Conductive filament

Abstract

A multi-component conductive yarn which includes a primary component and a secondary component. The primary component consists of at least one elongated filament formed of polymeric material while the secondary component consists of a blend of polymeric material and carbon nanotubes. The secondary component is bonded with the primary component along its length. The carbon nanotubes comprise up to 20% of the secondary component. The conductive yarn comprises no more than 10% carbon nanotubes.

1 . A multi-component conductive yarn comprising a primary component and a secondary component: 
 said primary component consists of at least one elongated filament formed of polymeric material;    said secondary component consists of a blend of polymeric material and carbon bonded with said primary component along its length;    said carbon material of said secondary component comprises carbon nanotubes which constitute up to 20% of said secondary component; wherein,    said conductive yarn comprises no more than 10% carbon nanotubes.    
     
     
         2 . The yarn of  claim 1  wherein said polymeric material of said primary component is formed of at least one of polyester, polyamide, polypropylene, polyethylene, PPS and PEEK.  
     
     
         3 . The yarn of  claim 1  wherein said polymeric material of said secondary component includes at least 80% of at least one of polyester, polyamide, polypropylene, polyethylene, PPS and PEEK.  
     
     
         4 . The yarn of  claim 1  wherein said secondary component comprises a sheath bonded with and surrounding said filament of said primary component.  
     
     
         5 . The yarn of  claim 1  wherein said secondary component comprises an elongated filament bonded with said filament of said primary component along its length.  
     
     
         6 . The yarn of  claim 1  wherein said secondary component comprises between 0.5% and 50% of said multi-component yarn.  
     
     
         7 . The yarn of  claim 5  wherein said carbon nanotubes comprise up to 20% of said secondary component.  
     
     
         8 . The conductive yarn of  claim 1  wherein said primary component is set prior to bonding with said secondary component.  
     
     
         9 . The conductive yarn of  claim 1  wherein said multi-component yarn is set.  
     
     
         10 . The conductive yarn of  claim 1  wherein said primary component comprises a plurality of elongated filaments of synthetic material.  
     
     
         11 . The conductive yarn of  claim 10  wherein at least two of said plurality of filaments are formed of different polymers.  
     
     
         12 . The conductive yarn of  claim 10  wherein said filaments are set prior to bonding with said secondary components.  
     
     
         13 . A method of forming a conductive multi-component yarn including: 
 providing a first component comprising at least one elongated filament of synthetic material and setting said filament;    providing a second component consisting of a composition including polymeric resin and carbon nanotubes and further providing that the carbon nanotubes comprise between 0.1% to 25% of the composition;    passing said first component through an extruder die and extruding said second component onto said first component forming a conductive filament along said first component; and,    curing said multi-component yarn.    
     
     
         14 . The method of  claim 13  including setting said elongated filament of said first component prior to passing said first component through said extruder.  
     
     
         15 - 16 . (canceled)  
     
     
         17 . A method of forming a multi-component conductive yarn including the steps: 
 providing a first component comprising at least one resin of polymer resin;    providing a second component including a composition including a polymeric resin and carbon nanotubes with the carbon nanotubes comprising between 0.1% to 25% of the composition;    providing two extruders and extruding simultaneously said first and second components forming said first and second filaments;    causing said first and second filaments to bond along their length forming a conductive multi-component yarn; and    curing said conductive multi-component yarn.    
     
     
         18 . The method of  claim 17  wherein said curing Includes passing said bonded first and second filaments between draw rolls and a heater causing said multi-component yarn to be heat set.  
     
     
         19 - 20 . (canceled)  
     
     
         21 . A method of fanning a conductive multi-component yarn including: 
 providing a first component comprising at least one polymeric resin;    providing a second component consisting of a composition including polymeric resin and carbon nanotubes with the carbon nanotube comprising no more than 25% of the composition;    extruding said first and second components and causing said first and second components to be engaged longitudinally;    curing said extruded and engaged components forming said multi-component yarn.