The present invention relates to a process for the preparation of an electrically conductive polymer composition comprising a thermoset polymer and up to 20 wt. % of electrically conductive particles of an iron or cobalt bases phthalocyanine complex, by mixing the conductive particles with one or more of the precursors of the thermoset polymer, after which the resulting mixture is crosslinked. It also relates to the resulting polymer composition, as well as to a coated product, comprising a substrate and the polymer composition.

Such a process, the resulting composition and its use are known from WO-A-93/24562.

In recent years, blending of an insulating polymer with conducting fillers has attracted considerable interest due to the potential applications of the resulting composites in many areas where a certain level of conductivity is required. The conductive fillers applied range from metallic powders to carbonaceous fillers including carbon black, graphite and carbon fibers. Intrinsically conductive polymers (ICPs), such as polyaniline or polypyrole, are sometimes also used. A broad range of standard polymers are used as the matrix, and the increase in conductivity is caused by the formation of a particle network through the polymer matrix. The main problem involved in this field is the large amount of conductive fillers required to achieve reasonable conductivity levels for practical applications. This large amount of filler deteriorates the mechanical properties of the composite, and leads to poor processabiltiy of the matrix. Furthermore, the cost of the final material is often beyond the acceptable range due to the heavy fraction of expensive conducting species.

Generally, the relationship between the dc volume conductivity (σ _v ) of a polymer composite and filler loading is not linear. The σ _v increases sharply at a critical conductive filler concentration known as the percolation threshold (φ _c ). Several theories were developed to understand such a drastic transition. Statistical percolation models have occupied the majority of the literature. These models predict a percolation threshold at a volume fraction of 0.16 in 3 dimensions for round particles.

It is a first objective of this invention to provide a process as a result of which the percolation threshold of the polymer composition is significantly lowered.

It has been found that, when practicing the teachings of the above- mentioned prior art, only conductivity of the polymer matrix was obtained. In fact an

isolating top layer having of a thickness of several microns was found.

Therefore another objective of the present invention is to provide a process resulting in the preparation of a substrate coated with a thermoset polymer wherein the coating shows substantially no difference in bulk and top layer conductivity.

Still another objective of the underlying invention is to provide a process to obtain a coating of which the conductivity level, at a given concentration of the conductive particles, can be tuned to desired levels.

The indicated objectives can be achieved by a process, in which the particles of the conductive complex are administered to the one or more precursors of the thermoset polymer in the form of a dispersion in a dispersion agent, the chemical structure of the dispersion agent being such that it comprises at least one of the following groups: -OH -C=O -S=O -Ph-R -NR ₂ , in which each R is hydrogen or a (substituted) hydrocarbon groups. a) Thermoset polymer.

The aim of the invention is to prepare an electrically conductive polymer composition based on a thermoset polymer. Thermoset polymers as such are known in the art. They are prepared by crosslinker a monomer or a mixture of monomers, conventionally with the aid of one or more crosslinker agents; such ingredients here and thereinafter also being referred to as precursor (s) of the thermoset polymer.

Preferably the thermoset polymer is selected from the group of thermoset epoxy resins, thermoset polyurethanes, thermoset formaldehyde resins, thermoset acrylic urethane systems, thermoset polyesters, and/or thermoset poly(alkyl-) acrylates. In case of the thermoset poly (alkyl-) acrylates, preference is given to thermoset polymethylacrylates or polymethylmethacrylates.

The conditions under which the crosslinker of the precursor(s) takes place are known to the skilled man. Said crosslinker eventually results in a thermoset polymer, which means that such a polymer is not melt-processable; this in contrast to thermoplastic polymers.

b) Electrically conductive particle.

This particle is an iron or cobalt based phthalocyanine complex. Such as complex is

known from WO 93/24562, the contents of which are herein incorporated by reference. Also EP-A-261 ,733 discloses these type of compounds. The primary particle sizes are generally well below 1 μm.

c) Dispersion agent.

The dispersion agent in and with which a dispersion of the electrically conductive particles is made, comprises at least one of the following groups:

- OH

- C=O

- S=O

- Ph-R

- NR ₂ , in which Ph stands for a (substituted) phenylgroup, and each R is hydrogen or a (substituted) hydrocarbon group. More preferred, the dispersion agent comprises two or more of the indicated groups, either identical or different from each other. An non-exhaustive list of applicable dispersion agents comprised the following chemicals: cyclohexanone, sulfolane, dimethylacetamide, ethylene glycol, glycerol, glycol monostearate, polyethylene glycol, DMPU, DMIL (2,3-dimethyl-2-imidazo- lidanone, n-methyl pyrrolidone, HMPTA (hexamethylphodphor triamide), Linevol (butylbenzylphthalate), concentrated H ₂ SO ₄ , trifluormethanesulphonic acid, m-cresol, ethylene carbonate.

A preference is present for the use of a dispersion agent selected from the group comprising alkylene glycols, or alkyl- or aryl phenols. More preferred, the dispersion agent is either ethylene glycol or m-cresol.

d) The dispersion.

In the present invention it is an essential element that the electrically conductive particles are premixed in a dispersion agent (both ingredients as described above). This mixing and dispersing is a process in which known techniques for preparing a dispersion can be used. Dependant on the properties of the respective ingredients, and the conditions of the polymerization, a skilled man is able to determine the process conditions under which the dispersion is prepared. The temperature at which the dispersion is made can either be room temperature or an elevated temperature. The concentration of the electrically conductive particles in the dispersion is not critical. In order to be easy processable, the dispersion comprises preferably up to 50 wt % of the phthalocyanine complex particles. It is preferable to

start with a dispersion in which the particles are finely dispersed.

e) The crosslinker,

In order to prepare a thermoset polymer, generally there is a need, next to the monomeric precursor(s) of the polymer, to use a crosslinker. As such, the skilled man is acquainted with applicable and suitable crosslinkers to be used for the preparation of the specific thermoset polymer. In the case of a thermoset epoxy resin, this polymer is preferably prepared from a precursor containing at least two epoxy groups, and a diamine-based crosslinker. In that case the crosslinker has the formula:

in which R _x and R _y are a hydrocarbon group, and in which n has a value between 1 and 75.

Preferably, the hydrocarbon groups R _x and R _y are both an isopropylene group.

It has surprisingly been found that by matching the length of the backbone of the crosslinker agent (i.e. by varying the value of n in the above formula, and thus the molecular weight), that a glassy or a rubbery nature of the coating can be achieved (the higher value of n, the more rubbery the coating becomes). In preference, n has a value between 3 and 60. The variation in the value of n, and thus of the molecular weight of the crosslinker, surprisingly also gives an opportunity to control the conductively level of the resulting conductive polymer composition: the higher the molecular weight, the lower the conductivity level (in S/cm), at a given concentration of the electrically conductive species in the polymer composition.

f) The electrically conductive polymer composition.

Through the present invention an improved conductive polymer composition is obtained, having a significantly lowered percolation threshold, compared to the polymer compositions known in the art. An additional, and significant effect of the present invention is the fact that there is substantially no difference in bulk and top layer conductivity; this in contrast with polymer compositions prepared according to a process known in the art. As a result, as electrically conductive polymer composition is achieved, comprising preferably up to 20 wt % of an electrically conductive iron or cobalt based phthalocyanine complex, and wherein there is substantially no difference in bulk and top layer conductivity.

It was found that the volume conductivity σ _v was dependent on the thickness of the coating. The thinner the coating, the lower the σ _Vl and the higher the percolation threshold (φ). The results are given in Fig.1.

In general, the polymer composition of the present invention can be used as a coating on a substrate. Said substrate can comprise either an organic or inorganic substrate. An organic substrate generally has a polymeric nature. Examples of a suitable substrate are: polyamide, polycarbonate, glass, metal.

The invention will be elucidated with the following Examples and comparative experiments, which are meant to illustrate the invention but had to restrict it.

Example I

0.056 g Phthalcon 11 (electrically conductive complex) was dispersed at room temperature in 0.497 g m-cresol for 1h. The dispersion was put in an ultrasonic both and dispersed further for 1 h at room temperature.

The resulting dispersion was mixed with 0.369 g Epikote 828

(polymer precursor) and 0.131 g Jeffamine D-230 (crosslinker) with a magnetic stirrer for 2 min at room temperature. Then the mixture was degassed in an ultrasonic bath (under degassing mode) for 5 minutes at room temperature. This degassed mixture was then applied on polycarbonate panels (GE Plastics, The Netherlands) with a doctor blade applicator (90 μm wet thickness).

The coated polycarbonate was put in a vacuum oven and cured (crosslinked) at 100 ⁰ C for 4 hours and postcured at 120 ⁰ C for 20 hours and then taken out of the oven to cool down to room temperature. The thickness of the dried coating measured with a micrometer is 49 μm, which is an average of at least 5 measurements at different places (fault of measurements within 10%).

On the top of the resulting coating four parallel stripes of silver paint (Silver conductive adhesive 416, EMS, USA) were applied, (1 cm in length, 2 mm in width and with 1 cm distance between two neighboring stripes to minimize the contact resistance between coating and electrodes). The conductivity was measured with four pin electrodes in contact with the four silver paint stripes. The outer two electrodes were connected to a power source (Keithley 237) and the inner two were connected to a high voltage electrometer (Keithley 6517A). The former unit supplied a constant current (/) through the coating; the latter unit measured the voltage difference (V) between the two inside electrodes. The measuring was carried out according to

standard ASTM D991 and instructions of Keithley "Low Level Measurements". The volume conductivity (σ^) was calculated according to the equation:

IL σ\, = ^■

Vbh

where L is the distance between two neighboring silver paint stripes, b is the length of the stripe and h is the coating thickness.

The actual conductivity measured of the above-mentioned coating was 1.12χ10 ^"7 S/cm, which is the average value of 6 measurements shown below, Table 1

10.0 8.97 49 -ι .i iχicr ⁷

Comparative experiments A-C

Example I was repeated, but without the preparation of a dispersion of the Phthalcon 11. The Phthalcon concentration was 5, 10 and 20 wt. % (respectively); the molar ratio between Epikote 828 and Jeffamine 230 was 2:1.

All these coatings appeared to be nonconductive (σ _v < 10 ^'12 S/cm), even at a filler concentration as high as 20 wt %. By both 2-D optical microscopy and 3- D confocal laser scanning microscopy it was revealed that the conductive network were inhomogeneously distributed through the coating; particle networks were not detected at the surface of the coatings. Because the 4-point conductivity measurements were carried out on the surface of the coating material, the surface morpholopgy of the coating, i.e., the absence of these networks at the surface may be responsible for (σ _v ) < 10 ^"12 S/cm. Therefore a non-contacting electrostatic volmeter method to measure the bulk conductivity was used. The results showed that the epoxy coating containing 10 wt % of Phthalcon 11 was already conductive (σ _v is 4.17 x 10 ^'7 S/cm) (comparative experiment B). No conductivity was found in coatings containing a smaller amount of Phthalcon 11 (comparative experiment A). Examples II-XVI were performed in a similar way as Example I. The details of the

experimental conditions and results are given in Table 2 and Fig 2.

Table 2

Example Phthalcon m-cresol Epikote Jeffamine Coating

11 (g) 828 species thickness (S/cm)

—

(g) (g) and (μm) amount

(g)

Il 0.020 0.505 0.378 D-230, 45 2.55x10- ⁹

0.131

III 0.026 0.505 0.365 D-230, 51 3.60x10- ⁹

0.130

IV 0.032 0.491 0.365 D-230, 37 1.34χ10- ⁸

0.131

V 0.037 0.490 0.372 D-230, 50 3.95x10 ^'8

0.132

Vl 0.125 0.504 0.370 D-230, 50 7.08x10 ^"8

0.131

VII 0.021 0.507 0.312 D-400, 37 3.81 x10- ¹²

0.171

VIII 0.032 0.505 0.315 D-400, 42 1.14x10- ¹⁰

0.171

VIX 0.043 0.505 0.311 D-400, 59 1.03x10 ^"9

0.170

X 0.056 0.500 0.315 D-400, 47 1.47x10 ⁹

0.169

Xl 0.088 0.503 0.311 D-400, 49 3.75x10- ⁹

0.171

XII 0.125 0.505 0.311 D-400, 34 4.50x10 ^"9

0.170

XIII 0.043 0.505 0.136 D-2000, 45 1.98x10- ¹⁰

0.365

XIV 0.056 0.502 0.135 D-2000, 49 7.54x10 ^"10

0.371

XV 0.088 0.505 0.132 D-2000, 42 7.80x10- ¹⁰

0.370

XVI 0.125 0.505 0.130 D-2000, 35 9.29x10- ¹⁰

0.370

Example XVII

Example I was repeated with the only exception of the wet thickness of the coating used in the doctor blade application: 300 μm instead of 90 μm. The thickness of the cured coating was 137 μm; the volume conductivity measured was 7.18χ10 ^"8 S/cm.

Examples XVIII-XXIII

These were performed in a similar way as Example I. The details of the experimental conditions and results are given in Table 3.

Table 3

Example Phthalcon m-cresol Epikote Jeffamine Coating σ _v

11 (g) 828 (g) thickness (S/cm)

(g) ( g) (μm)

XVIII 0.056 0.505 0.378 0.131 105 9.80x10 ^"8

XIX 0.056 0.503 0.375 0.130 82 5.64x10 ⁸

XX 0.056 0.500 0.370 0.131 37 6.34x10 ⁸

XXI 0.056 0.499 0.372 0.135 11 1.05x10 ^"11

XXII 0.056 0.505 0.375 0.131 9 7.85χ10 ^"12

XXIII 0.088 0.505 0.370 0.131 5 2.13χ10 ^"11

Example XXIV

Phtalcon 11 was dried at 8O ⁰ C for 48h under vacuum prior to use. 0.056 g Phtalcon 11 was added to 0.497 g m-cresol at room temperature. 0.014 g Epikote 828 was also added to the mixture. Then the mixture was dispersed for 1 hour magnetically and then ultrasonically dispersed for 1 hour. Both dispersions were performed at room temperature.

To this dispersion 0.361 g Epikote 828 and 0.13O g Jeffamine 230 were added. The mixture was magnetically stirred for 2 minutes and then ultrasonically degassed for 5 minutes at room temperature.

From this mixture a cured coating was made according to the procedure described in Example I. The thickness of the cured coating was 52 μm and the volume conductivity measured was 1.13χ10 ^"6 S/cm.

Examples XXV-XXXVI

These were executed as described in Example XXIV. The variations between the

Examples, and their results are given in Tables 4 and 5.

Table 4

Example Phthalcon m- Epikote Amount of Overall Coating σ _v

11 cresol 828 Jeffamine Jeffamine thickness (S/cm)

(g) (g) (g) added (g) (μm) during dispersion

(g)

XXV 0.056 0.505 0.370 0 0.131 42 3.84x10 ^-7

XXVI 0.056 0.495 0.375 0.007 0.131 53 6.55x10- ⁸

XXVII 0.056 0.500 0.370 0.014 0.134 29 4.78x10- ⁸

XXVIII 0.056 0.505 0.370 0.028 0.131 52 3.79x10- ⁸

XXIX 0.056 0.495 0.375 0.063 0.128 51 4.98x10 ⁸

XXX 0.056 0.505 0.370 0.130 0.130 50 4.95x10 ⁸

Table 5

Examples Phthalcon triJeffamine Amount of Overall Coating σ _v

11 cresol D-230 Epikote828 Epikote thickness (S/cm)

(g) (g) amount added 828 (μm)

(g) during amount dispersion (g)

(g)

XXXI 0.056 0.500 0.131 0.014 0.375 52 1.13χ10 ^"6

XXXII 0.056 0.505 0.127 0.038 0.370 50 1.27χ10 ^"7

XXXIII 0.056 0.500 0.130 0.075 0.370 35 4.42x10- ⁸

XXXIV 0.056 0.505 0.131 0.125 0.371 64 2.76x10- ⁸

XXXV 0.056 0.505 0.130 0.370 0.370 51 4.98x10 ^"8

XXXVI 0.056 0.505 0.370 0.130 0.130 47 3.04x10 ^"8

Examples XXXVI and XXXVII

Example I was repeated with different Phthalcon 11 concentrations, using either m-cresol or ethylene glycol as the dispersion agent. The results are given in Fig. 3.

By extrapolating the σ _v - [Phthalcon 11] curve to 10 ^"17 S/cm (the conductivity of the pure epoxy matrix), the percolation threshold of Phthalcon 11/ epoxy was determined. For the ethylene glycol dispersed coating a percolation threshold of 1.5 wt. % was achieved, for the m-cresol dispersed coating a value of 1.2 wt.% was found.

The curves in Fig. 3 were also fitted according to the scaling law of the percolation theory (according to Rolduglin et. al. (Progress in organic coatings, 2000, 39,81 ,100)):

σ _v ~ C (φ - φ _c ) '

where c is a constant, t is the critical exponent, and φ is the volume fraction of the filler particles and φ _c is the percolation threshold. The value of t is 2.03 for the ethylene glycol dispersed coating and 2.15 for the m-cresol dispersed coating (Fig. 4).

The percolation threshold (φ _c « 1.4 wt. %) found for both cured Phthalcon 11/ epoxy coatings is much lower than the values in the art.