Aggregation processes

A process for the preparation of conductive polymer particles which comprises the synthesis, or provision of a submicron anionic polymer latex, and which latex is prepared by batch emulsion polymerization;

• dispersing a conductive component submicron in size in the polymer latex;
• adding a cationic surfactant, or flocculent with high shear whereby the aggregation of the latex particles and the conductive component results, enabling aggregates of from about 5 to about 10 microns in average volume diameter;
• adding a base component to obtain a pH of from about 8 to 12;
• heating the formed aggregates above about the polymer Tg, which heating causes the severage, or breakage of the aggregates to smaller aggregates of from about 0.5 to about 1 micron;
• further heating above about the polymer Tg to coalesce the polymer and conductive particles;
• followed by washing and drying.

A process for the preparation of polymer compositions comprising mixing a conductive component with an anionic polymeric latex prepared by emulsion polymerization utilizing anionic surfactants, or a mixture of anionic and nonionic surfactants;

• adding a cationic surfactant, or flocculant whereby the aggregation of the latex particles and the conductive particles results;
• adding colloidal stabilizer, followed by the addition of an alkali base to obtain a pH of from about 7 to about 12;
• heating the formed aggregates above the polymer glass transition temperature thereby enabling the severage, or breakage of the aggregated particles;
• heating further above the polymer glass transition temperature enabling the coalescence of the polymer and conductive component particles;
• and washing and drying the resulting coalesced product.