Tailored secondary microstructure of carbon black in polymer nanocomposite to trigger the conductivity for developing coated fabric

We present the critical and systematic investigations on the normal/regular types of carbon black to trigger the conductivity of polymer nanocomposite in developing commercially viable coated flexible fabric. Regular grade carbon blacks are utilized to develop conductive fabric via nanocomposite preparation and application by knife-over-roll coating (average 90 microns thick). The study suggests, tailored secondary microstructure of carbon black particles having a diameter of 30 nanometers (with ∼0.6 packing fraction, 5.815E + 19 per cc charge carrier density, 0.774 ratios of Hall coefficient) has a profound effect on conductivity. The microstructure of carbon black is altered by the shearing force of a mechanical stirrer in a viscous solution of natural rubber latex and polyvinyl alcohol then self-restructured when an excess amount of water is evaporated by high-temperature drying. Thus, the tailored secondary microstructure of carbon black with a diameter of 30 nanometers provides the highest charge carrier density as compared to other types of carbon black used. We found that the attained conductivity (>113 S/m) in this process is 98% of the predicted value as per the classical model. This technique can be exploited to use normal grade carbon black in replacement of conductive grade carbon black and other carbonaceous material like graphene and carbon nanotube. We envision that this easily scalable, commercially viable technique can be utilized for large scale production of conductive fabric.