Composition of matter for composite plastic contact elements featuring controlled conduction pathways, and related manufacturing processes

摘要

Exemplary embodiments provide composite materials, methods for making and processing these materials, and systems for using the composite materials. The disclosed composite material (or composite member) can include fiber-like and/or particulate materials incorporated within a binder polymer. For example, the composite member can include fibril-shaped, semi-conductive elements that are contained in a suitable binder polymer to achieve a particular resistance value, wherein the fibrils can be integrated and interlinked in a manner as to create an array of resistive elements that precisely define and control current flows through the related device. The composite member can therefore have resistive characteristics and, none or neglectablely low amount of capacitive or inductive characteristics. The composite member can be used in electric test market, e.g., as high performance, dynamic probes/sensors for very frequency and/or complex mixed-frequency signals.

主权项

1. A composite member comprising:
an insulating binder polymer; a plurality of continuous filaments disposed within the insulating binder polymer to provide a primary electric conduction path, wherein the continuous filaments are separated along their lengths by the insulating binder polymer and the insulating binder polymer prevents electrical contact between separate continuous filaments within the insulating binder; a catalytic metal attached along surfaces of continuous filaments of the plurality of continuous filaments; one or more conductive fillers distributed within the insulating binder polymer to interlink the plurality of continuous filaments to create a secondary electric conduction path in the composite member; wherein the one or more conductive fillers comprise:
(a) in situ patterned and grown inter-fiber linkages disposed where the catalytic metal is attached along surfaces of filaments of the plurality of continuous filaments,(b) doped-silicon nanowires and more than one of carbon nanotubes, nanoscale graphene plates, and carbon nanofibers, wherein the one or more conductive fillers are about 101 to about 106 times shorter than the plurality of continuous filaments in at least one dimension, wherein the one or more conductive fillers have a total concentration of about 2% or less by weight based on a total weight of the composite member and have an aspect ratio of about 1.0 or higher; and wherein the plurality of continuous filaments has an equal or lower resistivity of the secondary electric conduction path, wherein each continuous filament has a resistance ranging from about 0.01 to about 1000 megaohms/cm, and wherein the composite member comprises one or more forms chosen from shafts, pillars, pipes, tubes, and hollow bodies.