Conductive carbon black is a special grade of carbon black that exhibits conductive properties. It is increasingly being used as a additive in various applications ranging from rubber products to printed circuit boards. In this article, we will explore the properties and uses of conductive carbon black along with its potential to drive innovation across different industries.
Properties of Conductive Carbon Black
Conductive carbon black is produced by controlled pyrolysis or thermal decomposition of hydrocarbons such as natural gas or oil under controlled conditions. The tightly packed spherical primary particles tend to aggregate into particle chains and agglomerates. This structure results in conductive carbon black having a high surface area typically ranging from 50-1500 m2/g.
The conductivity comes from a semi-crystalline graphitic structure and delocalized pi-orbitals that allow electrons to move within the material. Conductive carbon blacks have specific surface areas and structure optimized to provide conductivity values ranging from 10-2 to 101 S/cm. Other properties include hardness, abrasion resistance, conductivity stability and compatibility with different binder systems.
Uses in Rubber Products
One of the major applications of conductive carbon black is as a filler in rubber products like tires and belts where it is used to impart electrical conductivity. During tire rolling, static electrical charges tend to build up which need to be dissipated to avoid electrical sparking. Conductive carbon black facilitates charge dissipation and provides anti-static properties. It is added at loadings of 5-30 phr (parts per hundred rubber).
The material also enhances other physical properties of the rubber compound through reinforcement. This allows usage of lighter weight rubber formulations. Leading tire manufacturers extensively use optimized grades of conductive carbon black. The global carbon black market for tires is estimated to be over 5 million tons annually.
Conductive Plastics and Composites
Conductive carbon black is also finding increasing use as a additive for plastics and composites to impart electrical conductivity and EMI/RFI shielding properties. It is widely used in applications such as switch parts, connectors, shielding compounds etc. The conductive network structure provides surface and volume resistivities in the range of 100-104 ohm/sq.
Specialized grades optimized for compatibility with thermoplastics like PE, PP and nylon as well as thermosets like epoxy are available in the market. Loadings can range from 5-30 wt%. The conductive composites combine attributes of the polymer matrix along with electrical conductivity requirements.
Printed Circuit Boards
One of the emerging uses of Conductive Carbon Black is in conductive inks and pastes for printed circuit boards (PCB). Traditionally, silver flake based inks have been used for electrically connecting components on the circuit board. However, conductive carbon black offerspotential cost savings due to the lower raw material price compared to silver.
Grades optimized with narrow and controlled particle size distribution in the 10-80 nm range along with optimized BET surface area provide the percolation threshold and stable resistivity values required for electrical tracks on circuit boards. Loadings can range from 15-40 wt%. Leading manufacturers are utilizing conductive carbon black inks for industrial and commercial PCB applications.
Future Outlook and Innovation
With its versatility, conductivity and cost benefits, conductive carbon black continues to find increased usage. Future areas of focus include development of higher conductivity grades for applications like 5G antennas, printed electronics and sensors. Tailoring the surface chemistry, morphology and structure of carbon black nanoparticles can further enhance properties.
Conductive inks offer potential for innovative printed devices and Internet of Things (IoT) applications. Carbon black startups are working on applications like smart fabrics, 3D printed structures and flexible electronics. Overall, conductive carbon black promises to drive innovation across industries through new product development. Significant advancements in material properties are expected to further accelerate its adoption.
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