Progress in Organic Coatings 55 (2006) 1–4

Studies on graphite based conductive paint coatings

S. Syed Azim ∗ , A. Satheesh, K.K. Ramu, S. Ramu, G. Venkatachari
Central Electrochemical Research Institute, Karaikudi, Tamilnadu 630 006, India
Received 16 April 2005; accepted 2 September 2005

Abstract
Electrically conductive coatings are mainly required for static charge dissipation and electromagnetic/radio frequency interference (EMI/RFI)
shielding. Electrically conductive coatings are prepared by the incorporation of the metallic pigments/graphite onto the binder. In the present
investigation graphite is used as the conductive filler and epoxy polymer as binder. Optimization of the solid content and pigment volume
concentration (PVC) of the coating is done by varying the composition of the binder and pigment volume. To get the minimum resistivity value
offered by the coating. The resistivity of the coating was measured by means of the four-probe resistivity method. The effect of inclusion of carbon
black as additional pigment is also studied. The results are presented and discussed in this paper.
© 2005 Elsevier B.V. All rights reserved.

Keywords: Conductive coating; Graphite coating; Carbon black; Conductive carbon

1. Introduction attenuation can result form absorption, scattering or reflection

of electromagnetic radiation and specific methods are preferred
Paints are inherently non-conducting and would provide no upon the coating function. External EMI/RFI from either natural
shielding effect. To produce a paint, which is conductive, it is (e.g. electrical storms) or synthetic (e.g. transmitters) sources
necessary to incorporate conductive pigments into the system can cause electronic equipment failure, memory erasure, and
[1]. navigational errors and jammed radio reception.
Electrically conductive coatings are required for a variety of Conceptually, there are three methods possible to design con-
applications such as static charge dissipation and electromag- ductive coatings.
netic/radio frequency interference (EMI/RFI) shielding. They
are also used in the production of antistatic coatings, space heat- (1) Utilize conductive polymers as the continuous matrix.
ing, and in various electrical applications [2–4]. The amount of (2) Incorporate conductive pigments as sufficient pigment vol-
dc conductivity required is dependent upon the specific applica- ume concentration.
tion. Tribo electric charge buildup by dielectric substrates, such (3) Combination of both methods.
as fiberglass structures in frictional contact with other materials,
can result in very large static voltages that may lead to danger-
While there have been many recent advances in conductive
ous discharge sparks. The amount of surface resistance required
polymer technology, these materials have been limited use due
effectively to bleed off this charge and prevent sparking, is usu-
to loss of conductivity upon environmental exposure (e.g. oxida-
ally rather low 10−6 to 10−9
cm2 . At the other extreme, near
tion) and poor processability and solubility. Hence, incorporat-
metal like conductivity is required for directing large current
ing pigments such as conductive carbon blacks and metal flakes
such as those experienced in lighting strikes on composite air-
into a polymeric matrix that has desirable physical/chemical
craft structures. Currently, there are no organic coatings enough
properties produces most of high conducting coatings [6].
to provide complete lighting protection, but some can reduce or
To enlarge the available resistivity range, the use of
minimize damage to local areas [5]. The amount of ac conduc-
graphite/carbon black combinations were investigated in the
tivity required for striking applications is more complex since
present work. The advantage of graphite as pigment is due to
its high conductivity with low surface area, enhancing relatively
∗ Corresponding author. Tel.: +91 4565 227550; fax: +91 4565 227133. high loading without affecting the rheological properties of the
E-mail address: [email protected] (S.S. Azim). paint to the material structure. The objective of the present work

0300-9440/$ – see front matter © 2005 Elsevier B.V. All rights reserved.
doi:10.1016/j.porgcoat.2005.09.001
2 S.S. Azim et al. / Progress in Organic Coatings 55 (2006) 1–4

therefore was to determine the optimal graphite/carbon black cleaned glass plates at different thickness. The surface resistiv-
combination, in terms of conductivity, in a conductive paint and ity of films has been made for:
to suggest an explanation of the improvement in conductivity
achieved over the graphite loaded paint [7]. (i) optimization of solid content (Vs);
(ii) optimization of pigment content (PVC);
2. Experimental (iii) optimization of mix ratio between graphite and carbon
black.
2.1. Materials
3. Results and discussion
The binder used in the present work was, a poly sulphide
modified epoxy resin having 100% solids. It was cured with 3.1. Optimization of solid content
a polyethylene polyamine, diluted to application consistency
with measured quantities of mixed solvents (iso-propyl alco- To know the effect of amount of binder on the resistivity of
hol:methyl iso-butyl ketone:Cellosolve). dry paint films, the solid content of the paint was varied from 30
The graphite filler used was lamellar structured graphite. Its to 100% the PVC was kept at a constant volume, i.e. 55%. Fig. 2
carbon content is 98–99%, typical particle size is up to 50 ␮m shows the variation of resistivity of the film with volume solids.
and its density is 2.26 g/cc (SD fine chemicals). Volumetric oil When the pigment particles are closely packed then it gave a
absorption was determined according to ASTM D 285–94 and particle-to-particle contact which at 100% the resistivity was
was found to be 0.4 ml oil to ml of graphite, i.e. 40%. The around 3.7 × 10−2
M. When the solid content was reduced to
graphite used was a conductive grade. Carbon black used was a 60% the resistivity was suddenly decreased to 4.3 × 10−3
M.
commercial one. This decrease in resistivity was due to the close packing of the
pigment particles, that is, the particle-to-particle contact of the
2.2. Preparation and paint application method pigment would be more in 60% than in 100%. The particle-
to-particle contact of the pigments would be increased when
Paint formulations with various combinations of graphite and the solid content of the paint was further reduced. Hence, the
carbon black and epoxy binder in appropriate amounts. The resistivity would be reduced at the low solid content. When
resistivity of the formulated paints was measured using the four- the solid content was further reduced to 55% the resistivity
probe resistance method. In this method current is applied across was 1.3 × 10−3
M and the solid content was further reduced
the outer probes and the voltage is measured across the two inner to 50 and 40%, the resistivity was reduced to 8.6 × 10−4 and
probes. Fig. 1 shows the experimental set-up used for the resis- 6.3 × 10−5
M. Below 40% poor hiding problem occurs due to
tivity measurements. From the resistivity measured, the specific the low binder content in the paint. At the 40% solids the particle-
volumetric electrical resistance (
M) is calculated as per ASTM to-particle contact was maximum and thus the resistivity was at
D-4496-87. The coating composition, which had the minimum minimum value of 6.3 × 10−5
M.
specific volumetric electrical resistance, was concluded as the
optimized composition. The optimized pigment content is 55%. 3.2. Optimization of pigment volume concentration (PVC)
The optimized mix ratio between graphite and carbon black was
85:15. The paint base was dispersed well using a dispersing Similar to the binder optimization, the PVC, which had the
agent, dibutyl phthalate, the paint was applied over a solvent low resistivity value, would be considered as optimized PVC.
The PVC was varied from 30 to 60%. The PVC was optimized at
the optimized binder volume, i.e. 40%. Fig. 3 shows the nature

Fig. 1. Experimental setup. Fig. 2. Optimization of volume solids.

 S.S. Azim et al. / Progress in Organic Coatings 55 (2006) 1–4 3

Fig. 3. Optimization of PVC.

Fig. 4. Optimization of carbon black content.

of variation of resistivity and PVC. At 25%, the resistivity is

above 3.3 × 10−2
M. Upon increasing the pigment volume,
the resistivity was found to reduce. The increase in the pigment
content would increase the amount of the pigment particles in
the binder hence it causes the closer packing of the particles and
thus make the particle-to-particle contact, which in turn resulted
in minimum resistivity. At 30%, the resistivity was reduced to
1.6 × 10−2
M. At 40% PVC, the resistivity was further reduced
to 9.1 × 10−3
M. Upon increasing PVC to 50% the resistivity
was 6.7 × 10−4
M. At 55% PVC, the resistivity reached a min-
imum value of 6 × 10−5
M. This is due to the tight packing
of the pigment particles so that every particle is in contact with
the other, hence results in minimum resistivity. Above 55% the
dispersion of pigment was too difficult.
Fig. 5. Optimization of carbon black content.
3.3. Optimization of graphite and carbon black mix ratio

In order to reduce the resistivity further, carbon black is added the graphite and carbon black, the carbon black mix ratio was
as the additional pigment. The advantage of the use of car- further narrowed in between from 10 to 20%, as 10, 13, 15, 17
bon black as additional pigment is due to its low density and and 20%. From the resistivity values it is found that 15% mix
large dimensions of particles, relative to regular grades, result- ratio of the carbon black has the minimum resistivity (Fig. 5).
ing in low resistivity at low weight loading. The carbon black
particles would occupy the interstitial positions and so that the 4. Conclusion
particle-to-particle contact can be made evenly throughout the
dried paint film, which can result in the minimum resistivity Graphite and carbon black has assumed a highly important
value. The carbon black was added to graphite at various mix role in the formulation of conductive organic-based coatings for
ratios such as 90:10, 87:13, 85:15, 83:17, 80:20, 75:25, 60:40, use in electromagnetic and radio frequency shielding applica-
and their resistivities were measured. The variation of resistiv- tions. This is due to the fact that these coatings have a unique
ity with various mix ratios of graphite and carbon black is given combination of properties like electrical conductivity, oxidation
in Figs. 4 and 5. From the resistivity values it is observed that and corrosion resistance. The conductive paint composition was
the resistivity is reduced to 4 × 10−5
M at 90:10 mix ratio optimized by various mix ratios of binder pigment and solvent.
and the resistivity is further reduced with increasing the carbon The optimized composition having the minimum resistivity in
black ratio. This reduction in the resistivity is due the incorpo- the range of 2 × 10−5
M with volume solids (Vs) 40%, and pig-
ration of the carbon black particles in the interstitial position ment volume concentration (PVC) 55%. In the pigment content
between the graphite particles. The minimum resistivity value the graphite occupies the major portion of 85%, and remaining
(2 × 10−5
M) was observed at 85:15 mix ratio. When carbon portion is carbon black so as to reduce the resistivity of the paint
black content is increased above 15% there is no decrease in further.
resistivity. Hence, the ratio 85:15, which has the low resistivity
value is considered as the optimized mix ratio. The carbon black Acknowledgement
content is varied as 10, 20, 25, and 40%. From the resistivity val-
ues observed it is found that 20% of carbon black inclusion gives The authors thank Director for his kind permission to publish
the minimum resistivity. To know the exact mix ratio between this work.
4 S.S. Azim et al. / Progress in Organic Coatings 55 (2006) 1–4

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