# US 2008/0187649 A1 · Method of making electrical devices having an oxygen barrier coating

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- Number: US 2008/0187649 A1
- Document ID: US20080187649A1
- Status: Published application
- Kind: A1
- Application number: 12/080,657
- Filed: 2008-04-02
- Published: 2008-08-07
- Earliest claimed: 2004-09-03
- Assignees: Tyco Electronics Corporation
- Inventors: Mathew P. Galla
- Web page: https://patentgrep.com/patent/US20080187649A1

## CPC

- H01B 1/22: the conductive material comprising metals or alloys
- H01C 1/02: Housing; Enclosing; Embedding; Filling the housing or enclosure
- H01C 1/034: the housing or enclosure being formed as coating or mould without outer sheath (H01C1/032 takes precedence)
- H01C 7/027: {consisting of conducting or semi-conducting material dispersed in a non-conductive organic material}
- H01C 17/02: adapted for manufacturing resistors with envelope or housing (apparatus or processes for filling or compressing insulating material in heating element tubes H05B3/52)
- Y10T 428/2982: Particulate matter [e.g., sphere, flake, etc.]
- Y10T 428/31511: Of epoxy ether
- Y10T 428/31515: As intermediate layer
- Y10T 428/31529: Next to metal
- Y10T 428/31678: Of metal
- 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})
- H01C: RESISTORS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An electrical device includes two electrodes and a conductive polymer layer, containing a mixture of a polymer and a conductive filler, separating the electrodes. A oxygen barrier material containing a thermosetting polymer component is present on the exposed surface of the conductive polymer layer that is not in contact with the laminar electrodes. The oxygen barrier material may be a polyamine-polyepoxide material, and may provide for acceptable barrier properties over a wide range of humidity levels.

## Claims

### Claim 1

A method of making an electrical device, comprising:
forming a laminate of a conductive polymer layer, a first electrode, and a second electrode, the conductive polymer layer comprising a mixture of a polymer and a conductive filler, and the laminate comprising an exposed surface between the first and second electrodes; and
covering at least a portion of the exposed surface of the conductive polymer layer with a thermoset oxygen barrier material comprising a thermosetting polymer component.

### Claim 2 (depends on 1)

The method of claim 1, wherein the covering at least a portion of the exposed surface comprises contacting at least a portion of the region between the first and second electrodes with a mixture of a polyamine and a polyepoxide, and curing the mixture to form a polyamine-polyepoxide material that is a thermoset oxygen barrier.

### Claim 3 (depends on 2)

The method of claim 2, further comprising repeating the contacting at least a portion of the region with a mixture of a polyamine and a polyepoxide, and the curing the mixture to form a polyamine-polyepoxide material.

### Claim 4 (depends on 2)

The method of claim 2, wherein the mixture of the polyamine and polyepoxide further comprises a solvent.

### Claim 5 (depends on 2)

The method of claim 2, wherein the mixture of the polyamine and polyepoxide further comprises a platelet-type filler.

### Claim 6 (depends on 1)

The method of claim 1, wherein at least 65 weight percent of the polymer component of the oxygen barrier material comprises two or more groups selected from the group consisting of >N—CH2-Aryl-CH2—N<, >N-Aryl-N<, —O-Aryl-O—, —O(O═)C-Aryl-C(═O)O—, —O(O═)C—CH2-Aryl-CH2—C(═O)O—, and —CH2—CH(OH)CH2—; wherein -Aryl- is selected from the group consisting of phenylene, naphthylene and anthracenyl.

### Claim 7 (depends on 6)

The method of claim 6, wherein -Aryl- is selected from the group consisting of meta-phenylene and 2,6-naphthalene.

### Claim 8 (depends on 1)

The method of claim 1, wherein the conductive filler comprises nickel.

### Claim 9 (depends on 1)

The method of claim 1, wherein at least 90% of the exposed surface of the conductive polymer layer is covered by the oxygen barrier material.

### Claim 10 (depends on 1)

The method of claim 1, wherein at least 99% of the exposed surface of the conductive polymer layer is covered by the oxygen barrier material.

### Claim 11 (depends on 1)

The method of claim 1, wherein at 100% of the exposed surface of the conductive polymer layer is covered by the oxygen barrier material.

### Claim 12 (depends on 1)

The method of claim 1, wherein the covering at least a portion of the exposed surface comprises encapsulating the laminate.