Thermal overload device containing a polymer composition containing thermally exfoliated graphite oxide and method of making the same

1. A thermal overload protective device, comprising:

a conductive composition comprising:

a polymer matrix; and

thermally exfoliated graphite oxide configured to:

comprise a surface area of from about 300 m 2 /g to 2,600 m 2 /g;

display no signature of graphite and no signature of graphite oxide, as determined by X-ray diffraction; and

comprise a wrinkle topology at the nanoscale that mechanically interlocks with the polymer matrix;

wherein the conductive composition is configured to undergo an event when the conductive composition receives a threshold amount of heat or a current;

wherein the event comprises at least one member selected from the group consisting of an expansion of the polymer matrix and a decrease in electrical conductivity.

2. The thermal overload protective device of claim 1 , wherein the thermally exfoliated graphite oxide has a bulk density of from about 40 kg/m 3 to 0.1 kg/m 3 .

3. The thermal overload protective device of claim 1 , wherein the thermally exfoliated graphite oxide has a C/O ratio of from about 60/40 to 95/5.

4. The thermal overload protective device of claim 1 , wherein the polymer matrix comprises a polymer selected from the group consisting of polyethylene, polypropylene and copolymers thereof, polyesters, nylons, polystyrenes, polycarbonates, polycaprolactones, polycaprolactams, fluorinated ethylenes, polyvinyl acetate and its copolymers, polyvinyl chloride, polymethylmethacrylate and acrylate copolymers, high impact polystyrene, styrenic sheet molding compounds, polycaprolactones, polycaprolactams, fluorinated ethylenes, styrene acrylonitriles, polyimides, epoxys, polyurethanes, poly[4,4′-methylenebis(phenyl isocyanate)-alt-1,4-butanediol/poly(butylene adipate)], poly[4,4′-methylenebis(phenyl isocyanate)-alt-1,4-butanediol/poly(butylene adipate)], poly[4,4′-methylenebis(phenyl isocyanate)-alt-1,4-butanediol/poly(butylene adipate)], poly[4,4′-methylenebis(phenyl isocyanate)-alt-1,4-butanediol/di(propylene glycol)/polycaprolactone, poly[4,4′-methylenebis(phenyl isocyanate)-alt-1,4-butanediol/polytetrahydrofuran, amine terminated polybutadienes, carboxyl terminated polybutadienes, polybutadiene, dicarboxy terminated butyl rubber, styrene/butadiene copolymers, polyisoprene, poly(styrene-co-butadiene), polydimethysiloxane, and natural latex rubber.

5. The thermal overload protective device of claim 1 , wherein the conductive composition comprises a thermally exfoliated graphite oxide loading level of 0.1 to 90% by weight based on the total weight of the conductive composition.

6. The thermal overload protective device of claim 1 , wherein the event further comprises a loss of percolation of the thermally exfoliated graphite oxide.

7. A method for making a thermal overload protective device, comprising the step of:

pattering the thermal overload protective device by application of a fluid comprising:

a polymer;

a solvent; and

a modified graphite oxide material, comprising:

thermally exfoliated graphite oxide comprising:

a surface area of from about 300 m 2 /g to 2,600 m 2 /g;

an X-ray diffraction pattern that displays no signature of graphite and no signature of graphite oxide; and

a wrinkled topology at the nanoscale that mechanically interlocks with the polymer;

wherein the fluid is configured to form a conductive composition, the conductive composition configured to undergo an event when the conductive composition receives heat or a current, the event comprising at least one member selected from the group consisting of an expansion of the polymer matrix and a decrease in electrical conductivity.

8. The method of claim 7 , further comprising drying the fluid.

9. The method of claim 7 , wherein the thermally exfoliated graphite oxide has a bulk density of from about 40 kg/m 3 to 0.1 kg/m 3 .

10. The method of claim 7 , wherein the thermally exfoliated graphite oxide has a C/O ratio of from about 60/40 to 95/5.

11. The method of claim 7 , wherein the polymer comprises material selected from the group consisting of polyethylene, polypropylene and copolymers thereof, polyesters, nylons, polystyrenes, polycarbonates, polycaprolactones, polycaprolactams, fluorinated ethylenes, polyvinyl acetate and its copolymers, polyvinyl chloride, polymethylmethacrylate and acrylate copolymers, high impact polystyrene, styrenic sheet molding compounds, polycaprolactones, polycaprolactams, fluorinated ethylenes, styrene acrylonitriles, polyimides, epoxys, polyurethanes, poly[4,4′-methylenebis(phenyl isocyanate)-alt-1,4-butanediol/poly(butylene adipate)], poly[4,4′-methylenebis(phenyl isocyanate)-alt-1,4-butanediol/poly(butylene adipate)], poly[4,4′-methylenebis(phenyl isocyanate)-alt-1,4-butanediol/poly(butylene adipate)], poly[4,4′-methylenebis(phenyl isocyanate)-alt-1,4-butanediol/di(propylene glycol)/polycaprolactone, poly[4,4′-methylenebis(phenyl isocyanate)-alt-1,4-butanediol/polytetrahydrofuran, amine terminated polybutadienes, carboxyl terminated polybutadienes, polybutadiene, dicarboxy terminated butyl rubber, styrene/butadiene copolymers, polyisoprene, poly(styrene-co-butadiene), polydimethysiloxane, and natural latex rubber.

12. The method of claim 7 , wherein the solvent comprises one or more of water, n-methylpyrolidone (NMP), dimethyformamide (DMF), tetrahydrofuran (THF), an alcohol, a glycol, an aliphatic ester, an aromatic ester, a phthalates, a dibutyl phthalate, a methylene chloride, an acetic ester, an aldehyde, a glycol ether, a propionic ester, and a chlorinated solvent.

13. The method of claim 12 , wherein the glycol comprises one or more of ethylene glycol, propylene glycol, and butylene glycol.

14. The method of claim 7 , wherein the event further comprises a loss of percolation of the thermally exfoliated graphite oxide.

15. The method of claim 7 , wherein the solvent comprises water.