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357 West 910 South Heber City, UT 84032
435‐654‐3683 Main Office www.conductivecomposites.com
Enabling Conductivity in Plastics and Composites
"DISTRIBUTION STATEMENT B. Distribution authorized to U.S. Government agencies only. Proprietary Information and Critical Technology; other requests for this document shall be referred to AFRL/RXBC"
Export Control Warning Notice: WARNING ‐ This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App. 2401 et seq). Violations of these export laws are
subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25. ITAR restricted
UNCLASSIFIED
Nickel CVD Coated Fibers from Conductive Composites Company Material Background Carbon and aramid fibers are widely used in defense and commercial applications for their strength and weight properties. While these fibers can deliver structural performance, they fall short in conductivity and electromagnetic shielding performance. Conductive Composites has developed a proprietary Chemical Vapor Deposition (CVD) coating process where fibers can be coated with very thin and ductile films of pure nickel. This coating improves the electrical conductivity and electromagnetic shielding capabilities of the fiber by several orders of magnitude. CVD coated fibers retain their strength and stiffness properties with the added functionality of conductivity and shielding. The conductivity level and coating thickness are highly uniform, and can be engineered across a broad range (from 15 wt% nickel to 70 wt% nickel). The coating is ductile and robust, and is applied to each individual fiber in a filament or tow form with negligible fiber bridging. Woven cloths can also be coated. The coating process is a continuous reel‐to‐reel operation at low temperatures and atmospheric pressures. The nickel coating is ferromagnetic and corrosion resistant.
Material Use Coated fibers (NiFibers) can be used in all traditional industrial applications where carbon and aramid fibers are used, but with the additional performance advantages of conductivity and shielding. Coated fibers can be used in a continuous form or in a chopped fiber form. The continuous form is used in polymer composite laminate structures made with tows, cloths, and/or unidirectional tapes (in both thermosets and thermoplastics). Coated fibers are a multifunctional layer, presenting both strength and conductivity/shielding. They can be used as a single layer, multiple layers, or as every layer in a structure. The continuous tow form is also used in a non‐composite dry form for structural cables for X‐ray translucent medical wiring, braided shielding elements, and zero‐CTE applications. The chopped fiber form is a high performance structural and conductive additive in plastics for injection molding and compression molding with both thermosets and thermoplastics. The chopped form can also be used to produce conductive nonwovens. A very short precision‐chopped form of the fiber is very effective as a conductive element for paints, gaskets, and adhesives. Shielding applications range from ESD to HPM and EMP. CVD Coated fibers enable composite panels that pass MIL‐STD 464 and 188‐125.
Solutions and Applications Material Advantage Prototype? Fielded? TRL MRL NiCVD Coated Fibers Highly conductive, light and strong, very tight specifications,
smooth and ductile coatings, manufacturable, domestic source Y Y 9 9
Application Composite Structures Conductivity and shielding are easily inserted and engineered Y Y 7 7 Composites Enclosure Composites structures that shield well beyond traditional
benchmarks, including demanding EMP standards Y unknown 6 5
Lightning Strike Improved performance without parasitic weight Y unknown 6 5 Unidirectional Tapes Conductivity and strength, thermosets and thermoplastics Y Y 8 8 Zero‐CTE cable/structures CVD process is the only process capable of providing materials
needed for critical programs, successful DX‐A2 contracts Y Y 9 8
Injection Molding High conductivity and shielding for high volume manufacturing Y N 9 9 Compression Molding Very high conductivity and shielding for volume manufacturing Y N 5 5 Medical Lead Wires High strength X‐ray translucent wiring Y Y 9 8 Cable Shielding Overbraid High strength and very small diameter filaments, weight savings
and improved performance over braided metals Y unknown 7 7
Nonwovens Conductive fibers for short‐fiber reinforced broad goods Y Y 9 9 Precision Chopped High performance additive for paints, adhesives, and gaskets Y N 7 7
357 West 910 South Heber City, UT 84032
435‐654‐3683 Main Office www.conductivecomposites.com
Enabling Conductivity in Plastics and Composites
"DISTRIBUTION STATEMENT B. Distribution authorized to U.S. Government agencies only. Proprietary Information and Critical Technology; other requests for this document shall be referred to AFRL/RXBC"
Export Control Warning Notice: WARNING ‐ This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App. 2401 et seq). Violations of these export laws are
subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25. ITAR restricted
UNCLASSIFIED
Molded conductive plastic parts that are ”lighter, cheaper, and perform better than aluminum.” ‐A satisfied customer
X‐Ray translucent wiring for medical applications
Composite aircraft skins with improved electromagnetic shielding and reduced lightning strike damage • Standard composite (left) • Conductive composite (right)
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Shielding Eff
ecLvene
ss (d
B)
Frequency (GHz)
Shielding EffecLveness of 0.032" thick compression molded ABS plasLc
nickel coated carbon fiber 33% nickel carbon fiber
Composite Enclosures that match the shielding
performance of metals