Lowering the percolation threshold in carbon black-filled polymer composites

In an effort to lower the percolation threshold of carbon black-filled polymer composites, various polymer microstructures were examined. Composites prepared with a polyvinyl acetate (PVAc) latex and a poly(vinyl acetate - ethylene) water-dispersible powder showed a significantly lowered percolation threshold relative to an equivalently prepared composite that used a polyvinyl alcohol (PVA) solution to form the matrix phase. The percolation threshold of the dispersion-based composites occurred at 5 vol.% carbon black, while the equivalent solution-based composite produced a threshold at 14 vol.%. By excluding the carbon black from regions occupied by polymeric particles, the dispersion-based composites lead to preferential aggregation of carbon black, as evidenced by SEM, and a lowered percolation threshold.