IMPROVED POLYMERIC PTC COMPOSITIONS

Abstract: Circuit protection devices comprising PTC elements and circuits containing such devices. The PTC element includes a crystalline conductive polymer composition comprising a conductive particulate filler grafted to a modified polyolefin. The modified polyolefin comprises a polyolefin having a carboxylic acid or a carboxylic acid derivative grafted thereto. The conductive particulate filler is grafted via an esterification reaction to the modified polyolefin.

Description: IMPROVED POLYMERIC PTC COMPOSITIONS DESCRIPTION Cross Reference To Related Application This application claims the benefit of U.S. Provisional Application No. 60/004,600, filed September 29, 1995. Technical Field The present invention relates to electrical circuit protection devices comprising conductive polymer compositions which exhibit PTC behavior. Background of the Invention It is well known that the resistivity of many conductive materials change with temperature. The resistivity of a positive temperature coefficient (PTC) conductive material sharply increases as the temperature of the material increases over a par¬ ticular range. Many crystalline polymers, made electrically conductive by dispersing conductive fillers therein, exhibit this PTC effect. These polymers generally include polyolefins such as polyethylene, polypropylene and ethylene/propylene copolymers. At temperatures below a certain value, i.e., the critical or trip temperature, the polymer exhibits a relatively low, constant resistivity. However, as the temperature of the polymer increas- es beyond the critical point, the resistivity of the polymer sharply increases. Compositions exhib¬ iting PTC behavior have been used in electrical devices as over-current protection in electrical circuits comprising a power source and additional electrical components in series. Under normal operating conditions in the electrical circuit, the resistance of the load and the PTC device is such that relatively little current flows through the PTC device. Thus, the temperature of the device (due to I 2 R heating) remains below the critical or trip temperature. If the load is short circuited or the circuit experiences a power surge, the current flowing through the PTC device increases greatly. At this point, a great deal of power is dissipated in the PTC device. This power dissipa¬ tion only occurs for a short period of time (frac¬ tion of a second) , however, because the power dissipation will raise the temperature of the PTC device (due to I 2 R heating) to a value where the resistance of the PTC device has become so high, that the current is limited to a negligible value. The new current value is enough to maintain the PTC device at a new, high temperature/high resistance equilibrium point. The device is said to be in its "tripped" state. The negligible or trickle through current that flows through the circuit will not damage the electrical components which are connect¬ ed in series with the PTC device. Thus, the PTC device acts as a form of a fuse, reducing the current flow through the short circuit load to a safe, low value when the PTC device is heated to its critical temperature range. Upon interrupting the current in the circuit, or removing the condi¬ tion responsible for the short circuit (or power surge) , the PTC device will cool down below its critical temperature to its normal operating, low resistance state. The effect is a resettable, electrical circuit protection device. Conductive polymer PTC compositions and their use as protection devices are well known in the industry. For example, U.S. Patent Nos. 4,237,441 (Van Konynenburg et al. ) , 4,304,987 (Van Konynenbu- rg) , 4,545,926 (Fouts, Jr. et al. ) , 4,849,133 (Yoshida et al. ) , 4,910,389 (Sherman et al . ) , and 5,106,538 (Barma et al. ) disclose PTC compositions which comprise a thermoplastic crystalline polymer with carbon black dispersed therein. Conventional polymer PTC electrical devices include a PTC ele¬ ment interposed between a pair of electrodes. The electrodes can be connected to a source of power, thus, causing electrical current to flow through the PTC element. However, in prior conductive polymer PTC compositions and electrical devices employing such compositions, the polymer PTC composition has been susceptible to the effects of oxidation and changes in resistivity at high temperatures or high voltage applications. This thermal and electrical insta¬ bility is undesirable, particularly when the circuit protection device is exposed to changes in the ambient temperature, undergoes a large number of thermal cycles, i.e., changes from the low resistant state to the high resistant state, or remains in the high resistant (or "tripped") state for long periods of time. Further, in electrical devices employing prior conductive polymer PTC compositions, poor physical adhesion (i.e., poor ohmic contact) between the PTC composition and the electrodes has resulted in an increased contact resistance. As a result, PTC devices employing these prior compositions have had high initial or room temperature resistances, thus, limiting their applications. Attempts to overcome this poor ohmic contact in prior PTC devices have generally focused on changes to the electrode design. For example, U.S. Patent No. 3,351,882 (Kohler et al. ) discloses a resistive element composed of a polymer having conductive particles dispersed therein and electrodes of meshed con¬ struction (e.g., wire screening, wire mesh, spaced apart wire strands, or perforated sheet metal) embedded in the polymer. Japanese Patent Kokai No. 5-109502 discloses an electrical circuit protection device comprising a PTC element and electrodes of a porous metal material having a three-dimensional network structure. Other attempts at improving ohmic contact in PTC devices have included chemically or mechanical¬ ly treated electrodes to provide a roughened sur¬ face. For example, U.S. Patent Nos. 4,689,475 and 4,800,253 (Kleiner et al. ) , and Japanese Patent No. 1,865,237 disclose metal electrodes having chemi- cally or mechanically treated surfaces to enhance surface roughness. These treatments include elect¬ rodeposition, etching, galvanic deposition, rolling or pressing. These treatments, however, increase the number of processing steps and increase the overall cost of the PTC device. Summary of the Invention It is an object of the present invention to provide a conductive polymer PTC composition with improved electrical and thermal stability. It is a further object of the present invention to provide a conductive polymer PTC composition which exhibits excellent adhesion to metal electrodes having smooth surfaces. Accordingly, a circuit protection device can be provided whose resistance returns essentially to its initial value or lower even after repeated cycling (i.e., going from its low resistant state to its high resistant state and back again) and prolonged periods in its "tripped" state. The improved adhesion and the electrical and thermal stability of the conductive polymer PTC composition of the present invention also broaden the range of applications in which an electrical circuit protection device may be used. Accordingly, in one aspect of the present invention there is provided a crystalline conduc¬ tive polymer composition exhibiting PTC behavior. The composition comprises a modified polyolefin and a conductive particulate filler. Unlike prior conductive polymer PTC compositions where the conductive particulate filler is uniformly dis¬ persed within a crystalline polymer matrix, the conductive particulate filler of the present inven¬ tion is chemically bonded, i.e., grafted, to the modified polyolefin. In another aspect of the present invention, there is provided a crystalline conductive polymer composition exhibiting PTC behavior. The composi¬ tion comprises a conductive particulate filler and a modified polyolefin having the formula - [ CH 2 -CH 2 ] X - [CH 2 - ■ ICChH] y - wherein X x is selected from the group consisting of carboxylic acids and carboxylic acid derivatives, and wherein x and y are present in an amount such that the ratio by weight of x/y is at least 9. In another aspect of the present invention, there is provided a crystalline conductive polymer composition which exhibits PTC behavior and has a resistivity at 25°C of less than 5 ohm cm and a peak resistivity at a temperature greater than 25°C of at least 1,000 ohm cm. The composition com¬ prises a conductive filler component grafted to a modified polyolefin component. The present invention also provides an elec- trical device comprising: (a) a PTC element having a modified polyolefin component grafted to a conductive particulate filler component; and (b) two electrodes, each electrode being connectable to a source of power, and when so connected, causing current to flow through the PTC element . In another aspect, the present invention provides an electrical device comprising: (a) a PTC element having a modified polyolefin component grafted to a conductive particulate filler component, the modified polyolefin component comprised of about 90-99% by weight polyethylene and about 1-10% by weight carboxylic acid or a carboxylic acid derivative, the PTC element having a resistivity at 25°C of less than 5 ohm cm and a peak resistivity at a temperature greater than 25°C of at least 1,000 ohm cm; and (b) two electrodes, each electrode being connectable to a source of power, and when so connected, causing current to flow through the PTC element, the electrical device having a resistance, R int , at 25°C of less than 1 ohm. The present invention also provides an elec- trical device comprising: (a) a PTC element having a modified polyolefin component grafted to a conductive particulate filler component; and (b) two electrodes having a surface roughness, R a , the electrodes not being chemically or mechani¬ cally treated to enhance the surface roughness, R a , each electrode being connectable to a source of power, and when so connected, causing current to flow through the PTC element. In yet another aspect of the present inven¬ tion, there is provided an electrical circuit comprising: (a) a source of electrical power; (b) a circuit protection device comprising a PTC element and two electrodes, the PTC element being composed of a conductive polymer composition comprising a modified polyolefin and a conductive particulate filler; and (c) other circuit elements connected in series with the circuit protection device which have a resistance R L ohms. In a final aspect of the present invention there is provided an electrical circuit which includes a source of electrical power, a circuit protection device comprising a PTC element and two electrodes, and other circuit elements connected in series with the circuit protection device which have a resistance R L ohms, and which has a normal operating condition and a high temperature stable operating condition at the occurrence of a fault condition, wherein: (a) the PTC element is composed of a PTC con¬ ductive polymer comprising an organic polymer material and conductive carbon black, the PTC conductive polymer having a resistivity at 25°C of 5 ohm cm or less; (b) the circuit protection device having a resistance at 25°C of 1 ohm or less and 0.5 x R L ohm or less; (c) the ratio of the power in the circuit in the normal operating condition to the power in the high temperature stable operating condition, i.e., the Switching Ratio, is at least 8; the improvement comprising the organic polymer material being comprised of a modified polyolefin having the formula -[CH 2 -CH-jV[CH 2 -CH] y - wherein X x is selected from the group consisting of carboxylic acids and carboxylic acid derivatives, and wherein x and y are present in an amount such that the ratio by weight of x/y is at least 9. Other advantages and aspects of the present invention will become apparent upon reading the following description of the drawings and detailed description of the invention. Brief Description of the Drawings FIG. 1 illustrates the resistivity as a func¬ tion of temperature of a first embodiment of the present invention; FIG. 2 illustrates the resistivity as a func¬ tion of temperature of a second embodiment of the present invention; FIG. 3 illustrates a side view of an electri¬ cal device of the present invention; FIG. 4 illustrates a test circuit used to measure the dielectric strength of circuit protec¬ tion devices according to the present invention; and, FIG. 5 illustrates an application of the present invention as a circuit protection device in a typical electrical circuit. Detailed Description While this invention is susceptible of embodi¬ ment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments and methods of manufacture with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. The polymer component used in the present invention may be a modified polyolefin. The term modified polyolefin as used herein is defined as a polyolefin having a carboxylic acid or a carboxylic acid derivative grafted thereto. The carboxylic acid or the carboxylic acid derivative can comprise as much as 10% by weight of the modified polyolefin, preferably 5% by weight of the modified polyolefin, more preferably 3% by weight of the modified polyolefin, especially 1% by weight of the modified polyolefin. Polyolefins used in the present invention should have a crystallinity of at least 30%, preferably more than 70%. Suitable polyolefins include polyethylene, copolymers of polyethylene, polypropylene, ethylene/propylene copolymers, polybutadiene, polyethylene acrylates, and ethylene acrylic acid copolymers. Carboxylic acids have the general formula o R - C - OH . Suitable carboxylic acids for use in the present invention include formic acid, acetic acid, propi¬ onic acid, butyric acid, valeric acid, caproic acid, caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, oxalic acid, malonic acid, succinic acid, glutaric acid adipic acid, and maleic acid. A carboxylic acid derivative can be substitut¬ ed for carboxylic acid in the modified polyolefin component and also yield a conductive polymer PTC composition with improved electrical and thermal stability. Thus, for purposes of the present invention, it is understood that carboxylic acids and their derivatives are equivalent. Suitable carboxylic acid derivatives for use in the present invention include: carboxylic esters having the general formula carboxylic anhydrides having the general formula acyl chlorides having the general formula amides having the following general formulas 0 0 0 R - ICI - NH 2 R - ICI - NHR' R - 1C1 - NR 2 ; and, thiol esters having the general formula Suitable conductive particulate fillers for use in the present invention include nickel powder, silver powder, gold powder, copper powder, silver- plated copper powder, powders of metal alloys, carbon black, carbon powder, and graphite. The amount of conductive particulate filler in the present invention should be such that the conductive polymer composition exhibits PTC behav¬ ior and has: (1) an initial resistivity at 25°C of less than 5 ohm cm, preferably less than 2 ohm cm and especially less than 1 ohm cm; and, (2) a peak resistivity of at least 1,000 ohm cm, preferably at least 10,000 ohm cm and especially at least 100,000 ohm cm. Generally, compositions of the present invention will have a volume ratio of conductive particulate filler to modified polyolefin of at least 0.30, preferably at least 0.50 and especially at least 0.60. In the present invention, the conductive particulate filler can be grafted to the modified polyolefin via an esterification reaction. It has been found that the conductive particulate fillers previously mentioned, and particularly carbon black, carbon powder and graphite have a hydroxyl group, represented by the general formula -OH, attached to the surface. The oxygen atom of the hydroxyl group is divalent and, therefore, forms two bonds; one with the hydrogen atom and one with the surface of the conductive particulate filler. As a result, the oxygen atom has two pairs of unbonded electrons. Due to these unbonded elec¬ trons, the oxygen atom is electronegative in na- ture. Consequently, the oxygen atom has an affini¬ ty for electropositive atoms. The polyolefin component which is modified with a carboxylic acid, or a derivative thereof, is characterized by having a carbonyl group, repre- sented by the general formula C=0. Due to the double bond of the carbonyl group, the carbon atom is electropositive in nature. The esterification reaction is a thermally activated chemical reaction. Upon subjecting a mixture of the modified polyolefin and the conduc¬ tive particulate filler to heat and mechanical shear, a new carbon-oxygen bond is formed due to the affinity of the oxygen atom of the hydroxyl group for the carbon atom of the carbonyl group. Consequently, the conductive particulate filler is chemically bonded (i.e., grafted) to the modified polyolefin component. The esterification reaction can be illustrated with reference to a preferred embodiment . In a preferred embodiment of the present invention, the modified polyolefin comprises high density polyeth¬ ylene grafted with maleic anhydride . Such a poly¬ mer is available from Du Pont under the trade¬ name Fusabond™. The method for manufacturing such a polymer is also disclosed in U.S. Patent No. 4,612,155 (Wong et al . ) . The preferred conductive particulate filler of the present invention is carbon black. The esterification reaction which grafts the carbon black to- the modified polyethyl¬ ene (maleic anhydride grafted polyethylene) can be represented according to the formula below: With reference to Fig. 3, electrical devices 10 of the present invention comprise a PTC element 20 having a modified polyolefin component grafted to a conductive particulate filler component. The PTC element 20 has a first surface affixed to a first electrode 30 and second surface affixed to a second electrode 40. The electrodes 30 and 40 can be connected to a source of power, and when so con¬ nected, cause current to flow through the PTC element 20. EXAMPLE 1 A quantity of 121.15 g of modified polyolefin comprised of 99% by weight high density polyethyl¬ ene and 1% by weight maleic anhydride (manufactured by Du Pont under the tradename Fusabond 'E' MB- 100D) having a specific gravity of 0.90 - 0.96 and a melt temperature of approximately 130°C was placed in a C . Brabender Plasti-Corder PL 2000 equipped with a Mixer-Measuring Head and fluxed at 200°C for approximately 5 minutes at 5 rpm. A quantity of 118.85 g carbon black (manufactured by Columbian Chemicals under the tradename Raven 450) was incorporated into the fluxed modified polyolef¬ in and mixed for 5 minutes at 5 rpm. The speed of the Brabender mixer was then increased to 80 rpm, and the modified polyolefin and carbon black were thoroughly mixed at 200°C for 5 minutes. The energy input, due to the mixing, caused the temper¬ ature of the composition to increase to 240°C. The increased temperature of the composition allowed the esterification reaction, as previously described, to take place between the modified polyolefin and the carbon black. As a result, the carbon black is grafted to the modified polyolefin. After allowing the composition to cool, the composition was then placed into a C . Brabender Granu-Grinder where it was ground into small chips. The chips were then fed into the CW. Brabender Plasti-Corder PL 2000 equipped with an Extruder Measuring Head. The extruder was fitted with a die having an opening of 0.002 inch, and the belt speed of the extruder was set at 2. The temperature of the extruder was set at 200°C, and the screw speed of the extruder was measured at 50 rpm. The chips were extruded into a sheet approximately 2.0 inches wide by 8 feet long. This sheet was then cut into a number of 2 inch x 2 inch sample PTC elements, and pre-pressed at 200°C to a thickness of approxi¬ mately 0.01 inch. A sample PTC element was laminated between two metal foil electrodes in a heated press. The metal foil electrodes were treated to provide an average surface roughness, R a , of approximately 1.2 - 1.7 microns. Such foils are available from Fukuda Metal Foil & Powder Co., Ltd. under the tradename NiFT-25. After the laminate was removed from the press and allowed to cool without further pressure, the laminate was sheared into a number of 0.15 inch x 0.18 inch electrical devices. The resistance at 25°C of ten electrical devices made according to Example 1 is listed below in Table I. TABLE I INITIAL RESIST SAMPLE (OHMS) 1 1.2096 2 1.9092 3 1.8404 4 2.7570 5 2.6320 6 2.2970 7 2.4740 8 2.1130 9 2.2610 10 2.8110 AVERAGE 2.2304 EXAMPLE 2 A second composition was produced in substan¬ tially the same manner as that of Example 1 except that the initial components comprised a quantity of 108.15 g of modified polyolefin (manufactured by Du Pont under the tradename Fusabond 'E' MB-226D) having a specific gravity of 0.90 - 0.96 and a melt temperature of approximately 130°C and 131.85 g of carbon black (manufactured by Columbian Chemicals under the tradename Raven 430) . The resistivity of the composition as a function of temperature is illustrated in FIG. 1. The composition had an initial resistivity at 25°C of 2.8 ohm cm and a peak resistivity at approximately 120°C of 1.9 x IO 4 ohm cm. The procedure set forth in Example 1 was followed to produce a number of 0.15 inch x 0.18 inch electrical devices. The resistance at 25°C of ten electrical devices made according to Example 2 is listed below in Table II. TABLE II INITIAL RESIST SAMPLE (OHMS) 1 0.6786 2 0.6092 3 0.6669 4 0.6607 5 0.6340 6 0.6306 7 0.6431 8 0.6761 9 0.6398 10 0.6723 AVERAGE 0.6511 EXAMPLE 3 A third composition was produced in substan¬ tially the same manner as that of Example 1 except that the initial components comprised a quantity of 111.96 g of modified polyolefin (manufactured by Du Pont under the tradename Fusabond 'E' MB-100D) having a specific gravity of 0.90 - 0.96 and a melt temperature of approximately 130°C and 128.04 g of carbon black (manufactured by Columbian Chemicals under the tradename Raven 430) . The resistivity of the composition as a function of temperature is illustrated in FIG. 2. The composition had an initial resistivity at 25°C of 0.8 ohm cm and a peak resistivity at approximately 120°C of 5.1 x 10 s ohm cm. The procedure set forth in Example 1 was followed to produce a number of 0.15 inch x 0.18 inch electrical devices. The resistance at 25°C of ten electrical devices made according to Example 3 is listed below in Table III. TABLE III INITIAL RESIST SAMPLE (OHMS) 1 0.1268 2 0.1181 3 0.1169 4 0.1143 5 0.1196 6 0.1183 7 0.1202 8 0.1213 9 0.1240 10 0.1240 AVERAGE 0.1203 Laboratory tests have shown that PTC composi¬ tions of the present invention also adhere extreme¬ ly well to smooth foils. Accordingly, conventional metal foils having surfaces that are not chemically or mechanically treated to enhance their surface roughness can also be used as electrodes in elec¬ trical devices of the present invention. EXAMPLE 4 A fourth composition was produced using a Leistritz twin screw extruder compounding system, Model ZSE-27. A composition comprising 50.80% by weight modified polyethylene (manufactured by Du Pont under the tradename Fusabond 'E' MB-100D, having a specific gravity of 0.90 - 0.96 and a melt temperature of approximately 130°C) and 49.20% by weight carbon black (manufactured by Columbian Chemicals under the tradename Raven 430) was placed in a gravimetric feeder and fed to the Leistritz melt/mix/pump system. The processing conditions for the compounding system were as follows: melt temperature, 239°C; screw speed, 120 rpm; screw configuration, co-rotating; melt pressure, 2100 p.s.i.; and line speed 6.45 feet per minute. A sample PTC element was extruded to a thick¬ ness of 0.011 inch and laminated between two metal foil electrodes in a heated press. The metal foil electrodes were not chemically or mechanically treated to enhance their surface roughness, and thus, had an average surface roughness, R a , of approximately 0.3 - 0.5 microns. After the lami- nate was removed from the press and allowed to cool without further pressure, the laminate was sheared into a number of 0.15 inch x 0.18 inch electrical devices. The composition of Example 4 had a resis- tivity at 25°C of 1.54 ohm cm and a peak resis¬ tivity at a temperature greater than 25°C of 2.4 x 10 7 ohm cm. The electrical and thermal stability and the ohmic contact of devices made according to Example 4 were tested by subjecting the devices to cycle life and trip endurance tests. The cycle life test consisted of applying a current of 40 amps to the device for a period of 15 seconds, followed by a resting period of no current or voltage for 285 seconds. This comprised one cycle. The device was cycled 100 times, with the resistance of the device being measured after cycles 1, 2, 10 and 100. The results of cycle life tests for 10 devices made according to Example 4 are illustrated in Table IV A below. The devices tested had an average change in resistance after 100 cycles of -5.05%. TABLE IV A Resis¬ Resis¬ Resis¬ Resis¬ Initial tance tance tance tance Resis¬ After After After After Sample tance 1 Cycle 2 Cycles 10 Cycles lOOCycles Number (Ohms) (Ohms) (Ohms) (Ohms) (Ohms) 1 0.3255 0.2638 0.2516 0.2131 0.3592 2 0.3367 0.2709 0.2597 0.2188 0.3178 3 0.3212 0.2578 0.2459 0.2065 0.3036 4 0.3588 0.2869 0.2738 0.2311 0.4110 5 0.3314 0.2650 0.2527 0.2109 0.2974 6 0.3365 0.2707 0.2578 0.2173 0.3514 7 0.3636 0.2962 0.2843 0.2391 0.2903 β 0.3434 0.2804 0.2681 0.2236 0.3018 9 0.3484 0.2858 0.2730 0.2290 0.2721 10 0.3636 0.2968 0.2847 0.2379 0.3478 The trip endurance test consisted of initially tripping the device using a 40 amp current for a maximum duration of 15 seconds. The device was then held in the tripped state by switching to and maintaining 15 volts across the device. The resis¬ tance of the device was measured after 1, 24, 48 and 168 cumulative hours. The results of the trip endurance test for 10 devices made according to Example 4 are illustrated in Table IV B below. The devices tested had a average change in resistance of -13.06% after spending 168 hours in the tripped state. TABLE IV B Sample lnt "l hr trio ^24 hr trip ^ « hr trip *lil hr trip Number (ohms) (ohms) (ohms) (ohms) (ohms) 1 0.3463 0.2413 0.2590 0.2652 0.3217 2 0.3387 0.2372 0.2507 0.2489 0.2904 3 0.3663 0.2481 0.2628 0.2641 0.3138 4 0.3367 0.2356 0.2572 0.2575 0.3089 5 0.3258 0.2248 0.2389 0.2385 0.283B 6 0.3277 0.2249 0.2394 0.2369 0.2729 7 0.3217 0.2227 0.2441 0.2420 0.2818 8 0.3321 0.2305 0.2480 0.2465 0.2865 9 0.3511 0.2441 0.2649 0.2620 0.3037 10 0.3664 0.2513 0.2642 0.2624 0.3026 Circuit protection devices made according to Example 4 of the present invention were also incor¬ porated into a test circuit to measure the voltage breakdown and dielectric strength. The test cir¬ cuit is illustrated in FIG. 4. The circuit was supplied with a 30 volt/10 amp DC power source (reference numeral 50 in FIG. 4) and an alternate 600 volt/1.5 amp DC power source (reference numeral 60) . A relay switch 70 was used to alternate between power sources 50 and 60. The device 10 was connected in series with the power source. A 10 amp shunt (reference numeral 80) was placed in series with the 30 volt/10 amp power supply, while a 1 amp shunt (reference numeral 90) was placed in series with the 600 volt/1.5 amp power supply. For safety reasons, a 3 amp fuse was connected in series with the 600 volt/1.5 amp power supply. A FLUKE™ digital multimeter 100, 110 was placed in parallel with each shunt. At different times, the current through the device was measured by the voltage drop across either shunt. A FLUKE™ digital multimeter 120 was also placed in parallel with the PTC device. Under passive conditions, where power in the device is zero, the initial resistance of the device, R ιnt , was measured at 20°C. The voltage drop across the device was measured directly by multime¬ ter 120, while the current through the device was calculated from the voltage drop across shunt 80. Under active conditions, where the power in the device is greater than zero, the resistance of the device was calculated from the voltage/current measurements. The maximum current through the device, I^ x , was determined by increasing the 30 volt/10 amp power source to V trιp , a level where any further increase in voltage resulted in a decrease in current. At this point, with the device in the tripped state (i.e., high temperature, high resis- tance stable equilibrium point) , the relay was switched to the 600 volt/1.5 amp DC power supply in order to increase the applied voltage across the device. The voltage breakdown, V,,^, was determined by slowly increasing the voltage applied to the tripped device until dielectric breakdown occurred. The dielectric strength in volts/mm was calculated by dividing the voltage breakdown, V,,,, by the thickness of the PTC element. The maximum voltage breakdown, R int , 1^,,, and dielectric strength for five electrical devices made according to Example 4 of the present invention are shown below in Table IV C The devices tested had an average dielectric strength of 1116.68 volts/mm. TABLE IV C EXAMPLE 5 With reference to FIG. 5, the following illus¬ trates a typical application of the present inven¬ tion as a circuit protection device. A device 10 made according to Example 4 was placed in a circuit consisting of the PTC device 10, a resistive load (reference numeral 130 ) of 27.3 ohms in series with the device, and a 30 volt D.C. power supply 140. The resistance of the PTC device at 25°C was 0.365 ohms. A relay switch 150 was placed in the series circuit to simulate short circuit conditions by switching from the 27.3 ohm resistive load to a 1 ohm resistive load (reference numeral 160) . Under normal operating conditions, the current in the circuit was 1.1 amp. The voltage drop across the PTC device was 0.418 volts while the power in the circuit was 33.49 watts. To simulate short circuit conditions, the relay was switched to the 1 ohm resistive load so that the 1 ohm load was in series with the PTC device and the 30 volt power supply. Initially, there was a very substantial increase in current flowing in the circuit. Howev¬ er, due to I 2 R heating, the temperature of the PTC device rose to its critical temperature and the resistance of the PTC device greatly increased. At this high temperature stable equilibrium point, the PTC device had a resistance of 545 ohms while the current flowing through the circuit was cut to 0.055 amp. The power in the circuit decreased to 1.65 watts. The Switching Ratio, i.e., the ratio of power in the circuit in the normal operating condition to the power in the circuit at the high temperature stable equilibrium point was 33.49 watts/1.65 watts or 20.29. While the specific embodiments have been illustrated and described, numerous modifications come to mind without markedly departing from the spirit of the invention. The scope of protection is only intended to be limited by the scope of the accompanying claims.

Claims: C L A I M S I claim: 1. A crystalline conductive polymer composition exhibiting PTC behavior, the compo¬ sition comprising a modified polyolefin and a con¬ ductive particulate filler. 2. The composition of Claim 1, wherein the modified polyolefin comprises a polymer select- ed from the group consisting of polyethylene, copolymers of polyethylene, polypropylene and ethylene/propylene copolymers. 3. The composition of Claim 1, wherein the modified polyolefin comprises a carboxylic acid or a carboxylic acid derivative. 4. The composition of Claim 3, wherein the carboxylic acid derivative comprises a deriva¬ tive selected from the group consisting of acyl chlorides, carboxylic anhydrides, carboxylic es- ters, amides, and thiol esters. 5. The composition of Claim 1, wherein the modified polyolefin comprises polyethylene and maleic anhydride. 6. The composition of Claim 5, wherein the modified polyolefin comprises about 90-99% by weight polyethylene and 1-10% by weight maleic anhydride. 7. The composition of Claim 1, wherein the conductive particulate filler comprises carbon black. 8. The composition of Claim 1, wherein the conductive particulate filler forms a chemical bond with the modified polyolefin. 9. The composition of Claim 1, wherein the modified polyolefin comprises polyethylene grafted with maleic anhydride and the conductive particulate filler comprises carbon black. 10. The composition of Claim 1, wherein the composition has an electrical resistivity at 25°C of less than 5 ohm cm. 11. The composition of Claim 1, wherein the composition has an electrical resistivity at 25°C of less than 2 ohm cm. 12. A crystalline conductive polymer composition exhibiting PTC behavior, the compo¬ sition comprising a conductive particulate filler and a modified polyolefin having the formula - [CH 2 -CH 2 ] X - [CH--CH] y - wherein X x is selected from the group consisting of carboxylic acids and carboxylic acid derivatives, and wherein x and y are present in an amount such that the ratio by weight of x/y is at least 9. 13. The composition of Claim 12, wherein X- L comprises a carboxylic acid derivative selected from the group consisting of acyl chlorides, car¬ boxylic anhydrides, carboxylic esters, amides, and thiol esters. 14. The composition of Claim 12, wherein X- L is maleic anhydride. 15. The composition of Claim 12, wherein the ratio by volume of the conductive particulate filler to the modified polyolefin having the formu¬ la -[CH 2 -CH 2 ] x -[CH 2 - rCH] y - is at least 0.30. 16. The composition of Claim 1 or 12, wherein the composition has a peak resistivity at a temperature greater than 25°C of at least 1,000 ohm cm. 17. The composition of Claim 1 or 12, wherein the composition has a peak resistivity at a temperature greater than 25°C of at least 10,000 ohm cm. 18. The composition of Claim 1 or 12, wherein the composition has a peak resistivity at a temperature greater than 25°C of at least 100,000 ohm cm. 19. The composition of Claim 12, wherein the composition has a crystallinity of at least 30% and a resistivity at 25°C of less than 5 ohm cm. 20. The composition of Claim 19, wherein the composition has a resistivity at 25°C of less than 2 ohm cm. 21. A conductive polymer composition having a resistivity at 25°C of less than 5 ohm cm and a peak resistivity at a temperature greater than 25°C of at least 1,000 ohm cm, the composition comprising a conductive filler component grafted to a modified polyolefin component . 22. The composition of Claim 21, wherein the modified polyolefin component comprises: (a) a polyolefin selected from the group consisting of polyethylene, polyethylene copoly¬ mers, polypropylene and ethylene/propylene copoly- mers; and, (b) a carboxylic acid or a carboxylic acid derivative. 23. The composition of Claim 22, wherein the carboxylic acid derivative comprises a deriva- tive selected from the group consisting of acyl chlorides, carboxylic anhydrides, carboxylic es¬ ters, amides, and thiol esters. 24. The composition of Claim 21, wherein the modified polyolefin component comprises polyethylene and maleic anhydride. 25. The composition of Claim 21, wherein the modified polyolefin component comprises about 90-99% by weight polyolefin and about 1-10% by weight carboxylic acid or a carboxylic acid deriva¬ tive. 26. The composition of Claim 21, wherein the composition comprises about 30-45% by volume conductive filler component and about 55-70% by volume modified polyolefin component . 27. An electrical device comprising: (a) a PTC element having a modified polyolefin component grafted to a conductive particulate filler component; and (b) two electrodes, each electrode being connectable to a source of power, and when so connected, causing current to flow through the PTC element. 28. The electrical device of Claim 27, wherein the PTC element comprises about 30-45% by volume conductive particulate filler component and about 55-70% by volume modified polyolefin compo- nent . 29. The electrical device of Claim 27, wherein the PTC element comprises about 90-99% by weight polyethylene and about 1-10% by weight maleic anhydride. 30. The electrical device of Claim 27, wherein the device has a resistance at 25°C of less than 1 ohm. 31. The electrical device of Claim 27, wherein the device has a dielectric strength of at least 500 volts/millimeter. 32. An electrical device comprising: (a) a PTC element having a modified polyolefin component grafted to a conductive particulate filler component, the modified polyolefin component comprised of about 90-99% by weight polyethylene and about 1-10% by weight carboxylic acid or a carboxylic acid derivative, the PTC element having a resistivity at 25°C of less than 5 ohm cm and a peak resistivity at a temperature greater than 25°C of at least 1,000 ohm cm; and (b) two electrodes, each electrode being connectable to a source of power, and when so connected, causing current to flow through the PTC element, the electrical device having a resistance, R ιnt at 25°C of less than 1 ohm. 33. The electrical device of Claim 32, wherein the device after being subjected to a cycle test which consists of 10 successive test cycles, each cycle consisting of applying 40 amps to the device for 15 seconds followed by a resting period where no current or voltage is applied to the device for 285 seconds, the resistance of the device after the test cycles have been completed, Rio c yc l e is less than R lnt . 34. The electrical device of Claim 32, wherein the device after being subjected to a cycle test which consists of 100 successive test cycles, each cycle consisting of applying 40 amps to the device for 15 seconds followed by a resting period where no current or voltage is applied to the device for 285 seconds, the resistance of the device after the test cycles have been completed, R ιoo cycle ' which is between .75 x R int and 1.5 x R lnt . 35. The electrical device of Claim 32, wherein the device after being subjected to a trip endurance test which consists of applying a 40 amp current to the device for a maximum duration of 15 seconds to trip the device, holding the device in a tripped state for 48 hours by applying 15 volts across the device, the resistance of the device after the trip endurance 'test has been completed, R 4B hour , is less than R int . 36. The electrical device of Claim 32, wherein the device after being subjected to a trip endurance test which consists of applying a 40 amp current to the device for a maximum duration of 15 seconds to trip the device, holding the device in a tripped state for 168 hours by applying 15 volts across the device, the resistance of the device after the trip endurance test has been completed, R 648 hour is less than R ιnt . 37. An electrical device comprising: (a) a PTC element having a modified polyolefin component grafted to a conductive particulate filler component; and (b) two electrodes having a surface roughness, R a , the electrodes not being chemically or mechani- cally treated to enhance the surface roughness, R a , each electrode being connectable to a source of power, and when so connected, causing current to flow through the PTC element. 38. The electrical device of Claim 37, wherein the average surface roughness, R a , is less than 1 micron. 39. The electrical device of Claim 37, wherein the average surface roughness, R a , is between 0.3 and 0.5 microns. 40. An electrical circuit comprising: (a) a source of electrical power; (b) a circuit protection device comprising a PTC element and two electrodes, the PTC element being composed of a conductive polymer composition comprising a modified polyolefin and a conductive particulate filler; and (c) other circuit elements connected in series with the circuit protection device which have a resistance R L ohms. 41. The electrical circuit of Claim 40, wherein the modified polyolefin comprises an organ¬ ic polymer material selected from the group con¬ sisting of polyethylene, copolymers of polyeth- ylene, polypropylene and ethylene/propylene copoly¬ mers. 42. The electrical circuit of Claim 40, wherein the modified polyolefin comprises an organ¬ ic polymer material grafted with a carboxylic acid or a carboxylic acid derivative. 43. The electrical circuit of Claim 42, wherein the carboxylic acid derivative comprises a derivative selected from the group consisting of acyl chlorides, carboxylic anhydrides, carboxylic esters, amides, and thiol esters. 44. The electrical circuit of Claim 40, wherein the modified polyolefin comprises about 90- 99% by weight polyethylene and about 1-10% by weight maleic anhydride. 45. The electrical circuit of Claim 40, wherein the conductive particulate filler comprises carbon black. 46. The electrical circuit of Claim 40, wherein the conductive particulate filler is chemi¬ cally bonded to the modified polyolefin. 47. The electrical circuit of Claim 40, wherein the PTC element has a resistivity at 25°C of less than 5 ohm cm and a peak resistivity at a temperature greater than 25°C of at least 1000 ohm cm. 48. The electrical circuit of Claim 40, wherein the circuit has a normal operating condi- tion in which the circuit protection device has a resistance R^ which is less than 1 ohm. 49. The electrical circuit of Claim 40, wherein the circuit protection device has a resis¬ tance at 25°C of R ιnt and the device after being subjected to a cycle test which consists of 10 successive test cycles, each cycle consisting of applying 40 amps to the device for 15 seconds followed by a resting period where no current or voltage is applied to the device for 285 seconds, the resistance of the device after the test cycles have been completed, R 10 cycle , is less than R ιnt . 50. The electrical circuit of Claim 40, wherein the circuit protection device has a resis¬ tance at 25°C of R ιnt and the device after being subjected to a cycle test which consists of 100 successive test cycles, each cycle consisting of applying 40 amps to the device for 15 seconds followed by a resting period where no current or voltage is applied to the device for 285 seconds, the resistance of the device after the test cycles have been completed, R 100 cycle , is between .75 x R ιnt and 1.50 x R ιnt . 51. The electrical circuit of Claim 40, wherein the circuit protection device has a resis¬ tance at 25°C of R ιnt and the device after being subjected to a trip endurance test which consists of applying a 40 amp current to the device for a maximum duration of 15 seconds to trip the device, holding the device in a tripped state for 48 hours by applying 15 volts across the device, the resis¬ tance of the device after the trip endurance test has been completed, R 48 hour , is less than R ιnt . 52. The electrical circuit of Claim 40, wherein the device has a resistance at 25°C of R ιnt and the device after being subjected to a trip endurance test which consists of applying a 40 amp current to the device for a maximum duration of 15 seconds to trip the device, holding the device in a tripped state for 168 hours by applying 15 volts across the device, the resistance of the device after the trip endurance test has been completed, Ri 68 our / i less than R ιnt . 53. An electrical circuit which includes a source of electrical power, a circuit protection device comprising a PTC element and two electrodes, and other circuit elements connected in series with the circuit protection device which have a resis¬ tance R L ohms, and which has a normal operating condition and a high temperature stable operating condition at the occurrence of a fault condition, wherein: (a) the PTC element is composed of a PTC con¬ ductive polymer comprising an organic polymer material and conductive carbon black, the PTC conductive polymer having a resistivity at 25°C of 5 ohm cm or less; (b) the circuit protection device having a resistance at 25°C of 1 ohm or less and 0.5 x R L ohm or less; (c) the ratio of the" power in the circuit in the normal operating condition to the power in the high temperature stable operating condition, i.e., the Switching Ratio, is at least 8; the improvement comprising the organic polymer material being comprised of a modified polyolefin having the formula x, [CH 2 - CH 2 ] X - [CH 2 ■ CH] y - wherein X x is selected from the group consisting of carboxylic acids and carboxylic acid derivatives, and wherein x and y are present in an amount such that the ratio by weight of x/y is at least 9. 54. The electrical circuit of Claim 53, wherein at the high temperature stable operating condition the circuit protection device has a dielectric strength of at least 500 volts/millimeter. 55. The electrical circuit of Claim 53, wherein the circuit protection device has a resis¬ tance in the normal operating condition of less than 0.5 ohm. 56. The electrical circuit of Claim 53, wherein the modified polyolefin comprises 90-99% by weight polyethylene and 1-10% by weight maleic anhydride. 57. The electrical circuit of Claim 53, wherein the modified polyolefin is chemically bonded to the carbon black. 58. The electrical circuit of Claim 53, wherein the PTC conductive polymer has a peak resistivity at a temperature greater than 25°C of at least 10,000 ohm cm. 59. The electrical circuit of Claim 53, wherein the circuit protection device has a resis¬ tance at the high temperature stable operating condition which is at least 10 times greater than the resistance of the circuit protection device at the normal operating condition.

Inventors: HALL TOM J, HALL, TOM, J.
Applicants: LITTELFUSE INC, LITTELFUSE, INC.
Application year: 1996
Main classification: H01C7
IPC codes: B29B13, C08F255, C08F291, C08F292, C08J3, C08K3, C08L23, H01B1, H01C7, H01C17