FLEXIBLE CONDUCTIVE POLYMERIC SHEET
An electrically conductive article including a substrate and at least one electrically conductive layer disposed on the substrate. The conductive layer may include a thermoplastic resin and from about 1 to 30 weight percent of at least one conductive additive based on a total weight of the thermoplastic resin and the at least one conductive additive. The conductive article may have a surface resistance between 0.001 to 20Ω at a test distance of 2.54 cm (1 inch).
1 . An electrically conductive article, comprising:
a substrate;
at least one electrically conductive layer disposed on the substrate;
wherein the conductive layer comprises:
a thermoplastic resin; and
from about 1 to 30 weight percent of at least one conductive additive based on a total weight of the thermoplastic resin and the at least one conductive additive; and
wherein the conductive article has a surface resistance between 0.001 to 20Ω at a test distance of 2.54 cm (1 inch).
2 . The electrically conductive article of claim 1 , wherein the electrically conductive article has a surface resistance between 0.001 and 12Ω at a test distance of 5.08 cm (2 inches).
3 . The electrically conductive article of claim 1 , wherein the thermoplastic resin comprises a styrene-butadiene copolymer; a polyethylene homopolymer, copolymer, or multi-block interpolymer; a polypropylene homopolymer, copolymer, or multi-block interpolymer; and mixtures thereof.
4 . The electrically conductive article of claim 1 , wherein the at least one electrically conductive additive comprises at least one of a graphite, a metal, a metal oxide, and mixtures thereof.
5 . The electrically conductive article of claim 4 , wherein the at least one electrically conductive additive comprises particles having an acicular shape.
6 . The electrically conductive article of claim 1 , wherein the at least one electrically conductive additive comprises a mixture of titanium dioxide and antimony-doped tin oxide.
7 . The electrically conductive article of claim 6 , wherein the mixture of titanium dioxide and antimony-doped tin oxide comprises particles having an acicular shape.
8 . The electrically conductive article of claim 7 , wherein the acicular particle has an aspect ratio of at least 11.
9 . The electrically conductive article of claim 1 , wherein the conductive additive comprises conductive particles having an average particle size of 10 microns or less.
10 . The electrically conductive article of claim 1 , wherein the substrate comprises a non-woven textile.
11 . The electrically conductive article of claim 1 , comprising:
a first electrically conductive layer disposed on a first side of the substrate; and
a second electrically conductive layer disposed on a second side of the substrate;
wherein the substrate is apertured, porous, or calendered, and wherein the first electrically conductive layer conductively connects with the second electrically conductive layer.
12 . The conductive article of claim 11 , wherein the first electrically conductive layer has a greater surface resistance than the second electrically conductive layer.
13 . A method of making an electrically conductive article, the method comprising:
applying at least one electrically conductive layer to a substrate;
wherein the electrically conductive layer comprises:
a thermoplastic resin; and
at least one electrically conductive additive, wherein the conductive additive comprises from about 1 to 30 percent of a total weight of the thermoplastic resin and the at least one conductive additive; and
wherein the conductive article has a surface resistance between 0.001 to 20Ω at a test distance of 2.54 cm (1 inch).
14 . The method of claim 13 , wherein the electrically conductive article has a surface resistance between 0.001 and 12Ω at a test distance of 5.08 cm (2 inches).
15 . The method of claim 13 , wherein the thermoplastic resin comprises a styrene-butadiene copolymer; a polyethylene homopolymer, copolymer, or multi-block interpolymer; a polypropylene homopolymer, copolymer, or multi-block interpolymer; and mixtures thereof.
16 . The method of claim 13 , wherein the at least one electrically conductive additive comprises at least one of a graphite, a metal, a metal oxide, and mixtures thereof.
17 . The method of claim 13 , wherein the at least one electrically conductive additive comprises a mixture of titanium dioxide and antimony-doped tin oxide.
18 . The method of claim 17 , wherein the mixture of titanium dioxide and antimony-doped tin oxide comprises particles having an acicular shape.
19 . The method of claim 18 , wherein the acicular particle has an aspect ratio of at least 11.
20 . The method of claim 13 , wherein the electrically conductive additive comprises conductive particles having an average particle size of 10 microns or less.
21 . The method of claim 13 , wherein the substrate comprises a non-woven.
22 . The method of claim 13 , wherein the substrate comprises at least one of a fiber, a film, a foam, a woven, a fabric, a bicomponent fiber, a multi-layer film, a metal, a textile, and a ceramic.
23 . The method of claim 13 , further comprising:
applying a first electrically conductive layer to a first side of the substrate; and
applying a second electrically conductive layer to a second side of the substrate;
wherein the substrate is apertured, porous, or calendered, and wherein the first electrically conductive layer conductively connects with the second conductive layer.
24 . The method of claim 23 , wherein the first electrically conductive layer has a greater surface resistance than the second electrically conductive layer.
25 . The method of claim 13 , wherein the applying an electrically conductive layer comprises:
coating or impregnating a substrate with an aqueous dispersion comprising the thermoplastic resin, the electrically conductive additive, a dispersion stabilizing agent, and water; and
removing at least a portion of the water to form the electrically conductive layer.
26 . The method of claim 13 , wherein the applying an electrically conductive layer comprises:
coating or impregnating a substrate with a froth comprising the thermoplastic resin, the electrically conductive additive, a frothing surfactant, and water; and
removing at least a portion of the water to form the electrically conductive layer.
27 . An aqueous dispersion comprising:
a thermoplastic resin;
at least one stabilizing agent;
at least one electrically conductive additive; and
water.
28 . The aqueous dispersion of claim 27 , wherein the thermoplastic resin comprises a styrene-butadiene copolymer; a polyethylene homopolymer, copolymer, or multi-block interpolymer; a polypropylene homopolymer, copolymer, or multi-block interpolymer; and mixtures thereof.
29 . The aqueous dispersion of claim 27 , wherein the at least one electrically conductive additive comprises from about 1 to 30 percent of a total weight of the thermoplastic resin, the at least one stabilizing agent, and the at least one electrically conductive additive.
30 . The aqueous dispersion of claim 27 , wherein the at least one electrically conductive additive comprises at least one of a graphite, a metal, a metal oxide, and mixtures thereof.
31 . The aqueous dispersion of claim 27 , wherein the at least one electrically conductive additive comprises a mixture of titanium dioxide and antimony-doped tin oxide.