Thermally induced performance decay in conductive polymer composites

Abstract In the course of long‐term service, electrically conductive polymer composites acting as positive temperature coefficient (PTC) materials are faced with performance decay characterized by gradually increased room temperature resistivity and decreased PTC intensity. To reveal the influencing factors and to find appropriate ways for solving the problems, thermal‐cold cycling experiments (which simulate the extreme operating conditions of PTC type materials in a laboratory environment) and electrification tests are carried out in the current work. The results demonstrate that irreversible damage of partial conductive networks and, in particular, oxidation degradation induced crystallizability deterioration of the matrix polymer are responsible for the electrical performance decay. Additionally, an increase in the contact resistance formed at the metallic electrode/composite contacts exerts a negative influence on the service life of the composites. Polym. Compos. 25:270–279, 2004. © 2004 Society of Plastics Engineers.