Abstract: The invention is directed to carbon nanotube-containing compositions that have increased viscosity and stability. In particular, the invention is directed to methods for manufacturing carbon nanotube films and layers that provide superior electrical properties.

Abstract: This invention relates to flexible, transparent and conductive coatings and films formed using carbon nanotubes (CNT) and, in particular, single wall CNT, with polymer binders. Preferably, coatings and films are formed from CNT applied to transparent substrates forming one or multiple conductive layers at nanometer level of thickness. Polymer binders are applied to the CNT network coating having an open structure to provide protection through infiltration, and may comprise a basecoat, a topcoat, or a combination thereof, providing enhanced optical transparency, conductivity, moisture resistance, thermal resistance, abrasion resistance and interfacial adhesion. Polymers may be thermoplastics, thermosets, insulative, conductive or a combination thereof. A fluoropolymer containing binder is applied onto a CNT-based transparent conductive coating at nanometer level of thickness on a clear substrate. The fluoropolymers or blend can be either semi-crystalline or amorphous.

Abstract: A method for making a nanocomposite electrode or circuit pattern includes forming a continuous carbon nanotube layer impregnated with a binder and patterning the binder resin using various printing or photo imaging techniques. An alternative method includes patterning the carbon nanotube layer using various printing or imaging techniques and subsequently applying a continuous coating of binder resin to the patterned carbon nanotube layer. Articles made from these patterned nanocomposite coatings include transparent electrodes and circuits for flat panel displays, photovoltaics, touch screens, electroluminescent lamps, and EMI shielding.

Abstract: The invention is directed to compositions and methods for forming highly transparent and electrically conductive coatings/films by exploiting self patterning nanostructures composed of electrically conductive materials. The resulting layer is suitable for conducting electricity in applications where a transparent electrode is required. Typical applications include, but are not limited to; LC displays, touch screens, EMI shielding windows, and architectural windows. In one embodiment, carbon nanotubes are applied to an insulating substrate to form an electrically conductive network of nanotubes with controlled porosity in the network. The open area, between the networks of nanotubes, increases the optical transparency in the visible spectrum while the continuous nanotube phase provides electrical conductivity across the entire surface or patterned area.

Abstract: The present invention relates to a novel nanocomposite dielectric comprising a polymer matrix and a plurality of carbon nanotubes dispersed therein. A method for increasing a dielectric constant of a polymer matrix, as well as a laminate and mobile antenna comprising the novel dielectric are also disclosed.

Abstract: A method for making a nanocomposite electrode or circuit pattern includes forming a continuous carbon nanotube layer impregnated with a binder and patterning the binder resin using various printing or photo imaging techniques. An alternative method includes patterning the carbon nanotube layer using various printing or imaging techniques and subsequently applying a continuous coating of binder resin to the patterned carbon nanotube layer. Articles made from these patterned nanocomposite coatings include transparent electrodes and circuits for flat panel displays, photovoltaics, touch screens, electroluminescent lamps, and EMI shielding.

Abstract: The present invention relates to a novel nanocomposite dielectric comprising a polymer matrix and a plurality of carbon nanotubes dispersed therein. A method for increasing a dielectric constant of a polymer matrix, as well as a laminate and mobile antenna comprising the novel dielectric are also disclosed.

Abstract: A method for making a particulate filled polymeric matrix composite film includes mixing a polymeric matrix material with a dispersion of particulate filler in a carrier liquid to form a casting composition and adjusting the viscosity of the casting composition to retard separation of the particulate filler from the composition. A layer of the viscosity-adjusted casting composition is cast on a substrate and the layer is consolidated to form the particulate filled polymer matrix composite film. Films made by the method include very thin, e.g less than 1.0 mil, fluoropolymeric matrix films highly filled with very small diameter, preferably spherical, particles for use as, e.g. dielectric substrate materials in laminar electrical circuits.

Abstract: A particulate filled fluoropolymeric matrix composite article and method of making the same is presented. Preferably, the article comprises an electrical substrate material. The method for making the particulate filled polymeric matrix composite film includes mixing a polymeric matrix material with a dispersion of particulate filler in a carrier liquid to form a casting composition and adjusting the viscosity of the casting composition to retard separation of the particulate filler from the composition. A layer of the viscosity-adjusted casting composition is cast on a substrate and the layer is consolidated to form the particulate filled polymer matrix composite film. Films made by the method include very thin, e.g less than 1.0 mil, fluoropolymeric matrix films highly filled with very small diameter, preferably spherical, particles for use as, e.g. dielectric substrate materials in laminar electrical circuits.

Abstract: In accordance with the present invention, a circuit assembly is manufactured in an additive process using at least one layer of a fluoropolymer composite material and a conductive material. The conductive layers are plated, and the fluoropolymer composite layers are laminated. The use of the filled fluoropolymeric composite eliminates the need for a barrier metal layer between the insulation and the conductors. A plurality of these circuit assemblies are stacked, one on top of the other. At least, selected exposed locations of the conductive material comprise a diffusible conductive material (e.g., gold). Once stacked the circuit assemblies are subjected to lamination under heat and pressure to simultaneously fuse adjacent fluoropolymer composite material and diffuse adjacent diffusible conductive material together to form an integral multilayer circuit having solid conductive interconnects.

Abstract: A composite material is presented comprised of a ceramic filled fluoropolymer wherein the ceramic is coated with a silane and the ceramic has a volume % fraction of between about 26-45. The composite of this invention exhibits excellent chemical resistance, particularly to alkaline environments. Preferably, the silane comprises a blend of at least one phenyl silane and at least one fluorosilane. The silane is preferably coated to a level of 10% of the total weight of ceramic filler.

Abstract: A method for making a particulate filled polymeric matrix composite film includes mixing a polymeric matrix material with a dispersion of particulate filler in a carrier liquid to form a casting composition and adjusting the viscosity of the casting composition to retard separation of the particulate filler from the composition. A layer of the viscosity-adjusted casting composition is cast on a substrate and the layer is consolidated to form the particulate filled polymer matrix composite film. Films made by the method include very thin, e.g less than 1.0 mil, fluoropolymeric matrix films highly filled with very small diameter, preferably spherical, particles for use as, e.g. dielectric substrate materials in laminar electrical circuits.

Abstract: A composite material is disclosed. The material comprises a polymeric matrix and from about 20 volume percent to about 70 volume percent inorganic particles distributed throughout the matrix. Suitable inorganic particles include hollow inorganic microspheres and porous inorganic particles. The inorganic particles are coated with a surface coating. The composite material of the present invention exhibits a dielectric constant of less than about 2.5 and a thermal coefficient of expansion of less than about 70 ppm/.degree.C.

Abstract: A method for making a particulate filled polymeric matrix composite film includes mixing a polymeric matrix material with a dispersion of particulate filler in a carrier liquid to form a casting composition and adjusting the viscosity of the casting composition to retard separation of the particulate filler from the composition. A layer of the viscosity-adjusted casting composition is cast on a substrate and the layer is consolidated to form the particulate filled polymer matrix composite film. Films made by the method include very thin, e.g. less than 1.0 mil, fluoropolymeric matrix films highly filled with very small diameter, preferably spherical, particles for use as, e.g. dielectric substrate materials in laminar electrical circuits.

Abstract: A composite material is presented comprised of a ceramic filled fluoropolymer wherein the ceramic is coated with a zirconate coupling agent and/or a titanate coupling agent and the ceramic has a volume % fraction of between about 26-45.

Abstract: A composite material is presented comprised of a ceramic filled fluoropolymer wherein the ceramic is coated with a titanate and/or zirconate and the ceramic has a volume % fraction of between about 45-50.

Abstract: A composite material is presented comprised of a ceramic filled fluoropolymer wherein the ceramic is coated with a fluorosilane and the ceramic has a volume % fraction of between about 45-50.

Abstract: A thermoplastic composite material is presented which comprises a thermoplastic matrix which is highly filled with a coated ceramic filler. In an important feature of the present invention, the ceramic filler has been coated with a rubbery polymer that bonds to the filler. In a preferred embodiment, the thermoplastic matrix comprises a fluoropolymer, preferably a chlorofluoropolymer and the ceramic filler is a fused amorphous silica coated with a rubbery polymeric material. The thermoplastic composite material of this invention exhibits numerous advantages which makes it well suited for use as a bonding film, particularly a bonding film for producing multilayer printed wiring boards.

Abstract: A composite material is presented comprised of a ceramic filled fluoropolymer wherein the ceramic is coated with a silane and the ceramic has a volume % fraction of between about 45-50.

Abstract: A ceramic filled fluoropolymer-based electrical substrate material well suited for forming rigid printed wiring board substrate materials and integrated circuit chip carriers is presented which exhibits improved electrical performance over other printed wiring board materials and circuit chip carriers. Also, the low coefficients of thermal expansion and compliant nature of this electrical substrate material results in improved surface mount reliability and plated through-hole reliability. The electrical substrate material preferably comprises polytetrafluoroethylene filled with silica along with a small amount of microfiberglass. In an important feature of this invention, the ceramic filler (silica) is coated with a silane coating material which renders the surface of the ceramic hydrophobic and provides improved tensile strength, peel strength and dimensional stability.