# US 10,308,777 B2 · Pyrolized organic layers and conductive prepregs made therewith

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- Number: US 10,308,777 B2
- Document ID: US10308777B2
- Status: Granted
- Kind: B2
- Application number: 15/016,381
- Filed: 2016-02-05
- Published: 2016-07-07
- Granted: 2019-06-04
- Earliest claimed: 2013-09-24
- Assignees: Henkel IP & Holding GmbH
- Applicants: Henkel IP & Holding GmbH
- Inventors: Raymond S. Wong; Huabing Zheng
- Web page: https://patentgrep.com/patent/US10308777B2

## CPC

- B32B 15/08: of synthetic resin
- B32B 5/00: Layered products characterised by the non- homogeneity or physical structure {, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/024: {Woven fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/00: Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B 7/10: at least one layer having inter-reactive properties
- B32B 15/00: Layered products comprising {a layer of} metal
- B32B 15/04: comprising metal as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042)}
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/00: Layered products comprising {a layer of} synthetic resin {(fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18)}
- B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/16: specially treated, e.g. irradiated
- B32B 27/18: characterised by the use of special additives
- B32B 27/28: comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42}
- B32B 27/281: {comprising polyimides}
- C08J 5/005: {Reinforced macromolecular compounds with nanosized materials, e.g. nanoparticles, nanofibres, nanotubes, nanowires, nanorods or nanolayered materials}
- C08J 5/042: {with carbon fibres}
- C08J 5/248: {using pre-treated fibres}
- C08J 5/249: {characterised by the additives used in the prepolymer mixture}
- H01B 1/20: Conductive material dispersed in non-conductive organic material {(organic macromolecular compounds or compositions C08)}
- H01B 1/24: the conductive material comprising carbon-silicon compounds, carbon or silicon
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2262/00: Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/0269: Aromatic polyamide fibres
- B32B 2262/10: Inorganic fibres
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2264/00: Composition or properties of particles which form a particulate layer or are present as additives
- B32B 2307/00: Properties of the layers or laminate
- B32B 2307/20: having particular electrical or magnetic properties, e.g. piezoelectric
- B32B 2307/202: Conductive
- B32B 2307/30: having particular thermal properties
- B32B 2307/302: Conductive
- B32B 2307/50: having particular mechanical properties
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/542: Shear strength
- B32B 2307/558: Impact strength, toughness
- B32B 2307/732: Dimensional properties
- B32B 2605/00: Vehicles
- B32B 2605/18: Aircraft
- C08J 2379/04: Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K})

## Abstract

Pyrolized organic layers and conductive prepregs made therewith are provided.

## Claims

### Claim 1

A conductive prepreg, comprising
A matrix resin;
Fiber; and
One or more pyrolized organic layer(s) on at least a portion of a surface of which is disposed conductive metal.

### Claim 2 (depends on 1)

The conductive prepreg of claim 1 wherein the conductive metal is copper, silver or nickel.

### Claim 3 (depends on 2)

The conductive prepreg of claim 2, wherein the pyrolized organic layer has a thickness of about 25 to about 40 micrometers.

### Claim 4 (depends on 2)

The conductive prepreg of claim 2 wherein the conductive metal is disposed on the pyrolized organic layer at a thickness of about 2 to about 4 micrometers.

### Claim 5 (depends on 1)

The conductive prepreg of claim 1 wherein the pyrolized organic layer is a polyimide.

### Claim 6 (depends on 5)

The conductive prepreg of claim 5, wherein the pyrolized organic layer has a thickness of about 25 to about 40 micrometers.

### Claim 7 (depends on 5)

The conductive prepreg of claim 5 wherein the conductive metal is disposed on the pyrolized organic layer at a thickness of about 2 to about 4 micrometers.

### Claim 8 (depends on 1)

The conductive prepreg of claim 1, wherein the pyrolized organic layer has a thickness of about 25 to about 40 micrometers.

### Claim 9 (depends on 8)

The conductive prepreg of claim 8 wherein the conductive metal is disposed on the pyrolized organic layer at a thickness of about 2 to about 4 micrometers.

### Claim 10 (depends on 1)

The conductive prepreg of claim 1 wherein the conductive metal is disposed on the pyrolized organic layer at a thickness of about 2 to about 4 micrometers.

### Claim 11 (depends on 1)

The conductive prepreg of claim 1, wherein the matrix resin comprises one or more epoxies, episulfides, oxetanes, thioxetanes, maleimides, nadimides, itaconimides, oxazines, cyanate esters, and bisoxazolines.

### Claim 12 (depends on 1)

The conductive prepreg of claim 1, wherein the matrix resin further comprises nanostructures constructed from a conductive material.

### Claim 13 (depends on 12)

The conductive prepreg of claim 12, wherein the nanostructures are in the shape of one or more of nanotubes, nanocubes, nanowires, nanopyramids, nanoplatelets, nanospheres and multiply twinned particles.

### Claim 14 (depends on 1)

The conductive prepreg of claim 1, wherein the fiber is a member selected from the group consisting of carbon, glass, aramid, boron, polyalkylene, quartz, polybenzimidazole, polyetheretherketone, polyphenylene sulfide, poly p-phenylene benzobisoaxazole, silicon carbide, phenolformaldehyde, phthalate and napthenoate.

### Claim 15 (depends on 1)

The conductive prepreg of claim 1, wherein the glass is a member selected from the group consisting of S glass, S2 glass, E glass, R glass, A glass, AR glass, C glass, D glass, ECR glass, glass filament, staple glass, T glass and zirconium oxide glass.

### Claim 16 (depends on 1)

The conductive prepreg of claim 1, wherein the carbon fiber is made from pitch, polyacrylonitrile or rayon.

### Claim 17 (depends on 1)

The conductive prepreg of claim 1, wherein the carbon fiber has been sized with a benzoxazine-containing sizing agent.

### Claim 18 (depends on 1)

The conductive prepreg of claim 1, demonstrating electrical conductivity in the x direction of about 5 to 30×105 Siemens per meter.

### Claim 19 (depends on 1)

The conductive prepreg of claim 1, demonstrating electrical conductivity in the y direction of about 5 to 30×105 Siemens per meter.

### Claim 20 (depends on 1)

Cured conductive prepreg according to claim 1.

### Claim 21 (depends on 1)

Laminate comprising at least one of the conductive prepreg according to claim 1 and a nonconductive prepreg.

### Claim 22 (depends on 21)

Laminate according to claim 21, wherein the nonconductive prepreg is made with a matrix resin comprising a benzoxazine resin.

### Claim 23 (depends on 1)

Laminate comprising at least two of the conductive prepregs according to claim 1.

### Claim 24 (depends on 23)

Laminate according to claim 23, in a unidirectional, woven or quasi isotropic structure.

### Claim 25 (depends on 1)

A method of substantially maintaining electrical conductivity of a conductive prepreg of claim 1 while reducing the overall weight of the conductive prepreg, comprising the steps of:
Providing a matrix resin and fiber; and
Providing a pyrolized organic layer,
wherein the pyrolized organic layer demonstrates an electrical conductivity of about 5 to 30×105 Siemens per meter at a weight that is about 10% to about 95% less than the amount of copper mesh required to demonstrate substantially the same electrical conductivity.