Formulating Graphite-Filled PU Dispersions with Extended Shelf Life Using the Capillary Suspension Concept

Stabilizing micron-sized particles in low-viscosity polymer dispersions is challenging when density differences are present. This study demonstrates that graphite particles in aqueous polyurethane dispersions can be efficiently prevented from sedimentation using the capillary suspension concept. Capillary suspensions are solid/liquid/liquid systems and the capillary forces inferred from adding a second immiscible fluid can lead to drastic changes in texture and flow. Here, both spherical and flake-shaped graphite particles were used as fillers, with octanol as the secondary liquid. At low graphite concentrations, octanol increases the low-shear viscosity significantly attributed to the formation of loose particle aggregates immobilizing part of the continuous phase. Above a critical graphite concentration, capillary forces induce a self-assembling, percolating particle network, leading to a sharp yield stress increase (>100 Pa). The corresponding percolating particle network efficiently suppresses sedimentation; for the system including 28 vol% spherical particles, a shelf life of at least six months was achieved. Capillary forces do not affect the high-shear viscosity of suspensions; here, a hydrophobically modified polyether thickener can be used. Transfer of the stabilization concept presented here to other high-density particles like silver or metal oxides suspended in other polymer dispersions is straightforward and is applicable in various fields like flexible printed electronics.