Electrically Conductive Polymers Take Charge!

TAGS:  Electrical & Electronics      New Energy Solutions      Nanotechnologies    

Electrically conductive compounds play a vital role in the modern electronics industry. They provide critical protection for devices against uncontrolled static buildup and discharge and shielding from electromagnetic interference (EMI)/radio frequency interference (RFI). They are also finding application in the developing areas of alternative energy production and storage.

Batteries, fuel cells, and photovoltaics are all areas that present opportunities for electrically conductive plastics.

Other additives are growing in importance, while conductive carbon black (the most traditional way of increasing electrical conductivity) remains the workhorse conductive additive for:

• Plastics compounds
• Carbon nanotubes
• Graphite, and
• Graphene

That is not to write off carbon black, however. The material offers all sorts of advantages. It delivers performance in a highly cost-effective way and carbon black producers continue to make improvements. But not everybody in the market for conductive or antistatic plastics materials and end products wants or can accept the color (or more accurately the lack of it).

Electrically conductive plastic plays an important role in providing low cost protection against ESD or EMI in miniaturized electronic device. As, plastics replace traditional materials, industrial packaging such as flexible IBCs (Intermediate Bulk Containers) for bulk shipping purposes that must be protected from static discharge is also a growth market for ESD additives.

Also, new carbon nanotube production advances by major suppliers has significantly improved supply availability and reduced cost for these key materials.

Let’s check out the latest advances in electrically conductive market in detail…

Nanocyl’s NC7000 MultiWall Carbon NanoTubes (MWCNTs)

Carbon NanoTubes (CNTs) represent the apex of conductivity among all carbon-based materials. Application wise CNTs are critical to continually improve faster-charging EV (Electric Vehicle) batteries.



Nanocyl’s NC7000 MWCNTs-based compounds remain the market leader here over the last decade and a half.

NC7000 industry leading advantages includes:

• Low outgassing capability
• Low conductive particle count
• Enhanced mechanical and electrical properties
• Cleanroom cleanliness certification

Furthermore, NC7000 is capable of being easily injection moldable and sheet thermoformable making it ideal for a myriad of electronic packaging applications such as housings, cable harnesses, and bracket holders.

OCSiAl’s SWCNTs-based Compounds

#1. High Voltage Power Cable Compound

They are ideal for medium to high voltage power cable extruded sheathing covers. Their Tuball Matrix 801 compounds operate in a volume resistivity range starting at 15 ohm·cm (centimeter) at 23°C up to 95 ohm·cm at 90°C. These compounds remain mechanically tough and exhibit very permanent, consistent: Electrical conductivity Attractive cost performance weight reduction, and Very low moisture absorption

OCSiAl SWCNT High Voltage Power Cable Compound

#2. Packaging Containers

Elsewhere, OCSiAl SWCNTs thermoplastic compound systems are making inroads in specialty anti-static packaging applications. A good example here is their Tuball SWCNTs in rotationally molded anti-static containers.

Here, colored PolyEthylene (PE) drums are ideal for storing and more importantly transporting explosive, flammable powders and liquids. Stable and permanent surface resistivities built on their Tuball Matrix 801 concentrate operate in the 10⁶–10⁹ Ohm² (square) range.

More specifically, concentrate 0.07 wt% (weight percents) at 10⁷ Ohm² surface resistivity is perfect for colored tanks, whereas 0.1 wt% at 10⁶ Ohm² resistivities are best for black tanks.

Finally, mechanical toughness is maintained in these concentrate compound systems.

Mackinac Group’s Conductive Thermoplastic PolyUrethane

Novel nanoform thermoplastic conductive compounds are in development by The Mackinac Group.

This technology takes nanosized conductive metal transition materials and grafts them directly into the backbone of the polymer or its side groups as part of the basic polymerization process. In turn, this novel technology approach makes these conductive compounds more controllable and consistent versus traditional compound processing.

Mackinac will commercialize by year end a new Thermoplastic PolyUrethane (TPU) product based on its proprietary nanotechnology processing.

The TPU surface resistivity is a low 10² Ohm² and is available in ester or ether building block versions with transition metal loadings well below 1%.

It is easily extrudable or injection moldable and is targeting end-use applications in automotive, tubing/hose, and packaging.

Colloids’ E-TEC Conductive Compounds

Finally, let’s take a look at Colloids, a specialty compounder and masterbatch supplier focused on static dissipative as well as electrically conductive formulations by expanding its E-Tec product portfolio.

Their particulate-based compounds have surface resistivities in the 10⁹ to less than 10³ Ohm² range accompanied by very good percolation profile curves that indicate very consistent conductivity levels. These E-Tec compounds have ease of processing in injection molding, profile/film/sheet extrusion, thermoforming, and blow molding.

End-use application areas include static dissipative packaging, medical device, and automotive.

Other Developments in Electrically Conductive Polymer Market

• Stress-relieving conductive layers to prevent sparks
  Applications for electrically conductive plastics include stress-relieving conductive layers for power cables, packaging to prevent spark when handling electronic components, battery components, touch displays, and novel electrical EV interior vehicle heating systems. For example, the aim of the EU-sponsored JosPel project is to develop an energy-efficient system for optimizing interior temperature management in electric vehicles (EVs).


• Multiwall carbon nanotubes (MWCNTs) for on-line paintable automobile exterior panels
  Among MWCNT producers, Hyperion has one of the longest application histories in conductive thermoplastics. They started the ball rolling many years ago with the supply of masterbatches based on its MWCNTs (it calls them Fibrils) to GE Plastics (now SABIC) for its Noryl GTX polyamide/polyphe¬nylene ether blend for on-line paintable automobile exterior panels.


• Highly Dispersive, Anti-static MWCNT for ESD protection, conductivity and EMI shielding
  Arkema’s Graphistrength MWCNTs are available as masterbatches in several polymers. One of the big challenges in compounding of nanotubes has been exfoliation – breaking up of the carbon nanotube from the raw agglomerates. Good dispersion is much more readily obtained with the use of Arkema’s masterbatch products. A Graphistrength masterbatch is currently being used commercially in production of 10-micron filaments, which require excellent dispersion. Depending on loading level, the additive can provide antistatic and ESD protection, conductivity and EMI shielding.


• Electrically Conductive Nano-particulate Additive
  In the alternative, electrically conductive, nano forms, CarbonX is developing nano-particulate additive products based on its 3D network of nano fibers.





• Conductive Compounds for Injection Molding of static Dissipative Thick Section Packaging
  Carbon black suppliers still hold the lion’s share of the market for conductive additives by quite some distance. They are continuing to develop products. At Cabot a new addition to the company’s range of conductive compounds has been developed for injection molding of static dissipative thick section packaging. The new Cabelec XS6565A compound is specifically tailored for the growing need in this space of conductive plastics


• AkzoNobel’s Ketjenblack EC superconductive carbon blacks
  They can be used to make conductive compounds at low addition levels compared to conventional conductive carbon blacks. Uses include shoe soles and conductive flooring for cleanrooms and for hospitals with machinery that needs to be grounded, as well as conveyor belts, fuel tanks and hoses, and cables


• Imerys Graphite & Carbon’s Ensaco carbon blacks for unique requirements of low PAH
  They have proven to be a very good solution for demanding applications where their proprietary process enables the controlled production of extremely clean, easily dispersible, low moisture conductive carbon blacks that match the severest purity requirements for low PAH (Polycyclic Aromatic Hydrocarbons) carbon based materials.





• Pre-Elec POK (polyketone) as a replacement for PA and POM in multi-layer fuel system components
  Finnish specialty conductive compound maker Premix recently extended its product slate with the introduction of an electrically conductive polyketone (PK), which it is targeting at fuel filler and system component applications. Their Pre-Elec POK grade benefits from the very low gasoline permeation of PK and can be used as a replacement for PA and POM in multi-layer fuel system components.


• IonPhasE’s anti-static additives to prevent damage to electrical components
  Croda International recently acquired Finnish company IonPhasE, a supplier of static electricity protection products with a unique range of anti-static additives that help to prevent damage to electrical components, increase the safety of chemical and food packaging and improve the long-term appearance of consumer appliances. IonPhasE’s inherently dissipative polymers (IDPs) release static electricity in a controlled way and are a natural extension to its own product portfolio.

IonPhasE IPE anti-static additives release static electricity in a controlled way


• ElectriPlast’s conductive compounds are used in EMI/RFI shielding
  Their conductive compounds are used in EMI/RFI shielding, such as for battery charger cases and covers. Their materials were selected for a high voltage connector retainer in the Karma Revero plug-in hybrid electric vehicle. This is the first car to be sold in the US using a combination of electricity, gasoline and solar power (the vehicle is equipped with a solar roof that charges the 12V and high voltage batteries). The connector retainer holds the cable seals in place, limits cable movement, and provides EMI/RFI shielding


• Graphene 3D Lab
  Graphene 3D Lab sees potential for the application of highly electrically conductive graphene materials in a range of markets, including polymer compounds. They currently manufacture graphene by chemical vapor deposition and by a proprietary technology that is suitable for large-scale, low cost production. While graphene is currently used only in specialized markets such as aerospace and energy storage, it will soon be used in specialized consumer markets such as sporting goods and, in the near future, will be inexpensive enough for use in mass-market consumer goods.


• Compounded plastics for colored, non-sloughing ESD uses
  Milliken’s Zelec non-metallic electroconductive powders are well-established in the coatings and adhesives market, but they have recently expanded their application into compounded plastics. They are particularly suitable for non-sloughing ESD uses that need to be colored rather than black. Zelec’s ESD properties are not be dependent on humidity, while the additive is stable above 200˚C and is miscible with all types of polymers.

Plastics Professionals - Here's the 'Must Know' for You!

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Commercially Available Electrically Conductive Polymer Grades