polymer and an electrically conductive filler.

5. The method of claim 4 , wherein the electrically conductive filler is carbon black, carbon nanotubes, carbon fibers, metallic fillers, non-conductive fillers coated with metallic coatings, electrically conductive non-metallic fillers, or a combination comprising at least one of the foregoing electrically conductive fillers.

6. The method of claim 5 , wherein the carbon nanotubes are single wall carbon nanotubes, multiwall carbon nanotubes, vapor grown carbon fibers, or a combination comprising at least one of the foregoing carbon nanotubes.

7. The method of claim 4 , wherein the molten masterbatch comprises up to about 50 wt % of the electrically conductive fillers, based on the weight of the molten masterbatch.

8. The method of claim 3 , wherein the first extruder is a side compounder to the second extruder.

9. The method of claim 3 , wherein the first polymer is the same as the second polymer.

10. The method of claim 3 , wherein the first polymer is different from the second polymer.

11. The method of claim 3 , wherein the first polymer and the second polymer are compatibilized in the electrically conductive composition.

12. The method of claim 3 , wherein the first polymer and/or the second polymer is a thermoplastic, a thermoset, or a combination of a thermoplastic with a thermoset.

13. The method of claim 3 , wherein the first polymer and/or the second polymer is a

polyacetal, a polyacrylic, a polyarylene ether, a polycarbonate, a polystyrene, a polyester, a polyamide, a polyamideimide, a polyarylate, a polyurethane, a polyarylsulfone, a polyethersulfone, a polyarylene sulfide, a polyvinyl chloride, a polyetherimide, a polyimide, a polytetrafluoroethylene, a polyetherketone, a polyether ether ketone or a combination comprising at least one of the foregoing polymeric resins.

14. The method of claim 3 , wherein the first polymer is a polyamide and wherein the second polymer is a polyarylene ether.

15. The method of claim 3 , wherein the electrically conductive composition comprises a compatibilizer and an impact modifier.

16. The method of claim 3 , wherein the electrically conductive composition has a specific volume resistivity of less than or equal to about 10e 8 ohm-cm, a notched Izod impact strength of greater than 10 kilojoules/square meter and a Class A surface finish.

17. The method of claim 3 , wherein the electrically conductive composition has a specific volume resistivity of less than or equal to about 10e 8 ohm-cm and a notched Izod impact strength of greater than 15 kilojoules/square meter.

18. A method of manufacturing an electrically conductive composition comprising:

mixing a molten masterbatch with a polyamide in a first extruder, wherein the polyamide has a melt viscosity that is lower than the melt viscosity of the molten masterbatch;

reducing the melt viscosity of the molten masterbatch to form a reduced viscosity molten masterbatch; and

mixing the reduced viscosity molten masterbatch with a polyarylene ether in a second extruder to form the electrically conductive composition.

19. The method of claim 18 , wherein the molten masterbatch comprises a polyamide and carbon nanotubes.

20. The method of claim 18 , wherein the polyarylene ether is compatibilized with a polyamide prior to the mixing with the reduced viscosity molten masterbatch.

21. The method of claim 18 , further comprising molding the electrically conductive composition.