Electrically conductive polymer adhesives with complex dimensional filters

1. An electrically conductive polymer composition comprising:

at least one conductive metal filler material comprising a plurality of metal particles having a first aspect ratio;

at least one carbon-based filler material selected from the group consisting of edge-functionalized graphene, exfoliated natural graphene, edge-functionalized exfoliated natural graphite, and combinations thereof having a size in a shortest dimension of from about 0.3 nm to about 50 nm and a second aspect ratio wherein said second aspect ratio is from more than 10,000 to about 10 8 ; and

a polymer matrix;

wherein said second aspect ratio is at least ten times greater than said first aspect ratio.

2. The electrically conductive polymer composition of claim 1 wherein the difference between said first aspect ratio and said second aspect ratio is from about 10 to about 1×10 8 .

3. The electrically conductive polymer composition of claim 1 wherein the difference between said first aspect ratio and said second aspect ratio is from about 10,000 to about 1×10 8 .

4. The electrically conductive polymer composition of claim 1 wherein said conductive metal filler material comprises a metal selected from the group consisting of silver, silver flakes, copper, aluminum, silver coated metal, silver coated nickel, silver coated copper, silver coated aluminum, and combinations thereof.

5. The electrically conductive polymer composition of claim 1 wherein said conductive metal filler material comprises silver flakes.

6. The electrically conductive polymer composition of claim 1 wherein said first aspect ratio is from about 1 to about 10.

7. The electrically conductive polymer composition of claim 1 wherein the mean particle size of said conductive metal filler material is from about 1 μm to about 1000 μm.

8. The electrically conductive polymer composition of claim 1 wherein said carbon-based filler material is less than 50 nanometers long in at least one dimension.

9. The electrically conductive polymer composition of claim 1 wherein said polymer matrix comprises a substantially non-conductive polymer selected from the group consisting of polydimethylsiloxane, epoxy, polyacrylates, polymethacrylates, polyurethanes, and combinations thereof.

10. The electrically conductive polymer composition of claim 1 wherein said polymer matrix comprises polydimethylsiloxane.

11. The electrically conductive polymer composition of claim 1 wherein the carbon-based filler material has a percolation threshold of from about 0.001% to about 2%.

12. The electrically conductive polymer composition of claim 11 wherein the carbon-based filler material has a percolation threshold of less than 0.1%.

13. The electrically conductive polymer composition of claim 1 wherein said conductive metal filler material comprises less than about 16% percent of said electrically conductive polymer by volume.

14. A method of forming the electrically conductive polymer composition of claim 1 comprising:

A) preparing or obtaining at least one conductive metal filler material comprising a plurality of metal particles having a first aspect ratio;

B) preparing or obtaining at least one carbon-based filler material selected from the group consisting of edge-functionalized graphene, exfoliated natural graphene, edge-functionalized exfoliated natural graphite, and combinations thereof, said carbon-based filler material having a second aspect ratio, wherein said second aspect ratio is at least ten times greater than said first aspect ratio;

C) preparing or obtaining a substantially non-conductive polymer, said substantially non-conductive polymer comprising a polymer base;

D) combining said carbon-based filler material and said polymer base and mixing to distribute said carbon-based filler material throughout said polymer base;

E) adding said conductive metal filler material having to the mixture of step D, wherein said conductive metal filler material comprises less than 15% of the total volume of the mixture;

F) mixing to distribute said carbon-based filler material throughout said polymer base; and

G) curing the mixture to produce the electrically conductive polymer composition of claim 1 .

15. The method of claim 14 further comprising:

H) adding a quantity of solvent to the mixture of step E to facilitate distribution of the carbon-based filler material throughout said polymer base; and

I) removing said solvent by evaporation.

16. The method of claim 14 wherein the step of adding said conductive metal filler material (step E) further comprises adding a curing agent for said polymer base to the mixture of claim D.

17. The method of claim 14 wherein said conductive metal filler material comprises particles of a conductive metal selected from the group consisting of silver, silver flakes, copper, aluminum, silver coated metal, silver coated nickel, silver coated copper, silver coated aluminum, and combinations thereof.

18. The method of claim 14 wherein said carbon-based filler material is edge-functionalized exfoliated natural graphite.

19. The method of claim 14 wherein said substantially non-conductive polymer is selected from the group consisting of polydimethylsiloxane, epoxies, polyacrylates, polymethacrylates, polyurethanes, and combinations thereof.

20. The method of claim 14 wherein the step of mixing to distribute said carbon-based filler material throughout said polymer base is performed using a planetary mixer.

21. An electrically conductive polymer comprising:

from about 5 vol % to about 15 vol % of at least one conductive metal filler material comprising silver flakes having a first aspect ratio of from about 1 to about 10 and a particle size of from about 1 μm to about 1000 μm;

from about 0.001 wt % to about 8 wt % of one or more carbon-based filler material comprising at least one of multi-walled carbon nanotubes having a second aspect ratio of from more than 10,000 to about 10 8 and a particle size in a shortest dimension of from about 1 to about 50 nm and an edge-functionalized exfoliated natural graphite having a third aspect ratio of from more than 10,000 to about 10 8 and a particle size in a shortest dimension of from about 0.3 nm to about 20 nm; and

from about 75 vol % to about 95 vol % of a polymer matrix selected from the group consisting of polydimethylsiloxane, epoxies, polyacrylates, polymethacrylates, polyurethanes, and combinations thereof;

wherein said conductive metal filler material comprising silver flakes and said at least one of multi-walled carbon nanotubes or edge-functionalized exfoliated natural graphite are homogeneously distributed throughout said polymer matrix, and

wherein said second or third aspect ratio is at least 10 times larger than said first aspect ratio.